Sapphire Audio rage Service And Operation Manual
Service and Operation Manual
2604 Liberator Dr., Prescott, AZ 86301 1-928-445-3030
I
Congratulations on your purchase of the
RAGE® 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.SAPPHIRE
SCIENTIFIC.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
RAGE® 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 2013 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: September 2010
Revised: November 2010; Rev B
March 2012; Rev C
January 2013; Rev D
May, 2013; Rev E
June, 2013; Rev F
November 2013; Rev G
November 2015; Rev H
January 2016; Rev J
March 2016; Rev K
Printed in USA
RAGE® MANUAL
PART# 49-057
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
II
SAPPHIRE SCIENTIFIC LIMITED WARRANTY
Sapphire Scientific RAGE®
What Does This Warranty Cover?
This warranty covers the Sapphire Scientific RAGE® 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 1000 hours or 2 years, whichever comes first. 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.
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
III
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,
Fuel Hook-Up Kits By Vehicle
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,
Heat Bypass Operation, Shut Down and Daily Maintenance, Freeze Protection.
SECTION FOUR: MAINTENANCE and SERVICE 25
6. MAINTENANCE CHART 26
7. MAINTENANCE 27
8. GENERAL SERVICE ADJUSTMENTS 31
9. TROUBLESHOOTING 34
SECTION FIVE: PARTS and ACCESSORIES 39
10. ILLUSTRATED PARTS LISTINGS 40
11. ACCESSORIES 60
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
1
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
Fuel hook-up kits by vehicle 8
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
2
1. SAFETY
The following WARNING labels are on
your RAGE® console. These labels point
out important Warnings and Cautions,
which must be followed at all times. Failure
to follow warnings could result in personal
SECTION 1
For Your Safety!
injury or fatality to yourself and/or others or
property damage. Please follow these
instructions carefully! DO NOT remove
these decals.
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
3
!
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 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.
SECTION 1
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
4
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 it to
cool down and relieve the 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 wellventilated 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.
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 858 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. DO NOT operate this unit without the water
supply on and attached. The water pump and
other vital components could be seriously
damaged if the unit is operated dry.
20. Always keep your vehicle clean and orderly.
Wands, tools and accessories must be securely
stowed while driving the vehicle.
21. 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 criteria
and should never be used. Severe burns and
other injuries could result if hoses do not meet
these requirements.
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
SECTION 1
®
5
22. Ensure that you have received proper
training from the distributor that you purchased
the unit from prior to operation.
23. This unit produces high pressure and high
temperatures. Improper use could result in
serious injury.
24. DO NOT modify this unit in any manner.
Any modification could result in serious injury
or fatality.
25. 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.
SECTION 1
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
SECTION 1
6
SPECIFICATIONS
Engine Speed 3000 RPM (High Speed No Load)
1500 RPM (Idle No Load)
Water Pump RPM 1488 RPM
Vacuum Pump RPM 3273 RPM
Water Flow Rate 2.7 GPM (maximum)
Water Pump Pressure 1200 PSI (maximum)
Vacuum Relief Valve 13 in. Hg
Waste Tank Capacity 90 gal.
Console Weight 520 lbs.
Console Weight (w/standard waste tank & hoses) 858 lbs.
Operating Weight (w/full water box & standard waste tank) 1534 lbs.
TORQUE VALUES
Engine Hub Rear 160 inch/lbs. 13.3 ft/lbs.
Engine Hub Front 160 inch/lbs. 13.3 ft/lbs.
Vacuum Pump Hub 160 inch/lbs. 13.3 ft/lbs.
Pressure Pump Hub 130 inch/lbs. 10.8 ft/lbs.
JET SIZING
SAPPHIRE SCIENTIFIC recommends that the total floor tool tip size does not exceed
#6. Using larger jet sizes on your RAGE® unit may reduce cleaning
temperatures.
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
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7
INSTALLATION
Engine oil capacity
1.7 L
1.8 U.S.qts
Tightening torque
Drain Plug
13.6 N·m
1.4 kgf·m
10.0 lbf·ft
SECTION 1
REQUIREMENTS
Prior to beginning the installation, read the
ENTIRE “Installation” section of this manual.
Since the RAGE® Truck mount unit weighs
(with standard waste tank and hoses)
approximately 858 lbs., please adhere to the
following recommendations prior to installing the
unit.
!
The console and waste tank with accessories
must NOT exceed the vehicle’s axle weight
limit.
1. 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.
2. If mounting in a trailer, the RAGE
must be positioned so that it balances properly
with respect to the trailer axle. Ten percent (10%)
of the unit’s total overall weight (w/o accessories
or water) should be on the tongue. This unit has
an air cooled engine, and adequate ventilation
must be provided to prevent overheating.
3. If mounting in a trailer, the external fuel
tank must meet EPA requirements for
compliance.
3. The vehicle tires must have a load rating in
excess of the combined unit and vehicle weight.
4. 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.
5. Insulation under rubber mats should be
removed prior to installation of the unit.
®
console
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 warranty.
ENGINE OIL REQUIREMENTS
Use high-quality oil of at least API (American
Petroleum Institute) service class SG, SH, SJ or
higher. Do not use additives. High quality 30W
oil is recommended. A 10-30 synthetic blend
may be used after 50 hours of operation for a new
or rebuilt engine to allow the piston rings to
properly seat. It is never recommended to extend
oil change intervals past 100 hours.
NOTE: Using 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.
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
SECTION 1
8
CHEMICAL REQUIREMENTS
The SAPPHIRE SCIENTIFIC RAGE® 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 and CHEMSPEC 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
concentration.
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
SECTION 1
9
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 RAGE® 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
RAGE
items as well as any optional accessories:
EQUIPMENT LISTING
®
unit should arrive with the following
A. SAPPHIRE SCIENTIFIC RAGE
MODEL 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 filter and stainless steel
strainer basket.
50 ft. of ¼ in. high pressure solution hose
with shutoff valve and quick connects.
50 ft. of ¼ in. high pressure solution hose
with quick connects
2 50 ft. lengths of 2 in vacuum hose.
1 hose coupler – 2 inch.
50 ft. water supply hose with quick
connect.
OPTIONAL EQUIPMENT
A. Additional 50 ft.2 in. vacuum hose
Part # 18-003
Additional vacuum hose connectors
Part # 21-003
Additional high-pressure solution hoses
Part # 18-000
With shutoff valve Part # 18-001
Demand pump system
Part # 68-002
Automatic Waste Pump-Out Kit
Part #68-158
FUEL HOOK-UP KITS BY VEHICLE
Chevy 1997 to 2002 FI…….. 69-003FI
Chevy 2003 FI……………... 69-018FI
Chevy 2004+ Hook-Up Kit… 69-033
Chevy Box Truck 2004+…… 69-081
Dodge 1997 to 2002 FI…….. 69-004FI
Dodge ProMaster…………... 69-613S
Ford FI……………………... 69-005FI
Ford 2004 – 2010…………... 69-061
Ford 2011+…………………. 69-331
Ford Box Truck 2004+…….. 68-077
Ford Transit Connect ……... 69-261S
Ford Transit 2014+ …………69-671
Nissan NV………………….. 69-376
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
10
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# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
SECTION 2
11
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 RAGE®
weighs approximately 520 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 RAGE®. 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. Please refer to
SPECIFICATIONS in Section 1 for standard
unit and waste tank operating weight.
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 a minimum of six
13
(6)
⁄
in. diameter holes for the console and a
32
minimum of four (4)
the waste tank. It is best to use all provided holes
when possible. If installing into a Ford Transit,
use the Transit drill template and follow the
instructions included with the template.
B. Using the provided mounting hardware kit:
1. Insert a minimum of six (6) 3/8-16 × 4 in.
grade 5 hex head cap screws with flat
washers through the RAGE® console
mounting rail holes, and a minimum of
four (4) 3/8-16 × 4 in. grade 5 hex head
cap screws with flat washers through the
waste tank mounting holes. If installing
into a Ford Transit, use the two provided
5/16-18 x 6 in. grade 5 hex head cap
screws in the front flange holes of the
waste tank. Install all waste tank bolts
from the underbody side.
2. Install the provided mounting plates
underneath the vehicle floor. The larger
mounting plates were designed for use
where larger underbody space is
available, especially on the Ford Tranist.
3. Screw the provided 3/8-16 hex head nuts
on to the mounting bolts and tighten until
the console and waste tank are firmly
attached to the vehicle floor.
13
⁄
in. diameter holes for
32
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
SECTION 2
12
DIMENSIONAL DIAGRAM REAR MOUNT TANK
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
SECTION 2
12
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.
Avoid contact with moving parts, areas of
high temperature, brake lines, fuel lines,
catalytic converters, exhaust pipes, mufflers or
sharp objects.
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.
B. Use only fuel tanks that are
manufactured specifically for gasoline, that
are EPA compliant with 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.
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
SECTION 2
13
CONSOLE TO WASTE TANK CONNECTION
Waste Tank
Vacuum Relief
Vacuum Inlet 2”
16-011, HOSE, INT VAC2-7/8 X 36”
17-205
HOSE, INT VAC
2-1/2 X 60”
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
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14
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 20
Operation 21
Cleaning 21
Upholstery cleaning 21
Flood restoration/extraction 21
Heat bypass operation 22
Shut down and daily maintenance 22
Freeze protection 23
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
SECTION 3
15
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 water box and flows
through a float valve, which shuts off the water
when the water box is full.
The water then flows to the water pump where it
is pressurized. From there it flows to the heat
exchanger where it travels through tubing and is
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# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
SECTION 3
16
Filter Basket
Exhaust
Vacuum Inlet
Heat Exchanger
Vacuum Pump
Vacuum Relief
Filter
VACUUM SYSTEM
The engine turning an air pump (vacuum pump)
generates 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 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.
PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE
®
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