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Rage - Prochem

1. SMUT 8FF j _ SWITCH ELKWuY f c WASTE PUMP OUY L Sapphire 170 RAGE Wiring 08 23 10 PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 58 SECTION 5 Hose Identification 18 214 01 I I Exchanger I I Water Pump Solenoid 2 Valve 18 215 15 I 1821506 paw To Pressure i To Vacuum Gauge SSS Bracket M 18 215 08 Bek I STILL NM LN 18 215 04 Manifold 18 215 04 Valve Metering Valve 59 SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 5 WARNING 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 FATALITY DO NOT RUN THIS UNIT IN AN ENCLOSED AREA DO NOT OPERATE THIS UNIT WHERE THE EXHAUST MAY ENTER ANY BUILDING DOORWAY WINDOW VENT OR OPENING OF ANY TYPE 44 080 44 084 DECAL CAUTION HOT SURFACE 44 080 DECAL WARNING VENTILATED AREA AWARNING A WARNING A DANGER Q 3 E ELECTRICAL SHOCK COULD CAUSE SEVERE BURNS OR INJURY DO READTHE OPERATOR S MANUAL NOT TOUCH ELECTRICAL WIRES OR COMPONENTS ROTATING MACHINERY STARTING THIS UNIT FAILURE TO WHILE THE ENGINE S OT e ME e Fo RUNNING DISCONNECT CAN CAUSE INJURY OR BURNS SEVERE PERSONAL INJURY
2. 43 ROT 44 Vacuum Blower uiii eee Lese 46 Drake ouo ope hotel seeded 47 Water PUMP M 48 Heat ExcDaBpeE u aims NSSE 49 Chemical PUMP a aa annua h aa miata ts 50 Solution sianie Rev cut evade 51 Vacuum Brackets i e a S ce 52 Oil Cup and Bypass Valves an a aaa a ba diu ee eden 53 Water Box Ploat eii este eet rec s idee 54 Gas Line Bracket and Fittings uunc uet er ander 55 F el Pump 56 bur Mb quc 57 Electrical feis u nu 58 THOSE 59 Decalss cc once tiet da eth DC i cei 60 11 ACCESSORIES 1992 to 2002 Ford Fuel Line 61 Chevy and GMC Full Size Van Fuel Line 62 2003 Chevy and GMC Full Size Van Fuel Line Install 63 1997 2002 Dodge Full Size Van Fuel Line Install 64 Waste Pump Out Assembly 65 SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 5 FRAME AND COMPONENTS RAGE Item No Part Number Qty Description 1 61 607 1 WELDMENT FRAME 2 69 629 1 WELDMENT PUMP BRACKET 3 61 62
3. 8 31 015 2 CONN SEAL 39001 WAYTEK 9 31 019 2 PIN FEMALE 31035 WAYTEK 10 31 016 1 CONN 3 PRG 1 2 TWR 38045 11 31 047 1 STRAIN RELIEF 2612 12 31 166 1 CONNECTOR BUTT 14 16 WAYTEK 13 32 025 9 IN LOOM HI HEAT 250 DIA BLACK 14 31 033 1 TERM RING 14 16 GA 1 4 BLUE 15 10 147 2 SCREW 25 20 X 63 316 SS SHCS 16 12 002 2 WASHER FLAT 1 4 SS ANC 17 60 895 1 PLT TOP FUEL PUMP LONG HOUSING 18 10 025 4 SCREW MACH 1 4 20 X 3 4 HXHD GRD5 19 12 012 4 WASHER FLAT 1 4 USS 20 12 015 4 LKWSR 1 4 ZINC PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 56 57 SECTION 5 69 276 ASSY WASTE TANK Part Item No Number Qty Description 1 61 636 1 WELDMENT WASTE TANK 2 20 009 1 2 5 NPT X 5 0 FILTER SCREEN 3 61 002 1 WELDMENT STRAINER BASKET 4 69 000 1 FLOAT SWITCH 5 21 097 4 PLUG 1 1 4 IN PVC 6 19 009 1 CAP PLUG 2IN RUBBER 7 21 064 1 ELL 1 4 P X 1 4 T BRASS 8 41 018 136 25 IN GASKET SPONGE 1 IN X 45 FT 9 61 587 1 WELDMENT LID 10 40 003 2 LATCH PRE FILTER BOX 11 58 473 2 BRKT MNT WTR BOX HLD DWN 12 69 273 1 ASSY WATER BOX BLUEWAVE 13 60 979 1 MNT WATER BOX SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 5 ELECTRICAL DIAGRAM STYARYER 80 084 amp YARYER EBAY L BLI WHY FUEL PUMP YEMPERAYURE WASTE PUMP KIT 68 003 YRAMSFER PUMP EC
4. BLOWER VACUUM PUMP 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 SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV SECTION 4 TROUBLESHOOTING BLOWER VACUUM PUMP 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 le
5. 5 23 063 1 CHECK VALVE MANIFOLD 6 20 018 1 SCREEN CHECK VALVE MANIFOLD 7 21 264 3 PLUG 1 4 NPT BRASS 8 21 001 1 CONN 1 8 P X 1 4 T BR 9 21 064 1 ELL 1 4 P X 1 4 T BRASS 10 21 055 1 ELL 1 8 P X 1 4 T 45 DEG BRASS 11 21 012 1 CONN 1 2 NPT X 1 2 T BRASS SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 5 69 270 ASSEMBLY VACUUM BRACKET Item No Part Number Qty Description 1 61 651 1 WELDMENT VACUUM BRACKET 2 21 001 1 CONN 1 8 P X 1 4 T BR 3 21 007 1 FTTG BRB 1 8 P X 5 16 H BR PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 52 SECTION 5 69 269 ASSEMBLY OIL CUP AND BYPASS VALVE Item No Part Number Qty Description 1 61 514 1 WELDMENT OIL CUP AND BYPASS VALVE 2 21 011 1 ELL 1 8 NPT X 1 4 POLY BRASS 3 21 333 1 COUPLING 1 8 FNPT X 1 8 MNPT BRASS 4 28 000 1 CUP OILFILL 1 8 NPT 5 21 001 2 CONN 1 8 P X 1 4 T BR 6 21 336 1 TEE 1 8 NPT X 1 4 JIC X 1 4 JIC BRASS 7 23 029 1 VLV MET 1 8 FP RT ANG WHITEY 8 21 240 1 TEE 1 8 NPTE BRASS 9 16 017 1 TUBING 1 4 IN IMPOLENE 250 FT BULK 53 SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 5 69 273 ASSY WATER BOX FLOAT VALVE Item No Part Number Qty Description 1 51 002 1 MOLDING WATER BOX DISCOVERY 2 23 025 1 VLV FLOAT WTR BOX THERMALWAVE 3 11 001 2 NUT 1 4 20 SS 4 64 000 1 ROD FLOAT
6. and a minimum amount of down time AWARNING On OULD CAUSE SEVERE Y N ROTATING MACHINERY CAN CAUSE INJURY OR COULD BE FATAL WHILE THE ENGINE IS RUNNING DISCONNECT THE BATTERY BEFORE SERVICING THIS UNIT TO KEEP ALL GUARDS PREVENT ACCIDENTAL AND SAFETY DEVICES STARTING 44005 4 IN PLACE 44 085 Q gt WATER UNDER HIGH PRESSURE HIGH TEMPERATURE CAN CAUSE BURNS SEVERE PERSONAL OR COULD BE FATAL SYSTEM OF ALL PRESSURE BEFORE REMOVING VALVES CAPS PLUGS FITTING FILTERS BOLTS 44 083 A N WARNING 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 SAPPHIRE SCIENTIFIC RAGE 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 BRIGGS AND STRATTON 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 SG SH SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table 17L Engine oil capac
7. 005 1 GAUGE WATER PRESSURE 1500 PSI DUAL 10 26 004 1 GAUGE VAC 30IN HG DUALSCALE 11 29 050 1 SWITCH KIT BRIGGS AND STATTON 12 26 003 1 FLOWMETER 1 8 FP 13 26 018 1 GAUGE HOUR METER VORTEX PART 49 057 REV SAPPHIRE SCIENTIFIC RAGE 42 SECTION 5 REAR RAGE CONTROL PANEL 69 265 amp G e lt 45 APA lt e z E TZ Sala Elola Bley S lt m F x mA CASS eis zz mr S m 2 E 588 2 ERIS Zlolrlolale 5 49 057 REV SAPPHIRE SCIENTIFIC RAGE 43 SECTION 5 69 274 ASSEMBLY ENGINE RAGE DETAIL A Item No Part Number Qty Description 1 45 020 1 ENGINE BRIGGS STRATTON 18 HP 2 39 034 1 PX40 BUSHED FLANGE 3 39 035 1 PX40 FLEXIBLE ELEMENT 4 39 034 1 2 PX40 CLAMP RING 5 66 283 1 PX40 BUSHED V BELT FLANGE 6 38 066 1 HUB DODGE T L 1008 X 75 7 38 067 1 DODGE T L 1008 X 1 00 8 37 074 1 BELT AX32 GATES EPDM 9 12 004 5 WASHER M8 ZINC 10 12 005 5 LKWSR M8 HARD 11 58 456 1 PANEL BELT GUARD PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 44 45 SECTION 5 DETAIL A 69 274 ASSEMBLY ENGINE RAGE Item No Part Number Qty Desc
8. 7 MAINTENANCE J J aaL 27 8 GENERAL SERVICE ADJUSTMENTS I a aaa 31 9 TROUBLESHOOTING aaa 34 SECTION FIVE PARTS and ACCESSORIES 39 10 ILLUSTRATED PARTS LISTINGS J s 40 11 ACCESSORIES 61 PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE SECTION 1 GENERAL INFORMATION 1 SAFETY specifications es s o te Fe te Va bd a asua ada da fe Installation requirements FuelrequiremenffSs_ 222 72 22 iL Engine oil requirements Chemical requirements Water requirements O 00 t r3 2 RECEIVING YOUR TRUCKMOUNT UNIT Dealer responsibility em eee se e e e Acceptance of shipment Equipment listing oou 3429 cia pud chica coa cx cx ioa ox Optional equipment OO CO 1 SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 1 1 SAFETY WARNING For Your 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 injury or fatality to yourself and or others or property damage Please follow these instructions carefully DO NOT remove these decals WARNING 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 FATALITY DO N
9. 75 29 SAPPHIRE SCIENTIFIC RAGE WASTE TANK STRAINER BASKET The strainer basket located in the waste tank should be emptied and cleaned on a daily basis Microban QGC cleaner is the recommended product for cleaning and sanitizing the waste tanks as well as other parts of the system CHECK VALVE STRAINER OUTLET Unscrew the screen and inspect the strainer after the first week of operation Remove any debris present Inspect again after 2 and 4 weeks Thereafter inspect the strainer and screen at least monthly If a frequent build up of debris is noticed inspect and clean more frequently CHEMICAL PUMP The chemical pump should be rebuilt every 500 hours This involves changing the diaphragm check valves and inspecting the disk CHEMICAL METERING SYSTEM 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 PRESSURE REGULATOR Lubricate the o rings in the pressure regulator every 100 hours Use only o ring lubricant Part 1113 003 VACUUM HOSES To ensure maximum hose life SAPPHIRE SCIENTIFIC recommends that you wash out the hoses with fresh water daily Microban cleaner as the best product for cleaning and sanitizing the wands and hoses as well as other parts of the system PART 49 057 REV B SECTION 4 BATTERY ZA WARNING Explosive ga
10. OR COULD BE FATAL THE BATTERY BEFORE COULD BE FATAL INJURY OR COULD BE FATAL REPLACEMENT SERVICING THIS UNIT TO KEEP ALL GUARDS SAUT DOWN MACIE ps MANUALS CAN BE PURCHASED PREVENT ACCIDENTAL AND SAFETY DEVICES SYSTEM OF ALL PRESSURE FROM d S G IN PLACE BEFORE REMOVING VALVES apphire Scientific TARTING 414 066 44 085 A CAPS PLUGS FITTING FILTERS 2604 Liberator AND BOLTS 44 083 A Prescott AZ 86301 44 067 A 44 066 DECAL RED M 44 083 DECAL 44 067 DECAL WARNING ELECTRIC SHOCK MACHINERY WARNING HIGH PRESSURE WARNING READ MANUAL UNLEADED GASOLINE ONLY SEE OWNER S MANUAL DO NOT RUN ENGINE WITH COVER OFF VOIDS WARRANTY 81A 44 079 DECAL UNLEADED FUEL ONLY 44 081 DECAL ENGINE COVER WARRANTY 44 105 DECAL PRODUCT 170 RAGE PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 60 SECTION 5 11 ACCESSORIES 1992 TO 2002 FORD FUEL LINE INSTALLATION Vent Tube Cut Existing Hose 3 From Hose End E k Fuel Suction Line Fuel Return Line To Bottom of quee 69 005 KIT FUEL HOOKUP FORD FI Item No Part Number Qty Description 1 66 031 1 ADAPTOR VENT TUBE FORD 2 21 086 2 FTTG BULKHEAD 1 4 IN BRASS 3 21 039 2 ELL 1 4 IN LG STREET BRASS 4 21 038 1 ELL STREET 1 8 IN BRASS 5 21 007 2 FTTG BRB 1 8 X 5 16 H BR 6 21 006 4 FTTG BRB 1 4 X 5 16H BR 7 18 028 1 HOSE 3 16 X 25 1 8P X 1 8 NO COVER 8 14 011 6 CLAMP HOSE FUEL 6 9 14 000
11. SS THERMAL WAVE 5 28 001 1 BALL FLOAT 6 21 032 2 FTTG BRB 1 2 P X 3 4 H BRASS SLDPRT 7 21 025 1 CAP 5 IN WATER BOX TANK BLACK 8 21 044 1 ELL 1 2 NPT 45 DEG BRASS 9 21 065 1 PLUG 1 2 NPT SOLID BRASS HEXHD 10 21 047 1 1 2 IN HEX BRASS 11 21 030 1 NIPPLE HEX 1 2 NPT X 3 8 NPT BRASS 12 25 005 1 QUICK COUPLING 3 8 X 3 8 FNPT BRASS 13 20 014 1 STRAINER SUC END1 2FP 40 MESH 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 54 55 SECTION 5 69 259 ASSEMBLY GAS LINE BRACKET 1 61 489 1 WELDMENT GAS LINE BRACKET 2 12 011 2 WASHER FLAT 12 SAE 3 10 028 I SCREW MACH 1 4 20 X 2 3 4 HXHD 4 12 015 1 LKWSR 1 4 ZINC 5 11 004 1 NUT 1 4 20 ZINC 6 21 039 1 ELL 1 4 IN STREET BRASS 7 21 006 1 FTTG BRB 1 4 5 16 BR 8 21 166 1 FTTG 1 4 MP X 1 4 H BARB 9 14 011 1 CLAMP HOSE 6 SS SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 5 Pap IT a 4 68 157 ASSY FUEL PUMP LONG HOUSING Item No Part Number Qty Description 1 61 631 1 WELDMENT LWR FUEL PUMP LONG HOUSING 2 46 003 1 PUMP FUEL 101 3 36 097 1 FILTER FUEL KUBOTA 4 16 065 1 HOSE FUEL 5 16 30R9 DUEL FUEL 5 14 007 2 CLAMP HOSE 74 SS 6 32 054 10 5 IN WIRE 18 GA SXL VIOLET 10 5 IN CUT LENGTH 7 32 045 JOIN WIRE 18 GA BLK 10 IN CUT LENGTH
12. This section of the operator s manual explains ventilated area Exhaust fumes contain carbon how to prepare start operate shut down and monoxide which is an odorless and deadly maintain your SAPPHIRE SCIENTIFIC poison that can cause severe injury or death RAGE mobile cleaning unit The RAGE unit DO NOT run this unit in an enclosed area is easy to operate however only trained DO NOT operate this unit where the exhaust operators should proceed may enter a building doorway window vent or any other opening Water Pressure Vacuum Pressure Gauge Gauge Choke Cable Chemical Flow FLOW METER Gauge Throttle PRESSURE VACUUM THROTTLE OFF 7 Chemical A C 8 Prime 1 ON lt Valve PUMP OUT OFF MAIN PUMP OUT OFF Transfer Pump RUN Switch PRI CHEMICAL On Off i Ignition Switch Chemical Metering Valve Hour Meter 20 Amp Circuit Breakers 30 Amp Main Circuit Breaker PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 18 SECTION 3 Chemical Check Valve Vacuum Lube Cup Outlet Filter Temperature Bypass Control Pressure Outlet Vacuum Inlet Water Supply Inlet 15 located on the water box on the left side of the waste tank Exhaust ENSURE THERE IS ADEQUATE FUEL 2 Turn the water supply faucet on Water will Check the fuel tank to ensure there is adequate 1 the water box fuel to complete the job and transport the HIGH PRESSURE HOSE vehicle This unit consumes appr
13. X 5 16 H BR 7 21 039 2 ELL 1 4 IN LG STREET BRASS 8 21 006 4 FTTG BRB 1 4P X 5 16H BR 9 21 086 2 FTTG BULKHEAD 1 4 IN BRASS 63 SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 5 1997 2002 DODGE FULL SIZE VAN FUEL LINE INSTALLATION Remove Existing Hose and Cut in Half S 5 bh uem N gt S lt P di aS CAUTION Do Not Remove Ball lt amp d lt Fuel Suction Line Fuel Return Line Ew To Bottom of d 69 004 KIT FUEL HOOKUP CHEVY DODGE Item No Part Number Qty Description 1 14 010 2 CLAMP HOSE 32 2 66 030 1 ADAPTOR FUEL NECK CHEV Y 3 21 038 1 ELL STREET 1 8 IN BRASS 4 14 011 6 CLAMP HOSE FUEL 6 5 21 007 2 FTTG 1 8 X 5 16 H BR 6 18 028 1 HOSE 3 16 X 25 1 8P X 1 8 NO COVER 7 21 086 2 FTTG BULKHEAD 1 4 IN BRASS 8 21 006 4 FTTG BRB 1 4 X 5 16H BR 9 21 039 2 ELL 1 4 IN LG STREET BRASS PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 64 SECTION 5 CONNECTS 46 035 TO 21 036 CONNECTS 46 035 TO 21 032 MOUNTING HARDW ARE INSTALLS IN WASTETANK THREADED END CONNECTS TO WASTE TANK CONSOLE POW ER CONNECT TO 69 002 FLOAT SWITCH 68 158 ASSY WASTE PUMP OUT Item No Part Number Qty Description 1 46 035 1 PUMP WASTE 2 6
14. extremely hot from operation To prevent severe burns DO NOT touch these areas while the unit is running or shortly after the unit is shut off 10 DO NOT touch any part of the exhaust system while the system is running or for 20 minutes after the unit is shut off Severe burns could result 11 Water under high pressure at high temperature can cause burns severe personal injury or fatality Shut down unit allow to cool down and relieve system of all pressure before removing caps valves plugs fittings filters or hardware 12 NEVER leave the vehicle engine running while the unit is in operation 13 Battery acid contains sulfuric acid To prevent acid burns avoid contact with skin eyes and clothing Batteries also produce explosive hydrogen gases while charging To prevent fire or explosion charge batteries only in a well ventilated area Keep sparks open flames as well as other sources of ignition away from battery at all times Remove all jewelry prior to servicing batteries Keep batteries out of the reach of children Before disconnecting the negative ground cable ensure that all switches are in the off position If on a spark could occur at the ground connection terminal which could cause an explosion if hydrogen gas or gasoline vapors are present ALWA YS disconnect the negative terminal first 14 DO NOT smoke around the machine Gas fumes could accumulate and ignite Battery gases are extremely
15. flammable This will prevent possible explosions PART 49 057 REV B 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 650 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 This unit is equipped with a low pressure shut down switch which should NOT be
16. in the future for any reason 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 2009 by SAPPHIRE SCIENTIFIC No part of this work may be used or reproduced in any form or means without the express written consent and permission of SAPPHIRE SCIENTIFIC Published by SAPPHIRE SCIENTIFIC First printing September 2010 Revised November 2010 Rev B Printed in USA RAGE MANUAL 49 057 SAPPHIRE SCIENTIFIC RAGE I 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 e Two 2 years from the date of installation on parts and labor Excluding normal maintenance items Factory installed original belts are covered for 500 hours Water box recovery tank and frame are covered for five years All other components including seals o rings and electrical components are covered for the entire two year warranty period What Sapphire Scientific Will Do If a defect in materials or workmanship occurs within t
17. lbs 165 inch lbs 130 inch lbs 11 ft Ibs 13 75 ft lbs 11 ft Ibs SAPPHIRE SCIENTIFIC recommends that the total floor tool tip size does not exceed 4 Using larger jet sizes on your RAGE unit may reduce cleaning temperatures 5 SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 1 INSTALLATION REQUIREMENTS Prior to beginning the installation read the ENTIRE Installation section of this manual Since the RAGE Truck mount unit weighs with waste tank and accessories approximately 650 Ibs please adhere to the following recommendations prior to installing the unit A CAUTION 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 console must be positioned so that it balances properly with respect to the trailer axle Ten percent 1096 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 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 floorin
18. lubricant Part 13 003 and re install SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 4 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 B Chemical Prime Valve Adjust the packing nut by turning the packing ae bolt clockwise at 1 16 increments Loosen Set Screw and Remove Knob Chemical Metering Valve Packing Nut SAPPHIRE SCIENTIFIC RAGE 32 33 SECTION 4 PRESSURE REGULATOR The pressure regulator holds water pressure at a preset point and bypasses the excess water back to the
19. operator s manual describes how to look for and repair malfunctions which may occur TROUBLESHOOTING Accurate troubleshooting is based on a thorough and complete understanding of the WATER CHEMICAL VACCUM HEAT TRANSFER SAFETY and WIRING systems featured in this unit If there are malfunctions occurring on this unit which you do not understand refer back to the OPERATION section of this manual and review SYSTEM 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 Gardner Denver Service and Repair Manual Starter turns over engine but will not start Waste tank is full Empty the waste tank Defective fuel pump Replace the fuel pump Loose or broken wires leading to waste tank float switch Repair or replace any broken electrical connections Defective float switch in the waste
20. pulley and hub set screws for proper torque Chemical Pump 500 Hours Change diaphragm and check valves Inspect disk Engine Pump Coupling 500 Hours Replace boot see pg 29 for reference Belts 2000 Hours Replace belt Engine 1000 Hours Replace spark plugs Vacuum Pump 1000Hours Drain flush and replace oil Check Valve 1000 Hours Check Teflon seat for abnormal wear or debris Replace as needed Engine 1000 Hours Replace air filter element 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 Tnspect 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 EOL every 6 Months Whichever comes first Yearly Whichever comes first secesRetention all belts after first 25 hours then at every 100 hours of operation PART 49 057 REV SAPPHIRE SCIENTIFIC RAGE 26 SECTION 4 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
21. tank Check switch for proper operation replace as necessary Oil pressure switch located on engine fuel shut off solenoid located on engine Test these components If any are defective replace Consult the Briggs amp Stratton Engine Operation and Maintenance Manual Engine is malfunctioning Refer to Briggs amp Stratton 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 PART 49 057 REV SAPPHIRE SCIENTIFIC RAGE 34 35 SECTION 4 TROUBLESHOOTING ENGINE 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 Briggs amp Stratton Engine Operation and Maintenance Manual DO NOT
22. 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 SOLUTION OUTLET CHECK VALVE Inspect the check valve whenever performing service on the chemical pump or if flow problems are occurring in the chemical system 1 Remove the check valve ensuring that the small o ring on the seat comes out with it 2 Next remove the seat using a 5 16 in Allen wrench 3 Check the Teflon seat for wear or debris Clean and replace the seat if necessary 4 Inspect the poppet and the spring for wear or damage Clean and replace as necessary 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 CAP CHECK VALVE 44 007 ORING 7 8 ID X 1 1 16 OD SPRING CHECK POPPET CHECK INSERT SEAT CHK 2 Adjust the position of the belt tensioning SEAT CHECK VALVE EUH ASSY 41 008 ORING 2 ID 5 8 OD Note Improper seating of the check valve seat poppet damaged spring or o rings will result in poor performance of the chemical system 3 While checking the alignment tighten the nuts that hold the water pump to the base 6 Lubricate the o rings with o ring
23. 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 N WARNING 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 SAPPHIRE SCIENTIFIC RAGE Adjusting Cap Brass O Ring Housing PART 49 057 REV SECTION 4 9 TROUBLESHOOTING N WARNING 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
24. 1 656 1 WELDMENT HOSE BRACKET 3 21 032 1 FTTG BRB 4 H BRASS 4 21 398 1 HOSE 1 P X H 5 21 036 1 FTTG 1 1 4 P X 1 IN BARB 6 69 002 1 ASSY LVL SENSOR SHTOFF WASTE PUMP 7 14 006 2 CLAMP HOSE 20 SS 8 14 000 2 CLAMP HOSE 12 X 5 SS 9 41 038 1 WASHER GARDEN HOSE CAP 10 21 071 1 CAP GARDEN HOSE 34 BRASS 11 31 016 1 CONN 3 PRG 38045 WAYTEK 12 31 019 3 PIN FEMALE 31035 WAYTEK 13 47 031 1 HARNESS WASTE PUMP OUT 14 16 004 6 FT HOSE WTR IN HRZ 500 FT BULK 15 16 018 2FT HOSE WTR I IN HRZ 100 FT BULK 16 10 178 4 BOLT 5 16 18 X 2 1 2 Z 17 10 068 3 BOLT TAP 4 20 X 2 1 2 18 11 013 3 LKNUT 4 20 NYLOK 19 11 029 4 NUT 5 16 18 NYLOK 20 12 017 8 WASHER FLAT 5 16 SAE ZINC 21 12 012 6 WASHER FLAT USS SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B
25. 1 BOARD MILL 1 8 X 42 X 48 12 58 460 1 PLT HEAT EXCHANGER INSULATOR 13 12 011 28 WASHER FLAT 12 SAE 14 10 021 4 SCREW MACH 1 4 20 X 3 4 SOCHD SS 15 10 025 24 SCREW MACH 1 4 20 X 3 4 HXHD GRD5 16 12 015 28 LKWSR 1 4 ZINC 17 61 622 1 WELDMENT SILENCER ASSEMBLY 18 14 024 1 CLAMP HOSE 48 SS 19 21 030 1 NIPPLE HEX 1 2 NPT X 3 8 NPT BRASS 20 2 110 1 TEE 1 2 NPT 5 21 21 012 1 CONN 1 2 NPT X 1 2 T BRASS 22 14 025 1 CLAMP EXHAUST 2 5 IN 23 34 031 1 SENSOR TEMP 240 DEG SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 5 46 056 PUMP CHEMICAL GENERAL PUMP Item No Part Number Qty Description 1 36 350 1 BODY PULSE PUMP GP PULSE PUMP 2 36 351 1 PLASTIC DISC GP PULSE PUMP 3 36 352 1 RUBBER DIAPHRAGM GP PULSE PUMP 4 36 353 1 TOP COVER INLET GP PULSE PUMP 5 36 354 2 O RING 70 DURO GP PULSE PUMP 6 36 355 2 VALVE CAP 303SST GP PULSE PUMP 7 36 356 1 ASSY VALVE KIT GP CHEMICAL PULSE PUMP 8 36 357 1 SPACER RING 303 SST GP PULSE PUMP 9 36 358 1 VALVE CAP 303 SST GP PULSE PUMPMP 520196 PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 50 51 SECTION 5 69 260 ASSY MANIFOLD BLOCK RAGE Item No Part Number Qty Description 1 66 205 1 MANIFOLD BLOCK 2 21 146 1 PLUG 3 8 NPT BRASS 3 21 026 1 NIPPLE 1 4 NPT HEX BRASS 4 25 001 1 QUICK DISCONNECT 25 NPT SOCKET HANSEN SERIES B2 HK
26. 2 CLAMP HOSE 12 61 SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 5 CHEVY AND GMC FULL SIZE VAN FUEL LINE INSTALLATION Remove Existing Hose and Cut in Half EN CAUTION gt 4 Do Not Cut 2 EN Inner Hose T _ g Fuel Return Line To Bottom of Tank 69 003 KIT FUEL HOOKUP 97 amp 2002 FI Item No Part Number Qty Description 1 14 010 2 CLAMP HOSE 32 2 14 011 6 CLAMP HOSE FUEL 6 3 21 006 4 FTTG BRB 1 4 X 5 16H BR 4 21 007 2 FTTG BRB 1 8 X 5 16 H BR 5 21 038 1 ELL STREET 1 8 IN BRASS 6 21 039 2 ELL 1 4 IN LG STREET BRASS y 21 086 2 FTTG BULKHEAD 1 4 IN BRASS 8 21 116 1 ELL 1 8 X 1 8 FP BRONZE 9 66 030 1 ADAPTOR FUEL NECK CHEVY 10 18 027 2 HOSE 3 16 X 5 1 8P X 1 8 NO CVR PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 62 SECTION 5 2003 CHEVY AND GMC FULL SIZE VAN FUEL LINE INSTALLATION s e Cut Hose and Remove b V Flapper Valve PR 8 gt i 7 Trim Fuel Filler Neck 1 Reinstall Flapper Valve Inside of Fuel Filler Hose 69 018 KIT FUEL HOOKUP 2003 CHEVY FI Item No Part Number Qty Description 1 66 034 1 ADAPTOR FUEL FLR CHVY 2003 2 14 006 2 CLAMP HOSE 20 3 18 028 1 HOSE 3 16 X 25 1 8P X 1 8P NO COVER 4 14 011 6 CLAMP HOSE FUEL 6 5 21 038 1 ELL STREET 1 8 IN BRASS 6 21 007 2 FTTG BRB 1 8P
27. 63 1 PUMP WATER GENERAL 18135 2 38 064 1 PULLEY BROWNING AK79H 3 38 065 1 HUB H X 24MM 4 46 056 1 PUMP CHEMICAL GENERAL 100906 5 66 002 1 ADAPTOR CHEMICAL PUMP 25 NPT 6 37 074 1 BELT AX32 GATES EPDM 7 21 007 1 FTTG BRB 1 8 P X 5 16 H 8 21 032 1 FTTG 1 2 P X 3 4 H BRASS SLDPRT 9 21 038 1 ELL STREET 1 8 IN BRASS 10 21 043 1 ELL STREET 3 8 IN 45 DEG BRASS 11 21 052 1 NIP 3 8 X 1 4 HEX BRASS 12 21 054 1 ELL 1 8P X 1 4 T BRASS 13 21 062 1 TEE 3 8 FNPT X NPT X FNPT BRASS 14 21 323 1 FITTING 1 4 NPT X 1 2 H BRB BRASS 15 23 010 1 REGULATOR PRESSURE SUTTNER TM 16 21 044 1 ELL 1 2 NPT 45 DEG BRASS 17 21 057 1 CONN 3 8 NPT X 1 2 JIC BRASS 18 21 064 1 ELL 1 4 P X 1 4 T BRASS 19 10 000 4 SCREW 8 1 25 X 20 SOCHD 20 12 004 4 WASHER 8 ZINC 21 12 005 4 LKWSR M8 HARD PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 48 49 SECTION 5 69 264 ASSY HEAT EXCHANGER RAGE Item No Part Number Qty Description 1 61 634 1 WELDMENT HEAT EXCHANGER HOUSING 2 63 033 1 ASSY VAC HEATER CORE BLUEWAVE 3 61 633 1 WELDMENT HEAT EXCHANGER INLET 4 41 037 1 GASKET HIGH TEMP SILENCER EXHST 5 61 637 1 WELDMENT HEAT EXCHANGER OUTLET 6 61 638 1 WELDMENT HEAT EXCHANGER COVER 7 41 033 2 GROMMET 1 ID X 1 3 4OD 8 21 061 1 ELL 3 8 P X 1 2 T BRASS 9 43 003 1 BOARD MILL 1 8 X 42 X 48 10 43 003 1 BOARD MILL 1 8 X 42 X 48 11 43 003
28. 8 1 WELDMENT REAR BRACE 4 61 627 1 WELDMENT BEZEL FRAME PANEL 5 58 264 1 BRKT FLUID CONTROL COBALT 6 10 028 13 SCREW MACH 1 4 20 X 2 3 4 HXHD 7 11 004 13 NUT 1 4 20 ZINC 8 61 651 1 WELDMENT VACUUM BRACKET 9 61 489 1 WELDMENT GAS LINE BRACKET 10 12 012 30 WASHER FLAT 1 4 USS 11 12 015 17 LKWSR 1 4 ZINC 12 10 020 4 SCREW MACH 1 4 20 X 3 4 HXHD SS 13 23 014 1 SOLEN 1 4FPX 1 4FP PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 40 SECTION FRAME PANELS RAGE Item No Part Number Qty Description 1 PANEL TOP PANEL LEFT SIDE PANEL RIGHT SIDE PANEL LOWER FRONT NUT THUMB 1 4 20 FLWR HEAD KNOB SCREW MACH 1 420 X 2 3 4 HXHD NUT 1 4 20 ZINC 10 165 6 SCREW 1 40 X 3 4 SS FHSCS 1202 8 WASHER FLAT 1 4 USS 12 015 4 LKWSR 1 4 ZINC COND NY BIG bo n 41 SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 5 FLOW METER B oN PUMP OUT MAIN PUMP OUT OFF 69 265 RAGE CONTROL PANEL FRONT Item No Part Number Qty Description 1 61 627 1 WELDMENT BEZEL FRAME AND PANEL 2 23 003 1 VALVE 3 WAY BALL 1 8 FP BRASS 3 23 015 1 VLV MET 1 8 FP RT ANG BRASS 4 30 007 1 BREAKER 30 AMP 5 30 008 1 BREAKER 20 AMP 6 40 000 1 CABLE THROTTLE 7 40 001 1 CABLE CHOKE 8 29 016 1 SWITCH ROTARY NON ILLUMINATED 9 26
29. 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 PART 49 057 REV B Record your units serial number here for future reference or if you should need to contact the factory
30. EEZE PROTECTION A CAUTION If the unit is exposed to freezing weather conditions the water inside of the unit may freeze resulting in SERIOUS DAMAGE to the unit The following is recommended to prevent this from occurring during the cold weather season 1 Always park the unit in a heated building when not in use 2 While out in operation avoid long periods of shut down as the unit generates heat while running Keep the unit running just prior to leaving for the next job 3 If a heated building is not available winterize the unit with anti freeze It is not possible to winterize units that have auxiliary water tanks If the unit has an auxiliary water tank s it must be stored in a heated building WINTERIZING YOUR UNIT WITH ANTI FREEZE 1 Shut off the water supply to the unit and disconnect the water inlet hose from the water box 2 Connect all solution hoses and a tool to the console 3 Start the unit 4 Hill the water box with one gallon of 10096 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 SAPPHIRE SCIENTIFIC RAGE 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 appro
31. OSE 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 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 re
32. OT RUN THIS UNIT IN AN ENCLOSED AREA DO NOT OPERATE THIS UNIT WHERE THE EXHAUST MAY ENTER ANY BUILDING DOORWAY WINDOW VENT OR OPENING OF ANY TYPE 42 060 WARNING WARNING OU DANGER AWARNING a ELECTRICAL SHOCK COULD CAUSE SEVERE READ THE OPERATOR S MANUAL BURNS OR INJURY DO BEFORE INSTALLING OR ROTATING MACHINERY CAN CAUSE INJURY OR COULD BE FATAL KEEP ALL GUARDS AND SAFETY DEVICES IN PLACE 44 085 A PART 49 057 REV STARTING THIS UNIT FAILURE TO ADHERE TO INSTRUCTIONS CAN RESULT IN SEVERE PERSONAL INJURY OR COULD BE FATAL REPLACEMENT MANUALS CAN BE PURCHASED ROM Sapphire Scientific 2604 Liberator Prescott AZ 86301 44 067 A NOT TOUCH ELECTRICAL WIRES OR COMPONENTS WHILE THE ENGINE IS RUNNING DISCONNECT THE BATTERY BEFORE SERVICING THIS UNIT TO PREVENT ACCIDENTAL STARTING 44 066 WATER UNDER HIGH PRESSURE AT HIGH TEMPERATURE CAN CAUSE BURNS SEVERE PERSONAL INJURY OR COULD BE FATAL SHUT DOWN MACHINE ALLOW TO COOL DOWN AND RELIEVE SYSTEM OF ALL PRESSURE BEFORE REMOVING VALVES CAPS PLUGS FITTING FILTERS AND BOLTS 44 083 A DO NOT RUN ENGINE WITH COVER OFF VOIDS WARRANTY 44 081A SAPPHIRE SCIENTIFIC RAGE 2 N WARNING 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
33. acuum inlet connection at the front of the unit Connect the opposite end of the vacuum hose s the cleaning tool Let the unit run for a few minutes with the vacuum inlets partially blocked off to warm up the cleaning solution SAPPHIRE SCIENTIFIC recommends that the total floor tool size does not exceed 4 Using larger jet sizes on your 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 1 Insert the chemical prime tube and the chemical inlet tube into the chemical container PART 49 057 REV 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 bubb
34. ak 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 TROUBLESHOOTING WATER 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 PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 36 SECTION 4 TROUBLESHOOTING WATER PUMP 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 t
35. 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 3 SAPPHIRE SCIENTIFIC RAGE SECTION 1 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
36. bypassed 20 Always keep your vehicle clean and orderly Wands tools and accessories must be securely stowed while driving the vehicle PART 49 057 REV B SECTION 1 2 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 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 SAPPHIRE SCIENTIFIC RAGE 4 SPECIFICATIONS Engine Speed 1500 rpm Idle No Load Water Pump RPM Vacuum Pump RPM Water Flow Rate Water Pump Pressure Vacuum Relief Valve Waste Tank Capacity Console Weight Console Weight with waste tank amp accessories TORQUE VALUES Engine Hub Rear Water Pump Vacuum Pump Hub JET SIZING SECTION 1 3000 rpm High Speed No Load 1374 rpm 3000 rpm 3 0GPM maximum 1000 PSI maximum 13 in Hg 90 gal 476 lbs 650 Ibs 130 inch
37. 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 unit should arrive with the following items as well as any optional accessories I 2 50 ft 2 hose with shutoff valve and quick connects J 1 vacuum hose connector K 50 ft water supply hose with quick connect OPTIONAL EQUIPMENT A Additional lengths of vacuum hose Part 18 003 B Additional vacuum hose connectors Part 21 003 C Additional high pressure solution hoses Part 18 000 With shutoff valve Part 18 001 D Automatic waste pump kit Part 68 003 E Demand pump system Part 68 002 F KIT FUEL HOOKUP CHEVY 97 TO 2002 FI Part 69 003FI G KIT FUEL HOOKUP CHEVY DODGE FI Part 69 004FI H KIT FUEL HOOKUP FORD FI Part 69 005 FI I KIT FUEL HOOKUP 2003 CHEVY FI Part 69 018FI J KIT 2004 TF ADAPTER CHEVY Part 69 032 K KIT 2004 TF FUEL INJ CHEVY Part 69 033 L ADAPTOR 2004 FORD FUEL Part 69 041 M ADAPTOR 2004 FUEL INJ FORD Part 69 041FI N ASSY WASTE PUMP OUT EQUIPMENT LISTING Part 468 158 A SAPPHIRE SCIENTIFIC RAGE console B Operation and Service manual C Installation mounting plates and bolt down ki
38. cuum 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 Filter Basket Vacuum Brake SAPPHIRE SCIENTIFIC RAGE 16 17 SECTION 3 CHEMICAL PUMPING SYSTEM The chemicals are drawn from the chemical container through a strainer into the flow meter mounted on the control panel The flow meter indicates the rate of chemical flow The 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 Flow Meter 3 Way Select Valve Chemical Metering P od Valve SAPPHIRE SCIENTIFIC RAGE 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 Chemical Pump PART 49 057 REV B SECTION 3 5 OPERATION Z WARNING PREPARATION Operate this unit and equipment only in a well
39. e 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 PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 38 SECTION 5 PARTS and ACCESSORIES 10 ILLUSTRATED PARTS LISTINGS Frame and be bacc 40 Control Panel Front side Component List 42 Control Panel Back side Component List
40. emical Metering System 29 Pressure Regulators oo u usu ori ri pea Q us Na eae 29 Vacuum 29 So 30 High Pressure Solution 30 8 GENERAL SERVICE ADJUSTMENTS Engine 31 Vacuum Relief Valve LLL LLL 31 Water Pump Drive Bell me t a eat rr Means dece 31 Solution Outlet Check Valve 9 9 9 9 ssl 31 Chemical Pulp a nnd weet Arn ae ae ae ae a 32 Packing Nut Adjustment Chemical Metering and Selector Valves 32 Pressure Re SUI yt te te ets yy ee 33 9 TROUBLESHOOTING bo UD maan nsn 34 Blower Vacuum Pump cx eere he ee he ey A E E te ne he ey See 35 36 Chemical System 38 SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 4 6 MAINTENANCE CHART Engine Daily Check engine oil level Fill to proper level Vacuum Pump Daily Spray WD 40 or Equivalent into the lubrication cup for 5 seconds Water Pump Daily Check water pump oil level Fill to proper level Vacuum Inlet Filter Daily Inspect filter clean and or replace if required Waste Tank Strainer Basket Daily Empty and clean stainless steel basket Vacuum Hoses Daily Rinse with fresh water Waste Pump Out Optional Daily Inspect and remove any debris o
41. er 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 SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 4 TROUBLESHOOTING CHEMICAL SYSTEM 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 valv
42. g 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 PART 49 057 REV 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 1096 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 Select the viscosity based on the air temperature at the time of operation as shown in the following table Above 37 C 99 F 5 40 25 C to 37 C 77 F to 99 SAE30 0 C to 25 C 32 F to 77 F SAE10W 30 1 71 Engine oil capacity 1 8 U S qts 13 6 Tightening torque Drain Plug 1 4 kgf m 10 0 Ibf ft 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 switc
43. he 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 15 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 re adjust Pressure regulator o rings are dry Lubricate o rings using o ring lubricant Pressure regulator has worn o rings Check o rings If necessary replace Pressure regulator is dirty stuck open or improperly adjusted Clean or repair regulator Adjust to working pressure Lubricate o rings using o ring lubricant Part Low pump volume Measure the amount of water being returned to the water box from the pressure regulator It should fill a gallon container about every 17 6 seconds Examine the check valves plung
44. he 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 other components including seals o rings and electrical components are covered for the entire two year warranty period We limit all implied warranties to e 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 PURP
45. hing to synthetic oil SAPPHIRE SCIENTIFIC RAGE 6 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 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 312 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 SAPPHIRE SCIENTIFIC RAGE 49 057 REV B 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
46. il Filter Cap Oil Level Sight Gauge Oil Drain Vent Cap Oil Fill 2 After the first 50 hours of operation change the crankcase oil with general pump oil Change the crankcase oil every 500 hours thereafter Oil Level Sight Gauge Oil Drain PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 28 Replace boot every 500 hours SECTION 4 VACUUM INLET FILTER 1 The vacuum inlet filter in the waste tank should be inspected and cleaned daily A CAUTION When removing the vacuum inlet filter grip the plastic hexagon section of the filter Grasping filter by the screen will damage or destroy the filter Applying a grease to the threads will allow easier removal of filter when cleaning or replacement is required DRIVE BELT PULLEY HUB and COUPLING Check pulley hub and coupler screws after the first 25 hours of operation and again at 100 hours Re torque these screws with a torque wrench Follow the torque values on the following table Check pulley set screws and hub screws every 500 hours thereafter Insure belt is properly tensioned after checking the torque values Engine Pump Coupling Torque to 130 In Ibs after first 25 hrs of operation A CAUTION Ensure that when you re torque the screws you use a clockwise pattern and continue until the proper torque is achieved TORQUE VALUES Component Inch lbs Foot lbs Engine Coupler 130 11 Vacuum Pump Coupler 130 11 Water Pump Hub 165 13
47. ity 1 8 U S qts Tightening torque Drain Plug NOTE Using a lower service class oil or extending oil change intervals longer than recommended can cause engine damage NOTE Synthetic oils meeting the listed classifications may be used with oil changes performed at recommended intervals However to allow piston rings to properly seat a new or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to synthetic oil Above 37 C 99 F 25 C to 37 C 77 F to 99 F 0 C to 25 C 32 F to 77 F 13 6 N m 1 4 kgf m 10 0 Ibf ft 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 SECTION 4 Replace the in line fuel filter yearly NOTE Additional engine service information can be obtained from the provided Briggs and Stratton Operation and Maintenance manual If service or repair is required contact an authorized Briggs and Stratton Service Center They will require the serial number of the engine VACUUM PUMP NOTE Refer to the provided Vacuum Pump Operation and Service Manual for specific instructions Lubrication SAPPHIRE SCIENTIFIC recommends that you use only AEON PD XD Synthetic B
48. les 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 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 in I D NEVER use a waste pump hose as a water inlet hose SAPPHIRE SCIENTIFIC RAGE 20 SECTION 3 Z WARNING NEVER dispose of waste water in a storm drain water way or on ground areas Always dispose of waste in accordance with Local State and Federal laws OPERATION After you have completed the previous steps proceed with the cleaning or restoration operation Place the throttle control cable to a minimum of 50 of throttle control maximum for cleaning or restoration float shut off switch is located inside of the waste tank It will automatically shut down the unit if the tank reaches its full capacity If this occurs empty the waste tank before continuing When doing flood extraction the water pump should be in the OFF position NOTE During flood ex
49. ll as room for service and maintenance 2 The complete unit with waste tank and accessories MUST NOT exceed the vehicle s axle weight limit 49 057 REV FASTENING DOWN THE UNIT AND WASTE TANK N CAUTION Prior to drilling any holes in the vehicle floor ensure that while drilling you will not damage the fuel tank fuel lines or any other vital components which could affect the safety or operation of the vehicle A The console and waste tank mounting holes will serve as a template Drill six 6 5 in diameter holes for the console and four 4 in diameter holes for the waste tank B Using the provided mounting hardware kit 1 Insert six 6 16 x 4 in grade 5 hex head cap screws with flat washers through the RAGE console mounting holes and four 4 16 x 4 in grade 5 hex head screws with flat washers through the waste tank mounting holes 2 Install the provided mounting plates underneath the vehicle floor 3 Screw the provided 16 hex head lock nuts on to the mounting bolts and tighten until the console and waste tank are firmly attached to the vehicle floor SAPPHIRE SCIENTIFIC RAGE 10 11 SECTION 2 DIMENSIONAL DIAGRAM REAR MOUNT TANK SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 2 INSTALLATION OF FUEL LINES LN CAUTION READ THESE INSTRUCTIONS IN THEIR ENTIRETY PRIOR TO PROCEEDING N WARNING The Vehicle fuel line
50. losive 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 SAPPHIRE SCIENTIFIC RAGE 12 SECTION 2 CONSOLE TO WASTE TANK CONNECTION Waste Tank to Vacuum Brake 16 011 HOSE INT VAC 2 7 8 X 36 17 205 HOSE INT VAC 2 1 2 X 60 Vacuum Inlet PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 13 SECTION 3 OPERATION 4 SYSTEMS Water Heati
51. lower Lubricant in the vacuum pump for all operating temperatures AEON PD XD is formulated specifically for positive displacement blower service to provide maximum blower protection at any temperature One filling of AEON PD XD will last a minimum of twice as long as a premium mineral oil 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 Check the oil level weekly 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 2 A lubrication cup has been provided at the front of the console to prevent rust from building up inside of the vacuum pump Run the unit for at least 2 minutes to remove any moisture from the vacuum pump Then spray 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 yearly whichever comes first 4 Apply extreme pressure grease p n 13 002 in the grease fitting every 100 hours WATER PUMP Refer to the provided Water Pump Operation Manual for specific instructions Checkthe crankcase oil level daily to ensure the proper level If the level has dropped check for the source of leakage and repair O
52. ned tubing and is further heated by the vacuum blower and engine exhaust The hot water then flows through the check valve manifold that contains a strainer and a check valve At this point the chemical injection takes place The hot solution mixture of water and chemicals then flows through the solution outlet manifold to the cleaning tool Float Valve Vacuum Blower Silencer Exhaust From Engine Heat Exchanger PART 49 057 REV B SECTION 3 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 Vacuum Pump Heat Exchanger Exhaust PART 49 057 REV B Vacuum Inlet 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 va
53. ng system __ s t 15 Vacuum system _____ mf oeuf oeuf erfuhr te 16 Chemical pumping system 17 5 OPERATION Preparation er Pet ot 18 20 Priming the 2 222222222 20 Automatic waste 20 L puni eme u SEP MM a P 21 M e e tee er dc ur E AA Baap 21 Upholstery cleaning ReCK C C O 21 Flood restoration extraction 21 Shut down and daily maintenance 22 Breeze enean fot ht hh hk hk hl A 23 PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 14 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 Water Inlet 2 E we Water Pump 2 2 Check Valve Manifold Solution Outlet 15 SAPPHIRE SCIENTIFIC RAGE The water then flows to the water pump where it is pressurized From there it flows to the heat exchanger where it travels through fin
54. o 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 for at least 5 minutes with the bypass valve open This will also help to remove any excess moisture from the vacuum pump and cool the unit down NOTE If shutting down for the day Plug the vacuum 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 PART 49 057 REV Z WARNING NEVER dispose of wastewater in a storm d
55. oda to enter the battery cells as this will destroy the electrolyte resulting in battery failure PART 49 057 REV 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 N WARNING 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 SAPPHIRE SCIENTIFIC RAGE 30 SECTION 4 8 GENERAL SERVICE ADJUSTMENTS Z WARNING DO NOT attempt to service this unit while it is running High speed parts as well as high temperature components may result in severe injury severed limbs or fatality ENGINE SPEED 1 To adjust the engine RPM refer to the Briggs and Stratton Engine Operation and Service Manual for specific instructions N WARNING 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
56. oximately 1 US gallon of fuel per hour depending on the Before starting the unit connect the high speed setting pressure hose to the solution outlet connection at the front of the unit Connect the cleaning REMOVE TOOLS FROM THE tool to the opposite end of the pressure hose VEHICLE Remove any tools accessories or hoses from A DANGER the vehicle that you will require WATER SUPPLY CONNECTION NOTE Prior to connecting your water inlet G hose to any supply faucet flush out the faucet until the water is free of any debris Also c flush out any debris from your water inlet UI C MM hose 1 Connect 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 19 SAPPHIRE SCIENTIFIC RAGE 49 057 REV B SECTION 3 STARTING THE UNIT N CAUTION 1 Set throttle control in pull out engine choke and turn ignition key to start 2 Push in engine choke after engine has started 3 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 v
57. r sediment Engine Weekly Check air cleaner for damaged dirty or loose parts Engine Weekly Inspect air intake and cooling areas Clean if required Pump Filter Weekly Clean and inspect Vacuum Pump Weekly Check vacuum pump oil level Fill to proper level Do not overfill 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 Hist Pressure Solutio Hodes 25 Hours Inspect for wear damage or impending rupture Replace if damaged Belts 25 Hours Re tension belt Belts 100 Hours Re tension belt Engine 100 Hours Change engine oil and filter Vacuum Pump 100 Hours Check Oil level Vacuum Pump 100 Hours Apply extreme pressure grease p n 13 002 in grease fitting Vacuum Break 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
58. rain 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 1 4 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 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 SAPPHIRE SCIENTIFIC RAGE 22 SECTION 3 FR
59. restart the engine until the cause is determined and corrected No ignition in the engine or engine is malfunctioning Refer to the Briggs amp Stratton 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 1000 PSI Loss of temperature The heat output of the unit is LESS than normal Temperature relief valve on water box is stuck open Clean temperature relief valve and test Replace if necessary Engine RPM is low Reset engine RPM Defective temperature gauge Test gauge and sensor Replace failed component 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 TROUBLESHOOTING
60. rged 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 N WARNING 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 49 057 REV SAPPHIRE SCIENTIFIC RAGE 24 SECTION 4 SERVICE and MAINTENANCE 6 MAINTENANCE CHART Maintenance Chart eee 26 7 MAINTENANCE EEG m ara arisa PE PED DE P PEDE EAR ERE EA eA 27 Vacuum PUN ms DA rA LATI MTM ML TM DM ire 28 Water Pump 28 Vacuum Filter 0t tt ettet tests fuf ifto tst utate 29 Drive Belts Pulleys and 29 Strainer Basket 29 Check Valve Outlet 29 Chemical Pump Ch
61. ription 12 63 153 1 I MANIFOLD EXHAUST 13 60 958 I PLT STARTER HEAT SHIELD 14 61 641 I WELDMENT EXHAUST PIPE 15 21 112 I NIPPLE 3 8 NPT X 5 SS 16 21 326 I CAP PIPE 3 8 NPT 17 14 060 2 CLAMP EXHAUST 1 IN 18 34 011 I SOLENOID STARTER 19 12 010 1 WASHER FLAT M6 20 12 015 1 LKWSR 1 4 ZINC 21 10 000 1 SCREW 8 1 25 X 20 SOCHD 22 10 053 I SCREW MACH M6 01 0 X 20 12 9 SOCHD SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 5 69 272 ASSEMBLY RAGE VACUUM PUMP Item No Part Number Qty Description 1 46 064 1 VACUUM PUMP ROTARY POSITIVE BLOWER 3006 2 21 286 1 NIP 2 1 2 X 6 BLK SCH 40 3 14 024 1 CLAMP HOSE 48 SS 4 16 011 1 HOSE INT VAC 2 7 8 IN X 50 BLK 5 69 285 1 ASSY VAC BRAKE 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 46 47 SECTION 5 69 285 ASSEMBLY VACUUM BRAKE Item No Part Number Qty Description 1 61 653 1 WELDMENT VAC BRAKE 2 21 028 2 CONN 1 8 P X 1 4 POLY 3 61 077 1 STEM VACUUM RELIEF VLV 3L AM 4 41 010 1 DIAPHRAGM VACUUM RELIEF VLV 3L 4 5 15 002 1 SPRING VAC RELIEF VALVE 6 12 013 3 WASHER FLAT 3 8 SAE 7 11 012 2 NUT 7 16 14 ZP 8 66 294 1 SAPPHIRE SCIENTIFIC RAGE 49 057 REV B SECTION 5 69 271 ASSY WATER PUMP RAGE Item No Part Number Qty Description 1 46 0
62. s 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 have proper vented filling caps and outlet connections that are the same size as the inlet and return connections on the unit C DO NOT install fuel tanks inside any type of enclosed trailer or vehicle Z WARNING NEVER carry gasoline or flammable materials in an enclosed trailer or vehicle 49 057 REV 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 N WARNING Explosive gases Dangerous gases Batteries contain sulfuric acid To prevent acid burns avoid contact with skin eyes and clothing Batteries also produce exp
63. ses Dangerous acid Batteries contain sulfuric acid To prevent acid burns avoid contact with skin eyes and clothing Batteries also produce explosive hydrogen gases while charging To prevent fire or explosion charge batteries only in a well ventilated area Keep sparks open flames as well as any other sources of ignition away from batteries at all times Remove all jewelry prior to servicing batteries Keep batteries out of the reach of children Before disconnecting the negative ground cable ensure that all switches are in the OFF position If ON a spark could occur at the ground connection terminal which could cause an explosion if hydrogen gas or gasoline vapors are present ALWAYS disconnect the negative terminal first 1 If you do not have a maintenance free sealed battery check the fluid level in the battery at least once a week If low fill to the recommended level ONLY with distilled water DO NOT overfill the battery Early failure or poor performance will result due to loss of electrolyte 2 Keep cables terminals and external surfaces of the battery clean and dry A buildup of corrosive acid or grime on the external surfaces could cause the battery to self discharge 3 Battery terminals should be cleaned every 100 hours to prevent corrosion buildup Wash the cables terminals and external surfaces with a mild baking soda and water solution Rinse thoroughly with fresh water DO NOT allow baking s
64. sulted from causes not within the scope of our warranty then the product will be repaired or replaced only at your request and at your expense and you must bear all shipping costs How Does State Law Apply This warranty gives you specific legal rights and you may also have other rights which vary from state to state II SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B Table of Contents SECTION ONE GENERAL INFORMATION 1 1 SAFETY 2 Safety Specifications Installation Fuel Engine Oil Chemical Water Requirements 2 RECEIVING YOUR TRUCKMOUNT UNIT 8 Dealer Responsibility Acceptance of Shipment Equipment Listing Optional Equipment SECTION TWO INSTALLATION 9 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 7 7 22 18 Equipment setup Instrumentation Starting Your Unit Priming the Chemical Pump Waste Pump Operation Cleaning Upholstery Cleaning Stair Tool Cleaning Flood Restoration Shut Down and Daily Maintenance Freeze Protection SECTION FOUR MAINTENANCE and SERVICE 25 6 MAINTENANCE CHART _ 26
65. t D Hose clamps for vacuum and fuel hoses F Waste tank with shutoff switch H Waste tank filter and stainless steel strainer basket PART 49 057 REV B SAPPHIRE SCIENTIFIC RAGE 8 SECTION 2 INSTALLATION 3 INSTALLATION Lifting the unit into the vehicle 22222222 10 Positioning the unit into the vehicle a 10 Fastening down the unit and waste 10 Dimensional diagrams e C 11 Installation offuellines ee 12 Trailer fuel tank and fuel line installation 0 12 Battery Connection 12 Fire extinguisher 12 Console to waste tank connection 13 SAPPHIRE SCIENTIFIC RAGE PART 49 057 REV B SECTION 2 3 INSTALLATION Z WARNING 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 476 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 we
66. traction it is recommended the throttle control is 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 SAPPHIRE SCIENTIFIC RAGE 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 Upholstery tools have a lower flow rate and smaller orifices It may be necessary to partially open the bypass valve to maintain proper cleaning FLOOD RESTORATION EXTRACTION A CAUTION NOTE This machine can be used for limited water extraction only if connected to an adequate water source 1 Set the throttle control cable on the front control panel to a minimum of 50 of throttle control maximum Proceed into the extraction process 49 057 REV B SECTION 3 SHUT DOWN AND DAILY MAINTENANCE 1 Flush out the chemical system with fresh water t
67. ved container ALWAYS re use or re cycle anti freeze 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 B 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 pu

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