Sapphire Audio 2500HS User manual

PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® I
Congratulations on your purchase of the
MODEL 2500HS® 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
2500SS 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
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 2500HS® 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: August, 2010
Revised: October 2010; Rev B
Revised: May 2012; Rev C
Revised: August 2012; Rev D
Revised: November 2012; Rev E
Revised: October 2013; Rev F
Printed in USA
MODEL 2500HS® MANUAL
PART# 49-059

PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® II
SAPPHIRE SCIENTIFIC LIMITED WARRANTY
Sapphire Scientific Model 2500HS
What Does This Warranty Cover?
This warranty covers the Sapphire Scientific Model 2500HS 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. Water box, recovery tank and
frame are covered for five years. All other components including seals, o-rings and electrical
components are covered for the entire two year warranty period.
What Sapphire Scientific Will Do:
If a defect in materials or workmanship occurs within 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:
Two (2) years from the installation date on parts and labor. It is strongly recommended that this truck mount be used
with, and only with, Sapphire Scientific Chemicals and as directed by label instructions on chemical bottles.
OTHER THAN THE WARRANTIES PROVIDED HEREIN, SAPPHIRE SCIENTIFIC MAKES NO EXPRESS OR
IMPLIED, ORAL OR WRITTEN WARRANTIES WITH RESPECT TO THIS PRODUCT OR WORKMANSHIP AND
ALL WARRANTIES IMPLIED BY LAW INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR 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); and (c) have the serial number and original proof of installation date available. Proof
of proper maintenance may be required before warranty is granted.
Contact us at:
Sapphire Scientific
2604 Liberator, Prescott, AZ 86301
Phone: [phone]
If our dealer uncovers a defect we will repair or replace the product, at our election. Ground shipping and transportation
costs will be covered by the manufacturer. Returning defective parts to the manufacturer, if required, shall be the
responsibility of the purchaser. Warranty may be denied if defective parts are not returned within the allotted 30 days. If it
is determined that there is no defect in the product, or that the defect 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.
.

PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® III
Table of Contents
SECTION ONE: GENERAL INFORMATION 1
1. SAFETY .................................................................................................................................2
Safety, Specifications, Installation, Fuel, Engine Oil, Chemical, Water Requirements
2. RECEIVING YOUR TRUCKMOUNT UNIT ...................................................................8
Dealer Responsibility, Acceptance of Shipment, Equipment Listing, Optional Equipment
SECTION TWO: INSTALLATION 9
3. INSTALLATION .................................................................................................................10
Lifting the Unit into the Vehicle, Positioning the Unit into the Vehicle, Fastening Down the Unit
and Waste Tank, Dimensional Diagrams, Installation of Fuel Lines, Trailer Fuel Tank and Fuel
Line Installation, Battery Connection, Fire Extinguisher, Console to Waste Tank Connection
SECTION THREE: OPERATION 14
4. SYSTEMS .............................................................................................................................15
Water Pumping System, Heat Transfer System, Vacuum System, Chemical System
5. OPERATION .......................................................................................................................18
Equipment setup, Instrumentation, Starting Your Unit, Priming the Chemical Pump, Waste Pump,
Operation, Cleaning, Upholstery Cleaning, Stair Tool Cleaning, Flood Restoration, Shut Down
and Daily Maintenance, Freeze Protection.
SECTION FOUR: MAINTENANCE and SERVICE 25
6. MAINTENANCE CHART .......................................................................................................26
7. MAINTENANCE .......................................................................................................................27
8. GENERAL SERVICE ADJUSTMENTS ................................................................................32
9. TROUBLESHOOTING ............................................................................................................35
SECTION FIVE: PARTS and ACCESSORIES 40
10. ILLUSTRATED PARTS LISTINGS .....................................................................................41
11. ACCESSORIES .......................................................................................................................66

PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 1
SECTION 1:
GENERAL INFORMATION
1. SAFETY
Safety ..................................................................................................................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
Acceptance of shipment ......................................................................................8
Equipment listing ................................................................................................8
Optional equipment .............................................................................................8

SECTION 1
PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 2
1. SAFETY
For Your Safety!
The following WARNING labels are on
your MODEL 2500HS® 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# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 3
!
1. Read the operator’s manual before
starting this unit.
Failure to adhere to instructions could result in
severe personal injury or could be fatal.
2. Operate this unit and equipment only in a
well-ventilated area.
Exhaust fumes contain carbon monoxide,
which is an odorless and deadly poison that can
cause severe injury or death. DO NOT run this
unit in an enclosed area. DO NOT operate this
unit where the exhaust may enter a building
doorway, window, vent or other opening.
3. Gasoline is extremely flammable and its
vapors can explode if ignited.
Store gasoline only in approved containers, in
well-ventilated, unoccupied buildings and
away from sparks or flames. Never carry
gasoline or any flammable materials in the
vehicle. Fumes could accumulate inside of the
vehicle and ignite, causing an explosion.
4. This unit must be operated with the
vehicle doors and windows open in order to
ensure adequate ventilation to the engine.
5. DO NOT operate unit if gasoline is spilled.
Do not turn ignition switch until the gasoline
has been cleaned up. Never use gasoline for
cleaning purposes.
6. DO NOT place hands, feet, hair, clothing or
any body parts near rotating or moving parts.
Rotating machinery can cause severe injury or
death.
7. NEVER operate this unit without belt and
safety guards. High speed moving parts, such
as belts and pulleys, should be avoided while
the unit is running. Severe injury, fatality or
damage may result.
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 sulfuric acid. To
prevent acid burns, avoid contact with skin,
eyes and clothing. Batteries also produce
explosive hydrogen gases while charging. To
prevent fire or explosion, charge batteries only
in a well-ventilated area. Keep sparks, open
flames, as well as other sources of ignition
away from battery at all times. Remove all
jewelry prior to servicing batteries. Keep
batteries out of the reach of children.
Before disconnecting the negative (−) ground
cable, ensure that all switches are in the off
position. If on, a spark could occur at the
ground connection terminal which could cause
an explosion if hydrogen gas or gasoline
vapors are present. 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.

SECTION 1
PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 4
15. DO NOT damage the vehicle in any way
during the installation. When routing fuel lines
DO NOT configure the hose in any locations
where the hose or vehicle could be damaged.
Avoid contact with moving parts, hot surfaces,
brake lines, fuel lines, catalytic converters,
exhaust pipes, mufflers or sharp objects.
16. NEVER cut or splice any of the vehicle
fuel lines during fuel line installation. This will
result in fuel leaks and potentially dangerous
conditions. Use only the provided fuel hose for
fuel lines. When going through the vehicle
floor with fuel lines, always utilize bulkhead
adaptors. This will prevent fuel leaks and
ensure that hoses are not punctured by vehicle
vibration abrasion.
17. DO NOT exceed your vehicles weight
limit. The console with waste tank and
accessories weighs approximately 1152
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 in 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. 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.
21. 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.
23. WARNING! DO NOT alter or modify
your 2500SS 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
includes the use of any open ended hoses
CALIFORNIA PROPOSITION 65
WARNING: ENGINE EXHAUST FROM
THIS PRODUCT CONTAINS
CHEMICALS KNOWN BY THE STATE
OF CALIFORNIA TO CAUSE CANCER,
BIRTH DEFECTS, OR OTHER
REPRODUCTIVE HARM.
ALL FUEL LINES MUST MEET CARB
III and EPA PHASE 3 LOW
PERMEABILITY REQUIRMENTS.
ALL FUEL STORAGE TANKS MUST
MEET CARB 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.

SECTION 1
PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 5
SPECIFICATIONS
Engine Speed .........................................................................2900 rpm (High Speed No Load)
..........................................................................1500 rpm (Idle No Load)
Water Pump RPM ..............................................................................1639 rpm
Vacuum Pump RPM ..........................................................................3040 rpm
Water Flow Rate ................................................................................5.6 GPM (maximum)
Water Pump Pressure .........................................................................2500 PSI (maximum)
Vacuum Relief Valve .........................................................................14 in. Hg
Waste Tank Capacity .........................................................................90 gal.
Waste Tank Shut-Off .........................................................................75 gal.
Console Weight ..................................................................................908 lbs.
Console Weight (with standard waste tank and hoses) ......................1152 lbs.
Operating Weight (full standard waste tank and water box) .............1818 lbs.
TORQUE VALUES
Engine Hub Rear……………………………………... 160 inch/lbs. 13.3 ft/lbs.
Engine Hub Front…………………………………….. 185 inch/lbs. 15.4 ft/lbs.
Vacuum Pump Hub…………………………………... 185 inch/lbs. 15.4 ft/lbs.
JET SIZING
SAPPHIRE SCIENTIFIC recommends that the total floor tool tip size does not exceed
#6. Using larger jet sizes on your MODEL 2500HS® unit may reduce cleaning
temperatures.

SECTION 1
PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 6
INSTALLATION REQUIREMENTS
Prior to beginning the installation, read the
ENTIRE “Installation” section of this manual.
Since the MODEL 2500HS® Truck mount unit
weighs (with waste tank and accessories)
approximately 1152 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. If mounting the unit in a trailer, ensure that the
trailer is rated for the total weight of the unit and
trailer. Electric or hydraulic brakes must be
provided, and strict compliance with all State and
Federal laws must be maintained.
3. If mounting in a trailer, the MODEL 2500HS®
console must be positioned so that it balances
properly with respect to the trailer axle. With a
minimum of ten percent (10%) of the unit’s total
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 is 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.
FUEL REQUIREMENTS
Use unleaded fuel ONLY. Use only fresh, clean
unleaded gasoline with a minimum octane rating
of 87. Do Not use high octane gasoline. Gasoline
with up to, not exceeding, 10% ethanol is
acceptable.
NOTE: Using other gasoline/alcohol blends
including E20 and E85 will cause damage to
engine components and will void the warranty.
ENGINE OIL REQUIREMENTS
Use high-quality oil of at least API (American
Petroleum Institute) service class SF, SG, SH, SJ
or higher. Do not use additives. High quality
30W oil is recommended. A 10W-40 synthetic
blend may be used after 50 hours of operation for
a new or rebuilt engine to allow the piston rings to
properly seat. It is never recommended to extend
oil change intervals past 100 hours.
NOTE: Some oil will settle into the oil cooler
after the engine has run following an oil change.
To maintain full engine oil levels, add .5 L/U.S. qt
oil after running the engine briefly.
Engine oil capacity
2.8 L
2.9 U.S. qts
Oil Cooler Reservoir
.5 L
.5 U.S. qts
Tightening torque
Drain Plug
32.4 to 37.3 N·m
3.3 to 3.8 kgf·m
23.9 to 27.5 lbf·ft
NOTE: Using a lower service class oil or
extending oil change intervals longer than
recommended can cause engine damage.

SECTION 1
PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 7
CHEMICAL REQUIREMENTS
The SAPPHIRE SCIENTIFIC MODEL
2500HS® Truck mount unit’s unique last step
chemical injection system can be used with a wide
variety of water diluted chemical compounds,
either acidic or alkaline, depending on the work to
be performed. We recommend using only
SAPPHIRE SCIENTIFIC brand chemistry.
WATER REQUIREMENTS
Because hard water deposits will damage the
plumbing and heat exchange systems on this unit,
SAPPHIRE SCIENTIFIC recommends that a
high quality water softener be used in areas where
the water hardness exceeds 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
PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 8
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 2500HS® 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 2500HS® unit should arrive with the
following items as well as any optional
accessories:
EQUIPMENT LISTING
SAPPHIRE SCIENTIFIC MODEL 2500HS
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 filters and stainless steel strainer
basket
Two sections of 2 in. x 50 ft. vacuum hose
Two 50 ft. sections of high pressure solution
hose
Install kit
50 ft. water supply hose with quick connect
OPTIONAL EQUIPMENT
50 ft. 2in. vacuum hose
Part # 18-003
50 ft. 2-1/2in. vacuum hose
Part # 18-333
Vacuum hose connectors
Part # 21-003
Vacuum hose reducer
Part # 19-014
High-pressure solution hoses
Part # 18-000
With shutoff valve Part # 18-001
Automatic waste pump kit
Part # 68-158
Demand pump system
Part # 68-002
FUEL HOOK-UP KITS BY VEHICLE
Chevy 1997 to 2002 FI…….. 69-003FI
Chevy 2003 FI……………... 69-018FI
Chevy 2004+ Hook-Up Kit… 69-033
Chevy Box Truck 2004+…… 69-081
Dodge 1997 to 2002 FI…….. 69-004FI
Ford FI……………………... 69-005FI
Ford 2004 – 2010…………... 69-061
Ford 2011+…………………. 69-331
Ford Box Truck 2004+…….. 68-077
Ford Transit Connect ……... 69-261S
Nissan NV………………….. 69-376

PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 9
SECTION 2:
INSTALLATION
3 INSTALLATION
Lifting 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 installation ..........................................................12
Battery Connection ............................................................................................12
Fire extinguisher ................................................................................................12
Console to waste tank connection ......................................................................13

SECTION 2
PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 10
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
2500HS® console weighs approximately 908 lbs., a
forklift is necessary to place the unit into the
vehicle. Place the forks under the unit. Using two
“C” clamps, secure the console to the forks. Move
the unit into desired position.
POSITIONING THE UNIT INTO THE
VEHICLE
Vehicles vary in size and openings. Owners have
different preferences on where in the vehicle they
want their units positioned. SAPPHIRE
SCIENTIFIC strongly recommends a side door
installation for the MODEL 2500HS®. We DO
NOT recommend a rear door installation.
1. Ensure that enough space is provided to assure
adequate engine ventilation as well as room for
service and maintenance.
2. Operating weight of the complete installation
(which includes water weight) with waste tank and
ALL accessories MUST NOT exceed the
vehicle’s axle weight limit. Please refer to
SPECIFICATIONS in Section 1 for standard unit
and waste tank operating weight.
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 six (6) 13⁄32 in. diameter
holes for the console and four (4) 13⁄32 in. diameter
holes for the waste tank.
B. Using the provided mounting hardware kit:
1. Insert six (6), grade 5, ⅜-16 × 4 in. hex
head cap screws with flat washers through
the MODEL 2500HS® console mounting
holes, and four (4), 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.
! Do not alter or modify your
2500HS 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.

SECTION 2
PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 11
DIMENSIONAL DIAGRAM WITH STANDARD RECOVERY TANK

SECTION 2
PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 12
INSTALLATION OF FUEL LINES
!!!
READ THESE INSTRUCTIONS IN THEIR
ENTIRETY PRIOR TO PROCEEDING.
!
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, or vehicle could be 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 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 PHASE3
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.
!
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
!
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 in the OFF position. If
ON, a spark could occur at the ground connection
terminal, which could cause an explosion if hydrogen
gas or gasoline vapors are present. ALWAYS
disconnect the negative (−) terminal first.
A. Attach the red positive (+) battery cable from the
starter solenoid on the console to the positive (+)
terminal on the battery and tighten down the nut.
B. Attach the black negative (−) battery cable from
the ground on the console to the negative (−) terminal
on the battery and tighten down the nut.
FIRE EXTINGUISHER
SAPPHIRE SCIENTIFIC, and many government
agencies, recommend that a fire extinguisher rated
for A, B, and C type fires be installed into any
commercial vehicle.

SECTION 2
PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 13
CONSOLE TO WASTE TANK CONNECTION
Waste Tank to
Vacuum Brake
P/N 17-554
Vacuum Inlet
Waste Tank
Vacuum Inlet
To Waste Tank
P/N 17-205
Waste Tank
To Drain Outlet
P/N 17-421
Drain Outlet
Vacuum Brake

PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 14
SECTION 3:
OPERATION
4. SYSTEMS
Water/Heating system ........................................................................................15
Vacuum system ..................................................................................................16
Chemical pumping system .................................................................................17
5. OPERATION
Preparation .........................................................................................................18
Starting the unit ..................................................................................................20
Priming the chemical pump ...............................................................................20
Automatic waste pump ......................................................................................21
Operation............................................................................................................21
Cleaning .............................................................................................................21
Upholstery cleaning ...........................................................................................21
Stair tool cleaning ..............................................................................................21
Flood restoration/extraction ...............................................................................22
Shut down and daily maintenance .....................................................................22
Freeze protection ................................................................................................23

SECTION 3
PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 15
4. SYSTEMS
NOTE: Read and understand this section of
the manual entirely before proceeding.
This portion of the manual divides the unit up
into systems and describes how each system
works. Prior to proceeding into the operations
and maintenance sections of this manual it is
recommended that you acquire a basic
understanding of how the unit functions.
WATER RESERVOIR
The water reservoir is a pressurized vessel.
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
through the Inlet Pressure Regulator (where
incoming water pressure is reduced to 20 psi)
and into the water box.
WATER/HEATING SYSTEM
The water is pre-heated in the water box using
radiant heat generated by the vacuum blower,
engine and coil housing.
The water then flows to the water pump where
pressure is increased. 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. Solution pressure is
controlled by the Outlet Pressure Regulator.

SECTION 3
PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 16
VACUUM SYSTEM
The engine turning a vacuum pump generates the
vacuum. The air is channeled in one side of the
vacuum pump, compressed and discharged on
the opposite side, creating airflow. This airflow
is used to do the work necessary for the
extraction process. A vacuum nozzle applied to
the carpet surface removes moisture, dirt and
spent chemicals. These elements are conveyed
back to a separating tank utilizing hoses and the
force of air. Particles of moisture and dirt are
separated in the vacuum tank using a series of
changes in direction and velocity. The air is then
filtered and rushes into the vacuum pump.
The vacuum pump also heats incoming air as it is
compressed. The hot discharged air is forced
down
stream into a silencer for noise abatement.
Exiting the silencer, this hot air is directed
through the heat exchanger
The vacuum pump speed is factory set to
maximize 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 is located near the top of
the waste tank and will shut down the unit before
the tank is at full capacity. This protects the
vacuum pump from water damage. Note: Waste
tank level shut off will not shut the unit off due
to high levels of foam. The use of a quality
defoamer is recommended.

SECTION 3
PART# 49-059 REV F SAPPHIRE SCIENTIFIC MODEL 2500HS® 17
CHEMICAL PUMPING SYSTEM
The chemicals are drawn from the chemical
container through a strainer into the flow meter
mounted on the control panel. The flow meter
indicates the rate of chemical flow.
The chemicals then flow through the stainless steel
chemical pump, the chemical is then injected into a
three way selector valve located on the front panel.
This valve may be used to turn the chemical flow
ON, OFF, or to PRIME the chemical pump.
The chemicals then flow through the chemical
metering valve to the solution outlet. This valve
controls the rate of flow of chemical into the
cleaning solution, which is indicated on the flow
meter.