Pneumax 140-SP User manual

PTO-Driven Compressor Kit Installation Guide
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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: [phone]
www.pneumaxcafs.com

Pneumax PTO-Driven Compressor Kit Installation Guide
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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....................................................................13
Auto-Sync....................................................................................................................................... 15
1. UNLOAD Mode Adjustment.....................................................................................15
2. FIXED Mode Adjustment .........................................................................................16
3. AUTO Mode Adjustment..........................................................................................17
Suggested components for CAFS discharges:.................................................................................18
Discharge kits...............................................................................................................18
Air distribution manifold: ...............................................................................................18
Suggested air hose ......................................................................................................18
Air Pressure Gauge......................................................................................................18
Compressor System........................................................................................................................19
Schematics and Dimensional Drawings...........................................................................................23
Basic Compressed Air Foam System (CAFS) Schematic..............................................23
80-SP with 8-inch Vertical Sump, Hydraulic Schematic.................................................24
140/200-SP with 10-inch Vertical Sump, Hydraulic Schematic......................................25
80-SP Manual Auto-Sync Valves, Air and Water Connections.......................................26
140/200-SP Manual Auto-Sync Valves, Air and Water Connections..............................27
Compressor Installation Angles....................................................................................28
Eight-Inch Vertical Sump..............................................................................................29
Ten-Inch Vertical Sump................................................................................................30
80-P Heat Exchanger (Oil cooler).................................................................................31
140/200-SP Heat Exchanger (Oil Cooler) .....................................................................32
80-SP Separator Filter..................................................................................................33
140/200-SP Oil and Separator Filters ...........................................................................34
Balance Valve and Auto-Sync Controls, Panel Cutout...................................................35
Companion Flange.......................................................................................................36

Pneumax PTO-Driven Compressor Kit Installation Guide
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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.
Note: A note points out important information. Failure to read the note will not result in
physical harm to personnel or equipment. It may waste time and money.
Revision History
Revision Date Issued Comments
1.0 3/1/04 Original Release
2.0 5/4/04 2nd Release

Pneumax PTO-Driven Compressor Kit Installation Guide
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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.
Note: Air is always injected after the water/solution valve. This will give each discharge the
best performance possible.

Pneumax PTO-Driven Compressor Kit Installation Guide
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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.
Make sure that there will be room to install the air compressor on a bracket close to the
PTO, with their drive angles matched.
Caution: The driveline angles MUST be matched to prevent serious damage to the compressor,
PTO, or transmission.
Specific gear ratios vary among the different transmissions and PTO suppliers. The ratios
suggested below are a guide for selecting the PTO. With these ratios, the rated CFM is
usually achieved with the engine speed between 1400 to 1600 RPM.
Caution: A higher speed on the PTO means the CAFS system will reach the desired CFM at
lower engine speeds. Exceeding the compressor's rated RPM can damage the
compressor, and void the warranty. In such applications, an over speed cut-out
should be installed on the PTO to protect the compressor.
DO NOT engage PTO above 1000 Engine RPM.
To calculate the possible compressor RPM, use this equation:
Engine RPM x gear ratio on PTO x compressor gear ratio = compressor RPM
80-SP Compressor
CFM required PTO speed HP average
80 160% HI 22
80 184% HI 22
140/200-SP Compressor
CFM required PTO speed HP average
120-140 143% HI 32-40
200 160% HI 55-60
Some applications may require a PTO running faster than typical requirements, for
example:
200 187% HI 55-60

Pneumax PTO-Driven Compressor Kit Installation Guide
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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" circuit to trigger the PTO system.
Wiring the PTO switch circuit in parallel with the "OK to Pump" light is one way to ensure
that the PTO and compressor cannot be activated unless the fire pump is engaged.
From
“OK to Pump”
“OK to
Pump”
Light
PTO
Switch
Ground To PTO

Pneumax PTO-Driven Compressor Kit Installation Guide
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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.
Caution: The air compressor cannot be installed on its side. It must remain upright, with the
air intake on the top.
Once again, remember that the driveline angles on the compressor need to match the
driveline angles on the Power train.If driveline angles are not matched, this could
result in bad vibration issues that could lead to driveline failure or cause the Air
Compressor to fail.
If you have questions concerning driveline angles, please contact your driveline
supplier.
The air inlet on the Air Compressor can be turned to any direction, as the bolt pattern is
symmetrical. This way the air inlet can be turned any direction to ease installation of the air
filter.
The air filter is supplied with the kit along with a T-Bolt clamp. For basic installation, the air
inlet tubing supplied to connect the filter to the air inlet is steel tubing and rubber.
Remember it is an air inlet, just as in an engine. The easiest thing we have found is
aluminum or steel tubing thin wall. DO NOT use flexible exhaust tubing or anything water or
dirt can easily penetrate.

Pneumax PTO-Driven Compressor Kit Installation Guide
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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.
The sump works best when it is installed so that the sight glass opening is at or below the
level of the Air Compressor.
In some cases, finding room for the sump can be difficult. It is acceptable to mount the oil
sump up to 12 inches higher than the air compressor; however this may require the
installation of an oil inject check valve to prevent oil from flooding the compressor. It is
usually fine, though, without this check valve. Oil inject check valve may be ordered from
Pneumax when ordering the system or can be installed after the system has been tested.
Suggested part numbers for this check valve are available through Pneumax.
The oil fill-sight glass on the Oil Sump is next to the oil fill port. It is necessary to locate the
sight glass in an accessible location for ease of checking or adding oil, usually near a door.
It is the responsibility of the installer to make sure the oil can be reasonably checked and
added if necessary.
Suggested oil to be used in the system:
•ISO 68 wt Hydraulic Low Foaming Anti-Foaming

Pneumax PTO-Driven Compressor Kit Installation Guide
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80-SP Vertical Sump
The Safety Pressure Relief valve may be installed in either of the ports. The remaining ports
have no options.
Vertical sump, top view Vertical sump, side view
Out to
Separator Filter
Safety
Pressure Relief
Inlet from
Compressor
Oil Level
Sight Glass
Oil Drain
Oil out to
Filter
Oil
Fill

Pneumax PTO-Driven Compressor Kit Installation Guide
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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
Safety Pressure
Relief (alternate
installation point)
Safety
Pressure
Relief
Vertical sump, top fittings Vertical sump, lower fittings
Not
Used
Mounting
Bracket
Safety
Pressure
Relief
From
Compressor
Vertical sump, rear view Vertical sump, rear view
Oil Level
Sight Glass
Oil Fill
Air/Oil
from
Compressor