Waterous 80-P Troubleshooting guide

NOTE: Instructions subject to change without notice
Waterous Company, 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA [phone]
www.waterousco.com
F-1031, Section 2449 (Rev: 7/30/20)
Table of Contents
Safety Information ..................................................................2
Air Compressor Function.......................................................3
Operating Instructions:
Daily Checks .......................................................................3
Modes of Operation.............................................................3
Water Pumping Operations.................................................4
Foam Solutions Operations.................................................4
Compressed Air Foam Operations......................................4
Compressed Air Only Operations........................................5
Shut-Down Procedure.........................................................5
Air Compressor...................................................................5
System Service and Maintenance:
Guidelines...........................................................................6
Oil Cooler Strainer...............................................................6
Maintenance Schedule.....................................................6-7
CAFS Nozzle/Flow Rate/Hose Combinations:
Nozzles...............................................................................8
Foam Concentrate Ratios...................................................8
Hose....................................................................................8
Suggested Guidelines for the Production of Mid-Range
Compressed Air Foam:
1” Hose Diameter Jacked....................................................9
1-1/2” Hose Diameter..........................................................9
1-3/4” Hose Diameter..........................................................9
Master Stream...................................................................10
Troubleshooting Guide:
CAFS ...........................................................................11-13
Pump............................................................................14-17
Basic CAFS Schematic.........................................................18
Traditional CAF System
Operation and Maintenance Instructions
Read through the operation
instructions carefully before using
your Waterous CAF System.
Applies to the following CAFS Models:
System
Pump
Model
Transmission
Model
Compressor
CFM
CAFS Model
Air
Compressor
Only
--
--
80
80-P
100
100-B
140
140-P
200
200-P
Air
Compressor
and Water
Pump
CP-2
K
100
250-100-P
120
250-120-P
CLV
K
100
500-100-P
120
500-120-P
150
500-150-P
CXN
CXS
CXV
K or PA
150
750-150-P
1000-150-P
1000-150-PC
1250-150-P
1250-150-PC
T
150
750-150-T
1000-150-T
1250-150-T
C20
150
150-ESD
CM,
CMU,
CS,
CSU
C20
150
150-D
HL200
HL300
HL400
K
100
100-D
120
120-D
150
150-D
200
200-D
Air
Compressor
and PTO
TC20B, TC20C, TC20D,
TC20 E, TC20F
(TC20 Series PTO)
150
150-ESD

F-1031, Section 2449
Page 2 of 18
WARNING
Compressed air can be dangerous. Read and under-
stand the operating instructions for the Waterous
compressed air foam unit and individual components
prior to operating.
WARNING
Discharge outlets that are capped, hose lines that are
valved and charged and the air compressor sump
may contain compressed air. Relieve all pressure be-
fore attempting to remove any caps, fittings and noz-
zles or to perform maintenance to prevent serious
personal injury.
WARNING
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 un-
mixed pockets of water and air are passed through
the nozzle, causing erratic nozzle reaction.
CAUTION
Nozzle reaction force is significantly increased at the
time the nozzle valve is opened in compressed air
foam operations. Open CAFS nozzles slowly.
CAUTION
Do not use the compressed air foam unit as an air
source for SCBA or any breathing air supply
CAUTION
For compressed air foam operations, use only fire
hose that is rated at 200 PSI or higher working pres-
sure.
NOTICE
The unit operator should have a thorough under-
standing of “Boyle’s Law” (The law of compressed
gases) prior to operating the compressed air foam
unit.
NOTICE
When towing, disconnect the drive shaft that con-
nects the pump transmission’s rear output (coupling)
shaft to the vehicles differential. Failure to do so may
result in damage from lack of lubrication.
Safety Information
Read through the safety information and operating instructions before using your Waterous CAF System.

F-1031, Section 2449
Page 3 of 18
The air compressor used is a GHH Rand oil flooded rotary
screw type. Rotary screw air compressors are very com-
mon in industrial applications. This type of compressor in-
jects oil into itself, where it lubricates, seals, cools and si-
lences the compressor. The oil is then entrained into the
air discharge from the compressor. The air/oil mixture is
discharged into a sump tank where most of the oil sepa-
rates 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 re-
peated.
The oil mist the 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, re-
strictions in the cooling water system and for low oil level
in the sump.
The air compressor (air end) is driven by a dry Poly Chain.
The pump/air end are PTO driven by the engine. It is im-
portant to ensure that there is a water supply from the fire
pump whenever the system is running. Pump and/or com-
pressor damage may result from running the pump dry.
Daily Checks
Check the following fluid levels daily or prior to operating
the system:
•Compressor system oil (Oil level should be visible
within the sight glass on the sump and should be
checked daily or before or after used.)
•Foam concentrate
•Onboard water supply
Modes of Operation
The 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 possi-
ble to pump foam solution from one discharge while
pumping compressed air foam from another, or varying
foam consistencies (expansion ratios) from different dis-
charges simultaneously.
NOTE: Monitor engine and compressor instruments
during any and all operations
Air Compressor Function
Operation

F-1031, Section 2449
Page 4 of 18
Water Pumping
All unit operations begin with pumping water. These steps
must be followed for operations involving pumping water,
foam solution, compressed air or compressed air foam.
1. Connect the hose(s) to the desired discharge(s).
2. If pumping water from an on board booster tank, fully
open the tank to pump valve.
3. If pumping from an overboard source, the tank to
pump valve should be fully closed
4. If so equipped, turn on the main power switch to the
CAFS unit.
5. Engage the PTO.
6. Throttle-up to desired pressure. If pump pressure is
absent, it will be necessary to prime the pump.
7. Open desired discharge valves and throttle-up to
desired pressure.
CAUTION
Running the unit with a dry fire pump can cause dam-
age to the pump and air compressor system.
Foam Solutions
Turn on the foam proportioner to inject foam concentrate
into the water stream. Refer to the foam proportioner oper-
ation manual for instructions in the proper operation of the
installed proportioning system.
Compressed Air Foam
Follow instructions above 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.
1. Set water discharge pressure at the desired level.
Discharge pressures for compressed air foam opera-
tions 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 hy-
draulics practices do not apply to CAFS oper-
ations.
2. Select or confirm that the Auto-Sync controls are in
the AUTO position. 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 sys-
tem will balance the air and water pressures through-
out a range of 40 PSI up to 150 PSI. Optimal com-
pressed air foam system performance occurs at dis-
charge flow pressures of 80-120 PSI.
3. Set proportioner at 0.2% - 0.6% for normal Class A
combustibles. The type and brand of foam concen-
trate used and the tactical situation, dictate propor-
tioning rates objective
4. Open desired discharge(s). Controlling the amount of
foam solution entering the discharge stream sets the
foam expansion ratio. 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 admit-
ted.
5. Fully open the air valve(s) to the desired discharge(s).
6. 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 the section
“Suggested Guidelines for the Production of Mid-Range
Compressed Air Foam.”
WARNING
Nozzle reaction force is significantly increased at the
time the nozzle valve is opened in compressed air
foam operations. Open CAFS nozzles slowly.
Operation
Electric Auto-Sync Panel

F-1031, Section 2449
Page 5 of 18
Compressed Air Only
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 com-
pressor cooler and returned back to the booster tank. Dur-
ing 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. Maxi-
mum is 250F. Compressor system overheat is also indi-
cated by the panel mounted warning light and alarm.
1. After engine start, ensure that the water pressure as
shown on the panel mounted gauge rises.
2. Move Auto-Sync control the FIXED position. Air pres-
sure will rise to the preset pressure setting on the air
compressor, approximately 150-PSI with the engine
throttled-up.
3. For lower operating pressures, move the Auto-Sync
controls to the AUTO position and use the engine
throttle to control the water pressure, which in turn
will control the air pressure.
4. 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 far proper compres-
sor cooling. In this case, cooling water will flow into the
booster tank at 10-20 GPM, eventually overflowing the
tank, if the return is plumbed to tank.
Compressor Shut-Down
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. Shut down system
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 ap-
proximately 2-3 minutes prior to re-engaging. Other-
wise, re-engagement may cause the engine to stall.
Operation

F-1031, Section 2449
Page 6 of 18
Guidelines
Excessive heat build-up and oil system contamination are
the most common causes of compressor system prob-
lems 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 may prevent potentially costly damage.
1. There is a sight glass provided on the oil reser-
voir/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 stabi-
lize before checking the oil level. The compressor uses
common hydraulic oil. This oil is classified by an ISO
standard as ICO 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 sup-
pliers.
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 camp is located on top of that unit.
3. Change the compressor system oil filter at the same
time as the oil is changed. Call Waterous for replace-
ment 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.
Proper tension on the Poly Chain is to a no-slack set-
ting (if in doubt, do not tighten the Poly Chain). A
slightly loose Poly Chain is acceptable. An over-tight-
ened Poly Chain may cause equipment failure and may
void the product warranty.
6. Inspect the compressor air intake filter and clean or re-
place as necessary. The environment in which the unit
operates will determine the frequency of air filter ser-
vice 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 in-
creases. 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.
Oil Cooler Strainer
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.
System Service and Maintenance

F-1031, Section 2449
Page 7 of 18
Maintenance Schedule
Check oil
level & for oil
leaks
Change
compressor
oil
Change
oil filter
Change
separator
cartridge
Compressor
Hydraulic Oil
Daily or after
each use
x
ISOAUW68
Anti-Wear,
Low Foam-
ing, Anti-
Foaming
Annually
x
x
Every 24
months
x
Wye Strainer
Wye-strainer installed, with cleanout valve.
Clean Strainer
Dirty Strainer
Towing
When towing, disconnect the drive shaft that connects
the pump transmission’s rear output (coupling) shaft
to the vehicles differential. Failure to do so may result
in damage from lack of lubrication.
System Service and Maintenance (con’t)

F-1031, Section 2449
Page 8 of 18
Nozzles
Hose
Compressed air foam can be discharged through various
types and sizes of nozzles. Fog nozzles break down the
bubble structure of the foam, resulting in “wetter” or re-
duced expansion foam. The preferred way to make foam
is utilizing smooth bore nozzles with a given hose diame-
ter, smaller tips will discharge “wetter” foam.
Foam Concentrate Ratios
Proportioner setting of 0.2% - 0.6% is typicaly adequate to
produce compressed air foam that is formed in a hose line
and use don Class A combustibles. Higher settings will re-
sult 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 in-
structions provided by the foam concentrate manufac-
turer.
Utilize fire hose that is rated by the hose manufacturer for
use with CAFS. Since the foam is formed during its transi-
tion through the hose line, it is important to utilize the mini-
mum 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 section “Suggested Guide-
lines for the Production of Mid-Range Compressed Air
Foam.”
NOTE: Compressed air foam systems have the ability to
produce foam of shaving cream consistency.
While this type of foam is highly stable and pos-
sesses a long drain time, it is essential to ensure
that the foam will release sufficient water to extin-
guish a fire in a direct attack situation. This type of
foam typically suited for defensive operations
such as exposure protection, barriers or fuels pre-
treatment.
CAFS Flow

F-1031, Section 2449
Page 9 of 18
Hose
Diameter
Tip Size
Foam Type
Water Flow
Air Flow
Discharge
Pressure
Minimum
Hose Length
Hand Lines
1”
1/2”
Wet
20
20
100
35’
1”
3/4”
Wet
30
20
35’
1”
3/4”
Fluid
15
45
35’
1-1/2”
15/16”
Wet
80
40
100’
1-1/2”
1-3/8”
Fluid
30
110
100’
1-3/4”
15/16”
Wet
90
50
100’
1-3/4”
1-3/8”
Fluid
35
130
100’
2-1/2”
15/16
Wet
120
60
150’
2-1/2”
1-3/8”
Wet
190
90
150’
2-1/2”
2”
Fluid
50
155
150’
Portable Master Stream –fed by one 2-1/2’ line
2-1/2”
1-3/8”
Wet
300
100
140
150’
2-1/2”
1-1/2”
340
120
2-1/2”
1-3/4”
380
135
2-1/2”
2”
400
140
Wet Foam –melted ice cream consistency –fire attack
Fluid Foam –shaving cream consistency –exposure protection
Rules for Pumping from Tank or Draft
1. 15/16” orifice = Wetter Foam at 0.3%
2. 1-3/8” orifice = Dryer Foam at 0.3% to 0.8%
3. 100+ PSI = All interior hand lines
4. 1-3/4” = 80 to 100 GPM with 40 to 50 CFM
5. 2” = 110 to 120 GPM with 50 to 60 CFM
6. 2-1/2” = 130+ GPM with 60 to 80 CFM
7. 140 PSI = All Master Streams
Typical CAFS Flows

F-1031, Section 2449
Page 10 of 18
CAFS
Problem
Probable Cause
Recommended Action
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 dis-
charges 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 150 –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. Re-
pair 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
Relocated 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 incor-
rect.
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
leaked or is disconnected.
Repair leak or attach hose
Troubleshooting Guide

F-1031, Section 2449
Page 11 of 18
CAFS (Continued)
Problem
Probable Cause
Recommended Action
System overheating
Inadequate water flow
through cooler
Ensure adequate water flow through pump. Check Wye-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 from or
damaged (could be caused
by air flow of higher than 200
CFM)
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 flow-
ing air causes oil to accumu-
late 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 set-
ting
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
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
Troubleshooting Guide

F-1031, Section 2449
Page 12 of 18
CAFS (Continued)
Problem
Probable Cause
Recommended Action
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, Wye-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
manifold
Relocate line to discharge side of pump
Foam manifold check valve
defective
Rebuild/replace check valves
Water in compressor
oil/air
Leaking inside cooler Freeze
damage
Isolate cooler and check for leaks, replace if needed, check drain
Defective air check valve
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
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 bal-
ance
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
Troubleshooting Guide

F-1031, Section 2449
Page 13 of 18
Pump
Problem
Possible Cause
Recommended Action
Pump fails to prime or loses
prime
Air leaks
Clean and tighten all Intake connections. Make sure intake hoses
and gaskets are in good condition.
Use the following procedure to locate air leaks:
1. Connect Intake hose to pump and attach intake cap to end of
hose.
2. Close all pump openings.
3. Open priming valve and operate primer until vacuum gauge
indicates 22 in. Hg/.735 atmospheres. (If primer fails to draw
specified vacuum, it may be defective, or leaks are too large
for primer to handle.)
4. Close priming valve and shut off primer. If vacuum drops
more than 10 in. Hg/.334 atmospheres in 5 minutes,
serious air leaks are indicated. With engine stopped, air leaks
are frequently audible. If leaks cannot be heard,
apply engine oil to suspected points and watch for break in
film or oil being drawn into pump.
1. Completely fill water tank (if so equipped).
2. Connect intake hose to hydrant or auxiliary pump.
3. Open one discharge valve and run in water until pump is
completely filled and all air is expelled.
4. Close discharge valve, apply pressure to system and watch
for leaks or overflowing water tank. A pressure of 100 PSI is
sufficient.
DO NOT EXCEED RECOMMENDED PRESSURE.
1. If pump has not been operated for several weeks, packing
may be dried out.
2. Close discharge and drain valves and cap intake openings.
3. Operate primer to build up a strong vacuum in pump.
4. Run pump slowly and apply oil to impeller shaft near
packing gland.
5. Make sure packing is adjusted properly.
Dirt or Intake strainer
Remove all leaves, dirt and other foreign material from Intake
strainer.
When drafting from shallow water source with mud, sand or
gravel bottom, protect intake strainer in one of the following ways:
1. Suspend Intake strainer from a log or other floating object to
keep it off the bottom. Anchor float to prevent it from drifting
into shallow water.
2. Remove top from a clean barrel. Sink barrel so open end is
below water surface. Place intake strainer inside barrel.
3. Make an intake box, using fine mesh screen. Suspend
intake strainer inside box.
No oil in priming tank
With rotary primer, oil is required to maintain a tight rotor seal.
Check priming tank oil supply and replenish, if necessary.
Troubleshooting Guide

F-1031, Section 2449
Page 14 of 18
Pump (Continued)
Problem
Possible Cause
Recommended Action
Pump fails to prime or
loses prime (con’t)
Defective priming valve
A worn or damaged priming valve may leak and cause pump to
lose prime.
Consult primer instructions for priming valve repair.
Improper clearance in rotary gear
or vane primer
After prolonger service, wear may increase primer clearance re-
duce efficiency.
Refer to primer instructions for adjusting primer clearance.
Engine speed too low
Refer to instructions supplied with primer for correct priming
speeds. Speeds much higher than those recommended do not
accelerate priming, and may actually damage priming pump.
Bypass line open
If a bypass line is installed between the pump discharge and wa-
ter tank to prevent pump from overheating with all discharge
valves closed, look for a check valve in the line. If valve is stuck
open, clean it, replace it, or temporarily block off line until a now
valve can be obtained.
Lift too high
Do not attempt lifts exceeding 22 feet (6.7m) except at low
altitudes and with equipment in new condition.
End of intake hose not
submerged deep enough
Although intake hose might be immersed enough for priming,
pumping large volumes of water may produce whirlpools, which
will allow air to be drawn into intake hose.
Whenever possible, place end of intake hose at least two feet be-
low water source.
High point in intake line
If possible, avoid placing any part of intake hose higher than
pump inlet. If high point cannot be prevented, close discharge
valve as soon as pressure drops, and prime again. This
procedure will usually eliminate air pockets in intake line, but it
may have to be repeated several times.
Primer not operated long enough
Refer to instructions supplied with primer for required priming
time. The maximum time for priming should not exceed 45 sec-
onds for lifts up to 10 feet (3.0m).
Insufficient capacity
A. Engine and pump
speed low at full
throttle
Insufficient engine power
Engine requires maintenance.
Check engine in accordance with manufacturer’s instructions sup-
plied with truck.
Engine operated at high altitudes and/or high air temperatures.
Engine power decreases with an increase in altitude or air tem-
perature, except for turbo charged engines.
Adjusting carburetor or changing carburetor jets (or injector noz-
zles) may improve engine performance. Consult with
engine manufacturer.
Discharge relief valve set
improperly
If relief valve is set to relieve below desired operating pressure,
water will bypass and reduce capacity. Adjust relief valve in ac-
cordance with instructions supplied with valve.
Transfer valve set improperly
(Does not apply to single stage
pumps)
Place transfer valve in VOLUME (parallel) position when pumping
more than two thirds rated capacity.
When shifting transfer valve, make sure it travels all the way into
new position. Failure of transfer valve to move completely into
new position will seriously impair pump efficiency.
Truck transmission in too high a
gear
Consult vehicle instructions for correct pump gear. Pump
usually works best with transmission in direct drive.
If truck is equipped with an automatic transmission, be sure trans-
mission is in pumping gear.
Troubleshooting Guide

F-1031, Section 2449
Page 15 of 18
Pump (Continued)
Problem
Possible Cause
Recommended Action
Pump fails to prime or
loses prime (con’t)
Defective priming valve
A worn or damaged priming valve may leak and cause pump to
lose prime.
Consult primer instructions for priming valve repair.
Improper clearance in rotary gear
or vane primer
After prolonger service, wear may increase primer clearance re-
duce efficiency.
Refer to primer instructions for adjusting primer clearance.
Engine speed too low
Refer to instructions supplied with primer for correct priming
speeds. Speeds much higher than those recommended do not
accelerate priming, and may actually damage priming pump.
Bypass line open
If a bypass line is installed between the pump discharge and wa-
ter tank to prevent pump from overheating with all discharge
valves closed, look for a check valve in the line. If valve is stuck
open, clean it, replace it, or temporarily block off line until a now
valve can be obtained.
Lift too high
Do not attempt lifts exceeding 22 feet (6.7m) except at low
altitudes and with equipment in new condition.
End of intake hose not
submerged deep enough
Although intake hose might be immersed enough for priming,
pumping large volumes of water may produce whirlpools, which
will allow air to be drawn into intake hose.
Whenever possible, place end of intake hose at least two feet be-
low water source.
High point in intake line
If possible, avoid placing any part of intake hose higher than
pump inlet. If high point cannot be prevented, close discharge
valve as soon as pressure drops, and prime again. This
procedure will usually eliminate air pockets in intake line, but it
may have to be repeated several times.
Primer not operated long enough
Refer to instructions supplied with primer for required priming
time. The maximum time for priming should not exceed 45 sec-
onds for lifts up to 10 feet (3.0m).
Insufficient capacity
A. Engine and pump
speed low at full
throttle
Insufficient engine power
Engine requires maintenance.
Check engine in accordance with manufacturer’s instructions sup-
plied with truck.
Engine operated at high altitudes and/or high air temperatures.
Engine power decreases with an increase in altitude or air tem-
perature, except for turbo charged engines.
Adjusting carburetor or changing carburetor jets (or injector noz-
zles) may improve engine performance. Consult with
engine manufacturer.
Discharge relief valve set
improperly
If relief valve is set to relieve below desired operating pressure,
water will bypass and reduce capacity. Adjust relief valve in ac-
cordance with instructions supplied with valve.
Transfer valve set improperly
(Does not apply to single stage
pumps)
Place transfer valve in VOLUME (parallel) position when pumping
more than two thirds rated capacity.
When shifting transfer valve, make sure it travels all the way into
new position. Failure of transfer valve to move completely into
new position will seriously impair pump efficiency.
Truck transmission in too high a
gear
Consult vehicle instructions for correct pump gear. Pump
usually works best with transmission in direct drive.
If truck is equipped with an automatic transmission, be sure trans-
mission is in pumping gear.
Troubleshooting Guide

F-1031, Section 2449
Page 16 of 18
Pump (Continued)
Problem
Possible Cause
Recommended Action
Insufficient capacity
B. Engine and pump
speed low at full
throttle
Transfer valve set improperly
(Does not apply to single
stage pumps.)
Place transfer valve in VOLUME (parallel) position when
pumping more than two thirds rated capacity.
When shifting transfer valve, make sure it travels all the way
into new position. Failure of transfer valve to move completely
into new position will seriously impair pump efficiency.
Pump impeller(s) or wear
rings badly worn
Install undersize wear rings if impeller to wear ring clearance
is within limits indicated in MAINTENANCE INSTRUCTIONS.
If not, install new impeller(s) and wear rings.
Intake strainer, intake
screens or impeller vanes
fouled with debris
Remove intake strainer and hose, and clear away all debris.
Pressure backwash (preferably in parallel or “volume”
position) will usually clear impeller vanes when pump is
stopped.
Intake hose defective
On old intake hoses, the inner liner sometimes becomes so
rough it causes enough friction loss to prevent pump from
drawing capacity. Sometimes, the liner will separate from the
outer wall and collapse when drafting. It is usually impossible
to detect liner collapse, even with a light. Try drafting with a
new intake hose; if pump then delivers capacity, it may be
assumed that previous hose was defective.
Intake hose too small
When pumping at higher than normal lifts, or at high altitudes,
use a larger or additional intake hoses.
Insufficient capacity
C. Engine and pump
speed low at full
throttle
Truck transmission in too low
a gear
Consult vehicle instructions for correct pumping gear.
Pump usually works best with transmission in direct drive.
(Check both engine and pump speed, if possible, to be sure
transmission is in “direct”.)
Insufficient pressure
Pump speed too low
In general, the above causes and remedies for low pump
capacity will also apply to low pump pressure.
Check pump speed with a tachometer.
If pump speed is too low, refer to engine manufacturer’s
instructions for method of adjusting engine speed governor.
Pump capacity limits pump
pressure
Do not attempt to pump greater volume of water at the desired
pressure than the pump is designed to handle.
Exceeding pump capacity may cause a reduction in pressure.
Exceeding maximum recommended pump speed will produce
cavitations, and will seriously impair pump efficiency.
Flap valve stuck open
When pump is in PRESSURE (series), discharge will bypass
to first stage intake. Operate pump at 75m PSI/52 bar, and
rapidly switch transfer valve back and forth between positions.
If this fails, try to reach valve with a stick or wire and work it
free.
Troubleshooting Guide

F-1031, Section 2449
Page 17 of 18
Pump (Continued)
Problem
Possible Cause
Recommended Action
Relief Valve Malfunction
A. Pressure not relieved
when discharge
valves are closed
Sticky pilot valve
Disassemble and clean. Replace noticeably worn parts.
Plugged tube lines.
Disconnect lines and inspect.
Relief Valve Malfunction
B. Pressure will not
return to original
seeing after
discharge valve are
reopened
Sticky pilot valve
Disassemble and clean. Replace noticeably worn parts.
Sticky main valve
Disassemble and clean. Replace noticeably worn parts.
Incorrect installation
Check all lines to be sure installation instructions have been
followed.
Relief Valve Malfunction
C. Fluctuating pressure
Sticky pilot valve
Disassemble and clean. Replace noticeably worn parts.
Water surges
(relief valve)
Pressure fluctuation can result from a combination of intake
and discharge conditions involving the pump, relief valve and
engine.
When the elasticity of the intake and discharge system and
the response rate (reaction time) of the engine, pilot valve and
relief valve are such that the system never stabilizes,
fluctuation results.
With the proper combination of circumstances, fluctuation can
occur regardless of the make or type of equipment involved.
Changing one or more of these factors these factors enough
to disrupt this timing should eliminate fluctuation.
Relief Valve Malfunction
D. Slow response
Plugged filter or line
Clean lines and filter.
Troubleshooting Guide

F-1031, Section 2449
Page 18 of 18
Basic CAFS Schematic