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Summary of Contents for Pneumax 140-SP
- Page 1 PTO-Driven Compressor Kit Installation Guide PTO-Driven Compressor Kit Installation Guide Applies to the Pneumax models 140-SP 200-SP FOR INSTALLATION CENTER USAGE ONLY Pneumax, Inc. 8557 North 78th Ave. Peoria, Arizona 85345 623-979-3398 Fax: 623-979-6949 www.pneumaxcafs.com Page 1 of 36...
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Page 2: Table Of Contents
Pneumax PTO-Driven Compressor Kit Installation Guide Table of Contents Installation Overview ......................... 4 Power take-off suggestions ....................... 5 PTO installation..........................6 Air compressor installation......................... 7 Air-oil sump installation........................8 Oil Temperature Gauge (all sumps) ....................11 Separator/filter installation ....................... 12 Air Compressor Cooler and Hydraulic Filter Installation.............. - Page 3 Pneumax PTO-Driven Compressor Kit Installation Guide Warnings, Cautions, and Notes Warning A warning alerts you to a procedure, practice or condition that may result in death or long-term injury to personnel or destruction of equipment. Caution A caution alerts you to a procedure or condition that may result in serious damage to equipment or its failure to operate as expected.
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Page 4: Installation Overview
Pneumax PTO-Driven Compressor Kit Installation Guide PNEUMAX PTO-driven Compressor Installation Guide Installation Overview This guide is for installation of the compressor system. There may be some variables depending on specific applications. Since there are many ways to which discharges can be configured, if the application on a particular vehicle is not covered in this guideline, we will be happy to assist with specific needs of the customer in the design of the system. -
Page 5: Power Take-Off Suggestions
Pneumax PTO-Driven Compressor Kit Installation Guide Power take-off suggestions There are many PTO suppliers and various types of transmissions available, and the choice of PTO will in part depend on what can be installed in the vehicle. "Hot Shift" PTOs are commonly used. -
Page 6: Pto Installation
Pneumax PTO-Driven Compressor Kit Installation Guide PTO installation Follow the PTO manufacturer's installation guidelines. Caution: Because the compressor is cooled by water from the water pump, we strongly suggest that the compressor is only engaged while the water pump is engaged. This is accomplished by using the "OK to PUMP"... -
Page 7: Air Compressor Installation
Pneumax PTO-Driven Compressor Kit Installation Guide Air compressor installation Compressor mounting bracket is supplied with kit. Mounting bolts of the proper size are provided with the Compressor Kits since these are metric thread. The installer can manufacture a mounting bracket for the Compressor if so desired. -
Page 8: Air-Oil Sump Installation
PTO-Driven Compressor Kit Installation Guide Air-oil sump installation Note: Pneumax will not be responsible for systems where the sump and sight glass are installed such that the oil level cannot be checked or does not display the correct oil level due to improper installation. - Page 9 Pneumax PTO-Driven Compressor Kit Installation Guide 80-SP Vertical Sump The Safety Pressure Relief valve may be installed in either of the ports. The remaining ports have no options. Out to Safety Separator Filter Pressure Relief Inlet from Compressor Oil Level...
- Page 10 Pneumax PTO-Driven Compressor Kit Installation Guide 140/200-SP Vertical Sump The Safety Pressure Relief valve may be installed in either of the ports. The remaining ports have no options. From Compressor Oil Fill Oil Level Sight Glass Safety Pressure Relief (alternate...
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Page 11: Oil Temperature Gauge (All Sumps)
• The smaller prong, which is labeled "WK", may be used to activate an oil temperature warning light or alarm (not provided). Pneumax recommends installing an over- temperature device. This prong is one side of a temperature sensitive switch that will close at 250°F. The other side is grounded through the metal of the sump. -
Page 12: Separator/Filter Installation
Pneumax PTO-Driven Compressor Kit Installation Guide Separator/filter installation The separator filter can be installed anywhere there is room to securely mount it and run the hydraulic and air lines. The only requirements are to make sure that the filter element can be serviced reasonably and that the assembly is installed properly. -
Page 13: Air Compressor Cooler And Hydraulic Filter Installation
Pneumax PTO-Driven Compressor Kit Installation Guide Air Compressor Cooler and Hydraulic Filter Installation Caution: Do not install a shutoff valve in the heat exchanger water supply. This will result in system overheat and failure, and void the manufacturer’s warranty. The oil returning to the compressor is cooled by passing it through a water-cooled heat exchanger, usually called the cooler. - Page 14 The cooler water is supplied by diverting water through the wye-strainer supplied by Pneumax from the discharge side of the fire pump (see the Hydraulic Schematic). The cooling water supply hose should be 0.5” to 0.625 I.D. for the 140/200-SP to supply the proper flow for cooling the system.
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Page 15: Auto-Sync
Pneumax PTO-Driven Compressor Kit Installation Guide Installation and Adjustment of the Auto-Sync Air Balancing System Colored hoses and fittings are supplied with the compressor kit for the average installation. The schematic is color coded to simplify installation. This also makes future service issues easier to resolve, provided suggested hose colors are used. -
Page 16: Fixed Mode Adjustment
Pneumax PTO-Driven Compressor Kit Installation Guide 4. Turn the valve clockwise until it is completely closed, then open it three full turns. 5. Locate the Piloted Balance Valve (PBTV), and turn the needle valve counterclockwise to full open. Valve Piloted Balance Trim Valve (PBTV) 6. -
Page 17: Auto Mode Adjustment
Pneumax PTO-Driven Compressor Kit Installation Guide 3. AUTO Mode Adjustment The pressure for the FIXED mode must have been correctly set before you attempt to adjust the AUTO mode. 1. Make sure the fire pump is operating at 100 PSI at the main discharge, with minimal flow. -
Page 18: Suggested Components For Cafs Discharges
Suggested components for CAFS discharges: Discharge kits Kits are available for most of the valve types (Waterous, Akron, Elkhart) or suggested components lists are also available. Please contact Pneumax for assistance. Fittings on all hoses should be 37 JIC. Air distribution manifold: Suggest NPT fittings with appropriate number and size ports. -
Page 19: Troubleshooting
Pneumax PTO-Driven Compressor Kit Installation Guide Troubleshooting Compressor System Observed Symptom Probable cause Suggested fix Lack of air pressure from compressor Lack of air supply to clutch Repair air leak or re-establish air supply (for air-clutch systems) Compressor not engaging... - Page 20 Pneumax PTO-Driven Compressor Kit Installation Guide Observed Symptom Probable cause Suggested fix Inadequate water flow Ensure adequate water flow through pump through cooler Check Y strainer for obstruction, clean and reinstall Drain and flush cooler water tubes Adequate water flow through On-board tank used for cooling for a cooler.
- Page 21 Pneumax PTO-Driven Compressor Kit Installation Guide Observed Symptom Probable cause Suggested fix High oil level Check oil level, adjust level to half of the sight (compressor is flooded) glass with vehicle parked on a level surface Compressor locked up Sump fire...
- Page 22 Pneumax PTO-Driven Compressor Kit Installation Guide Observed Symptom Probable cause Suggested fix Engaging in RUN position Engage in AUTO/UNLOAD only Slight air leak from solenoid Repair air leak to clutch High RPM engagement Engage in lower RPM Clutch smoking Not allowing compressor to...
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Page 23: Schematics And Dimensional Drawings
PTO-Driven Compressor Kit Installation Guide Schematics and Dimensional Drawings DRAWINGS ARE NOT TO SCALE! ALL DIMENSIONS ARE IN INCHES, UNLESS OTHERWISE SPECIFIED. Basic Compressed Air Foam System (CAFS) Schematic Page 23 of 36... -
Page 24: 80-Sp With 8-Inch Vertical Sump, Hydraulic Schematic
PTO-Driven Compressor Kit Installation Guide 80-SP with 8-inch Vertical Sump, Hydraulic Schematic Page 24 of 36... -
Page 25: 140/200-Sp With 10-Inch Vertical Sump, Hydraulic Schematic
PTO-Driven Compressor Kit Installation Guide 140/200-SP with 10-inch Vertical Sump, Hydraulic Schematic Page 25 of 36... -
Page 26: 80-Sp Manual Auto-Sync Valves, Air And Water Connections
PTO-Driven Compressor Kit Installation Guide 80-SP Manual Auto-Sync Valves, Air and Water Connections Page 26 of 36... -
Page 27: 140/200-Sp Manual Auto-Sync Valves, Air And Water Connections
PTO-Driven Compressor Kit Installation Guide 140/200-SP Manual Auto-Sync Valves, Air and Water Connections Page 27 of 36... -
Page 28: Compressor Installation Angles
PTO-Driven Compressor Kit Installation Guide Compressor Installation Angles Page 28 of 36... -
Page 29: Eight-Inch Vertical Sump
PTO-Driven Compressor Kit Installation Guide Eight-Inch Vertical Sump Page 29 of 36... -
Page 30: Ten-Inch Vertical Sump
PTO-Driven Compressor Kit Installation Guide Ten-Inch Vertical Sump Page 30 of 36... -
Page 31: 80-P Heat Exchanger (Oil Cooler)
PTO-Driven Compressor Kit Installation Guide 80-P Heat Exchanger (Oil cooler) Page 31 of 36... -
Page 32: 140/200-Sp Heat Exchanger (Oil Cooler)
PTO-Driven Compressor Kit Installation Guide 140/200-SP Heat Exchanger (Oil Cooler) Page 32 of 36... -
Page 33: 80-Sp Separator Filter
PTO-Driven Compressor Kit Installation Guide 80-SP Separator Filter Separator Filter Page 33 of 36... -
Page 34: 140/200-Sp Oil And Separator Filters
PTO-Driven Compressor Kit Installation Guide 140/200-SP Oil and Separator Filters Oil Filter Separator Filter Page 34 of 36... -
Page 35: Balance Valve And Auto-Sync Controls, Panel Cutout
PTO-Driven Compressor Kit Installation Guide Balance Valve and Auto-Sync Controls, Panel Cutout Balance Valve Auto-Sync Controls, Panel Cutout Page 35 of 36... -
Page 36: Companion Flange
PTO-Driven Compressor Kit Installation Guide Companion Flange Front View Side View Page 36 of 36...
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