Ultimate Warrior Owners Manual-web.pmd
Transcription
Ultimate Warrior Owners Manual-web.pmd
SP ARTAN Hi-Flow Ultimate Warrior Water Jet Record the Serial Number of your Owners Manual Hi-Flow Ultimate Warrior and give the number to the factory when ordering parts. Serial Number ....................................... Spartan Tool L.L.C. 800.435.3866 www.spartantool.com 79940010 5-3-11 © 2011 Spartan Tool LLC Warning — Read the safety and operating instructions before using any Spartan Tool products. Drain and sewer cleaning can be dangerous if proper procedures are not followed and appropriate safety gear is not utilized. — Before starting unit, be sure to wear personal protective equipment such as safety goggles or face shield and protective clothing such as gloves, coveralls or raincoat, rubber boots with metatarsal guards, and hearing protection. — Drains and sewer can carry bacteria and other infectious micro-organisms or materials which can cause death or severe illness. Avoid exposing eyes, nose, mouth, ears, hands and cuts and abrasions to waste water or other potentially infectious materials during drain and sewer cleaning operations. To further help protect against exposure to infectious materials, wash hands, arms and other areas of the body, as needed, with hot, soapy water and, if necessary, flush mucous membranes with water. Also, disinfect potentially contaminated equipment by washing such surfaces with a hot soapy wash using a strong detergent. — For any questions contact the company at the address shown below. “California Prop. 65: This product may contain an extremely small amount of lead in the coating. Lead is a material known to the State of California to cause cancer or reproductive toxicity.” SPARTAN TOOL L.L.C. 1506 W. Division Street Mendota, IL 61342 800.435.3866 Fax 888.876.2371 www.spartantool.com Page 2 Hi-Flow Ultimate Warrior Overview Anti-Freeze Tank Front Enclosure Four 150 Gallon Baffled Water Tanks Break-Away Brake Controller Electric Brakes Antifreeze Supply Valve Hydraulic Reservoir 12 Volt Battery Pressure Gauge Fill Reel Control Panel 500 Ft. H.P. Hose Rear Enclosure Articulated High Pressure Reel Hose Guide Hose Reel Hydraulic Control Anti-freeze Recirculation Selector Valves Page 3 Warning — Read the safety and operating instructions before using any Spartan Tool products. Drain and sewer cleaning can be dangerous if proper procedures are not followed and appropriate safety gear is not utilized. Read the engine owners manual for instruction and safety precautions on engine operation. — Diesel is flammable and is explosive under certain conditions. Refuel in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where the engine is refueled or where diesel is stored. Do not overfill the fuel tank (there should be no fuel in the filler neck). After refueling, make sure the tank cap is closed properly and securely. — Use Diesel STA-BIL Fuel Stabilizer during storage and during normal use to prevent fuel deterioration. — Before starting unit, be sure to wear personal protective equipment such as safety goggles or face shield and protective clothing such as gloves, coveralls or raincoat, rubber boots with metatarsal guards, and hearing protection. — Carbon monoxide exhaust and/or gasoline fumes from this equipment can create a hazardous atmosphere in confined spaces (which may include, but are not limited to, manholes and septic tanks), closed garages or other areas which may not be properly ventilated. In particular, excess gasoline fumes can create an explosion hazard. Such hazardous atmospheres can cause death or severe injury. Do not operate this equipment in any confined space or area with inadequate ventilation. Operate this equipment only when located outdoors or in an open, well ventilated area. — Insure the jet hose has been placed in the pipe (minimum of 6 feet suggested) before engaging the water pressure to prevent the hose from coming out of the pipe prematurely and causing injury. Always use the red leader hose provided. — Always shut the water pressure off before pulling the hose out of the pipe. Mark the hose a minimum of 6 feet from the end to help insure the hose is not accidentally pulled out of the pipe while still under pressure. Shut off the water pressure when the hose mark is encountered. WARNING: Portions of the system can still be under pressure even if the unit is not operating. — Never point the wash gun at anyone while operating the unit. Injury may result. — Drains and sewer can carry bacteria and other infectious micro-organisms or materials which can cause death or severe illness. Avoid exposing eyes, nose, mouth, ears, hands and cuts and abrasions to waste water or other potentially infectious materials during drain and sewer cleaning operations. To further help protect against exposure to infectious materials, wash hands, arms and other areas of the body, as needed, with hot, soapy water and, if necessary, flush mucous membranes with water. Also, disinfect potentially contaminated equipment by washing such surfaces with a hot soapy wash using a strong detergent. — For any questions contact the company at the address shown below. SPARTAN TOOL L.L.C. 1506 W. Division Street Mendota, IL 61342 800.435.3866 Fax 888.876.2371 www.spartantool.com Page 4 Table of Contents Hi-Flow Ultimate Warrior Overview .................. 3 Power Pack Assembly - 79965000 .......... 48-52 Warning .......................................................... 4 Starter Relay Assembly - 79946130 .............. 53 Table of Contents ............................................ 5 HP Pump Assembly - 79965100 .............. 54-55 High Pressure Pump - 79865500 ............. 56-57 OPERATING SECTION Water Jet Specifications ................................. 6 Hi-Flow Unloader - 79965600 .................. 58-59 Water Jet Features .......................................... 7 Hydraulic Tank Assembly - 79922200 ............ 60 Towing Instructions ..................................... 8-10 Water/Antifreeze Supply - 79940100 ............. 61 Pump and Pressure System ........................... 11 Drain Valve Assembly - 79959000 ................ 62 High Pressure Water Jetting .......................... 12 Water Tank Fill Tee - 79921300 ..................... 63 Water Tank Filling .......................................... 12 Fill Reel Assembly - 79940400 ...................... 64 Engine Operating Procedure ......................... 13 Wash Down Package - 73817300 ................. 65 Setting up for Operation ................................ 13 Handgun Lance VNozzle - 77799800 ............ 65 Hydraulic Rewind Operating Instructions ........ 14 Baseplate Assembly - 79958100 ............. 66-67 Operating Instructions ............................... 14-15 Recirculation Hose Assemblies ................ 67-68 Pipe Jetting Procedure ................................. 16 When Obstructions Are Encountered ............. 16 Pulsation ....................................................... 17 Wash Down Gun ........................................... 17 Cold Weather Protection .......................... 18-19 Lubrication and Maintenance ................... 20-24 Pump System Malfunction Chart .................... 25 Control Panel ........................................... 26-27 Troubleshooting ............................................. 28 Electric Braking Systems ........................ 29-30 Hydrant Fill Assembly - 79949000 ................. 68 Lower Latch Assembly - 79957000 ............... 69 HP Reel Assembly - 79958300 ................ 70-71 Hose Guide - 79962700................................ 72 Hydraulic Control Valve - 79948170 .............. 73 Control Box Assembly - 79965800 ........... 74-75 Final Assembly Wiring Schematic ............ 76-80 Control Panel Wiring Assembly ..................... 81 Trailer Harness - 79954200 ...................... 82-83 Standard Accessories .................................. 84 PARTS & ACCESSORIES SECTION How To Use Manual ....................................... 31 Special Note ................................................. 31 Final Assembly - 79940000 ...................... 32-44 Front Enclosure Assembly - 79958400 .......... 45 Lift Up Door Assembly - 79961000 .......... 46-47 SAFETY INFORMATION SECTION Tire Safety Information .............................. 85-87 Reporting Safety Defects .............................. 88 Engine Emissions Information ....................... 89 Warranty Information ...................................... 90 Page 5 Hi-Flow Ultimate Warrior Water Jet Specifications GENERAL Pipe Sizes ...................... 4” to 36” Max. Water Delivery ..... 35 GPM Max. Pressure Delivery ..... 3000 psi TRAILER Gross Vehicle Weight Rating (GVWR) ................. 9900 Lbs (4495 kg) Gross Axle Weight Rating (GAWR) ...................... 4700 Lbs (2134kg) (each) Trailer Length ........................................................ 191” Trailer Width ........................................................... 73” Trailer Height ......................................................... 74” Hitch ........................................................................ 2-5/16” Ball Type (Class IV) Tires ........................................................................ ST225-75-R15BD Water Tank ............................................................. 600 Gallon Capacity Tires (Max Load) ................................................... 2540 lbs (each) Cold Inflation Pressure ........................................ 65 PSI / 448 kPa (each) Rim (Diameter X Width X Capacity) ..................... 15” x 6” x 2600 lbs (each) ENGINE Kubota Turbocharged Diesel (Tier IV) Model ...........................................V3300-TE Horsepower ................................. 83@2600 RPM Cylinders ...................................... 4 Bore & Stroke .............................. 3.86 x 4.33 Displacement .............................. 202.53 Fuel...............................................Diesel Fuel Oil No. 2-D (ASTM D975) Fuel Tank Capacity .................... 20 Gal. Cooling ......................................... Water Cooled Oil Capacity .................................. 3.5 Gal. Alternator ..................................... 65 Amp Electric ......................................... 12 Volt / Negative Ground Powered Engagement Clutch... NACD Clutch / Power Take Off enables engine to run without circulating pump PUMP Max. Pressure .............. 3000 psi Max. Water Output ........ 35 GPM Max. Temperature ........ 140º F RPM ................................ 1000 Plungers ......................... 3 REWIND Hydraulic/Capacity ........ Hydraulic Pump & Motor with 8 Gallon Reservoir Page 6 Hi-Flow Ultimate Warrior Features FEATURES Low Water and Oil Protection High Engine Temperature Protection 5/8" x 500' Thermal Plastic High Pressure Hose 1/2" x 15' Colored Leader hose ,, 5/8" x 100' Supply Hose, Mounted On Reel Torsion Double Axle Suspension With Electric Brakes Tier IV Diesel Engine Meets US Emissions Standards Thru 2012 Easy Access Pump Inlet Filter Safety Engagement Clutch (enables engine warm up without running pump) Hydraulic Hose Rewind and Hose Rewind Guide Rear Operator Control and Instrument Gauge 12 Volt Accessory Plug Negative Ground Wiring 5' Break Away Wiring Harness Hitch Jack with Swivel Caster Wheel Class IV 2-5/16" Hitch with Safety Tether Brake Automatic Pressure Regulator 180 Degree Pivoting Hose Reel and Controls Fully Enclosed (and Lockable) 5 Position Nozzle Holder Wash Down Gun Top-Mounted Amber Strobe Light Dial-A-Pressure Engine Setting ST225-75-R15BD - Tires/Wheels Bearing Buddies Open and Closed Nozzles for 5/8” Hose Hose and Hydrant Fill Valves Anti-Freeze Recovery / Winterization System Electric Pulsator National Association of Trailer Manufactures Certified Page 7 Towing Instructions Before hitching and towing on public roads, check that the tow vehicle uses a 2-5/16” ball on a hitch rated class IV, make sure keeper engages ball to secure hitch. Adjust if necessary. The four 150 gallon water tanks are equipped with internal baffles which minimize water sloshing when towed, however; the following 2 rules may limit your vehicles towing capacity and the tank fill level when towed. Determine towing capacity as described below and follow guidelines in using the lowest value from the 2 rules. Trailer Hitch — Check rating of vehicle’s trailer hitch - Class IV - 12,000 lbs. Towing Capacity Vehicle GCWR (Gross Combined Weight Rating) — Towing capacity = GCWR minus vehicle weight minus cargo weight minus passenger weight. NOTE: GCWR is provided on your vehicle or in vehicle manual. Vehicle Towing Capacity — Refer to your vehicle owner’s manual for listed trailer towing capacity. — Trailer towing capacity should equal GCWR (gross combined weight rating) minus vehicle weight, cargo weight, people weight and (vehicle) fluids weight. — Check axle load rating. Wire the plug receptacle to your vehicle as shown below. Note: The wire colors used on the jet running lights are also indicated in Fig. 8-1 for re-wiring to a different plug design. — Always use trailer lights. Fig. 8-1 Page 8 Towing Instructions (cont.) Towing 1. Check that the ball Load Rating is the same or greater than the coupler Load Rating. 2. Check that the ball size is the same as the coupler. 3. Loosen loop nut until spring pushes lip down far enough to insert trailer hitch ball. 4. Position hitch coupler above trailer hitch ball. 5. Lower trailer tongue until ball rests in ball socket.. 6. Tighten loop nut to pull lip up to ball. While tightening loop nut feel under the coupler to make sure square bolt head is up in the square lip cavity is under the ball head. Jiggle coupler up and down while tightening to make sure it is snugly seated on ball. 7. Lift coupler upwards to test that it will not separate from ball. Breakaway Cable Standard Coupler uses 2-5/16” ball CAUTION: Hand-Tighten coupler snug on ball. Do not use a wrench or bar to tighten coupler. Over tightening strains and wears bolt and nut threads, and may cause coupler to seize on the ball and turn on its own nut thus loosening the ball on right turns. 9. Connect breakaway cable solidly to bumper or frame of tow vehicle as near to center as possible. The cable must hang clear of trailer tongue and be long enough to permit short radius turns without pulling breakaway cable forward. Safety Chains Make sure breakaway cable is in the released position. CAUTION: Do not use breakaway cable as a parking brake. 8. Fig. 10-1 Breakaway Cable NOTE: Check location of breakaway cable periodically during each trip. Accidental application will cause brakes to drag and heat up, causing failure. 10. Fig. 10-2 Cross safety chains under tongue and securely attach to bumper or frame of tow vehicle. CAUTION: Always use Safety chains. Chains hold trailer if connection fails. 11. Fully retract hitch jack and remove caster wheel. This will provide adequate ground clearance for transport. 12. Return high pressure reel to towing position, engage the transit lock, and place the hydraulic control lever in the neutral position. 13. You are now ready to tow your trailer. CAUTION: Avoid sharp turns. This could bend, create extreme stress or fracture either the actuator or trailer tongue. Page 9 Towing Instructions (cont.) Cast Steel Couplers No Wrench or Bar Needed to Tighten Nut Down Snug Lip fits up in between body ledges Loop Nut Coupler Body Assembled Coupler with Ball in Place Fig. 10-1 2-5/16” Standard Ball Spring Lip (Ball Clamp) fits up in between body ledges Tension washer (Loop Nut may jam without washer) Fig. 10-2 Bolt (Square head and special length Thread) Parts Function. There is a definite safety purpose for each part. Install ALL parts as shown. The body and parts shown comprise a positive locking device. The square bolt head cannot turn in the lip (ball clamp), the loop nut must turn uphill against gravity and ratchet up and down over the ribs around the bolt hole in order to loosen. Both the washer and the spring exert pressure down, joining the ribs and notches securely. A safety chain may be passed through the loop nut handle for added safety. All these features prevent loosening. Do not ignore them. DO NOT substitute regular nuts or other loop nuts. DO NOT use hex head bolts in place of square head bolt. DO NOT leave out washer or spring. Check coupler to make sure the lip and all parts are in place correctly before using or renting. Fig. 10-3 Optional - P/N 79853700 2 1/2” ID Pintle Ring Page 10 Pump and Pressure System The pump and relief valve are the heart of your jet. They have been specially designed for use with cold water (140°F max.) for pipe jetting but can provide useful water flow for many other cleaning jobs using the optional wash down gun and special attachments. The positive displacement pump (each crankshaft revolution has to move a certain amount of water) uses 3 plungers (similar to pistons in an engine) to create water flow. Pressure is not created until the pump outlet is restricted with a valve or nozzle. The pump, valving and hoses can support 3000 psi working pressures. The regulator valve acts to direct the water flow to the water tank when the hose reel and gun valves are off or if nozzles provide too much restriction for total flow. Always use clean water to keep the regulator valve operating properly. The hose and nozzle are designed to allow full flow at 3000 psi and the wash down gun operates at 1000 PSI max pressure. If leaks develop in the system between the relief valve and hose reel valve (or gun valve) you will hear intermittent engine surges in bypass as the bypass pressure gradually drops and is built up again by the pump. Tighten or otherwise repair the leaks for smooth running. Always stop engine and release pressure before any plumbing changes or repairs. Fig. 11-1 Because of the inherent hazards with high pressure, use only Spartan high pressure hoses and components when repairing your machine. If the nozzles become worn or if the gun is used with the jet hose, the regulator valve allows the same total flow but at lower pressure because the restriction is lower. To maintain desired PSI - replace nozzles. If nozzles become plugged, the regulator valve will direct some of the flow back to the water tank while providing pressures over 3000 psi. If these pressures are seen with normal engine speed check and clean the nozzles. When using optional lengths of 1/4” hose (>75’) the operating pressure can also be over 3000 psi at full gpm. Reducing engines rpm will produce lower pressures to prevent regulator valve from bypassing off and on. Clean water filter daily. A clogged filter will cause pump to run dry and can cause expensive damage to pump. Page 11 Filter High Pressure Water Jetting High pressure water jetting is the utilization of high pressure water combined with sufficient water flow to remove debris in drain/sewer pipes. High pressure water jetting can also be used to remove debris on surfaces. A high pressure water jet consists of a pump, a motor or engine, a hose reel, a given length of hose and a various assortment of nozzles. A pipe is cleaned with a high pressure water jet by directing water pressure and flow through a nozzle. Controlled water pressure and flow propels a water jet through the sewer pipe allowing it to remove and wash away the obstruction. (See Fig. 12-1.) Ideally, a sewer pipe is cleaned from the lower end of the pipe and the hose propels itself to the higher end of the pipe. By slowly withdrawing the jet hose, the water pressure and flow cleans the line most effectively. When it is impossible to clean from the lower end of the pipe, the pipe must be water jetted several times to remove all the debris. A skilled operator can effectively clean a drain/sewer regardless of the obstacles in his way. How A Jet Works (Penetrating Nozzle) 79824700 Nozzle to be used for initial penetration of sewer pipe. (Closed Nozzle) 79824600 Nozzle to be used for thorough cleaning of sewer pipe. Fig. 12-1 Water Tank Filling Fill the water tank from a clean water source. Always flush rust out of hydrants before connecting fill hose. Trailer jet unit can be filled using 5/8” garden hose on fill reel or using fire hydrant fill. Fire hydrant fill requires fire hose with 2” cam lock female quick coupler. Important Note: (If the next 4 items are not followed, cavitation of the pump could occur and reduce operating efficiency and severely damage the pump.) — Use water temperatures under 140°F. — Ensure that water strainer is clean (check daily or as needed). — Make sure the strainer valve (between the tank and the pump) is fully open during operations. This valve stops tank flow to allow strainer service. — The pump drain valve must be closed. It must not drip when engine is off and strainer valve is open. Page 12 Engine Operating Procedure Kubota V3300-TE Diesel Engine is equipped with an electronic governor for speed control and engine regulation. Engine speeds are preset at the factory and should require no adjustment in the field. The Spartan Warrior is equipped with an automatic clutch engagement system. The water control switch will automatically trigger the clutch to engage when “On” or disengage clutch and return engine to Idle when “Off.” The Warrior is also equipped with a low water safety gauge, which indicates critical water levels in the supply tanks. When tripped, the low water safety switch will disengage the clutch and return the engine to Idle. Start Up — Check water tank level. This water jet is equipped with a Low Water Shut-Off switch that will prevent the clutch from engaging at low water levels. — Check fuel level. Note: Also Check engine and pump oil levels per manufacturer specifications (attached). — Turn fuel valve ON. — Turn pressure selector switch to 1000 psi / LO setting. — Turn key to “Preheating (Glow Plug)” position until Glow Lamp turns off on instrument panel. Note: No preheating required if ambient temperature is above 50° F or when the engine is warmed up. — Turn key switch to crank position and start engine — Allow engine to warm up on 1000 psi position for several minutes. Note: Engine will operate at a preset slow idle for 30 seconds after starting. Pressure selector switch will not operate during the preset 30 second slow idle. Note: If the low water switch is tripped, the clutch will disengage and the engine will run at Idle. To protect the Warrior’s systems, the water control will not operate during the safety Idle mode. Engine Shut-Down — Turn pressure selector switch to 1000 psi / LO setting — Turn Water Control Switch to “OFF.” — Turn “OFF” key switch — Turn the fuel valve OFF. Setting up for Operation Always locate the jet in the driest and safest place possible. Avoid high traffic areas and use flashers and safety cones. Position the jet so that hose can be pulled directly off of the reel for use. Remember that jetting is most effective when you jet against the water flow. See Fig.13-1 for the recommended positioning of the jet for best visibility during manhole work. Note that loose hose and damaging corners are minimized when the jet is parked as shown. (See pages 12 and 13 for instructions on using upper and lower manhole guides.) When operating upon unlevel ground, position trailer with the hitch (tank suction) end at the downhill side. For non-manhole use, allow extra space for handling the hose before it is wound back on the reel or run the hose directly to the pipe inlet using extra hose guards to protect the hose from cutting when going around corners. Warning: Do not unhitch or operate trailer jet unhitched upon unlevel ground. When unhitching the machine from towing vehicle, always follow these steps: — Disconnect ball hitch by raising lever and jacking hitch up. Disconnect safety chains and light cord before driving away. Page 13 Fig. 13-1 Hydraulic Rewind Operating Instructions The hydraulic rewind control valve can be used to feed out high pressure hose and rewind hose back to the reel. The control lever should be left in its neutral position while transporting trailer jet unit. The high pressure hose reel is hydraulically locked from rotating when in neutral (position between hose in and out). Move hydraulic control back to rewind hose on reel and forward to power feed hose off reel. Move hydraulic control completely forward until spool goes into detent; reel will now free spin. Fig. 14-1 Operating Instructions Operation: Move hydraulic control lever completely forward into “Free Spin” position. Select and install nozzle, hose guards(s) and roller guides. Always insert sewer hose several feet into pipe opening before actuating water control switch. Never stand in front of pipe opening when nozzle is near pipe opening. As described in “Setup Section,” work upstream whenever possible. You are ready to start pipe cleaning operations after tank filling and engine starting procedures are followed. Note: At this time, put on safety goggles to prevent eye injury from flying water and debris. Page 14 Operating Instructions (cont.) Turn H.P. water control switch to “ON” and choose operating pressure desired. As the nozzle pulls hose into the pipe, the hose reel can free spin or hydraulically feed hose out. Untwist hose kinks as necessary before they enter the pipe. Since it is impossible to know exactly what the nozzle “sees” as it advances in a pipe, always proceed slowly and cautiously. Pull back 1-2 feet for every 4-5 feet of progress to make sure that the hose is not burying itself or tying itself up in an open cavity or larger pipe. Continue working up the line while watching and feeling for speed changes as the nozzle makes its way into a blockage. When working over a manhole, you often will see dirty water, chunks of grease or debris flow past as the nozzle penetrates a blockage. When backed up water flows, the line is probably open. Continue working up the line to open restrictions as desired. Now pull the “working” nozzle back slowly to re-clean and scour the pipe walls. When working through heavy and long blockages you may have to flush debris back to machine every few ft. Repeat until water runs clean from the pipe. Note: The automatic clutch engagement system will cause a momentary delay following the activation of the water control switch. Warning: Do not operate unit in 3000 psi setting with reel supply valve closed or clutch disengaged. When finished, turn water control switch to “OFF” before removing nozzle from pipe. Hint: Use 15’ leader hose as indicator of how close the nozzle is to the pipe opening. Wind hose back onto reel, remove hose guard and install hose end and nozzle in holder. Secure hose end to recirculation valve located on the right side of the H.P. reel. Store all parts in tool box compartment. Follow engine shut down procedure. Reminder: Engine key switch must be off to prevent battery drain while engine is shut down. Reverse setup instructions, drain tank and disconnect fill hose. Replace manhole cover or pipe caps and clean up machine and job site before leaving. Operating Hints: The following techniques can be tried if the going gets slow. — Grab the hose into an “S” shape and twist the hose to help it get around corners and off of pipe edges. (See Fig. 18-1 & 18-2.) — Turn water valve off and pull hose back out of line. Look for traces of clay or other material to determine if nozzle is burying itself outside of pipe. — Try different nozzle or different pipe openings. — Walk to nearby buildings and manholes and listen for water sound to determine if hose is going where it should. The hose may tie itself up in a manhole and need help going into the next pipe. Use a pole or pipe to guide hose so entering the manhole can be avoided. Page 15 Pipe Jetting Procedure Equipment: Although the Hi-Flow Ultimate Warrior is capable of various high pressure cleaning jobs, jetting pipes of 4” - 36” is typically the major work required of the jet. The hose reel is designed for outdoor applications. An optional portable hose reel and 1/4” drain hose can be purchased for indoor applications, remote applications, and for lines smaller than 6”. The sewer hose should always be replaced when the reinforcement cord can be seen due to a worn cover. The Warrior nozzles are designed to match the pressure and flow performance of your jet. They are key to efficient operation because they convert all of the engine and pump power to water speed for hose pull and for cleaning impact. Nozzles 79966100 and 79966000 are standard equipment. See parts book for part numbers to order additional nozzles and nozzle holders. Nozzle holes will wear after continuous use. If the system pressure drops, try a new nozzle to check for wear. Check for nozzle plugging occasionally by removing the nozzle from the hose and holding up to the light. Clean by inserting small diameter wire if necessary. Plugged nozzles will cause poor hose pull even though the gauge pressure will show higher. When Obstructions Are Encountered — When obstruction or corners are encountered it may be necessary to manually rotate the hose (See Fig. 18-1) to enable feed through that area. The rotation will cause the jetting nozzle to jump over or around those areas. When it becomes necessary to manually rotate the hose to clear obstructions, any rotations in one direction must be followed by an equal number in the opposite direction to prevent kinks from building in the hose. Fig. 16-1 Fig. 16-2 — At times, it will be necessary to move the hose slightly in and out of the drain line to assist the jetting nozzle in clearing stubborn clogs, obstructions, or tight corners (See Fig. 18-2). Page 16 Pulsation To activate the pulsation feature, turn toggle switch labeled PULSE to the ON position. To deactivate pulsation, turn toggle switch to OFF position. Electric Pulsator Electric Pulsation Pulsation Fig. 17-1 Fig. 17-2 Note: Operating pressure will decrease and fluctuate when pulsation is activated. See below (Fig. 19-3) for approximate pressures. Pressure Selector Switch Setting 1000 psi 2000 psi 3000 psi Pulsation Pressure (PSI) 200 - 700 800 - 1600 1100 - 1700 Fig. 17-3 Wash Down Gun Note: To use wash-down gun do the following: 1 2 3 Turn water control switch “OFF”. Connect wash-down gun to end of 500’ HP hose. Select 1000 psi / LO setting. Turn water control switch “ON”. The wash down gun is used to control the spray lance. The lance is attached by pulling back on the ring of the guns quick connect fitting. Insert adapter nipple of lance (or 1/4” hose) until ring can slide back to original position. The lance is equipped with an adjustable spray nozzle for general use. The wash down gun can also be used with the optional portable hose reel with 1/4” drain hose. Caution: HOLD HAND GUN / WASH WAND WITH TWO HANDS AT ALL TIMES. Back pressure buildup on the wash wand / hand gun requires two hands firmly gripping the wand when the trigger is initially pulled. Caution: Under no circumstances should you ever operate the wash down gun in the direction of any other person(s). To do so may cause serious damage to eyes or other bodily tissue and may even cause death! Page 17 Cold Weather Protection The Warrior comes equipped with versatile anti-freeze system that allows the user to choose between different levels of protection. Antifreeze Recirculation: Full Winterization The pump and all hoses charged with anti-freeze solution. Antifreeze is conserved by re-circulating back to anti-freeze tank. Water Recirculation: Temporary Freeze Resistance Water is re-circulated through hoses and returned to main water tank. Water Supply Valve Full Winterization Procedure 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Fig. 18-1 Drain Valve Fill antifreeze tank with Propylene Glycol Antifreeze and water mixture. (Follow manufacturer’s recommendation regarding ratio of water to antifreeze.) Close water supply valve at pump and open antifreeze supply valve. Remove nozzle or handgun from H.P. hose reel. Move the selector valves to “Recycle Direct to Tank” and “Antifreeze Re-circulate”. Confirm the H.P. hose is secured before turning the water on. Follow engine start up procedures. Turn pressure selector switch to lowest (1000 psi) setting. Turn water control switch to “On.” Caution: Running the engine faster than the lowest setting during recirculation will result in excessive pressure which could cause serious damage and personal injury. Allow water to discharge from H.P. hose. Once the water has visibly changed to antifreeze, turn the water control switch to “Off.” Optional Winterization: Portable Reel a. The portable reel can be omitted from the full winterization procedure if it has already been filled with antifreeze, or if it is known to have no water in it. If the portable reel winterization is omitted, skip to step 11. b. Connect the Portable Connection Hose (79951100) to the H.P. Hose. c. Connect the Portable Connection Hose to the portable reel quick coupling. d. Remove nozzle and handgun from the Antifreeze portable reel. Supply Valve Fig. 18-2 e. Turn pressure selector switch to lowest (1000 psi) setting. Turn water control switch to “On”. Caution: Running the engine faster than the lowest setting during recirculation will result in excessive pressure which could cause serious damage and personal injury. f. Once the portable reel discharges antifeeze, turn water control switch to “Off”. g. Disconnect Portable Connection Hose from the H.P. Hose Reel. Connect the Handgun to the 500 foot H.P. hose. Turn pressure selector switch to lowest setting (1000 psi) Turn water control switch to “On” and leave on for10 seconds. Turn water control switch to “Off” position. With a firm grasp of the handgun. press handgun trigger to release pressure. Caution: HOLD HAND GUN WITH TWO HANDS AND ALWAYS POINT HANDGUN AWAY FROM ANY OTHER PERSON(S). Disconnect handgun from H.P. hose. Connect the 500 foot H.P. hose to the recirculation connection fitting located on the H.P. reel. Optional Winterization: Fill Reel Page 18 Cold Weather Protection 12. 13. 14. 15. 16. a. The fill reel can be omitted from the full winterization procedure if it has already been filled with antifreeze, or if it is known to have no water in it. If the fill reel Selector Valves winterization is omitted, skip to step 11. b. Connect the fill hose to the re-circulation fitting. Open the fill hose valve. Note: The fill hose valve located below the recirculation valves must be open during this operation. c. Move the selector valves to “Recycle Thru Fill Reel” and “Antifreeze Re-circulate”. Fill Reel Turn pressure selector switch to lowest (1000 psi) setting. Valve Turn on water by changing water control switch to “On.” Caution: Running the engine faster than the lowest setting during recirculation will result in excessive pressure which could cause serious damage and personal injury. Fig. 19-1 Re-circulate anti-freeze solution for as long as desired. Turn “Off” water control switch and stop engine. Open drain valve and water supply valve at pump to empty tank completely. Close drain and antifreeze valves. Open Hydrant fill valve to confirm that no water is trapped. Water Recirculation Procedure To provide temporary freezing resistance, plain water can be set to recirculate continuously. The moving water will resist freezing, but only provided the pump continues to run. This condition can only be maintained for a limited time. It must be noted that water recirculation will not prevent freezing in very low temperature conditions. When operating in below freezing weather, monitor the water condition closely to avoid costly damage to the system. It also must be noted that the recirculation plumbing itself needs to be protected from freezing by draining or antifreeze treatment. 1. 2. 3. 4. 5. 6. Hydrant Fill Fig. 19-2 Remove nozzle or handgun from H.P. hose reel. Connect the 500 foot H.P. hose to the recirculation connection fitting located on the H.P. reel. If re-circulating thru fill reel, connect fill hose to recirculation fitting and change selector valve to “Recycle Thru Fill Reel.” If the fill reel is omitted, selector valve should be set to “Recycle Direct to Tank.” Set selector valve to “Water Re-circulate.” Follow engine start up procedures. Turn pressure selector switch to lowest (1000 psi) setting. Turn on water by changing water control switch to “On.” Caution: Running the engine faster than the lowest setting during recirculation will result in excessive pressure which could cause serious damage and personal injury. Re-circulate water for as long as desired. Turn water control switch to “Off” and stop engine. Engine Speed Recirculation Connection Water Control Switch Fig. 19-4 Fig. 19-3 Page 19 Lubrication and Maintenance Note: Use a #2 consistency lithium base grease formulated from a high quality mineral oil with rust and oxidation inhibitors. c. a. b. Engine PTO and clutch. a. Grease main bearings every 100 hours. b. Grease pilot bearing every 100 hours ( 1 or 2 pumps) c. Grease PTO cross shaft every 500 hours d. Open cover and grease release bearing every 8-10 hours (1 or 2 pumps) Fig. 20-1 High pressure reel Oil chain every 200 hours (SAE 30 or heavier oil.) Chain Fig. 20-2 Filter Change hydraulic oil and filter every 500 hours. Use Amoco - Rykon AW oil 46. Hydraulic Oil Filter: Spartan P/N 79807100. Fill Fig. 20-3 Page 20 d. Lubrication and Maintenance (cont.) Fill Change pump oil after first 50 hours and every 500 hours thereafter. Use SAE 80 gear oil. Fig. 21-1 Inlet Filter. Clean daily. Filter Cup Fig. 21-2 Page 21 Lubrication and Maintenance (cont.) Main Fuel Filter Oil Fill Brake Adjusting Slot Oil Filter Oil Level Gauge Fig. 22-1 Fig. 22-2 Adjust brakes after the first 200 miles and at 3000 miles intervals thereafter, or as use and performance requires. For brake adjustment procedure refer to the Dexter Axle service manual Follow maintenance instructions in Kubota Diesel Engine Operator’s Manual. Note: Use Diesel STA-BIL Fuel Stabilizer during storage and during normal use to prevent fuel deterioration. Also will keep fuel system clean. - Filters available at local Kubota Dealer: Engine Oil Filter 1C010-32430 Main Fuel Filter 16631-43560 Fuel Pre-Filter 12581-43012 - Available at local Enginaire distributor: Outer Air Filter 3.75-E1-828889 Inner Air Filter 3.75-E2-829333 Breakaway Switch Fig. 22-3 Grease wheel bearings every 12000 miles or 12 months. Follow greasing procedure in the Dexter Axle Service Manual. Fig. 22-4 For additional maintenance information review the following section in the Dexter Axle Service Manual: • Braking System - Electric • Hubs/Drums/Bearings • Wheels and Tires Page 22 Lubrication and Maintenance (cont.) Check clutch engagement pressure: Clutch Lever Check clutch engagement force after the first 4 hours of engine operation. Then check again after another 4 hours. Then 8 hours after that. After the initial breakin period, check clutch engagement force periodically. Actuator Bolt a. With clutch in the disengaged “OFF” position, remove actuator bolt from front clutch lever. See Fig. 23-1. b. Using a torque wrench, 1-1/2” socket, and an extension (if needed), attach socket to clutch lever hex nut. See Fig. 23-2. c. Check the engagement torque. The correct clutch engagement force is between 101-108 ft.lbs. If the engagement force has decreased 10% (91 ft.-lbs.) to 15% (86 ft.-lbs.), adjustment to the clutch needs to be made (refer to clutch adjustment procedure on page 24). If the clutch is properly adjusted, reattach clutch linkage by reversing step a. Fig. 23-1 Clutch Lever Torque Wrench 1-1/2” Socket & Extension Fig. 23-2 Page 23 Lubrication and Maintenance (cont.) Clutch Adjustment Procedure: Water Supply Lever PTO NamePlate Fig. 24-1 Lock Bolt & Adjusting Lock a. Remove PTO nameplate and rotate the shaft until you can access the adjusting ring lock. b. Remove the lock bolt and adjustment lock. c. Rotate the adjusting ring counter-clockwise to tighten the clutch. Rotating the adjusting ring clockwise will loosen the clutch. Adjust to obtain the proper handle engagement force. d. Recheck the engagement force using the torque wrench. Once clutch is properly adjusted, reposition the locking finger in a slot and tighten the adjustment lock. e . Secure PTO nameplate onto clutch. Adjusting Ring Fig. 24-2 Page 24 Pump System Malfunction Chart MALFUNCTION The Pressure and/ or the Delivery Drops REMEDY CAUSE Unloader Replace packing seals Replace spring Tighten or Replace belt Replace nozzle Clean valve assembly Clean strainer Repair/ Replace hose Clean, Reset, Replace worn parts Check suction lines on inlet of pump for restrictions Check for proper operation Water in crankcase High humidity Worn seals Reduce oil change interval Replace seals Noisy Operation Worn bearings Replace bearings, Refill crankcase oil with recommended lubricant Check inlet lines for restrictions and/ or proper sizing Worn packing seals Broken valve spring Belt slippage Worn or Damaged nozzle Fouled discharge valve Fouled inlet strainer Worn or Damaged hose Worn or Plugged relief valve on pump Cavitation Cavitation Rough/ Pulsating Operation with Pressure Drop Worn packing Inlet restriction Accumulator pressure Unloader Cavitation Replace packing Check system for stoppage, air leaks, correctly sized inlet plumbing to pump Recharge/ Replace accumulator Check for proper operation Check inlet l ines for restrictions and/ or proper size Pulsator doesn't work Wireless remote switch on panel is in the "ON" position Turn switch to "OFF" position Excessive Leakage Worn plungers Worn packing/ seals Excessive vacuum Cracked plungers Inlet pressure too high Replace plungers Adjust or Replace packing seals Reduce suction vacuum Replace plungers Reduce inlet pressure No water flow Wireless remote switch on panel is in the "ON" position Turn switch to "OFF" position Page 25 Hi-Flow Ultimate Warrior Control Panel Key Switch. RPM Glow Plug Light 12 VDC Outlet Hour Meter Water Tank Antifreeze Tank Fig. 26-1 Strobe Fuel Pulsation Voltmeter Water Control Switch Engine Temp Fig. 26-2 Page 26 Oil Pressure Engine Speed Selector Hi-Flow Ultimate Warrior Control Panel Optional: Wireless Remote Control If the Warrior is equipped with Wireless Remote Contol Activation Note: If this switch is in the “ON” position, all on-board controls are disabled (except ignition switch and beacon). Activate Remote control Fig. 27-1 Handheld Remote Control Transmitter Fig. 27-2 Page 27 Troubleshooting SYMPTOMS CAUSES Fuel Tank Empty Fuel Valve Shut Off Engine Will Not Run Low Pressure or Flow Engine Speed Won't Change Erratic Flowar Pressure Noisy Pump REMEDIES Fill Fuel Tank and Bleed Air from Fuel System (See Engine Operator's Manual) Turn Fuel Valve ON Water Level Low Fill Water Tank or Check Low Water Shut - Down Oil Pressure Low Check Oil Line to Rear of Unit, Replace as Required Coolant Temperature High Check Coolant Level and Thermostat, Refill and Replace as Required Clogged Inlet Filter Clean Inlet Filter Element Jetting Nozzle Worn Check for Wear of Orifice in Jetting Nozzle, Replace Nozzle if Required, Use only Approved Jetting Nozzle. Wireless Control Switch is on Turn Switch off Worn or Dirty Pump Valves Clean or Replace Worn or Dirty Regulator Parts Clean or Replace Worn Jetting Nozzle Replace Jetting Nozzle Low Oil Level Add or Replace Oil Worn or Dirty Valves Clean or Replace Bad Bearings Inspect and Replace as Required Page 28 Electric Braking Systems Troubleshooting S ym p to m N o Bra ke s W e a k B ra ke s L o ckin g B ra ke s C a u se s O pen C irc uits F ind & Correc t S evere Underadjus tm ents A djus t B rak es F aulty Controller Tes t & Correc t S hort C irc uits F ind & Correc t G reas e or O il on M agnets or Linings C lean or R eplac e C orroded Connec tions C lean & C orrec t Caus e of C orros ion W orn Linings or M agnets R eplac e S c ored or G rooved B rak e D rum s M ac hine or R eplac e Im proper S y nc hroniz ation C orrec t U nderadjus tm ent A djus t B rak es G laz ed Linings R eburnis h or Replac e O verloaded Trailer C orrec t U nderadjus tm ent A djus t B rak es Im proper S y nc hroniz ation C orrec t F aulty Controller Tes t & Correc t Loos e, B ent or B rok en B rak e C om ponents O ut -of-Round B rak e D rum s Ins uffic ient W heel Load B reak away P rot ec t ion A c tivated In te rm itte n t B ra ke s R e m e d ie s R eplac e C om ponents M ac hine or R eplac e A djus t S y s tem R es is tor and S y nc hroniz e R es et B reak away P rotec tion F aulty Controller Tes t & Correc t B rok en W ires R epair or R eplac e Loos e Connec tions F ind & Repair F aulty G round F ind & Repair Page 29 Electric Braking Systems (cont.) Troubleshooting Symptom Brakes Pull to One Side Harsh Brakes Noisy Brakes Surging Brakes Dragging Brakes Causes Wrong Magnet Led W ire Color Remedies Find & Correct Incorrect Adjustment Adjust Brakes Grease or Oil on Magnets or Linings Clean or Replace Broken W ires Find & Repair Bad Connections Find & Repair Underadjustment Adjust Brakes Improper Controller Change Faulty Controller Test & Correct Improper Synchronization Correct Underadjustment Test & Correct Lack of Lubrication Lubricate Incorrect Brake Components Broken Brake Components Out-of-Round or Cracked Brake Drums Correct Replace Components Machine or Replace Faulty Controller Test & Correct Grease or Oil on Magnets or Linings Clean or Replace Overadjustments Re-adjust Out-of-Round or Cracked Brake Drums Incorrect Brake Components Loose, Bent or Broken Brake Components Machine or Replace Replace Replace Components Faulty Breakaway Switch Repair or Replace Loose W heel Bearing Adjustment Adjust Bent Spindle Replace Axle Page 30 How To Use Parts & Accessories Manual Spartan Tool will supply all parts or accessories you require as quickly as possible. In order to do so, we must have information from you, including machine serial number and part numbers. Please record the serial number of your machine in the space provided below: Spartan Warrior Serial No. _______________________ Using the part numbers, please contact your Spartan Territory Manager, the home office at (800) 435-3866, or online at www.spartantool.com. Thank You. Special Note We at Spartan wish to help you maintain the safety, performance and appearance of your new Spartan Warrior. This manual is provided to aid in ordering replacement parts. It is not intended to be used as an operating guide. See your operating manual for important safety precautions, operating instructions and troubleshooting aids. Though much of your Warrior Jet is user serviceable, trained professional mechanics may be needed with pump, plumbing, engine, lights, hitch and axle experience. — Contact Spartan Tool for all engine repair or troubleshooting. — Contact Spartan Tool or consult the Pump Repair Manual for all pump repair or troubleshooting. — All plumbing repairs should use Spartan parts. The high pressure plumbing has been designed for pressures greater than 4000 PSI. Substituting parts is dangerous and voids Spartan warranties. Use standard pipe sealing compound or “Teflon”® tape to seal all joints except swivel joints and hose nozzles (o-rings, seals, and tapered seat designs do not require sealing materials Page 31 Hi-Flow Ultimate Warrior Final Assembly 79940000 Item Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 4 8 45 2 6 5 22 1 3 16 4 6 3 4 1 2 12 4 62 16 6 4 16 8 20 1 1 16 1 4 15 2 1 1 1 2 21 1 50 1 1 1 2 2 6 16 PART # 00113500 00113600 00113700 00114800 00115100 00117500 00162700 00163300 00165300 00165400 00165600 00165800 01588200 01733900 02761500 02820700 02821200 02824000 02825100 02899200 03004100 03312001 03366300 03850100 04723100 44121300 44298100 521012-04 542106-04 71705500 72715100 73807400 73811700 73817300 73817400 73817900 73821200 73826800 73826900 73827600 73827800 73829700 73830200 73830400 73831200 75822400 DESCRIPTION SCREW, HEX HD CAP 1/ 4-20 X 1/ 2 SCREW, HEX HD CAP 1/ 4-20 X 5/ 8 SCREW, HEX HD CAP 1/ 4-20 X 3/ 4 SCREW, HEX HD CAP 5/ 16-18 X 1 SCREW, HX HD CAP 5/ 16-18 X 1" SCREW, HX HD CAP 3/ 8-16 X 4 WASHER, FLAT 3/ 8 WASHER, 2" OD X 13/ 16" ID X 5/ 32 SPLIT LOCKWASHER#10 ZINCPLTD WASHER, LOCK SPLIT 1/ 4 KANTLINK LOCKWASHER WASHER, LOCK SPLIT 3/ 8 WASHER, FLAT #10 SAEZINCPLTD NUT, HEX 3/ 8-16 BUMPERRECESSED BLACK RUBBER NUT, HEAVYHEX JAM 5/ 16-18 NUT, NYLOCK JAM 1/ 4-20 PHILLIPSFILLISTERHD MACH. WASHER, FLAT 1/ 4 USS WASHER, FLAT 5/ 16 USS NUT, STD HEX 5/ 16-18 NUT KEP #8-32 ZINCPLTD WASHER, FLAT 3/ 8 SAE NUT, HEX KEP 10-32 SCREW, MACHINE10-32 X 5/ 8" GROMMET KEYCHAIN, SPARTAN LOGO SCREW, HEX HD 1/ 4-20 X 1-1/ 2 COUPLING, 1/ 2 STEEL SCREW, HX HD 1/ 4-20 X 1-1/ 4 CLAMP, HOSE1-1/ 8 I.D. RUBBR GROMMET, 7/ 8" ID NIPPLE, REDUCER3/ 4 X 1/ 2 HP WASH DOWN ACCESSORYPCKG DECAL, MADEIN THEUSA HOLDER, PLASTICMANUAL NUT, NYLON LOCKING 1/ 4-20 WIRE-LOOM, BLCK 3/ 8" WASHER, FLAT 1/ 2 USSHS BUSHING, REDUCER(MODIFIED) BULKHEAD FITTINGW/ PVCCAP U-BOLT, SQRE2" X 2-5/ 8" (3/ 8-16) BEARING, FLANGEBRNZ 7/ 8 SHAFT WASHER, FLAT 7/ 8 SAE CLAMP, HOSE1-1/ 16" - 2" #24 SPACER, NYLON 1/ 2 DIA X 1/ 2 Item Qty 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 Page 32 1 3 1 1 1 8 80 2 1 10 1 6 6 2 12 6 9 5 21 38 6 8 4 2 1 35 2 1 6.7 1 1 4 1 2 1 1 1 1 1 3 1 2 1 1 1 1 PART # DESCRIPTION 75823200 SWITCH, LIQUID LEVEL 75824700 HOSEBARB, 1-1/ 2 MPT X 1-1/ 4 75844500 ASSEMBLY, JACK-SIDEWIND 75845700 CASTER, JACK 75851406 STRIKERPLATE, TRANSIT LOCK 75852401 WASHER, .281 ID X 1.5 OD BLACK 75852700 WASHER, 3/ 8" ID USSGRD 9 75860900 SOLDIERENCLOSUREAEROLATCH 75867300 ELBOW, NOZZLEBODY- 5/ 8 77710200 HOSE1-1/ 4 X 4 SPIRAL SM 77724800 ADAPTER, SWIVEL 3/ 8" X 1/ 2" 77736900 CLAMP, HOSE1-9/ 16 - 2-1/ 2 #32 77738100 SCREW, CAP HX HD 3/ 8-16 X 1 77742600 BUSHING, REDUCER3/ 4 X 1/ 2 77743400 WASHER, LOCK SPLIT 5/ 16 77746000 CLAMP, HOSE7/ 32 - 5/ 8 S.S. 77748000 NUT, STOVERLOCK 3/ 8-16 UNC 77748200 HOSE1-1/ 2 ID X 4 SPIRAL 77751600 DISCONNECT, FEMALEBULLET 77751700 DISCONNECT, MALEBULLET 77754900 WASHER, ROBO 1/ 2" 77755000 WASHER, ROBO 3/ 8" 77760000 SCREW HEX HD CAP 3/ 8-16 X 1-1/ 2 77765803 GROMMET, GASTANK 77765804 VALVE, GASTANK 77765900 TIE, NYLON CABLE3/ 16 X 15.5" 77767600 CLAMP, HOSE11/ 16 - 1-1/ 4 S.S. 77770800 NIPPLE, HEX 1/ 2 NPT 77785900 HOSE, PUSH LOK 3/ 4 77799800 SPRAYGUN ASSEMBLY 77800600 ASSY, HOSEGUARD 2" 79804200 TIRE,225/ 75R15 79811200 NIPPLECLOSE4", 1-1/ 2 X 1-1/ 2 P 79811400 ELBOW, 90 DEG STREET 1-1/ 2 POLY 79811500 VALVE, BALL 1-1/ 4FNPT X 1-1/ 4F 79811800 NIPPLE1-1/ 2" X 1-1/ 2" MPT POLYP 79812000 HOSEBARB, 1-1/ 4 POLY 79812100 BARB, HOSE1-1/ 2 X 1-1/ 2 79818600 HOSEBARB, 1-1/ 4 POLY 79821200 EL 1-1/ 2 MPT X 1-1/ 2 HOSEBARB 79821500 ADAPTER, 3/ 4 MNPT/ - 12 JIC 79824400 SCREW, SOCK CAP 1/ 4-20 X 1.5 79824900 HOSE, LEADER1/ 2" X 15' RED 79827000 ELBOW, 90 DEG STREET 3/ 4 79827100 CLAMP, MUFFLER2" 79827200 GARDEN HOSEADPT. 3/ 4 X 1/ 2 Hi-Flow Ultimate Warrior Final Assembly 79940000 Item Qty 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 1 14 1 13 14 4 20 7 1 2 1 1 1 1 2 1 1 2 2 8 1 11 32 20 34 74 32 12 8 16 4 2 1 2 2 1 3 2 6 2 1 1 1 1 1 2 PART # 79829300 79842200 79849600 79849800 79849900 79854500 79860000 79868500 79873500 79900200 79900300 79900600 79901800 79904200 79904478 79904930 79906900 79908100 79909900 79912300 79920100 79920140 79920141 79920145 79920150 79920151 79920152 79920153 79920160 79920161 79920170 79920330 79920500 79920625 79920630 79920700 79920720 79920770 79920975 79921300 79921330 79921400 79921500 79921510 79921520 79921610 DESCRIPTION CLAMP, MUFFLER2-1/ 2 ZINCPL CLAMP, HOSE1/ 2 TAPE, SELF FUSING1-1/ 2" HOSEFUEL 5/ 16 ID HOSEFUEL 3/ 16 ID NUT, HEX LOCK 5/ 8-11 CLAMP, VINYL COATED 5/ 8" ID CLAMP, HOSE2" VINYL COATED ASSY, HOSEANTI-TURN AROUND AXLE, SINGLEW/ ELECTRICBRAKES CONNECTOR, 7 POLE- TRAILER ASSY, 7 POLEQUICK RELEASE6' WELDMENT, HITCH BREAKAWAYKIT, WITH CHARGER EL 90D 1/ 2NPT-BARB BRASS COUPLING, HEX 1/ 2 NPT STEEL STROBE, BEACON SCREW, HX HD 1/ 4-20 X 3 SCREW, SOCKET HD 3/ 8-16 X 1-3/ 4 SCREW, HEX HD 5/ 16-18 X 4 WELDMENT, FRAME1 OR2 AXLE HEX HD BOLT 1/ 2-13 X 4-1/ 2 GR8 NUT, HX GR8 1/ 2-13 STOVER HEX HD BOLT 1/ 2-13 X 1-1/ 2 GR8 HEX HD BOLT 3/ 8-16 X 1-1/ 2 GR8 HEX NUT, 3/ 8-16 GRADE8 HEX HD BOLT 3/ 8-16 X 3 GR8 HEX HD BOLT 3/ 8-16 X 4-1/ 2 GR8 SCREW, HEX HD GR8 - 5/ 8-18 X 2 WASHER, FLAT 5/ 8 GR8 SCREW, HEX GR8 5/ 8-18 X 5 CLAMP, EXHAUST 2-1/ 2 WELDMENT, REARTRANSFORMER BRACKET, LOWERGASSTRUT SPARTAN LOGO ASSY, REARENCLOSURE BREAKLIGHT, OVAL LAMP ANGLE, REARENCLSFRAMEMNTS SCREW, 1/ 4-20 THRD 5/ 16" SHLDR ASSY, TANK FILL TEE HEAT SHIELD TANK, ANTI-FREEZE(2008) TANK, DIESEL FUEL 2008 REDUCING COUPLING3/ 8 X 1/ 4 PLUG, BRASS1/ 4 NPT HX HD HOSE, 4" LAYFLAT Item Qty 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 Page 33 6 1 1 2 4 8 1 1 2 1 1 1 1 1 1 1 1 1 1 2 3 1 1 1 2 2 1 1 1 2 1 5 8 1 48 2 1 1 2 4 1 2 1 2 2 4 PART # 79921620 79921650 79921660 79921670 79921700 79921710 79921800 79921900 79922000 79922200 79922400 79922500 79922550 79922600 79922710 79922800 79923000 79931100 79931300 79931330 79931360 79931400 79931700 79931800 79936600 79936700 79940100 79940400 79940600 79942000 79942200 79942300 79942400 79942560 79942600 79942700 79942800 79942900 79943000 79943100 79944100 79944200 79944300 79945810 79945830 79945860 DESCRIPTION CLAMP, 4" WORM DRIVE TANK, 150 GAL MODIFIED REAR TANK, 150 GAL WATERWARRIOR TANK, 150 GAL MIDDLEPOSITION BAFFLE-INSERT CLAMP, TANK FILL PIPE WELDMENT, FRONT CROSSBRACE WELDMENT, REARCROSSMEMBER WELDMENT, HEAT SHIELD ASSY-HYD RESERVOIR WELDMENT, REARTANK WELDMENT, CURB SIDEFRONT WELDMENT, STREET SIDEFRONT WELDMENT, REARCURB PLATE, HP REEL SUPPORT BASE WLDMNT, HP REEL CROSSSPPRT WLDMNT, ANGLEBRACEHP REEL WELDMENT, 90 DEG PIV FRAME WELDMENT, PIVOT PIN 90 DEG WELDMENT, PIVOT PIN 180 DEG SCREW, FLT HD 10-32 X 1/ 4" UND BRACKET, ANTI-FREEZEVALVE BRACKET WATERFILTER FILL TEE-ULTIMATEWARRIOR WLDMT, S-SIDEULT-WARAXLE WLDMT, C-SIDEULT-WARAXLE ASSY, WATERSUPPLY/ ANTIFRZ ASSY, FILL REEL 2008 BIGJET BRACKET, TIGERTAIL 2010 WELDMENT, STRETCH FRAME ASSYSTRETCH FRAMEFIBRGLAS PLATE, FIBERGLASSFRAMEMNT BUMPER, VIBRATION DAMPENER LOW REARFBRGLSS-STREET SIDE WASHER, FLAT SAE1/ 2'' - .074 NUT, HEX JAM 1/ 2-20 COVER, BACK FENDERSTRT SIDE COVER, BACK FENDERCURB SIDE WELDMENT, BOLT PAIR WASHER, 17/ 32 ID X 2 OD HOSE, GARDEN 5/ 8 X 100' SENDER, TANK LEVEL (150GAL) SENDER, TANK LEVEL (150GAL) LIGHT, SIDEMARKERRED REFLECTOR, RED SCREW, 8-32x1-1/ 4 FLT HD ZNC Hi-Flow Ultimate Warrior Final Assembly 79940000 Item Qty 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 4 1 1 1 1 1 1 1 1 2 1 2 3 1 1 21 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 PART # DESCRIPTION 79945960 NUT, 10-24 HX JAM NUT - BLCK 79947400 SPRING HANGER- BLACK 79947410 ANGLE, SPRAYGUN HOLSTER 79947640 BRACKET, 7PIN RECEPTICLE 79948060 HOSEASSY, HYD SUCTION WAR 79948075 HOSEASSY, HYD VALVEOUT (ULT) 79948095 HOSEASSY, HYD PUMP ULT 79948130 NIPPLE, 3/ 4 NPT ZNCPLT STEEL 79948700 RECIRCHOSEASSYFILL REEL 79948800 RECIRCHOSEASSYFILL SHUTOFF 79949000 RECIRCHOSEASSYWATERTANK 79949105 RECIRCHOSEASSYANTFREEZ ULT 79949300 FLANGEGASKET 3/ 4" PIPE 79950000 HOSE, HP REEL INLET HOSE(VIS) 79950205 HOSE, SUPPLYPUMP-REEL (ULT) 79950410 CLEARVIEW PVCHOSE 79950500 ELBOW, 12 MALE37DEG 3/ 4NPT 79950700 BLOCK HP RESTINGW/ STEP 79950800 BLOCK, HP REEL STOPPER 79950810 BUMPER, 1-1/ 2" DIA X 3/ 4" HG 79950820 SCREW,5/ 16-18X1 SCK CAP 79952100 DECAL, VIN NUMBER 79952300 DECAL, WHEEL & LUG NUTS 79952400 DECAL, SAFETYCHAINS 79952600 DECAL, ELECTRICBRAKES 79952700 DECAL, NATM COMPLIANCE 79954100 WIREHARNESSULT MAIN 79954200 WIREHARNESSWARLIGHTS 79954300 WIREHARNESSREMOTEUW 79956900 ANGLEFILL REEL SHUTOFF MNT 79957000 LATCH ASSY90 D LOWERINDEX 79957090 U-BOLT, 3/ 8-16 X 2.5" ID 79957100 GRIP, FOAM CUT - 7/ 16" ID X 6" 79957140 BRACKET, RELIEF VALVEWAR 79957600 SEALED TOOL BOX W/ DECAL 79958000 HYDRANT FILL ASSYWARRIOR Item Qty 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 Page 34 1 1 1 1 13 2 1 1 2 2 4 4 2 2 2 5 8 1 2 1 1 1 1 1 1 1 1 154 1 1 1 2 1 1 1 8 PART # DESCRIPTION 79958100 BASEPLATEASSEMBLY(WAR) 79958300 HP REEL ASSEMBLY(WARRIOR) 79958400 ASSY, FRONT ENCLOSURE 79959000 DRAIN VALVEASSEMBLY(WAR) 79959200 RUBBERTRIM 3/ 4 X 7/ 16 X 3/ 16 79960000 CHAIN, SAFETY 79960200 ANGLE, REARSUPPORT ULT. WAR 79961000 DOOR, LIFT UP FBRGLSASSEMBLY 79961030 PLATE, HINGELIFT UP FBRGLS 79961050 GASSTRUT 110 LBS-22.36" EX 79961060 BALL SOCKET 10MM-M6 THRD 79961070 BALL STUD 10MM W/ 5/ 16-18 THD 79961100 BRACKET, STRUT SUPPORT- DOOR 79961130 FLANGEBEARING3/ 8" SHAFT BRN 79961140 SCREW, SHLDR3/ 8" DIA X 3/ 4 LG 79961160 EDGETRIM, RBBRSEAL - 7/ 16 SIDE 79961200 WASHER, NEOPRN .23ID X .50 OD 79962020 BRACE, OIL PAN PREVENTER 79962300 CLAMP, INSULATED 7/ 8 ID 79962310 CLAMP, INSULATED 1-1/ 4 ID 79962320 HOSE, HP REEL PROTCT COVER 79962650 GUARD HOSE- HP REEL 79963000 DECAL, MASTERSHT WAR/ ULT 79963200 DECAL, ULT TIRE& LOAD PRINT 79964000 HP HOSEASSY1/ 2"X500 FT 79965000 ASSY, POWERPACK WARRIOR 79965550 PULSATORVALVE, ELECTRIC 79965700 OIL, GEARSAE80 (HIGH FLOW) 79965800 ASSY, CONTROL BOX WARRIOR 79966000 NOZZLE, 798 CLOSED 79966100 NOZZLE, OPEN HIGH FLOW 79966200 FLEX HEAT SHRINK TUBING 79966300 ADJ, COUPLER-2-5/ 16" 12000 LB 79966330 STRIKERPLATE, REARDOORLATCH 79967200 WLDMNT, ULT WARBP SUPPORT 82020100 SCREW, 1/ 4-20 X 1 BUTTON HEAD Page 35 101 123 253 226 103 165 104 124 161 45 105 113 123 49 246 224 102 78 135 246 70 96 71 62 96 180 97 136 75 180 133 134 151 125 107 125 168 181 175 144 171 146 143 75 118 120 53 149 172 141 74 142 2 17 31 142 125 5 130 61 20 51 179 176 155 219 111 63 146 202 232 221 140 221 233 77 125 167 20 89 71 240 245 252 211 220 254 53 117 118 6 213 222 249 Hi-Flow Ultimate Warrior Final Assembly 79940000 Hi-Flow Ultimate Warrior Final Assembly 79940000 253 105 49 206 50 223 244 224 E E 169 109 127 128 220 129 199 228 201 184 238 229 23 59 12 14 128 213 182 211 158 2 237 19 17 249 222 Page 36 Hi-Flow Ultimate Warrior Final Assembly 79940000 14 59 12 23 232 230 F 77 21 186 166 146 146 250 180 129 182 219 202 222 183 203 220 102 78 163 204 254 53 117 118 102 Page 37 102 Hi-Flow Ultimate Warrior Final Assembly 79940000 180 180 54 45 83 134 145 137 56 41 47 40 148 41 65 66 SECTION E-E SCALEPage 1 / 10 From 36 246 229 23 234 16 DETAIL F 235 20 128 68 DETAIL F From Page SCALE 1 /2 Page 38 37 Hi-Flow Ultimate Warrior Final Assembly 79940000 253 105 210 49 50 207 209 208 113 126 126 246 124 165 210 189 45 148 161 64 45 222 56 45 134 180 135 180 151 150 125 62 2 96 31 143 136 75 97 200 53 120 118 132 142 171 141 75 144 200 162 170 143 16 10 19 74 144 140 176 20 233 77 175 155 118 120 53 118 53 119 232 2 125 132 31 14 10 19 119 53 118 53 119 118 152 154 170 153 171 187 111 23 63 115 114 39 202 53 120 118 43 157 220 51 166 223 76 186 219 19 30 37 A 215 39 114 115 251 250 221 130 5 61 20 Page 39 Hi-Flow Ultimate Warrior Final Assembly 79940000 123 98 253 105 226 206 49 50 246 244 212 165 21 20 70 64 133 224 147 135 145 247 75 120 118 53 78 102 132 177 171 170 132 118 53 117 116 115 168 125 143 233 115 116 118 119 53 125 42 219 225 199 166 149 76 171 172 220 39 115 114 213 156 211 89 158 120 53 118 158 249 245 5 59 239 222 Page 40 Hi-Flow Ultimate Warrior Final Assembly 79940000 253 226 98 123 212 188 25 178 173 24 114 39 115 174 31 246 246 64 51 31 71 20 70 106 85 51 81 160 64 224 50 47 31 85 45 83 64 80 102 84 40 56 134 45 102 78 163 164 117 115 113 122 102 164 139 163 138 220 194 76 225 G 195 196 227 199 201 G 194 197 193 166 166 214 19 37 30 214 39 115 114 125 Page 41 Hi-Flow Ultimate Warrior Final Assembly 79940000 143 249 179 166 77 239 12 59 222 186 210 171 170 187 251 146 171 172 42 180 250 223 191 203 76 199 204 205 201 78 102 254 53 117 118 Page 42 Hi-Flow Ultimate Warrior Final Assembly 79940000 198 44 197 From Page 41 SECTION G-G SCALE 1 / 2 29 60 74 201 199 229 23 234 16 From Page 39 DETAIL A 235 20 128 68 DETAIL F SCALE 1 / 2 Page 43 Hi-Flow Ultimate Warrior Final Assembly - 79940000 Rear Enclosure Only 1 109 2 128 3 129 1293 5 183 182 4 3 129 5 183 Page 44 79958400 Front Enclosure Assembly Item Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 6 4 4 2 12 4 6 10FT 4 2 2 2 1 2 4 1 1 2 7FT 2 6 2 2 4 Pa rt # 00113901 00162400 00162700 02820700 02825100 03312001 73821200 75841010 75853710 77760000 79858000 79920141 79920600 79920623 79920628 79920658 79920659 79920669 79920750 79941620 79942600 79943300 79945850 79945860 De scription SCREW , HX HD CAP 1/4-20 X 1 ZN W ASHER, FLAT 3/16 W ASHER, FLAT 3/8 NUT, HEAVY HEX JAM 5/16-18 W ASHER, FLAT 1/4 USS NUT, HEX KEP 8-32 ZINC PLATED NUT, NYLON LOCKING 1/4-20 VINYL EDGE TRIM BLACK 10MM GAS STRUT SOCKET SCREW HEX HD CAP 3/8-16 X 1-1/2 SCREW , HEX HD CAP 1/2-13 X 1-1/2 NUT, 1/2-13 HX GR8 CENTER LOCK ASSY, FRONT ENCLOSURE GAS SPRING, M8 THRD 125# BALL STUD, GAS STRUT HINGE BASE FRONT STREET HINGE BASE FRONT CURB HINGE VERTICAL TAB EDGE TRIM, BLACK RUBBER 1/4" PLATE, UPPER GAS STRUT ANGLED W ASHER, FLAT SAE 1/2'' - .074 NUT, HEX JAM 3/8-16 ZNC PLT LIGHT, SIDE MARKER AMBER SCREW , 8-32x1-1/4 FLT HD ZNC 13 8 24 23 4 20 7 1 6 19 2 23 22 3 10 18 12 21 11 16 17 1 7 5 15 Page 45 9 14 24 79961000 - Lift Up Door Assembly Item Qty 1 2 3 4 5 6 7 8 10 11 12 13 14 17 18 19 21 22 23 24 25 26 6 6 4 10 ft 4 1 1 10 ft 2 3 3 1 1 1 1 17.6 ft 1 1 1 2 1 8 ft Part # 00162400 00165300 03850100 44222400 44294600 44298500 77722100 77733100 77742400 77751600 77751700 79961010 79961080 79961120 79961300 79961150 77735301 79961110 79966340 79961180 79970100 73826800 Description WASHER, FLAT 3/16 SPLIT LOCKWASHER #10 ZINC PTLD NUT, HEX KEP 10-32 ZINC PLATED WIRE, HOOK-UP 16 AWG - BLACK SCREW, MACHINE 10-32X 1-1/4 JETTER LICENSE PLATE INSERT FRAME, LIGHTED LICENSE WIRE, 16 AWG - RED STRANDED CU NYLOCK LOCK NUT 10-24 DISCONNECT, FEMALE BULLET DISCONNECT, MALE BULLET FIBRGLSS DOOR, LIFT UP (BRKTS) NYLON WEBBING, 1-1/2" WIDE WEBBING FEED THRU PLATE, 1-1/2 WELDMENT, PULL DOWN STRAP EDGE TRIM, RBBR SEAL-TOP 3/8 ADJUSTABLE LATCH 2-1/2" T-HANDLE, KEY LATCH-CCW CHRM SHAFT COLLAR, 7/16" BORE SCREW, FLT HD 10-24 X 1-1/4" WELDMENT, DOOR LATCH SUPPORT WIRE-LOOM, BLACK PLASTIC 3/8" 19 19 7 6 13 22 24 Page 46 79961000 - Lift Up Door Assembly 19 19 11 12 19 19 19 5 1 12 3 11 11 12 18 7 14 17 D 19 4 8 26 23 21 25 1 DETAIL D SCALE 1 / 2 Page 47 24 10 19 79965000 - Power Pack Assembly Item Qty 1 4 2 1 3 2 4 12 5 6 6 2 7 2 8 8 9 8 10 2 11 2 12 4 13 4 14 5 15 16 16 1 17 1 18 1 19 8 20 8 21 8 22 2 23 2 24 11 25 3 26 2 27 1 28 1 29 1 30 1 31 1 32 2 33 4 34 4 35 4 36 5 37 4 38 1 Part # Description 00117500 SCREW, HEX HD 3/ 8-16 X 4 00118900 HEX HD SCREW 1/ 2-13 X 2-1/ 2 00162600 WASHER, FLAT 5/ 16 USS 00162700 WASHER, FLAT 3/ 8 00165400 WASHER, LOCK SPLIT 1/ 4 00165800 WASHER, LOCK SPLIT 3/ 8 00778000 NUT, HEX 1/ 2-13 01588200 WASHER, FLAT #10 SAE 02825100 WASHER, FLAT 1/ 4 USS 02939000 SCREW, HEX HD 5/ 16-18 X 3/ 4 04728200 SCREW, HEX HD 1/ 4-20 X 3/ 8 44181400 WASHER, LOCK-SPLIT M12 71705500 SCREW, HX HD 1/ 4-20 X 1-1/ 4 73821200 NUT, NYLON LOCKING1/ 4-20 73826900 WASHER, FLAT 1/ 2 USSHS 73830900 CABLE, NEGATIVEBATT 60" LG 75814700 STRAP, BATTERYHOLD DOWN 75815300 BOX, BATTERY(MODIFIED) 75841621 SCREW, #10-24 x 1 3/ 4" PAN 77738100 SCREW, CAP HX HD 3/ 8-16 X 1 77742400 10-24 Zinc Nylon Lock Nut 77744800 NUT, STOVERLCK 1/ 2-13 UNC 77747800 NUT, HEX 5/ 16-18 77748000 NUT, STOVERLCK 3/ 8-16 UNC 79829300 CLAMP, MUFFLER2-1/ 2'' ZN 79829900 SCREW, HX HD 1/ 2-13 X 2 79846500 ADAPTER-10 O-RING/ -8JIC 79846600 ADAPTER-12 O-RING/ JIC45 DEG 79847800 BATTERY, DIESEL 875 CCA 79847900 CABLE, POSITIVEBATTERY798 79874700 PUMP, BUCHERHYDRAULIC 79908500 SCREW, HEX HD 1/ 2-13 X 3 79920141 NUT, HX GR8 1/ 2-13 STOVER 79920145 HEX BOLT 1/ 2-13 X 1-1/ 2 GR8 79920150 HEX BOLT 3/ 8-16 X 1-1/ 2 GR8 79920151 HEX NUT, 3/ 8-16 GRADE8 79920158 SCREW,HEX M12X25mm CL8.8 79920200 WLDMNT, POWERSUB-FRAME Item Qty 39 40 41 42 43 44 45 46 47 48 49 50 51 55 56 57 58 59 60 61 62 63 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 Page 48 1 1 1 1 1 1 1 2 1 1 2 1 1 1 2 1 1 4 1 1 1 1 1 1 4 1 1 1 1 2 1 4 1 1 1 1 1 Part # Description 79920220 WELDMENT, BATTERYTRAY 79920240 ACTUATOR, ELECTRICCLUTCH 79920241 PLATE, CLUTCH ACTUATORBRKT 79920243 WLDMNT, CLTCH ACTUATORBRKT 79920250 WELDMENT, CLUTCH LEVER 79920261 BEARING, 1"IDX2"ODX1/ 8 DELRIN 79920264 WELDMENT, LIMIT SWITCH FLAG 79920269 SWITCH, LIMIT 79920290 WLDMNT, LOW CLUTCH LIM SWTCH 79920295 WELDMENT, LIM SWITCH BRACKET 79920297 CORD GRIP 79920300 ENGINE, KUBOTA V-3600 79920340 WELDMENT, EXHAUST SUPPORT 79920375 EXHAUST PIPE2-1/ 2" X (3) 90 DEG 79920380 HOSE, AIRFILTER 79920385 WELDMENT 2-1/ 2" EXHAUST 45 DEG 79920390 PIPE-2-1/ 2" SCH 40 PVCCONDUIT 79921620 CLAMP, 4" WORM DRIVE 79922330 SPROCKET, DRIVE14MM X 85MM 79922350 BUSHING, QD-SK 2-1/ 4 BORE 79922355 KEY, STEP 1/ 2 X 5/ 8 SQ 79922370 BELT, DRIVE1400 PTH 14M42 79931650 WELDMENT, AIRFILTER 79931900 WELDMENT, PUMP SUPPORT HF 79942600 WASHER, FLAT SAE1/ 2'' - .074 THCK 79946130 ASSY, STARTERRELAY 79965010 PLATE, UNLOADERSUPPORT BASE 79965020 ANGLE, UNLOADERSUPPORT VERT. 79965030 PLATE, UNLOADERSUPPORT UBOLT 79965040 U-BOLT, 3/ 8-16 X 2-3/ 4" ID 79965100 PUMP ASSEMBLY798 79965630 SCREW, M14X35MM SOCCAP SS 79844800 FUEL FILTER, DIESEL 79920305 RADIATOR, DIESEL 79920460 MODULE, ENGCONTROL - HI-FLOW 79875000 MAGPICKUP 79871700 ACTUATOR, FUEL SOLENOID 79965000 - Power Pack Assembly 57 51 25 77 55 25 50 77 60 50 46 61 44 19 21 8 49 45 63 51 37 74 12 58 72 4 59 48 20 33 71 69 1 15 56 3 59 23 66 38 Page 49 36 67 79965000 - Power Pack Assembly 57 25 51 45 63 44 60 27 31 17 28 11 43 13 26 22 9 5 47 1 39 38 24 51 56 51 46 50 19 21 8 45 49 30 16 11 23 Page 50 3 17 66 74 79965000 - Power Pack Assembly 4 71 72 73 18 17 70 4 24 20 11 57 51 55 56 59 25 4 73 24 46 49 60 62 72 48 73 63 61 26 63 74 24 4 20 71 36 70 43 15 35 33 34 46 32 7 21 8 Page 51 22 19 47 15 33 34 40 79965000 - Power Pack Assembly A 15 38 34 56 41 40 5 9 13 22 8 5 21 19 60 46 21 49 14 13 50 47 35 15 D E TA IL A SCALE 1 / 2 Page 52 Assy, Starter Relay 79946130 2 3 6 2 4 5 1 Item Qty 1 2 3 4 5 6 1 5 1 2 1 4 Part # 75823600 79946140 79946150 79925500 79925520 79946160 Description RELAY JUMPER W IRE, STARTER POW ER JUMPER W IRE, STARTER CONTROL 5 PIN W EATHERPROOF CONNECTOR TERMINAL, 12GA SEALED CONNECT JUMPER W IRE-PUSH ON Page 53 79965100 - High Pressure Pump Assembly Item Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 2 3 2' 3 1 3 3 1 1 1 1 1 1 1 3 1 1 1 1 1 1 Pa rt # 41006000 77736900 77748200 79811200 79811800 79812100 79812600 79816200 79821500 79823000 79871900 79922340 79922360 79965500 79965510 79965520 79965600 79965640 79965650 79965660 79838300 De scription BUSHING, REDUCER 1" X 3/4" CLAMP, HOSE 1-9/16 - 2-1/2 #32 HOSE 1-1/2 ID X 4 SPIRAL NIPPLE CLOSE 4", 1-1/2 X 1-1/2 P NIPPLE, 1-1/2 X 1-1/2 MPT POLYP BARB, HOSE 1-1/2 MPT X 1-1/2 PO ELBOW , 90 DEG. 1-1/2 NPT FEMALE ELBOW , 90 DEG STREET 3/4 STEEL ADAPTER, 3/4" MNPT/ -12 JIC NIPPLE, HEX 1 X 3/4 TEE, 1-1/2 FNPT POLYPRO SPROCKET, DRIVE 60 TOOTH 14MM X 85MM BUSHING, 35MM BORE W / 10MM KEY PUMP, GIANT MODEL GP5132 VALVE, DUMP GIANT MODEL 2256A MANIFOLD FITTING, DUMP VALVES UNLOADER, GIANT 22949 TEE, 1" NPTF - MALE/FEMALE ZN PLT NIPPLE, ADAPTER 1" MNPTF X 1" MBSPP ELBOW 90, 3/4(MPT) STL PLUG, G1 (SUPPLIED W /PUMP) 13 14 7 3 14 19 11 Page 54 18 79965100 - High Pressure Pump Assembly 12 7 7 5 6 14 2 4 18 20 17 11 10 15 16 6 4 2 4 20 2 15 16 1 17 1 8 9 12 Page 55 Pump Parts List 79965500 Item Qty Part # Description 1 1 79965101 Crankcase 2 1 79965102 Oil Filler Plug Assembly 3 1 79965103 Oil Sight Glass Assy. 4 1 79965104 Crankcase Cover 5 1 79965105 O-Ring 8 1 79965106 Oil Dip Stick 9 1 79965107 O-Ring, Dip Stick 10 4 79965108 Inner Hexagon Screw 11 4 79965109 Spring Washer 12 1 79965110 Drain Plug G 3/4" 13 1 79965111 Gasket, Drain Plug 14 2 79965112 Bearing Cover 15 2 79965113 Radial Shaft Seal 16 2 79965114 O-Ring 17 8 79965115 Hexagon Screw 18 8 79965116 Spring Washer 20 2 79965117 Taper Roller Bearing 20A 5 79965118 Fitting Disc (Shim) 21 1 79965119 Shaft Protector 22 1 79965120 Crankshaft 23 1 79965121 Fitting Key 24 3 79965122 Connecting Rod Assy. 25 3 79965123 Crosshead Assy. 28 3 79965124 Crosshead Pin 29A 3 79965125 Centering Sleeve 29B 3 79965126 Plunger Pipe 29C 3 79965127 Tensioning Screw 29D 3 79965128 Copper Ring 30 3 79965129 Oil Scraper 31 3 79965130 Radial Shaft Seal 35 3 79965131 Seal Sleeve 35B 3 79965132 O-Ring 36 3 79965133 Grooved Ring Item Qty Part # Description 37 3 79965134 Seal Case 37A 3 79965135 O-Ring 37B 3 79965136 O-Ring 39 3 79965137 Pressure Ring 40 6 79965138 V-Sleeve 41 3 79965139 Sleeve Support Ring 42 3 79965140 Tension Spring 43 1 79965141 Valve Casing 46 3 79965142 Suction Valve Assy. 46A 1 79965143 O-Ring 46B 1 79965144 O-Ring 46C 1 79965145 Suction Valve Seat 46D 1 79965146 Valve Plate 46E 1 79965147 Valve Spring 46F 1 79965148 Spring Tension Cap 46G 1 79965149 Spacer Pipe 47 3 79965150 Discharge Valve Assy. 47A 1 79965151 O-Ring 47B 1 79965152 O-Ring 47C 1 79965153 Discharge Valve Seat 47D 1 79965154 Valve Plate 47E 1 79965155 Valve Spring 47F 1 79965156 Spring Tension Cap 48 3 79965157 Plug 48A 12 79965158 Inner Hexagon Screw 48B 3 79965159 O-Ring 48C 3 79965160 Pressure Ring 49 8 79965161 Inner Hexagon Screw 52 1 79965162 Disc for Crankshaft 53 1 79965163 Hexagon Screw 54 1 79965164 Plug G 1" 55 2 79965165 Plug G 1-1/2" Page 56 Pump - Exploded View 79965500 Plunger Packing Kit 79965166 (1 Required) Part # 79965132 79965133 79965138 QTY 3 3 6 Description O-RING GROOVED RING V-SLEEVE Discharge Valve Kit 79965168 (1 Required) Part # 79965151 79965152 79965153 79965146 79965147 QTY 1 1 1 1 1 Description O-RING O-RING VALVE SEAT VALVE PLATE VALVE SPRING Inlet Valve Kit 79965167 (1 Required) Part # 79965143 79965144 79965145 79965146 79965147 Page 57 QTY 1 1 1 1 1 Description O-RING O-RING VALVE SEAT VALVE PLATE VALVE SPRING Hi-Flow Unloader - 79965600 Item 1 2 2A 3 3A 4 4A 5 5A 6 7 8 9 10 11 12 13 14 15 16 17 18 19A 19B 19C 19D 20 20A 20B 21 22 23 23A 23B 23C 23D 24 24A 25 25A Qty 1 2 2 1 1 1 1 1 1 1 1 1 1 1 3 2 1 2 1 1 1 1 1 2 1 1 1 4 4 1 19 1 1 2 2 1 1 1 6 6 Part # 79965169 79965170 79965171 79965172 79965173 79965174 79965175 79965176 79965177 79965178 79965179 79965180 79965181 79965182 79965183 79965184 79965185 79965186 79965187 79965188 79965189 79965190 79965191 79965192 79965193 79965194 79965195 79965196 79965197 79965198 79965199 79965200 79965201 79965202 79965203 79965204 79965205 79965206 79965207 79965208 Description CASING, UNLOADER TENSION PLUG, UNLOADER SPRING TENSION DISC, UNLOADER RETAINER, VALVE RETAINER, DISCHARGEVALVE SPRING, DISCHARGEVALVE SPRING, INLET VALVE BALL VALVE, INLET SPACERDISC VALVE, DISCHARGE VALVESEAT, DISCHARGE VALVESEAT, INLET CYLINDER GUIDE O-RING SUPPORT RING O-RING, DISCHARGEVALVESEAT O-RING PISTON SPACER PACKING VALVESTEM O-RING, VALVESTEM SPACER, VALVESTEM KEY TENSION SLEEVE SUPPORT RING ALLEN SCREW WASHER, SPRING DISC SPRING, RED NUT, ADJUSTING SPACERDISC, .2m SPACERDISC, .5mm SPACERDISC, 1.0mm SPACERDISC, 5mm NUT, LOCKING TENSION PIN PLUG, 1/ 4" WASHER Page 58 Hi-Flow Unloader - 79965600 ORING REPAIRKIT - 79965209 Part # Qty Description 79965183 3 O-RING 79965184 2 SUPPORT RING 79965185 1 O-RING, DISCHRG VALVESEAT 79965186 2 O-RING 79965189 1 PACKING 79965191 1 O-RING, VALVESTEM 79965194 1 TENSION SLEEVE UNLOADERREPAIRKIT - 79965210 Part # Qty Description 79965174 1 SPRING, DISCHARGEVALVE 79965175 1 SPRING, INLET VALVE 79965176 1 BALL VALVE, INLET 79965178 1 VALVE, DISCHARGE 79965183 3 O-RING 79965184 2 SUPPORT RING 79965185 1 O-RING, DSCHRGVALVESEAT 79965186 2 O-RING 79965189 1 PACKING 79965191 1 O-RING, VALVESTEM 79965192 2 SPACER, VALVESTEM 79965194 1 TENSION SLEEVE Page 59 79922200 Hydraulic Tank Assembly Item Qty 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 10 10 2 1 1 1 1 1 1 1 1 1 1 1 1 Pa rt # 00113700 00165400 71101200 72763000 77742600 79807000 79807100 79821600 79826000 79827000 79842700 79922220 79922260 79922270 79948010 De scription SCREW , HEX HD 1/4-20 X 3/4 W ASHER, LOCK SPLIT 1/4 PLUG, INTERNAL HEX 1/2 NPT DECAL, MASTER SHEET BUSHING, REDUCER 3/4 X 1/2 FILTER HEAD FILTER, ELEMENT ELBOW , 90 DEG FEM ALE 2/4 BLACK 3/4 X 6" NIPPLE BLK PIPE STEEL ELBOW , 90 DEG STREET 3/4 BLACK CAP, HYDRAULIC TANK HYD RESERVOIR, MACHINED W ELDMENT, COVER HYD RESERVOIR GASKET, HYD RESERVOIR REDUCER, PIPE 1/2 X 3/8NPT 10 6 9 5 16 14 11 15 7 8 18 2 4 13 Page 60 3 79940100 - Water/ Antifreeze Supply Assembly P a rt # 7 5824 700 7 9811 400 7 9811 700 7 9811 800 7 9812 100 7 9821 200 7 9871 900 7 5853 650 7 9812 600 Ite m Q ty 1 2 3 4 5 6 7 8 9 2 1 2 1 1 1 1 1 1 1 De sc rip ti o n HO S E B A R B , 1-1/2 M P T X 1-1/4 E LB O W , 9 0 D E G R E E S TRE E T 1-1/ 2 P O LY S TR A INE R, 1-1/2 NP T NIP P LE , 1-1/2 X 1-1 /2 M P T P O LY P B A R B , H O S E 1-1/2 M P T X 1-1/2 P O E L 90D 1-1/2M P T X 1-1 /2 HO S E B A R B TE E , 1 -1/ 2 F N P T P O LY P R O NIP P LE , 1-1/2 " X 6" P P (B LA C K ) E LB O W , 9 0 D E G . 1-1/2 NP T F E M A LE 2 6 1 7 3 5 2 6 7 4 8 3 9 Page 61 79959000 Drain Valve Assembly Item Qty 1 2 3 4 5 6 7 8 2 1 2 3 2 1 1 1 Part # 73831000 75853620 79811500 79811600 79812100 79871900 79931490 79968000 Description U-BOLT, 3" TUBE OD W/NUTS 1-1/2" POLY STREET ELBOW 45 DEG VALVE, BALL 1-1/4FNPT X 1-1/4F NIPPLE, 1-1/2 X 1-1/4 MPT POLYP BARB, HOSE 1-1/2 MPT X 1-1/2 PO TEE, 1-1/2 FNPT POLYPRO BRACKET, DRAIN VALVE 1-1/2 COUPLING 5 8 2 3 7 5 4 1 4 6 4 3 1 Page 62 79921300 Water Tank Fill Tee Item Qty 1 2 4 5 9 2 1 1 1 2 Part # 79921350 79921340 79921322 79921323 79921360 Description PIPE, 1-1/2" SCH 40 PVC TEE, 1-1/2" SCH 40 PVC ADAPTER, 1-1/2 PVC TO 1-1/2 NPT ADAPTER, 1-1/2 HOSE BARB TO 1-1/2 NPT ELBOW 1-1/2" 90D SCH 40 PVC 5 4 9 1 2 Page 63 79940400 Fill Reel Assembly Item Qty 1 2 4 5 6 10 11 12 13 14 16 17 18 22 24 2 6 8 4 1 1 1 1 1 2 1 1 1 1 1 Pa rt # 00113700 00113901 01950800 02825100 72704800 79904462 79904477 79904478 79904491 79904492 79940300 79940420 79940430 79931560 79966320 De scription SCREW , HEX HD CAP1/4-20 X 3/4 SCREW , HX HD CAP 1/4-20 X 1 ZINC NUT, 1/4-20 HEX KEP W ASHER, FLAT 1/4 USS VALVE, BALL 1/2 M X 1/2 F ST ELB 45D 1/2 NPT BRASS ADAPTER,1/2NPT-BARB BRASS EL 90D 1/2NPT-BARB BRASS PLATE, HOSE SW IVEL MOUNT ADAPTER, GARDEN HOSE 3/4M-1/2FM RAPID REEL, 2008 FILL CONNECTOR, 3/4 FGHT SW IVEL FILL HOSE RECIRC W ELDMENT W ELDMENT, FILL REEL LEFT LATCH, SPRING BOLT ZN PLT 16 17 17 24 4 2 14 22 14 22 18 18 5 1 12 4 2 13 10 14 5 13 4 6 Page 64 11 Wash Down Accessory Package 73817300 4 2 5 Item Qty 1 2 3 4 5 1 1 1 1 1 Part # 73816500 77719500 77721400 77799800 77815800 Description ADAPTER, SW IVEL 3/8 M X 3/8 F HOSE, 1/4" X 75' COUPLER, QUICK GUN MALE HANDGUN LANCE VNOZZLE ASSEMBLY NOZZLE, 1/4" DOMED (6) 3 1 HandGun Lance Vnozzle Assembly 77799800 Item Qty 1 2 3 4 5 6 1 1 1 1 1 1 Pa rt # 77720100 77721300 77721400 553006-01 71126100 79874400 De scription GUN, HAND COUPLER, QUICK GUN, 1/4" NPT M ALE COUPLER, QUICK GUN, M ALE LANCE, INSULATED GRIP, 18" NOZZLE - VARIABLE .080 FITTING, W AND ANTI-KICKBACK 3 2 1 Page 65 5 6 4 79958100 - Baseplate Assembly Item Qty 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 2 2 2 1 1 1 4 1 1 1 1 1 1 1 1 2 2 Part # 03366300 77748000 79909900 79934000 79950600 79904410 79904476 79904466 79904475 79934200 79934100 77752800 79934300 521012-04 73821200 79908200 00125100 Description WASHER, FLAT 3/8 SAE NUT, STOVER LOCK 3/8-16 UNC SCREW, SOCKET HD 3/8-16 X 1-3/4 PLATE, BACKEND BASE COVER BLOCK HP RESTING WARRIOR VALVE, 1/2 BRASS 3 WAY ADAPTER,1/2NPT-8JIC 45D BRASS TEE, 1/2" NPT BRASS VALVE, RELIEF BRONZE 50-175 PSI DECAL, WARRIOR RECIRC CLAMP 3/4 CONDUIT 1 HOLE ADAPTER, SWIVEL 1/2 SPACER-RELIEF VALVE SCREW, HX HD 1/4-20 X 1-1/2 NUT, NYLON LOCK 1/4-20 WASHER, FLAT 1/4 SAE SCREW, MACHI RD HD SL 8-32 X 3/8 B 4 A 5 11 18 B 15 13 6 Page 66 1 2 79958100 Baseplate Assembly 9 8 12 10 4 2 14 17 16 15 6 13 1 8 8 7 8 DETAIL A SCALE 1 / 4 DETAIL B SCALE 1 / 4 Recirc Hose Assembies 79948700; 79948800 & 79949105 Recirc Hose Assembly, Fill Reel 79948700 Item Qty 1 2 1 2.3ft Item Qty 1 2 1 6.3ft Pa rt # De scription 79904479 SW IVEL,8JIC 45D-BARB BRASS 79904483 HOSE, 1/2 PUSH-ON 300 PSI Recirc Hose Assembly, Fill Shutoff 79948800 Pa rt # De scription 79904479 SW IVEL,8JIC 45D-BARB BRASS 79904483 HOSE, 1/2 PUSH-ON 300 PSI 2 Recirc Hose Assembly, Antifreeze - Ultimate 79949105 1 Item Qty 1 2 1 12.5ft P a rt # De scription 79904479 S W IV EL,8JIC 45D-BA RB B RA S S 79904483 HOS E , 1/2 P US H-ON 300 PS I Page 67 Recirc Hose Assy, Water Tank 79949000 3 2 1 Item Qty 1 2 3 8.6ft 1 1 Pa rt # 79904483 79904479 79904478 De scription HOSE, 1/2 PUSH-ON 300 PSI SW IVEL,8JIC 45D-BARB BRASS EL, 90D 1/2NPT-BARB BRASS Hydrant Fill Assy, Warrior 79958000 13 3 2 4 7 9 7 8 10 1 3 2 12 6 5 11 Item Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 4 6 6 2 1 2 2 1 1 1 1 1 1 Page 68 Part # 00116900 03366300 522132-00 77738100 79812100 79819401 79819600 79830200 79842800 79921321 79921322 79935100 79950400 Description SCREW, HEX HD 3/8-16 X 1-3/4 WASHER, FLAT 3/8 SAE NUT, NYLON LOCKING 3/8-16 SCREW, HEX HD 3/8-16 X 1 BARB, HOSE 1-1/2 MPT X 1-1/2 PO ELBOW, 90 DEGREE 2" PVC PIPE, PVC 2" X 3" ADAPTER, 2" MALE SCHED 80 PVC BALL VALVE 2" w/ QUICK COUPLER REDUCER, 2" TO 1-1/2 SCH 40 PVC ADAPTER, 1-1/2 PVC TO 1-1/2 NPT PLATE, BALL VALVE MNT BRACKET PLATE, HYDRANT FILL MOUNT 79957000 Latch Assembly, 90 Deg Lower 10 8 4 5 9 2 7 6 1 3 Item Qty 1 2 4 5 6 7 8 9 10 11 1 2 1 1 1 1 1 1 1 1 Part # 00113700 73821200 79957010 79957020 79957030 79957040 79957050 79957060 79957070 79957080 Description SCREW, HEX HD CAP 1/4-20 X 3/4 NUT, NYLOCK LOCK 1/4-20 WLDMENT, SPRING PIN-MNT BRCKT PLATE, PIVOT LEVER ARM PLATE, HANDLE LEVER ARM COUPLER, LEVER ARM-SPRING PIN SCREW, SHOULDER 5/16 X 1/4 SS SCREW, SHOULDER 5/16 X 1/2 SS HANDLE, BLK PLST 3" LNG 1/4-20 SCREW, SHOULDER 5/16 X 3/4 SS Page 69 79958300 High Pressure Reel Assembly Item Qty 1 2 3 4 7 8 9 10 11 12 13 14 17 18 19 21 22 23 24 25 26 27 28 29 63 64 65 71 72 74 75 4 7 6 6 5 2 2 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 4 4 1 1 2 1 Part # Description 00115100 SCREW, HEX HD CAP 5/16-18 X 1" 00165800 WASHER, LOCK SPLIT MEDIUM 3/8 02825100 WASHER, FLAT 1/4 03366300 WASHER, FLAT 3/8 SAE 77738100 SCREW, CAP HEX HD 3/8-16 X 1 77748000 NUT, STOVER LOCK 3/8-16 UNC 79867500 ADAPTER, 90 DEG -10 MALE O-RING 79904930 COUPLING, HEX 1/2NPT STEEL 79932000 REEL, HP WARRIOR 79932055 ELBOW, FEMALE PIPE 1/2NPSMX1/2NPT 79932060 SWIVEL, 1/2-14 NPT-NPSM ELBOW 79947360 SCREW, 3/8-16 x 3-3/4 HX HD 79948010 REDUCER, PIPE 1/2 X 3/8NPT 79948080 HOSE, ASSY HYD BYPASS WARRIOR 79948110 ELBOW, 12 MALE STREET 37DEGREE 79962100 SWIVEL, HP REEL 1/2" 79962200 WELDMENT, CONTROL PANEL MNT 79962400 LATCH ASSY 180 PIVOT DBL PIN 79962500 BRACKET, HP REEL NIPPLE SPRT 79962600 ASSY, HP NIPPLE - GAUGE - WARRIOR 09 79962630 PIPE SS, 1/2" NPT - 10" LONG 77770800 NIPPLE, HEX 1/2 NPT 79962700 ASSY, HOSE GUIDE PIVOT WAR 09 79947870 DECAL WATER OFF BEFORE ENGINE 79966320 LATCH, SPRING BOLT ZN PLT 71705500 SCREW, HEX HD 1/4-20 X 1-1/4 00165400 WASHER, LOCK SPLIT MEDIUM 1/4 79947540 PLATE, BUCHER VALVE MOUNT 79948170 ASS'Y, HYD VALVE BUCHER 522132-00 NUT, NYLOCK 3/8-16 79970200 DECAL HOSE IN-OUT-SPIN NOTE 79948140 ADD-ON HYDRAULIC FLOW CONTROL KIT 27 10 21 D VIEW A-A Page 70 79958300 High Pressure Reel Assembly 25 22 2 23 7 23 25 24 1 2 18 A 2 7 12 13 26 19 71 72 A 11 4 74 17 7 28 9 28 8 14 4 14 4 14 22 12 25 29 75 17 9 28 63 64 65 Page 71 79962700 - Hose Guide Assembly Item Qty 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 1 4 1 1 4 2 2 4 2 1 1 2 1 1 1 1 Pa rt # 00113901 00162600 02821200 02825100 02939000 44218300 75845090 77743400 79911500 79911600 79950810 79962710 79962720 79962800 79962900 79966310 De scription SCREW , HX HD CAP 1/4-20 X 1 ZN W ASHER, FLAT 5/16 USS NUT, NYLOCK JAM 1/4-20 W ASHER, FLAT 1/4 USS SCREW , CAP HX HD 5/16-18 X 3/4 FITTING STANDARD DRIVE SHAFT, SS .75 O.D. W ASHER, LOCK SPLIT 5/16 BEARING, FLANGED 3/4 ID X 1/2 COILED HOSE GUIDE w/BEARINGS BUMPER, 1-1/2" DIA X 3/4" HG PIN, 3/8" DIA - 4" USABLE -T-HNDL LEVER, STEEL BALL HANDLE 4" W LDMNT, HG CANTILEVER SUPPORT W LDMNT, PIVOT HG 90DEG ARM PIN, LOCKING 3/8" DIA - 1-3/8" USABLE 14 4 3 1 16 10 7 12 2 8 5 17 17 9 13 5 15 13 5 2 8 2 8 6 Page 72 79948170 - Assy, Hyd Valve Bucher Item Qty 1 2 3 4 1 4 2 2 Part # 79948160 79948020 79948030 72710000 De scription VALVE BUCHER HYDRAULIC ADAPTER, 3/4-16 O-RING-1/2 NPT SW IVEL NIPPLE, HEX 3/8 NPT STEEL ELBOW , 90 DEG FEMALE 3/8 STEEL 2 2 3 4 1 2 Page 73 79965800 - Control Box Assembly Ite m Qty 1 9 2 8 3 1 4 2 5 11 6 4 7 1 8 5 9 2 10 2 11 4 12 1 13 1 14 2 15 1 16 1 17 1 18 5 19 1 20 1 21 1 22 1 23 1 24 2 25 50 26 19 27 1 28 1 30 2 31 2 32 2 33 2 34 2 35 2 36 2 37 1 38 5 39 .16 43 1 Pa rt # 01588200 02823800 02824000 03312001 03850100 44294100 44294600 532000-01 61021600 62017800 75823600 79804500 79830300 79850400 79859905 79859906 79859908 79903510 79903540 79903541 79945110 79945200 79945300 79945400 79945500 79945510 79945530 79945550 79945610 79945620 79945710 79945720 79945730 79945740 79946700 79946900 79957500 79963000 79947810 De scription W ASHER, FLAT #10 SAE SCREW , MACHINE 10-32 X 3/8 PHILLIPS FILLISTER HD MACHINE NUT, KEP #8-32 ZN PLATED NUT, HEX KEP 10-32 JUMPER W IRE PIGGYBACK SCREW , SOC HD 10-32X 1.25 zinc plt SW ITCH, TOGGLE SPST NUT, 8-32 SCREW , FLAT HD 8-32 X 3/8 RELAY PLUG, 12V DC SW ITCH, ROTARY 4 POS. FUSE, 15AMP LAMP TIMER (SUPPLIED W /ENGINE) INDICATOR, GLOW PLUG SW ITCH, IGNITION BOOT, TOGGLE SW ITCH (GRAY) RELAY, 4-POLE 5 AMP SOCKET, 5A RELAY ENCLOSURE, W ARRIOR MODIFIED GAUGE, 4-IN-1 FUEL-VOLTS-OIL-TEM P 2008 GAUGE, TACH W / HOUR METER 2008 GAUGE, TANK LEVEL 2008 TERMINAL BLOCK, DIN RAIL SCREW LESS JUMPER-TERMINAL BLOCK END BRK - TERM RELAY, IDEC SMART DIN RAIL- 17 INCHES DIN RAIL- 8.5 INCHES ORING, BUNA 3/8ID - 1/2OD 012 ORING, BUNA 1/2ID - 5/8OD 014 ORING, BUNA 1-7/8ID - 2"OD 032 ORING, BUNA 3-1/4ID - 3-3/8OD FUSE HOLDER, DIN RAIL SCREW LESS SET, W ARRIOR CONTROL JUMPERS DESICCANT BAG, INDICATING DECAL, MASTER SHT W ARRIOR/ULT STARTER INTERLOCK RELAYS Part # Qty Description 77909700 1 DECAL, 3000 PSI, 35 GPM JET 79945410 1 DECAL, ANTIFREEZE GAUGE Page 74 79965800 - Control Box Assembly 28 31 25 26 36 12 32 14 30 1 2 20 43 19 11 8 30 21 17 22 13 18 23 15 32 18 17 16 21 18 24 23 22 39 77909700 13 24 39 79945410 9 10 28 7 15 5 31 MOUNTING DETAIL 5 39 79945410 Page 75 39 77909700 Final Wiring Schematic Part A Page 76 Final Wiring Schematic Part B Page 77 Final Wiring Schematic Part C - Control Box VIEW OF MATING SIDE OF CONNECTOR (7 PIN FEMALE - 63008500) 7 1 6 2 5 3 4 Page 78 79954100 - Final Wiring Schematic Part D - Terminal Block Page 79 79954100 - Final Wiring Schematic Part E - Remote Control 6 5 4 7 1 2 3 VIEW OF MATING SIDE OF CONNECTOR (7 PIN MALE - 63008600) Page 80 Page 81 (PART OF 79859906) BULLET CONNECTORS (TERMINAL 8) REMOTE TOGGLE SWITCH (PART OF 79830300) (TERMINAL 7) YELLOW WIRE ANTI-FREEZE LEVEL ORANGE WIRE QUICK CONNECTORS WATER LEVEL (TERMINAL 9) RED WIRE TERMINAL BLOCK 1 PULSE TOGGLE SWITCH STROBE TOGGLE SWITCH WATER TOGGLE SWITCH JUMPERS (TYP) LIGHTS TOGGLE SWITCH TERMINAL BLOCK 50 RELAY # 1 RELAY # 2 ENGINE SHUTDOWN ALL ITEMS SHOWN ARE CONTAINED IN 79945000 = TERMINAL BLOCK DESTINATION = WIRE HARNESS WIRE NUMBER WATER LEVEL RELAY # 3 REMOTE CLUTCH ENGAGE PULSATION RELAY # 4 Warrior Wiring Assembly Control Panel 79954200 - Trailer Wiring Harness Page 82 79954200 - Trailer Wiring Harness Page 83 Hi-Flow Ultimate Warrior Standard Accessories Part No. 02893400 02893500 02893600 02893700 02895300 44262300 44256200 44256000 44262200 71109900 73817300 77752600 77763700 77800600 79873500 79922950 79923400 79929910 79944100 79946000 79964000 79966000 79966100 79968100 79968200 79968300 79968400 79968500 Description 1-1/2 INCH FLUSHER 2 INCH FLUSHER 4 INCH FLUSHER 6 INCH FLUSHER 3 INCH FLUSHER HANDBOOK, PROFESSIONAL S & D GLOVES, FULL LENGTH LINER, GLOVE LINER, GLOVE (BOX OF 25) TIP CLEANER SET WASH DOWN ACCESSORY KIT ASSY., MOBILE HOSE REEL - U.S. ASSY., VENTURI PUMPING ATTACHMENT HOSE GUARD (TIGER TAIL) HOSE, ANTI - TURNAROUND DEVICE NOZZLE, WTHG - 79922940 W/1/2 SUPERCENTRALIZER WARTHOG 6-18" SERVICE KIT, WARTHOG 6-18" HOSE, GARDEN 5/8" X 100' REMOTE CONTROL, WARRIOR 5/8" X 500' THERMOPLASTIC HOSE NOZZLE, CLOSED HIGH FLOW NOZZLE, OPEN HIGH FLOW NOZZLE, ROCKET HIGH FLOW NOZZLE, "Q" HIGH FLOW NOZZLE, ROTATING HIGH FLOW NOZZLE, GRENADE HIGH FLOW NOZZLE KIT, HIGH FLOW Page 84 Tire Safety Information This portion of the User’s Manual contains tire safety information as required by 49 CFR 575.6. The National Traffic Safety Administration (NHTSA) has published a brochure (DOT HS 809 361) that discusses all aspects of Tire Safety, as required by CFR 575.6. It can be obtained and downloaded from NHTSA, free of charge, from the following web site: http://www.nhtsa.dot.gov/cars/rules/TireSafety/ridesonit/tires_index.html Tire Safety Terminology Glossary - Cold tire inflation pressure - The pressure in the tire before you drive. - Gross Axle Weight Rating (GAWR) - The maximum weight that any axle can support, as published on the Certification / VIN label on the front left side of the trailer. Actual weight determined by weighing each axle on a public scale, with the trailer attached to the towing vehicle. - Gross Vehicle Weight Rating (GVWR)- The maximum weight of the fully loaded trailer, as published on the Certification / VIN label. Actual weight determined by weighing trailer on a public scale, without being attached to the towing vehicle. - Load rating - The maximum load that a tire is rated to carry for a given inflation pressure. - Maximum load rating - The load rating for a tire at the maximum permissible inflation pressure for that tire. - Maximum permissible inflation pressure - The maximum cold inflation pressure to which a tire may be inflated. - Outer diameter - The overall diameter of an inflated new tire. - Recommended inflation pressure - The inflation pressure provided by the vehicle manufacturer on the Tire Information label and the Certification/VIN tag. - Rim - A metal support for a tire or a tire and tube assembly upon which the tire beads are seated. - Vehicle maximum load on the tire - The load on an individual tire that is determined by distributing to each axle its share of the maximum loaded vehicle weight and dividing by two. Tire Information Placard The Spartan Warrior’s Federal Certification/VIN label is located on the forward half of the left (road) side of the unit. The VIN label will identify the units GVWR and GAWR. The Spartan Warrior’s Tire Information Placard can be located adjacent to the trailer’s VIN (Certification) label at the left front of the trailer. The placard includes the Warrior’s tire size, cold tire inflation pressure, and load limitations. The load limitation statement will give an indication of the maximum cargo capacity. Any items (cargo) added to the Warrior must not cause the total weight of the Warrior to exceed the stated GVWR. Fig. 34-1 Page 85 Tire Safety Information Steps for Determining Correct Load Limit - Locate the statement “The weight of cargo should never exceed 2265 kg or 5000 lbs” on your tire information placard. - This figure equals the available amount of cargo and luggage load capacity. - Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not safely exceed the available cargo and luggage load capacity. General Tire Information - - - Tire inflation pressure is the level of air in the tire that provides the load-carrying capacity and affects the overall performance of the vehicle. The tire inflation pressure is a number that indicates the amount of air pressure a tire requires to be properly inflated. Since tires are designed to be used on more than one type of vehicle, tire manufacturers list the “maximum permissible inflation pressure” on the tire sidewall. This number is the greatest amount of air pressure that should ever be put in the tire under normal driving conditions. Improper inflation is the main cause of tire failure. Excessive loads and/or under inflation cause tire overloading, which leads to abnormal tire flexing. Check the cold tire inflation pressures at least once a week for proper inflation levels. o The proper air pressure may be found on the Certification/VIN label and/or the Tire Information placard. High speed towing in hot conditions degrades the life of the Warrior’s tires. The internal heat generated from high speeds breaks down the tire’s internal structure. It is recommended to drive at moderate speeds. If the trailer is stored for an extended period of time, the tires should be fully inflated to the maximum rated pressure. The Warrior should be stored in a cool, dry place. Use tire covers to protect the trailer tires from the harsh effects of the sun. Tire Maintenance Checking Tire Pressure - The recommended tire inflation pressure that vehicle manufacturers provide reflects the proper PSI when a tire is cold. A cold tire is one that has not been driven on for at least three hours. Since driving raises the tires temperature, the internal air pressure also increases. To prevent inflated tire readings, the tire must be measured when cold. Maintaining Proper Tire Pressure a. Locate the recommended tire pressure on the vehicle’s tire information placard, certification label, or in the owner’s manual. b. Record the tire pressure of all tires. c. If the tire pressure is too high in any tires, slowly release air by gently pressing on the tire valve stem with the edge of your tire gauge until the correct pressure is reached. d. If the tire pressure is too low, note the difference between the measured tire pressure and the correct tire pressure. Add the missing pounds of air pressure to each tire that is under inflated. e. Check all the tires to make sure they have the same air pressure Note: If the tires are warm due to driving, but testing confirms under inflation, fill the tire to the recommended cold inflation pressure. While the tire may be slightly under inflated due to extra pressure in the warm tire, it is safer to drive a slightly under inflated tire then to drive a significantly under inflated tire. Since this is a temporary fix, the tire must be re-checked and adjusted once a cold reading can be obtained. Tire Size and Tread - Tires should be replaced when the tread is worn down 1/16 of an inch. Treadwear indicators on the bottom of the tire can be used as a guide. The indicators are raised sections spaced intermittently in the bottom of the tread groves. If they appear even with the outside of the tread, the tire should be replaced. Replacement tires should be the same size as the Warrior’s original tires. To prevent error and maintain safety, it is recommended that all replacement parts be purchased through Spartan Tool LLC. Page 86 Tire Safety Information Tire Balance and Wheel Alignment - Tires must be properly balanced to avoid vibrations and shaking of the trailer. A wheel alignment adjusts the angles of the wheels to position them correctly relative to the trailer’s frame. Such adjustments can maximize the life of the tires, but should be performed by a qualified technician. Tire Repair - A punctured tire can be repaired by plugging the hole and patching the area that surrounds the puncture hole. A small puncture in the tire tread can be repaired, but punctures to the sidewall should not. Tires should be removed from the rim to be properly inspected before plugging. Special Trailer Designation Tire Fundamentals Fig. 36-1 Federal law requires tire manufacturers to place standardized information on the sidewall of all tires. This information identifies and describes the fundamental characteristics of the tire. It also provides a tire identification number for safety standard certification and in case of a recall. Tire Safety Tips Preventing Tire Damage - Slow down before driving over a pothole or other object in the road - Do not run over curbs or other foreign objects in the roadway. Tire Safety Checklist - Check tire pressure regularly (at least once a month). - Inspect tires for uneven wear patterns on the tread, cracks, foreign objects, or other signs of wear or trauma. - Remove bits of glass and foreign objects wedged in the tread. - Make sure tire valves have valve caps. - Check tire pressure before any long trips. - Do not overload trailer. Check the Tire Information Placard for the maximum recommended trailer load. Page 87 Safety Information Confirm that: • The coupler is secure to the hitch and is locked, • Electrical connections are made, • There is appropriate slack in the safety chains, • There is appropriate slack in the breakaway switch pull-pin cable, • The tires are not visibly low on pressure, and the cargo is secure and in good condition. Reporting Safety Defects If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Spartan Tool LLC. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Spartan Tool LLC. To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800424-9153), go to http://www.safecar.gov; or write to Administrator NHTSA 1200 New Jersey Avenue S.E. Washington, DC 20590 You can also obtain other information about motor vehicle safety from http://www.safecar.gov. Spartan Tool LLC 1506 W. Division St. Mendota, IL 61342 Page 88 Diesel Engine Emissions All Kubota Diesel engines are tested to meet emissions standards. See Figure 83-2 for the emissions authentication label. SAMPLE EMISSIONS LABEL Fig. 83-1 Page 89 Warranty Information ONE YEAR WARRANTY Spartan Tool warrants its equipment to free from defects in material and workmanship for one year from the date of purchase. To obtain warranty service, a purchaser should notify Spartan Tool in writing, at the address provided below, within the warranty period, and Spartan Tool will direct where to take or send the equipment for service. If the defect is covered by the warranty, Spartan Tool will repair or replace, at its option, the defective equipment, without charge for labor or materials. (Freight and insurance are the purchaser’s responsibility.) This warranty is limited to the original retail purchaser and is not transferable. Spartan Tool assumes no responsibility for damage due to accident, neglect, abuse, tampering or misuse, nor damage from repairs or alterations by others. This warranty does not cover dhe equipmente equipment resulting from the use of replacement parts other than Spartan Tool parts. Spartan Tool’s sole obligation and the original retail purchaser’s exclusive remedy under this warranty shall be for repair or replacement as described above. ALL OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE DISCLAIMED. IN NO EVENT SHALL SPARTAN TOOL BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES. SPARTAN TOOL L.L.C. MENDOTA, ILLINOIS 61342 SPARTAN TOOL L.L.C. 1506 W. Division Street Mendota, IL 61342 (800)435-3866 Fax (888)876-2371 www.spartantool.com Page 90