Waterous CAFS-CP-2 Series Installation, Operation And Maintenance Manual Download

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Traditional CAFS—CP-2, CL, CX, HL Series Pumps,

and TC20 Series Power Take-Offs

Installation, Operation, and Maintenance

Form Number: F-2937

Issue Date: Jan. 18, 2022

Waterous Company • 125 Hardman Avenue South • South Saint Paul, MN 55075 • (651) 450-5000

www.waterousco.com

Summary of Contents for CAFS-CP-2 Series

Page 1: ...HL Series Pumps and TC20 Series Power Take Offs Installation Operation and Maintenance Form Number F 2937 Issue Date Jan 18 2022 Waterous Company 125 Hardman Avenue South South Saint Paul MN 55075 651...

Page 2: ...0 Inch Version 41 Dimensions Tee Sump 42 Dimensions Oil Cooler 150 P 43 Dimensions Separator Filter 100 P and 120 P 44 Dimensions Separator Filter 150 P and 200 P 45 Dimensions Air Intake Components 1...

Page 3: ...0 Shutting Down the System 91 Maintenance 92 Maintenance Schedule 92 Checking the Sump Oil Level 93 Adding Oil to the Sump 94 Changing the Sump Oil 95 Changing the Air Filter 96 Changing the Separator...

Page 4: ...ly perform the required procedures proper installation is the responsibility of the purchaser Do not operate the equipment when safety guards are removed Do not modify the equipment Regularly check fo...

Page 5: ...ll ground wire connections before applying high current Drain the pump after use and before servicing Liquid ejected at high pressure can cause serious injury High Pressure Do not touch the surface du...

Page 6: ...bleshooting Maintenance Rotating parts can cause severe injury or death Moving Parts Do not enter or reach into the compartment when equipment is operating Do not operate beyond recommended pressure L...

Page 7: ...d alert symbols that are in this document Introduction This section is an overview of the document Product Overview This section describes the components that make up the system and the various system...

Page 8: ...2 V or 24 V Some components are assembled at the factory while other components are shipped loose and require installation The components that require installation depend on the configuration of your...

Page 9: ...ails warnings associated with operating the system 6 Check valve This prevents liquid from flowing backwards through the system 7 Oil temperature sender This measures the sump oil temperature and trig...

Page 10: ...uction Product Overview Installation Operation Troubleshooting Maintenance System Components The CAFSystem includes the additional illustrated components The components are color coded for troubleshoo...

Page 11: ...ponents Feature Feature Description Description 1 Black tubing This 1 4 inch air brake tube connects various components in the system 2 Red tubing This 1 4 inch air brake tube connects various compone...

Page 12: ...oubleshooting Maintenance 100 D 120 D and 150 D CAFS HLK Configurations Assembled at the Factory Shipped Loose 100 P and 120 P CAFS CPK 2 Configuration Assembled at the Factory Shipped Loose 100 P and...

Page 13: ...on Operation Troubleshooting Maintenance 150 D CAFS CSC20 Configuration Assembled at the Factory Shipped Loose 150 ESD CAFS CXSC20 Configuration Assembled at the Factory Shipped Loose 150 ESD CAFS TC2...

Page 14: ...ation Operation Troubleshooting Maintenance 150 P CAFS CLVK Configuration Assembled at the Factory Shipped Loose 150 P CAFS CXVK Configuration Assembled at the Factory Shipped Loose 150 P CAFS CXVPA C...

Page 15: ...tion Operation Troubleshooting Maintenance 150 T CAFS CXVT Configuration Assembled at the Factory Shipped Loose 200 D CAFS HL400K Configuration Assembled at the Factory Shipped Loose 200 P CAFS CXVK C...

Page 16: ...16 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Operation Overview...

Page 17: ...s air pressure to the balance valve and pressure modulation control PMC assembly where it is used to synchronize air and water pressure in auto mode 3 Cooling The cooling portion of the system include...

Page 18: ...18 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Compressor Components 150 P 1 3 9 7 2 4 6 5 8...

Page 19: ...to the compressor 4 Pressure modulation control PMC This part of the air control circuit sets the fixed pressure during operation and bleed off during shutdown 5 Compressor This pumps the compressed a...

Page 20: ...20 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Air Filtration Components 5 4 1 2 3...

Page 21: ...mp This secures the air filter to the air inlet tube 3 Air inlet tube This routes fresh air to the compressor It is supplied as a 4 foot 1 22 m aluminum tube that is cut to length as required by your...

Page 22: ...22 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Oil Sump Vertical 6 1 2 3 5 7 4 8 9 10...

Page 23: ...lays the oil level in the sump 4 Oil out port This routes the oil to the compressor 5 Oil fill port This is where the oil is added to the sump 6 Air oil in port This receives air oil from the compress...

Page 24: ...24 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Oil Sump Tee 5 4 3 2 1 6 7 8 9 13 12 11 10 14...

Page 25: ...6 Wye strainer oil fill port This is where the oil is added to the sump 7 Mounting bracket This mounts the sump on the apparatus The sump must be oriented vertically with the sump body toward the top...

Page 26: ...26 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Separator Filter 7 1 4 5 6 2 3 8 9...

Page 27: ...e separator filter 4 Air oil input port This is where the compressed air oil mixture enters the separator filter 5 Separator filter This is the final stage of air oil separation when any remaining oil...

Page 28: ...28 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Oil Cooler 10 9 7 8 2 3 4 1 5 6 5...

Page 29: ...e fitting clean out valve This allows you to quickly remove accumulated debris from the wye fitting 5 Mounting bracket This mounts the oil cooler on the apparatus 6 Oil drain This allows you to drain...

Page 30: ...30 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Sump Vent Optional 1 2 3 4 5 6...

Page 31: ...ion Description 1 2 way solenoid valve This actuates to vent the sump 2 Vent fitting This connects to the separator filter 3 Mounting hole This secures the assembly to the apparatus 4 Vent muffler Thi...

Page 32: ...32 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Balance Valve 3 1 2 6 5 4 7...

Page 33: ...rcuit 2 Separator filter output This connects to the separator filter 3 Direction of flow indicator This indicates the direction the air flows through the balance valve 4 Balance trim valve This adjus...

Page 34: ...34 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Auto Sync Mode Switch 3 1 2 4 5 6 7...

Page 35: ...essor at approximately 40 psi 2 8 bar The compressor generates a minimum pressure of 40 psi 2 8 bar to circulate the compressor oil and cool the system Always start the compressor in this mode or auto...

Page 36: ...36 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Auto Sync Solenoid Assembly 1 2 3 4 5 6 7...

Page 37: ...cts to the auto sync switch 2 Pressure gauge output This connects to the optional pressure gauge 3 Balance valve input This connects to the balance valve 4 Mounting bracket This mounts the auto sync o...

Page 38: ...begin the installation Make sure that you remove any shipping plugs or caps before installing components Make sure that you bring all fluids to operating levels before using the equipment NOTICE Befor...

Page 39: ...lity during operation and maintenance Install instruction plates near their applicable operator panels Determining Hose Routing Use the following guidelines when routing the hoses Route hoses in a str...

Page 40: ...Overview Installation Operation Troubleshooting Maintenance Dimensions Sump 8 Inch Long Version 6x 1 373in 34 88mm 6X 1 2 13UNC 2B 27 044in 686 93mm 3 000in 76 20mm 6 000in 152 40mm 13 816in 350 94mm...

Page 41: ...verview Installation Operation Troubleshooting Maintenance Dimensions Sump 10 Inch Version 6X 1 940in 49 28mm 6X 1 2 13 UNC 2B 26 736in 679 10mm 11 944in 303 38mm 2X 4 000in 101 60mm 2X 8 000in 203 20...

Page 42: ...n Product Overview Installation Operation Troubleshooting Maintenance Dimensions Tee Sump 37 389in 949 67mm 13 500in 342 90mm 0 250in 6 35mm 21 060in 534 92mm 4 000in 101 60mm 5 000in 127 00mm 8 318in...

Page 43: ...Product Overview Installation Operation Troubleshooting Maintenance Dimensions Oil Cooler 150 P 30 169in 766 29mm 0 500in 12 70mm 21 321in 541 54mm 12 659in 321 54mm 1 250in 31 75mm 0 285in 7 25mm Re...

Page 44: ...44 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Dimensions Separator Filter 100 P and 120 P...

Page 45: ...oduction Product Overview Installation Operation Troubleshooting Maintenance Dimensions Separator Filter 150 P and 200 P 10 000in 254mm 13 750in 349 25mm 4 375in 111 13mm 150 P 15 966in 405 53mm 200 P...

Page 46: ...46 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Dimensions Air Intake Components 100 P 150 P and 200 P 11 068in 280 99mm...

Page 47: ...47 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Dimensions Balance Valve...

Page 48: ...48 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Dimensions Auto Sync Solenoid Assembly...

Page 49: ...troduction Product Overview Installation Operation Troubleshooting Maintenance Dimensions Optional Sump Vent Assembly 6 506in 165 26mm 0 313in 7 95mm 1 750in 44 45mm 1 000in 25 40mm 4 123in 104 72mm 4...

Page 50: ...50 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Dimensions Auto Sync Switch...

Page 51: ...51 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Dimensions Warning Instruction and Serial Plates...

Page 52: ...52 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Dimensions Temperature Gauge...

Page 53: ...Notes...

Page 54: ...54 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Pneumatic Connections Overview 4 8 7 10 1 2 3 6 5 9...

Page 55: ...llow air brake tube that routes balanced air from the balance valve to the auto sync solenoid assembly 5 Regulated air line This line is a red air brake tube that routes regulated air from the auto sy...

Page 56: ...Installation Operation Troubleshooting Maintenance Hose Connections Overview 150 P Use the illustration to plan the hose routing for the apparatus Contact Waterous for more information about availabl...

Page 57: ...sump 1 3 8 inch hydraulic hose 4 Compressed air hose This routes compressed air from the sump to the separator filter 1 3 8 inch hydraulic hose 5 Oil cooler hose This routes oil from the sump to the o...

Page 58: ...ion Operation Troubleshooting Maintenance Fittings Overview 150 P Use the illustration to plan the hose routing for the apparatus Contact Waterous for more information about available hose and fitting...

Page 59: ...Hose fitting This is for a 1 2 inch hose 8 FJIC 5 Push on hose fitting This is for a 3 4 inch hose 12 FJIC 6 Hose fitting This is for a 5 8 inch hose 1 2 MNPT 7 Reducer bushing This is a 1 MNPT x 1 2...

Page 60: ...60 107 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Temperature Gauge and Sender Connections Overview 5 7 6 3 9 2 1 4 10 8...

Page 61: ...ender wire This connects the small tab on the temperature sender to the warning light 4 Temperature sender This reacts when the oil temperature in the sump reaches a predetermined temperature 5 Bulb p...

Page 62: ...3 Install the sump so that the sight window is clearly visible 4 Make sure that the sight window is visible Note If the sight window is not visible premature damage can occur and will void your warra...

Page 63: ...e sure to install the oil cooler so that it is easy to access You must be able to perform regular maintenance and drain the oil cooler to prevent freeze damage 1 Install the oil cooler with the drain...

Page 64: ...he separator filter so that it is easy to access 1 Install the separator filter with the filter toward the bottom 2 For maintenance purposes make sure that you can either remove the filter or remove t...

Page 65: ...ake sure to install the balance valve so that it is easy to access Installing the balance valve where it is not able to be adjusted will void your warranty 1 Install the balance valve with the trim va...

Page 66: ...and instructions to install the auto sync solenoid assembly 1 Install the auto sync solenoid assembly with the mounting bracket toward the bottom 2 Drill the mounting holes for the auto sync solenoid...

Page 67: ...tion and instructions to mount the auto sync switch on the apparatus Note Make sure to install the auto sync switch so that it is easy to access 1 Create the cutout and drill the mounting holes for th...

Page 68: ...Sync System 2 3 1 Use the illustration and instructions to connect the auto sync switch wires and components 1 Secure the power wire to the appropriate power distribution rail 2 Connect the ground sc...

Page 69: ...ctions to mount the warning instruction and serial plates on the apparatus Note Make sure to install the plates near the auto sync switch 1 Drill the mounting holes for the warning instruction and ser...

Page 70: ...on and instructions to install the compressed air hoses 1 Install the fitting 24 FJIC onto the compressor and sump 2 Install the 1 3 8 inch hydraulic hose into the fittings 24 FJIC 3 Install the 90 ad...

Page 71: ...shooting Maintenance Installing the Scavenge Oil Hose 150 P 1 1 Use the illustration and instructions to install the scavenge oil hose 1 Install the fittings 4 FJIC onto the air compressor and separat...

Page 72: ...Use the illustration and instructions to install the oil hoses for the oil cooler 1 Install the fittings 8 FJIC onto the compressor and oil cooler 2 Install the 1 2 inch hydraulic hose into the fittin...

Page 73: ...e low pressure outlet of an HL Series pump 3 Install the air brake hose 5 8 inch black into the straight fittings 1 2 MNPT x 5 8 AB 4 Install the reducer bushing 1 MNPT x 1 2 FNPT into the oil cooler...

Page 74: ...pressure side of the pump 2 Connect the orange air brake hose to the balance valve and a discharge port on the pump Note Always connect to the first stage of a multistage pump or the low pressure outl...

Page 75: ...oting Maintenance Installing the PMC Hoses 150 P 2 1 Use the illustration and instructions to install the PMC hoses 1 Connect the red air brake hose to the auto sync solenoid assembly and PMC assembly...

Page 76: ...engine startup to prevent engine stall 1 Drill the mounting holes for the mounting bracket Refer to Dimensions Optional Sump Vent Assembly on page 49 2 Use locally sourced hardware to secure the sump...

Page 77: ...structions to install the pressure gauge The pressure gauge is required by NFPA standards and locally sourced by the installer 1 Create the cutout for the pressure gauge For dimensions refer to the sp...

Page 78: ...he temperature gauge signal terminal to the larger spade on the temperature sender 3 Connect the temperature gauge positive terminal to the appropriate power distribution circuit 4 Connect the tempera...

Page 79: ...ll tools towels and debris are removed from the apparatus Make sure that the hardware and connections are properly tightened Make sure that the drain valves are closed Make sure to flow water through...

Page 80: ...up to 10 seconds Note Do not operate the compressor for more than 10 seconds during this procedure Doing so will damage the compressor and void your warranty 4 Allow time for the pressure to be comple...

Page 81: ...ng this procedure Rotating parts can cause severe injury or death Moving Parts Do not enter or reach into the compartment when equipment is operating 2 Toggle the auto sync switch to the Unload positi...

Page 82: ...em with the compressor oil temperature above 250 F 121 C 1 Use caution when performing this procedure Rotating parts can cause severe injury or death Moving Parts Do not enter or reach into the compar...

Page 83: ...r to regulate the compressor oil temperature during operation Never operate the system with the compressor oil temperature above 250 F 121 C 1 Toggle the auto sync switch to the Unload position to mak...

Page 84: ...e the system with the compressor oil temperature above 250 F 121 C 1 Use caution when performing this procedure Rotating parts can cause severe injury or death Moving Parts Do not enter or reach into...

Page 85: ...r and water pressure 6 If the air pressure is lower than the water pressure turn the air inlet trim valve 1 2 turn counterclockwise After the adjustment takes effect compare the air and water pressure...

Page 86: ...chronizes the air pressure with the water pressure The air pressure rises and falls automatically as you raise and lower the static water pressure Auto mode operates between approximately 50 to 150 ps...

Page 87: ...pplied to the valve the shuttle returns to its resting position and bleeds off any remaining air in the system to atmosphere Note The illustrates the main air pressure route described in the instructi...

Page 88: ...n air pressure route described in the instructions 1 The compressor builds air pressure in the system to 40 psi 2 8 bar To adjust the set point refer to Calibrating the System Unload Mode on page 81 2...

Page 89: ...nteracts with the regulator components 3 Both solenoids are closed which allows the air pressure to operate independently from the water pressure 4 Pressure builds until it reaches the set point when...

Page 90: ...2 As the air pressure surpasses 40 psi 2 8 bar the minimum pressure valve opens allowing air to move into the manifold 3 Inside the balance valve The water side of the balance valve closes the path f...

Page 91: ...injecting Fast flashing Manual mode 4 Lower Red LED Flashing Concentrate in tank low 2 min to shutdown Solid on No concentrate system shutdown FOAM ON OFF 2 4 Use the illustrations and instructions to...

Page 92: ...n Daily Daily Weekly Weekly 12 Months 12 Months 24 Months 24 Months Comment Comment Check the oil level X X Inspect the hoses and fittings X X Service operation X Operate the system in air only mode o...

Page 93: ...level daily and replenish the oil accordingly 1 The oil level is too high when it is higher than halfway up the sight window Drain the appropriate amount of oil Refer to Changing the Sump Oil on page...

Page 94: ...ure can cause serious injury High Pressure Open the pressure relief valve to make sure that you purge the pressure from the system before beginning the procedure 1 Use the sight window to approximate...

Page 95: ...ressure Open the pressure relief valve to make sure that you purge the pressure from the system before beginning the procedure 1 Place a suitable container under the sump to collect the drained oil No...

Page 96: ...s to change the air filter 1 Locate the T bolt clamp that secures the air filter to the air tube 2 Loosen the T bolt clamp 3 Remove and discard the air filter 4 Position the new air filter over the ai...

Page 97: ...sure can cause serious injury High Pressure Open the pressure relief valve to make sure that you purge the pressure from the system before beginning the procedure 1 Remove the separator filter from th...

Page 98: ...the pressure from the system before changing the oil filter Purge all pressure before servicing Liquid ejected at high pressure can cause serious injury High Pressure Open the pressure relief valve to...

Page 99: ...pen the pressure relief valve to make sure that you purge the pressure from the system before beginning the procedure 1 Open the clean out valve and allow the system drain 2 Remove the clean out valve...

Page 100: ...e When performing this procedure Always start the system in auto or unload mode Always circulate enough cool water to regulate the compressor oil temperature during operation Never operate the system...

Page 101: ...The air supply is insufficient The air lines are the wrong size Replace the lines with the correct size The minimum pressure valve is restricted Clear any debris hindering valve operation The throttle...

Page 102: ...sending unit and or temperature gauge is malfunctioning Check the wire connections at the sending unit Make sure that the wiring is not damaged or corroded repair or replace any damaged or corroded w...

Page 103: ...looded with oil Allow the air pressure in the compressor to bleed off then start the compressor and flow air The engine horsepower was underrated Increase the engine speed rpm before engaging the comp...

Page 104: ...bled and there is foam in the water system Foam concentrate was poured into the on board water tank Flush the tank and pump with clean water then refill The foam manifold drain line is not isolated fr...

Page 105: ...valve is restricted Clear any debris hindering the trim valve operation The bleed down time seems too long during system shutdown The bleed down time varies between systems If the auto sync system is...

Page 106: ...pressure The clutch is not engaging Make sure that the clutch is operating properly check air clutch systems for leaks Make sure that the OK to Pump light is illuminated Check the wire connections at...

Page 107: ...Waterous Company 125 Hardman Avenue South South Saint Paul MN 55075 651 450 5000 www waterousco com...

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