Waterous 150-70 User manual

10/4/2010
Installation Guide
Applies to Waterous “Skid” Model
150-70
200-100
Rev 1
FOR INSTALLATION CENTER USAGE ONLY
Unit Serial Number ______________________
Waterous, Arizona Operations
7612 North 74th Ave.
Glendale, Arizona 85303
623-979-3398
Fax: [phone]
www.waterousco.com

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DOCUMENT TITLE: 150-70 / 200-100 Installation
DOC. NO.
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ISSUE DATE: 6/17/2010
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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 may not result in
physical harm to personnel or equipment. It may waste time and money.
ATTENTION:
Defects in replacement part(s), component(s) or product(s) manufactured by others and furnished by
WATEROUS is understood that the only warranty provided for such replacement part(s), component(s) or
product(s), shall be the warranty provided by the manufacturer of said replacement part(s), component(s)
or product thereof which, if assignable, WATEROUS will assign to Buyer, if requested by Buyer.
Defects in replacement part(s), component(s) or product(s), not furnished by Waterous, but suggested in
the installation guide, are the responsibility of the installer and the manufacturer of said replacement
part(s), component(s) or product(s). Waterous will not be responsible for any replacement part(s),
component(s) or product(s) that are not furnished or purchased from Waterous.
WARRANTY INSERT: (last page)
The aforesaid warranty excludes any responsibility or liability of WATEROUS for:
c) any product or part, altered, modified, serviced or repaired other than by WATEROUS, without
its prior written consent; and
d) the cost of dismantling, removing, transporting, storing, or insuring the defective product or part
and the cost of reinstallation.
Revision History
Revision
Date Issued
Comments
---
5/5/2008
Original Release
Reformatted, new logo, added T/S Guide ,
updated drawings
1
6/17/2010
Added warranty information
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.
Waterous reserves the right to make modifications to the system without notice

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DOCUMENT TITLE: 150-70 / 200-100 Installation
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Table of Contents
SECTION 1. MODULE OVERVIEW ........................................................................................................5
SECTION 2. INSTALLING THE CAF SYSTEM.......................................................................................6
A. Fork Lifting a CAFS..........................................................................................................................6
B. Hold Down Tabs...............................................................................................................................6
C. Engine Air Supply for Combustion and Cooling...............................................................................7
D. Battery Connections.........................................................................................................................7
E. Fuel supply.......................................................................................................................................8
I. Fuel Filtering................................................................................................................................8
II. Fuel Tanks...................................................................................................................................8
III. Supply and Return Fuel Lines for Fuel Injection..........................................................................8
IV. Fuel line Materials........................................................................................................................8
V. Tank height offsets ......................................................................................................................9
SECTION 3. INITIAL POWERUP ..........................................................................................................11
A. Post-Installation, Pre-Power up Safety Check...............................................................................11
B. Initial Engine and Fire Pump Power up..........................................................................................11
I. Initial Compressor System Power up ........................................................................................12
SECTION 4. VERIFYING THE AUTO SYNC AIR BALANCING SYSTEM............................................13
A. UNLOAD mode verification............................................................................................................13
B. FIXED mode verification ................................................................................................................14
C. AUTO mode verification.................................................................................................................14
SECTION 5. OPTIONAL PROGRAMMABLE VALVE CONTROLLER..................................................15
A. Operation .......................................................................................................................................15
B. Programming..................................................................................................................................15
C. Wiring Harness Pin-Out .................................................................................................................15
SECTION 6. SUGGESTED THIRD-PARTY COMPONENTS ...............................................................16
A. Suggested components for CAFS discharges:..............................................................................16
B. Suggested Air and Hydraulic Hose................................................................................................16
I. Push-On.....................................................................................................................................17
II. Air Brake....................................................................................................................................17
III. Hydraulic....................................................................................................................................17
SECTION 7. TROUBLESHOOTING......................................................................................................18
A. CAFS..............................................................................................................................................19
B. Pump..............................................................................................................................................23
SECTION 8. INITIAL ADJUSTMENT OF THE AUTO-SYNC AIR BALANCING SYSTEM ...................27
A. Electric Auto-Sync Initial Setup......................................................................................................27
I. UNLOAD Mode Initial Setting....................................................................................................27
II. FIXED Mode Initial Setting.........................................................................................................29
III. AUTO Mode Initial Setting.........................................................................................................30
SECTION 9. CONDITIONAL 5-YEAR WARRANTY POLICY ...............................................................38

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Figure(s)
Figure 1 12VDC Terminals Negative (left) and Positive (right)....................................................................7
Figure 8 Typical CAFS Discharge..............................................................................................................16
Figure 2 Electrical Auto-sync section..........................................................................................................28
Figure 3 Basic Front Panel.........................................................................................................................31
Figure 4 Basic CAFS Layout......................................................................................................................32
Figure 5 Hydraulic Schematic 5in Vertical Sump.......................................................................................33
Figure 6 Electrical Schematic Auto-sync ...................................................................................................34
Figure 7 Air Schematic Electric Auto-sync 90° Inlet ..................................................................................35
Figure 8 Tank Placement - Low.................................................................................................................36
Figure 9 Tank Placement - High ................................................................................................................37

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SECTION 1. MODULE OVERVIEW
The Waterous DS series CAFS modules consist of an engine, compressor, fire pump, foam pump
and control panel mounted as a modular unit on a steel base. A water tank is included with the
unit, on the same base.
See the dimensional drawings at the rear for the size of the module you are installing.
Installation Overview
Warning:
Do not start the engine unless the system is connected to a source of water. The pump
and compressor are operating whenever the engine is running. Running without water will
seriously damage the pump and the compressor.
Note: 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.
This system does not include:
•Fuel lift pump and fuel lines
•Battery and cables
Installation tasks include:
•Installing the module into the vehicle
•Connecting the fuel system
•Connecting the battery/12VDC power supply
•Filling all system fluids
•Final testing of the installed system

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SECTION 2. INSTALLING THE CAF SYSTEM
Warning:
Do not damage the vehicle chassis during installation. Check with the vehicle manufacturer
to make sure the planned bolts are installed in acceptable areas.
A. Fork Lifting a CAFS
The modules are designed for installation into a cargo area equivalent to an 8' pickup bed. With a
forklift, lift the unit and slide it onto the bed of the vehicle.
Warning:
Make sure the forklift is rated to safely lift the CAF system.
Make sure the water/foam tank is empty before attempting to remove the system from a vehicle.
B. Hold Down Tabs
There are four hold-down tabs inside the frame, one at each corner of the engine section.
Bolt the CAF system to the bed of the truck.
Use forklift hereUse forklift here
Tab
Tab
Tab
Tab

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C. Engine Air Supply for Combustion and Cooling
The units are usually left open at the top and sides. Only fresh air is suitable for combustion and
cooling. If side and top covers are installed, they must allow fresh air flow.
Engine air intake
Compressor air intake
D. Battery Connections
Connect the 12VDC supply to the terminals at the left side of the unit (as seen from the front).
The positive terminal is mounted on an insulated block (Figure 1). The negative terminal is
welded directly to the system frame.
•Both positive and negative cables must be adequately sized to supply power to the
system.
•The negative terminal must be connected to the truck chassis.
•The chassis must be properly grounded. Check the grounding after installation to
ensure that module and chassis are grounded.
Figure 1 12VDC Terminals Negative (left) and Positive (right)

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DOCUMENT TITLE: 150-70 / 200-100 Installation
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E. Fuel supply
I. Fuel Filtering
The engine has an integral fuel filter with a replaceable element to protect the fuel
pump.
If the fuel has high water content, or if temperature fluctuations produce water
condensation in the tank, a water separator is required.
If the vehicle will be operated under extreme conditions (poor fuel quality, dirt
contamination of fuel likely, high water content, and poor access to spares) it is
recommended that a combination of strainers and filters be used.
II. Fuel Tanks
The basic requirements for tanks are:
•Tanks must be ventilated adequately at any angle the engine is likely to be
operated 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 out-gassing.
•Tanks must have a sludge drain valve at the bottom.
III. Supply and Return Fuel Lines for Fuel Injection
Fuel injected engines require a closed loop full of fuel (in lines and tank) from the
tank to the injector and back. The engine 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.
IV.Fuel line Materials
Minimum I.D. at the smallest cross section in the system:
Fuel line length
Minimum inner diameter
Less than 6ft (2m)
3/8in (10mm)
6ft (2m) to 18ft (6m)
1/2in (12mm)
•Lines must be copper or non-scaling stainless steel.

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•If the lines are not metal, the material must be heat-resistant 212° F (100°C)
•Lines runs must be as straight and short as possible between tank and inlets or
outlets, with no kinks.
V. Tank height offsets
The engine uses an integral fuel pump that is capable of lifting the fuel a maximum of
78in (2m).
•The lowest part of the fuel intake must not be more than 78in (2m) below the fuel
inlet on the engine.
•If the highest possible fuel level in the tank is more than 79 inches higher than
the fuel inlet, a pressure compensator must be installed to limit the pressure at
the suction side to no more than 3lb (0.2 bar).

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DOCUMENT TITLE: 150-70 / 200-100 Installation
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Comments
Installation technique
If the auxiliary engine will draw fuel from the tank
used by the engine that moves the truck, NFPA
standards specify that the auxiliary engine 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.
Recommended for shared tank
Alternate fuel supply and return line layout
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 from 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
Recommended for separate auxiliary tank.
NOT Recommended for shared tanks.
Ending the return line at the top of the tank is not
recommended for shared or auxiliary tanks. The
fuel will drain back into the tank whenever the
engine is shut off. The engine will be slow to
start, if it starts at all.
This return line style also increases any tendency
of the fuel to foam
Not recommended for any tank
Supply
Return
Filler neck with tank
ventilation
Supply
1/2 inch
12 inch minimum
recommended
Return
6 inch minimum
recommended
Filler neck with
tank ventilation
Return
Supply
1/2 inch
A2
Supply
Return
C