Page 1
Congratulations on your purchase of the
MODEL 454 SS® Truck mount cleaning unit. This
instruction/parts manual is a guide for operating
and servicing your SAPPHIRE SCIENTIFIC
Truck mount unit.
Proper operation and service are necessary to
ensure the outstanding performance of this unit.
When properly maintained, your Truck mount will
have a long and trouble-free life.
The following service methods outlined in this
manual are detailed in a manner that operation and
servicing may be performed properly and safely.
Because service levels vary due to the skill of the
mechanic, tools and parts availability, ensure that
prior to attempting any repair, you are familiar with
this equipment and have the proper tools. Any
questions regarding the operation, service, or repair
of this unit should be directed to your nearest
SAPPHIRE SCIENTIFIC dealer.
The headings WARNING and CAUTION are
utilized to warn you that steps must be taken to
prevent personal injury or damage to the
equipment. Please make sure that you have read
and understand these instructions entirely before
proceeding with the operation of this unit.
THIS UNIT MUST BE INSTALLED BY THE
DEALER THAT YOU PURCHASED IT
FROM IN ACCORDANCE WITH THE
SAPPHIRE SCIENTIFIC INSTALLATION
PROCEDURES.
BE SURE TO FILL OUT THE WARRANTY
CARD ONLINE AT
WWW.SAPPHIRESCIENTIFIC.COM
Record your units’ serial number here for future
reference or if you should need to contact the
factory in the future for any reason.
S/N:
This service and operations manual is written
specifically for SAPPHIRE SCIENTIFIC
MODEL 454 SS® Truck mount Cleaning units
manufactured by:
SAPPHIRE SCIENTIFIC
2604 Liberator
Prescott, AZ 86301
USA
The information contained in this document is
subject to change without notice and does not
represent a commitment on the part of
SAPPHIRE SCIENTIFIC.
All rights reserved. Copyright 2009 by
SAPPHIRE SCIENTIFIC. No part of this work
may be used or reproduced in any form or means
without the express written consent and
permission of SAPPHIRE SCIENTIFIC.
Published by SAPPHIRE SCIENTIFIC.
First printing: October 2009
Revised: July 2010; Rev A
September 2010; Rev B
Printed in USA
MODEL 454 SS® MANUAL
PART# 49-042
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
I
Page 2
SAPPHIRE SCIENTIFIC LIMITED WARRANTY
Sapphire Scientific Model 454 SS
What Does This Warranty Cover?
This warranty covers the Sapphire Scientific Model 454 SS and is provided to the original purchaser only.
How Long Does This Warranty Last?
This warranty runs for:
Two (2) years from the date of installation on parts and labor (Excluding normal maintenance
items.) Factory installed original belts are covered for 500 hours. Water box, recovery tank and
frame are covered for five years. All other components including seals, o-rings and electrical
components are covered for the entire two year warranty period.
What Sapphire Scientific Will Do:
If a defect in materials or workmanship occurs within the warranty period, Sapphire Scientific at its election will
repair or replace the defective part at no charge.
What This Warranty Does Not Cover:
This warranty does not cover or apply to defects due directly or indirectly to misuse, abuse, disassembly, alteration,
corrosive chemicals, improper voltage, improper fuel, fire, flood, negligence, accident, improperly or incorrectly
performed maintenance or repair, or failure to perform necessary or recommended maintenance or repair (See your
Owner’s Manual) or if the use of this product is not in compliance with the instructions and specifications for its use.
This warranty does not cover normal maintenance items such as air and oil filters, lubricants and tune up parts. Paint is
not covered. Water box, recovery tank and frame are covered for five years. All other components including seals, o-
rings and electrical components are covered for the entire two year warranty period. We limit all implied warranties to:
Two (2) years from the installation date on parts and labor. It is strongly recommended that this truck mount be
used with, and only with, Sapphire Scientific Chemicals and as directed by label instructions on chemical bottles.
OTHER THAN THE WARRANTIES PROVIDED HEREIN, SAPPHIRE SCIENTIFIC MAKES NO EXPRESS OR
IMPLIED, ORAL OR WRITTEN WARRANTIES WITH RESPECT TO THIS PRODUCT OR WORKMANSHIP AND
ALL WARRANTIES IMPLIED BY LAW INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO THE DURATION OF THIS WARRANTY. Some
states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.
WE SHALL IN NO EVENT BE LIABLE FOR DEATH, INJURIES TO PERSONS OR PROPERTY OR FOR
INCIDENTAL, CONTINGENT, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING FROM USE OF OUR
PRODUCTS. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation or exclusion may not apply to you.
How Do I Get Service?
In order to be eligible for service under this warranty you MUST do the following: (a) fill out the warranty registration
card on-line within thirty (30) days of the installation of our product; (b) have your dealer write or call for a return
material authorization (RMA); and (c) have the serial number and original proof of installation date available. Proof
of proper maintenance may be required before warranty is granted.
Contact us at:
Sapphire Scientific
2604 Liberator, Prescott, AZ 86301
Phone: 928-445-3030
If our dealer uncovers a defect we will repair or replace the product, at our election. Ground shipping and transportation
costs will be covered by the manufacturer. Returning defective parts to the manufacturer, if required, shall be the
responsibility of the purchaser. Warranty may be denied if defective parts are not returned within the allotted 30 days. If it
is determined that there is no defect in the product, or that the defect resulted from causes not within the scope of our
warranty, then the product will be repaired or replaced only at your request and at your expense and you must bear all
shipping costs.
How Does State Law Apply?
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
.
II SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 3
Table of Contents
SECTION ONE: GENERAL INFORMATION 1
1. SAFETY .....................................................................................................................................2
Safety, Specifications, Installation, Fuel, Engine Oil, Chemical, Water Requirements
2. RECEIVING YOUR TRUCKMOUNT UNIT .......................................................................8
Dealer Responsibility, Acceptance of Shipment, Equipment Listing, Optional Equipment
SECTION TWO: INSTALLATION 9
3. INSTALLATION .....................................................................................................................10
Lifting the Unit into the Vehicle, Positioning the Unit into the Vehicle, Fastening Down the Unit
and Waste Tank, Dimensional Diagrams, Installation of Fuel Lines, Trailer Fuel Tank and Fuel
Line Installation, Battery Connection, Fire Extinguisher, Console to Waste Tank Connection
SECTION THREE: OPERATION 14
4. SYSTEMS .................................................................................................................................15
Water Pumping System, Heat Transfer System, Vacuum System, Chemical System
5. OPERATION ...........................................................................................................................18
Equipment setup, Instrumentation, Starting Your Unit, Priming the Chemical Pump, Waste Pump,
Operation, Cleaning, Upholstery Cleaning, Stair Tool Cleaning, Flood Restoration, Shut Down
and Daily Maintenance, Freeze Protection.
SECTION FOUR: MAINTENANCE and SERVICE 25
6. .. MAINTENANCE CHART .....................................................................................................26
7. .. MAINTENANCE .....................................................................................................................27
8. .. GENERAL SERVICE ADJUSTMENTS ..............................................................................32
9. .. TROUBLESHOOTING ..........................................................................................................35
SECTION FIVE: PARTS and ACCESSORIES 41
10. ILLUSTRATED PARTS LISTINGS .....................................................................................42
11. ACCESSORIES .......................................................................................................................69
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
III
Page 4
Page 5
SECTION 1:
GENERAL INFORMATION
1. SAFETY
Safety ..................................................................................................................2
Specifications ......................................................................................................5
Installation requirements .....................................................................................6
Fuel requirements................................................................................................6
Engine oil requirements ......................................................................................6
Chemical requirements .......................................................................................7
Water requirements .............................................................................................7
2. RECEIVING YOUR TRUCKMOUNT UNIT
Dealer responsibility ...........................................................................................8
Acceptance of shipment ......................................................................................8
Equipment listing ................................................................................................8
Optional equipment .............................................................................................8
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
1
Page 6
1. SAFETY
The following WARNING labels are on
your MODEL 454 SS® console. These
labels point out important Warnings and
Cautions, which must be followed at all
times. Failure to follow warnings could
SECTION 1
For Your Safety!
result in personal injury or fatality to
yourself and/or others or property damage.
Please follow these instructions carefully!
DO NOT remove these decals.
2 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 7
!
1. Read the operator’s manual before
starting this unit.
Failure to adhere to instructions could result in
severe personal injury or could be fatal.
2. Operate this unit and equipment only in a
well-ventilated area.
Exhaust fumes contain carbon monoxide,
which is an odorless and deadly poison that can
cause severe injury or death. DO NOT run this
unit in an enclosed area. DO NOT operate this
unit where the exhaust may enter a building
doorway, window, vent or other opening.
3. Gasoline is extremely flammable and its
vapors can explode if ignited.
Store gasoline only in approved containers, in
well-ventilated, unoccupied buildings and
away from sparks or flames. Never carry
gasoline or any flammable materials in the
vehicle. Fumes could accumulate inside of the
vehicle and ignite, causing an explosion.
4. This unit must be operated with the
vehicle doors and windows open in order to
ensure adequate ventilation to the engine.
5. DO NOT operate unit if gasoline is spilled.
Do not turn ignition switch until the gasoline
has been cleaned up. Never use gasoline for
cleaning purposes.
6. DO NOT place hands, feet, hair, clothing or
any body parts near rotating or moving parts.
Rotating machinery can cause severe injury or
death.
7. NEVER operate this unit without belt and
safety guards. High speed moving parts, such
as belts and pulleys, should be avoided while
the unit is running. Severe injury, fatality or
damage may result.
8. NEVER service this unit while it is running.
High speed mechanical parts as well as high
temperature components may result in injury or
severed limbs.
9. Engine components will be extremely hot
from operation. To prevent severe burns, DO
NOT touch these areas while the unit is
running or shortly after the unit is shut off.
10. DO NOT touch any part of the exhaust
system while the system is running or for 20
minutes after the unit is shut off. Severe burns
could result.
11. Water under high pressure at high
temperature can cause burns, severe
personal injury, or fatality. Shut down unit,
allow to cool down, and relieve system of all
pressure before removing caps, valves, plugs,
fittings, filters or hardware.
12. NEVER leave the vehicle engine running
while the unit is in operation.
13. Battery acid contains sulfuric acid. To
prevent acid burns, avoid contact with skin,
eyes and clothing. Batteries also produce
explosive hydrogen gases while charging. To
prevent fire or explosion, charge batteries only
in a well ventilated area. Keep sparks, open
flames, as well as other sources of ignition
away from battery at all times. Remove all
jewelry prior to servicing batteries. Keep
batteries out of the reach of children.
Before disconnecting the negative (−) ground
cable, ensure that all switches are in the off
position. If on, a spark could occur at the
ground connection terminal which could cause
an explosion if hydrogen gas or gasoline
vapors are present. ALWAYS disconnect the
negative (−) terminal first.
14. DO NOT smoke around the machine. Gas
fumes could accumulate and ignite. Battery
gases are extremely flammable. This will
prevent possible explosions.
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
SECTION 1
®
3
Page 8
SECTION 1
15. DO NOT damage the vehicle in any way
during the installation. When routing fuel lines
DO NOT configure the hose in any locations
where the hose or vehicle could be damaged.
Avoid contact with moving parts, hot surfaces,
brake lines, fuel lines, catalytic converters,
exhaust pipes, mufflers or sharp objects.
16. NEVER cut or splice any of the vehicle
fuel lines during fuel line installation. This will
result in fuel leaks and potentially dangerous
conditions. Use only the provided fuel hose for
fuel lines. When going through the vehicle
floor with fuel lines, always utilize bulkhead
adaptors. This will prevent fuel leaks and
ensure that hoses are not punctured by vehicle
vibration abrasion.
17. DO NOT exceed your vehicles weight
limit. The console with waste tank and
accessories weighs approximately 1100
pounds. Make certain that the vehicle has the
correct axle rating. This will prevent unsafe or
hazardous driving conditions.
18. High back seats are required for all vehicles
that units are to be installed for head and neck
protection. Metal partitions between the seats
and equipment are strongly recommended.
19. Always keep your vehicle clean and
orderly. Wands, tools and accessories must be
securely stowed while driving the vehicle.
20. All high-pressure hoses must be rated at
3000 PSI and have a heat rating of 250 degrees
F. Thermoplastic hoses do not meet this
criterion and should never be used. Severe
burns and other injuries could result if hoses do
not meet these requirements.
21. Ensure that you have received proper
training from the distributor that you purchased
the unit from prior to operation.
22. This unit produces high pressure and high
temperatures. Improper use could result in
serious injury.
23. DO NOT modify this unit in any manner.
Any modification could result in serious injury
or fatality. This includes the use of any open
ended hoses.
CALIFORNIA PROPOSITION 65
WARNING: ENGINE EXHAUST FROM
THIS PRODUCT CONTAINS
CHEMICALS KNOWN BY THE STATE
OF CALIFORNIA TO CAUSE CANCER,
BIRTH DEFECTS, OR OTHER
REPRODUCTIVE HARM.
ALL FUEL LINES MUST MEET CARB
III and EPA PHASE 3 LOW
PERMEABILITY REQUIRMENTS.
ALL FUEL STORAGE TANKS MUST
MEET CARB III and EPA PHASE 3
PERMEATION and VENTING
REQUIRMENTS.
ALL FUEL ADAPTOR KITS AND FUEL
TANKS USED IN THE STATE OF
CALIFORNIA MUST MEET CURRENT
CALIFORNIA AIR RESOURCES
BOARD (ARB) REGULATIONS.
CARB EXECUTIVE INFORMATION
LABEL(S) MUST BE INSTALLED IN A
VISABLE LOCATION.
4 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 9
SECTION 1
SPECIFICATIONS
Engine Speed …………………………. 3000 rpm (High Speed No Load)
…………………………. 1500 rpm (Idle No Load)
Water Pump RPM…………………….. 1500 rpm
Vacuum Pump RPM…………………... 3000 rpm
Water Flow Rate………………………. 5.0 GPM (maximum)
Water Pump Pressure…………………. 1500 PSI (maximum)
Vacuum Relief Valve…………………. 14 in. Hg
Waste Tank Capacity…………………. 90 gal.
Waste Tank Shut-Off…………………. 75 gal.
Console Weight……………………….. 893 lbs.
Console Weight (with standard waste tank
& hoses) Approximately………..............1292 lbs.
Operating Weight (full standard waste tank and water box) Approximately 2012 lbs.
TORQUE VALUES
Engine Hub Rear……………………………………... 180 inch/lbs. 15 ft/lbs.
Engine Hub Front…………………………………….. 180 inch/lbs. 15 ft/lbs.
Vacuum Pump Hub…………………………………... 180 inch/lbs. 15 ft/lbs.
JET SIZING
SAPPHIRE SCIENTIFIC recommends that the total floor tool tip size does not exceed
#4. Using larger jet sizes on your MODEL 454 SS® unit may reduce cleaning
temperatures.
Sapphire Scientific recommends using the
Stryker Cleaning and Extraction Wand:
* Rotomolded ergonomic handle provides
balanced handling and substantially reduces
operator fatigue.
* Stainless steel extraction tube for rugged
service and long life.
* Rotomolded head resists dents and scratches
and doesn’t readily gouge molding or furniture.
* Purge valve for easy cleaning.
* Classic S-shape makes reaching under
objects or furniture easy.
* Rotomolded 14" head with full-width high
pressure injector and two-way extraction glide
provides maximum coverage and extraction.
* Forged brass valve, centrally positioned for
right- or left-handed operation.
* Glide assembly is easy to replace when worn
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
5
Page 10
SECTION 1
Above 37º C (99º F)
SAE40
25° C to 37º C (77° F to 99º F)
SAE30 or SAE10W-30
0° C to 25° C (32° F to 77° F)
SAE20 or SAE10W-30
Engine oil capacity
2.4 L
2.53 U.S.qts
Tightening torque
Drain Plug
32.4 to 37.3 N·m
3.3 to 3.8 kgf·m
23.9 to 27.5 lbf·ft
INSTALLATION
REQUIREMENTS
Prior to beginning the installation, read the
ENTIRE “Installation” section of this manual.
Since the MODEL 454 SS® Truck mount unit
weighs (with standard waste tank and hoses)
approximately 1300 lbs., please adhere to the
following recommendations prior to installing
the unit.
1. The unit should NOT be installed in any
motor vehicle rated less than 3/4 ton capacity.
!
The console and waste tank with accessories
must NOT exceed the vehicle’s axle weight
limit.
2. If mounting the unit in a trailer, ensure that
the trailer is rated for the total weight of the
unit and trailer. Electric or hydraulic brakes
must be provided, and strict compliance with
all State and Federal laws must be maintained.
3. If mounting in a trailer, the MODEL 454
SS® console must be positioned so that it
balances properly with respect to the trailer
axle. With a minimum of ten percent (10%) of
the unit’s total overall weight (w/o accessories
or water) should be on the tongue. Adequate
ventilation must be provided to prevent overheating. Either two sets of doors or a roof
ventilation system is highly recommended.
4. The vehicle tires must have a load rating in
excess of the combined unit and vehicle
weight.
5. SAPPHIRE SCIENTIFIC does not
recommend using any type of flooring
materials that absorb water. This condition will
result in rust and corrosion of the vehicle floor.
6. Insulation under rubber mats should be
removed prior to installation of the unit.
FUEL REQUIREMENTS
Use unleaded fuel ONLY. Use only fresh,
clean unleaded gasoline with a minimum
octane rating of 87. Do Not use high octane
gasoline. Gasoline with up to, not exceeding,
10% ethanol is acceptable.
NOTE: Using other gasoline/alcohol blends
including E20 and E85 will cause damage to
engine components and will void the warranty.
ENGINE OIL
REQUIREMENTS
Use high-quality oil of at least API (American
Petroleum Institute) service class SF, SG, SH,
SJ or higher. Do not use additives. Select the
viscosity based on the air temperature at the
time of operation as shown in the following
table.
NOTE: Using a lower service class oil or
extending oil change intervals longer than
recommended can cause engine damage.
NOTE: Synthetic oils meeting the listed
classifications may be used with oil changes
performed at recommended intervals. However
to allow piston rings to properly seat, a new or
rebuilt engine should be operated for at least 50
hours using standard petroleum based oil
before switching to synthetic oil.
6 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 11
SECTION 1
CHEMICAL REQUIREMENTS
The SAPPHIRE SCIENTIFIC MODEL 454
SS® Truck mount unit’s unique last step
chemical injection system can be used with a
wide variety of water diluted chemical
compounds, either acidic or alkaline,
depending on the work to be performed. We
recommend using only SAPPHIRE
SCIENTIFIC brand chemistry.
WATER REQUIREMENTS
Because hard water deposits will damage the
plumbing and heat exchange systems on this
unit, SAPPHIRE SCIENTIFIC recommends
that a high quality water softener be used in
areas where the water hardness exceeds 3½
grains. If a water softener is used, it must have
a flow capacity of at least five (5) GPM or
greater, without any hose constrictions.
The use of a water softening system will reduce
maintenance and reduce down time caused by
hard water scaling. It will also enhance the
performance of cleaning chemicals, which will
result in greater efficiency in lower
concentrations.
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
7
Page 12
SECTION 1
2. RECEIVING YOUR
TRUCKMOUNT UNIT
DEALER RESPONSIBILITY
THE SAPPHIRE SCIENTIFIC DEALER
THAT YOU PURCHASED THIS
TRUCKMOUNT CLEANING UNIT FROM
IS RESPONSIBLE FOR THE PROPER
INSTALLATION OF THIS MACHINE. THE
DEALER IS ALSO RESPONSIBLE FOR
THE PROPER INITIAL TRAINING OF
YOUR OPERATORS AND MAINTENANCE
PERSONNEL.
ACCEPTANCE OF SHIPMENT
Your MODEL 454 SS® Truck mount cleaning
unit was thoroughly tested, checked and
inspected in its entirety prior to leaving our
manufacturing facility. When receiving your
unit, please make the following acceptance
check:
1. The unit should not show any signs of
damage. If there is damage, notify the common
carrier immediately.
2. Carefully check your equipment and packing
list. The standard SAPPHIRE SCIENTIFIC
MODEL 454 SS® unit should arrive with the
following items as well as any optional
accessories:
EQUIPMENT LISTING
SAPPHIRE SCIENTIFIC MODEL 454
SS® console.
Operation and Service manual.
Installation mounting plates and bolt down
kit.
Hose clamps for vacuum and fuel hoses.
Waste tank with shutoff switch.
Waste tank filters and stainless steel
strainer basket.
Two sections of 2 in. x 50 ft. vacuum hose
Two sections of 2.5 in. x 37.5 ft. vacuum
hose.
Two 50 ft. sections of high pressure
solution hose
Two 37.5 ft. sections of high pressure
solution hose
Two vacuum hose connectors.
Two hose-reducing cuffs to 2 in.
50 ft. water supply hose with quick
connect.
OPTIONAL EQUIPMENT
A. Additional lengths of vacuum hose
Part # 18-003
B. Additional vacuum hose connectors
Part # 21-003
C. Additional high-pressure solution hoses
Part # 18-000
(With shutoff valve Part # 18-001)
D. Automatic waste pump kit
Part # 68-003
E. Demand pump system
Part # 68-002
F. KIT, FUEL HOOKUP CHEVY 97 TO
2002. FI Part # 69-003
G. KIT, FUEL HOOKUP CHEVY/DODGE FI
Part # 69-004
H. KIT, FUEL HOOKUP FORD FI
Part # 69-005
I. KIT, FUEL HOOKUP 2003 CHEVY FI
Part #69-018
J. KIT, 2004 & UP, TF FUEL INJ. CHEVY
Part # 69-033
K. ADAPTOR, 2004 & UP, FORD FUEL
Part # 69-061
L. KIT, FUEL FORD CUT AWAY 04-05
Part # 69-077
M. KIT, FUEL CHEVY CUT AWAY 04-05
Part # 69-081
N. ASSY, WASTE PUMP OUT
Part #68-158
8 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 13
SECTION 2:
INSTALLATION
3 INSTALLATION
Lifting the unit into the vehicle ..........................................................................10
Positioning the unit into the vehicle...................................................................10
Fastening down the unit and waste tank ............................................................10
Dimensional diagrams .......................................................................................11
Installation of fuel lines .....................................................................................12
Trailer fuel tank and fuel line installation ..........................................................12
Battery Connection ............................................................................................12
Fire extinguisher ................................................................................................12
Console to waste tank connection ......................................................................13
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
9
Page 14
SECTION 2
3. INSTALLATION
!!!
This unit must be bolted to the floor of the
vehicle by an authorized SAPPHIRE
SCIENTIFIC DISTRIBUTOR.
LIFTING THE UNIT INTO THE
VEHICLE
Because the SAPPHIRE SCIENTIFIC MODEL
454 SS® console weighs approximately 900 lbs., a
forklift is necessary to place the unit into the
vehicle. Place the forks under the unit. Using two
“C” clamps, secure the console to the forks. Move
the unit into desired position.
POSITIONING THE UNIT INTO
THE VEHICLE
Vehicles vary in size and openings. Owners have
different preferences on where in the vehicle they
want their units positioned. SAPPHIRE
SCIENTIFIC strongly recommends a side door
installation for the MODEL 454 SS®. We DO
NOT recommend a rear door installation.
1. Ensure that enough space is provided to assure
adequate engine ventilation as well as room for
service and maintenance.
2. Operating weight of the complete installation
(which includes water weight) with waste tank and
all accessories MUST NOT exceed the vehicle’s
axle weight limit.
FASTENING DOWN THE UNIT
AND WASTE TANK
!!!
Prior to drilling any holes in the vehicle floor,
ensure that while drilling, you will not damage
the fuel tank, fuel lines, or any other vital
components which could affect the safety or
operation of the vehicle.
A. The console and waste tank mounting holes will
serve as a template. Drill six (6)
holes for the console and four (4)
holes for the waste tank.
B. Using the provided mounting hardware kit:
1. Insert six (6), grade 5, ⅜-16 × 4 in. hex
head cap screws with flat washers through
the MODEL 454 SS® console mounting
holes, and four (4), grade 5, ⅜-16 × 4 in.
hex head cap screws with flat washers
through the waste tank mounting holes.
2. Install the provided mounting plates
underneath the vehicle floor.
3. Screw the provided ⅜-16 hex head lock
nuts on to the mounting bolts and tighten
until the console and waste tank are firmly
attached to the vehicle floor.
13
⁄
in. diameter
32
13
⁄
in. diameter
32
10 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 15
SECTION 2
DIMENSIONAL DIAGRAM REAR MOUNT TANK
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
11
Page 16
SECTION 2
INSTALLATION OF FUEL LINES
!!!
READ THESE INSTRUCTIONS IN THEIR
ENTIRETY PRIOR TO PROCEEDING.
!
The Vehicle fuel lines should NOT be spliced
under ANY circumstances. Severe injury or
fatality could result.
DO NOT damage the vehicle in any way during
the installation. When routing fuel lines, DO NOT
configure the hoses in any location where the
hoses, or vehicle could be damaged. All fuel lines
must meet CARB TIER III and EPA PHASE 3
low permeability requirements. Avoid contact
with moving parts, areas of high temperature,
brake lines, fuel lines, catalytic converters, exhaust
pipes, mufflers or sharp objects. Fuel pump must
be mounted in a vertical position as near as
possible to the fuel supply, and not located near
any heat sources. Excess heat from exhaust or
other heat sources may cause the fuel pump to
work improperly.
TRAILER FUEL TANK AND FUEL
LINE INSTALLATION
The following are recommendations for trailer
installations:
A. Strict compliance with all federal and state laws
must be maintained. Tanks must meet CARB
TIER III and EPA PHASE3 permeation and
venting emissions requirements.
B. Use only fuel tanks that are manufactured
specifically for gasoline, have proper vented filling
caps, and outlet connections that are the same size
as the inlet and return connections on the unit.
C. DO NOT install fuel tanks inside any type of
enclosed trailer or vehicle.
!
NEVER carry gasoline or flammable materials in
an enclosed trailer or vehicle.
NEVER store any type of flammable material in
an enclosed trailer or vehicle.
D. Always mount fuel tanks where they will be
protected from any vehicle collision.
E. When installing fuel lines from the fuel tank to
the unit, use the proper size fuel line.
BATTERY CONNECTION
!
Explosive gases, Dangerous gases!
Batteries contain sulfuric acid. To prevent acid
burns, avoid contact with skin, eyes and clothing.
Batteries also produce explosive hydrogen gases
while charging. To prevent fire or explosion,
charge batteries only in a well ventilated area.
Keep sparks, open flames, as well as any other
sources of ignition away from batteries at all times.
Remove all jewelry prior to servicing batteries.
Keep batteries out of the reach of children.
Before disconnecting the negative (−) ground
cable, ensure that all switches are in the OFF
position. If ON, a spark could occur at the ground
connection terminal, which could cause an
explosion if hydrogen gas or gasoline vapors are
present. ALWAYS disconnect the negative (−)
terminal first.
A. Attach the red positive (+) battery cable from
the starter solenoid on the console to the positive
(+) terminal on the battery and tighten down the
nut.
B. Attach the black negative (−) battery cable from
the ground on the console to the negative (−)
terminal on the battery and tighten down the nut.
FIRE EXTINGUISHER
SAPPHIRE SCIENTIFIC, and many government
agencies, recommend that a fire extinguisher rated
for A, B, and C type fires be installed into any
commercial vehicle.
12 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 17
SECTION 2
CONSOLE TO WASTE TANK CONNECTION
Waste Tank to
Vacuum Brake
Vacuum Inlet
Waste Tank
17-701
HOSE, INT VACUUM 3-1/2 X 25”
16-014
HOSE, INT VAC 3-1/2 X 60”
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
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Page 18
SECTION 3:
OPERATION
4. SYSTEMS
Water/Heating system ........................................................................................ 15
Vacuum system .................................................................................................. 16
Chemical pumping system ................................................................................. 17
5. OPERATION
Preparation ......................................................................................................... 18
Starting the unit .................................................................................................. 20
Priming the chemical pump ............................................................................... 20
Automatic waste pump ...................................................................................... 21
Operation ........................................................................................................... 21
Cleaning ............................................................................................................. 21
Upholstery cleaning ........................................................................................... 21
Stair tool cleaning .............................................................................................. 21
Flood restoration/extraction ............................................................................... 22
Shut down and daily maintenance ..................................................................... 22
Freeze protection................................................................................................ 23
14 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 19
SECTION 3
Heat
Coils
Float Valve
Water Box
Water Pump
Solution
Outlets
Solution
Manifold
Bypass Orifice
Manifold
Bypass Cylinder
Closed – Heating
Open – No Heat
To Water
Inlet
4. SYSTEMS
NOTE: Read and understand this section of the
manual entirely before proceeding.
This portion of the manual divides the unit up into
systems and describes how each system works.
Prior to proceeding into the operations and
maintenance sections of this manual it is
recommended that you acquire a basic
understanding of how the unit functions.
WATER/HEATING SYSTEM
Cold water enters the console through the water
inlet connection located on the lower left corner of
the lower front panel. The water then flows to the
water box through a float valve, which shuts off
the water when the water box is full.
The water is pre-heated in the water box using
radiant heat generated by the vacuum blower and
the engine.
The water then flows to the water pump where it is
pressurized. From there it flows to the heat
exchanger where it travels through finned tubing
and is further heated by the vacuum blower and
engine exhaust.
The hot water then flows through the check valve
manifold that contains a strainer and a check valve.
At this point, the chemical injection takes place.
The hot solution mixture of water and chemicals
then flows through the solution outlet manifold to
the cleaning tool.
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
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Page 20
SECTION 3
Vacuum
Brake
Vacuum
Pump
Water Box/Dual Exhaust
Heat Exchanger
Vacuum
Inlets
Strainer
Basket
Filters
Exhaust
VACUUM SYSTEM
The engine turning an vacuum pump generates the
vacuum. The air is channeled in one side of the
vacuum pump, compressed and discharged on the
opposite side, creating airflow. This airflow is used
to do the work necessary for the extraction process.
A vacuum nozzle applied to the carpet surface
removes moisture, dirt and spent chemicals. These
elements are conveyed back to a separating tank
utilizing hoses and the force of air. Particles of
moisture and dirt are separated in the vacuum tank
using a series of changes in direction and velocity.
The air is then filtered and rushes into the vacuum
pump.
The vacuum pump also heats incoming air as it is
compressed. The hot discharged air is forced down
stream into a silencer for noise abatement. Exiting
the silencer, this hot air is directed through the heat
exchanger
The vacuum pump speed is factory set to maximize
vacuum pressure and provide sustained system life.
Do not alter the vacuum speed outside the
recommended range shown in the Technical
Specifications section.
A level shut off sensor is located near the top of
the waste tank and will shut down the unit before
the tank is at full capacity. This protects the
vacuum pump from water damage. Note: Waste
tank level shut off will not shut the unit off due to
high levels of foam. The use of a quality defoamer
is recommended.
16 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 21
SECTION 3
CHEMICAL PUMPING SYSTEM
The chemicals are drawn from the chemical
container through a strainer into the flow meter
mounted on the control panel. The flow meter
indicates the rate of chemical flow.
The chemicals then flow through the stainless steel
chemical pump, the chemical is then injected into a
three way selector valve located on the front panel.
This valve may be used to turn the chemical flow
ON, OFF, or to PRIME the chemical pump.
The chemicals then flow through the chemical
metering valve to the solution outlet. This valve
controls the rate of flow of chemical into the
cleaning solution, which is indicated on the flow
meter.
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
17
Page 22
SECTION 3
Chemical Flow
Auxilary
Ignition Switch
Throttle
Control Cable
Engine
Water Pump
Temperature
Gauge
Chemical Prime
Chemical Metering
30 Amp Main
Diverter
Engine Hour
Thermostatic
Temperature
Control
20 Amp Circuit
Water Pressure
Gauge
Vacuum
Gauge
Transfer Pump-out
Switch
5. OPERATION
PREPARATION
This section of the operator’s manual explains
how to prepare, start, operate, shut down and
maintain your SAPPHIRE SCIENTIFIC
MODEL 454 SS® mobile cleaning unit. The
MODEL 454 SS® unit is easy to operate,
however only trained operators should proceed.
!
Operate this unit and equipment only in a well
ventilated area. Exhaust fumes contain carbon
monoxide, which is an odorless and deadly
poison that can cause severe injury or death.
DO NOT run this unit in an enclosed area.
DO NOT operate this unit where the exhaust
may enter a building doorway, window, vent
or any other opening.
18 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 23
SECTION 3
Outlet
Filter
Chemical
Check Valve
Pressure
Outlets
Water Supply
Inlet
Exhaust
Vacuum Lube
Cup
Preheat
Valve
Vacuum
Inlets
Pressure
Regulator
ENSURE THERE IS ADEQUATE FUEL
Check the fuel tank to ensure there is adequate
fuel to complete the job and transport the
vehicle. This unit consumes approximately 1.5
US gallon of fuel per hour, depending on the
speed setting.
REMOVE TOOLS FROM THE
VEHICLE
Remove any tools, accessories or hoses from
the vehicle that you will require.
WATER SUPPLY CONNECTION
NOTE: Prior to connecting your water inlet
hose to any supply faucet, flush out the faucet
until the water is free of any debris. Also,
flush out any debris from your water inlet
hose.
1. Connect the water supply hose to the water
inlet quick connector on the front of the unit.
Connect the hose to the faucet.
NOTE: Never use a waste pump outlet hose
as a water inlet hose. Use only clean hoses for
water supply.
2. Turn the water supply faucet on. Water will
fill the water box.
HIGH PRESSURE HOSE
Before starting the unit, connect the high
pressure hose to the pressure outlet connection
at the front of the unit. Connect the cleaning
tool to the opposite end of the pressure hose.
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
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Page 24
SECTION 3
STARTING THE UNIT
!
1. Set throttle control in, pull out engine
choke, turn water pump switch to override
(OVR) and turn ignition key to start.
2. Push in engine choke after engine has
started.
3. Set throttle control to desired speed.
NOTE: Do not operate the unit with throttle
control set below 50% of maximum throttle
setting.
4. Turn the water pump switch to the ON
position.
NOTE: If the unit does not build water
pressure after 5 seconds, check for adequate
water supply. See “Loss of Water Pump
Pressure in the Troubleshooting section of
this manual.
VACUUM HOSE
Connect the vacuum hose(s) to the vacuum
inlet connection at the front of the unit.
Connect the opposite end of the vacuum
hose(s) the cleaning tool. Let the unit run for a
few minutes with the vacuum inlets partially
blocked off to warm up the cleaning solution.
SAPPHIRE SCIENTIFIC recommends that
the total floor tool size does not exceed #4.
Using larger jet sizes on your MODEL 454
SS® unit may reduce cleaning temperatures.
PRIMING THE CHEMICAL
PUMP
NOTE: SAPPHIRE SCIENTIFIC
recommends that the chemical pump be
primed whenever the water pump is on. This
eliminates possible pressure fluctuations and
water pump pulsations related with running
the chemical pump dry.
1. Insert the chemical prime tube and the
chemical inlet tube into the chemical
container.
NOTE: When inserting the chemical tube into
the chemical container, ensure that it stays
submerged, as the chemical pump will not
function if air is allowed to enter the inlet line.
2. Turn the 3-way chemical prime valve
located on the control panel to the PRIME
position. The chemical will then flow from the
chemical container through the chemical
prime tube into the vacuum system.
If the pump does not prime, then:
Seal off the vacuum port. The vacuum will
quickly draw chemical from the chemical
container. After the flow begins, turn the
chemical prime valve to OFF position and
turn the chemical prime valve back to the
PRIME position and continue the
procedure.
3. When the chemical flows with no air
bubbles, priming has been achieved. Turn the
chemical prime valve from PRIME to ON.
With the cleaning tool open, check the flow
meter and adjust the chemical metering valve
until the desired rate of chemical flow is
achieved.
20 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 25
SECTION 3
AUTOMATIC WASTE PUMP
1. If your unit is equipped with an optional
automatic waste pump, connect one end of the
⅝ in. or larger garden hose to the pump-out
connection and the other end to an acceptable
waste disposal.
2. Turn the pump-out switch located on the
front console control panel to the ON position.
The waste pump will now operate
automatically throughout the cleaning period.
DO NOT use an outlet hose that is smaller
than ⅝ in. I.D.
NEVER use a waste pump hose as a water
inlet hose.
!
NEVER dispose of waste water in a storm
drain, water way or on ground areas.
Always dispose of waste in accordance with
Local, State and Federal laws.
OPERATION
After you have completed the previous steps,
proceed with the cleaning or restoration
operation. Place the throttle control cable to a
minimum of 50% of throttle control maximum
for cleaning or restoration. A float shut-off
switch is located inside of the waste tank. It
will automatically shut down the unit if the
tank reaches its full capacity. If this occurs,
empty the waste tank before continuing. When
doing flood extraction, the water pump switch
should be in the OFF position.
NOTE: Vacuum pressure must have a
minimum 7”hg for the diverter valve to work
properly. Attaching 1 length of hose should
create enough vacuum pressure to achieve
this.
NOTE: During flood extraction it is
recommended the throttle control is set to
maximum.
CLEANING
Observe the following guidelines:
1. Before cleaning, ensure that the wand
nozzles are functioning properly.
A. Hold the wand approximately one foot
above the surface to be cleaned and
open the wand valve. A full even spray
should emit from the cleaning nozzles.
B. If the nozzles are not showing a full
even spray pattern, adjust, clean, or
replace the nozzles, if required.
2. Usually, chemical solution is applied during
the push stroke of the wand during cleaning,
and extraction is done on the pull stroke. For
heavily soiled carpets, the wand may be used
in a scrubbing action, with chemical solution
applied in both push and pull strokes,
provided that the final stroke is a pull stroke
with no chemical injection.
UPHOLSTERY CLEANING
1. Run unit on low speed. Upholstery tools
have a lower flow rate and smaller orifices.
Adjust the thermostatic temperature control to
the desired temperature. To maintain proper
cleaning temperatures, make certain that the
unit has been fully heated up prior to cleaning.
STAIR TOOL CLEANING
1. Run unit on low speed. Adjust the
thermostatic temperature control to the desired
temperature.
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
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Page 26
SECTION 3
FLOOD
RESTORATION/EXTRACTION
!
1. Set the throttle control cable on the front
control panel to a minimum of 50% of throttle
control maximum. Make certain that the
water pump switch is in the OFF position
and depress and turn the Diverter Lockout
button. Proceed into the extraction process.
SHUT DOWN AND DAILY
MAINTENANCE
1. Flush out the chemical system with fresh
water to remove any chemical residue.
2. Remove as much moisture from the vacuum
hoses as possible. This will prevent spillage of
wastewater in your vehicle when returning
hoses.
3. Disconnect the vacuum hose from the front
of the unit.
4. Adjust the throttle control cable to the idle
position.
5. Adjust the thermostatic temperature control
to the lowest setting.
6. Allow the unit to run for at least 5 minutes
with bypass valve open. This will also help to
remove any excess moisture from the vacuum
pump and cool the unit down.
NOTE: If shutting down for the day: Plug the
vacuum inlets on the front of the unit and set
the throttle control cable to high. Spray WD40 (or equivalent) into the vacuum
lubrication cup, located on the right hand
side of the control panel, for 5 seconds. Let
machine run 2 minutes to disperse lube to
blower. Unplug the vacuum inlet and remove
load. Next, return the throttle control cable to
idle position, and let idle for 3 to 5 minutes.
7. Turn the ignition switch to the OFF
position.
8. Turn the water supply faucet off. Loosen
the water supply hose at the water supply to
bleed off any pressure. Unhook the water
supply hose and return it to the vehicle.
9. Activate the valves on all cleaning tools.
This will relieve any remaining pressure.
Disconnect the cleaning tools and solution
hoses and return them to the vehicle.
10. Drain the waste tank, disposing of
wastewater in a suitable and proper location.
!
NEVER dispose of wastewater in a storm
drain, water way or on ground areas. Always
dispose of waste in accordance with Local,
State, and Federal laws.
11. Remove the strainer basket from the waste
tank. Clean out any debris and re-install.
Microban QGC cleaner is the best product for
cleaning and sanitizing the waste tanks as well
as other parts of the system
NOTE: Damage may occur to the vacuum
pump. Replacement and maintenance of the
filter will prevent rust and corrosion from
entering the vacuum pump.
12. Inspect the vacuum inlet filter inside the
waste tank daily. Remove and clean the filter
if there is any lint or debris present.
NOTE: To remove the vacuum inlet filter,
grip the plastic hexagon section of the filter.
Gripping the filter by the screen will collapse
or destroy the filter. After cleaning, grease the
threads on the filter and replace the filter.
Tighten the filter until hand tight and then
loosen ¼ turn. This will make the filter easier
to remove when cleaning or replacement is
required.
22 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 27
SECTION 3
NEVER operate this unit with the filter
removed, damaged or improperly installed.
13. At the end of the work day, rinse out the
waste tank with fresh water. Microban QGC
cleaner as the best product for cleaning and
sanitizing the waste tanks as well as other
parts of the system
14. Clean the vehicle interior, unit, tools,
hoses etc., as needed. Inspect ALL equipment
and accessories for any damage, leaks, wear,
etc.
FREEZE PROTECTION
!
If the unit is exposed to freezing weather
conditions, the water inside of the unit may
freeze, resulting in SERIOUS DAMAGE to
the unit. The following is recommended to
prevent this from occurring during the cold
weather season:
1. Always park the unit in a heated building
when not in use.
2. While out in operation, avoid long periods
of shut down as the unit generates heat while
running. Keep the unit running just prior to
leaving for the next job.
3. If a heated building is not available,
winterize the unit with anti-freeze.
It is not possible to winterize units that have
auxiliary water tanks. If the unit has an
auxiliary water tank(s), it must be stored in a
heated building.
WINTERIZING YOUR UNIT WITH
ANTI-FREEZE:
1. Shut off the water supply to the unit and
disconnect the water inlet hose from the
console.
2. Connect all solution hoses and a tool to the
console.
3. Start the unit with the water pump switch in
the ON position. Open a valve on the tool.
4. Fill the water box with one gallon of 100%
glycol based anti-freeze.
5. Start the unit and set the throttle control
cable to the idle position. Insure the water
pump is on. Open the tool valve until antifreeze comes out of the tool. Repeat this
procedure with ALL remaining tools and
hoses.
6. After the tools and solution hoses have been
filled with anti-freeze, disconnect and store
them.
Recover all anti-freeze that comes out of the
tools and hoses and store in an approved
container. ALWAYS re-use or re-cycle antifreeze.
7. Prime the chemical injection system with a
100% glycol based antifreeze. Insert the
chemical inlet and prime tube into the antifreeze container. Turn the chemical prime
valve to PRIME until anti-freeze comes out
of the prime hose. Turn the chemical prime
valve to the ON (chemical) position. Ensure
that the flow meter indicates flow while the
attached tools solution valves are opened.
Ensure that all anti-freeze that comes out of
the chemical hose goes into an approved
container.
After 25 seconds, turn the chemical valve to
the OFF position.
8. Allow the unit to run for at least 3 minutes.
The unit is now winterized.
REMOVING ANTI-FREEZE FROM THE
UNIT:
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
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Page 28
SECTION 3
1. Connect the solution hoses to the unit, with
a tool attached to the opposite end. Start the
unit. Turn the water pump on. Open the tool
valve and ensure that the anti-freeze goes into
an approved container. Allow the anti-freeze
to flow into the container until all anti-freeze
has been drained.
2. Fill the water box with fresh water and
repeat step 1.
3. Connect the water inlet hose to the unit and
turn the water supply on. Connect all tools and
solution hoses that were winterized to the
solution outlet connection.
Open all tool valves and drain the anti-freeze
into an approved container until the water runs
clear and all of the anti-freeze is purged from
the hoses and tools.
4. Insert the chemical prime hose into the
approved container. Submerge the chemical
hose into fresh water. Turn the chemical prime
valve to the PRIME position until the water
runs clear through the prime hose. Remove the
prime hose from the container.
5. Turn the chemical prime valve to the ON
(chemical) position and open attached tools
solution valves. This will allow water to flow
to the other side of the system.
After all of the anti-freeze has been removed,
the unit is ready to operate.
The anti-freeze in your approved storage
container will eventually become diluted with
water. When the anti-freeze level drops below
70% of the total mixture, properly dispose of
it and start over with fresh 100% anti-freeze.
!
DO NOT drain used anti-freeze on the
ground or into storm drains.
Dispose of anti-freeze only in an approved
location. Observe Local, State and Federal
laws when disposing of anti-freeze.
24 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 29
SECTION 4:
SERVICE and MAINTENANCE
6. MAINTENANCE
Maintenance Chart ............................................................................................26
7. MAINTENANCE
Engine ...............................................................................................................27
Vacuum Pump ..................................................................................................28
Water Pump ......................................................................................................29
Vacuum Inlet Filter ...........................................................................................29
Drive Belts, Pulleys and Hubs ..........................................................................29
Strainer Basket ..................................................................................................30
Check Valve (Outlet) ........................................................................................30
Chemical Pump, Chemical Metering System ...................................................30
Pressure Regulator ............................................................................................30
Vacuum Hoses ..................................................................................................30
Battery...............................................................................................................30
High Pressure Solution Hoses ..........................................................................31
8. GENERAL SERVICE ADJUSTMENTS
Engine ...............................................................................................................32
Vacuum Relief Valve .......................................................................................32
Water Pump Drive Belt ....................................................................................32
Solution Outlet Check Valve ............................................................................32
Chemical Pump .................................................................................................32
Packing Nut Adjustment, Chemical Metering and Selector Valves .................33
Pressure Regulator ............................................................................................34
9. TROUBLESHOOTING
Engine ...............................................................................................................35
Blower / Vacuum Pump....................................................................................37
Water Pump ......................................................................................................37
Chemical System ..............................................................................................39
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
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Page 30
SECTION 4
6. MAINTENANCE CHART
Engine
5 Hours
Change engine oil after first 5 hrs of operation. Then every 100 hrs.
Engine
Daily
Check engine oil level.** Fill to proper level.
Vacuum Pump
Daily
Spray WD-40 (or Equivalent) into the lubrication cup for 5 seconds.
Water Pump
Daily
Check water pump oil level.*** Fill to proper level.
Vacuum Inlet Filter
Daily*
Inspect filter, clean and or replace if required.
Waste Tank Strainer
Basket
Daily
Empty and clean stainless steel basket.
Vacuum Hoses
Daily
Rinse with fresh water.
Waste Pump-Out
(Optional)
Daily*
Inspect and remove any debris or sediment.
Vacuum Pump
Daily*
Check vacuum pump oil level. Fill to proper level. Do not overfill.
Engine
Monthly
Check air cleaner for damaged, dirty, or loose parts.
Pump Filter
Monthly
Clean and Inspect
Engine
Monthly
Inspect air intake and cooling areas. Clean if required.
Battery
Monthly*
Check fluid level. Fill with distilled water only. Do not overfill.
Engine
Monthly
Inspect drive belts for wear. Replace as needed.
Water Box
Monthly
Check float valve for proper operation.
Thermal Well
Monthly
Lubricate diverter shaft; anti seize
Check Valve Strainer
Monthly*
Clean and remove any debris.****
High Pressure Solution
Hoses
25 Hours
Inspect for wear, damage, or impending rupture. Replace if damaged.
Belts
25 Hours
Re-tension all belts********
Belts
100 Hours
Re-tension all belts********
Engine
100 Hours
Change engine oil and filter.
Vacuum Pump
100 Hours
Check Oil level
Vacuum Break
100 Hours
Check and adjust vacuum relief valve to 14” Hg if needed.
Pressure Regulator
100 Hours
Lubricate o-rings. Use only o-ring lubricant part # 13-003.
Battery
100 Hours
Clean battery terminals.
Engine
200 Hours
Check spark plugs (only use OEM spark plugs).
Engine
200 Hours
Clean engine air filter.
Chemical Metering
System
200 Hours
Inspect packing nut on selector and metering valve. Adjust as needed.
Engine
500 Hours
Replace in-line fuel filter.******
Water Pump
500 Hours
Change crankcase oil.***
Pulleys and Hubs
500 Hours
Check pulley and hub set screws for proper torque.*****
Chemical Pump
500 Hours
Change diaphragm and check valves. Inspect disk.
Belts
1000 Hours
Replace all belts.
Engine
1000 Hours
Replace spark plugs.
Check Valve
1000 Hours
Check Teflon seat for abnormal wear or debris. Replace as needed.
Engine
1000 Hours
Replace air filter element.
Vacuum Pump
1000 Hours
Drain, flush, and replace oil.*******
To maximize the operating life and performance, use only recommended oils, filters and greases.
*Or as often as required.
**Change engine oil and oil filter after first 5 hours of operation.
***Change water pump crankcase oil after first 50 hours of operation
****Inspect after first week of operation, and remove any debris present. Inspect again after 2 to 4 weeks.
26 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 31
*****Check pulley and hub set screws after first 50 hours of operation, and again at 100 hours of operation.
******Or every 6 Months. Whichever comes first.
*******Or Yearly. Whichever comes first.
********Re-tension all belts after first 25 hours then at every 100 hours of operation.
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
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Page 32
SECTION 4
Above 37º C (99º F)
SAE40
25° C to 37º C (77° F to 99º F)
SAE30 or SAE10W-30
0° C to 25° C (32° F to 77° F)
SAE20 or SAE10W-30
Engine oil capacity
2.4 L
2.53 U.S.qts
Tightening torque
Drain Plug
32.4 to 37.3 N·m
3.3 to 3.8 kgf·m
23.9 to 27.5 lbf·ft
7. MAINTENANCE
This section of the operator’s manual contains the
service and maintenance information for the
MODEL 454 SS® unit. A planned preventative
maintenance program will ensure that your
SAPPHIRE SCIENTIFIC MODEL 454 SS® has
optimum performance, long operating life, and a
minimum amount of down time.
ENGINE
1. Check the engine oil level daily. Ensure that the
proper oil level is maintained. NEVER overfill.
2. Change the oil after the first 5 hours of
operation. Thereafter, change oil and oil filter
every 100 hours of operation.
USE ONLY BRIGGS & STRATTON BRAND
OIL FILTERS. USE OF ANY OTHER TYPE OF
OIL FILTER WILL VOID ENGINE
WARRANTY.
Use high-quality oil of at least API (American
Petroleum Institute) service class SF, SG, SH, SJ
or higher. Do not use additives. Select the
viscosity based on the air temperature at the time
of operation as shown in the following table.
!
DO NOT attempt to service this unit while it is
running. High speed parts as well as high
temperature components may result in severe
injury, severed limbs, or fatality.
NOTE: Refer to the hour meter as a guide for
coordinating a maintenance schedule.
NOTE: Using a lower service class oil or
extending oil change intervals longer than
recommended can cause engine damage.
NOTE: Synthetic oils meeting the listed
classifications may be used with oil changes
performed at recommended intervals, however, to
allow piston rings to properly seat, a new or rebuilt
engine should be operated for at least 50 hours
using standard petroleum based oil before
switching to synthetic oil.
28 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 33
SECTION 4
Vent Cap/
Oil Fill
Vent Cap/
Oil Fill
Oil Level
Sight Gauge
Oil Drain
3. Check the spark plugs every 200 hours. Replace
spark plugs every 1000 hours. Use only OEM
specified spark plugs.
4. Clean the engine air filter element every 200
hours. Replace the element every 1000 hours.
Replace the in-line fuel filter yearly.
NOTE: Additional engine service information can
be obtained from the provided Briggs & Stratton
Operation and Maintenance manual. If service or
repair is required, contact an authorized Briggs &
Stratton Service Center. They will require the
serial number of the engine.
VACUUM PUMP
NOTE: Refer to the provided Vacuum Pump
Operation and Service Manual for specific
instructions.
Lubrication: SAPPHIRE SCIENTIFIC requires
that you use only AEON PD-XD Synthetic Blower
Lubricant in both sides of the vacuum pump for all
operating temperatures. AEON PD-XD is
formulated specifically for positive displacement
blower service to provide maximum blower
protection at any temperature.
NOTE: AEON PD-XD (Part # 13-004) is the only
oil that SAPPHIRE SCIENTIFIC puts in the
vacuum pump at the factory. Adding petroleum oil
to synthetic oil is NOT recommended.
1. Check the oil level weekly on both sides to
ensure they are at the proper level. Too little oil
will damage and ruin the bearings and gears. Too
much oil will result in overheating.
2. A lubrication cup has been provided at the front
of the console, to prevent rust from building up
inside of the vacuum pump.
Run the unit for at least 2 minutes to remove any
moisture from the vacuum pump. Then, spray WD40 (or Equivalent) into the lubrication cup for 5
seconds while the unit is running and the vacuum
inlet port is sealed. This procedure should be done
at the end of every working day.
3. Drain, flush and replace the oil every 1000
hours or yearly, whichever comes first.
NOTE: Two drains are on your vacuum pump.
Ensure that both sides of the vacuum pump are
filled to their proper level when servicing.
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
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Page 34
SECTION 4
Oil Level
Sight Gauge
Oil Filter Cap
Oil Drain
WATER PUMP
Refer to the provided Water Pump Operation
Manual for specific instructions.
1. Check the crankcase oil level daily to ensure
the proper level. If the level has dropped,
check for the source of leakage and repair.
8) Slide the blower back (away from engine)
9) Lower front 2 nuts located under the front
of blower mounting plate approximately ½”
10) Tip the back of blower up
11) Remove all belts. Install new belts
12) Reverse procedures to install new belts
13) After belts have been installed, check for
proper tension and alignment. Do this using
a belt gauge. Set deflection to 1/4”; 10-12
lbs tension
14) Check pulleys for alignment using a
straight edge (example: ½” key stock).
Make sure pulley flange touches on 2
places on each pulley (4 total places)
2. After the first 50 hours of operation, change the
crankcase oil with CAT Pump Crankcase Oil,
(Part # 13-000). Change the crankcase oil every
500 hours thereafter.
Vacuum Pump:
Belt Replacement Procedures for Model 454:
ONLY use EPDM belts:
1) Disconnect the negative battery cable
2) Remove hose from waste tank to vacuum
pump
3) Remove hoods
4) Remove top panel (6 screws)
5) Remove left and right hand belt guards
6) Loosen all 4 blower mounting nuts
7) Remove clamp between blower & silencer
15) Estimated time, 20 minutes
VACUUM INLET FILTER
1. The vacuum inlet filter in the waste tank should
be inspected and cleaned daily.
!
When removing the vacuum inlet filter, grip the
plastic hexagon section of the filter. Grasping
filter by the screen will damage or destroy the
filter. Applying a grease to the threads will
allow easier removal of filter when cleaning or
replacement is required.
DRIVE BELTS, PULLEYS and
HUBS
Check pulley set screws and hub screws after the
first 25 hours of operation and again at 100 hours.
Re-torque these screws with a torque wrench.
Follow the torque values on the following table.
30 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 35
SECTION 4
TORQUE VALUES
Component
Inch/lbs
Foot/lbs
Engine Hub #38-019
180
15
Vacuum Pump Hub #38-032
180
15
Engine Hub #38-021
180
15
Check pulley set screws and hub screws every 500
hours thereafter.
Insure belts are properly tensioned after checking
the torque values. Use Gates EPDM belts.
!
Ensure that when you re-torque the screws, you
use a clockwise pattern and continue until the
proper torque is achieved.
WASTE TANK
STRAINER BASKET
The strainer basket located in the waste tank
should be emptied and cleaned on a daily basis.
Microban QGC cleaner is the recommended
product for cleaning and sanitizing the waste tanks
as well as other parts of the system.
CHECK VALVE STRAINER
(OUTLET)
Unscrew the screen and inspect the strainer after
the first week of operation. Remove any debris
present. Inspect again after 2 and 4 weeks.
Thereafter, inspect the strainer and screen at least
monthly. If a frequent build-up of debris is
noticed, inspect and clean more frequently.
CHEMICAL PUMP
The chemical pump should be rebuilt every 500
hours. This involves changing the diaphragm,
check valves, and inspecting the disk. DO NOT
attempt to reuse o-rings after the check valves have
been removed. Replace all o-rings when servicing
check valves.
CHEMICAL METERING
SYSTEM
Check and inspect the packing nut on the chemical
selector and metering valves every 200 hours.
Keeping the valve packing’s properly adjusted will
prevent leaks and add to the overall life of the
valves.
PRESSURE REGULATOR
Lubricate the o-rings in the pressure regulator
every 100 hours. Use only o-ring lubricant (Part
#13-003).
VACUUM HOSES
To ensure maximum hose life, SAPPHIRE
SCIENTIFIC recommends that you wash out the
hoses with fresh water daily. Microban QGC
cleaner as the best product for cleaning and
sanitizing the wands and hoses as well as other
parts of the system
BATTERY
!
Explosive gases, Dangerous acid!
Batteries contain sulfuric acid. To prevent acid
burns, avoid contact with skin, eyes and clothing.
Batteries also produce explosive hydrogen gases
while charging. To prevent fire or explosion,
charge batteries only in a well ventilated area.
Keep sparks, open flames, as well as any other
sources of ignition away from batteries at all times.
Remove all jewelry prior to servicing batteries.
Keep batteries out of the reach of children.
Before disconnecting the negative (−) ground
cable, ensure that all switches are in the OFF
position. If ON, a spark could occur at the ground
connection terminal, which could cause an
explosion if hydrogen gas or gasoline vapors are
present. ALWAYS disconnect the negative (−)
terminal first.
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
31
Page 36
SECTION 4
1. If you do not have a maintenance free sealed
battery, check the fluid level in the battery at least
once a week. If low, fill to the recommended level
ONLY with distilled water. DO NOT overfill the
battery. Early failure or poor performance will
result due to loss of electrolyte.
2. Keep cables, terminals and external surfaces of
the battery clean and dry. A buildup of corrosive
acid or grime on the external surfaces could cause
the battery to self-discharge.
3. Battery terminals should be cleaned every 100
hours to prevent corrosion buildup. Wash the
cables, terminals and external surfaces with a mild
baking soda and water solution. Rinse thoroughly
with fresh water. DO NOT allow baking soda to
enter the battery cells, as this will destroy the
electrolyte, resulting in battery failure.
HIGH PRESSURE SOLUTION
HOSES
Inspect your high-pressure solution hoses for wear
after the first 100 hours. Thereafter, inspect every
25 hours. If the hoses show any signs of damage
or impending rupture, replace the hoses.
!
NEVER attempt to repair high-pressure
solution hoses. Repairing high-pressure solution
hoses may result in severe burns and serious
injury.
All high-pressure solution hoses must be rated for
3000 PSI at 250 deg. F. Thermoplastic hoses do
not meet this requirement and should not be used.
Severe burns and injury may result if the hoses do
not meet these requirements.
32 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 37
SECTION 4
8. GENERAL SERVICE
ADJUSTMENTS
!
DO NOT attempt to service this unit while it is
running. High speed parts as well as high
temperature components may result in severe
injury, severed limbs, or fatality.
ENGINE SPEED
1. To adjust the engine RPM, refer to the Briggs &
Stratton Engine Operation and Service Manual for
specific instructions.
!
DO NOT attempt to adjust without a tachometer
and NEVER adjust the engine above 3000 RPM.
VACUUM RELIEF VALVE
With the unit running at full RPM, block off the
airflow at the vacuum inlet port and read the
vacuum gauge. If adjustment is required, shut the
unit down and adjust the locking nut tension on the
vacuum relief valve. Re-start the unit and read the
vacuum gauge. Repeat this process until the
vacuum relief valve opens at 14” Hg. Always
ensure lock nut is retightened.
WATER PUMP DRIVE BELT
To tighten the water pump belt:
1. Loosen the four nuts, which hold the water
pump base to the frame.
2. Adjust the position of the belt tensioning
adjusting bolt until the proper belt tension is
achieved (1/2” deflection in the center of the belts,
half way between the pulleys).
Do not over tighten. Damage to pump may
occur.
3. While checking the alignment, tighten the nuts
that hold the water pump to the base.
Over tightening of belts may cause damage to
pump casing, causing it to fail.
SOLUTION OUTLET CHECK
VALVE
Inspect the check valve whenever performing
service on the chemical pump or if flow problems
are occurring in the chemical system.
1. Remove the check valve, ensuring that the small
o-ring on the seat comes out with it
2. Next, remove the seat using a 5/16 in. Allen
wrench
3. Check the Teflon seat for wear or debris. Clean
and replace the seat if necessary.
4. Inspect the poppet and the spring for wear or
damage. Clean and replace as necessary.
NOTE: New o-rings must be installed anytime the
check valve is removed.
5. Re-assemble the check valve. Thread the seat by
hand until snug. Then tighten with a 5/16 in
Allen wrench. DO NOT over-tighten.
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
33
Page 38
SECTION 4
Item #
Part Number
Qty.
Description
1
27-009
1
CAP, CHECK VALVE
ASSY. SS
2
41-007
1
ORING, 7/8 ID X 1-
1/16 OD
3
15-007
1
SPRING, CHECK
VALVE ASSY.
4
27-010
1
POPPET, CHECK
VALVE ASSY
5
27-004
1
INSERT, SEAT-CHK
VLV ASSY TM
6
27-011
1
SEAT, CHECK
VALVE ASSY.
7
41-008
1
ORING, ½ ID 5/8 OD
7 6 5
4
3
2
1
Chemical Metering Valve
Packing Nut
Adjust the packing nut
by turning the packing
bolt clockwise at 1/16”
increments.
Chemical Prime Valve
Loosen Set Screw
and Remove Knob
23-063 VLV, CHECK, CHECK VLV MANIFOLD
(Part #13-003) and reassemble.
To replace the check valves, remove the check
valve caps, replace the check valves and
reassemble using new o-rings. DO NOT attempt to
reuse o-rings after the check valves have been
removed.
PACKING NUT ADJUSTMENT
CHEMICAL METERING/
SELECTOR VALVES
Inspect the packing nut for proper tension on the
chemical metering and chemical selector valves
every 200 hours. When turning the knob, there
should be some resistance. If not, slightly tighten
the packing nut. DO NOT over-tighten. Keeping
the packing properly adjusted will eliminate
possible leaks and will add to the overall life of the
valves.
Note: Improper seating of the check valve seat,
poppet, damaged spring or o-rings will result in
poor performance of the chemical system.
6. Lubricate the new o-rings with o-ring lubricant.
(Part # 13-003) and re-install.
CHEMICAL PUMP
The MODEL 454 SS® unit features a stainless
steel chemical pump and metering system. The
chemical pump requires only the replacement of
the diaphragm and check valves (see page 56). To
replace the diaphragm, unscrew the cover from the
body. When replacing the diaphragm, lube the
outer edges of the diaphragm with o-ring lubricant
34 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 39
SECTION 4
O-Rings
Valve
Nut
Valve
Stem
Body
Valve
Cap
Loosen nut & remove
entire valve stem
from valve body to
service seals.
PRESSURE REGULATOR
The pressure regulator holds water pressure at a
preset point and bypasses the excess water back to
the water box.
To adjust:
1. With the unit running, close the cleaning tool
valve. Check the pressure gauge. Open the tool
valve. Set the pressure regulator so that the
pressure gauge reads 450 PSI with the tool valve
closed. With the tool valve open, there should
be a normal drop in pressure. If the drop is
greater than 100 PSI, it may be necessary to
lubricate the pressure regulator o-rings.
2. To adjust the pressure regulator, turn the
adjusting knob (while observing the pressure
gauge on the control panel) until you reach the
desired pressure.
!
DO NOT loosen the adjusting body (cap) all the
way (counterclockwise) or remove it while the
unit is running.
We recommend that you lubricate the pressure
regulator o-ring every 50 hours or whenever
required. If you do not, the stem may become
seized due to inadequate lubrication. If this occurs:
a) Shutdown the unit.
b) Relieve all pressure from the water system.
c) Remove the cap from the pressure regulator
and remove the stem with long nose pliers.
d) Clean and lubricate stem.
e) Reassemble pressure regulator
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
35
Page 40
SECTION 4
PROBLEM
CAUSE
SOLUTION
Heat exchanger leaks
NOTE: The heat exchanger will
produce water condensation
discharge at times during
normal operation. DO NOT
confuse this with a leak.
Engine/vacuum exhaust heat
exchanger is damaged from frozen
water.
Inspect heat exchanger for leaks.
Visually inspect for damage. Pressure
check after removing from the unit.
(Maximum test pressure 1200 PSI).
Loss of temperature
The heat output of the unit is
LESS than normal.
No vacuum hose connected.
Connect vacuum hose to vacuum inlet.
Temperature relief valve on water box
is stuck open.
Clean temperature relief valve and test.
Replace, if necessary.
Engine RPM is low.
Reset engine RPM.
Defective temperature gauge.
Test gauge and sensor. Replace failed
component.
Temperature balance orifice missing
Replace orifice
Automatic waste pump is
malfunctioning or not
operating normally.
Defective waste pump float switch.
Replace float switch.
Broken diaphragm(s).
Replace diaphragm(s).
Weak battery.
Charge or replace battery if needed.
Check charging station.
Pump-out circuit breaker on control
panel has been tripped.
After inspecting waste pump to
determine the cause of the tripped
circuit breaker, press the reset button.
Inspect check valve for debris or
damage.
Clean or replace if necessary.
9. TROUBLESHOOTING
!
DO NOT attempt to service this unit while it is
running. High-speed parts as well as high
temperature components may result in severe
injury, severed limbs or fatality.
TROUBLE SHOOTING:
ENGINE
This section of the operator’s manual describes
how to look for and repair malfunctions, which
may occur.
Accurate troubleshooting is based on a thorough
and complete understanding of the WATER,
CHEMICAL, VACCUM, HEAT TRANSFER,
SAFETY and WIRING systems featured in this
unit.
If there are malfunctions occurring on this unit
which you do not understand, refer back to the
OPERATION section of this manual and review
SYSTEM
36 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 41
TROUBLE SHOOTING:
PROBLEM
CAUSE
SOLUTION
Engine will not start
The engine does not turn
over
Main circuit breaker on the
control panel has been tripped.
After inspecting the unit to
determine the cause of the tripped
circuit breaker, press the reset
button.
Loose or corroded battery.
Clean, tighten, or replace the
battery terminals.
Dead battery.
Recharge or replace battery.
Defective ignition switch.
Test ignition switch for power
going into the switch. If there is
power going in but NO power
going out, replace the switch.
Defective starter motor.
Test the starter motor. If necessary
replace.
Vacuum pump seized.
Refer to Gardner Denver Service
and Repair Manual.
Starter turns over engine,
but will not start
Waste tank is full.
Empty the waste tank.
Defective fuel pump.
Replace the fuel pump.
Loose or broken wires leading to
waste tank float switch.
Repair or replace any broken
electrical connections.
Defective float switch in the waste
tank.
Check switch for proper
operation, replace as necessary.
Oil pressure switch (located on
engine), fuel shut-off solenoid
(located on engine).
Test these components. If any are
defective, replace. Consult the
Briggs & Stratton Engine
Operation and Maintenance
Manual.
Starter turns over engine,
but will not start
Engine is malfunctioning
Refer to Briggs & Stratton Engine
Operation and Maintenance
Manual.
Engine stops running
While doing normal
cleaning, the engine stops
running
Engine is out of gasoline
Add gasoline to the fuel tank.
Waste tank is full
Empty waste tank.
Main circuit breaker on the
control panel has been tripped.
After inspecting the unit to
determine the cause of the tripped
circuit breaker, press the reset
button.
Defective fuel pump.
Replace fuel pump.
Defective float switch inside the
waste tank.
Check switch for proper
operation. Replace as necessary.
Oil pressure switch on engine has
shut down, due to insufficient oil
pressure.
Refer to the Briggs & Stratton
Engine Operation and
Maintenance Manual. DO NOT
restart the engine until the cause is
determined and corrected.
No ignition in the engine or
engine is malfunctioning.
Refer to the Briggs & Stratton
Engine Operation and
Maintenance Manual.
Excessive heating
Flow restriction caused by hard
water scaling.
Descale unit, repair or replace
damaged plumbing components as
necessary. Install water softener.
Not enough water flow.
Check jet size of tool.
ENGINE
SECTION 4
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
37
Page 42
SECTION 4
PROBLEM
CAUSE
SOLUTION
Excessive Vacuum
Improper throttle adjustment.
Adjust throttle to set desired vacuum
pressure.
Vacuum relief valve requires
adjustment.
Readjust the vacuum relief valve.
Loss of vacuum. While
cleaning, the vacuum is not up
to specification. Engine RPM is
normal.
Vacuum gauge is giving an improper
reading.
Examine the tubing between the
vacuum relief valve and the vacuum
gauge and remove any blockage.
Vacuum hose(s) is damaged, causing a
suction leak.
Inspect hose(s), repair or replace.
Waste tank gaskets not sealing
properly, not positioned properly
Inspect the gasket. Repair seal or
replace Re-position lid(s).
Plugged vacuum hose or vacuum
plumbing between vacuum inlet and
strainer basket.
Unplug vacuum hose or inlet
plumbing.
Waste tank filter or strainer basket is
plugged.
Clean or replace filter. Clean strainer
basket.
Loose vacuum pump drive belts.
Tighten the drive belts
Waste tank drain valve is damaged or
left open, causing a vacuum leak.
Drain the waste tank. Close drain
valve, if open. Remove the dump valve
and, after inspecting, replace the
defective components.
Vacuum relief valve requires
adjustment or has a vacuum leak due to
damaged diaphragm.
Re-adjust the vacuum relief valve. If
the vacuum does not increase, remove
and inspect the relief valve diaphragm.
If damaged, replace
Vacuum exhaust heat exchanger
plugged.
Remove and clean.
Vacuum pump is worn out.
Replace the vacuum pump.
PROBLEM
CAUSE
SOLUTION
Loss of solution volume at
cleaning tool orifice. Solution
pressure gauge reads normal.
Plugged orifice and/or screen in the
cleaning tool.
Unplug or replace orifice and/or screen
Internal block between the pressure
regulator manifold and the outlet
manifold, or the solution screen is
clogged
Inspect all lines, remove accumulated
debris which is blocking proper flow.
Replace any defective hoses. Remove,
inspect, and clean the solution screen.
De-scale unit and install a water
softener, if necessary.
TROUBLE SHOOTING:
BLOWER / VACUUM PUMP
TROUBLE SHOOTING:
WATER PUMP
38 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 43
SECTION 4
PROBLEM
CAUSE
SOLUTION
Loss of solution volume at
cleaning tool orifice. Solution
pressure gauge reads normal.
Outlet check valve is plugged
Examine the check valve, remove any
debris
Defective quick-connect on one or
more of the high pressure hoses.
Replace defective quick-connects(s) on
high pressure hoses(s).
Cleaning tool valve is malfunctioning.
Repair or replace valve.
Hose inner lining is constricted.
Remove restriction or replace hose.
Air leak in chemical supply line,
priming valve or metering valve.
Check for air leaks. Replace faulty
parts.
Loss of solution pump pressure.
With the cleaning tool open, the
solution pressure gauge reads
below the normal operating
pressure.
Water supply is turned off or the float
valve is stuck.
Turn the water supply on or up. Check
for kinks in the water supply hose.
Examine the float or replace.
Solution pump inlet supply line is
plugged or drawing air.
Examine the water inlet filter inside
the water box. Remove accumulated
debris and replace if required. Check
for suction leaks and loose clamps or
fittings. Tighten any loose fittings or
clamps. Replace any ruptured hose(s).
Improper engine speed
Using a tachometer, check the engine
speed. Full throttle engine speed is
3000 RPM. Idle engine speed is 1500
RPM. Refer to the “engine speed”
section for instructions on how to readjust.
Pressure regulator o-rings are dry.
Lubricate o-rings, using o-ring
lubricant
Pressure regulator has worn o-rings
Check o-rings. If necessary, replace.
Pressure regulator is dirty, stuck open,
or improperly adjusted.
Clean or repair regulator. Adjust to
working pressure. Lubricate o-rings,
using o-ring lubricant Part
Low pump volume. (Measure the
amount of water being returned to the
water box from the pressure regulator.
It should fill a gallon container about
every 17.6 seconds).
Examine the check valves, plunger
cups, and cylinder head on the water
pump. Repair, whenever required
(refer to the water pump service
manual).
Defective water pressure gauge.
Replace gauge
Orifice (spray nozzle) in the cleaning
tool is worn, defective, or wrong size.
Replace Nozzle or change nozzle size.
Debris clogging water lines or water
inlet disconnect.
Clean or replace as needed.
Belts loose or broken
Re-tension or replace as needed.
Loss of pump prime
Manually prime water pump.
Temperature Balance Orifice missing
Replace Orifice
TROUBLE SHOOTING:
WATER PUMP
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
39
Page 44
SECTION 4
PROBLEM
CAUSE
SOLUTION
Loss of chemical. With the
cleaning tool valve open, no
chemical
Chemical pump is improperly primed.
Refer to chemical pump priming
instructions.
The strainer at the inlet end of the
chemical inlet line is clogged
Unclog the strainer. If damaged,
replace.
Suction leak in the inlet line leading
into the chemical pump.
Inspect inlet lines and flow meter for
air leaks or damage and replace, if
required.
Chemical pump check valve(s) is
clogged
Remove any debris from the chemical
check valve(s). Replace chemical
check valve(s) or seals, if necessary.
Chemical prime/on-off valve or
chemical metering valve is defective.
Replace valve(s).
Chemical pump diaphragm is ruptured.
Disassemble the chemical pump and
replace the damaged diaphragm.
Defective cylinder in the water pump.
Measure the pump volume. If the
pump volume is less than normal, refer
to “Loss of Pump Volume” in the
Troubleshooting section in this
manual.
Solution pump does not engage
Solution pump circuit breaker has been
tripped
Check the solution pump circuit
breaker on the control panel. Press the
circuit breaker reset button.
Defective electrical connection in the
console wiring or defective switch.
Examine switch, electrical
connections, and wiring. Repair any
defective connections. If there is power
going to the switch but not going out,
replace the defective switch.
Solution pump has not been activated
Turn solution pump switch to on.
Defective solution pump clutch.
NOTE: The clutch may be manually
engaged by inserting two ¼-20 x ½
bolts. Line up the holes on the clutch
and insert the bolts. To disengage the
pump, remove the bolts.
If there is power in the switch, but not
power at the clutch, replace the
defective wire. If there is power at the
clutch, replace the defective switch.
Loose or broken solution pump belts.
Tighten or replace belts.
Chemical flow meter indicates
flow with the tool valve closed
External leak in chemical piping
Tighten fittings. Re-apply thread
sealant where required. If any fittings
are damaged, replace.
Outlet check valve is full of debris or
damaged, not allowing it to close
properly
Close the chemical valve on the
instrument panel. If the flow meter
does not indicate flow, remove debris
or replace check valve, if necessary.
Chemical pump diaphragm is ruptured
Close the chemical valve on the
instrument panel. If the flow meter still
indicates flow, replace the chemical
pump diaphragm.
TROUBLE SHOOTING:
CHEMICAL SYSTEM
40 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 45
TROUBLE SHOOTING:
PROBLEM
CAUSE
SOLUTION
Chemical flow meter indicates
flow with the tool valve closed
Internal leak in chemical valve causing
continual flow through prime tube
returning to container.
Tighten valve packing nut (see
“General Service Adjustments” section
in this manual). Replace valve, if
necessary.
CHEMICAL SYSTEM
SECTION 4
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
41
Page 46
SECTION 5
PARTS and ACCESSORIES
10. ILLUSTRATED PARTS LISTINGS
Frame and Enclosures ..................................................................................... 42
Instrument Panel – Front side Component List .............................................. 45
Instrument Panel – Back side Component List .............................................. 46
Engine ............................................................................................................. 47
Vacuum Blower .............................................................................................. 48
Water Pump .................................................................................................... 50
Thermal Well .................................................................................................. 52
Chemical Pumping System ............................................................................. 55
Chemical Pump .............................................................................................. 56
Solution Manifold and Bypass ....................................................................... 57
Pressure Regulator .......................................................................................... 58
Vacuum Bracket ............................................................................................. 59
Oil Cup and Bypass Valve.............................................................................. 60
Float Valve ..................................................................................................... 61
Gas Line Bracket and Fittings ........................................................................ 62
Belt Guard Blower .......................................................................................... 63
Quick Disconnect Fittings and Bracket .......................................................... 64
Waste Tank ..................................................................................................... 65
Electrical Diagram .......................................................................................... 66
Hose Routings ................................................................................................ 67
Decals ............................................................................................................. 68
11. ACCESSORIES
Wand ............................................................................................................... 69
1992 to 2002 Ford Fuel Line Install ........................................................................... 70
Chevy and GMC Full Size Van Fuel Line Install .......................................... 71
2003 Chevy and GMC Full Size Van Fuel Line Install ................................. 72
1997-2002 Dodge Full Size Van Fuel Line Install ......................................... 73
Waste Pump Out Assembly. ........................................................................... 74
42 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 47
SECTION 5
Item No.
Part Number
Qty
Description
1
61-503
1
WELDMENT, FRAME BIG BLOCK BRIGGS
2
61-486
1
WELDMENT, CONTROL PANEL, 20 INC
3
60-468
1
REAR SUPPORT BRACE
4
61-592
1
WELDMENT, DUAL 2.5 TO 3.5 IN VAC BRACKET
5
58-398
2
ANGLE, HOOD MOUNTING
6
58-363
1
3 AND 5CP ADJUSTMENT TAB
7
12-012
37
WASHER, FLAT 1/4 USS
8
10-028
18
SCREW, MACH 1/4-20 X 2-3/4 HXHD
9
12-015
19
LKWSR, 1/4 ZINC
10
11-004
18
NUT, 1/4-20 ZINC
11
12-013
1
WASHER, FLAT 3/8 SAE
12
12-014
1
LKWSR, 3/8 ZINC
13
10-029
1
SCREW, MACH 3/8-16 X 1 HXHD
14
60-467
1
PANEL, AIR DAM 454 SS
ASSY, FRAME, FRONT 454SS
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
43
Page 48
SECTION 5
Item No.
Part Number
Qty
Description
1
12-012
16
WASHER, FLAT 1/4 USS
2
10-028
4
SCREW, MACH 1/4-20 X 2-3/4 HXHD
3
12-015
8
LKWSR, 1/4 ZINC
4
11-004
8
NUT, 1/4-20 ZINC
5
12-014
4
LKWSR, 3/8 ZINC
6
60-885
1
PANEL, WATER BOX CRADLE
7
41-095
4
ISOLATOR, 1.5 OD X 1.5 TALL 50 DURO
8
12-049
8
WASHER, 3/8 X 1.5 FENDER ZINC
9
58-588
1
BRACKET, ANGLE CLAMP
10
11-006
4
NUT, 3/8-16 ZINC
11
10-025
4
SCREW, MACH 1/4-20 X 3/4 HXHD GRD5
12
58-591
1
BRACKET, WATER BOX MOUNTING LS
13
58-592
1
BRACKET, WATER BOX MOUNTING RS
14
41-091
3
PAD, 1/4 SILICONE SPONGE 1.5W X 16.5L
ASSY, FRAME, BACK 454SS
44 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 49
SECTION 5
Item No.
Part Number
Qty
Description
1
69-196
1
ASSY, INSTRUMENT PANEL
2
66-230
1
PANEL, LOWER FRONT 454 & 570 SS
3
58-393
1
PANEL, LEFT SIDE 454 SS
4
58-392
1
PANEL, TOP MODEL 454 SS
5
58-394
1
PANEL, RIGHT SIDE 454 SS
6
11-007
6
NUT, THUMB 1/4-20 FKWR. HEAD KNOB
7
10-165
9
SCREW, MACH 1/4-20 X 3/4 FLTHD SS
8
11-002
8
NUT, WELL G 10-32 .375
9
10-016
8
SCREW, MACHINE 10-32 X 1 SOCHD SS
10
10-028
4
SCREW, MACH 1/4-20 X 2-3/4 HXHD
11
12-011
4
WASHER, FLAT #12 SAE
12
12-015
4
LKWSR, 1/4 ZINC
13
11-004
4
NUT, 1/4-20 ZINC
FRONT SHEET METAL
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
45
Page 50
SECTION 5
Item No.
Part Number
Qty
Description
1
66-229
1
PANEL INSTRUMENT 454 SS
2
26-003
1
FLOWMETER, 1/8P
3
26-005
1
GAUGE, WTR. PRESS1500PSIDUAL
4
26-004
1
GUAGE, VAC 30in.HG DUALSCALE
5
26-034
1
GAUGE, WTR TEMP CHROME 320 DEG F
6
26-033
1
HOURMETER, HOBBS CHROME BEZEL
7
29-049
1
SWITCH, ROTARY, 3 POS, SR FROM LEFT, 1 NO, 2 NC
8
40-001
1
CABLE, CHOKE
9
40-000
1
CABLE, THROTTLE
10
29-016
2
SWITCH, ROTARY NON ILLUMINATED
11
29-047
1
KEY SET, BRIGGS & STRATTON 496603
12
23-027
1
VLV, 3-WAY BALL 1/8 FP SS
13
23-028
1
VLV, CHEM SS
14
34-007
1
CONTROL, TEMP 275 DEGREE
15
23-066
1
MACVALVE, 45A-AA1-DDBJ-4KA
16
30-007
1
BREAKER, 30 AMP
17
30-008
2
BREAKER, 20 AMP
69-196 ASSY, INSTRUMENT PANEL
46 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 51
SECTION 5
Item No.
Part Number
Qty
Description
1
58-364
1
BRACKET, DIVERTER LOCKOUT VALVE
2
21-007
3
FTTG,BRB 1/8 PX 5/16 H BR
3
21-037
2
ELL, 1/4 IN. BRASS
4
21-076
1
BUSHING, 1/4 M X 1/8 F BRASS
5
21-050
1
CONN, 1/4 NPT X -04 JIC BRASS
6
21-028
2
CONN, 1/8 P X 1/4 POLY
7
21-038
1
ELL, STREET 1/8 IN. BRASS
8
21-055
2
ELL, 1/8 P X 1/4 T 45DEG BRASS
9
20-030
1
1/8" AIR MUFFLER
10
21-331
2
CONNECTOR, 1/8 M NPT X 1/4 HOSE 90DEG SWIVEL
11
21-042
1
NIP, CLOSE 1/8 IN. BRASS (NOT SHOWN)
69-196 ASSY, INSTRUMENT PANEL
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
47
Page 52
SECTION 5
Item No.
Part Number
Qty
Description
1
45-021
1
ENGINE, BRIGGS 35 HP AIR COOLED
2
61-535
1
EXHAUST PIPE RS
3
61-534
1
EXHAUST PIPE LS
4
37-066
2
BELT, 5VX412
5
38-028
1
PULLEY,5V710SK 2G C,CPR,BW,HAZ
6
38-019
1
HUB, SK-1 1/8
7
38-061
1
PULLEY, 3TA40P1
8
37-068
2
BELT, AX41 GATES EPDM
9
69-184
1
ASSEMBLY, BLOWER, BELT GUARD
10
37-019
1
BELT, 3L230 GATES EDPM
11
36-349
4
GASKET, EXHAUST BRIGGS & STRATTON 35HP
12
38-062
1
HUB, P1 X 1-1/8
13
61-509
1
WELDMENT, 454 SS BELT GUARD
14
58-401
1
PANEL, BELT GUARD, LS, 454 SS
15
58-403
1
PLATE, BELT GUARD INSPECTION COVER
16
58-402
1
PANEL, BELT GUARD, RS, 454 SS
17
10-145
4
SCREW, MACH, 5/16-18 X 4 HXHD
18
12-017
14
WASHER, FLAT 5/16 SAE
19
11-029
4
NUT, 5/16-18 NYLOCK
20
10-007
9
SCREW, MACH 1/4-20 X 1/2 SOCHD SS
21
12-003
9
LKWSR, 1/4 IN SS
22
12-002
9
WASHER, FLAT 1/4 SS ANC
23
12-014
4
LKWSR, 3/8 ZINC
ASSEMBLY, ENGINE, 406TMT
48 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 53
SECTION 5
69-212 ASSEMBLY, HF408 VACUUM BLOWER
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
SEE FOLLOWING PAGE FOR PARTS LIST
®
49
Page 54
SECTION 5
Item No.
Part Number
Qty
Description
1
46-058
1
VACUUM PUMP, HELI FLOW HF408 HORZ RH CW
2
61-564
1
WELDMENT, VACUUM PUMP MTG PLATE 408
3
58-447
1
PANEL, HEAT SHIELD
4
12-014
16
LKWSR, 3/8 ZINC
5
10-070
4
BOLT - .375-16 X .75 HH ZP
6
10-004
12
SCREW, MACH 3/8-16 X 1-1/4 HEXHD
7
66-227-04
4
THREADED ROD, .625-18 X 7.0 IN
8
12-040
16
WASHER, FLAT .625 USS
9
12-039
16
WASHER, LOCK, .625
10
11-062
16
NUT, 5/8-18 JAM
11
10-027
3
SCREW, MACH, 1-4-20 X 2 1-4 HXHD ZP
12
12-015
3
LKWSR, 1/4 ZINC
13
38-032
1
HUB, SK 1.25
14
38-027
1
PULLEY, 5V630SK
15
11-012
2
NUT, 7/16-14 ZP
16
12-021
1
WASHER, FLAT 7/16 ZINC
17
15-002
1
SPRING, VAC RELIEF VALVE
18
66-001
1
VACUUM BRAKE, MACHINED 4L
19
21-028
3
CONN, 1/8 P X 1/4 POLY
20
41-009
1
DIAPHRAGM, VAC RELIEF VLV 4L, 5M
21
14-032
1
PIN, COTTER 7/64 X 3/4 SS
22
10-001
1
SCREW, MACH 7/16-14 X 4-1/2 HEXHD
23
59-219
1
PNL, STEM VAC 3L/4M
24
66-249
1
ADAPTER, 4 IN NPT TO 3 IN NPT
69-212 ASSEMBLY, HF408 VACUUM BLOWER
50 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 55
SECTION 5
Item No.
Part Number
Qty
Description
1
46-057
1
PUMP, WATER, CATP 5CP5120
2
35-005
1
CLUTCH, ELECT CAT 5CP 2 GROOVE
3
46-056
1
PUMP, CHEMICAL, MFG BY GENERAL PUMP
4
21-062
1
TEE, 3/8 FNPT X NPT X FNPT BRASS
5
21-057
1
CONN, 3/8 NPT X 1/2 JIC BRASS
6
18-214-03
1
HOSE ASSEMBLY, 7/16 ID X 08 FJIC X 08 FJIC X 15.0 L W / SS
7
21-059
1
ELL, 3/8 NPT X 1/2 JIC 45 DEG BRASS
8
21-096
1
PLUG, 1/4 JIC BRASS
9
21-050
1
CONN, 1/4 NTP X -04 JIC BRASS
10
21-038
1
ELL, STREET 1/8 IN BRASS
11
21-007
1
FTTG, BRB 1/8 P X 5/16 H BR
12
21-066
1
ELL, 1-8 NPT X 1-4 JIC BRASS
13
18-215-18
1
HOSE ASSEMBLY, 3/16 ID X 04 FJIC X 04 FJIC X 21.0 L W / SS
14
21-324
1
ELL, 1/2 NPT X 5/8 BARB 45 DEG BRASS
15
61-491
1
WELDMENT, MTG BRCKT CAT PUMP
16
18-215-19
1
HOSE ASSEMBLY, 3/16 ID X 04 FJIC X 04 FJIC X 7.0 L W / SS
69-215 ASSEMBLY, PUMP WATER, 70-454
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
51
Page 56
SECTION 5
Item No.
Part Number
Qty
Description
17
18-199
1
HOSE, PULSE 3/8 S 36 IN
18
21-146
1
PLUG, 3/8 NPT BRASS
19
12-017
4
WASHER, FLAT 5/16 SAE ZINC
20
12-016
2
LKWSR, 5/16 ZINC
21
11-005
2
NUT, 5/16-18 ZINC
22
10-124
2
BOLT, 5/16-18 X 5.00 HH ZP
23
21-065
1
PLUG, 1/2 NPT SOLID BRASS HEXHD
24
20-033
1
FILTER, MICRO INLINE CAT 1/2 FNPT X 1/2 FNPT
25
21-047
1
NIP, 1/2 IN HEX BRASS
26
32-025
1
LOOM, HI HEAT .250 DIA. BLACK
27
21-231
1
NIPPLE, 1/4 X 3/8 SS NPT
28
66-064
1
ADAPTER, PUMP SS HP
69-215 ASSEMBLY, PUMP WATER, 70-454….CONT.
52 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 57
Item No.
Part Number
Qty
Description
1
61-612
1
WELDMENT, WATER BOX
2
61-504
1
WELDMENT, END PLATE ADAPTER
3
61-528
1
WELDMENT, DIVERTER COVER, 454 SS
4
61-529
1
WELDMENT, DIVERTER HOUSING PLATE
5
61-530
1
WELDMENT, DIVERTER PLATE
6
61-531
1
WELDMENT, DIVERTER CHAMBER
7
61-532
1
WELDMENT, FINNED TUBE COIL
8
61-537
1
WELDEMENT, SILENCER 454 SS
9
61-459
1
WELDMENT, INSPECTION COVER
10
69-230
1
ASSY, FLOAT VALVE (HIGH FLOW)
11
16-085
1
4.00 ID HOSE
12
10-143
4
BOLT, 1/4-20 X 3 SHCS
13
15-028
2
SNAP RING, .375 EXT E (FAST 1168079)
14
66-211
1
.875 SQ CLEVIS WITH 5E-11 THREAD
15
66-221
1
RND STOCK, 3/8" DIA RULON X 12"
SECTION 5
69-200 ASSY, THERMAL WELL
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
53
Page 58
SECTION 5
Item No.
Part Number
Qty
Description
16
23-067
1
CYLINDER, AIR, BIMBA FO-701.5-CMTV
17
41-069
1
GASKET, DIVERTER CYLINDER
18
21-109
1
FTTG, 1/2 NPT X 5/8 BARB BRASS
19
41-076
1
GASKET, INSPECTION COVER
20
21-154
1
FITTING, 1-2 NPT X 1-2 BARB BRASS
21
21-065
1
PLUG, 1/2 NPT SOLID BRASS HEXHD
22
23-033
1
VALVE, 165 DEG THERMAL CAT 7145
23
21-152
1
ELL, 3/8 FNPT X 3/8 FNPT BRASS
24
21-261
1
FITTING, 5/8 HOSE BARB X 3/8 NPT BRASS
25
21-034
1
ELL, STREET 1-2 NPT BRASS
26
21-001
1
CONN, 1/8 P X 1/4 T BR
27
21-073
1
COUPLING, 3/8 NPT BRASS
28
21-059
1
ELL, 3/8 NPT X 1/2 JIC 45 DEG BRASS
29
21-076
2
BUSHING, 1/4 M X 1/8 F BRASS
30
21-011
2
ELL, 1/8 NPT X 1/4 POLY BRASS
69-200 ASSY, THERMAL WELL
54 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 59
SECTION 5
Item No.
Part Number
Qty
Description
31
21-382
1
PLUG, 1-1/4 NPT SQ HEAD BRASS
32
21-050
1
CONN, 1/4 NTP X -04 JIC BRASS
33
66-246
1
MANIFOLD, TEMPERATURE SENSORS
34
34-008
1
SENSOR, TEMP 285DEG NASON
35
34-000
1
SENSER, TEMP, 140-320 DEGREE
36
21-363
1
ELL, 1/2 NPT X 1/2 JIC 45 DEG BRASS
37
14-050
2
CLAMP, HOSE 4 1/2 TO 2 1/2 HD SS
38
10-021
28
SCREW, MACH 1-4-20 X 3-4 SOCHD SS
39
10-007
2
SCREW, MACH 1-4-20 X 1-2 SOCHD SS
40
21-040
1
FITTING, STR ELL, .375 IN NPT, BRASS
41
21-324
1
ELL, 1/2 NPT X 5/8 BARB 45 DEG BRASS
69-200 ASSY, THERMAL WELL
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
55
Page 60
SECTION 5
Item No.
Part Number
Qty
Description
1
20-002
1
STRAINER, SUCTION END 1/8FP
2
21-007
1
FTTG,BRB 1/8 PX 5/16 H BR
3
46-056
1
PUMP, CHEMICAL, MFD BY GENERAL PUMP
4
26-003
1
FLOWMETER, 1/8P
5
23-027
1
VLV, 3-WAY BALL 1/8 FP SS
6
23-028
1
VLV, BYPASS SS
CHEMICAL PUMPING SYSTEM
56 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 61
SECTION 5
Item No.
Part Number
Qty
Description
1
36-350
1
BODY, PULSE PUMP, GP PULSE PUMP
2
36-351
1
PLASTIC DISC, GP PULSE PUMP
3
36-352
1
RUBBER DIAPHRAGM, GP PULSE PUMP
4
36-353
1
TOP COVER INLET, GP PULSE PUMP
5
36-354
2
O-RING, 70 DURO, GP PULSE PUMP
6
36-355
2
VALVE CAP 303SST, GP PULSE PUMP
7
36-356
1
ASSY, VALVE KIT, GP CHEMICAL PULSE PUMP
8
36-357
1
SPACER RING, 303 SST, GP PULSE PUMP
9
36-358
1
VALVE CAP, 303 SST, GP PULSE PUMPMP 520196
46-056 PUMP, CHEMICAL, GENERAL PUMP
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
57
Page 62
SECTION 5
Item No.
Part Number
Qty
Description
1
66-205
1
MANIFOLD BLOCK
2
21-264
3
PLUG, 1/4 NPT BRASS
3
21-026
2
NIPPLE, 1/4 NPT NPT HEX BRASS
4
25-001
2
QUICK DISCONNECT, .25 NPT, SOCKET, HANSEN SERIES B2-HK
5
23-063
1
CHECK VALVE MANIFOLD
6
21-374
1
NIPPLE, 1/2 NPT X 2-1/2L 304SS
7
66-277
1
MANIFOLD, TEMPERATURE SENSOR
8
21-336
1
TEE, 1/8 NPT X 1/4 JIC X 1/4 JIC BRASS
9
21-055
1
ELL, 1-8 P X 1/4 T 45 DEG BRASS
10
21-012
1
CONN, 1/2 NPT X 1/2 T BRASS
11
66-286
1
ADAPTER, THERMOCOUPLE
12
20-018
1
SCREEN, CHECK VALVE MANIFOLD
13
21-037
1
FITTING, ELBOW, .25 IN NPT, BRASS
14
21-052
1
NIP, 3-8 X 1-4 HEX BRASS
15
18-215-06
1
HOSE ASSEMBLY, 3/16 ID X 04 FJIC X 04 FJIC X 13.5L
16
18-215-07
1
HOSE ASSEMBLY, 3/16 ID X 04 FJIC X 04 FJIC X 14.75L
17
18-214-04
1
HOSE ASSEMBLY, 7/16 ID X 08 FJIC X 08 FJIC X 18.0L
18
66-011
1
MANIFOLD, BYPASS
19
66-017
1
CAP, CHECK VALVE
20
20-015
1
SCREEN, BYPASS MANIFOLD
21
21-029
1
PLUG, 1/8 NPT SOCKET HD BRASS
22
41-003
1
ORING, .676 ID .816 OD
23
21-054
2
ELL, 1-8P X 1-4 T BRASS
24
66-019
1
ORFICE, BYPASS MANIFOLD, .024 RED
25
18-215-10
1
HOSE ASSEMBLY, 3/16ID X 04FJIC X 04 FJIC X 18.0L
26
18-215-08
1
HOSE ASSEMBLY, 3/16 ID X 04 FJIC X 04 FJIC X 15.5L
27
34-000
1
SENSER, TEMP, 140-320 DEGREE
28
21-064
1
ELL, 1/4 P X 1/4 T BRASS
69-217 ASSEMBLY, MANIFOLD BOLCK
58 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 63
SECTION 5
Item No.
Part Number
Qty
Description
1
61-541
1
BRACKET, REGULATOR MOUNTING
2
23-021
1
REGULATOR, PRESSURE CAT #7670 VITON
3
21-361
1
PLUG, .375 NPT X HEX HEAD BRASS
4
66-252
1
FITTING, REGULATOR MOUNTING
5
41-086
1
O-RING, VITON (MC 9263K584)
6
21-059
1
ELL, 3/8 P X 1/2 T 45 DEG BRASS
7
21-040
1
FITTING, ST ELL .375 IN NPT, BRASS
8
21-014
1
FTTG, BRB .375 X .50H BR
9
18-214-03
1
HOSE ASSEMBLY, 1/2 IDA X 1/2 FJIC X 1/2 FJIC 15.0 L W/SLEEVE
69-209 ASSEMBLY, REGULATOR BRACKET, 454 SS
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
59
Page 64
SECTION 5
Item No.
Part Number
Qty
Description
1
61-592
1
WELDMENT, DUAL 2.5 TO 3.5 IN VAC BRACKET PC CIRCUIT GRAY
2
21-054
1
ELL, 1-8P X 1-4 T BRASS
3
21-007
1
FTTG, BRB 1/8 P X 5/16 H BR
69-258, ASSEMBLY, VAC BRACKET
60 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 65
SECTION 5
Item No.
Part Number
Qty
Description
1
23-028
1
VLV, MET18 FP (CHEM) RT ANG SS
2
21-090
1
ELL, 1/8 FNPT X 1/8 FNPT BRASS
3
21-001
2
CONN, 1/8 P X 1/4 T BR
4
21-011
1
ELL, 1/8 NPT X 1/4 POLY BRASS
5
21-333
1
COUPLING, 1/8 FNPT X 1/8 MNPT BRASS
6
28-000
1
CUP, OILFILL, 1/8 NPT
7
61-514
1
WELDMENT, OIL CUP AND BYPASS VALVE
8
18-215-12
1
HOSE, 3/16 DIA X 1/4 FJIC X 1/4 FJIC X 22.0 L W-CVR
9
18-215-05
1
HOSE, 3/16 DIA X 1/4 FJIC X 1/4 FJIC 12.5 L W/CVR
10
16-017
1
TUBING, 1/4 IN IMPOLENE 250 FT BULK
69-210, ASSEMBLY, OIL CUP AND BYPASS VALVE
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
61
Page 66
SECTION 5
Item No.
Part Number
Qty
Description
1
66-256
1
BODY, FLOAT VALVE BOTTOM HALF
2
66-257
1
BODY, FLOAT VALVE TOP HALF
3
66-235
1
NUT, FLOAT VALVE MOUNTING
4
61-565
1
WELDMENT, FLOAT VALVE LEVER
5
10-148
1
SCREW, SHOULDER, 8-32 X Ø3/16 X 1.0L
6
11-001
1
NUT, 1/4-20 SS
7
11-067
1
NUT, 8-32 HEX LOCK SS
8
28-009
1
FLOAT, OBLONG BALL 2.5 X 4.0, 7 OZ
9
28-010
1
BALL, .375 HARDENED SS
10
41-085
1
O-RING, SILICONE AS568A DASH NO. 910
11
15-031
1
PIN, SPRING, .125 X .375 SS
69-230 ASSY, FLOAT VALVE
62 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 67
SECTION 5
Item No.
Part Number
Qty
Description
1
16-086
1
HOSE, FUEL 1/4 30R7
2
14-007
2
CLAMP, HOSE FUEL #4
3
16-086
1
HOSE, FUEL 1/4 30R7
4
21-166
1
1/4 MP X 1/4 H BARB
5
21-039
1
ELL, 1/4 IN STREET BRASS
6
61-489
1
ASSY,GAS LINE BRACKET
7
21-006
1
FTTG, BRB 1/4P X 5/16H BR
8
16-065
1
HOSE, FUEL 5/16 30R7
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
69-259, ASSY, GAS LINE BRACKET
®
63
Page 68
SECTION 5
Item No.
Part Number
Qty
Description
1
61-465
1
WELDMENT, BLOWER HOUSING
2
39-008
1
ASSY, BEARING & SHAFT
3
66-215
1
PULLEY, 3L BELT X 2.340 OD
4
36-335
1
IMPELLER, BELT GUARD BLOWER
5
60-398
1
PLATE, BLOWER HOUSING FRONT RING
6
15-027
1
SNAP RING, 1.187 INTERNAL
7
10-146
4
SCREW, 8-32 X .375 PHP F THREAD CUTTING ZP
69-184 ASSEMBLY, BLOWER, BELT GUARD
64 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 69
SECTION 5
Item No.
Part Number
Qty
Description
1
61-507
1
WELDMEN, BRACKET QD MOUNTING
2
25-005
1
QUICK COUPLING, .375F X .375FP, BRASS
3
21-073
1
COUPLING, 3/8 NPT BRASS
4
21-261
1
FITTING, 5-8 H BARB X 3-8 NPT BRASS
69-211 ASSEMBLY, BRACKET QD FITTING
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
65
Page 70
SECTION 5
Item No.
Part Number
Qty
Description
1
61-593
1
WELDMENT, WASTE TANK
2
20-009
2
2.5 NPT X 5.0 FILTER SCREEN
3
61-002
1
WELDMENT, STRAINER BASKET
4
61-587
1
WELDMENT, LID
5
41-018
1
GASKET, SPONGE 1 IN X 45 IN
6
40-003
2
LATCH, PRE-FILTER BOX
7
21-064
1
ELL, 1/4 P X 1/4 T, BRASS
8
18-215-16
1
HOSE ASSEMBLY, 3-16 ID X 38 OL
9
19-009
1
CAP, PLUG 2IN RUBBER
10
69-000
1
FLOAT SWITCH
11
21-097
4
PLUG, 1-1/4 IN PVC
69-250, ASSEMBLY, WASTE TANK
66 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 71
SECTION 5
ELECTRICAL DIAGRAM
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
67
Page 72
SECTION 5
18-215-05
18-214-03
18-214-03
16-003
18” lg.
18-215-12
18-215-06
18-215-07
18-214-04
16-005
8” lg.
16-005
22” lg.
To
Vacuum
Brkt.
Hose Identification
68 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 73
SECTION 5
44-084 DECAL, 44-080 DECAL,
CAUTION, HOT SURFACE WARNING, USE IN WELL VENTILATED AREA
44-085 DECAL, 44-067 DECAL, 44-066, DECAL
WARNING, ROTATING MACHINERY WARNING READ MANUAL WARNING ELECTRICAL SHOCK
44-090 DECAL, MANIFOLD MAINTENANCE 44-079 DECAL, UNLEADED FUEL ONLY
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
44-077 DECAL, 454 SS
®
®
69
Page 74
11. ACCESSORIES
Solution line
coupling.
Solution control
valve. Turn 45°
counter-clockwise to
open fully.
FIG. A: HANDLE DETAIL
FIG. B: EXTRACTION HEAD (Bottom view)
Purge valve. To
flush out or debris
from injector,
loosen purge valve
and allow solution
to flow at full
force.
Injector/extraction
manifold
SECTION 5
67-014 STRYKER WAND
70 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 75
SECTION 5
1992 TO 2002 FORD FUEL LINE INSTALLATION
69-005 KIT, FUEL HOOKUP FORD FI
Item No.
Part Number
Qty
Description
1
66-031
1
ADAPTOR,VENT TUBE(FORD)
2
21-086
2
FTTG, BULKHEAD 1/4 IN BRASS
3
21-039
2
ELL,1/4 IN LG STREET BRASS
4
21-038
1
ELL, STREET 1/8 IN BRASS
5
21-007
2
FTTG, BRB 1/8P X 5/16 H BR
6
21-006
4
FTTG, BRB 1/4P X 5//16H BR
7
18-028
1
HOSE, 3/16 X 25 (1/8P X 1/8P NO COVER)
8
14-011
6
CLAMP, HOSE FUEL # 6
9
14-000
2
CLAMP, HOSE #12
Cut Existing Hose
3” From Hose End
Vent Tube
Fuel Suction Line
Fuel Return Line
To Bottom of Tank
1 9 7 5 4
8
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
71
Page 76
SECTION 5
CHEVY AND GMC FULL SIZE VAN FUEL LINE INSTALLATION
Item No.
Part Number
Qty
Description
1
14-010
2
CLAMP, HOSE # 32
2
14-011
6
CLAMP, HOSE FUEL # 6
3
21-006
4
FTTG, BRB 1/4P X 5//16H BR
4
21-007
2
FTTG, BRB 1/8P X 5/16 H BR
5
21-038
1
ELL, STREET 1/8 IN BRASS
6
21-039
2
ELL,1/4 IN LG STREET BRASS
7
21-086
2
FTTG, BULKHEAD 1/4 IN BRASS
8
21-116
1
ELL, 1/8 FP X 1/8 FP BRONZE
9
66-030
1
ADAPTOR,FUEL NECK(CHEVY)
10
18-027
2
HOSE, 3/16 X 5 (1/8P X 1/8P NO CVR)
2 1 9 4 1
8
Remove Existing
Hose and Cut in Half
CAUTION:
Do Not Cut
Inner Hose
To Bottom of Tank
Fuel Return Line
Fuel Suction Line
69-003 KIT, FUEL HOOKUP 97 & 2002 FI
72 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 77
SECTION 5
Item No.
Part Number
Qty
Description
1
66-034
1
ADAPTOR, FUEL FLR CHVY 2003
2
14-006
2
CLAMP, HOSE # 20
3
18-028
1
HOSE, 3/16 X 25 (1/8P X 1/8P NO COVER)
4
14-011
6
CLAMP, HOSE FUEL # 6
5
21-038
1
ELL, STREET 1/8 IN BRASS
6
21-007
2
FTTG, BRB 1/8P X 5/16 H BR
7
21-039
2
ELL,1/4 IN LG STREET BRASS
8
21-006
4
FTTG, BRB 1/4P X 5//16H BR
9
21-086
2
FTTG, BULKHEAD 1/4 IN BRASS
2 3 4 5 6
1
Cut Hose and Remove
Flapper Valve
Trim Fuel Filler Neck 1”.
Reinstall Flapper Valve
Inside of Fuel Filler Hose
2003 CHEVY AND GMC FULL SIZE VAN FUEL LINE
INSTALLATION
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
69-018 KIT, FUEL HOOKUP 2003 CHEVY FI
®
73
Page 78
SECTION 5
1997-2002 DODGE FULL SIZE VAN FUEL LINE
INSTALLATION
69-004 KIT, FUEL HOOKUP CHEVY/DODGE
Item No.
Part Number
Qty
Description
1
14-010
2
CLAMP, HOSE # 32
2
66-030
1
ADAPTOR,FUEL NECK(CHEVY)
3
21-038
1
ELL, STREET 1/8 IN BRASS
4
14-011
6
CLAMP, HOSE FUEL # 6
5
21-007
2
FTTG, BRB 1/8P X 5/16 H BR
6
18-028
1
HOSE, 3/16 X 25 (1/8P X 1/8P NO COVER)
7
21-086
2
FTTG, BULKHEAD 1/4 IN BRASS
8
21-006
4
FTTG, BRB 1/4P X 5//16H BR
9
21-039
2
ELL,1/4 IN LG STREET BRASS
1
2 3 4
5
Fuel Suction Line
Remove Existing Hose
and Cut in Half
CAUTION:
Do Not Remove Ball
To Bottom of Tank
Fuel Return Line
74 SAPPHIRE SCIENTIFIC MODEL 454 SS
®
PART# 49-042 REV B
Page 79
SECTION 5
Item No.
Part Number
Qty
Description
1
46-035
1
PUMP, WASTE
2
61-656
1
WELDMENT, HOSE BRACKET
3
21-032
1
FTTG, BRB ½ P X ¾ H BRASS
4
21-398
1
FTTG, GRDN HOSE ½ P X ¾ H
5
21-036
1
FTTG, BARB 1-1/4 P X 1 IN BARB
6
69-002
1
ASSY, LVL SENSOR SHTOFF WASTE PUMP
7
14-006
2
CLAMP, HOSE #20 SS
8
14-000
2
CLAMP, HOSE #12 X .5 SS
9
41-038
1
WASHER, GARDEN HOSE CAP
10
21-071
1
CAP, GARDEN HOSE ¾ BRASS
11
31-016
1
CONN, 3 PRG ½ TWR #38045 WAYTEK
12
31-019
3
PIN, FEMALE #31035 WAYTEK
13
47-031
1
HARNESS, WASTE PUMP OUT
14
16-004
6 FT
HOSE, WTR ¾ IN HRZ 500 FT BULK
15
16-018
2 FT
HOSE, WTR 1 IN HRZ 100 FT BULK
16
10-178
4
BOLT, TAP 5/16-18 X 2-1/2 HXHD Z
17
10-068
3
BOLT, TAP ¼-20 X 2-1/2
18
11-013
3
LKNUT, ¼-20 NYLOK
19
11-029
4
NUT, 5/16-18 NYLOK
20
12-017
8
WASHER, FLAT 5/16 SAE ZINC
21
12-012
6
WASHER, FLAT ¼ USS
68-158, ASSY, WASTE PUMP OUT
PART# 49-042 REV B SAPPHIRE SCIENTIFIC MODEL 454 SS
®
75
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