Pneumax 120-60-DS Installation Manual Download | Manualshive

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Pneumax

CAFS "DS" Series Installation Guide

Page 4 of 40

Revision History

Revision Date

Issued

Comments

1.0

Dec 2, 2005

Original Release

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Summary of Contents for 120-60-DS

Page 1: ...Installation Guide Applies to Pneumax Model 120 60 DS Deutz engine 250 120 DS FOR INSTALLATION CENTER USAGE ONLY Pneumax Inc 8557 North 78th Ave Peoria Arizona 85345 623 979 3398 Fax 623 979 6949 www...

Page 2: ...to personnel or equipment It may waste time and money Disclaimer These instructions are guidelines only and in no way meant to be definitive During installation standard safety precautions and equipm...

Page 3: ...Power up 15 Verifying the Auto Sync Air Balancing System 16 1 UNLOAD mode verification 16 2 FIXED mode verification 16 3 AUTO mode verification 16 Suggested Third party Components 17 Suggested compone...

Page 4: ...Pneumax CAFS DS Series Installation Guide Page 4 of 40 Revision History Revision Date Issued Comments 1 0 Dec 2 2005 Original Release...

Page 5: ...points occupy the locations shown here The standard model has two discharges plumbed to the control panel Other discharges may be present such as discharges for a hose reel or deck gun 12VDC Connect...

Page 6: ...shown in this manual may differ slightly from the parts that were shipped Pneumax systems do not include Fuel pump and fuel lines Battery and cables Fittings and pipe for plumbing Installation tasks i...

Page 7: ...ust have the specified unobstructed clearances for cooling The fuel tank must be installed with no more than the specified height differentials between tank and fuel inlet If this height differential...

Page 8: ...Air Intake 120 60 DS 6 inches minimum between module and tank 250 120 DS 11 inches minimum between module and tank Fuel Supply The engines are fuel injected diesel Pneumax CAFS Unit Fuel Consumption F...

Page 9: ...e filters it is strongly recommended that a combination of strainers and filters be used in the supply line Fuel Tanks The basic requirements for tanks are Tanks must be ventilated adequately at any a...

Page 10: ...he truck the chassis tank NFPA standards specify that the auxiliary motor must not be able to draw more than 75 of the fuel from the tank This minimizes the chances of running out of fuel and being un...

Page 11: ...at the top of the tank is not recommended for shared or auxiliary tanks The fuel will drain back into the tank whenever the motor is shut off The motor will be slow to start if it starts at all This...

Page 12: ...al is welded directly to the system frame Both positive and negative cables must be adequately sized to supply power to the system The negative terminal must be connected to the truck chassis The chas...

Page 13: ...n fittings The tubing is capped and secured for shipment Run the drain lines to a convenient service location Typical oil drain as shipped Water Level Indicator Install the water level sensor in the v...

Page 14: ...n the discharge line of the fire pump The flow meter and its tee are next to the foam manifold The injection fitting or a capped port for the fitting will be about a foot away from it between the tee...

Page 15: ...t glass You will need to add more later to compensate for oil that remains in the hydraulic lines and the compressor Initial Power up Warning Do not start the engine unless the system is connected to...

Page 16: ...nk recirculation 5 The main air pressure gauge will read 40 50 PSI for the 250 120 DS model It will be lower for the 120 60 DSC and in some systems the gauge needle may barely move In UNLOAD mode this...

Page 17: ...below The air check valve prevents foam solution from backflowing into the compressor and contaminating the oil The water check valve isolates the discharge preventing CAF from backflowing into the f...

Page 18: ...150 psi Also the hose and fittings for hydraulic hose are bulky and expensive Air brake hose may also be used provided the inside diameters are correct 375 OD is 250 ID 500 OD is 375 ID 625 OD is 500...

Page 19: ...n correct position Verify when in FIXED RUN that the pressure reflects 145 150 PSI Air discharge solenoid not working Repair replace solenoid electric valves Verify there is power to the air solenoid...

Page 20: ...water too hot to effectively cool the compressor Locate source of lower temperature water Low compressor oil level Check oil level Adjust level to half of the sight glass on level surface Check the h...

Page 21: ...with vehicle parked on a level surface Check system and repair Check system and repair Air flow meter stuck at 0 CFM Air flow meter stuck at high CFM Magnet uncoupled in meter Turn air flow on and off...

Page 22: ...side of pump Rebuild replace check valve Water in compressor oil air Leaking inside cooler Freeze damage Defective air check valves Missing air check valves for discharges Isolate cooler and check for...

Page 23: ...cooler strainer is clean and the air lines do not have leaks Always start by adjusting UNLOAD mode then FIXED then AUTO A common problem is unauthorized adjustment of the balance valve in an attempt...

Page 24: ...l discharges closed Some systems may read lower This is acceptable 2 FIXED Mode Adjustment 1 Locate the Fixed Manual Pressure Regulator on the compressor and loosen the lock nut on the adjustment scre...

Page 25: ...in 5 of the water pressure adjust it as follows If the air pressure is too high turn the Air Inlet Trim Valve clockwise in 1 2 turn increments to close it checking air and water pressure after each 1...

Page 26: ...ints Note The compressors vary slightly from system to system as do the position of the adjustment points but the adjustment points look the same The compressor will be above the fire pump Air in from...

Page 27: ...the connections are the same Oil cooler Note The Oil Air Separator filter may be mounted directly to the sump or on a bracket on the frame Oil Scavenger to Compressor behind bracket To Balance Valve...

Page 28: ...Hydraulic Filter To Drain Left 120 60 DS Sump with separator filter Right 250 120 DS Sump during installation left front corner directly behind control panel Note The temperature sender fitting is on...

Page 29: ...SE SPECIFIED 120 60 DS 30 120 60 DS Mounting Tab Spacing 31 250 120 DS 32 250 120 DS Mounting Tab Spacing 33 Basic Compressed Air Foam System CAFS Schematic 34 250 120 Hydraulic Flow 35 120 60 Hydraul...

Page 30: ...CAFS DS Series Installation Guide Page 30 of 40 Modules 120 60 DS Top Side Front...

Page 31: ...CAFS DS Series Installation Guide Page 31 of 40 120 60 DS Mounting Tab Spacing 120 60 DS Mounting Tabs...

Page 32: ...CAFS DS Series Installation Guide Page 32 of 40 250 120 DS...

Page 33: ...CAFS DS Series Installation Guide Page 33 of 40 250 120 DS Mounting Tab Spacing 250 120 DS Mounting Tabs...

Page 34: ...CAFS DS Series Installation Guide Page 34 of 40 Schematics Basic Compressed Air Foam System CAFS Schematic...

Page 35: ...CAFS DS Series Installation Guide Page 35 of 40 250 120 Hydraulic Flow COMPRESSOR OIL RESERVOIR SUMP OIL AIR FLOW OIL FLOW AIR OUT OIL FLOW SEPARATOR FILTER...

Page 36: ...CAFS DS Series Installation Guide Page 36 of 40 120 60 Hydraulic Flow...

Page 37: ...CAFS DS Series Installation Guide Page 37 of 40 Auto Sync Wiring Schematic electric...

Page 38: ...CAFS DS Series Installation Guide Page 38 of 40 Auto Sync Air Schematic electric...

Page 39: ...CAFS DS Series Installation Guide Page 39 of 40 Auto Sync Air Schematic manual...

Page 40: ...CAFS DS Series Installation Guide Page 40 of 40 Heat Exchanger Water Schematic Aux Engine cooler notin all systems...

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