Chapters
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for Pneumax CAFS DS Series
Summary of Contents for Pneumax CAFS DS Series
- Page 1 CAFS "DS" Series 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.pneumaxcafs.com...
-
Page 2: Warnings, Cautions, And Notes
Pneumax CAFS "DS" Series 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. -
Page 3: Table Of Contents
Table of Contents Warnings, Cautions, and Notes ....................2 PNEUMAX DS Series Overview ..................... 5 Installation Overview ........................6 Installing the Pneumax DS CAFS ................... 7 Fuel Supply ..........................8 Water, Battery, and Oil Drain Connections ................12 Installing the FoamPro Pump....................14 Initial Power up ........................15 Verifying the Auto Sync Air Balancing System .............. - Page 4 Pneumax CAFS "DS" Series Installation Guide Revision History Revision Date Issued Comments Dec 2, 2005 Original Release Page 4 of 40...
-
Page 5: Pneumax Ds Series Overview
CAFS "DS" Series Installation Guide PNEUMAX DS Series Overview The Pneumax DS series CAF systems consist of an engine, compressor, fire pump mounted as a modular unit on a frame with a control panel. A foam proportioner is also provided. -
Page 6: Installation Overview
Notes: The instructions are for a typical system. A custom order system will have a similar installation procedure. The illustrations shown in this manual may differ slightly from the parts that were shipped. Pneumax systems do not include: • Fuel pump and fuel lines •... -
Page 7: Installing The Pneumax Ds Cafs
Pneumax CAFS "DS" Series Installation Guide Installing the Pneumax DS CAFS Refer to the Basic CAFS schematic in this manual to see how the components connect to the vehicle's foam and water distribution systems. Within the guidelines given here, components can be installed wherever there is room for them to be securely mounted. See the dimensional drawings in the rear. -
Page 8: Fuel Supply
Clearance for 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 Fuel Consumption (max) Model Engine @RPM Fuel Type (lbs/bhp-hr) - Page 9 Pneumax CAFS "DS" Series Installation Guide Maximum Vertical Fuel Lift Model Engine Maximum vertical lift 120-60-DS Deutz F3L1011 3m (118 inches) 250-120-DS VW 1.9L Turbo 1.2m (48 inches) Fuel Filtering Refer to the engine user and service manual for the type of filtering provided with the engine.
- Page 10 Pneumax CAFS "DS" Series Installation Guide Fuel injection motors require a closed loop full of fuel (in lines and tank) from the tank to the injector and back. The motor is provided with an excess of fuel, and the unused fuel flows back to the tank.
- Page 11 Pneumax CAFS "DS" Series Installation Guide Comments Installation technique Ending the return line at the top of the Supply Return tank is not recommended for shared or auxiliary tanks. The fuel will drain back into the tank whenever the motor is shut off.
-
Page 12: Water, Battery, And Oil Drain Connections
Pneumax CAFS "DS" Series Installation Guide Water, Battery, and Oil Drain Connections Water Tank: The tank connection is at the rear of the system, usually at the lower right corner (as seen from the front of the module). Rear of 250-120-DSC, with tank fitting at lower corner. - Page 13 Pneumax CAFS "DS" Series Installation Guide Oil drains: Hydraulic tubing is attached to the sump and engine oil drain fittings. The tubing is capped, and secured for shipment. Run the drain lines to a convenient service location. Typical oil drain, as shipped...
-
Page 14: Installing The Foampro Pump
Pneumax CAFS "DS" Series Installation Guide Installing the FoamPro Pump 120-60-DS and 250-120-DS Because of limited space in the CAFS system frame, these models require that the FoamPro pump be installed in one of the vehicle's compartments. The flow meter and the foam injection fitting are installed in the discharge line of the fire pump. -
Page 15: Initial Power Up
Initial Power up Post-Installation, Pre-Power up Safety Check Before you power-up the Pneumax system: 1. Remove all tools, shop towels, hose trimmings and other debris from the compartments. 2. Check all of the unused inlets: plastic shipping caps must be removed and replaced with the appropriate plug or cap. -
Page 16: Verifying The Auto Sync Air Balancing System
Pneumax CAFS "DS" Series Installation Guide Verifying the Auto Sync Air Balancing System This system seldom needs adjusting. For CAFS pre-built systems, the Auto Sync system is adjusted at the factory before shipment. The FIXED mode is factory set for 145-150 PSI. In most cases the factory settings will be satisfactory for typical CAFS and auxiliary air applications. -
Page 17: Suggested Third-Party Components
These are suggested parts for the common discharge sizes. If the planned discharge system is not covered in this guideline, please contact Pneumax. Note: Pneumax strongly suggests that every CAFS discharge have an air check valve and a water check valve, as shown below. - Page 18 Pneumax CAFS "DS" Series Installation Guide The other type of hose that is commonly used for air discharges is hydraulic hose. Usually this is an SAE 100R1 type. Typically, hydraulic hose is not necessary on the air discharge circuit, because the system air pressure will not exceed 150 psi. Also, the hose and fittings for hydraulic hose are bulky and expensive.
-
Page 19: Troubleshooting
Pneumax CAFS "DS" Series Installation Guide Troubleshooting Diesel Motor Make sure that all required maintenance has been performed, that all required fluids are at the correct level, and that the batteries are charged and connected. If the problem persists, see the user manual's troubleshooting section. - Page 20 Pneumax CAFS "DS" Series Installation Guide Observed Symptom Probable cause Suggested fix Check line for proper installation, with FIXED has pressure but No water supply to balance no kinks or obstructions. AUTO has no pressure valve. Refer to trim valve instructions.
- Page 21 Pneumax CAFS "DS" Series Installation Guide Observed Symptom Probable cause Suggested fix Engaging compressor while Allow compressor to bleed down under load before re-engagement Running system without Bleed down air, restart compressor, flowing air causes oil to and move air...
- Page 22 Pneumax CAFS "DS" Series Installation Guide Observed Symptom Probable cause Suggested fix Foam concentrate was Flush tank and pump with clean water, poured into the on-board refill water tank Foam manifold drain lines not isolated from water drain lines Isolate to separate drain valve...
-
Page 23: Auto Sync System
Pneumax CAFS "DS" Series Installation Guide Auto Sync System This seldom needs adjusting after the initial setup if the rest of the system is well maintained. Note: Do not adjust the Auto Sync components to compensate for problems elsewhere in the CAFS system. - Page 24 Pneumax CAFS "DS" Series Installation Guide Air Inlet Trim Valve Fixed/Manual Pressure Regulator Compressor adjustment points 4. Turn the AITV 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.
- Page 25 Pneumax CAFS "DS" Series Installation Guide 5. Verify that the fixed regulator is performing properly by varying the engine speed as you watch the air pressure gauge. The pressure should remain steady at the setting you made. Repeat steps 2 through 4 if needed.
-
Page 26: Component Identification
Pneumax CAFS "DS" Series Installation Guide Component Identification Air Pressure and Auto Sync Components Air Inlet Trim Valve Fixed/Manual Pressure Regulator Compressor Adjustments points Note: The compressors vary slightly from system to system, as do the position of the adjustment points, but the adjustment points look the same. -
Page 27: Oil Cooler And Filters
Pneumax CAFS "DS" Series Installation Guide Oil Cooler and Filters Note: The coolers and filters vary in size from model to model, but the connections are the same. Oil Inlet and Outlet Water Inlet and Outlet Drain Oil cooler Note: The Oil/Air Separator filter may be mounted directly to the sump, or on a bracket on the frame. -
Page 28: Sumps
Pneumax CAFS "DS" Series Installation Guide Sumps Fill To Separator Filter From Compressor Sight Glass To Drain To Drain To Hydraulic To Hydraulic Filter Filter 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 the far side of the sumps in this view, about 6 inches above the drain. -
Page 29: Schematics And Dimensional Drawings
CAFS "DS" Series Installation Guide Schematics and Dimensional Drawings DRAWINGS ARE NOT TO SCALE! ALL DIMENSIONS ARE IN INCHES, UNLESS OTHERWISE 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 Hydraulic Flow ................................36 Auto Sync Wiring Schematic (electric) ............................37 Auto Sync Air Schematic (electric).............................38... -
Page 30: Modules
CAFS "DS" Series Installation Guide Modules 120-60-DS Front Side Page 30 of 40... -
Page 31: 120-60-Ds Mounting Tab Spacing
CAFS "DS" Series Installation Guide 120-60-DS Mounting Tab Spacing 120-60-DS Mounting Tabs Page 31 of 40... -
Page 32: 250-120-Ds
CAFS "DS" Series Installation Guide 250-120-DS Page 32 of 40... -
Page 33: 250-120-Ds Mounting Tab Spacing
CAFS "DS" Series Installation Guide 250-120-DS Mounting Tab Spacing 250-120-DS Mounting Tabs Page 33 of 40... -
Page 34: Schematics
CAFS "DS" Series Installation Guide Schematics Basic Compressed Air Foam System (CAFS) Schematic Page 34 of 40... -
Page 35: 250-120 Hydraulic Flow
CAFS "DS" Series Installation Guide 250-120 Hydraulic Flow COMPRESSOR OIL/AIR FLOW SEPARATOR/FILTER OIL RESERVOIR (SUMP) OIL FLOW FLOW Page 35 of 40... -
Page 36: 120-60 Hydraulic Flow
CAFS "DS" Series Installation Guide 120-60 Hydraulic Flow Page 36 of 40... -
Page 37: Auto Sync Wiring Schematic (Electric)
CAFS "DS" Series Installation Guide Auto Sync Wiring Schematic (electric) Page 37 of 40... -
Page 38: Auto Sync Air Schematic (Electric)
CAFS "DS" Series Installation Guide Auto Sync Air Schematic (electric) Page 38 of 40... -
Page 39: Auto Sync Air Schematic (Manual)
CAFS "DS" Series Installation Guide Auto Sync Air Schematic (manual) Page 39 of 40... -
Page 40: Heat Exchanger Water Schematic
CAFS "DS" Series Installation Guide Heat Exchanger Water Schematic Aux. Engine cooler (notin all systems) Page 40 of 40...
Need help?
Do you have a question about the CAFS DS Series and is the answer not in the manual?
Questions and answers