Sapphire Audio rage, Service And Operation Manual

Page 1: ...Service and Operation Manual 2604 Liberator Dr Prescott AZ 86301 1 928 445 3030...

Page 2: ...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 SCIENTIFI...

Page 3: ...cted 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 WORK...

Page 4: ...tion 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...

Page 5: ...2 Specifications 5 Installation requirements 6 Fuel requirements 6 Engine oil requirements 6 Chemical requirements 7 Water requirements 7 2 RECEIVING YOUR TRUCKMOUNT UNIT Dealer responsibility 8 Accep...

Page 6: ...els 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 yourse...

Page 7: ...ed 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 ign...

Page 8: ...e machine Gas fumes could accumulate and ignite Battery gases are extremely flammable This will prevent possible explosions 15 DO NOT damage the vehicle in any way during the installation When routing...

Page 9: ...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...

Page 10: ...ty 90 gal Console Weight 520 lbs Console Weight w standard waste tank hoses 858 lbs Operating Weight w full water box standard waste tank 1534 lbs TORQUE VALUES Engine Hub Rear 160 inch lbs 13 3 ft lb...

Page 11: ...ype of flooring materials that absorb water This condition will result in rust and corrosion of the vehicle floor 5 Insulation under rubber mats should be removed prior to installation of the unit FUE...

Page 12: ...QUIREMENTS 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 wate...

Page 13: ...IRE SCIENTIFIC RAGE MODEL console Operation and Service manual Installation mounting plates and bolt down kit Hose clamps for vacuum and fuel hoses Waste tank with shutoff switch Waste tank filter and...

Page 14: ...the unit into the vehicle 10 Positioning the unit into the vehicle 10 Fastening down the unit and waste tank 10 Dimensional diagrams 11 Installation of fuel lines 12 Trailer fuel tank and fuel line in...

Page 15: ...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 wast...

Page 16: ...SECTION 2 PART 49 057 REV K SAPPHIRE SCIENTIFIC RAGE 12 DIMENSIONAL DIAGRAM REAR MOUNT TANK...

Page 17: ......

Page 18: ...le 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 Explos...

Page 19: ...SECTION 2 PART 49 057 REV K SAPPHIRE SCIENTIFIC RAGE 13 CONSOLE TO WASTE TANK CONNECTION Waste Tank Vacuum Relief Vacuum Inlet 2 16 011 HOSE INT VAC2 7 8 X 36 17 205 HOSE INT VAC 2 1 2 X 60...

Page 20: ...uum system 16 Chemical pumping system 17 5 OPERATION Preparation 18 Starting the unit 20 Priming the chemical pump 20 Automatic waste pump 20 Operation 21 Cleaning 21 Upholstery cleaning 21 Flood rest...

Page 21: ...ons WATER HEATING SYSTEM Cold water enters the water box and flows through a float valve which shuts off the water when the water box is full The water then flows to the water pump where it is pressur...

Page 22: ...ed and rushes into the vacuum pump The vacuum pump also heats incoming air as it is compressed The hot discharged air is forced down stream into a silencer for noise abatement Exiting the silencer thi...

Page 23: ...e chemical is then injected into a three way selector valve located on the front panel This valve may be used to turn the chemical flow ON OFF or to PRIME the chemical pump The chemicals then flow thr...

Page 24: ...nly in a well ventilated area Exhaust fumes contain carbon monoxide which is an odorless and deadly poison that can cause severe injury or death DO NOT run this unit in an enclosed area DO NOT operate...

Page 25: ...water is free of any debris Also flush out any debris from your water inlet hose 1 Connect the water supply hose to the water inlet quick connector on the water box Connect the hose to the faucet NOT...

Page 26: ...rt the chemical prime tube and the chemical inlet tube into the chemical container NOTE When inserting the chemical tube into the chemical container ensure that it stays submerged as the chemical pump...

Page 27: ...strokes provided that the final stroke is a pull stroke with no chemical injection UPHOLSTERY CLEANING 1 Upholstery tools have a lower flow rate and smaller orifices It may be necessary to slow the e...

Page 28: ...sition 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 Unho...

Page 29: ...e idle position Insure the water pump is on Open a tool valve until anti freeze comes out of the tool Repeat this procedure with ALL remaining tools and hoses 6 After the tools and solution hoses have...

Page 30: ...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...

Page 31: ...Valve Outlet 29 Chemical Pump 29 Chemical Metering System 29 Pressure Regulator 30 Vacuum Hoses 30 Battery 30 High Pressure Solution Hoses 30 8 GENERAL SERVICE ADJUSTMENTS Engine Speed 31 Vacuum Reli...

Page 32: ...100 Hours Change engine oil and filter Vacuum Relief 100 Hours Check and adjust vacuum relief valve to 13 Hg if needed Pressure Regulator 100 Hours Lubricate o rings Use only o ring lubricant part 13...

Page 33: ...of at least API American Petroleum Institute service class SJ or higher Do not use additives High quality 30W oil is recommended A 10 30 synthetic blend may be used after 50 hours of operation for a...

Page 34: ...vel Too little oil will damage and ruin the bearings and gears Too much oil will result in overheating NOTE Two drains are on your vacuum pump Ensure that BOTH sides of the vacuum pump are filled to t...

Page 35: ...destroy the filter Applying grease to the threads will allow easier removal of filter when cleaning or replacement is required DRIVE BELT AND PULLEYS Ensure that when you re torque the screws you use...

Page 36: ...irst 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...

Page 37: ...ing 3 While checking the alignment tighten the nuts that hold the water pump to the base SOLUTION OUTLET CHECK VALVE Inspect the check valve whenever performing service on the chemical pump or if flow...

Page 38: ...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...

Page 39: ...sure regulator o rings 2 To adjust the pressure regulator turn the adjusting knob while observing the pressure gauge on the control panel until you reach the desired pressure DO NOT loosen the adjusti...

Page 40: ...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 powe...

Page 41: ...rmal 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 remov...

Page 42: ...um leak Drain the waste tank Close drain valve if open Remove the dump valve and after inspecting replace the defective components Vacuum relief valve requires adjustment or has a vacuum leak due to d...

Page 43: ...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 e...

Page 44: ...e Adjustments section in this manual Replace valve if necessary Loss of chemical With the cleaning tool valve open no chemical Chemical pump is improperly primed Refer to chemical pump priming instruc...

Page 45: ...al Pump 50 Solution Manifold 51 Vacuum Inlet Bracket 52 Regulator Bracket 53 Belt Guard Blower 54 Water Box Float Valve 55 Waste Tank 56 Electrical Diagram 57 Hose Identification Flow Diagram 58 Decal...

Page 46: ...SECTION 5 PART 49 057 REV K SAPPHIRE SCIENTIFIC RAGE 40 CONSOLE ASSEMBLY DETAIL 1...

Page 47: ...SECTION PART 49 057 REV K SAPPHIRE SCIENTIFIC RAGE 41 CONSOLE ASSEMBLY DETAIL 2...

Page 48: ...SECTION 5 PART 49 057 REV K SAPPHIRE SCIENTIFIC RAGE 42...

Page 49: ...SECTION PART 49 057 REV K SAPPHIRE SCIENTIFIC RAGE 43 69 544 ASSY BEZEL AND PANEL 1 16...

Page 50: ...SECTION 5 PART 49 057 REV K SAPPHIRE SCIENTIFIC RAGE 44 69 445 ASSY BEZEL AND PANEL 17 25...

Page 51: ...SECTION 5 PART 49 057 REV K SAPPHIRE SCIENTIFIC RAGE 45...

Page 52: ...SECTION 5 PART 49 057 REV K SAPPHIRE SCIENTIFIC RAGE 46 69 710 VACUUM PUMP ASSEMBLY...

Page 53: ...SECTION 5 PART 49 057 REV K SAPPHIRE SCIENTIFIC RAGE 47 69 432 ASSEMBLY VACUUM RELIEF...

Page 54: ...SECTION 5 PART 49 057 REV K SAPPHIRE SCIENTIFIC RAGE 48 69 610 ASSY PRESSURE PUMP Pulse Pump 46 056 Pump 46 072...

Page 55: ...61 901 1 WELDMENT HEAT EXCHANGER COVER 6 61 889 1 WELDMENT HEAT EXCHANGER HOUSING 7 58 615 1 PNL HEAT EXCHANGER INSULATOR COVER 8 41 033 2 GROMMET 1 ID X 1 3 4OD 9 21 061 1 ELL 3 8 P X 1 2 T BRASS 10...

Page 56: ...E 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 36 356 2 ASSY VALVE KIT GP CHE...

Page 57: ...SECTION 5 PART 49 057 REV K SAPPHIRE SCIENTIFIC RAGE 51 69 260 MANIFOLD BLOCK ASSEMBLY...

Page 58: ...ASSY VACUUM INLET BRACKET Item No Part Number Qty Description 1 61 902 1 WELDMENT VACUUM INLET BRACKET 2 25 005 1 QUICK COUPLING 3 8 F X 3 8 FNPT BRASS 3 21 434 1 FTTG 3 8 FP X 1 2 BARB BRASS 4 21 007...

Page 59: ...8 FP RT ANG WHITEY 4 23 010 1 REGULATOR PRESSURE 5 21 336 1 TEE 1 8 NPT X 1 4 JIC X 1 4 JIC BRASS 6 21 333 1 COUPLING 1 8 FNPT X 1 8 MNPT BRASS 7 21 325 1 ADAPTER 1 4 NPT X 1 2 JIC BRASS 8 21 323 1 FI...

Page 60: ...BLOWER HOUSING 2 66 263 1 BEARING SHAFT BLR HSG STD 3 15 027 1 SNAP RING 1 187 INTERNAL 4 66 215 1 PULLEY 3L BELT X 2 340 OD 5 10 219 1 SCREW FULL DOG SET 1 4 20 X 1 2 BLK 6 51 042 1 AIR WHEEL MOLDED...

Page 61: ...4 23 033 1 VALVE 165 DEG THERMAL CAT 7145 5 23 025 1 VLV FLOAT WTR BOX THERMALWAVE 6 21 154 1 FITTING 1 2 NPT X 1 2 BARB BRASS 7 21 109 1 FTTG 1 2 NPT X 5 8 BARB BRASS 8 21 047 1 NIP 1 2 IN HEX BRASS...

Page 62: ...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 W...

Page 63: ...SECTION 5 PART 49 057 REV K SAPPHIRE SCIENTIFIC RAGE 57 ELECTRICAL DIAGRAM...

Page 64: ...SECTION 5 PART 49 057 REV K SAPPHIRE SCIENTIFIC RAGE 58 HOSE IDENTIFICATION FLOW DIAGRAM...

Page 65: ...UNLEADED FUEL ONLY 44 081 DECAL ENGINE COVER WARRANTY 44 066 DECAL WARNING ELECTRIC SHOCK 44 085 DECAL WARNING ROTATING MACHINERY 44 083 DECAL WARNING HIGH PRESSURE 44 067 DECAL WARNING READ MANUAL 44...

Page 66: ...E 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 BRASS 11 31 016 1 CONN 3 PRG TWR 38045 WAYTEK 12 31 019 3 PIN FEMALE 31...

Page 67: ...G BULKHEAD 1 4 IN BRASS 3 21 039 2 ELL 1 4 IN LG STREET BRASS 4 21 038 1 ELL STREET 1 8 IN BRASS 5 21 007 2 FTTG BRB 1 8P X 5 16 H BR 6 21 006 4 FTTG BRB 1 4P X 5 16H BR 7 18 028 1 HOSE 3 16 X 25 1 8P...

Page 68: ...3 21 006 4 FTTG BRB 1 4P X 5 16H BR 4 21 007 2 FTTG BRB 1 8P X 5 16 H BR 5 21 038 1 ELL STREET 1 8 IN BRASS 6 21 039 2 ELL 1 4 IN LG STREET BRASS 7 21 086 2 FTTG BULKHEAD 1 4 IN BRASS 8 21 116 1 ELL 1...

Page 69: ...CHVY 2003 2 14 006 2 CLAMP HOSE 20 3 18 028 1 HOSE 3 16 X 25 1 8P X 1 8P NO COVER 4 14 011 6 CLAMP HOSE FUEL 6 5 21 038 1 ELL STREET 1 8 IN BRASS 6 21 007 2 FTTG BRB 1 8P X 5 16 H BR 7 21 039 2 ELL 1...

Page 70: ...0 1 ADAPTOR FUEL NECK CHEVY 3 21 038 1 ELL STREET 1 8 IN BRASS 4 14 011 6 CLAMP HOSE FUEL 6 5 21 007 2 FTTG BRB 1 8P X 5 16 H BR 6 18 028 1 HOSE 3 16 X 25 1 8P X 1 8P NO COVER 7 21 086 2 FTTG BULKHEAD...

Page 71: ...e supplied hose in the finished assembly 2 Drill a 3 4 inch hole through the vehicle floor at the location chosen for the bulkhead connector 3 Install the bulkhead connector by inserting the fitting a...

Page 72: ...cation for the fuel pump assembly housing to mount underneath the vehicle that will not cause damage to the vehicle or compromise the fuel line routing or components 2 Remove the housing lid from the...

Page 73: ...bypass filter return port back to the vehicle fuel supply Figure 3 Fuel Pump and Filter Detail 5 Attach the 90 degree elbow and hose barb fittings to the bulkhead connector underneath the vehicle 6 Co...