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