Waterous 80-P User manual

Waterous Company, 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA [phone]
www.waterousco.com
80-P, 80-SP PTO-Driven Compressor Kit
Operation Guide
Read through the Operation
instructions carefully.
NOTE: Instructions subject to change without notice.
SECTION 1. OPERATING INSTRUCTIONS................................................ 3
A. For Manual Auto-sync.............................................................................. 3
B. Multiple Uses ........................................................................................... 3
C. Water Pumping Operations...................................................................... 3
D. Foam Solution Operations ....................................................................... 3
E. Compressed Air Foam Operations........................................................... 4
F. Compressed Air Only Operation.............................................................. 4
G. Shut-Down Procedure.............................................................................. 6
SECTION 2. AIR COMPRESSORS...............................................................7
A. How It Works............................................................................................ 7
SECTION 3. SYSTEM SERVICE AND MAINTENANCE ............................... 8
A. Maintenance Schedule............................................................................. 9
B. Maintenance Items................................................................................... 9
C. Wye Strainer for Cooler.......................................................................... 10
SECTION 4. CAFS NOZZLE / FLOW RATE / HOSE COMBINATIONS........ 11
A. Nozzles.................................................................................................. 11
B. Foam Concentrate Ratios...................................................................... 11
C. Hose....................................................................................................... 11
SECTION 5.SUGGESTED GUIDELINES FOR THE PRODUCTION OF MID-
RANGE COMPRESSED AIR FOAM ....................................................... 12
A. 1” (25 mm) Hose Diameter Jacketed ..................................................... 12
B. 1-1/2” (38 mm) Hose Diameter .............................................................. 12
C. 1-3/4” (44 mm) Hose Diameter .............................................................. 13
D. Master Stream ....................................................................................... 14
SECTION 6.TROUBLESHOOTING - CAFS............................................... 15
SECTION 7.CONDITIONAL 1-YEAR WARRANTY POLICY........................ 23
F-1031, Section 2416 (Revised: 02/02/10)

F-1031, Section 2416 Page 2 of 23
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 may 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, setscrews, 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.
Figure(s)
Figure 1 Manual Auto-sync panel................................................................................................................3
Figure 2 CE 55 G.........................................................................................................................................7
Figure 3 Wye Strainer.................................................................................................................................10
Figure 4 Wye-strainer installed, with cleanout valve .................................................................................10
Figure 5 Clean Strainer..............................................................................................................................10
Figure 6 Dirty Strainer................................................................................................................................10
Figure 7 80-SP...........................................................................................................................................19
Figure 8 Basic CAFS Schematic ...............................................................................................................20
Figure 9 Air Schematic w/ Manual Auto-sync............................................................................................21
Figure 10 Hydraulic Schematic..................................................................................................................22

F-1031, Section 2416 Page 3 of 23
SECTION 1. OPERATING INSTRUCTIONS
A. For Manual Auto-sync
Figure 1 Manual Auto-sync panel
B. Multiple Uses
A pumper equipped with a Waterous compressed air foam unit can be operated in several pumping
modes; water only, foam solution without compressed air, compressed air foam and compressed air
only for support operations such as operating air tools, filling rescue air bags, etc. It is possible to pump
foam solution from one discharge while pumping compressed air foam from another, or varying foam
consistencies (expansion ratios) from different discharges simultaneously.
NOTE: Monitor compressor instruments during any and all operations.
C. Water Pumping Operations
All unit operations begin with pumping water. Follow the instructions provided in the apparatus manuals
for operations involving pumping water.
For water only operations, the compressor PTO shift control should be in the “OFF” position, which
disengages the air compressor.
CAUTION: Running the unit with a dry fire pump can cause damage to the pump and air compressor
system.
D. Foam Solution Operations
Follow the instructions above for water pumping operations. Turn on the foam proportioner to inject
foam concentrate into the water stream. Refer to the foam proportioner operation manual for
instructions in the proper operation of the installed proportioning system.

F-1031, Section 2416 Page 4 of 23
E. Compressed Air Foam Operations
Follow the instructions above for foam solution operations. Safe operations dictate the presence of
foam concentrate in the water stream prior to the injection of compressed air. If foam concentrate is not
present, a condition known as “slug flow” will occur. This is where unmixed water and air is discharged
through a nozzle in an erratic manner.
Set water discharge pressure at the desired level. Discharge pressures for compressed air foam
operations typically range between 80 and 120 PSI in a flow state.
NOTE: Compressed air foam does not have the hydraulic characteristics of plain water or foam
solution. Therefore, standard pump hydraulics practices do not apply to CAFS operations.
•Engage the air compressor by moving the PTO switch to the “ON” position.
•Move the Auto-Sync controls to the AUTO / RUN positions. Air pressure as shown on the air
pressure gauge should rise to within plus or minus 5% of the water discharge pressure. The Auto-
Sync system will balance the air and water pressures + or - 5% throughout a range of 40 PSI up to
150 PSI.
•Set proportioner at 0.2% - 0.6% for normal Class A combustibles.
The type and brand of foam concentrate used and the tactical objective, dictate proportioning rates.
•Open desired discharge valve(s). The foam expansion ratio is set by controlling the amount of foam
solution entering the discharge stream. High solution flows restrict the amount of air admitted and
result in lower expansion or “wet” foam. To produce higher expansion or “drier” foam, simply gate
back the amount of solution admitted.
•Fully open the air valve(s) to the desired discharges.
•Adjust the solution flow to produce the desired foam consistency.
Foam is formed during the transition through the hose. To produce acceptable finished foam,
sufficient hose length must be provided on the discharge. Refer to Section “Suggested Guidelines
for the Production of Mid-Range Compressed Air Foam”, for minimum hose lengths for CAFS
operations.
WARNING Nozzle reaction force is significantly increased at the time the nozzle valve is opened in
compressed air foam operations. OPEN CAFS NOZZLES SLOWLY!
F. Compressed Air Only Operation
Follow instructions for water pumping operations without opening discharge valves. Air compressor
cooling is via water that is circulated by the fire pump through the compressor cooler and returned back
to the booster tank. During this operation, time is limited by the amount of available cooling water. The
water in the booster tank will eventually become heat saturated and ineffective at cooling the air
compressor. Watch the compressor temperature gauge closely! Maximum 250° F. Compressor
system overheat is also indicated by the panel mounted warning light and alarm.
•After engaging the fire pump, ensure that the water pressure as shown on the panel mounted
master pressure gauge rises.
•Engage the air compressor PTO

F-1031, Section 2416 Page 5 of 23
•Move the Auto-Sync controls to the RUN / FIXED positions. Air pressure will rise to the preset
pressure setting on the air compressor, approximately 150 PSI with the engine throttled-up.
•For lower operating pressures, move the Auto-Sync controls to the RUN / AUTO positions and use
the engine throttle to control the water pressure / air pressure.
•Connect the air discharge hose to the fitting on the pump operator’s panel and open the air supply
valve.
Extended compressed air only operations necessitate connection of an external water source to the
pump inlet and closing of the tank to pump valve for proper compressor cooling. In this case, cooling
water will flow into the booster tank at 10-20 GPM, eventually overflowing the tank.
WARNINGS •Compressed air can be dangerous. Read and understand the operating instructions for the
Waterous compressed air foam unit and individual components prior to operating.
•DO NOT use the compressed air foam unit as an air source for SCBA or any breathing air
supply.
•Discharge outlets that are capped, hose lines that are valved and charged and the air
compressor sump may contain compressed air. Relieve all pressure BEFORE attempting
to remove any caps, fittings, and nozzles or to perform maintenance to prevent serious
personal injury.
•Nozzle reaction force is significantly increased at the time the nozzle valve is opened in
compressed air foam operations. OPEN CAFS NOZZLES SLOWLY!
•Operating the compressed air foam unit with water and compressed air pumped through a
discharge without foam concentrate will create a potentially dangerous condition known as
"Slug Flow"; where unmixed pockets of water and air are passed through the nozzle,
causing erratic nozzle reaction.
•For compressed air foam operations, use only fire hose that is rated at 200 PSI or higher
working pressure.
•The unit operator should have a thorough understanding of "Boyle's Law" (The law of
compressed gases) prior to operating the compressed air foam unit.

F-1031, Section 2416 Page 6 of 23
G. Shut-Down Procedure
1. Close air valve(s)
2. Turn off Foam proportioner
3. Flow clear water through discharge hose(s) until no bubbles are present
4. Close discharge valve(s)
5. Move Auto-Sync controls to AUTO / UNLOAD
6. Move the air compressor PTO switch to the “OFF” position
After the compressor PTO is disengaged, the system will vent itself, creating an audible hiss as
compressed air is evacuated from the pressure vessel / sump.
CAUTION: Allow system to bleed down the pressures for approximately 2-3 minutes prior to re-
engaging. Otherwise, re-engagement may cause engine to stall.

F-1031, Section 2416 Page 7 of 23
SECTION 2. AIR COMPRESSORS
Figure 2 CE 55 G
A. How It Works
The air compressor used in this application is an oil flooded rotary screw type. Rotary screw air
compressors are very common in industrial applications. This type of compressor injects oil into itself,
where it lubricates, seals, cools, and silences the compressor. The oil is then entrained into the air
discharge from the compressor. This air/oil mixture is discharged into a sump tank where most of the
oil separates from the air. The oil is then sent via hydraulic hose to a combination cooler / filter unit. It is
cooled to remove compression and friction heat, filtered, and sent to the oil injection port on the
compressor. The cycle is then repeated.
The oil mist that remains in the air stream is recovered by an air/oil separator system. This system
recovers the oil mist in a spin-on cartridge that has a siphon tube that picks-up the recovered oil for
return to the air compressor.
The compressor’s air output is controlled by a modulating inlet valve. The inlet valve is opened and
closed by the Auto-Sync pressure control system.
The compressor cooling system circulates water from the fire pump through the compressor oil cooler
and back to the tank to remove heat from the compressor oil system. The compressor oil temperature
should not exceed 250° F. If this occurs, check the water supply; pump prime, restrictions in the cooling
water system and for low oil level in the sump.
The air compressor (air end) is driven via a transmission power take-off. It is important to ensure that
there is a water supply from the fire pump whenever the engine is running. Pump and/or compressor
damage may result from running the pump dry.

F-1031, Section 2416 Page 8 of 23
SECTION 3. SYSTEM SERVICE AND MAINTENANCE
Excessive heat build-up and oil system contamination are the most common causes of compressor system
problems and premature wear. With proper operation and maintenance, the compressor system should far
outlast the vehicle it is mounted on. Adherence to the following guidelines will prevent potentially costly
damage.
1. There is a sight gauge provided on the oil reservoir/sump. The oil level should be at approximately
halfway up the window. Check the oil on level ground, prior to system start up. If the system has
recently been run, wait 10 minutes after shutdown for the oil to stabilize before checking the oil level.
The compressor uses common hydraulic oil. This oil is classified by an ISO standard as ISO 68
viscosity and is sold under various trade names. Many are sold as “anti wear” hydraulic oil and are
available from auto parts or lubricating oil suppliers.
2. The oil should be changed after the first 30 hours of system operation. After that, the oil should be
changed annually. There is a drain plug located at the bottom of the sump. The oil fill cap is located on
top of the unit.
3. Change the compressor system oil filter at the same time as the oil is changed. Call Waterous for
replacement elements.
4. Run the compressor for 2 minutes after changing the oil, then re-check the oil level and add oil as
necessary. DO NOT OVERFILL.
5. Visually inspect the compressor oil system weekly for signs of leaks. Check the air compressor Poly
Chain drive for proper tension and signs of wear monthly or more frequently as dictated by the amount
of use.
6. Inspect the compressor air intake filter and clean or replace as necessary. The environment in which
the unit operates will determine the frequency of air filter service and replacement. In any situation,
replace no less frequently than yearly.
7. Replace the oil / air separator cartridge every 24 months, or if the unit’s oil consumption suddenly
increases. A sudden increase may be caused by a hole in the internal media of the cartridge allowing
oil to carry through and discharge with the compressed air. Call Waterous for replacement separator
cartridges.
8. Completely drain the water from the compressor oil cooler in cold weather to prevent freeze damage.

F-1031, Section 2416 Page 9 of 23
A. Maintenance Schedule
Check
oil level
and for
oil leaks
Change Compressor
Oil Change Oil Filter Change Separator Cartridge
Run Air system
15 minutes per
Compressed Air
Only Operation
Daily or After
Each Use X
Weekly X- pg 5
Annually X X
Every 24 Months X
Inspect the air compressor air intake filter monthly and change as necessary.
B. Maintenance Items
COMPRESSOR
Waterous part#
AIR FILTER: CO85005
(1)
2030043
HYDRAULIC FILTER: WD 920
(
2
)
2030058
SEPARATOR FILTER: ----------- -----------
Boss Compressor: LB 1374/2
(
2
)
2030015
Ingersoll Compressor LB 962/2
(
2
)
2030050
HYDRAULIC OIL
ISOAUW68 Anti-Wear, Low-Foaming, Anti-Foaming
(1) = Donaldson (2) = Mann & Hummel (3) = Gates

F-1031, Section 2416 Page 10 of 23
C. Wye Strainer for Cooler
A wye-strainer is provided to strain water before it enters the cooler's water inlet. The wye strainer
requires regular inspection, and should be in an easily accessible location for inspection, removal, and
cleaning.
Caution: Waterous is not responsible for damage due to plugged strainers. If the customer's
water system contains excessive debris, or the vehicle relies on drafting for its water
supply, it may be necessary to install a larger strainer and/or a clean-out valve on the
wye-strainer.
Without good water flow through the heat exchanger, the compressor will overheat. Compressor
performance will be inadequate, and it may fail completely.
Omitting the Wye-strainer or removing the screen from the Wye does not improve water flow. It will
allow debris into the cooler, which can clog the tiny heat exchanger tubes and restrict water flow.
Figure 3 Wye Strainer Figure 4 Wye-strainer installed, with
cleanout valve
Figure 5 Clean Strainer Figure 6 Dirty Strainer

F-1031, Section 2416 Page 11 of 23
SECTION 4. CAFS NOZZLE / FLOW RATE / HOSE
COMBINATIONS
A. Nozzles
Compressed air foam can be discharged through various types and sizes of nozzles. Fog nozzles
break down the bubble structure of the foam. This results in “wetter” or reduced expansion foam. The
preferred way to make foam is utilizing smooth bore nozzles with a given hose diameter, smaller tips
will discharge “wetter” foam.
B. Foam Concentrate Ratios
Proportioner settings of 0.2% and 0.6% are typically adequate to produce compressed air foam that is
formed in a hose line and used on Class A combustibles. Higher settings will result in “drier” appearing
foam. Lower settings may result in “slug flow” or discharge pulsation caused by insufficient foam
concentrate in solution to form foam in the hose line.
For Class B or other type foam ratio settings, follow the instructions provided by the foam concentrate
manufacturer.
C. Hose
Utilize fire hose that is rated by the hose manufacturer for use with CAFS. Since the foam is formed
during its transition through the hose line, it is important to utilize the minimum recommended hose
lengths, unless a static mixer is utilized. There is significantly less friction and head loss with
compressed air foam as compared to water or foam solution. Hence, effective fire streams can be
achieved with longer hose lays. Refer to the section, “Suggested Guidelines for the Production of Mid-
Range Compressed Air Foam”.
NOTE: Compressed air foam systems have the ability to produce foam of shaving cream consistency.
This type of foam is typically suited for defensive operations such as exposure protection,
barriers or fuels pretreatment. While this type of foam is highly stable and possesses a long
drain time, it is essential to ensure that the foam will release sufficient water to extinguish a fire
in a direct attack situation.

F-1031, Section 2416 Page 12 of 23
SECTION 5. SUGGESTED GUIDELINES FOR THE PRODUCTION
OF MID-RANGE COMPRESSED AIR FOAM
A. 1” (25 mm) Hose Diameter Jacketed
1 GPM to 1 CFM
½” Tip Solution Flow: 15 GPM (56.78 LPM)
Air Flow: 15 CFM (0.42 m3/min)
Disch. Pressure: 100-150 PSI (6.804 - 10.206 BAR) (689.5 - 1034.25 KPA)
Min/Max Hose Length: 35’ to over 400’ (10.668 – 121.92 meters)
2 GPM to 1 CFM
½” Tip Solution Flow: 30 GPM (113.56 LPM)
Air Flow 15 CFM (0.42 m3/min)
Disch. Pressure: 100-150 PSI (6.804 - 10.206 BAR) (689.5 - 1034.25 KPA)
Min/Max Hose Length: 35’ to over 400’ (10.668 – 121.92 meters)
1 GPM to 1 CFM
¾” Tip Solution Flow: 20 GPM (75.71 LPM)
Air Flow: 20 CFM (0.56 m3/min)
Disch. Pressure: 100-150 PSI (6.804 - 10.206 BAR) (689.5 - 1034.25 KPA)
Min/Max Hose Length: 35’ to over 200’ (10.668 – 60.96 meters)
2 GPM to 1 CFM
¾” Tip Solution Flow: 40 GPM (151.41 LPM)
Air Flow: 20 CFM (0.56 m3/min)
Disch. Pressure: 100-150 PSI (6.804 - 10.206 BAR) (689.5 - 1034.25 KPA)
Min/Max Hose Length:35’ to over 200’ (10.668 – 60.96 meters)
B. 1-1/2” (38 mm) Hose Diameter
1 GPM to 1 CFM
1” Tip Solution Flow: 30-40 GPM (113.56 – 151.41 LPM)
Air Flow: 30-40CFM (0.84 – 1.12 m3/min)
Disch. Pressure: 100-150 PSI (6.804 - 10.206 BAR) (689.5 - 1034.25 KPA)
Min/Max Hose Length: 100’ to over 800’ (30.48 – 243.84 meters)

F-1031, Section 2416 Page 13 of 23
2 GPM to 1 CFM
1” Tip Solution Flow: 60-80 GPM (227.12 – 302.82 LPM)
Air Flow: 30-40CFM (0.84 – 1.12 m3/min)
Disch. Pressure: 100-150 PSI (6.804 - 10.206 BAR) (689.5 - 1034.25 KPA)
Min/Max Hose Length: 100’ to over 800’ (30.48 – 243.84 meters)
1 GPM to 1 CFM
1-3/8” Tip Solution Flow: 50-60 GPM (189.27 – 227.12 LPM)
Air Flow: 50-60 CFM (1.4 – 1.68 m3/min)
Disch. Pressure: 100-150 PSI (6.804 - 10.206 BAR) (689.5 - 1034.25 KPA)
Min/Max Hose Length: 100’ to over 800’ (30.48 – 243.84 meters)
2 GPM to 1 CFM
1-3/8” Tip Solution Flow: 90-120 GPM (340.68 – 454.24 LPM)
Air Flow: 50-60 CFM (1.4 – 1.68 m3/min)
Disch. Pressure: 100-150 PSI (6.804 - 10.206 BAR) (689.5 - 1034.25 KPA)
Min/Max Hose Length: 100’ to over 800’ (30.48 – 243.84 meters)
C. 1-3/4” (44 mm) Hose Diameter
1 GPM to 1 CFM
1” Tip Solution Flow: 30-40 GPM (113.56 – 151.41 LPM)
Air Flow: 30-40 CFM (0.84 – 1.12 m3/min)
Disch. Pressure: 100-150 PSI (6.804 - 10.206 BAR) (689.5 - 1034.25 KPA)
Min/Max Hose Length: 100’ to over 1400’ (30.48 – 426.72 meters)
2 GPM to 1 CFM
1” Tip Solution Flow: 60-90 GPM (227.12 – 340.68 LPM)
Air Flow: 30-50 CFM (0.84 – 1.4 m3/min)
Disch. Pressure: 100-150 PSI (6.804 - 10.206 BAR) (689.5 - 1034.25 KPA)
Min/Max Hose length: 100’ to over 1400’ (30.48 – 426.72 meters)
1-3/8” Tip Solution Flow: 50-90 GPM (189.27 – 340.68 LPM)
Air Flow: 50-80 CFM (1.4 – 2.24 m3/min)
Disch. Pressure: 110-150 PSI (7.4844- 10.206 BAR) (758.45- 1034.25 KPA)
Min/Max Hose Length: 100’ to over 700’ (30.48 – 213.36 meters)
NOTE: With 1-3/4” hose lengths of 100’-250’ (30.48 – 76.2 meters), up to 90-120 GPM (340.68 – 454.24
LPM) of water and 40-100 CFM (1.12 – 2.8 m3/min) of air may be utilized as a highly effective initial
attack flow.
System flows are very flexible. The flow of any discharge can vary according to the situation and
conditions.

F-1031, Section 2416 Page 14 of 23
It is possible to make the discharge stream wetter or drier by changing the amount of solution or air in the
hose.
The stream can also vary by changing the tip size at the nozzle.
•The bigger the diameter tip, the drier the foam.
•The smaller the diameter tip, the wetter the foam.
D. Master Stream
1” Tip Solution Flow:
90-120 GPM (340.68 – 454.24 LPM)
Air Flow: 60-80 CFM (1.68 – 2.24 m3/min)
1-3/8” Tip Solution Flow:
100-150 GPM (378.53 – 567.80 LPM)
Air Flow: 70-100 CFM (1.96 – 2.8 m3/min)
1-1/2” Tip Solution Flow:
120-200 GPM (454.24 – 757.06 LPM)
Air Flow: 80-120 CFM (1.68 – 3.36 m3/min)
1-3/4” Tip Solution Flow:
180-250 GPM (681.35 – 946.33 LPM)
Air Flow: 120-150 CFM (3.36 – 4.2 m3/min)
2” Tip Solution Flow:
250-450 GPM (946.33 – 1703.39 LPM)
Air Flow: 200 CFM (5.6 m3/min)
Disch. Pressure: 120-150 PSI (8.1648 – 10.206 BAR) (827.4 – 1034.25 KPA)
NOTE: Typical master stream operations utilize lower foam expansion ratios (“wetter” foam) for
increased foam density and longer stream reach.

F-1031, Section 2416 Page 15 of 23
SECTION 6. TROUBLESHOOTING - CAFS
Observed
Symptom Probable Cause Suggested Remedy
Lack of air pressure
from compressor
Lack of air supply to
clutch (for air-clutch
systems) Repair air leak or re-establish air supply
Compressor not
engaging No PTO engagement Confirm OK TO PUMP light is on, if not check wiring for damage or disconnected wire,
check PTO.
Compressor
engaging. No air
supply to
discharges or
insufficient air
supply.
Auto-Sync switches not
in correct position.
Confirm 40 PSI in UNLOAD position (200 CFM systems) and 50+ in run position.
Smaller compressors have lower UNLOAD pressures.
Verify when in FIXED/RUN whether pressure reflects 145-150 PSI
(electric valves) Verify
there is power to the air
solenoid and check
operation of solenoid.
Air discharge solenoid not working.
Repair/replace solenoid
Air solenoid working - leak between solenoid and discharge. Repair leak.
Air check valve defective Replace or correct installation.
Trim valve out of
adjustment Refer to trim valve instructions
Restricted minimum
pressure valve Clean rust or debris from valve
Air plumbed before
discharge valve seal Relocate to discharge side of discharge valve
Incorrect air line size Size according to discharge and replace line with correct size.
System functioning
correctly, pressure
gauge reading
obviously incorrect.
Gauge malfunction, air
line detached Check for air leaks, replace gauge
FIXED has
pressure but AUTO
has
no pressure
No water supply to
balance valve. Check line for proper installation, with no kinks or obstructions. Refer to trim valve instructions.
Air discharge
pressure too high
Red hose circuit
(compressed air control)
has leak or is
disconnected.
Repair leak or attach hose

F-1031, Section 2416 Page 16 of 23
Observed
Symptom Probable Cause Suggested Remedy
System overheating
Inadequate water flow
through cooler Ensure adequate water flow through pump. Check Y strainer for obstruction, clean and reinstall Drain and flush cooler water tubes
Adequate water flow
through cooler.
On-board tank used for cooling for a prolonged period - water too hot to effectively cool
the compressor. Locate source of lower temperature water.
Check oil level -
Adjust level to half of the sight glass on level surface.
Low compressor oil
level:
Check the hydraulic lines for kinks
Change oil filters
Temperature sending
unit and or gauge circuit
malfunction. Check wire connections at sending unit
High Oil
Consumption
Overfull compressor oil Adjust level to half of the sight glass on level surface.
Excess of 200 CFM air
flow (on 200 CFM
systems)
Back down RPM's and flow CAFS to relieve pressure, then recheck
Replace Air/Oil Separator Filter
Air/oil Separator Filter
torn or damaged (could
be caused by air flow of
higher than 200CFM)
System being operated at higher than capacity
"Excessive"
compressor bleed
down time on
shutoff
Systems vary in bleed
down time. If Auto-Sync is operating correctly, and compressor output is within spec, do nothing.
Engine stalls upon
compressor
engagement
Engaging compressor
while under load Allow compressor to bleed down before re-engagement
Running system without
flowing air causes oil to
accumulate in
compressor acting like
hydraulic pump
Bleed down air, restart compressor, and move air
Underrated engine
horsepower Raise engine RPM
Auto-Sync in FIXED /
RUN setting Engage in AUTO/UNLOAD, then switch to FIXED/RUN
High oil level Check oil level, adjust level to half of the sight glass with vehicle parked on a level
surface
Compressor locked up Repair/replace compressor
Compressor locked
up High oil level (compressor is flooded) Check oil level, adjust level to half of the sight glass with vehicle parked on a level surface

F-1031, Section 2416 Page 17 of 23
Observed
Symptom Probable Cause Suggested Remedy
Sump fire Check system and repair
Low oil level or no oil Check system and repair
Air flow meter stuck
at "0" CFM Magnet uncoupled in meter Turn air flow on and off to re-couple
Air flow meter stuck
at high CFM Move large amounts of air out discharge and turn air flow on and off to re-couple
Poor foam (wet or
dry) or no foam
(assuming air
pressure to
discharges is OK)
Using wetting agent and
not foam concentrate. Use foam concentrate
Foam proportioning
control turned too low. Increase amount of concentrate delivered to manufacturer recommended amount.
Foam proportioning
control OFF or turned
too low, foam tank
empty.
Make sure proportioner is turned on, foam supply valve is open, foam tank has
concentrate, Y strainer is clean, and supply line is connected to injector.
Discharge hose
shaking (slug flow)
Foam proportioner ON,
setting correct, and tank
has foam concentrate,
but not providing foam
solution.
Refer to foam proportioner manufacturer's instructions for detailed calibration and
troubleshooting instructions
Foam in the water
system (when
proportioner turned
off)
Foam concentrate was
poured into the on-board
water tank Flush tank and pump with clean water, refill
Foam manifold drain
lines not isolated from
water drain lines Isolate to separate drain valve
Cooler line plumbed
from foam manifold Relocate line to discharge side of pump
Foam manifold check
valve defective Rebuild/replace check valve
Water in
compressor oil/air
Leaking inside cooler
Freeze damage Isolate cooler and check for leaks, replace if needed, check drain
Defective air check
valves Replace or check
Missing air check valves
for discharges Install check valves
Clutch smoking
Engaging in RUN
position Engage in AUTO/UNLOAD only
Slight air leak from
solenoid to clutch Repair air leak

F-1031, Section 2416 Page 18 of 23
Observed
Symptom Probable Cause Suggested Remedy
High RPM engagement Engage in lower RPM
Not allowing compressor
to bleed down before
engaging clutch again Allow for bleed down
Contaminated clutch
disc Clean or replace
Safety pop off valve
opening at low
pressure
Auto-Sync system out of
balance Adjust the Auto-Sync system, making sure to not open the trim valve on the compressor more than 3 turns.
Sump fire damaged pop
off valve Check system for other damage and replace valve
Safety pop off valve
repeatedly opening Trim valve or inlet completely open Refer to trim valve instructions

F-1031, Section 2416 Page 19 of 23
Figure 7 80-SP

F-1031, Section 2416 Page 20 of 23
Figure 8 Basic CAFS Schematic