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Congratulations
on your purchase of the
®
MODEL 460SS
Truck mount cleaning unit.
This manual is a guide for operating and
servicing your SAPPHIRE SCIENTIFIC
Truckmount unit.
Proper operation and service are necessary to
ensure outstanding performance of this unit.
When properly maintained, your Truck mount
will have a long and trouble-free life.
The following service methods outlined in this
manual are detailed in a manner that operation
and servicing may be performed properly and
safely. Because service levels vary due to the
skill of the mechanic, tools and parts
availability, ensure that prior to attempting any
repair, you are familiar with this equipment and
have the proper tools. Any questions regarding
the operation, service, or repair of this unit
should be directed to your nearest SAPPHIRE
SCIENTIFIC dealer.
The headings WARNING and CAUTION are
utilized to warn you that steps must be taken to
prevent personal injury or damage to the
equipment. Please make sure that you have read
and understand these instructions entirely before
proceeding with the operation of this unit.
!
Do not alter or modify your
460SS in any way. Use only replacement parts
authorized by SAPPHIRE SCIENTIFIC, Inc.
Modifications or use of unapproved parts could
create a hazard and will void your warranty.
Contact your authorized Sapphire dealer for
assistance.
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
PART# 49-100 REV B
SAPPHIRE SCIENTIFIC
Record your unit's serial number here for future
reference or if you should need to contact the
factory in the future for any reason.
S/N:
This service and operations manual is written
specifically for SAPPHIRE SCIENTIFIC
®
MODEL 460SS
Truck mount Cleaning units
manufactured by:
SAPPHIRE SCIENTIFIC
2604 Liberator
Prescott, AZ 86301
USA
The information contained in this document is
subject to change without notice and does not
represent a commitment on the part of
SAPPHIRE SCIENTIFIC.
All rights reserved. Copyright 2013 by
SAPPHIRE SCIENTIFIC. No part of this
work may be used or reproduced in any form or
means without the express written consent and
permission of SAPPHIRE SCIENTIFIC.
Published by SAPPHIRE SCIENTIFIC.
First printing: November, 2013
Rev B: August 2014
Printed in USA
MODEL 460SS
PART# 49-100
MODEL 460SS
®
MANUAL
®
I
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Table of Contents
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Summary of Contents for Sapphire Audio 460SS
- Page 1 First printing: November, 2013 Rev B: August 2014 Do not alter or modify your 460SS in any way. Use only replacement parts Printed in USA authorized by SAPPHIRE SCIENTIFIC, Inc. Modifications or use of unapproved parts could ®...
- Page 2 SAPPHIRE SCIENTIFIC LIMITED WARRANTY Sapphire Scientific Model 460SS What Does This Warranty Cover? This warranty covers the Sapphire Scientific Model 460SS and is provided to the original purchaser only. How Long Does This Warranty Last? This warranty runs for: Two (2) years from the date of installation on parts and labor (Excluding normal maintenance items.) Factory installed original belts are covered for 500 hours.
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Page 3: Table Of Contents
SECTION FOUR: MAINTENANCE and SERVICE 6. MAINTENANCE CHART .......................25 7. MAINTENANCE ........................26 8. GENERAL SERVICE ADJUSTMENTS ................31 9. TROUBLESHOOTING ......................34 SECTION FIVE: PARTS and ACCESSORIES 10. ILLUSTRATED PARTS LISTINGS ..................41 11. ACCESSORIES ........................65 ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 4: Section One: General Information
Installation requirements ..................6 Fuel requirements....................6 Engine oil requirements ..................6 Chemical requirements ..................7 Water requirements .....................7 2. RECEIVING YOUR TRUCKMOUNT UNIT Dealer responsibility ...................8 Acceptance of shipment ..................8 Equipment listing ....................8 Optional equipment .....................8 ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 5: Safety
1. SAFETY For Your Safety! ® The following WARNING labels are on your MODEL 460SS 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 DO NOT remove these decals. - Page 6 When routing fuel lines 8. NEVER service this unit while it is running. DO NOT configure the hose in any locations High speed mechanical parts as well as high ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 7 23. WARNING! DO NOT alter or modify 16. NEVER cut or splice any of the vehicle fuel your 460SS in any way. Use only replacement lines during fuel line installation. This will parts authorized by SAPPHIRE SCIENTIFIC, result in fuel leaks and potentially dangerous Inc.
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Page 8: Specifications
Vacuum Pump Hub…………………………………... 185 inch/lbs. 15.4 ft/lbs. JET SIZING SAPPHIRE SCIENTIFIC recommends a minimum #6 floor tool jet size. We do not ® recommend using a #4. Using larger jet sizes on your MODEL 460SS unit may reduce cleaning temperatures. ®... -
Page 9: Installation Requirements
It is never recommended to extend oil change intervals past 100 hours. ® 3. If mounting in a trailer, the MODEL 460SS console must be positioned so that it balances NOTE: Some oil will settle into the oil cooler properly with respect to the trailer axle. -
Page 10: Chemical Requirements
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. ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 11: Receiving Your Truckmount Unit
Ford 2011+…………………. 69-331 EQUIPMENT LISTING Ford Box Truck 2004+…….. 68-077 Ford Transit Connect ……... 69-261S SAPPHIRE SCIENTIFIC MODEL 460SS Nissan NV………………….. 69-376 console Operation and Service Manual Installation mounting plates and bolt down ... -
Page 12: Section Two: Installation
Fastening down the unit and waste tank ............10 Dimensional diagrams ..................11 Installation of fuel lines ..................12 Trailer fuel tank and fuel line installation ............12 Battery Connection ....................12 Fire extinguisher ....................12 Console to waste tank connection ..............13 ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 13: Installation
Do not alter or modify 2. Operating weight of the complete installation your 460SS in any way. Use only replacement (which includes water weight) with waste tank parts authorized by SAPPHIRE SCIENTIFIC, and ALL accessories MUST NOT exceed the Inc. -
Page 14: Dimensional Diagrams
DIMENSIONAL DIAGRAM WITH STANDARD RECOVERY TANK ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 15: Installation Of Fuel Lines
A, B, and C type fires be of enclosed trailer or vehicle. installed into any commercial vehicle NEVER carry gasoline or flammable materials in an enclosed trailer or vehicle. ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 16: Console To Waste Tank Connection
CONSOLE TO WASTE TANK CONNECTION ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 17: Section Three: Operation
Priming the chemical pump ................20 Automatic waste pump ..................20 Operation......................21 Cleaning ......................21 Upholstery cleaning ...................21 Stair tool cleaning ....................21 Flood restoration/extraction ................21 Shut down and daily maintenance ..............21 Freeze protection ....................22 ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 18: Systems
Inlet Pressure Regulator (where to the cleaning tool. Solution pressure is incoming water pressure is reduced to 20 psi) controlled by the Outlet Pressure Regulator. and into the water box. ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 19: Vacuum System
The vacuum pump also heats incoming air as necessary for the extraction process. A it is compressed. The hot discharged air is vacuum nozzle applied to the carpet surface forced down removes moisture, dirt and spent chemicals. ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 20: Chemical Pumping System
The chemicals then flow through the stainless steel chemical pump, the chemical is then ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 21: Operation
DO NOT run this unit in an enclosed maintain your SAPPHIRE SCIENTIFIC area. DO NOT operate this unit where the ® MODEL 460SS mobile cleaning unit. The exhaust may enter a building doorway, ® MODEL 460SS unit is easy to operate, window, vent or any other opening. - Page 22 1. Connect the water supply hose to the water inlet quick connector on the front of the unit. Connect the hose to the faucet. ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
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Page 23: Starting The Unit
#6. connection and the other end to an acceptable ® Using larger jet sizes on your MODEL 460SS waste disposal. unit may reduce cleaning temperatures. 2. Turn the pump-out switch located on the front console control panel to the ON position. -
Page 24: Operation
For heavily 6. Allow the unit to run for at least 5 minutes soiled carpets, the wand may be used in a with bypass valve open. This will also help to ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 25: Freeze Protection
Remove and clean the filter if building. there is any lint or debris present. WINTERIZING YOUR UNIT WITH ANTI- FREEZE: ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... - Page 26 The unit is now winterized. 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. REMOVING ANTI-FREEZE FROM THE UNIT: ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
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Page 27: Section Four: Maintenance And Service
Chemical Pump ....................31 Packing Nut Adjustment, Chemical Metering and Selector Valves ....32 Pressure Regulator ....................33 9. TROUBLESHOOTING Engine .......................34 Blower / Vacuum Pump..................36 Water Pump ......................37 Chemical System ....................38 Temperature Control ..................39 ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 28: Maintenance Chart
*****Check pulley and hub set screws after first 50 hours of operation, and again at 100 hours of operation. ******Or every 6 Months. Whichever comes first. *******Or Yearly. Whichever comes first. ********Re-tension all belts after first 25 hours then at every 100 hours of operation. ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 29: Maintenance
A planned preventative overfill. maintenance program will ensure that your ® SAPPHIRE SCIENTIFIC MODEL 460SS 2. Change the oil after the first 5 hours of has optimum performance, long operating life, operation. Thereafter, change oil and oil filter and a minimum amount of down time. -
Page 30: Vacuum Pump
Too much oil will result in overheating. 2. A lubrication cup has been provided at the front of the console, to prevent rust from building up inside of the vacuum pump. ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 31: Water Pump
# 13-030). Change the crankcase oil every 500 should be inspected and cleaned daily. hours thereafter. Vacuum Pump: Belt Replacement Procedures for Model 460SS: When removing the vacuum inlet filter, grip ONLY use EPDM belts: the plastic hexagon section of the filter. -
Page 32: Drive Belts, Pulleys And Hubs
Remove any debris present. Inspect again after 2 and 4 weeks. Thereafter, inspect the strainer and screen at least monthly. If a frequent build-up of debris is noticed, inspect and clean more frequently. ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 33: Battery
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. ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 34: General Service Adjustments
2. Adjust the position of the belt tensioning adjusting bolt until the proper belt tension is achieved (1/2” deflection in the center of the belts, half way between the pulleys). ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 35: Packing Nut Adjustment, Chemical Metering And Selector Valves
Chemical Metering Valve lubricant. (Part # 13-003) and re-install. CHEMICAL PUMP ® The MODEL 460SS unit features a stainless steel chemical pump and metering system. The Packing Nut chemical pump requires only the replacement of the diaphragm and check valves (see page 56). -
Page 36: Pressure Regulator
Relieve all pressure from the water system. d) Remove the cap from the pressure regulator and remove the stem with long nose pliers. e) Clean and lubricate stem. f) Reassemble pressure regulator ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 37: Troubleshooting
Pump-out circuit breaker on control operating normally. determine the cause of the tripped panel has been tripped. circuit breaker, press the reset button. Inspect check valve for debris or Clean or replace if necessary. damage. ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... - Page 38 Descale unit, repair or replace Flow restriction caused by hard damaged plumbing components as water scaling. Excessive heating necessary. Install water softener. Not enough water flow. Check jet size of tool. ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
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Page 39: Blower / Vacuum Pump
Replace any defective hoses. Remove, pressure gauge reads normal. manifold, or the solution screen is inspect, and clean the solution screen. clogged De-scale unit and install a water softener, if necessary. ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 40: Water Pump
Debris clogging water lines or water Clean or replace as needed. inlet disconnect. Belts loose or broken Re-tension or replace as needed. Loss of pump prime Manually prime water pump. Temperature Balance Orifice missing Replace Orifice ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 41: Chemical System
Tighten valve packing nut (see Internal leak in chemical valve causing “General Service Adjustments” section continual flow through prime tube in this manual). Replace valve, if returning to container. necessary. ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 42: Temperature Control
Check to see if the RTD sensor is Unit shut down when pump is RTD sensor not connected plugged in. If it is, replace the RTD engaged sensor Bad controller Replace the controller ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... -
Page 43: Section Five: Parts And Accessories
2003 Chevy and GMC Full Size Van Fuel Line Install .........68 1997-2002 Dodge Full Size Van Fuel Line Install .........69 Fuel Line Bulkhead Installation..............70 Fuel Pump Assembly Installation..............71 Fuel Supply & Return Line Installation............72 ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... - Page 44 70-460 SS, CONSOLE ASSEMBLY, DETAIL 1 ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 45 70-460 SS, CONSOLE ASSEMBLY, DETAIL 2 ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 46 69-576, ASSEMBLY, FRAME AND PANELS, DETAIL 1 ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 47 69-576, ASSEMBLY, FRAME AND PANELS, DETAIL 2 ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 48 69-196, ASSEMBLY, INSTRUMENT PANEL ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 49 69-568, ASSEMBLY, ENGINE ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 50 69-563, ASSEMBLY, OIL COOLER ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 51 69-558, ASSEMBLY, VACUUM BLOWER ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 52 69-049 ASSEMBLY, VACUUM RELIEF ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 53 69-471 ASSY, WATER PUMP ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 54 68-180 KIT, WATER PUMP 46-060 CHEMICAL PUMP ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 55 CHEMICAL SYSTEM HOSE ROUTING AND IDENTIFICATION ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 56 69-577 ASSY, THERMAL WELL, BOM TABLE ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 57 69-577 ASSY, THERMAL WELL ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 58 69-217 ASSEMBLY, MANIFOLD BLOCK ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 59 69-569 ASSEMBLY, REGULATOR BRACKET ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 60 69-438 ASSEMBLY, VACUUM INLET BRACKET ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 61 69-184 ASSEMBLY, BLOWER, BELT GUARD 69-211 ASSEMBLY, BRACKET QD FITTING ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 62 69-635 ASSEMBLY, EA MODULE ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 63 69-649 ASSY, TERMINAL BLOCK 8 CIRCUIT ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 64 69-241 ASSY, WASTE TANK ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 65 ELECTRICAL DIAGRAM ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 66 ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 67 44-067 DECAL, 44-066, DECAL WARNING, ROTATING MACHINERY WARNING READ MANUAL WARNING ELECTRICAL SHOCK 44-104, DECAL CAUTION, CHEM PUMP PSI 44-090 DECAL, MANIFOLD MAINTENANCE 44-079 DECAL, UNLEADED FUEL ONLY ® 44-102 DECAL, 2500HS ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
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Page 68: Accessories
HOSE, WTR 1 IN HRZ 100 FT BULK 10-178 BOLT, TAP 5/16-18 X 2-1/2 HXHD Z 10-068 BOLT, TAP ¼-20 X 2-1/2 11-013 LKNUT, ¼-20 NYLOK 11-029 NUT, 5/16-18 NYLOK 12-017 WASHER, FLAT 5/16 SAE ZINC ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B... - Page 69 FTTG, BRB 1/8P X 5/16 H BR 21-006 FTTG, BRB 1/4P X 5//16H BR 18-028 HOSE, 3/16 X 25 (1/8P X 1/8P NO COVER) 14-011 CLAMP, HOSE FUEL # 6 14-000 CLAMP, HOSE #12 ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 70 ELL,1/4 IN LG STREET BRASS 21-086 FTTG, BULKHEAD 1/4 IN BRASS 21-116 ELL, 1/8 FP X 1/8 FP BRONZE 66-030 ADAPTOR,FUEL NECK(CHEVY) 18-027 HOSE, 3/16 X 5 (1/8P X 1/8P NO CVR) ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 71 ELL, STREET 1/8 IN BRASS 21-007 FTTG, BRB 1/8P X 5/16 H BR 21-039 ELL,1/4 IN LG STREET BRASS 21-006 FTTG, BRB 1/4P X 5//16H BR 21-086 FTTG, BULKHEAD 1/4 IN BRASS ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 72 FTTG, BRB 1/8P X 5/16 H BR 18-028 HOSE, 3/16 X 25 (1/8P X 1/8P NO COVER) 21-086 FTTG, BULKHEAD 1/4 IN BRASS 21-006 FTTG, BRB 1/4P X 5//16H BR 21-039 ELL,1/4 IN LG STREET BRASS ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 73 Inside the vehicle, attach the hose barb fitting and connect the fuel line from the console. Drill a 1/2 inch hole nearby the bulkhead fitting for the fuel pump electrical extension harness to pass through. Figure 1. Fuel Line Bulkhead Assembly ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 74 Remove the housing lid from the fuel pump assembly. Use the supplied Tek screws to install the lid of the fuel pump housing to the vehicle. Figure 2. Fuel Pump Assembly Detail ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
- Page 75 Connect the electrical extension harness to the fuel pump harness, running the other end up through a hole in the floor of the vehicle, connecting to the console harness. Figure 4. Vehicle Underside Fuel Line Installation ® MODEL 460SS SAPPHIRE SCIENTIFIC PART# 49-100 REV B...
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