Sapphire Audio rage Service And Operation Manual

Download

Page 1

Service and Operation Manual

2604 Liberator Dr., Prescott, AZ 86301 1-928-445-3030

Page 2

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

Page 3

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

Page 4

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

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 Fuel hook-up kits by vehicle 8

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 6

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

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 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

Page 8

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

Page 9

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

Page 10

SECTION 1

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

Page 11

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

Page 12

SECTION 1

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

Page 13

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 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

Page 14

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

Page 15

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 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

(6)

⁄

in. diameter holes for the console and a

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.

⁄

in. diameter holes for

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 16

SECTION 2

DIMENSIONAL DIAGRAM REAR MOUNT TANK

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 17

Page 18

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. 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

Page 19

SECTION 2

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

Page 20

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

Page 21

SECTION 3

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

Page 22

SECTION 3

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

Page 23

SECTION 3

Chemical Pump

Solution Outlet

Solution

Manifold

Chemical

3-Way

Select Valve

Flow

Chemical Prime Line

Chemical Supply Line

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 chemical then flows 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.

Meter

Metering

Valve

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Outlet

Page 24

5. OPERATION

Choke

Pump Out

Switch

On / Off

Ignition Switch

Water Pressure

Gauge

Vacuum Pressure

Gauge

Throttle

Chemical

Flow

Gauge

Chemical

Prime Valve

20 Amp Circuit

Breakers

30 Amp Main

Circuit Breaker

Hour Meter

Chemical

Metering

Valve

Engine Override

Pushbutton

PREPARATION

This section of the operator’s manual explains

how to prepare, start, operate, shut down and maintain your SAPPHIRE SCIENTIFIC

RAGE® mobile cleaning unit. The RAGE®

unit is easy to operate, however only trained operators should proceed.

SECTION 3

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.

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 25

Exhaust

Chemical Check

Valve

Pressure Outlet

Outlet Filter

Temperature Bypass Control

Vacuum Lube Cup

Vacuum Inlet

Water Inlet

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 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 water box. 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.

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

SECTION 3

HIGH PRESSURE HOSE

Before starting the unit, connect the high pressure hose to the solution outlet connection at the front of the unit. Connect the cleaning tool to the opposite end of the pressure hose.

Page 26

SECTION 3

STARTING THE UNIT

1. Set throttle control in.

2. Pull out engine choke.

3. Press and hold the OVERRIDE button while turning the ignition key to start the engine.

4. Push in engine choke after engine has started.

5. Let the engine warm up at 1/2 throttle.

6. Set throttle control to maximum.

Note: Do not operate the unit with throttle control set below 50% of maximum throttle setting.

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 #6. Using larger jet sizes on your RAGE® 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.

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 selector valve located on the control panel to the PRIME position. The chemical will then flow from the chemical container through the chemical prime tube.

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 selector valve to OFF position and turn the chemical selector 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 selector valve from PRIME to METER. With the cleaning tool open, check the flow meter and adjust the chemical metering valve until the desired rate of chemical flow is achieved.

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.

1. Insert the chemical prime tube and the chemical inlet tube into the chemical container.

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 27

SECTION 3

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

When operating the unit for cleaning or restoration, the unit should be in the maximum throttle position. This ensures full vacuum and performance from the unit.

NOTE: During flood extraction the throttle control must be set to maximum.

CLEANING

While 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. Upholstery tools have a lower flow rate and smaller orifices. It may be necessary to slow the engine down and partially open the bypass valve to maintain proper cleaning.

FLOOD RESTORATION/EXTRACTION

This machine can be used for limited water extraction only if connected to an adequate water source and the bypass valve is opened 1/4 turn.

NEVER RUN THE PRESSURE PUMP DRY.

Doing so will quickly build up heat in the pump which may cause severe damage to internal components

An automatic waste pump-out is highly recommended when performing flood extraction to avoid shutdown from filling the waste tank.

1. Set the throttle control cable on the front control panel to maximum.

2. If an automatic waste pump-out is equipped, set the PUMP OUT switch to the ON position.

3. Proceed into the extraction process.

To prevent excess heat build-up in the unit, do not restrict air flow to the wand head when not extracting water. If the wand must be placed down, position the head sideways or upside down.

NOTE: 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.

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 28

SECTION 3

HEAT BYPASS OPERATION

The heat bypass has 2 purposes.

1. To cool down the unit at the end of the job when using for carpet cleaning. When finished with the job, open the heat bypass while coiling up the hoses to allow water to circulate through the unit and prevent excess heat buildup.

2. In flood extraction mode, open the valve 1/4

turn to keep water circulating through the pump to prevent pump overheating and premature failure.

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 cable to the idle position.

5. Allow the unit to run at 50% throttle for a few minutes. 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 inlet on the front of the unit and set the throttle control cable to high. Spray WD-40 (or equivalent) into the blower lubrication cup, located on the left 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.

6. Turn the ignition switch to the OFF position.

7. 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.

8. 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.

9. 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.

10. 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.

11. 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.

NEVER operate this unit with the filter removed, damaged or improperly installed.

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 29

SECTION 3

12. 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

13. 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.

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 ANTIFREEZE:

1. Shut off the water supply to the unit and disconnect the water inlet hose from the water box.

2. Connect all solution hoses and a tool to the console.

3. Start the unit.

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 a tool valve until anti-freeze 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 anti-freeze container. Turn the chemical valve to PRIME until anti-freeze comes out of the prime hose. Turn the chemical 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:

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.

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 30

SECTION 3

REMOVING ANTI-FREEZE FROM THE UNIT CONTINUED:

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 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 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.

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 31

SECTION 4: SERVICE and MAINTENANCE

6. MAINTENANCE CHART

Maintenance Chart 26

7. MAINTENANCE

Engine 27 Vacuum Pump 28 Water Pump 28 Vacuum Inlet Filter 29 Drive Belts, Pulleys and Hubs 29 Strainer Basket 29 Check Valve (Outlet) 29 Chemical Pump 29 Chemical Metering System 29 Pressure Regulator 30 Vacuum Hoses 30 Battery 30 High Pressure Solution Hoses 30

8. GENERAL SERVICE ADJUSTMENTS

Engine Speed 31 Vacuum Relief Valve 31 Water Pump Drive Belt 31 Solution Outlet Check Valve 31 Chemical Pump 32 Packing Nut Adjustment, Chemical Metering and Selector Valves 32 Pressure Regulator 33

9. TROUBLESHOOTING

Engine 34 Blower / Vacuum Pump 35 Water Pump 36 Chemical System 38

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 32

SECTION 4

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.

Vacuum Pump

Daily*

Check vacuum pump oil level. Fill to proper level. Do not overfill.

Waste Pump-Out (Optional)

Daily*

Inspect and remove any debris or sediment.

Engine

Weekly

Check air cleaner for damaged, dirty, or loose parts.

Engine

Weekly

Inspect air intake and cooling areas. Clean if required.

Pump Inlet Filter

Weekly

Clean and inspect.

Battery

Weekly*

Check fluid level. Fill with distilled water only. Do not overfill.

Engine

Monthly

Inspect drive belt for wear. Replace as needed.

Water Box

Monthly

Check float valve for proper operation.

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 belt********

Water Pump

50 Hours

Change crankcase oil.***

Engine

8 Hours

Change engine oil and filter.

Belts

100 Hours

Re-tension belt********

Engine

100 Hours

Change engine oil and filter.

Vacuum Relief

100 Hours

Check and adjust vacuum relief valve to 13” 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 and clean if necessary.

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 Hrs

Replace belts.

Engine

1000 Hrs

Replace spark plugs.

Vacuum Pump

1000 Hrs

Drain, flush, and replace oil.*******

Check Valve

1000 Hrs

Replace Teflon seat for abnormal wear or debris.

Engine

1000 Hrs

Replace air filter element.

6. MAINTENANCE CHART

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 50 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. *****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# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 33

SECTION 4

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

7. MAINTENANCE

This section of the operator’s manual contains

the service and maintenance information for the

RAGE® unit. A planned preventative

maintenance program will ensure that your SAPPHIRE SCIENTIFIC RAGE® 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 to 8 hours of operation. Thereafter, change oil and oil filter every 50 to 100 hours of operation. USE ONLY KOHLER 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 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.

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.

3. Check the spark plugs every 200 hours and clean if necessary. Replace spark plugs every 1000 hours. NEVER sandblast spark plugs. Spark plugs should be cleaned only by scraping or wire brushing.

4. Clean the engine air filter element every 200

hours. Replace the element every 1000 hours.

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 34

SECTION 4

Vent Cap/

Oil Fill

Oil Level

Sight Gauges

Oil Drains

Oil Filter Cap

Oil Level

Sight Gauge

Oil Drain

Replace the in-line fuel filter yearly. NOTE: Additional engine service information can be obtained from the provided Operation and Maintenance manual. If service or repair is required, contact an authorized Kohler 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 vacuum pump Lubricant in both sides of the vacuum pump for all operating temperatures. AEON PD-XD is formulated specifically for positive displacement vacuum pump service to provide maximum vacuum pump 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 daily to ensure it is at the proper level. Too little oil will damage and ruin the bearings and gears. Too much oil will result in overheating.

NOTE: Two drains are on your vacuum pump. Ensure that BOTH sides of the vacuum pump are filled to their proper level when servicing.

2. A lubrication port 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 WD-40 (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 1 year, whichever comes first.

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.

2. After the first 50 hours of operation, change the crankcase oil with general pump oil. Change the crankcase oil every 500 hours thereafter.

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 35

SECTION 4

TORQUE VALUES

Component

Inch/lbs

Foot/lbs

Engine Rear Hub

160

13.3

Engine Front Hub

160

13.3

Vacuum Pump Hub

160

13.3

Pressure Pump Hub

130

10.8

Vacuum Pump: Belt Replacement Procedures for The RAGE:

1) Disconnect the negative battery cable

2) Remove hose from waste tank to vacuum

pump

3) Remove side hoods and top panel

4) Remove left and right hand belt guards

5) Loosen the hose clamp under the blower

6) Slide the blower back (away from engine)

7) Lower the blower plate approximately ½”

8) Tip the back of blower up

9) Remove all belts. Install new belts

10) Reverse procedures to install new belts

11) After belts have been installed, check for

proper tension and alignment. Do this using a belt gauge. Set deflection to 1/8”; 10-12 lbs tension

DRIVE BELT AND PULLEYS

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

12) 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)

(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

13) Ensure that the blower plate is level (equal

distance from frame at four mounting points)

14) Estimated time, 2 hours

VACUUM INLET FILTER

1. The vacuum inlet filter in the waste tank should be inspected and cleaned daily.

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.

CHEMICAL METERING SYSTEM

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 grease to the threads will allow easier removal of filter when cleaning or replacement is required.

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Check and inspect the packing nut on the chemical selector and metering valves every 200 hours. Keeping the valve packings properly adjusted will prevent leaks and add to the overall life of the valves.

Page 36

SECTION 4

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

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.

Explosive gases, Dangerous acid!

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.

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.

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.

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 37

SECTION 4

Item #

Part

Number

Qty.

Description

27-009

CAP, CHECK VALVE ASSY. SS

41-007

ORING, 7/8 ID X 1-

1/16 OD

15-007

SPRING, CHECK

VALVE ASSY.

27-010

POPPET, CHECK

VALVE ASSY

27-004

INSERT, SEAT-CHK

VLV ASSY TM

27-011

SEAT, CHECK VALVE ASSY.

41-008

ORING, ½ ID 5/8 OD

7 6 5

4 3 2

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 Engine Operation and Service Manual for specific instructions.

DO NOT attempt to adjust without a tachometer and NEVER adjust the engine above 3200 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 13” Hg. Always ensure the 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.

3. While checking the alignment, tighten the nuts that hold the water pump to the base.

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 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.

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.

23-063 VLV, CHECK, CHECK VLV MANIFOLD

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 o-rings with o-ring lubricant. (Part # 13-003) and re-install.

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 38

SECTION 4

Adjust the packing nut by turning the packing bolt clockwise at 1/16” increments.

Loosen Set Screw and Remove Knob

Packing Nut

CHEMICAL PUMP

The RAGE® unit features a stainless steel chemical pump and metering system. The chemical pump requires only the replacement of the diaphragm and check valves. 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 (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.

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 39

SECTION 4

Valve Nut

Brass Housing

O-Ring

Adjusting Cap

Spring

Back Ring

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 100 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# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 40

9. TROUBLESHOOTING

TROUBLESHOOTING: ENGINE

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 your blower 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 Operation and Maintenance Manual.

Engine is malfunctioning

Refer to Engine Operation and Maintenance Manual.

Excessive heating

Flow restriction caused by hard water scaling.

De-scale unit, repair or replace damaged plumbing components as necessary. Install water softener.

Not enough water flow.

Check jet size of tool.

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.

This section of the operator’s manual

describes how to look for and repair malfunctions, which may occur.

SECTION 4

Accurate troubleshooting is based on a thorough and complete understanding of the WATER,

CHEMICAL, VACUUM, 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

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 41

TROUBLESHOOTING:

PROBLEM

CAUSE

SOLUTION

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 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 Engine Operation and Maintenance Manual.

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.

Solenoid switch stuck open

Replace temperature switch Engine RPM is low.

Reset engine RPM.

Defective temperature gauge.

Test gauge and sensor. Replace failed component.

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.

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 to 13”Hg

ENGINE

SECTION 4

TROUBLESHOOTING: BLOWER / VACUUM PUMP

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 42

TROUBLESHOOTING:

PROBLEM

CAUSE

SOLUTION

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 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.

Outlet check valve is plugged

Examine the check valve, remove any debris

Cleaning tool valve is malfunctioning.

Repair or replace valve.

BLOWER / VACUUM PUMP

SECTION 4

TROUBLESHOOTING: WATER PUMP

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 43

TROUBLESHOOTING:

PROBLEM

CAUSE

SOLUTION

Loss of solution volume at

cleaning tool orifice: Solution

pressure gauge reads normal.

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.

Defective quick-connect on one or more of the high pressure hoses.

Replace defective quick-connects(s) on high pressure hoses(s).

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 orings

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.

WATER PUMP

SECTION 4

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 44

TROUBLESHOOTING:

PROBLEM

CAUSE

SOLUTION

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.

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.

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.

Loss of chemical: With the cleaning tool valve open, no chemical

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.

CHEMICAL SYSTEM

SECTION 4

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 45

SECTION 5: PARTS and ACCESSORIES

10. ILLUSTRATED PARTS LISTINGS

Console Assembly .......................................................................................... 40

Frame and Enclosures..................................................................................... 42

Control Panel Assembly – Component List Front ......................................... 43

Control Panel Assembly – Component List Back .......................................... 44

Engine Assembly ............................................................................................ 45

Vacuum Blower Assembly ............................................................................. 46

Vacuum Relief. ............................................................................................... 47

Water Pump Assembly ................................................................................... 48

Heat Exchanger .............................................................................................. 49

Chemical Pump .............................................................................................. 50

Solution Manifold ........................................................................................... 51

Vacuum Inlet Bracket ..................................................................................... 52

Regulator Bracket ........................................................................................... 53

Belt Guard Blower .......................................................................................... 54

Water Box/Float Valve ................................................................................... 55

Waste Tank ..................................................................................................... 56

Electrical Diagram .......................................................................................... 57

Hose Identification / Flow Diagram ............................................................... 58

Decals ............................................................................................................. 59

11. ACCESSORIES

Waste Pump Out Assembly. ........................................................................... 60

1992 to 2002 Ford Fuel Line Install ............................................................... 62

Chevy and GMC Full Size Van Fuel Line Install .......................................... 63

2003 Chevy and GMC Full Size Van Fuel Line Install ................................. 64

1997-2002 Dodge Full Size Van Fuel Line Install ......................................... 65

Fuel Line Bulkhead Installation. ..................................................................... 66

Fuel Pump Assembly Installation. .................................................................. 67

Fuel Supply and Return Line Installation. ...................................................... 68

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 46

SECTION 5

CONSOLE ASSEMBLY, DETAIL 1

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 47

SECTION

CONSOLE ASSEMBLY, DETAIL 2

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 48

SECTION 5

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 49

SECTION

69-544, ASSY, BEZEL AND PANEL, 1-16

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 50

SECTION 5

69-445, ASSY, BEZEL AND PANEL, 17-25

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 51

SECTION 5

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 52

SECTION 5

69-710, VACUUM PUMP ASSEMBLY

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 53

SECTION 5

69-432, ASSEMBLY, VACUUM RELIEF

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 54

SECTION 5

Pulse Pump

46-056

Pump

46-072

69-610, ASSY, PRESSURE PUMP

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 55

SECTION 5

Item No.

Part Number

Qty

Description

64-055

INSULATOR, HEAT EXCHANGER SIDE

64-054

INSULATOR, HEAT EXCHANGER BACK

64-053

INSULATOR, HEAT EXCHANGER TOP

63-033

ASSY, VAC HEATER CORE BLUEWAVE

61-901

WELDMENT, HEAT EXCHANGER COVER

61-889

WELDMENT, HEAT EXCHANGER HOUSING

58-615

PNL, HEAT EXCHANGER INSULATOR COVER

41-033

GROMMET, 1 ID X 1-3/4OD

21-061

ELL, 3/8 P X 1/2 T BRASS

21-057

CONN, 3/8 NPT X 1/2 JIC BRASS

21-041

TEE, 3/8 NPT BRASS

21-161

FTTG, .38M X .38M 90 DEG

34-044

SENSOR, TEMP 3/8 NPT 240 DEG

14-019

RIVET, ALUM NAMEPLATE

12-015

LKWSR, 1/4 ZINC

12-011

WASHER, FLAT #12 SAE

10-025

SCREW, MACH 1/4-20 X 3/4 HXHD GRD5

69-441, ASSY, HEAT EXCHANGER

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 56

SECTION 5

Item No.

Part Number

Qty

Description

36-350

BODY, PULSE PUMP, GP PULSE PUMP

36-351

PLASTIC DISC, GP PULSE PUMP

36-352

RUBBER DIAPHRAGM, GP PULSE PUMP

36-353

TOP COVER INLET, GP PULSE PUMP

36-354

O-RING, 70 DURO, GP PULSE PUMP

36-356

ASSY, VALVE KIT, GP CHEMICAL PULSE PUMP

36-355

VALVE CAP 303SST, GP PULSE PUMP

36-357

SPACER RING, 303 SST, GP PULSE PUMP

36-358

VALVE CAP, 303 SST, GP PULSE PUMPMP 520196

46-056, ASSEMBLY, CHEMICAL PUMP

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 57

SECTION 5

69-260, MANIFOLD BLOCK ASSEMBLY

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 58

SECTION 5

Item No.

Part Number

Qty

Description

61-902

WELDMENT, VACUUM INLET BRACKET

25-005

QUICK COUPLING, 3/8 F X 3/8 FNPT BRASS

21-434

FTTG, 3/8 FP X 1/2 BARB BRASS

21-007

FTTG, BRB 1/8 P X 5/16 H BR

21-001

CONN, 1/8 P X 1/4 T BR

69-450, ASSY, VACUUM INLET BRACKET

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 59

Item No.

Part Number

Qty

Description

61-456

WELDMENT, BRACKET, REGULATOR MOUNTING

28-000

CUP, OILFILL, 1/8 NPT

23-029

VLV, MET 1/8 FP RT ANG WHITEY

23-010

REGULATOR, PRESSURE

21-336

TEE, 1/8 NPT X 1/4 JIC X 1/4 JIC BRASS

21-333

COUPLING, 1/8 FNPT X 1/8 MNPT BRASS

21-325

ADAPTER, 1/4 NPT X 1/2 JIC BRASS

21-323

FITTING, 1/4 NPT X 1/2 H BRB BRASS

21-122

FITTING, TEE 1/4NPT BRASS

21-090

ELL, 1/8 FNPT X 1/8 FNPT BRASS

21-051

ELL, 1/4P X 1/4T 45 DEG BRASS

21-011

ELL, 1/8 NPT X 1/4 POLY BRASS

21-001

CONN, 1/8 P X 1/4 T BR

SECTION 5

69-449, ASSEMBLY, REGULATOR BRACKET

PART# 49-057 REV J SAPPHIRE SCIENTIFIC RAGE

Page 60

SECTION 5

Item No.

Part Number

Qty

Description

61-465

WELDMENT, BLOWER HOUSING

66-263

BEARING & SHAFT, BLR HSG STD

15-027

SNAP RING, 1.187 INTERNAL

66-215

PULLEY, 3L BELT X 2.340 OD

10-219

SCREW, FULL DOG SET 1/4-20 X 1/2 BLK

51-042

AIR WHEEL, MOLDED

12-017

WASHER, FLAT 5/16 SAE ZINC

11-029

NUT, 5/16-18 NYLOK

51-043

COVER, AIR WHEEL

10-146

SCREW, 8-32 X .375 PHP F THREAD CUTTING ZP

69-184 ASSEMBLY, BELT GUARD BLOWER

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 61

SECTION 5

Item No.

Part Number

Qty

Description

64-000

ROD, FLOAT SS THERMAL WAVE

51-002

MOLDING, WATER BOX DISCOVERY

28-001

BALL, FLOAT

23-033

VALVE, 165 DEG THERMAL CAT 7145

23-025

VLV, FLOAT WTR BOX THERMALWAVE

21-154

FITTING, 1/2 NPT X 1/2 BARB BRASS

21-109

FTTG, 1/2 NPT X 5/8 BARB BRASS

21-047

NIP, 1/2 IN HEX BRASS

21-034

ELL, STREET 1/2 BRASS

21-032

FTTG, BRB 1/2 P X 3/4 H BRASS.SLDPRT

21-025

CAP, 5 IN WATER BOX_TANK BLACK

21-001

CONN, 1/8P X 1/4T BR

20-014

STRAINER, SUC END1/2FP 40 MESH

11-001

NUT, 1/4-20 SS

69-273, ASSY, WATER BOX / FLOAT VALVE

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 62

SECTION 5

Item No.

Part Number

Qty

Description

61-636

WELDMENT, WASTE TANK

20-009

2.5 NPT X 5.0 FILTER SCREEN

61-002

WELDMENT, STRAINER BASKET

69-000

FLOAT SWITCH

21-097

PLUG, 1-1/4 IN PVC

19-009

CAP, PLUG 2IN RUBBER

21-064

ELL, 1/4 P X 1/4 T BRASS

41-018

136.25 IN

GASKET, SPONGE 1 IN X 45 FT

61-587

WELDMENT, LID

40-003

LATCH, PRE-FILTER BOX

58-473

BRKT, MNT WTR BOX HLD DWN

69-273

ASSY, WATER BOX BLUEWAVE

60-979

MNT, WATER BOX

10-026

SCREW, MACH 1/4-20 X 1 HXHD

12-011

WASHER, FLAT #12 SAE

12-015

LKWSR, 1/4 ZINC

11-004

NUT, 1/4-20 ZINC

10-004

SCREW, MACH 3/8-16 X 1-1/4 HEXHD

12-013

WASHER, FLAT 3/8 SAE

12-014

LKWSR, 3/8 ZINC

11-006

NUT, 3/8 ZINC

69-276 ASSY, WASTE TANK

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 63

SECTION 5

ELECTRICAL DIAGRAM

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 64

SECTION 5

HOSE IDENTIFICATION / FLOW DIAGRAM

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 65

SECTION 5

44-281 DECAL, PRODUCT 170 RAGE

44-079 DECAL, UNLEADED FUEL ONLY

44-081 DECAL, ENGINE COVER WARRANTY

44-066 DECAL,

WARNING ELECTRIC SHOCK

44-085 DECAL,

WARNING ROTATING

MACHINERY

44-083 DECAL,

WARNING HIGH PRESSURE

44-067 DECAL,

WARNING READ MANUAL

44-080 DECAL, WARNING VENTILATED AREA

44-084 DECAL, CAUTION HOT SURFACE

44-131 DECAL, LOWER FRONT PANEL

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 66

11. ACCESSORIES

Item No.

Part Number

Qty

Description

46-035

PUMP, WASTE

61-656

WELDMENT, HOSE BRACKET

21-032

FTTG, BRB ½ P X ¾ H BRASS

21-398

FTTG, GRDN HOSE ½ P X ¾ H

21-036

FTTG, BARB 1-1/4 P X 1 IN BARB

69-002

ASSY, LVL SENSOR SHTOFF WASTE PUMP

14-006

CLAMP, HOSE #20 SS

14-000

CLAMP, HOSE #12 X .5 SS

41-038

WASHER, GARDEN HOSE CAP

21-071

CAP, GARDEN HOSE ¾ BRASS

31-016

CONN, 3 PRG ½ TWR #38045 WAYTEK

31-019

PIN, FEMALE #31035 WAYTEK

47-031

HARNESS, WASTE PUMP OUT

16-004

6 FT

HOSE, WTR ¾ IN HRZ 500 FT BULK

16-018

2 FT

HOSE, WTR 1 IN HRZ 100 FT BULK

10-178

BOLT, TAP 5/16-18 X 2-1/2 HXHD Z

10-068

BOLT, TAP ¼-20 X 2-1/2

11-013

LKNUT, ¼-20 NYLOK

11-029

NUT, 5/16-18 NYLOK

12-017

WASHER, FLAT 5/16 SAE ZINC

12-012

WASHER, FLAT ¼ USS

SECTION 5

68-158, ASSY, WASTE PUMP OUT

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 67

SECTION 5

1992 TO 2002 FORD FUEL LINE INSTALLATION

69-005FI KIT, FUEL HOOKUP FORD FI

Item No.

Part Number

Qty

Description

66-031

ADAPTOR,VENT TUBE(FORD)

21-086

FTTG, BULKHEAD 1/4 IN BRASS

21-039

ELL,1/4 IN LG STREET BRASS

21-038

ELL, STREET 1/8 IN BRASS

21-007

FTTG, BRB 1/8P X 5/16 H BR

21-006

FTTG, BRB 1/4P X 5//16H BR

18-028

HOSE, 3/16 X 25 (1/8P X 1/8P NO COVER)

14-011

CLAMP, HOSE FUEL # 6

14-000

CLAMP, HOSE #12

FIG. B: EXTRACTION HEAD (Bottom view)

Cut Existing Hose 3” From Hose End

Vent Tube

Fuel Suction Line

Fuel Return Line

To Bottom of Tank

1 9 7 5 4

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 68

SECTION 5

CHEVY AND GMC FULL SIZE VAN FUEL LINE INSTALLATION

Item No.

Part Number

Qty

Description

14-010

CLAMP, HOSE # 32

14-011

CLAMP, HOSE FUEL # 6

21-006

FTTG, BRB 1/4P X 5//16H BR

21-007

FTTG, BRB 1/8P X 5/16 H BR

21-038

ELL, STREET 1/8 IN BRASS

21-039

ELL,1/4 IN LG STREET BRASS

21-086

FTTG, BULKHEAD 1/4 IN BRASS

21-116

ELL, 1/8 FP X 1/8 FP BRONZE

66-030

ADAPTOR,FUEL NECK(CHEVY)

18-027

HOSE, 3/16 X 5 (1/8P X 1/8P NO CVR)

Remove Existing Hose and Cut in Half

CAUTION:

Do Not Cut Inner Hose

To Bottom of Tank

Fuel Return Line

Fuel Suction Line

69-003FI KIT, FUEL HOOKUP 97 & 2002 FI

PART# 49-057 REV E SAPPHIRE SCIENTIFIC RAGE

Page 69

SECTION 5

Item No.

Part Number

Qty

Description

66-034

ADAPTOR, FUEL FLR CHVY 2003

14-006

CLAMP, HOSE # 20

18-028

HOSE, 3/16 X 25 (1/8P X 1/8P NO COVER)

14-011

CLAMP, HOSE FUEL # 6

21-038

ELL, STREET 1/8 IN BRASS

21-007

FTTG, BRB 1/8P X 5/16 H BR

21-039

ELL,1/4 IN LG STREET BRASS

21-006

FTTG, BRB 1/4P X 5//16H BR

21-086

FTTG, BULKHEAD 1/4 IN BRASS

3 4 5

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

69-018FI KIT, FUEL HOOKUP 2003 CHEVY FI

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 70

SECTION 5

1997-2002 DODGE FULL SIZE VAN FUEL LINE

INSTALLATION

69-004FI KIT, FUEL HOOKUP CHEVY/DODGE

Item No.

Part Number

Qty

Description

14-010

CLAMP, HOSE # 32

66-030

ADAPTOR,FUEL NECK(CHEVY)

21-038

ELL, STREET 1/8 IN BRASS

14-011

CLAMP, HOSE FUEL # 6

21-007

FTTG, BRB 1/8P X 5/16 H BR

18-028

HOSE, 3/16 X 25 (1/8P X 1/8P NO COVER)

21-086

FTTG, BULKHEAD 1/4 IN BRASS

21-006

FTTG, BRB 1/4P X 5//16H BR

21-039

ELL,1/4 IN LG STREET BRASS

Fuel Suction Line

Remove Existing Hose and Cut in Half

CAUTION:

Do Not Remove Ball

To Bottom of Tank

Fuel Return Line

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 71

SECTION 5

Fuel Line Bulkhead Installation (Inside Vehicle)

1. Select an appropriate location on the vehicle floor away from operator or maintenance traffic and away from

contact with any accessories or tools while in use or transit. Make sure your hole is within adequate reach of the supplied hose in the finished assembly.

2. Drill a 3/4 inch hole through the vehicle floor at the location chosen for the bulkhead connector.

3. Install the bulkhead connector by inserting the fitting and tightening the nut and lock washer on the opposite side

of the vehicle floor.

4. Inside the vehicle, attach the hose barb fitting and connect the fuel line from the console.

5. Drill a 1/2 inch hole nearby the bulkhead fitting for the fuel pump electrical extension harness to pass through.

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Figure 1. Fuel Line Bulkhead Assembly

Page 72

SECTION 5

Fuel Pump Assembly Installation (Underneath the Vehicle Floor)

1. Locate an appropriate location for the fuel pump assembly housing to mount underneath the vehicle that will not

cause damage to the vehicle or compromise the fuel line routing or components.

2. Remove the housing lid from the fuel pump assembly.

3. Use the supplied Tek screws to install the lid of the fuel pump housing to the vehicle.

Figure 2. Fuel Pump Assembly Detail

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE

Page 73

SECTION 5

HOSE INCLUDED IN TRANSFER KIT

TO FUEL

INJECTION KIT

Fuel Supply & Return Line Installation (Underneath the Vehicle Floor)

1. Refer to the transfer flow kit instructions found with the appropriate kit for your vehicle.

2. Connect the fuel line from the transfer flow kit to the inlet side of the fuel pump.

3. Connect the outlet side of the fuel pump to the inlet side of the fuel bypass filter.

4. Connect the return line from the bypass filter return port back to the vehicle fuel supply.

Figure 3. Fuel Pump and Filter Detail

5. Attach the 90 degree elbow and hose barb fittings to the bulkhead connector underneath the vehicle.

6. Connect a segment of hose between the outlet side of the fuel bypass filter to the hose barb fitting.

7. Ensure that all hose clamps are properly tightened.

8. Connect the electrical extension harness to the fuel pump harness, running the other end up through a hole in the

floor of the vehicle, connecting to the console harness.

Figure 4. Vehicle Underside Fuel Line Installation

PART# 49-057 REV K SAPPHIRE SCIENTIFIC RAGE