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570SS - Prochem

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1. 29 Drive Belts Pulleys and FDS ro ea opes 29 30 wie la 629506 30 Check Valve Ous u uuu a aa u unas Qa iens 30 Chemical Pump Chemical Metering System 30 Pressure 260090 R MN n ne ON a eo 30 EN a ag TO A aab ere d NI 30 30 High Pressure anan aqa Po o Melek 31 o MM N aa A tua cafum br 32 Vacon RESE VaV u a a 32 Water Pump Drive en osea umb els Paten e kule 32 Solution ae 22 Chemie eg O EI A O NAR NA 33 Packing Nut Adjustment Chemical Metering and Selector Valves 33 Pressure M ee 34 Ense EEA O s 35 Blower Va uumi POD 37 Wak r PUN EO OO ROE Da a 37 C lk ini ako y 39 PART 49 053 REV SAPPHIRE SCIENTIFIC MODEL 570 55 25 SECTION 4 6 MAINTENANCE CHART Po pc opo o o o o zz ez oa Sn lee _ Er Belts Re tension all belts 8 High Pressure Solution Hoses Inspect for wear damage or impending rupture Replace if damaged r z
2. maintain your SAPPHIRE SCIENTIFIC NOT run this unit in an enclosed area DO NOT MODEL 570 SS mobile cleaning unit The operate this unit where the exhaust may enter a MODEL 570 55 unit is easy to operate building doorway window vent or any other however only trained operators should proceed PERE Transfer Pump out Switch Water Pump Switch Water Pressure Vacuum Gauge Gauge Ignition Switch C _ 1 Engine 9 9 v Choke FLOW METER PRESSURE PUMP IGNITI CHOKE Chemical Flow LA n P Meter ei O Li O Throttle Control PRESSURE PUMP OUT AUXILIARY THROTTLE Cable OFF OFF A D Temperature NG Gauge OFF ge TEMPERATURE HOURS DIVERTER MAIN PRESSURE did 8 6 Auxiliary SEL 2 Switch Chemical Prime CHEMICAL METERING TEMP 7 CONTROL Valve 30 Amp Main 20 Amp Circuit Chemical Metering Thermostatic Circuit Breaker Breakers Valve Temperature Engine Hour Meter Diverter Lockout Control 18 SAPPHIRE SCIENTIFIC MODEL 570 55 PART 49 053 REV B SECTION 3 Chemical Check Valve Vacuum Lube g H Cup LI CONDENSED OPERATING INSTRUCTIONS Preheat HESEN XEWAN WA MAWA tt Valve OUTLET 4 PULL am DKE PUMP SWITCH 0VR POSITION Outlet FILTER g 5 E N CHOKE AND RELEASE PRESSURE PUMP Hi 6 PLACE CHEMICAL AND PRIME HOSES INTO CHEMICAL CONTAINER G
3. CONNECTS 46 035 Ko e saz Tp gt N TO 21 032 Pa n E a MOUNTING e G HARDW ARE 8 7 Za SK A 227 _ EN lt A gt gt V 3 b dua u T 27 NNN P KI A12 INSTALLS N NA ku 6 W ASTETAI O P di gt st E A E lt te CONNECT gt 4 0 c j f A 7 M E PUMP E E 4 N 2 sa VG 2 3 T IR EADED ENE CN Y NNECTS f 4 D M A C B q uh f STE TANI 19 PETI NS DNI L CONNECT TO OLE POWER SWITCH 68 158 ASSY WASTE PUMP OUT 20 12017 8 WASHER FLAT 5 16 SAEZINC ______________ 21 1202 6 WASHERJFLATMUSS n SAPPHIRE SCIENTIFIC MODEL 570 55 PART 49 053 REV B
4. 9 200 1 CONN 14NTPX 04JICBRASS PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 55 51 22 5 69 237 ASSEMBLY HEAT EXCHANGER Part Number Qty Description 63 144 HEAT EXCHANGER ENGINE COOLANT 21 381 FTTG 3 4P X IH BRASS NIP 3 8 IN HEX BRASS ELL 3 8 ENPT X 3 8 BRASS FITTING 5 8 H BARB X 3 8 NPT BRASS 6 21 043 1 ELL STREET 3 8 IN 45 DEG BRASS SAPPHIRE SCIENTIFIC MODEL 570 55 PART 49 053 REV B SECTION 5 Description WELDMENT INLET ADAPTER 61 528 1 WELDMENT DIVERTER COVER 2307 1 CYLINDER AIR BIMBA 701 5 6920 1 ASSEMBLY FLOAT VALVE 61 5668 1 WELDMENT SILENCER 570 SS 61559 1 WELDMENT EXHAUST EXTENSION 23 5 IN 61574 1 WELDMENT WATER BOX LL 8 21154 1 FTTING 1 2NPTX1 2BARBBRASS 04 PARTY 49 053 REV SAPPHIRE SCIENTIFIC MODEL 570 SS 53 SECTION 5 SCALE 1 8 69 231 ASSY THERMAL WELL 2 OF 3 54 SAPPHIRE SCIENTIFIC MODEL 570 55 PART 49 053 REV B SECTION 5 69 231 ASSY THERMAL WELL 3 OF 3 Description 30 WELDMENT INLET ADAPTER 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 SS 55 SECTION 5 69 240 ASSY COOLING AND HEAT EXCHANGE Description WELDMENT RADIATOR SUPPORT ISOLATER KUBOTA RADIATOR MOUNT WELDMENT UPPER RADIATOR MOUNT BRACKET WASHER FLAT 12 SAE 6
5. N CAUTION READ THESE INSTRUCTIONS IN THEIR ENTIRETY PRIOR TO PROCEEDING N WARNING 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 vehicle could damaged All fuel lines must meet CARB TIER III and EPA PHASE 3 low permeability requirements Avoid contact with moving parts areas of high temperature brake lines fuel lines catalytic converters exhaust pipes mufflers or sharp objects Fuel pump must be mounted in a vertical position as near as possible to the fuel supply and not located near any heat sources Excess heat from exhaust or other heat sources may cause the fuel pump to work improperly TRAILER FUEL TANK AND FUEL LINE INSTALLATION The following are recommendations for trailer Installations A Strict compliance with all federal and state laws must be maintained Tanks must meet CARB TIER III and EPA permeation and venting emissions requirements B Use only fuel tanks that are manufactured specifically for gasoline have proper vented filling caps and outlet connections that are the same size as the inlet and return connections on the unit C DO NOT install fuel tanks inside any type of enclosed trailer or vehicle 12 SAPPHIRE SCIENTIFIC MODEL 570 SS Z WARNING
6. Deseription 21 001 CONN 1 8 P X 1 4 T BR SAPPHIRE SCIENTIFIC MODEL 570 55 PART 49 053 REV B SECTION 5 a 69 230 ASSY FLOAT VALVE Item No Part Number Qty Description BODY FLOAT VALVE BOTTOM HALF 6627 1 BODY FLOAT VALVE TOP HALF 66235 1 NUT FLOAT VALVE MOUNTING 61 5665 WELDMENT FLOAT VALVE LEVER 10 148 1 SCREW SHOULDER 8 32 X 03 16 X 1 0L lt 1100 1 NUT 1 4 20 SS 11 067 1 NUT 8 32 HEX LOCK SS 2809 1 FLOAT OBLONG BALL 2 5 X 4 0 7 OZ 28 000 1 _ 375 HARDENED SS 41 088 1 O RING SILICONE ASS68A DASH NO 910 1 15 01 1 PIN SPRING 125X 375SS PARTY 49 053 REV SAPPHIRE SCIENTIFIC MODEL 570 SS 65 SECTION 5 CARBURETOR INLET 69 257 ASSY GAS LINE BRACKET Part Number 61 489 WELDMENT GAS LINE BRACKET 16 065 11IN FUEL 5 16 30R9 DUEL FUEL 6 1608 BIN 66 SAPPHIRE SCIENTIFIC MODEL 570 55 PART 49 053 REV B SECTION 5 69 208 ASSEMBLY BLOWER BELT GUARD 2 66264 1 BEARING amp SHAFL BLOWERHSGLG 3 66216 1 PULLEY 2340D3LIGWITHHUB 4 36335 1 IMPELLER BELT GUARD BLOWER 5 603988 1 PLATE BLOWER HOUSING FRONT RING 6 1507 1 SNAPRING 1 187 INTERNAL _ 8 1004 1 SCREW SET 1 420X 50 PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 SS 67 SECTION 5
7. 3 INSTALLATION the unit into the ye hic 10 Positioning the unit into the vehtcle 10 Fastening down the unit and waste tank 10 DimensiOnal 0199 2800 ete annuns Sm ier AN aaa ek 11 installation of fuel Nes 8 12 Trailer fuel tank and fuel line Installation 12 Battery OMNCCHON 12 KUN S USTA ada a aaa K a u aS Conte EW k 12 Console to waste tank connection 13 PARTY 49 053 REV SAPPHIRE SCIENTIFIC MODEL 570 SS 9 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 MODEL 570 55 console weighs approximately 1008 Ibs forklift Is necessary to place the unit into the vehicle Place the forks under the unit Using two clamps secure the console to the forks Move the unit into desired position POSITIONING THE UNIT INTO THE VEHICLE Vehicles vary in size and openings Owners have different preferences on where in the vehicle they want their units positioned SAPPHIRE SCIENTIFIC strongly recommends a side door installation for the MODEL 570 SS
8. 69 236 ASSEMBLY 375 QD FITTING Part Number 61 507 WELDMENT BRACKET QD MOUNTING 25 005 QUICK COUPLING 375F X 375FP BRASS 21 152 ELL 3 8 FNPT X 3 8 FNPT BRASS 21 261 FITTING 58 H BARB X 3 8 NPT BRASS 68 SAPPHIRE SCIENTIFIC MODEL 570 55 PART 49 053 REV B SECTION 5 69 250 ASSEMBLY WASTE TANK Description WELDMENT WASTE TANK 2 5 NPT X 5 0 FILTER SCREEN WELDMENT STRAINER BASKET WELDMENT LID GASKET SPONGE 1 IN X 45 IN 6 4000 2 LATCH PRE FILTER BOX 8 1821546 1 3 1610 305 9 1909 1 CABPLUG2ZINRUBBER O PARTY 49 053 REV SAPPHIRE SCIENTIFIC MODEL 570 SS 69 SECTION 5 TEMP BSENBER 1487 830 SMUT BFF SWITCM 83 000 MERECE Z m e Sapphire 570 55 Wiring 8 22 10 Electrical Diagram 70 SAPPHIRE SCIENTIFIC MODEL 570 SS PART 49 053 REV B 49 053 REV B SECTION 5 Hose Identification 18 2 14 03 TO VAC BRKT 18 214 03 18 215 05 E SAPPHIRE SCIENTIFIC MODEL 570 55 16 003 18 Ig LJ 71 SECTION 5 WARNING THIS UNIT AND EQUIPMENT ONLY IN A WELL VENTILATED AREA EXHAUST FUMES CONTAIN CARBON MONOXIDE WHICH IS AN ODORLESS AND DEADLY POISON 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 AN
9. 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 Z WARNING 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 1n 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 FI
10. PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 55 29 SECTION 4 WASTE TANK STRAINER BASKET The strainer basket located 1n the waste tank should be emptied and cleaned on a daily basis Microban cleaner 15 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 15 noticed inspect and clean more frequently CHEMICAL PUMP The chemical pump should be rebuilt every 500 hours This involves changing the diaphragm check valves and inspecting the disk DO NOT attempt to reuse o rings after the check valves have been removed Replace all o rings when servicing check valves CHEMICAL METERING SYSTEM Check and inspect the packing nut on the chemical selector and metering valves every 200 hours Keeping the valve packing s properly adjusted will prevent leaks and add to the overall life of the valves PRESSURE REGULATOR Lubricate the o rings in the pressure regulator every 100 hours Use only o ring lubricant Part 113 003 VACUUM HOSES To ensure maximum hose life SAPPHIRE SCIENTIFIC recommends that you wash out the hoses with fresh water daily Micro ban QGC cleaner as the best product for clean
11. 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 9 LO Adjusting Cap Loosen nut amp remove entire valve stem from valve body to service seals 2 VI e yM Spring SAPPHIRE SCIENTIFIC MODEL 570 SS PARTY 49 053 REV SECTION 4 9 TROUBLESHOOTING Z WARNING Accurate troubleshooting is based on a thorough and complete understanding of the WATER DO NOT attempt to service this unit while it is CHEMICAL VACCUM HEAT TRANSFER 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 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 TROUBLESHOOTING ENGINE PROBLEM CAUSE SOLUTION Engine will not start The engine does not turn over Starter turns over engine but will not start Excessive heating After inspecting the unit to determine the cause of the tripped circuit breaker Main circuit breaker on the control press the reset button panel has been tripped Clean tighte
12. 4 or Equivalent into the lubrication cup for 5 seconds while the unit is running and the vacuum 28 SAPPHIRE SCIENTIFIC MODEL 570 55 inlet port is sealed This procedure should be done at the end of every working day 3 Drain flush and replace the oil every 1000 hours or yearly whichever comes first NOTE Two drains are on your vacuum pump Ensure that both sides of the vacuum pump are filled to their proper level when servicing 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 Oil Level Sight Gauge Oil Drain 2 After the first 50 hours of operation change the crankcase oil with CAT Pump Crankcase Oil Part 13 000 Change the crankcase oil every 500 hours thereafter PART 49 053 REV B SECTION 4 Pump Belt Replacement Procedures for Model 570 Only use Gates EPDM belts 1 Disconnect the neeative battery cable 2 Remove hose from waste tank to vacuum pump 3 Remove hoods 4 Remove top panel 6 screws 5 Remove left and right hand belt guards 6 Loosen all 4 blower mounting nuts 7 Remove clamp between blower amp silencer 8 Slide the blower back away from engine 9 Lower front 2 nuts located under the front of blower mounting plate approximately 1 2 10 Tip the back of blower up 11
13. Note Waste tank level shut off will not shut the unit off due to high levels of foam The use of a quality de foamer is recommended Filters Strainer 49 053 REV B SECTION 3 CHEMICAL PUMPING SYSTEM The chemicals then flow throueh the chemical metering valve to the solution outlet This valve controls the rate of flow of chemical into the cleaning solution which 15 indicated on the flow meter The chemicals are drawn from the chemical container through a strainer into the flow meter mounted on the control panel The flow meter indicates the rate of chemical flow The chemicals then flow through the stainless steel chemical pump the chemical 1s 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 Chemical Supply Line Chemical Prime Line Flow Meter Three Way Selector Valve Stainless Steel Chemical Pump Chemical Metering Valve Solution Outlet Manifold Solution Outlets PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 SS 17 SECTION 3 5 OPERATION Z 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 death DO PREPARATION This section of the operator s manual explains how to prepare start operate shut down and
14. Remove all belts Install new belts 12 Reverse procedures to install new belts 13 After belts have been installed check for proper tension and alignment Do this using a belt gauge Set deflection to 1 4 10 12 Ibs tension VACUUM INLET FILTER 1 The vacuum inlet filter in the waste tank should be inspected and cleaned daily AN 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 grease to the threads will allow easier removal of filter when cleaning or replacement is required DRIVE BELTS PULLEYS and HUBS Check pulley set screws and hub screws after the first 25 hours of operation and again at 100 hours Re torque these screws with a torque wrench Follow the torque values on the following table Check pulley set screws and hub screws every 500 hours thereafter Insure belts are properly tensioned after checking the torque values Use Gates EPDM belts CAUTION Ensure that when you re torque the screws you use a clockwise pattern and continue until the proper torque is achieved TORQUE VALUES Inch lbs 14 Check pulleys for alignment using a straight edge example M2 key stock Engine Front Pulley Bolt Vacuum Pump Hub 38 032 Note Engine Pulley flywheel is factory set at 868 in lbs 72 3 ft lbs Make sure pulley flange touches on 2 places on each pulley 4 total places
15. engine RPM normal Test gauge and sensor Replace failed component Temperature balance orifice missing Replace orifice Defective waste pump float switch Replace float switch Broken diaphragm s Replace diaphragm s Weak batter Charge or replace battery if needed Automatic waste pump is Check charging station je not After inspecting waste pump to determine the cause of the tripped circuit breaker press the reset button Inspect check valve for debris or Clean replace 1f necessary damage Engine vacuum exhaust heat Pump out circuit breaker on control panel has been tripped SAPPHIRE SCIENTIFIC MODEL 570 55 PART 49 053 REV B SECTION 4 TROUBLESHOOTING BLOWER VACUUM PUMP PROBLEM CAUSE SOLUTION Examine the tubing between the vacuum relief valve and the vacuum gauge and remove any blockage Vacuum hose s is damaged causing a Waste tank gaskets not sealing Inspect the gasket Repair seal or properly not positioned properly replace Re position lid s Plugged vacuum hose or vacuum plumbing between vacuum inlet and strainer basket Loss of vacuum While oe filter or strainer basket 15 awr or replace filter Clean strainer cleaning the vacuum is not up to specification Engine 15 Loose vacuum pump Loose vacuum pump drive belts belts Tighten the drive Oooo the drive belts normal Vacuum gauge i
16. mm 69 239 ASSY FRAME AND ENCLOSURES 3 OF 3 Description PANEL TOP FRONT SECTION 4 1201 8 WASHERFLATSI2SAE gt gt O 6 104 6 j NUTIA20ZINNC 00 0 7 1407 8 NUTLTHUMBIA 20FLWR HEADKNOB 8 12015 14 LKWSRIAZINC 5850 11 PANEL RIGHT SIDE 570SS_ 44 SAPPHIRE SCIENTIFIC MODEL 570 55 PART 49 053 REV B SECTION 5 IIIIIIIIIIIIIIIII 69 227 ASSY INSTRUMENT PANEL 570 FRONT 2 2603 1 HOURMETER HOBBS CHROME BEZEL_______________ 5 4041 1 6 400 1 8 30068 2 BREAKER20AMP _ 9 23 066 VALVE MACVALVE 45A AA1 DDBJ 4KA 26 005 GAUGE WATER PRESSURE 1500 PSI DUAL 23 027 VALVE 3 WAY BALL 1 8 FP SS 23 029 VALVE BYPASS WHITEY 34 007 CONTROL TEMPERATURE 275 DEGREE 29 007 SWITCH STARTER amp KEY 3 POSITION PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 55 45 SECTION 5 69 227 ASSY INSTRUMENT PANEL 570 BACK Description BRACKET DIVERTER LOCKOUT VALVE FITTING ELBOW 25 IN NPT BRASS BUSHING 1 4 M X 1 8 BRASS CONN 1 8 P X 1 4 POLY CONNECTOR 1 8 MNPT X 1 4 HOSE 90 DEG SWIVEL 204 2 ELL 1 8P X 1 4 T BRASS ELL STREET 1 8 IN BRASS 8 20 030 1 8 IN AIR MUFFLER EE 11 002 8 NUT WELL 10 32 10 150 SCREW 10 32 X 500 PHP ZP 10 149 SCREW 6 32 X 1 2 PHP ZP 11 021 NUT 6 32 NYLOK 12 027 LKWSR EXT TOOTH 12 12 018 WASHER FLAT 1 2 USS 46 S
17. 1002 4 SCREW MACH 1 4 20 X 34X50 _______ 00 GROMMET 7 8 OD X 3 8 ID X 1 8 PANEL 8 4 7 1 GROMMET 1 3 8 OD X 3 4 ID X 1 8 PANEL 9 63 141 1 RADIATORJ570SS 20 56 SAPPHIRE SCIENTIFIC MODEL 570 55 PART 49 053 REV B SECTION 5 CHEMICAL PUMPING SYSTEM Description VLV 3 WAY BALL 1 8 FP SS 1 VLV BYPASS SS FTTG BRB 1 8 PX 5 16 H BR za A Z m 2 z 2 lt x 23 028 46 056 1 PUMP CHEMICAL BY GENERAL PUMP 21 007 4 2603 1 FLOWMETER 18 5 23027 1 HEK TER 1 2000 ME SAPPHIRE SCIENTIFIC MODEL 570 SS 57 49 053 REV B SECTION 5 46 056 PUMP CHEMICAL GENERAL Description BODY PULSE PUMP GP PULSE PUMP 2 3632 1 PLASTIC DISC GP PULSE PUMP 00 3 332 1 RUBBER DIAPHRAGM GP PULSE PUMP 4 333 1 TOPCOVERINLET GPPULSEPUMP 00 N 5 36354 2 O RING 70 DURO GP PULSE PUMP_________________ 6 36355 2 VALVECAP 303SST GPPULSEPUMP ________________ 7 36356 ASSY VALVE KIT GP CHEMICAL PULSEPUMP 8 36357 1 SPACER RING 303 SST GPPULSEPUMP 36358 VALVE 303 SST GP PULSE PUMPMP 520196 N 58 SAPPHIRE SCIENTIFIC MODEL 570 55 PART 49 053 REV B SECTION 5 69 249 ASSY MANIFOLD BLOCK 4 55 1 THRU 10 Description SENSER TEMP 140 320 DEGREE MANIFOLD BLOCK 6 23
18. While Defective fuel pump Replace fuel pump doing normal cleaning the Defective float switch inside the waste Check switch for proper operation engine stops running tank Replace as necessary Refer to the Briggs amp Stratton Engine Oil pressure switch on engine has shut Operation and Maintenance Manual down due to insufficient oil pressure DO NOT restart the engine until the cause is determined and corrected No ignition in the engine or engine is Refer to the Briggs amp Stratton Engine malfunctioning Operation and Maintenance Manual 5 tarter turns over engine but Refer to Briggs amp Stratton Engine will not start 5 5 Operation and Maintenance Manual Heat exchanger leaks NOTE The heat exchanger will Main circuit breaker on the control panel has been tripped Inspect heat exchanger for leaks produce water condensation Visually Inspect for damage Pressure exchanger 15 damaged from frozen 2 discharge at times during check after removing from unit normal operation DO NOT Maximum test pressure 1200 PSD confuse this with a leak No vacuum hose connected Connect vacuum hose to vacuum inlet Temperature relief valve water box Clean temperature relief valve and test Loss of temperature The heat is stuck open if necessary output of the unit is LESS than Engine RPM is low RPM is Engine RPM is low m Reset engine RPM
19. after first 50 hours of operation and again at 100 hours of operation 6 Every 500 hours or 6 Months whichever comes first 7 Every 1000 hours or yearly whichever comes first 8 After first 25 hours and then at every 100 hours of operation 26 SAPPHIRE SCIENTIFIC MODEL 570 55 PART 49 053 REV B SECTION 4 7 MAINTENANCE This section of the operator s manual contains the service and maintenance information for the MODEL 570 55 unit A planned preventative maintenance program will ensure that your SAPPHIRE SCIENTIFIC MODEL 570 SS has optimum performance long operating life and a minimum amount of down time A WARNING WARNING Ia COULD CAUSE SEVERE BURNS OR INJURY DO t NOT TOUCH ELECTRICAL WIRES OR COMPONENTS WHILE THE ENGINE IS RUNNING DISCONNECT THE BATTERY BEFORE SERVICING THIS UNIT TO PREVENT ACCIDENTAL STARTING 44 066 ROTATING CAUSE INJURY OR COULD BE FATAL KEEP ALL GUARDS AND SAFETY DEVICES IN PLACE 44 085 DANGER UNDER HIGH PRESSURE HIGH TEMPERATURE CAN CAUSE BURNS SEVERE PERSONAL INJURY OR COULD BE FATAL SHUT DOWN MACHINE ALLOW TO DOWN AND RELIEVE APS PLUGS FITTING FILTERS ND BOLTS 44 083 A 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
20. belt tension is achieved 1 2 deflection in the center of the belts half way between the pulleys Do not over tighten damage to pump may occur INSERT SEAT CHK em VLV ASSY TM 3 While checking the alignment tighten the nuts that hold the water pump to the base SEAT CHECK VALVE ASSY 41 008 ID 5 8 OD 32 SAPPHIRE SCIENTIFIC MODEL 570 SS PARTY 49 053 REV SECTION 4 Note Improper seating of the check valve seat poppet damaged spring o rings will result in poor performance of the chemical system 7 Lubricate the new o rings with o ring lubricant Part 13 003 and re install GHEMIGAL PUMP The MODEL 570 55 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 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 t
21. 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 1s smaller than ys In I D NEVER use a waste pump hose as a water inlet hose PART 49 053 REV B SECTION 3 N 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 A float shut off switch is located inside of the waste tank It will automatically shut down the unit if the tank reaches its full capacity If this occurs empty the waste tank before continuing When doing flood extraction the water pump should be in the OFF position NOTE Vacuum pressure must have a minimum 7 hg for the diverter valve to work properly Attaching 1 length of hose should create enough vacuum pressure to achieve this CLEANING While cleaning observe the following guidelines 1 Before cleaning ensure that the wand nozzles are functioning pr
22. inlet port and read the vacuum gauge If adjustment is required shut the unit down and adjust the locking nut tension on the vacuum relief valve Re start the unit and read the vacuum gauge Repeat this process until the vacuum relief valve opens at 14 Hg Always ensure 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 AN CAUTION Over tightening of belts may cause damage to pump casing causing it to fail SOLUTION OUTLET CHECK VALVE Inspect the check valve whenever performing service on the chemical pump or if flow problems are occurring in the chemical system Shut down Unit 2 Remove the check valve ensuring that the small o ring on the seat comes out with it 3 Next remove the seat using a 5 16 In Allen wrench 4 Check the Teflon seat for wear or debris Clean and replace the seat 1f necessary 5 Inspect the poppet and the spring for wear or damage Clean and replace as necessary NOTE New o rings must be installed anytime the check valve is removed 6 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 Part Number CAP CHECK VALVE ORING 7 8 ID X I SPRING CHECK POPPET CHECK VALVE ASSY 2 Adjust the position of the belt tensioning adjusting bolt until the proper
23. larger Jet sizes on your MODEL 570 SS unit may reduce cleaning temperatures PRIMING THE CHEMICAL PUMP NOTE SAPPHIRE SCIENTIFIC recommends that the chemical pump be primed whenever the water pump is on This eliminates possible pressure fluctuations and water pump pulsations related with running the chemical pump dry 20 SAPPHIRE SCIENTIFIC MODEL 570 SS 1 Insert the chemical prime tube and the chemical inlet tube 1nto the chemical container NOTE When inserting the chemical tube into the chemical container ensure that it stays submerged as the chemical pump will not function if air is allowed to enter the inlet line 2 Turn the 3 way chemical 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 into the vacuum system If the pump does not prime then Seal off the vacuum port The vacuum will quickly draw chemical from the chemical container After the flow begins turn the chemical 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 15 achieved AUTOMATIC WASTE PUMP 1 If your unit Is
24. of the unit Connect the cleaning the vehicle that you will require tool to the opposite end of the pressure hose 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 U hose 2 WATER UNDER HIGH PRESSURE RATURE C 1 Connect the water supply hose to the water Inlet quick connector on the front of the unit Connect the hose to the faucet ALVES UGS FITTING FILTERS 44 083 A PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 55 19 SECTION 3 STARTING THE UNIT CAUTION 1 Set throttle control in pull out engine choke turn solution pump switch to override and turn ignition key to start 2 Push in engine choke after engine has started 3 Set throttle control to desired speed 4 Turn the water pump switch to the ON position NOTE If the unit does not build water pressure after 5 seconds check for adequate water supply See Loss of Water Pump Pressure in the Troubleshooting section of this manual VACUUM HOSE Connect the vacuum hose s to the vacuum Inlet connection at the front of the unit Connect the opposite end of the vacuum hose s the cleaning tool Let the unit run for a few minutes with the vacuum inlets partially blocked off to warm up the cleaning solution SAPPHIRE SCIENTIFIC recommends that the total floor tool size does not exceed 4 Using
25. plumbing and heat exchange systems on this unit SAPPHIRE SCIENTIFIC recommends that a high guality water softener be used in areas where the water hardness exceeds 372 gralns If a water softener 15 used it must have a flow capacity of at least five 5 GPM or greater without any hose constrictions The use of a water softening system will reduce maintenance and reduce down time caused by hard water scaling It will also enhance the performance of cleaning chemicals which will result in greater efficiency in lower concentrations PARTY 49 053 REV SAPPHIRE SCIENTIFIC MODEL 570 55 SECTION 1 2 RECEIVING YOUR TRUCKMOUNT UNIT DEALER RESPONSIBILITY THE SAPPHIRE SCIENTIFIC DEALER THAT YOU PURCHASED THIS TRUCKMOUNT CLEANING UNIT FROM IS RESPONSIBLE FOR THE PROPER INSTALLATION OF THIS MACHINE THE DEALER IS ALSO RESPONSIBLE FOR THE PROPER INITIAL TRAINING OF YOUR OPERATORS AND MAINTENANCE PERSONNEL ACCEPTANCE OF SHIPMENT Your MODEL 570 SS Truck mount cleaning unit was thoroughly tested checked and inspected in its entirety prior to leaving our manufacturing facility When receiving your unit please make the following acceptance check 1 The unit should not show any signs of damage If there is damage notify the common carrier immediately 2 Carefully check your equipment and packing list The standard SAPPHIRE SCIENTIFIC MODEL 570 55 unit should arrive with the following items as well as any optional ac
26. pump Balance Orifice mis A os Unplug or replace orifice and or screen cleaning tool Inspect all lines remove accumulated Internal block between the pressure debris which is blocking proper flow regulator manifold and the outlet Replace any defective hoses Remove Replace Nozzle or change nozzle size Repseeommee Replace Orifice manifold or the solution screen 1S inspect and clean the solution screen clogged De scale unit and install a water softener if necessary Loss of solution volume at cleaning tool orifice Solution Examine the check valve remove any pressure gauge reads normal Outlet check valve is plugged debris Defective quick connect on one or Replace defective quick connects s on more of the high pressure hoses 7 pressure hoses s Cleaning tool valve is malfunctioning Repair or Repair or replace valve valve Hose inner lining is constricted Remove restriction or replace hose Air leak in chemical supply line Check for air leaks Replace faulty priming valve or metering valve parts SAPPHIRE SCIENTIFIC MODEL 570 55 PART 49 053 REV B SECTION 4 TROUBLESHOOTING CHEMICAL SYSTEM PROBLEM CAUSE SOLUTION Tighten fittings Re apply thread External leak in chemical piping sealant where required If any fittings are damaged replace Chemical flow meter indicates flow with the tool valve closed Outlet check valve is full of debris or Clo
27. solution to flow at full force Injector extraction manifold PARTY 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 SS 78 SECTION 5 1992 2002 FORD FUEL LINE INSTALLATION Cut Existing 3 From End 78 Return Line To Bottom of Tank 69 005 KIT FUEL HOOKUP FORD FI Description l ADAPTOR VENT TUBE FORD 2 21086 2 FTTG BULKHEAD 1 4 IN BRASS 3 2109 2 ELL 1 4IN LG STREET BRASS 21088 1 ELL STREET 1 8 IN BRASS 5 2107 2 FITG BRB1 8PX5 16HBR o Z o 206 4 FTTG BRB14PX5716HBR 8 6 CLAMP HOSEFUEL46 gt Z 0 9 1400 2 CLAMEHOSES2 74 SAPPHIRE SCIENTIFIC MODEL 570 SS PART 49 053 REV B SECTION 5 AND FULL SIZE VAN FUEL LINE INSTALLATION Remove Existing Hose and Cut In Half CAUTION Do Not Cut 4 ES Inner Hose gt X Fuel Suction Line Fuel Return Line Bottom of Tank dp 69 003 KIT FUEL HOOKUP 97 amp 2002 FI Description CLAMP 32 2 1401 6 CLAMP HOSE FUEL 6 3 201000 4 FTTG BRB 1 4P X 5 16H BR 4 21007 2 FTTG BRB 1 8 X 5 16 H BR 5 2148 1 ELL STREET UBINBRASS 02 6 2109 2 ELLI AINLGSTREETBRASS 8 2116 1 ELL I 8FPXI 8FPBRONZE 9 6600 1 ADAPTORFUELNECKCHEVY ______________ PARTY 49 053 REV SAPPHIRE SCI
28. the clutch replace the defective switch pump remove the bolts Loose or broken solution pump belts Tighten or replace belts m Refer to chemical pump priming The strainer at the inlet end of the Unclog the strainer If damaged chemical inlet line is clogged replace 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 Suction leak in the inlet line leading into the chemical pump Remove any debris from the chemical check valve s Replace chemical check valve s or seals if necessary Chemical prime on off valve or Replace valve s chemical valve 15 defective Chemical pump check valve s 15 clogged PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 SS 39 SECTION 5 TROUBLESHOOTING CHEMICAL SYSTEM PROBLEM CAUSE SOLUTION Disassemble the chemical pump and Chemical pump diaphragm is ruptured replace the damaged nn en Loss of chemical With the Measure the pump volume If the cleaning tool valve open no pump volume is less than normal refer chemical Defective cylinder in the water pump to Loss of Pump Volume in the Troubleshooting section in this manual 40 SAPPHIRE SCIENTIFIC MODEL 570 SS PARTY 49 053 REV SECTION 5 5 and ACCESSORIES 10 ILLUSTRATED PARTS LISTINGS Frame ah Ku u a aaa ga pa abs 42
29. wastewater in a suitable and proper location NEVER dispose of wastewater in storm drain water way or on ground areas Always dispose of waste In accordance with Local State and Federal laws 12 Remove the strainer basket from the waste tank Clean out any debris and re install Micro ban QGC cleaner 15 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 enterlng the vacuum pump 13 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 turn This will make the filter easier to remove when cleaning or replacement 15 required NEVER operate this unit with the filter removed damaged or improperly installed 14 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 15 Clean the vehicle interior unit tools hoses etc as needed Inspect ALL e
30. 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 vehtcle when returning hoses 3 Disconnect the vacuum hose from the front of the unit 4 Adjust the throttle cable to the idle position 5 Adjust the thermostatic temperature control to the lowest setting 6 Allow the unit to run for at least 5 minutes with 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 4 or equivalent into the blower lubrication cup located on the right hand side of the lower panel for 5 seconds Let machine run 2 minutes to disperse lube to blower 7 Unplug the vacuum inlet and remove load Next return the throttle control cable to idle position and let idle for 3 to 5 minutes 8 Turn the ignition switch to the OFF position 9 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 10 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 22 SAPPHIRE SCIENTIFIC MODEL 570 55 11 Drain the waste tank disposing of
31. 03 1 CHECKVALVEMANIFOLD 8 21 374 1 NIPPLE 12NPTX2 12L304SS 66 277 1 MANIFOLD TEMPERATURE SENSOR PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 SS 59 SECTION 5 69 249 ASSY MANIFOLD BLOCK amp BYPASS 11 THRU 27 Description ELL 1 8 P X 1 4 T 45 DEG BRASS ELL 1 2 PX 1 2T BR 60 SAPPHIRE SCIENTIFIC MODEL 570 SS PARTY 49 053 REV SECTION 5 69 256 ASSEMBLY REGULATOR 570 SS Description BRACKET REGULATOR MOUNTING REGULATOR PRESSURE CAT 7670 VITON PLUG 375 NPT X HEX HEAD BRASS 6 2140 1 FITTING STR ELL 375INNPT BRASS 8 182403 1 HOSE ASSEMBLY 1 2 IDA X 1 2 X 1 2 15 01 W SLEEVE 9 2107 1 CONN 3 8 NPT X l2 JICBRASS PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 55 61 SECTION 5 69 242 ASSEMBLY BELT GAURD 4 1201 8 WASHER FLAT I2SAE 6 10007 8 SCREW MACH 1 4 20 X 1 2 S0CHD55_______________ 8 558 1 PLATE INSPECTION COVER 62 SAPPHIRE SCIENTIFIC MODEL 570 55 PART 49 053 REV B SECTION 5 69 258 ASSEMBLY BRACKET Part Number Description 61 592 WELDMENT DUAL 2 5 TO 3 5 IN VAC BRACKET PC CIRCUIT GRAY 21 054 ELL 1 8P X 1 4 T BRASS 21 007 FTTG 1 8 P X 5 16 H BR PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 SS 63 64 Item No 7 SECTION 5 69 247 ASSEMBLY OIL CUP AND BYPASS VALVE Part Number Qty
32. 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 15 spilled Do not turn ignition switch until the gasoline has been cleaned up Never use gasoline for cleaning purposes 6 DO NOT place hands feet hair clothing or any body parts near rotating or moving parts Rotating machinery can cause severe injury or death 7 NEVER operate this unit without belt and safety guards High speed moving parts such as belts and pulleys should be avoided while the unit is running Severe injury fatality or damage may result 8 NEVER service this unit while it is running High speed mechanical parts as well as high temperature components may result in injury or severed limbs 9 Engine components will be extremely hot from operation To prevent severe burns DO NOT touch these areas while the unit is running or shortly after the unit is shut off 10 DO NOT touch any part of the exhaust system while the system is running or for 20 minutes after the unit is shut off Severe burns could result 11 Water under high pressure at high temperature can cause burns severe personal injury or fatality Shut down unit allow to cool down and relieve system of all pressure before removing caps valves plugs fittings filters or hardware 12 NEVER leave the vehicle engine running while the unit is in operation 13 Battery acid contains sulfuri
33. 9 to 27 5 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 49 053 REV B SECTION 1 ANTIFREEZE COOLANT Always use quallty permanent ethylene glycol based antifreeze coolant Distilled soft or pure rain water 1s recommended for the cooling system If impure water has to be used completely flush the system and add rust preventive 1 Mix antifreeze coolant and water at the specified ratio before pouring into engine 2 For replenishment add 50 50 mix to cooling system for permanent types Note Antifreeze and water must be mixed thoroughly before putting into the coolant system or hot spots may develop leading to engine overheating CHEMICAL 5 SAPPHIRE SCIENTIFIC MODEL 570 SS Truck mount unit 5 unique last step chemical injection system can be used with a wide variety of water diluted chemical compounds either acidic or alkaline depending the work to be performed We recommend using only SAPPHIRE SCIENTIFIC brand chemistry WATER REOUIREMENTS Because hard water deposits will damage the
34. APPHIRE SCIENTIFIC MODEL 570 SS PART 49 053 REV B SECTION 5 EO j Apa A oui 10 AN p ne 4 69 244 55 ENGINE 570 55 1 THRU 1 Description SWITCH 230 DEG KUBOTA TEMP WELDMENT CROSSOVER INLET FAN BLADE 12 00 DIA 5 BLADE KUBOTA 570SS ENGINE KUBOTA 31 HP MECH GOVERNOR 61577 1 WELDMENT ENGINEMOUNTRS 0 8 21 381 1 j FITG34PXIHBRASS 202 9 21142 1 j FITG 38MJICXMI2XLS90DEG gt PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 55 47 SECTION 5 69 244 ASSY ENGINE 570 SS 19 THRU 30 Description BELT XL7350 EPDM ASSY STARTER HEAT SHIELD WELDMENT EXHAUST PIPE 48 SAPPHIRE SCIENTIFIC MODEL 570 55 PART 49 053 REV B SECTION 5 69 228 ASSEMBLY HF408 VACUUM BLOWER 570 SEE FOLLOWING PAGE FOR 5 LIST 49 SAPPHIRE SCIENTIFIC MODEL 570 SS PART 49 053 REV B SECTION 5 69 228 ASSEMBLY 408 VACUUM BLOWER 570 SEE PREVIOUS PAGE FOR ITEM IDENTIFICATIONS 10 12 13 14 15 16 17 18 19 20 21 23 24 SAPPHIRE SCIENTIFIC MODEL 570 55 PARTY 49 053 REV SECTION 5 13 69 238 ASSEMBLY SCPS120 CAT PUMP Description PUMP WATER CATP 5CP5120 CLUTCH ELECT CAT 5CP 2 GROOVE PUMP CHEMICAL MFG BY GENERAL PUMP TEE 3 8 X NPT X FNPT BRASS 6 18214035 1 HOSE ASSEMBLY 7 16 ID X 08 X 08 I50LW SS 8 2109 1 PLUG 14JICBRASS
35. Coneratulations your purchase of the MODEL 570 SS Truck mount cleaning unit This Instruction parts manual is a guide for operating and servicing your SAPPHIRE SCIENTIFIC Truck mount unit Proper operation and service are necessary to ensure the outstanding performance of this unit When properly maintained your Truck mount will have a long and trouble free life The following service methods outlined in this manual are detailed in a manner that operation servicing may be performed properly and safely Because service levels vary due to the skill of the mechanic tools and parts availability ensure that prior to attempting any repair you are familiar with this equipment and have the proper tools Any questions regarding the operation service or repair of this unit should be directed to your nearest SAPPHIRE SCIENTIFIC dealer The headings WARNING and CAUTION are utilized to warn you that steps must be taken to prevent personal injury or damage to the equipment Please make sure that you have read and understand these instructions entirely before proceeding with the operation of this unit THIS UNIT MUST BE INSTALLED BY THE DEALER THAT YOU PURCHASED IT FROM IN ACCORDANCE WITH THE SAPPHIRE SCIENTIFIC INSTALLATION PROCEDURES BE SURE TO FILL OUT THE WARRANTY CARD ONLINE AT WWW SAPPHIRESCIENTIFIC COM 49 053 REV B Record your units serial number here for future reference or if you shou
36. ENTIFIC MODEL 570 SS 75 SECTION 5 2003 AND FULL SIZE VAN FUEL LINE INSTALLATION KA lt A Cut Hose and Remove Flapper Valve Trim Fuel LIIICL Neck 1 Reinstall Flapper Valve Inside of Fuel Filler Hose 69 018 KIT FUEL HOOKUP 2003 CHEVY FI Description ADAPTOR FUEL FLR CHVY 2003 2 14046 2 CLAMP HOSE 20 3 184908 1 HOSE 3 16 X25 1 8P X 1 8P NO COVER 4 1401 6 CLAMP HOSE FUEL 6 5 21088 1 ELL STREET 1 8 IN BRASS 6 21007 2 FTIG BRB 1 8P X 5 16 H BR ELL 1 4 IN LG STREET BRASS 8 21 006 4 FTTG BRB 1 4P X 5 BR 9 2 06 2 FTTG BULKHEAD I 4INBRASS 76 SAPPHIRE SCIENTIFIC MODEL 570 SS PART 49 053 REV B SECTION 5 1997 2002 DODGE FULL SIZE VAN FUEL LINE INSTALLATION Remove Existing Hose and Cut In Half 69 004 KIT FUEL HOOKUP CHEVY DODGE FI Description CLAMP HOSE 32 2 66030 1 ADAPTOR FUEL NECK CHEVY 3 21088 1 ELL STREET 1 8 IN BRASS 4 1401 6 CLAMP HOSE FUEL 6 5 21007 2 FTTG BRB 1 8 X 5 16 H BR 6 18 028 1 HOSE 3 16 X 25 1 8P X 1 8P NO COVER FTTG BULKHEAD 1 4 IN BRASS 8 21006 4 FTTG BRB 1 4P X 5 16 BR 9 209 2 ELLAI A IN LG STREET BRASS 24 PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 SS 77 78 SECTION 5 is amp NNECTS 46 035 B SIT 1 0 a x
37. Engine Change engine oil after first 50 hrs of operation High Pressure Solution Hoses Inspect for wear damage or impending rupture Replace if damaged S i Belts Re tension all belts 8 Vacuum Break Check and adjust vacuum relief valve to 14 Hg if needed Pressure Regulator Lubricate o rings Use only o ring lubricant part 13 003 Battery Clean battery terminals Engine Check spark plugs only use OEM spark plugs o ij Engine 200 Hours Change engine oil and filter Chemical Metering System 200 Hours Inspect packing nut on selector and metering valve Adjust as needed Engine Replace in line fuel filter 6 Water Pump Change crankcase oil 3 Pulleys and Hubs Check pulley and hub set screws for proper torque 5 Chemical Pump Change diaphragm and check valves Inspect disk TT Belts Replace all belts Engine Replace spark plugs Vacuum Pump Drain flush and replace oil 7 Engine Replace air filter element Engine 1000 Hours Valve Adjustment 0057 0073 in s To maximize the operating and performance use only recommended olls filters and greases 1 Or as often as required 2 Change engine oil and oil filter after first 50 hours of operation and then every 200 hours 3 Change water pump crankcase oll after first 50 hours of operation 4 Inspect after first week of operation and remove any debris present Inspect again after 2 to 4 weeks 5 Check pulley and hub set screws
38. If it is determined that there is no defect in the product or that the defect resulted from causes not within the scope of our warranty then the product will be repaired or replaced only at your request and at your expense and you must bear all shipping costs How Does State Law Apply This warranty gives you specific legal rights and you may also have other rights which vary from state to state II SAPPHIRE SCIENTIFIC MODEL 570 SS PART 49 053 REV B Table of Contents ____ 2 lt _ _ _ _ 2 Safety Specifications Installation Fuel Engine Oil Chemical Water Requirements 2 RECEIVING YOUR TRUCKMOUNT UNITI 8 Dealer Responsibility Acceptance of Shipment Equipment Listing Optional Equipment SECTION TWO INSTALLATION 9 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 LI 15 Water Pumping System Heat Transfer System Vacuum System Chemical System OPERATION G u dd n u uuu 18 Equipment setup Instrumentation Starting Your Unit Priming the Chemical Pump Waste Pump Operation Cleaning Upholstery Cleaning Stair Tool Clean
39. Instrument Panel Front side Component LiIst 45 Instrument Panel Back side Component List 46 WAGON 49 Wales 51 Heat 52 we 53 GCooling sin Heat E x Dan SE ao Qusa kerka Aka 56 Chemical PUMPIDE alle a Sis 57 Chemical POM ps Spo ii EN A 58 Solution Manifold and Bypass 50 Pressure SU 61 Beli Gia Gl D awtu aaa a kusana M 62 Vacuum Dile KOL easte 63 OI Cup in Bypass WAV 64 Jo u e t 65 Gas Line Brack et and ET 66 Beli Guard BIOWET c kone kal e eke e ek e era 67 Quick Disconnect Fittings and Bracket 68 Wei 09 Electrical DASTA 70 Hose ROUNE S 71 es 12 11 ACCESSORIES lt 3 lt 233 __ _ _ _ __ 3 _ _ _ _ _ __ _ _ 73 1992 o 2002 Ford Fuel Tane ot 74 Chevy and GMC Full Size Van Fuel Line Instal 75 2003 Chevy GMC Full Size Van F
40. NCLUDING 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 c have the serial number and original proof of installation date available Proof of proper maintenance may be required before warranty 1s 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
41. PPHIRE SCIENTIFIC MODEL 570 55 49 053 REV 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 1s recommended that you acquire a basic understanding of how the unit functions WATER HEATING SYSTEM Cold water enters the console through the water inlet connection located on the lower left corner of the lower front panel The water then flows to the water box through a float valve which shuts off the water when the water box is full Heat Exchanger Solution Manifold Solution Outlets Closed Heating 49 053 REV B The water 1s pre heated in the water box using radiant heat generated by the vacuum blower and engine exhaust as well as the water used to cool the engine The water then flows to the water pump where it is pressurized From there it flows to the heat exchanger where it travels through finned tubing and is further heated by the vacuum blower and engine exhaust The hot water then flows through the check valve manifold that contains a strainer and a check valve At this point the chemical injection takes place The hot solution mixture of water and chemicals then flows through the solution outlet manifold to the cleaning tool Float Valve He
42. RE 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 49 053 REV B SECTION 2 CONSOLE WASTE TANK CONNECTION Waste Tank Waste Tank to Vacuum Brake 17 554 HOSE INT VACUUM 3 1 2 X 25 16 014 HOSE INT VAC 3 1 2 X 60 Vacuum Inlet 13 SAPPHIRE SCIENTIFIC MODEL 570 55 PART 49 053 REV B 4 SYSTEMS 5 OPERATION 14 SECTION 3 OPERATION a D A pa 15 Vacu m mm 16 Chemical 800021708 S lee aa a aa ank na EUR E uns 17 STRA d ka 18 519101060 yh in e AN RN 20 Priming the chemical pump sisa aaa uyan 20 Attomall PUM MMMX 20 Das e 21 CVC ni 2 Upholstery cahi V M 21 MOO e I ANJO nr td tuit teenies N 21 Flood 05 0 2 6 vej 21 Shut down and daily malntenance 22 re ZE DIOL I 23 SA
43. RODUCT CONTAINS CHEMICALS KNOWN BY THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM ALL FUEL LINES MUST MEET CARB III and EPA PHASE 3 LOW PERMEABILITY REQUIRMENTS ALL FUEL STORAGE TANKS MUST MEET III and EPA PHASE 3 PERMEATION and VENTING REQUIRMENTS ALL FUEL ADAPTOR KITS AND FUEL TANKS USED IN THE STATE OF CALIFORNIA MUST MEET CURRENT CALIFORNIA AIR RESOURCES BOARD ARB REGULATIONS CARB EXECUTIVE INFORMATION LABEL S MUST BE INSTALLED IN A VISABLE LOCATION PART 49 053 REV B SECTION 1 SPECIFICATIONS Engine Speed 3000 rpm High Speed No Load 1500 rpm Idle No Load Water Pump RPM 1500 rpm Vacuum Pump RPM 3000 rpm Water Flow Rate 5 0 GPM maximum Water Pump Pressure 1500 PSI maximum Vacuum Relief Valve 22 14 in Hg Waste Tank Capacity Waste Tank Shut Off Console Weight 1008 Ibs Console Weight with waste tank amp accessories Approximately 1130 Ibs TORQUE VALUES Engine Pulley Rear 39 8 43 4 ft Ibs Engine Pulley Front 72 3 79 6 ft lbs Vacuum Pump Pulley Hub 180 inch Ibs 15 ft Ibs JET SIZING SAPPHIRE SCIENTIFIC recommends that the total floor tool tip size be 6 min Sapphire Scientific recommends using the Stryker Cleaning and Extraction Wand Roto molded ergonomic handle provides balanced handling and substantially reduces operator fatigue Stainless steel extraction tube for rugged service and long life Roto molde
44. URE 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 WITH COVER OFF VOIDS WARRANTY 44 081 SAPPHIRE SCIENTIFIC MODEL 570 55 COULD CAUSE SEVERE BURNS OR INJURY DO TOUCH ELECTRICAL WIRES COMPONENTS WHILE THE ENGINE IS RUNNING DISCONNECT THE BATTERY BEFORE SERVICING THIS UNIT TO PREVENT ACCIDENTAL STARTING 44 065 PART 49 053 REV B 49 053 REV SECTION 1 1 Read 5 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 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
45. We DO NOT recommend a rear door installation 1 Ensure that enough space 15 provided to assure adequate engine ventilation as well as room for service and maintenance 2 The complete unit with waste tank and accessories MUST NOT exceed the vehicle s axle weight limit 10 SAPPHIRE SCIENTIFIC MODEL 570 SS FASTENING DOWN THE UNIT AND WASTE TANK LN 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 6 134 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 grade 5 78 16 x 4 in hex head cap screws with flat washers through the MODEL 570 SS console mounting holes and four 4 grade 5 78 16 x 4 in hex head cap screws with flat washers through the waste tank mounting holes 2 Install the provided mounting plates underneath the vehicle floor 3 Screw the provided 38 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 PART 49 053 REV B 49 053 REV B SECTION 2 DIMENSIONAL DIAGRAM SAPPHIRE SCIENTIFIC MODEL 570 SS SECTION 2 INSTALLATION OF FUEL LINES
46. Y BUILDING DOORWAY WINDOW VENT OR OPENING OF ANY TYPE 42 080 44 080 DECAL WARNING USE IN WELL VENTILATED AREA 44 084 DECAL CAUTION SURFACE A WARNING WARNING t A WARNING ELECTRICAL SHOCK COULD CAUSE SEVERE BURNS OR INJURY DO READ THE OPERATOR S MANUAL BEFORE INSTALLING OR NOT TOUCH ELECTRICAL STARTING THIS UNIT FAILURE TO ROTATING MACHINERY CAN CAUSE INJURY OR COULD BE FATAL KEEP ALL GUARDS WIRES OR COMPONENTS WHILE THE ENGINE IS RUNNING DISCONNECT THE BATTERY BEFORE ADHERE TO INSTRUCTIONS CAN RESULT IN SEVERE PERSONAL INJURY OR COULD BE FATAL REPLACEMENT MANUALS CAN BE PURCHASED SERVICING THIS UNIT TO AND SAFETY DEVICES PREVENT ACCIDENTAL Sapphire Scientific IN PLACE 44 085 A STARTING 44066 2604 Liberator Prescott AZ 86301 44 067 A 44 085 DECAL 44 066 DECAL 44 067 DECAL WARNING ROTATING MACHINERY WARNING ELECTRICAL SHOCK WARNING READ MANUAL CLEAN SCREEN x d LV 44 090 DECAL MANIFOLD MAINTENANCE ORIFICE WY CO MONTHLY UNLEADED GASOLINE ONLY SEE OWNER S MANUAL WA w 44 087 DECAL 570 SS 72 SAPPHIRE SCIENTIFIC MODEL 570 SS PARTY 49 053 REV SECTION 5 11 ACCESSORIES Solution control valve Turn 45 counter clockwise to open fully FIG A HANDLE DETAIL Purge valve To flush out or debris from InJector loosen purge valve and allow
47. a 7 TURN ON PRESSURE PUM TURN VALE TO THE PRIME Filter i PRESSURE LAL M BOLE HAVE BEEN A REMON D i Can TOO AND ADJUST THE CHEMICAL MET ZN V NG Vi val ur TNE DESIRED VALVE HEMICAL FLOW RATE WHILE 9 SET THROTTLE TO THE DESIRED OPERATING SPEED AND DAILY MAINTENANCE 8 A 1 ALLOW T A WATER DSPLA ENENIA NUTEST d MX OVE mostu ME Pr 85 Sur T O 2 TU m me THE ON MM ICAL VALVE THE OFF POSITION REMOVE THE PRESSURE won HOSES an um NIRE we TO WD mak RO gt Outlets D WASTE TI TANK INTO AN APP We SOURCE AND CLEAN THE 4 PRESSURE STRAINER BASKET AND WASTE TANK REG V U acuum NG a gt _ Inlets a A A WARNING WATER 7 INLET 4 o 1 Water Supply inlei Pressure Regulator Exhaust ENSURE THERE IS ADEQUATE FUEL NOTE Never use a waste pump outlet hose as a water inlet hose Use only clean hoses for Check the fuel tank to ensure there is adequate water supply fuel to complete the job and transport the vehicle This unit consumes approximately 1 5 2 Turn the water supply faucet on Water will US gallon of fuel per hour depending on the fill the water box speed setting HIGH PRESSURE HOSE REMOVE TOOLS FROM THE l Before starting the unit connect the high pressure to the solution outlet connection Remove any tools accessortes or hoses from at the front
48. at Coils Open No Heat SAPPHIRE SCIENTIFIC MODEL 570 SS 15 SECTION 3 VACUUM SYSTEM The engine turning a vacuum pump eenerates the vacuum The atr 1s 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 1s then filtered and rushes into the vacuum pump The vacuum pump also heats incoming air as it 1s compressed The hot discharged air 1s forced down Vacuum Brake Vacuum Pump Water Box Dual Exhaust Heat Exchanger Exhaust 16 SAPPHIRE SCIENTIFIC MODEL 570 SS Inlets stream into a silencer for noise abatement Exiting the silencer this hot air 1s directed through the heat exchanger The vacuum pump speed is factory set to maximize vacuum pressure and provide sustained system life Do not alter the vacuum speed outside the recommended range shown in the Technical Specifications section A level shut off sensor 1s located near the top of the waste tank and will shut down the unit before the tank 1s at full capacity This protects the vacuum pump from water damage
49. c 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 batterles 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 SAPPHIRE SCIENTIFIC MODEL 570 55 3 SECTION 1 15 DO NOT the vehicle in 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 v
50. cessories EQUIPMENT LISTING e SAPPHIRE SCIENTIFIC MODEL 570 55 console e Operation and Service Manual e Installation mounting plates and bolt down kit e Hose clamps for vacuum and fuel hoses e Waste tank with shutoff switch e Two Waste tank filters and stainless steel strainer basket Two sections of 2 in x 50 ft vacuum hose 8 SAPPHIRE SCIENTIFIC MODEL 570 55 Two sections of 2 5 in x 37 5 ft vacuum hose Two 50 ft sections of high pressure solution hose Two 37 5 ft sections of high pressure solution hose Two vacuum hose connectors Two hose reducing cuffs to 2 in 50 ft water supply hose with quick connect OPTIONAL EQUIPMENT A Additional lengths of vacuum hose Part 18 003 B Additional vacuum hose connectors Part 21 003 C Additional high pressure solution hoses Part 18 000 With shutoff valve Part 18 001 D Automatic waste pump kit Part 68 003 E Demand pump system Part 68 002 F KIT FUEL HOOKUP CHEVY 97 TO 2002 FI Part 69 003 G KIT FUEL HOOKUP CHEV Y DODGE Part 69 004 H KIT FUEL HOOKUP FORD Part 69 005 I KIT FUEL HOOKUP 2003 CHEV Y Part 69 018 J KIT 2004 amp UP TF FUEL INJ CHEV Y Part 69 033 K ADAPTOR 2004 amp UP FORD FUEL Part 69 061 L KIT FUEL FORD CUT AWAY 04 05 Part 69 077 M KIT FUEL CHEV Y CUT AWAY 04 05 Part 69 081 N ASSY WASTE PUMP OUT Part 4468 158 PART 49 053 REV B SECTION 2 INSTALLATION
51. cientific 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 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 I
52. d head resists dents and scratches and doesn t readily gouge molding or furniture Purge valve for easy cleaning Classic S shape makes reaching under objects or furniture easy Roto molded 14 head with full width high pressure injector and two way extraction glide provides maximum coverage and extraction Forged brass valve centrally positioned for right or left handed operation Glide assembly is easy to replace when worn PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 SS SECTION 1 INSTALLATION REQUIREMENTS Prior to beginning the Installation read the ENTIRE Installation section of this manual Since the MODEL 570 SS Truck mount unit weighs with waste tank and accessories approximately 1130 I please adhere to the following recommendations prior to installing the unit 1 The unit should NOT be installed in any motor vehicle rated less than 3 4 ton capacity AN CAUTION The console and waste tank with accessories must NOT exceed the vehicle s axle weight limit 2 If mounting the unit in a trailer ensure that the trailer 1s rated for the total weight of the unit and trailer Electric or hydraulic brakes must be provided and strict compliance with all State and Federal laws must be maintained 3 If mounting in a trailer the MODEL 570 SS console must be positioned so that it balances properly with respect to the trailer axle With a minimum of ten percent 1096 of the unit s to
53. ehicle 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 1130 pounds Make certain that the vehicle has the correct axle rating This will prevent unsafe or hazardous driving conditions 18 High back seats are required for all vehicles that units are to be installed for head and neck protection Metal partitions between the seats and equipment are strongly recommended 19 Always keep your vehicle clean and orderly Wands tools and accessories must be securely stowed while driving the vehicle 20 AII high pressure hoses must be rated at 3000 PSI and have a heat rating of 250 degrees F Thermoplastic hoses do not meet this criterion and should never be used Severe burns and other injuries could result if hoses do not meet these requirements 2 Ensure that you have received proper training from the distributor that you purchased the unit from prior to operation 22 This unit produces high pressure and high temperatures Improper use could result In serious injury SAPPHIRE SCIENTIFIC MODEL 570 SS 23 DO NOT modify this unit in any manner Any modification could result 1n serious injury or fatality This includes the use of any open ended hoses CALIFORNIA PROPOSITION 65 WARNING ENGINE EXHAUST FROM THIS P
54. en all tool valves and drain the anti freeze Into an approved container until the water runs clear and all of the anti freeze 15 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 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 24 SAPPHIRE SCIENTIFIC MODEL 570 SS PARTY 49 053 REV SECTION 4 SERVICE and MAINTENANCE 6 MAINTENANCE CHART 26 SI 27 civ mu a 28 s 28
55. eplace the in line fuel filter every 500 hours or vearly whichever comes first NOTE Additional engine service information can be obtained from the Kubota operation and maintenance manual If service or repair is required contact an authorized Kubota Service Center They will require the serial number of the engine SAPPHIRE SCIENTIFIC MODEL 570 SS 27 SECTION 4 VACUUM PUMP NOTE Refer to the provided Vacuum Pump Operation and Service Manual for specific Instructions Lubrication SAPPHIRE SCIENTIFIC requires that you use only AEON PD XD Synthetic Blower Lubricant in both sides of the vacuum pump for all operating temperatures AEON PD XD is formulated specifically for positive displacement blower service to provide maximum blower protection at any temperature NOTE AEON PD XD Part 13 004 1s 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 both sides to ensure they are at the proper level Too little oil will damage and ruin the bearings and gears Too much oil will result In overheating Vent Cap Oil Fill Vent Cap Oil Fill Oil Level Sight Gauge Oil Drain 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
56. g air PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 SS 37 38 SECTION 4 TROUBLESHOOTING WATER PUMP PROBLEM CAUSE SOLUTION Using a tachometer check the engine speed Full throttle engine speed 15 3000 RPM ldle engine speed 15 li ena L 1500 RPM Refer to the engine speed section for instructions on how to re adjust Lubricate o rings using o ring lubricant Pressure regulator has worn o rings Check o rings If necessary replace Clean or repair regulator Adjust to working pressure Lubricate o rings using o ring lubricant Part Pressure regulator o rings are dry Pressure regulator is dirty stuck open or improperly adjusted Loss of solution pump pressure With the cleaning tool open the solution pressure gauge reads below the normal operating pressure Low pump volume Measure the Examine the check valves plunger amount of water being returned to cups and cylinder head on the water the water box from the pressure pump Repair whenever reguired regulator It should fill a gallon refer to the water pump service container about every 17 6 seconds manual Defective water pressure gauge Replace gauge Orifice spray nozzle in the cleaning tool Is worn defective or wrong size Debris clogging water lines or water C Clean or replace as needed inlet disconnect Belts loose or broken Re tension or replace as needed Loss of pump prime Manually prime water
57. he 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 Chemical Prime Valve Adjust the packing nut by turning the packing bolt clockwise at 1 16 increments Loosen Set Screw and Remove Knob Chemical Metering Valve Packing Nut PARTY 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 SS 33 SECTION 4 PRESSURE REGULATOR The pressure regulator holds water pressure at a preset point and bypasses the excess water back to the water box To adjust l 34 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 To adjust the pressure regulator turn the adjusting knob while observing the pressure gauge on the control panel until you reach the desired pressure Valve O Rings 7 NWARN ING DO loosen the adjusting body cap all the way counterclockwise or remove it while the unit is running We recommend that you lubricate the pressure regulator o ring every 50 hours or whenever required If you do not the stem may become seized due to inadequate lubrication If this occurs
58. ing Flood Restoration Shut Down and Daily Maintenance Freeze Protection SECTION FOUR MAINTENANCE and SERVICE 25 6 5 26 Ts MAINTENANCE V 27 8 GENERAL SERVICE ADJUSTMENTS ean kulane k 32 _ _ lt _ __ ey 35 SECTION FIVE PARTS and ACCESSORIES 38 10 ILLUSTRATED PARTIS LES DLN C ___ PR e n naa S PEE PEE HER e e 42 VGL C ESSO t S 72 PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 SS III SECTION 1 GENERAL INFORMATION 1 SAFETY Sua aaa P E 2 O aa oa aaa am 5 Installation u uuu io 6 106600106 MEN a a ene Usus nA e ess E len y n 6 Engine oil requirements a 6 I9 7 Chen cal xe quite re uy uuu h KEK uuu k Ke adis 7 MX ek 7 2 RECEIVING YOUR TRUCKMOUNT UNIT TES DONS TEN MM 9 JACCeDtance ada 9 men
59. ing and sanitizing the wands and hoses as well as other parts of the system 30 SAPPHIRE SCIENTIFIC MODEL 570 SS BATTERY Z WARNING Explosive gases Dangerous acid Batteries contain sulfuric acid To prevent acid burns avoid contact with skin eyes and clothing Batteries also produce explosive hydrogen gases while charging To prevent fire or explosion charge batteries only in a well ventilated area Keep sparks open flames as well as any other sources of ignition away from batteries at all times Remove all jewelry prior to servicing batteries Keep batteries out of the reach of children Before disconnecting the negative ground cable ensure that all switches are 1n 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 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 buildu
60. ld need to contact the factory in the future for any reason This service and operations manual is written specifically for SAPPHIRE SCIENTIFIC MODEL 570 SS Truck mount Cleaning units manufactured by SAPPHIRE SCIENTIFIC 2604 Liberator Prescott AZ 86301 USA The information contained in this document is subject to change without notice and does not represent a commitment on the part of SAPPHIRE SCIENTIFIC All rights reserved Copyright 2009 by SAPPHIRE SCIENTIFIC No part of this work may be used or reproduced in any form or means without the express written consent and permission of SAPPHIRE SCIENTIFIC Published by SAPPHIRE SCIENTIFIC First printing October 2009 Revised June 2010 Rev A September 2010 Rev B Printed in USA MODEL 570 SS MANUAL PART 49 053 SAPPHIRE SCIENTIFIC MODEL 570 SS SAPPHIRE SCIENTIFIC LIMITED WARRANTY Sapphire Scientific Model 570 SS What Does This Warranty Cover This warranty covers the Sapphire Scientific Model 570 SS and 15 provided to the original purchaser only How Long Does This Warranty Last This warranty runs for Two 2 years from the date of Installation on parts and labor Excluding normal maintenance items Factory installed original belts are covered for 500 hours Water box recovery tank and frame are covered for five years All other components including seals o rings and electrical components are covered for the entire two year warranty period What Sapphire S
61. lution 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 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 SAPPHIRE SCIENTIFIC MODEL 570 55 23 SECTION 3 Op
62. n or replace the battery Loose or corroded s Dead ENE haa or replace battery Test ignition switch for power going into the switch If there is power going in but NO power going out replace the switch Defective ignition switch Test the starter motor If necessary Defective starter motor replace Refer to Gardner Denver Service and Vacuum pump seized Repair Manual Waste tank is full Empty the waste tank Defective fuel pump Replace the fuel pump Loose or broken wires leading to waste Repair or replace any broken electrical tank float switch connections Defective float switch in the waste Check switch for proper operation tank replace as necessary Oil pressure switch located on Test these components If any are engine fuel shut off solenoid located defective replace Consult the Briggs on engine amp Stratton Engine Operation and Maintenance Manual Descale unit repair or replace damaged plumbing components as necessary Install water softener Flow restriction caused by hard water scaling Not enough water flow Check jet size of tool PARTY 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 SS 35 SECTION 4 TROUBLESHOOTING ENGINE PROBLEM CAUSE SOLUTION Engine 15 out of gasoline Add gasoline to the fuel tank Waste tank 15 full Empty waste tank After inspecting the unit to determine the cause of the tripped circuit breaker press the reset button Encinestops running
63. operly A Hold the wand approximately one foot above the surface to be cleaned and open wand valve A full even spray should emtt from the cleaning nozzles B Ifthe nozzles are not showing a full even spray pattern adjust clean or replace the nozzles 1f required PART 49 053 REV B 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 scrubbing action with chemical solution applied in both push and pull strokes provided that the final stroke 15 pull stroke with no chemical injection UPHOLSTERY CLEANING 1 Run unit on low speed Upholstery tools have a lower flow rate and smaller orifices Adjust the thermostatic temperature control to the desired temperature To maintain proper cleaning temperatures make certain that the unit has been fully heated up prior to cleaning STAIR TOOL CLEANING 1 Run unit on low speed Adjust the thermostatic temperature control to the desired temperature ELOOD RESTORATION EXTRACTION AN CAUTION 1 Set the throttle control cable on the front control panel to a minimum of 5046 of throttle control maximum Make certain that the water pump switch is in the OFF position Proceed into the extraction process SAPPHIRE SCIENTIFIC MODEL 570 SS 21 SECTION 3 SHUT DOWN AND DAILY MAINTENANCE 1 Flush out the chemical system with fresh
64. p 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 49 053 REV SECTION 4 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 Z 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 PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 55 31 SECTION 4 8 GENERAL SERVICE ADJUSTMENTS DO NOT attempt 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 Adjust the engine speed to 3000 RPM max Z WARNING DO NOT attempt to adjust without a tachometer and NEVER adjust the engine above 3000 RPM VACUUM RELIEF VALVE With the unit running at full RPM block off the airflow at the vacuum
65. quipment and accessories for any damage leaks wear etc PART 49 053 REV B SECTION 3 FREEZE PROTECTION 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 console 2 Connect all solution hoses and a tool to the console 3 Start the unit with the water pump in the ON position Open a valve on the tool 4 Fill the water box with one gallon of 100 glycol based anti freeze 5 Start the unit and set the throttle control cable to the idle position Insure the water pump is on Open a tool valve until anti freeze comes out of the tool Repeat this procedure with ALL remaining tools and hoses 49 053 REV B 6 After the tools and so
66. s giving an improper reading Unplug vacuum hose or inlet plumbing Drain the waste tank Close drain Waste tank drain valve is damaged or valve if open Remove the dump valve left open causing a vacuum leak and after inspecting replace the defective components Re adjust the vacuum relief valve If the vacuum does not increase remove and inspect the relief valve diaphragm If damaged replace Vacuum exhaust heat exchanger Remove and clean ARM j Vacuum pump is worn out pump is worn out Replace the vacuum pump the vacuum pump Adjust throttle to set desired vacuum i pressure Excessive Vacuum lief val acuum relief valve requires 4 Readjust the vacuum relief valve adjustment TROUBLESHOOTING WATER PUMP PROBLEM CAUSE SOLUTION Turn the water supply on or up Check for kinks in the water supply hose Examine the float or replace Vacuum relief valve requires adjustment or has a vacuum leak due to damaged diaphraem Water supply 15 turned off or the float valve 15 stuck Loss of solution pump pressure With the cleaning 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 tool open the solution pressure gauge reads below Solution pump inlet supply line is the normal operating pressure plugged or drawin
67. se the chemical valve on the Instrument panel If the flow meter damaeed not allowing it to close p P 5 does not Indicate flow remove debris proper y or replace check valve if necessary Close the chemical valve on the instrument panel If the flow meter still indicates flow replace the chemical pump diaphragm Chemical pump diaphragm is ruptured Chemical flow meter indicates flow with the tool valve closed Tighten valve packing nut see General Service Adjustments section in this manual Replace valve if necessary Internal leak in chemical valve causing continual flow through prime tube returning to container Check the solution pump circuit breaker on the control panel Press the circuit breaker reset button Solution pump circuit breaker has been tripped Examine switch electrical connections and wiring Repair any defective connections If there is power going to the switch but not going out replace the defective switch Defective electrical connection in the console wiring or defective switch Solution pump does not engage 545 Solutlon pump has not been activated Turn solution pump switch to on Defective solution pump clutch NOTE The clutch may be manually If there 15 power in the switch but not engaged by inserting two 4 20 x l2 power at the clutch replace the bolts Line up the holes on the clutch defective wire If there is power at the and Insert the bolts To disengage
68. t Ji ST nm 9 Opuonal 600130060 E E yl a ol sep a nr RANA Ea 9 PART 49 053 REV SAPPHIRE SCIENTIFIC MODEL 570 55 l SECTION 1 1 SAFETY ZN WARNING For Your Safety The following WARNING labels are your MODEL 570 SS 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 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 DOORWA Y WINDOW VENT OR OPENING OF ANY TYPE 42 080 A WARNING IH A WARNING OR DANGER O WARNING ELECTRICAL SHOCK READ THE OPERATOR S MANUAL BEFORE INSTALLING OR STARTING THIS UNIT FAILURE TO ADHERE TO INSTRUCTIONS CAN RESULT IN SEVERE PERSONAL INJURY OR COULD BE FATAL REPLACEMENT MANUALS CAN BE PURCHASED FROM OM Sapphire Scientific 2604 Liberator Prescott AZ 86301 44 067 A ROTATING MACHINERY CAN CAUSE INJURY OR COULD BE FATAL KEEP ALL GUARDS AND SAFETY DEVICES IN PLACE 44 085 A DO NOT RUN ENGINE WATER UNDER HIGH PRESS
69. tal overall weight w o accessories or water should be on the tongue Adequate ventilation must be provided to prevent over heating Either two sets of doors or a roof ventilation system 1s highly recommended 4 The vehicle tires must have a load rating in excess of the combined unit and vehicle weight 5 SAPPHIRE SCIENTIFIC does not recommend using any type of flooring materials that absorb water This condition will result In rust and corrosion of the vehicle floor 6 Insulation under rubber mats should be removed prior to installation of the unit 6 SAPPHIRE SCIENTIFIC MODEL 570 SS FUEL REQUIREMENTS Use unleaded fuel ONLY Use only fresh clean unleaded gasoline with a minimum octane rating of 87 Do Not use high octane easoline Gasoline with up to not exceeding 1096 ethanol 15 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 SH or higher Do not use additives Select the viscosity based on the air temperature at the time of operation as shown in the following table Above 37 C 99 SAE40 25 C to 37 77 F to 99 P SAE30 or SAE10W 30 0 C to 25 C 32 F to 77 P SAE20 or SAE10W 30 Engine oil capacit UE 5 pau 3 59 U S qts 32 4 to 37 3 Nm Tightening torque Drain Plug 3 3 to 3 8 23
70. the hour meter as a guide for coordinating a maintenance schedule ENGINE 1 Check the engine oil level daily Ensure that the proper oil level is maintained NEVER overfill 49 053 REV B 2 Change the oil after the first 50 hours of operation Thereafter change oil and oil filter every 200 hours of operation Use high quality oil of at least API American Petroleum Institute service class SF SG SH SJ or higher Do not use additives Select the viscosity based on the air temperature at the time of operation as shown in the following table SAE40 SAE30 SAEIOW 30 Above 37 C 99 F 25 C to 37 C 77 F to 99 P 0 C to 25 C 32 F to 77 P SAE20 or SAEIOW 30 3 59 U S qts 32 4 to 37 3 Nm Tightening torque Drain Plug 3 3 to 3 8 23 9 to 27 5 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 switching to synthetic oil 3 Check the spark plugs every 100 hours Replace spark plugs every 1000 hours Use only OEM specified spark plugs 4 Clean the engine air filter element weekly Replace the element every yearly 5 R
71. uel Line Install 76 1997 2002 Dodge Full Size Van Fuel Line Install 77 Waste Pump OU ASSEMD MEN SE H e 78 PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 55 41 SECTION 5 69 239 ASSY AND ENCLOSURES 1 OF 2 Description WELDMENT HINGED CONTROL PANEL WELDMENT MIDDLE FRAME BRACE LKWSR UU LKWSR 1 4 ZINC 6 1101 ___ 20 WASHER FLAT 12SAE 8 104 1 INOUT 14 20ZINC _ O 9 61592 WELDMENT DUAL 2 5 TO 3 5 IN VACBRACKET 42 SAPPHIRE SCIENTIFIC MODEL 570 SS PART 49 053 REV B SECTION 5 e AN ka aaa SKA e 69 239 ASSY FRAME AND ENCLOSURES 2 OF 3 Qty Description BRACKET ANGLE CLAMP WELDMENT COIL MTG BRKT SUPPT WELDMENT COIL MIG BRACKET LKWSR 1 4 ZINC SCREW MACH 1 4 20 X 3 4 HXHD GRD5 6 J 120 28 WASHER FLAT 12 SAE 7 1008 8 SCREW MACH14 20X2 34HXHD 8 044 0 JNULIA420ZINC 9 10 020 2 SCREW MACH 1 4 20 X 3 4HXHDSS 02 10 12 049 8 WASHER 3 8 X 1 5 FENDERZINC________ l PART 49 053 REV B SAPPHIRE SCIENTIFIC MODEL 570 55 43 SECTION 5 lt lt X A 57 2 V i 972 A O

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