Pneumax CAFS DS Series User manual

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: [phone]
www.pneumaxcafs.com

Pneumax CAFS "DS" Series 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.
Disclaimer: These instructions are guidelines only and in no way meant to be definitive. During
installation, standard safety precautions and equipment should be used where
appropriate. Because the tools used and the skill/experience of the installer can vary
widely, it is impossible to anticipate all conditions under which this installation is
made, or to provide cautions for all possible hazards. Proper installation is the
responsibility of the purchaser. All bolts, set-screws, and belts must be checked prior
to start-up AND after the initial operation. Damages due to poor installation are the
responsibility of the installer.

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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 ..................................................................... 16
1. UNLOAD mode verification..................................................................................................16
2. FIXED mode verification ......................................................................................................16
3. AUTO mode verification.......................................................................................................16
Suggested Third-party Components ..................................................................................... 17
Suggested components for CAFS discharges:........................................................................17
Troubleshooting .................................................................................................................... 19
Diesel Motor .............................................................................................................................19
Water Pump .............................................................................................................................19
Compressor System.................................................................................................................19
Auto Sync System....................................................................................................................23
Component Identification ...................................................................................................... 26
Air Pressure and Auto Sync Components ...............................................................................26
Oil Cooler and Filters ...............................................................................................................27
Sumps ......................................................................................................................................28
Schematics and Dimensional Drawings................................................................................ 29
Modules....................................................................................................................................30
Schematics...............................................................................................................................34

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Revision History
Revision Date Issued Comments
1.0 Dec 2, 2005 Original Release

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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.
Pneumax Model Pump Type Engine Type
120-60-DS* Waterous CPK-1 Deutz 1011F
250-120-DS Waterous CPK-2 Volkswagen 1.9L Turbodiesel
*This version has been superceded, and is included for historical purposes only.
Connection Points:
The systems vary because of customer
requests, but the connection 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
Terminals
Water Tank
Connections
Manifold
Controls
Motor, Pump,
and Compressor
System
Discharge
Valves and
Plumbing
X
X
X
X
Overboard
Suction
Usual Connection Point Locations
Hydraulic and Auto Sync Systems:
The position of the components of the hydraulic and Auto Sync systems varies from model
to model and may vary within units of the same model. See the component identification
photos in the rear of the manual.
Dimensions:
See the dimensional drawings in the rear of the manual for the critical measurements of the
module you are installing.

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Installation Overview
Warning: Do not start the engine unless the system is connected to a source of water.
The pump and compressor are in service whenever the engine is running.
Running without water will seriously damage the pump. It will also damage
the compressor.
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
•Battery and cables
•Fittings and pipe for plumbing
Installation tasks include:
•Installing the module into the vehicle
•Installing the Foam-Pro proportioner pump (120-60-DS and 250-120-DS) and
connecting it to the controls and the foam solution distribution lines.
•Plumbing the tank fill and tank-to-pump lines to the onboard tank
•Plumbing any discharges that are not plumbed through the control panel (if any)
•Connecting the fuel system
•Connecting the battery/12VDC power supply
•Filling all system fluids
•Final testing of system

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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.
Warning: Do not damage the vehicle chassis (also called frame or undercarriage) during
installation. Check with the vehicle manufacturer to make sure the planned
welds and bolts are in acceptable areas.
•The module must be bolted to brackets welded to the pump compartment frame, or
bolted directly to the pump compartment frame.
•The module must 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 must be exceeded, a fuel pump
capable of providing adequate fuel flow must be installed.
•Allow enough clearance at the sides of the module for routine maintenance. Most
maintenance can be performed through the top access doors, but service hatches at
the sides can make maintenance easier.
Lifting instructions
Warning: Make sure the lift and chains are rated to lift the weight of the CAFS system.
Using a Forklift
The system's drains are mounted on an
apron at the bottom of the unit. This
covers the frame.
Remove the apron at the bottom of
the system before fork-lifting.
Leave clearance between the CAFS
system and the front of the forklift to
avoid damage to the controls on the
front of the system.
Apron with drains

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Using an Overhead Lift or Engine Lift
Each corner of the frame has a UNC ½-
13 threaded insert for an eye bolt to use
in lifting.
Use spreader bars on the chains so that
the lifting stress on the eye bolts is
vertical.
Lifting point (1 of 4)
Engine Air Supply for Combustion and Cooling
•Only fresh air is suitable for combustion and cooling. The vehicle design must
prevent exhaust or hot air from returning to the engine intake area.
•Restrictions in the air intake and discharge must be avoided as far as possible.
•The clearance area at the rear must not be obstructed by other equipment.
•The vented access covers on top must not be obstructed by other equipment.
Required Engine Clearances
Model 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 BHP @RPM Fuel Type (lbs/bhp-hr) gal/hr
120-60-DS Deutz F3L1011 44.9 3000 Diesel 0.399 2.52
250-120-DS VW 1.9L Turbo 75 4000 Diesel 0.500 5.28
Tank Placement
If the fuel tank is below the engine, the difference in height between the inlet tip of the fuel
supply line and the fuel inlet on the engine must not be greater than the distance given here.
If the difference is greater, a fuel-line mounted lift pump is required. The pump capacity
required will depend on the tank position and other vehicle design factors. Consult with the
fuel pump manufacturer to select a suitable pump.
If the fuel tank is above the engine, an in-line pressure regulator may be needed. Consult
with the engine manufacturer to select a suitable regulator.

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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. Depending on the operating environment, additional filtration may be required.
If the fuel has a high water content, or if temperature fluctuations produce water
condensation in the tank, a water separator is required in the fuel supply line.
If the vehicle will be operated under extreme conditions (poor fuel quality, dirt contamination
of fuel likely, high water content, poor access to spare 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 angle the engine may operate in.
•Tanks must not be galvanized with zinc or made of any metal high in zinc because
some fuels will react with the tank and build up a soapy zinc compound that clogs the
fuel injectors.
•Tanks must be constructed to have a large surface area at any fuel level to facilitate
outgassing.
•Tanks must have a sludge drain valve at the bottom.
Supply and Return Fuel Lines for Fuel Injection
•Metal lines must be non-scaling.
•If the lines are not metal, the material must be heat-resistant (to 100°C).
•Line runs must be as straight and short as possible between tank and inlets or
outlets.
•The return line must not be connected to the supply line. It must return fuel to the
tank.

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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. This ensures a continual supply of fuel at the injector. The return line
must end 1/2 inch below the supply line to prevent air entering the fuel loop between the
tank and auxiliary engine.
Comments Installation technique
ReturnSupply
Filler neck with tank
ventilation
12 inch minimum
recommended
½ inch
Recommended for shared tank
If the auxiliary motor will draw fuel from the
tank used by the motor that moves the 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 unable to move the vehicle
out of a dangerous situation.
Return
Supply
Filler neck with tank
ventilation
6 inch minimum
recommended
½ inch
Alternate
Fuel Line
Alternate fuel supply and return line
layout for shared tank
If the fuel pickup for the auxiliary engine
goes to the bottom of the tank, as shown
here, the auxiliary engine can use almost all
of the fuel from the tank.
The best practice is for the supply line
opening to be 1.5 inches above the bottom
of the tank, to avoid drawing sludge or water
into the line, with the return line ending 0.5
inch below the supply line opening.
A2
ReturnSupply
Recommended for separate auxiliary tank.
NOT Recommended for shared tanks.