Sapphire Audio PRO-1200 SE User manual

1 SAPPHIRE SCIENTIFIC MODEL PRO-1200 PART # 49-074 REV A
Congratulations on your purchase of the
MODEL PRO-1200® Direct Drive
cleaning unit. This instruction/parts
manual is a guide for operating and
servicing your SAPPHIRE
SCIENTIFIC Direct Drive unit.
Proper operation and service are necessary to
ensure the outstanding performance of this unit.
When properly maintained, your Truck-mount
will have a long and trouble-free life.
The following service methods outlined in this
manual are detailed in a manner that operation
and servicing may be performed properly and
safely. Because service levels vary due to the
skill of the mechanic, tools and parts
availability, ensure that prior to attempting any
repair, you are familiar with this equipment and
have the proper tools. Any questions regarding
the operation, service, or repair of this unit
should be directed to your nearest SAPPHIRE
SCIENTIFIC dealer.
The headings WARNING and CAUTION are
utilized to warn you that steps must be taken to
prevent personal injury or damage to the
equipment. Please make sure that you have read
and understand these instructions entirely before
proceeding with the operation of this unit.
THIS UNIT MUST BE INSTALLED BY
THE DEALER THAT YOU PURCHASED
IT FROM IN ACCORDANCE WITH THE
SAPPHIRE SCIENTIFIC INSTALLATION
PROCEDURES.
BE SURE TO FILL OUT THE WARRANTY
CARD ONLINE AT
WWW.SAPPHIRESCIENTIFIC.COM
Record your units’ serial number here for future
reference or if you should need to contact the
factory in the future for any reason.
S/N:
This service and operations manual is written
specifically for SAPPHIRE SCIENTIFIC
MODEL PRO-1200® Direct Drive 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 2011 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: June 2011
Printed in USA
MODEL PRO-1200® MANUAL
PART# 49-074

3 SAPPHIRE SCIENTIFIC MODEL PRO-1200 PART # 49-074 REV A
Table of Contents
SECTION ONE: GENERAL INFORMATION 4
1. SAFETY ...............................................................................................................................5
Safety, Specifications, Installation, Fuel, Engine Oil, Chemical, Water Requirements
2. RECEIVING YOUR DIRECT DRIVE UNIT .................................................................9
Dealer Responsibility, Acceptance of Shipment, Equipment Listing, Optional Equipment
SECTION TWO: INSTALLATION 10
3. INSTALLATION ...............................................................................................................11
Lifting the Unit into the Vehicle, Positioning the Unit into the Vehicle, Fastening Down the Unit and
Waste Tank, Front End Installation, Electrical Installation and Console Installation
SECTION THREE: OPERATION 41
4. SYSTEMS ...........................................................................................................................42
Water Pumping System, Heat Transfer System, Vacuum System, Chemical System
5. OPERATION .....................................................................................................................45
Equipment setup, Instrumentation, Starting Your Unit, Priming the Chemical Pump, Waste Pump,
Operation, Cleaning, Upholstery Cleaning, Stair Tool Cleaning, Flood Restoration, Shut Down and
Daily Maintenance, Freeze Protection.
SECTION FOUR: MAINTENANCE and SERVICE 56
6. MAINTENANCE CHART ...............................................................................................57
7. MAINTENANCE ...............................................................................................................58
8. GENERAL SERVICE ADJUSTMENTS ........................................................................61
9. TROUBLESHOOTING ....................................................................................................64
SECTION FIVE: PARTS and ACCESSORIES 69
10. ILLUSTRATED PARTS LISTINGS ...............................................................................70
11. ACCESSORIES ................................................................................................................95

SECTION 1
PART # 49-074 REV A SAPPHIRE SCIENTIFIC MODEL PRO-1200 4
SECTION 1:
GENERAL INFORMATION
1. SAFETY
Safety ......................................................................................................5
Specifications ..........................................................................................7
Installation requirements .........................................................................8
Chemical requirements ...........................................................................8
Water requirements .................................................................................8
2. RECEIVING YOUR DIRECT DRIVE UNIT
Dealer responsibility .............................................................................. 9
Acceptance of shipment ......................................................................... 9
Equipment listing ................................................................................... 9
Optional equipment ................................................................................ 9

SECTION 1
5 SAPPHIRE SCIENTIFIC MODEL PRO-1200 PART # 49-074 REV A
1. SAFETY
For Your Safety!
The following WARNING labels are on
your MODEL PRO-1200® 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.

SECTION 1
PART # 49-074 REV A SAPPHIRE SCIENTIFIC MODEL PRO-1200 6
!
1. Read the operator’s manual before
starting this unit.
Failure to adhere to instructions could result in
severe personal injury or could be fatal.
2. DO NOT place hands, feet, hair, clothing
or any body parts near rotating or moving
parts. Rotating machinery can cause severe
injury or death.
3. 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.
4. 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.
5. Blower exhaust 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.
6. 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.
7. 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.
8. DO NOT damage the vehicle in any way
during the installation. When routing fuel lines
DO NOT configure the hose in any locations
where the hose or vehicle could be damaged.
Avoid contact with moving parts, hot surfaces,
brake lines, fuel lines, catalytic converters,
exhaust pipes, mufflers or sharp objects.
9. DO NOT exceed your vehicles weight
limit. The console with waste tank and
accessories weighs approximately 705 pounds.
Make certain that the vehicle has the correct
axle rating. This will prevent unsafe or
hazardous driving conditions.
10. 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.
11. Always keep your vehicle clean and
orderly. Wands, tools and accessories must be
securely stowed while driving the vehicle.
12. All high-pressure hoses must be rated at
3000 PSI and have a heat rating of 250
degrees F. Thermoplastic hoses do not meet
this criterion and should never be used.
Severe burns and other injuries could
result if hoses do not meet these
requirements.
13. Ensure that you have received proper
training from the distributor that you
purchased the unit from prior to operation.
14. This unit produces high pressure and high
temperatures. Improper use could result in
serious injury.
15. DO NOT modify this unit in any manner.
Any modification could result in serious
injury or fatality. This includes the use of any
open ended hoses

SECTION 1
7 SAPPHIRE SCIENTIFIC MODEL PRO-1200 PART # 49-074 REV A
SPECIFICATIONS
Van Engine Speed (Low)……………….. 1100 RPM (no load)
Van Engine Speed (Medium)……………1300 RPM (no load)
Van Engine Speed (High)...........................1500 RPM (no load)
Water Pump RPM……………………… .1025 RPM
Vacuum Pump RPM……………………..2350 RPM
Water Flow Rate…………………………5.0 GPM (maximum)
Water Pump Pressure……………………1200 PSI (maximum)
Vacuum Relief Valve…………………....14 in. Hg
Waste Tank Capacity……………………145 gal
Waste Tank Shut-Off……………………100 gal
Console Weight…………………………..480 lbs
Console Weight (with waste tank
& accessories) Approximately…………...705 lbs.
TORQUE VALUES
Pulley Hub 180 inch/lbs. (15 ft/lbs)
JET SIZING
SAPPHIRE SCIENTIFIC recommends that the total floor tool tip size be #4 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-molded 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

SECTION 1
PART # 49-074 REV A SAPPHIRE SCIENTIFIC MODEL PRO-1200 8
INSTALLATION REQUIREMENTS
Prior to beginning the installation, read the
ENTIRE “Installation” section of this manual.
Since the MODEL PRO-1200® Direct Drive unit
weighs (with waste tank and accessories)
approximately 705 lbs., 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.
!
The console and waste tank with accessories
must NOT exceed the vehicle’s axle weight
limit.
2. The vehicle tires must have a load rating in
excess of the combined unit and vehicle weight.
3. 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.
4. Insulation under rubber mats should be
removed prior to installation of the unit.
CHEMICAL REQUIREMENTS
The SAPPHIRE SCIENTIFIC MODEL PRO-
1200 ® Direct Drive unit’s unique last step
chemical injection system can be used with a wide
variety of water diluted chemical compounds,
either acidic or alkaline, depending on the work to
be performed. We recommend using only
SAPPHIRE SCIENTIFIC brand chemistry.
WATER REQUIREMENTS
Because hard water deposits will damage the
plumbing and heat exchange systems on this unit,
SAPPHIRE SCIENTIFIC recommends that a
high quality water softener be used in areas where
the water hardness exceeds 3½ grains. If a water
softener is used, it must have a flow capacity of at
least five (5) GPM or greater, without any hose
constrictions.
The use of a water softening system will reduce
maintenance and reduce down time caused by
hard water scaling. It will also enhance the
performance of cleaning chemicals, which will
result in greater efficiency in lower
concentrations.

SECTION 1
9 SAPPHIRE SCIENTIFIC MODEL PRO-1200 PART # 49-074 REV A
2. RECEIVING YOUR
DIRECT DRIVE UNIT
DEALER RESPONSIBILITY
THE SAPPHIRE SCIENTIFIC DEALER
THAT YOU PURCHASED THIS DIRECT
DRIVE 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 PRO-1200® Direct Drive 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 PRO-1200® unit should arrive with the
following items as well as any optional
accessories:
EQUIPMENT LISTING
SAPPHIRE SCIENTIFIC MODEL PRO-
1200® console.
Operation and Service Manual
Installation mounting plates and bolt down kit.
Hose clamps for vacuum hoses.
Waste tank with shutoff switch.
Waste tank filter and stainless steel strainer
basket.
Two sections of 2 in. x 50 ft. vacuum hose
One section of 2.5 in. x 50 ft. vacuum hose.
Two 50 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. ASSY, WASTE PUMP OUT
Part #68-158

PART # 49-074 REV A SAPPHIRE SCIENTIFIC MODEL PRO-1200 10
SECTION 2:
INSTALLATION
3. INSTALLATION
Lifting the unit into the vehicle ..............................................................11
Positioning the unit into the vehicle.......................................................11
Fastening down the unit and waste tank ................................................11
Front End Preparation ............................................................................12
Front End Kit Installation ......................................................................18
Electrical Installation .............................................................................30
Driveshaft and Console Installation .......................................................33
Speed Adjustment ..................................................................................39

SECTION 2
11 SAPPHIRE SCIENTIFIC MODEL PRO-1200 PART # 49-074 REV A
3. INSTALLATION
!!!
This unit must be bolted to the floor of
the vehicle by an authorized
SAPPHIRE SCIENTIFIC
DISTRIBUTOR.
LIFTING THE UNIT INTO
THE VEHICLE
Because the SAPPHIRE SCIENTIFIC
MODEL PRO-1200® console weighs
approximately 480 lbs., a forklift is
necessary to place the unit into the vehicle.
Place the forks under the unit. Using two
“C” clamps, secure the console to the
forks. Move the unit into desired position.
POSITIONING THE UNIT
INTO THE VEHICLE
MODEL PRO-1200® is designed for a
rear door installation and must properly
align with the drive shaft.
The complete unit with waste tank and
accessories MUST NOT exceed the
vehicle’s axle weight limit.
FASTENING DOWN THE
UNIT AND WASTE TANK
!!!
Prior to drilling any holes in the vehicle
floor, ensure that while drilling, you will
not damage the fuel tank, fuel lines, or
any other vital components which could
affect the safety or operation of the
vehicle.
A. The console and waste tank mounting
holes will serve as a template. Drill four
(4) 13⁄32 in. diameter holes for the console
and eight (8) 13⁄32 in. diameter holes for the
waste tank.
B. Using the provided mounting hardware kit:
1. Insert four (4), grade 5, ⅜-16 × 4 in. hex
head cap screws with flat washers through
the MODEL PRO-1200® console
mounting holes, and eight (8),grade 5, ⅜-
16 × 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 ⅜-16 hex head lock
nuts on to the mounting bolts and tighten
until the console and waste tank are firmly
attached to the vehicle floor.

SECTION 2
PART # 49-074 REV A SAPPHIRE SCIENTIFIC MODEL PRO-1200 12
FRONT END PREPARATION
1. Put the vehicle in park on level ground.
Remove the negative battery cable.
2. Remove anti-freeze overflow tank by
un-screwing the 10mm bolt. Set aside
and take care not to let flow out of the
overflow, lid or hose.

SECTION 2
13 SAPPHIRE SCIENTIFIC MODEL PRO-1200 PART # 49-074 REV A
3. Remove air intake tube by un-
screwing the two 10mm bolts and
removing the MAF sensor
connector.
4. Loosen clamps and remove air
tube.
5. Remove the clamp from the upper
radiator hose with a flathead
screwdriver.

SECTION 2
PART # 49-074 REV A SAPPHIRE SCIENTIFIC MODEL PRO-1200 14
6. Remove bolt holding oil fill
tube with 13mm socket to make
room to remove the upper radiator
fan shroud.
7. Remove these bolts
with a 10mm socket
from both sides of the
upper fan shroud then
remove upper shroud.
Caution! Take care
not to damage the
radiator fins.

SECTION 2
15 SAPPHIRE SCIENTIFIC MODEL PRO-1200 PART # 49-074 REV A
8. Remove the fan.
Use a thin 36mm
wrench. Note:
Keep the belt on for
tension; it may be
necessary to add
more tension to keep
the belt from
slipping.
9. Remove the
seats using an
18mm socket on
4 bolts. Make
sure to disconnect
the wire from
under the driver’s
seat.
10. Remove these
panels on the
instrument panel
with a 10mm
socket.

SECTION 2
PART # 49-074 REV A SAPPHIRE SCIENTIFIC MODEL PRO-1200 16
11. Remove the
center glove box by
popping it out of the
console.
12. Remove the cup
holders by removing
the 4 10mm bolts

SECTION 2
17 SAPPHIRE SCIENTIFIC MODEL PRO-1200 PART # 49-074 REV A
13. Detach the 4
latches to remove
the dog house from
around the engine.

SECTION 2
PART # 49-074 REV A SAPPHIRE SCIENTIFIC MODEL PRO-1200 18
FRONT END KIT INSTALLATION
15. Locate puller jaws
on three tabs as shown.
Photo is taken on the
back of the balancer.
14. Remove balancer
bolt (right handed
thread) after installing
flywheel holding tool.
(DO NOT DISCARD
BOLT). You will
need a heavy duty
impact gun or breaker
bar.

SECTION 2
19 SAPPHIRE SCIENTIFIC MODEL PRO-1200 PART # 49-074 REV A
16. Place
crankshaft end
protector in
crankshaft, and
then use the
balancer puller to
remove balancer.
17. When
installing supplied
modified balancer,
be sure end of
crankshaft and
inner diameter of
modified balancer
are clean and
lightly oiled.
18. Slide
modified
balancer over
shaft and thread
installation rod
into crankshaft
at least 1”.

SECTION 2
PART # 49-074 REV A SAPPHIRE SCIENTIFIC MODEL PRO-1200 20
19. Remove the
installation tool.
Check that the end of
the crankshaft is
recessed in the
balancer 0.094”-
0.176”. This is
important to assure
balancer is properly
seated.
20. Use OLD balancer
bolt and tighten to 240
ft lb torque. Remove
bolt, wipe balancer
clean and install new
bolt. DO NOT use any
lubricant, Loc-Tite,
etc., of any kind.
Tighten bolt to 37 ft lb.