Graco 334946D, Reactor 2 Hydraulic Proportioning Systems, Repair-Part Owner's Manual

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Graco 334946D, Reactor 2 Hydraulic Proportioning Systems, Repair-Part Owner's Manual | Manualzz

Repair-Parts

Hydraulic, coatings. Not or hazardous locations.

Important

Read all warnings and instructions in this manual. Save these instructions.

For model information, see page 10.

334946D

EN

PROVEN QUALITY. LEADING TECHNOLOGY.

Warnings ............................................................. 3

Important Isocyanate Information........................... 7

Related Manuals .................................................. 9

Accessories.......................................................... 9

Approvals............................................................. 9

Models............................................................... 10

Troubleshooting.................................................. 16

Troubleshoot Errors ..................................... 16

Hydraulic Drive System ................................ 35

Proportioning System ................................... 37

Pressure/Material Imbalance ........................ 38

Pumps Do Not Reverse Direction.................. 39

Hose Heat System ....................................... 41

Primary Heater ............................................ 44

Pressure Relief Procedure .................................. 46

Shutdown........................................................... 47

Flushing ............................................................. 48

Repair................................................................ 49

Before Beginning Repair............................... 49

Repair Proportioning Pumps ......................... 49

Clean Flow Meter......................................... 50

Change Lubricant......................................... 51

Change Hydraulic Fluid and Filter ................. 51

Replace Electric Motor ................................. 53

Replace Belt ................................................ 55

Replace Fluid Inlet Sensor............................ 56

Replace Pressure Transducers ..................... 56

Repair Primary Heater.................................. 57

Repair Heater Overtemperature

Switch............................................ 57

Replace RTD ............................................... 58

Repair Heated Hose..................................... 59

Repair Fluid Temperature Sensor

(FTS) ............................................. 61

Repair Circuit Breaker Module ...................... 62

Transformer Primary Check .......................... 63

Transformer Secondary Check ..................... 63

Replace Power Supply ................................. 64

Replace Surge Protector .............................. 64

Replace TCM .............................................. 64

Replace HCM .............................................. 65

Replace ADM .............................................. 65

Parts.................................................................. 66

Elite Proportioners ....................................... 66

Proportioner Parts........................................ 67

Proportioner Assembly Parts ........................ 79

Hydraulic Cylinder Parts, 17G499 ................. 81

Electrical Enclosure...................................... 86

System Din Rail and Harness Module

Kits ................................................ 88

H-30, H-XP2 Power Supply and Terminal

Block Module ................................. 89

H-30, H-XP2 System Circuit Breaker

Module........................................... 89

Inlet Sensor Kit ............................................ 91

H-40, H-50, H-XP3 Power Supply and

Terminal Block Module.................... 94

H-40, H-50, H-XP3 System Circuit Breaker

Module........................................... 94

Electrical Schematics .......................................... 95

Hydraulic Reactor 2 Repair Spare Parts

Reference........................................... 100

Technical Specifications.................................... 101

Notes............................................................... 103

Graco Extended Warranty ................................. 104

2 334946D

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these

Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

• Do not expose to rain. Store indoors.

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled or swallowed.

• Read Safety Data Sheet (SDS) for handling instructions and to know the specific hazards of the fluids you are using, including the effects of long-term exposure.

• When spraying, servicing equipment, or when in the work area, always keep work area

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

Always wear appropriate personal protective equipment and cover all skin when spraying, servicing equipment, or when in the work area. Protective equipment helps prevent serious injury, including long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and hearing loss. This protective equipment includes but is not limited to:

• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority.

• Protective eyewear and hearing protection.

334946D 3

Warnings

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce

• Engage trigger lock when not spraying.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

4

or solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static sparking).

• Never spray or flush solvent at high pressure.

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are anti-static or conductive.

equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

334946D

334946D

Warnings

Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.

• Open a valve to relieve the fluid expansion during heating.

• Replace hoses proactively at regular intervals based on your operating conditions.

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage.

• Use only compatible water-based solvents to clean plastic structural or pressure-containing parts.

solvent manufacturer’s MSDSs and recommendations.

5

6

Warnings

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing

Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

334946D

Isocyanates (ISO) are catalysts used in two component materials.

Important Isocyanate Information

Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates.

• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards and precautions related to isocyanates.

• Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless you are trained, qualified, and have read and understood the information in this manual and in the fluid manufacturer’s application instructions and SDS.

• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material, which could cause off gassing and offensive odors. Equipment must be carefully maintained and adjusted according to instructions in the manual.

• To prevent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the work area must wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include a supplied-air respirator. Ventilate the work area according to instructions in the fluid manufacturer’s SDS.

• Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority. Follow all fluid manufacturer recommendations, including those regarding handling of contaminated clothing. After spraying, wash hands and face before eating or drinking.

• Hazard from exposure to isocyanates continues after spraying. Anyone without appropriate personal protective equipment must stay out of the work area during application and after application for the time period specified by the fluid manufacturer. Generally this time period is at least 24 hours.

• Warn others who may enter work area of hazard from exposure to isocyanates. Follow the recommendations of the fluid manufacturer and local regulatory authority. Posting a placard such as the following outside the work area is recommended:

334946D 7

8

Important Isocyanate Information

Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and SDS.

Exposure to moisture (such as humidity) will cause

ISO to partially cure, forming small, hard, abrasive crystals that become suspended in the fluid.

Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity.

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage to equipment. To prevent cross-contamination:

B wetted parts.

• Never use solvent on one side if it has been contaminated from the other side.

Partially cured ISO will reduce performance and the life of all wetted parts.

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere.

• Keep the ISO pump wet cup or reservoir (if installed) filled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.

• Use only moisture-proof hoses compatible with

ISO.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Always lubricate threaded parts with an appropriate lubricant when reassembling.

crystallization varies depending on the blend of ISO, the humidity, and the temperature.

Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

• When changing between epoxies and urethanes or polyureas, disassemble and clean all fluid components and change hoses. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.

Some foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system.

334946D

Related Manuals

Manuals are available at www.graco.com.

334945

3A3085

Reactor 2 Operation

Pump Repair-Parts

309572

309852

309815

309827

309550

312666

313213

3A3009

3A1907

332735

3A3010

333276

3A3084

Heated Hose, Instructions-Parts

Circulation and Return Tube Kit,

Instructions-Parts

Feed Pump Kits, Instructions-Parts

Feed Pump Air Supply Kit,

Instructions-Parts

Fusion AP Gun

Fusion CS Gun

Probler P2 Gun

Inlet Sensor Kit, Instructions-Parts

Remote Display Module Kit,

Instructions-Parts

Air Manifold Kit, Instructions-Parts

Caster Kit, Instructions-Parts

Graco InSite ™ Kit, Instructions-Parts

Elite Kit, Instructions-Part

Kit Number Description

24U315

17G340

17F837

Air Manifold (4 outlets)

Caster Kit

16X521

Inlet Sensor Kit

Graco InSite Extension cable 24.6 ft

(7.5 m)

24N449

24K207

50 ft (15 m) CAN cable (for remote display module)

Fluid Temperature Sensor (FTS) with RTD

24U174

15V551

15M483

24M174

121006

Remote Display Module Kit

ADM Protective Covers (10 pack)

Remote Display Module Protective

Covers (10 pack)

Drum Level Sticks

24N365

17F838

24N748

150 ft (45 m) CAN cable (for remote display module)

RTD Test Cables (to aide resistance measurements)

Elite Kit

Ratio Monitoring

Intertek approvals apply to proportioners without hoses.

Conforms to ANSI/UL Std. 499

Certified to CAN/CSA Std. C22.2 No. 88

334946D 9

Models

System Load

(Watts)

Fusion ® AP �

(Gun Part No.)

Fusion ® CS �

(Gun Part No.)

P2 Package �

(Gun Part No.)

24K240 (scuff guard)

24Y240 (Xtreme-wrap)

***

17H031

2000 (14, 140)

0.074 (0.28)

28 (12.7)

200–

240

79

17,960

200–

240

3Ø∆

46

350–

415

3ØY

35

17H032

2000 (14, 140)

0.074 (0.28)

28 (12.7)

200–

240

100

23,260

200–

240

3Ø∆

59

350–

415

3ØY

35

17H131

2000 (14, 140)

0.074 (0.28)

28 (12.7)

200–

240

79

17,960

200–

240

3Ø∆

46

350–

415

3ØY

35

17H132

2000 (14, 140)

0.074 (0.28)

28 (12.7)

200–

240

100

23,260

200–

240

3Ø∆

59

350–

415

3ØY

35

APH031

(246102)

CSH031

(CS02RD)

P2H031

(GCP2R2)

24K240

Qty: 1

AHH031

(246102)

CHH031

(CS02RD)

PHH031

(GCP2R2)

24K240

Qty: 5

APH032

(246102)

CSH032

(CS02RD)

P2H032

(GCP2R2)

24K240

Qty: 1

AHH032

(246102)

CHH032

(CS02RD)

PHH032

(GCP2R2)

24K240

Qty: 5

APH131

(246102)

CSH131

(CS02RD)

P2H131

(GCP2R2)

24Y240

Qty: 1

AHH131

(246102)

CHH131

(CS02RD)

PHH131

(GCP2R2)

24Y240

Qty: 5

APH132

(246102)

CSH132

(CS02RD)

P2H132

(GCP2R2)

24Y240

Qty: 1

AHH132

(246102)

CHH132

(CS02RD)

PHH132

(GCP2R2)

24Y240

Qty: 5

246050 246050 246050

246050

Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

Total system watts used by system, based on maximum heated hose length for each unit.

• H–30 series: 310 ft (94.5 m) maximum heated hose length, including whip hose.

★ See

Approvals, page 9

.

� Packages include gun, heated hose, and whip hose. Elite packages also include Ratio

Monitoring and fluid inlet sensors. All Elite hose and gun system packages include

Xtreme-Wrap™ 50 ft (15 m) heated hose.

For part numbers, see

Accessories, page 9 .

Ø

Y

PHASE

DELTA

WYE

10 334946D

Models

System Load

(Watts)

Phase (VAC

50/60 Hz)

Fusion ® AP �

(Gun Part No.)

Fusion ® CS �

(Gun Part No.)

P2 Package �

(Gun Part No.)

Heated Hose

50

24K240 (scuff guard)

24Y240 (Xtreme-wrap)

Heated Whip

10

***

17H043

2000 (14, 140)

0.063 (0.24)

45 (20)

26,600

200–240 3Ø∆

71

17H044

2000 (14, 140)

0.063 (0.24)

45 (20)

31,700

200–240 3Ø∆

95

17H143

2000 (14, 140)

0.063 (0.24)

45 (20)

26,600

200–240 3Ø∆

71

17H144

2000 (14, 140)

0.063 (0.24)

45 (20)

31,700

200–240 3Ø∆

95

APH043

(246102)

CSH043

(CS02RD)

P2H043

(GCP2R2)

24K240

Qty: 1

AHH043

(246102)

CHH043

(CS02RD)

PHH043

(GCP2R2)

24K240

Qty: 6

APH044

(246102)

CSH044

(CS02RD)

P2H044

(GCP2R2)

24K240

Qty: 1

AHH044

(246102)

CHH044

(CS02RD)

PHH044

(GCP2R2)

24K240

Qty: 6

APH143

(246102)

CSH143

(CS02RD)

P2H143

(GCP2R2)

24Y240

Qty: 1

AHH143

(246102)

CHH143

(CS02RD)

PHH143

(GCP2R2)

24Y240

Qty: 6

APH144

(246102)

CSH144

(CS02RD)

P2H144

(GCP2R2)

24Y240

Qty: 1

AHH144

(246102)

CHH144

(CS02RD)

PHH144

(GCP2R2)

24Y240

Qty: 6

246050 246050 246050

246050

Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

Total system watts used by system, based on maximum heated hose length for each unit.

• H–40 series: 410 ft (125 m) maximum heated hose length, including whip hose.

★ See

Approvals, page 9

.

� Packages include gun, heated hose, and whip hose. Elite packages also include Ratio

Monitoring and fluid inlet sensors. All Elite hose and gun system packages include

Xtreme-Wrap™ 50 ft (15 m) heated hose.

For part numbers, see

Accessories, page 9 .

Ø

Y

PHASE

DELTA

WYE

334946D 11

Models

System Load

(Watts)

Phase (VAC

50/60 Hz)

Fusion ® AP �

(Gun Part No.)

Fusion ® CS �

(Gun Part No.)

P2 Package �

(Gun Part No.)

Heated Hose

50

24K240 (scuff guard)

24Y240 (Xtreme-wrap)

Heated Whip

10

***

17H045

2000 (14, 140)

0.063 (0.24)

45 (20)

26,600

350–415 3ØY

41

17H046

2000 (14, 140)

0.063 (0.24)

45 (20)

31,700

350–415 3ØY

52

17H145

2000 (14, 140)

0.063 (0.24)

45 (20)

26,600

350–415 3ØY

41

17H146

2000 (14, 140)

0.063 (0.24)

45 (20)

31,700

350–415 3ØY

52

APH045

(246102)

CSH045

(CS02RD)

P2H045

(GCP2R2)

24K240

Qty: 1

AHH045

(246102)

CHH045

(CS02RD)

PHH045

(GCP2R2)

24K240

Qty: 6

APH046

(246102)

CSH046

(CS02RD)

P2H046

(GCP2R2)

24K240

Qty: 1

AHH046

(246102)

CHH046

(CS02RD)

PHH046

(GCP2R2)

24K240

Qty: 6

APH145

(246102)

CSH145

(CS02RD)

P2H145

(GCP2R2)

24Y240

Qty: 1

AHH145

(246102)

CHH145

(CS02RD)

PHH145

(GCP2R2)

24Y240

Qty: 6

APH146

(246102)

CSH146

(CS02RD)

P2H146

(GCP2R2)

24Y240

Qty: 1

AHH146

(246102)

CHH146

(CS02RD)

PHH146

(GCP2R2)

24Y240

Qty: 6

246050 246050 246050

246050

Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

Total system watts used by system, based on maximum heated hose length for each unit.

• H–40 series: 410 ft (125 m) maximum heated hose length, including whip hose.

★ See

Approvals, page 9

.

� Packages include gun, heated hose, and whip hose. Elite packages also include Ratio

Monitoring and fluid inlet sensors. All Elite hose and gun system packages include

Xtreme-Wrap™ 50 ft (15 m) heated hose.

For part numbers, see

Accessories, page 9 .

Ø

Y

PHASE

DELTA

WYE

12 334946D

Models

Fluid Working

Pressure psi

Fusion ® AP �

(Gun Part No.)

Fusion ® CS �

(Gun Part No.)

P2 Package �

(Gun Part No.) ft (15

24K240 (scuff guard)

24Y240 (Xtreme-wrap)

***

17H053

2000 (14, 140)

0.074 (0.28)

52 (24)

31,700

200–240 3Ø∆

95

17H056

2000 (14, 140)

0.074 (0.28)

52 (24)

31,700

350–415 3ØY

52

17H153

2000 (14, 140)

0.074 (0.28)

52 (24)

31,700

200–240 3Ø∆

95

17H156

2000 (14, 140)

0.074 (0.28)

52 (24)

31,700

350–415 3ØY

52

APH053

(246102)

CSH053

(CS02RD)

P2H053

(GCP2R2)

24K240

Qty: 1

AHH053

(246102)

CHH053

(CS02RD)

PHH053

(GCP2R2)

24K240

Qty: 6

APH056

(246102)

CSH056

(CS02RD)

P2H056

(GCP2R2)

24K240

Qty: 1

AHH056

(246102)

CHH056

(CS02RD)

PHH056

(GCP2R2)

24K240

Qty: 6

APH153

(246102)

CSH153

(CS02RD)

P2H153

(GCP2R2)

24Y240

Qty: 1

AHH153

(246102)

CHH153

(CS02RD)

PHH153

(GCP2R2)

24Y240

Qty: 6

APH156

(246102)

CSH156

(CS02RD)

P2H156

(GCP2R2)

24Y240

Qty: 1

AHH156

(246102)

CHH156

(CS02RD)

PHH156

(GCP2R2)

24Y240

Qty: 6

246050 246050 246050

246050

Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

Total system watts used by system, based on maximum heated hose length for each unit.

• H–50 series: 410 ft (125 m) maximum heated hose length, including whip hose.

★ See

Approvals, page 9

.

� Packages include gun, heated hose, and whip hose. Elite packages also include Ratio

Monitoring and fluid inlet sensors. All Elite hose and gun system packages include

Xtreme-Wrap™ 50 ft (15 m) heated hose.

For part numbers, see

Accessories, page 9 .

Ø

Y

PHASE

DELTA

WYE

334946D 13

Models

Fluid Working

Pressure psi

System Load

(Watts)

Fusion ® AP �

(Gun Part No.)

P2 Package �

(Gun Part No.)

Heated Hose

50

***

200–240

100

APH062

(246101)

P2H062

(GCP2R1)

24K241

Qty. 1

17H062

3500 (24.1, 241)

0.042 (0.16)

1.5 (5.7)

23,260

200–240

3Ø∆

59

246055

350–415

3ØY

35

AHH062

(246101)

PHH062

(GCP2R1)

24K241

Qty. 5

Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

Total system watts used by system, based on maximum heated hose length for each unit.

• H–XP2 series: 310 ft (94.5 m) maximum heated hose length, including whip hose.

200–240

100

APH162

(246101)

P2H162

(GCP2R1)

24Y241

Qty. 1

17H162

3500 (24.1, 241)

0.042 (0.16)

1.5 (5.7)

23,260

200–240

3Ø∆

59

350–415

3ØY

35

AHH162

(246101)

PHH162

(GCP2R1)

24K241

Qty. 5

246055

★ See

Approvals, page 9

.

� Packages include gun, heated hose, and whip hose. Elite packages also include fluid inlet sensors. All Elite hose and gun system packages include Xtreme-Wrap™ 50 ft (15 m) heated hose. For part numbers, see

Accessories, page 9

.

Ø

Y

PHASE

DELTA

WYE

14 334946D

Models

Fluid Working

Pressure psi

System Load

(Watts)

Fusion ® AP �

(Gun Part No.)

P2 Package �

(Gun Part No.)

Heated Hose

50

24K240 (scuff guard)

24Y240 (Xtreme-wrap)

Heated Whip

10

***

17H074

3500 (24.1, 241)

0.042 (0.16)

2.8 (10.6)

31,700

200–240 3Ø∆

95

17H076

3500 (24.1, 241)

0.042 (0.16)

2.8 (10.6)

31,700

350–415 3ØY

52

17H174

3500 (24.1, 241)

0.042 (0.16)

2.8 (10.6)

31,700

200–240 3Ø∆

95

17H176

3500 (24.1, 241)

0.042 (0.16)

2.8 (10.6)

31,700

350–415 3ØY

52

APH074

(246102)

P2H074

(GCP2R2)

24K241

Qty: 1

AHH074

(246102)

PHH074

(GCP2R2)

24K241

Qty: 6

APH076

(246102)

P2H076

(GCP2R2)

24K241

Qty: 1

AHH076

(246102)

PHH076

(GCP2R2)

24K241

Qty: 6

APH174

(246102)

P2H174

(GCP2R2)

24Y241

Qty: 1

AHH174

(246102)

PHH174

(GCP2R2)

24Y241

Qty: 6

APH176

(246102)

P2H176

(GCP2R2)

24Y241

Qty: 1

AHH176

(246102)

PHH176

(GCP2R2)

24Y241

Qty: 6

246055 246055 246055

246055

Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

Total system watts used by system, based on maximum heated hose length for each unit.

• H–XP3 series: 410 ft (125 m) maximum heated hose length, including whip hose.

★ See

Approvals, page 9

.

� Packages include gun, heated hose, and whip hose. Elite packages also include Ratio

Monitoring and fluid inlet sensors. All Elite hose and gun system packages include

Xtreme-Wrap™ 50 ft (15 m) heated hose.

For part numbers, see

Accessories, page 9 .

Ø

Y

PHASE

DELTA

WYE

334946D 15

Troubleshooting

See

Error Codes

, for causes and solutions to each error code.

To troubleshoot the error:

1.

Press the soft key for help with the active error.

To avoid injury due to unexpected machine operation initiated by a remote controller, disconnect the cellular module from the system prior to troubleshooting. Refer to your Reactor 2

App manual for instructions.

There are three types of errors that can occur. Errors are indicated on the display as well as by the light tower (optional).

Note

Press or to return to the previously displayed screen.

2.

The QR code screen will be displayed. Scan the QR code with your smartphone to be sent directly to online troubleshooting for the active error code. Otherwise, manually navigate to http://help.graco.com and search for the active error.

A parameter critical to the process has reached a level requiring the system to stop. The alarm needs to be addressed immediately.

A parameter critical to the process has reached a level requiring attention, but not sufficient enough to stop the system at this time.

A parameter that is not immediately critical to the process. The advisory needs attention to prevent more serious issues in the future.

3.

If no internet connection is available, see

Error Codes

error code.

, for causes and solutions for each

16 334946D

Troubleshooting

Note

When an error occurs be sure to determine the code before resetting it. If you forget which error code occurred, see the Errors screen to view the last 200 errors, with date, time, and description.

A4DA

A4DB

A4DH

A7DA

A7DB

A7DH

Heater A

Heater B

Hose

Heater A

Heater B

Hose

High Current A

High Current B

High Current Hose

Unexpected Current

A

Unexpected Current

B

Unexpected Current

Hose

Short circuit in heater wiring.

Bad Heater.

Short circuit in heater wiring.

Bad Heater.

Short circuit in hose wiring.

Shorted TCM

Shorted TCM

Shorted TCM

Check wiring for touching wires.

Confirm resistance of heater. Heater resistance should be 18–21 Ω for each heater element, 9–12

Ω combined for 10 kW systems, 6-8 Ω for 15 kW systems, and 4–6 Ω for

20 kW systems. If out of tolerance, replace heater element.

Check wiring for touching wires.

Confirm resistance of heater. Heater resistance should be 18–21 Ω for each heater element, 9–12

Ω combined for 10 kW systems, 6-8 Ω for 15 kW systems, and 4–6 Ω for

20 kW systems. If out of tolerance, replace heater element.

Check continuity of transformer windings.

Normal readings are about

0.2Ω on both primary and secondary. If reading is 0Ω replace transformer.

Check for shorts between the primary winding and the support frame or enclosure.

If error cannot be cleared or regenerates consistently, replace module.

If error cannot be cleared or regenerates consistently, replace module.

If error cannot be cleared or regenerates consistently, replace module.

334946D 17

Troubleshooting

A8DA Heater A

A8DB Heater B

A8DH Hose

CACM HCM

18

No Current A

No Current B

No Current Hose

HCM Communication Error

Tripped circuit breaker.

Loose/broken connection.

Tripped circuit breaker.

Loose/broken connection.

Tripped circuit breaker.

Loose/broken connection.

Module does not have software.

Dial set to wrong position.

No 24 VDC supply to module.

Loose or broken

CAN cable.

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

Insert a system token into the ADM module and cycle the power. Wait until the upload is complete before removing the token.

Ensure the HCM dial is set to the correct position:

• H-30 = 0

• H-40 = 1

• H-50 = 2

• H-XP2 = 3

• H-XP3 = 4

Green light on each module should be lit. If green light is not lit, check to make sure each CAN cable connection is tight. Verify the power supply is outputting 24

VDC. If not, check power supply wiring. If wiring is okay, replace the power supply.

Check the CAN cables running between GCA modules and tighten of needed. If the problem still persists move each cable around the connector and watch the flashing yellow light on the GCA modules. If the yellow light stops flashing, replace the

CAN cable.

334946D

CACT TCM

DADX HCM

F9FA ADM

F9FB ADM

334946D

Troubleshooting

TCM Communication

Error

Pump Runaway

Flow Cutback Low

Inlet A Pressure

Flow Cutback Low

Inlet B Pressure

Module does not have software.

No 24 VDC supply to module.

Loose or broken

CAN cable.

Flow rate is too large.

ISO Inlet pressure is too low

ISO inlet flow is too low

Resin inlet pressure is too low

Resin inlet flow is too low

Insert a system token into the ADM module and cycle the power. Wait until the upload is complete before removing the token.

Green light on each module should be lit. If green light is not lit, check to make sure each CAN cable connection is tight. Verify the power supply is outputting 24

VDC. If not, check power supply wiring. If wiring is okay, replace the power supply.

Check the CAN cables running between GCA modules and tighten of needed. If the problem still persists move each cable around the connector and watch the flashing yellow light on the GCA modules. If the yellow light stops flashing, replace the

CAN cable.

Mix chamber too large for system selected. Use mix chamber rated for system.

Ensure the system has chemical and the feed pumps are operating correctly.

No material in pumps.

Verify pumps are supplying chemical. If necessary, replace or refill drums.

Inlet ball valves are closed.

Open ball valves.

Increase ISO feed pump pressure

Change to larger ISO feed pump

Increase resin feed pump pressure

Change to larger resin feed pump

19

Troubleshooting

EVCH ADM

EAUX ADM

EVSX HCM

EVUX ADM

H2MA Heater A

H2MB Heater B

H2MH Hose

H3MA Heater A

H3MB Heater B

H3MH Hose

L1AX ADM

L1BX ADM

MMUX USB

20

Manual Hose Mode

Enabled

USB Busy

Standby

USB disabled

Low Frequency A

Low Frequency B

Low Frequency Hose

High Frequency A

High Frequency B

High Frequency

Hose

Low Chemical Level

A

Manual hose mode has been enabled in System Setup screen.

USB drive has been inserted to the ADM.

System has entered standby.

USB download/uploads are disabled.

Line frequency is below 45 Hz

Line frequency is below 45 Hz

Line frequency is below 45 Hz

Line frequency is above 65 Hz

Install a functioning fluid temperature sensor (FTS) on the hose. Manual hose mode will automatically turn off.

Do not remove USB drive until download/upload is complete.

Trigger gun to resume spraying.

Turn off standby in setup screens.

Enable USB download/uploads on the Advanced

Setup screen before inserting a USB drive.

Ensure line frequency of incoming power is between

45 and 65 Hz.

Ensure line frequency of incoming power is between

45 and 65 Hz.

Ensure line frequency of incoming power is between

45 and 65 Hz.

Ensure line frequency of incoming power is between

45 and 65 Hz.

Line frequency is above 65 Hz

Line frequency is above 65 Hz

Ensure line frequency of incoming power is between

45 and 65 Hz.

Ensure line frequency of incoming power is between

45 and 65 Hz.

Low material level.

Refill material and update drum level on ADM

Maintenance screen.

Low Chemical Level

B

Alarm can be disabled on the System Setup screen.

Low material level.

Refill material and update drum level on ADM

Maintenance screen.

Maintenance Due -

USB

USB logs have reached a level where data loss will occur if logs are not downloaded.

Alarm can be disabled on the System Setup screen.

Insert a USB drive into the

ADM and download all logs.

334946D

P0AX HCM

P0BX HCM

Troubleshooting

Pressure Imbalance

A High

Pressure Imbalance

B High

Pressure difference between

A and B material is greater than the defined value.

Pressure imbalance is defined too low.

Out of material.

Fluid leaking from heater inlet rupture disk.

Feed system defective.

Pressure difference between

A and B material is greater than the defined value.

Pressure imbalance is defined too low.

Ensure material flow is equally restricted on both material lines.

Ensure that the pressure imbalance value, on the

System Setup screen, is at an acceptable maximum pressure to prevent unnecessary alarms and abort dispenses.

Fill tanks with material

Check if heater and PRESSURE

RELIEF/SPRAY valve are plugged. Clear. Replace rupture disk. Do not replace with a pipe plug.

Check feed pump and hoses for blockage. Check that feed pumps have correct air pressure.

Ensure material flow is equally restricted on both material lines.

Out of material.

Fluid leaking from heater inlet rupture disk.

Feed system defective.

Ensure that the pressure imbalance value, on the

System Setup screen, is at an acceptable maximum pressure to prevent unnecessary alarms and abort dispenses.

Fill tanks with material

Check if heater and PRESSURE

RELIEF/SPRAY valve are plugged. Clear. Replace rupture disk. Do not replace with a pipe plug.

Check feed pump and hoses for blockage. Check that feed pumps have correct air pressure.

334946D 21

Troubleshooting

P1FA HCM

P1FB

P2FA

P2FB

P4AX

HCM

HCM

HCM

HCM

Low Inlet Pressure A Inlet pressure lower than defined value.

Value defined too high.

Ensure that inlet pressure to the pump is sufficient.

Ensure that the low pressure alarm level defined on the System

Setup screen is acceptable.

Ensure that inlet pressure to the pump is sufficient.

Low Inlet Pressure B Inlet pressure lower than defined value.

Value defined too high.

Ensure that the low pressure alarm level defined on the System

Setup screen is acceptable.

Ensure that inlet pressure to the pump is sufficient.

Low Inlet Pressure A Inlet pressure lower than defined value.

Value defined too high.

Ensure that the low pressure alarm level defined on the System

Setup screen is acceptable.

Ensure that inlet pressure to the pump is sufficient.

Low Inlet Pressure B

High Pressure A

Inlet pressure lower than defined value.

Value defined too high.

System pressurized before allowing heat to reach setpoint.

Bad pressure transducer.

H-XP2 or H-XP3 system configured as H-30, H-40, or

H-50.

Ensure that the low pressure alarm level defined on the System

Setup screen is acceptable.

Pressure in the hose and pumps will increase as the system heats up. Turn on heat and allow all zones to reach the temperature setpoint before turning on the pumps.

Verify the ADM pressure reading and the analog gauges at the manifold.

Replace transducer if they do not match.

Alarm level is lower for

H-30, H-40 and H-50 than for H-XP2 and H-XP3..

Ensure dial on HCM is set to position "3" for H-XP2 or

“4” for H-XP3.

22 334946D

P4BX HCM

P4FA

P4FB

P6AX

ADM

ADM

HCM

Troubleshooting

High Pressure B

A Pump Inlet Leak

B Pump Inlet Leak

Pressure Sensor

Error A

System pressurized before allowing heat to reach setpoint.

Bad pressure transducer.

H-XP2 or H-XP3 system configured as H-30, H-40, or

H-50.

Pressure in the hose and pumps will increase as the system heats up. Turn on heat and allow all zones to reach the temperature setpoint before turning on the pumps.

Verify the ADM pressure reading and the analog guages at the manifold.

Alarm level is lower for

H-30, H-40 and H-50 than for H-XP2 and H-XP3..

Ensure dial on HCM is set to position "3" for H-XP2 or

“4” for H-XP3.

Condition the drum material to the ambient temperature of the Reactor

Thermal expansion is occurring between the drum and Reactor inlet

Damaged ISO pump inlet ball or seat

Thermal expansion is occurring between the drum and Reactor inlet

Damaged resin pump inlet ball or seat

Loose/bad connection.

Bad sensor.

Replace ISO pump inlet ball and seat

Condition the drum material to the ambient temperature of the Reactor

Replace resin pump inlet ball and seat

Check to ensure the pressure transducer is properly installed and all wires are properly connected.

Check if the error follows the transducer. Disconnect transducer cables from the HCM (connectors 6 and 7). Reverse A and B connections and check if the errors follows. If the error follows the transducer, replace the pressure transducer.

334946D 23

Troubleshooting

P6BX HCM

P6FA

P6FB

HCM

HCM

Pressure Sensor

Error B

Pressure Sensor

Error Inlet A

Pressure Sensor

Error Inlet B

Loose/bad connection.

Bad sensor.

Inlet sensors not installed.

Loose/bad connection.

Bad sensor.

Inlet sensors not installed.

Loose/bad connection.

Bad sensor.

Check to ensure the pressure transducer is properly installed and all wires are properly connected.

Check if the error follows the transducer. Disconnect transducer cables from the HCM (connectors 6 and 7). Reverse A and B connections and check if the errors follows. If the error follows the transducer, replace the pressure transducer.

If inlet sensors are not installed, inlet sensors should be disabled on the

System Setup screen.

Check to ensure inlet sensor is properly installed and all wires are properly connected.

Check if the error follows the inlet sensor. Disconnect inlet sensor cables from the HCM (connectors 8 and 9). Reverse A and B connections and check if the errors follows. If the error follows the sensor, replace the inlet sensor.

If inlet sensors are not installed, inlet sensors should be disabled on the

System Setup screen.

Check to ensure inlet sensor is properly installed and all wires are properly connected.

Check if the error follows the inlet sensor. Disconnect inlet sensor cables from the HCM (connectors 8 and 9). Reverse A and B connections and check if the errors follows. If the error follows the sensor, replace the inlet sensor.

24 334946D

P7AX HCM

P7BX HCM

Troubleshooting

Pressure Imbalance

A High

Pressure Imbalance

B High

Pressure difference between

A and B material is greater than the defined value.

Pressure imbalance is defined too low.

Out of material.

Fluid leaking from heater inlet rupture disk.

Feed system defective.

Pressure difference between

A and B material is greater than the defined value.

Pressure imbalance is defined too low.

Ensure material flow is equally restricted on both material lines.

Ensure that the pressure imbalance value, on the

System Setup screen, is at an acceptable maximum pressure to prevent unnecessary alarms and abort dispenses.

Fill tanks with material

Check if heater and PRESSURE

RELIEF/SPRAY valve are plugged. Clear. Replace rupture disk. Do not replace with a pipe plug.

Check feed pump and hoses for blockage. Check that feed pumps have correct air pressure.

Ensure material flow is equally restricted on both material lines.

Out of material.

Fluid leaking from heater inlet rupture disk.

Feed system defective.

Ensure that the pressure imbalance value, on the

System Setup screen, is at an acceptable maximum pressure to prevent unnecessary alarms and abort dispenses.

Fill tanks with material

Check if heater and PRESSURE

RELIEF/SPRAY valve are plugged. Clear. Replace rupture disk. Do not replace with a pipe plug.

Check feed pump and hoses for blockage. Check that feed pumps have correct air pressure.

334946D 25

Troubleshooting

R1D0 ADM

R4D0

R9AX

R9BX

ADM

ADM

ADM

Low Ratio Low Flow

A

High Ratio Low Flow

B

No Pulses A Flow

Meter

No Pulses B Flow

Meter

Damaged ISO pump

Fluid leak between

ISO pump and meter

Damaged ISO recirculation valve

Damaged ISO flow meter

ISO material drum is empty

Cavitation in the

ISO pump

Damaged resin pump

Fluid leak between resin pump and meter

Damaged resin recirculation valve

Damaged resin flow meter

Resin material drum is empty

Cavitation on resin pump

Damaged ISO flow meter

No ISO flow

Inspect ISO pump and replace if necessary

Inspect fluid lines for ISO leak

Replace ISO valve

Replace ISO meter

Repalce ISO drum

Increase ISO feed pump pressure

Inspect resin pump and replace if necessary

Inspect fluid lines for resin leak

Replace resin valve

Replace resin meter

Replace resin drum

Increase resin feed pump pressure

Replace ISO meter

The ISO flow meter is clogged

Damaged resin flow meter

No resin flow

Flow resin meter is clogged

Verify ISO inlet valves are open

Clean the ISO flow meter

Replace resin meter

Verify resin inlet valves are open

Clean the resin flow meter

26 334946D

T2DA Heater A

T2DB Heater B

T2DH Hose

Troubleshooting

Low Temperature A

Low Temperature B

Low Temperature

Hose

Flow is too high at current setpoint.

Bad RTD or bad

RTD placement against heater.

Bad heater element.

Loose heater wires.

Flow is too high at current setpoint.

Bad RTD or bad

RTD placement against heater.

Bad heater element.

Loose heater wires.

Flow is too high at current setpoint.

Cold chemical in unheated portion of system passed hose FTS at startup.

Use a smaller mix chamber that is rated for the unit in use. If recirculating, decrease flow or decrease temperature setpoint.

Swap A and B heater output cables and RTD cables and see if issue follows. If so, replace RTD.

Confirm resistance of heater. Heater resistance should be 9-12 Ω for 10 kW systems and 6-8 Ω for

15 kW systems. If out of tolerance, replace heater element.

Check for loose heater element wires.

Use a smaller mix chamber that is rated for the unit in use. If recirculating, decrease flow or decrease temperature setpoint.

Swap A and B heater output cables and RTD cables and see if issue follows. If so, replace RTD.

Confirm resistance of heater. Heater resistance should be 9-12 Ω for 10 kW systems and 6-8 Ω for

15 kW systems. If out of tolerance, replace heater element.

Check for loose heater element wires.

Use a smaller mix chamber that is rated for the unit in use. If recirculating, decrease flow or decrease temperature setpoint.

Recirculate heated chemical back to drum in cold conditions before startup.

334946D 27

Troubleshooting

T2FA HCM

T2FB HCM

T3CH Hose

T3CT TCM

T4CT TCM

28

Low Temperature

Inlet A

Low Temperature

Inlet B

Hose Cutback

TCM Cutback

High Temperature

TCM

Inlet fluid temperature is below the defined level.

Inlet fluid temperature is below the defined level.

Hose current has been reduced because hose has been drawing current for an extended period.

High ambient temperature.

Enclosure fan not operating.

Module fan not operating.

High ambient temperature.

Enclosure fan not operating.

Module fan not operating.

Recirculate fluid through heaters until inlet fluid temperature is above defined error level.

Increase the low temperature deviation level on the System Setup screen.

Recirculate fluid through heaters until inlet fluid temperature is above defined error level.

Increase the low temperature deviation level on the System Setup screen.

Hose setpoint higher than A and B setpoints. Decrease hose setpoint.

Hose FTS is in a colder environment than the rest of the hose. Expose FTS to the same environment as the rest of the hose.

Ensure ambient temperature is below

120°F(48°C) before using the system.

Ensure fan in electrical enclosure is spinning. If it is not, check fan wiring or replace fan.

If a TCM fan error (WMI0) has occurred, fan inside the module is not working properly. Check TCM fan for debris and clear with forced air if necessary.

Ensure ambient temperature is below

120°F(48°C) before using the system.

Ensure fan in electrical enclosure is spinning. If it is not, check fan wiring or replace fan.

If a TCM fan error (WMI0) has occurred, fan inside the module is not working properly. Check TCM fan for debris and clear with forced air if necessary.

334946D

T4DA Heater A

T4DB Heater B

T4DH Hose

Troubleshooting

High Temperature A

High Temperature B

High Temperature

Hose

Bad RTD or bad

RTD placement against heater.

Flow too high for temperature setpoint, causing temperature overshoots when gun is de-triggered.

Bad RTD or bad

RTD placement against heater.

Swap A and B heater output cables and RTD cables and see if issue follows. If so, replace RTD.

Use a smaller mix chamber that is rated for the unit in use.

Swap A and B heater output cables and RTD cables and see if issue follows. If so, replace RTD.

Use a smaller mix chamber that is rated for the unit in use.

Flow too high for temperature setpoint, causing temperature overshoots when gun is de-triggered.

Hose portion exposed to an excessive heat source, like hot sun or coiled hose, can pass fluid more than

27°F (15°C) over hose temperature setting to the FTS.

Setting the A or

B setpoint much higher than hose setpoint can cause fluid more than

27°F (15°C) over hose temperature setting to reach the

FTS.

Cold ambient temperature is causing hose to heat

Shade exposed hose from hot sun or expose FTS to same environment when at rest. Uncoil entire hose before heating to avoid self-heating.

Increase hose setpoint so it is closer to A and B setpoints.

Cold ambient temperature is chilling the FTS and causing hose heat to stay on longer than needed.

Insulate the FTS area of the hose so that it heats at the same rate as the rest of the hose.

334946D 29

Troubleshooting

T4EA Heater A

T4EB Heater B

T6DA Heater A

T6DB Heater B

30

High Temperature

Switch A

High Temperature

Switch B

Sensor Error A

Sensor Error B

Overtemperature switch sensed a fluid temperature above 230°F

(110°C).

Disconnected or loose overtemperature switch cable/connection.

Overtemperature switch failed in the open position.

Overtemperature switch sensed a fluid temperature above 230°F

(110°C).

Disconnected or loose overtemperature switch cable/connection.

Overtemperature switch failed in the open position.

Disconnected or loose RTD cable or connection.

Bad RTD.

Heater was delivered too much power, causing the overtemperature switch to open. RTD is not reading properly. After the heater cools down, replace RTD.

Switch closes and the error can be cleared when the heater temperature falls below 190°F (87°C).

If heater is not actually over temperature, check all wiring and connections between the TCM and the overtemperature switches.

Replace overtemperature switch.

Heater was delivered too much power, causing the overtemperature switch to open. RTD is not reading properly. After the heater cools down, replace RTD.

Switch closes and the error can be cleared when the heater temperature falls below 190°F (87°C).

If heater is not actually over temperature, check all wiring and connections between the TCM and the overtemperature switches.

Replace overtemperature switch.

Check all wiring and connection to RTD.

Switch the RTD with another and see if the error message follows the RTD.

Replace RTD if the error follows the RTD.

Check all wiring and connection to RTD.

Disconnected or loose RTD cable or connection.

Bad RTD.

Switch the RTD with another and see if the error message follows the RTD.

Replace RTD if the error follows the RTD.

334946D

T6DH Hose

T6DT TCM

T8DA Heater A

334946D

Troubleshooting

Sensor Error Hose

Sensor Error TCM

No Temperature

Rise A

Disconnected or shorted RTD cable in hose or bad FTS.

Expose each hose RTD connection to check and retighten any loose connector. Measure hose RTD cable and FTS continuity.

See

Repair Heated Hose, page 59 . Order RTD Test

kit 24N365 for measurement.

Shorted RTD cable in hose or FTS.

Disconnect hose RTD and use manual hose mode to finish job until repair can be completed.

Expose each hose RTD connection to check for exposed and shorted RTD wires. Measure hose RTD cable and FTS continuity.

See

Repair Heated Hose, page 59 . Order RTD Test

kit 24N365 for measurement.

Shorted A or B

Heater RTD

Bad RTD or bad

RTD placement against heater.

Bad heater element.

Loose heater wires.

Started spraying before heater reached operating temperature.

Disconnect hose RTD and use manual hose mode to finish job until repair can be completed.

If the error still occurs with the hose FTS unplugged, one of the heater RTDs is bad. Unplug the A or

B RTD from the TCM. If unplugging an RTD fixes the T6DT error, replace the

RTD.

Swap A and B heater output cables and RTD cables and see if issue follows. If so, replace RTD.

Confirm resistance of heater. Heater resistance should be 9-12 Ω for 10 kW systems, 6-8 Ω for 15 kW systems, 4–6 Ω for 20 kW systems. If out of tolerance, replace heater element.

Check for loose heater element wires.

Wait until operating temperature has been reached before spraying or recirculating.

31

T8DH Hose

V1IT TCM

V2IT TCM

V2MA TCM

V2MB TCM

V2MH TCM

Troubleshooting

T8DB Heater B

32

No Temperature

Rise B

No Temperature

Rise Hose

Low Voltage CAN

Low Voltage CAN

Low Voltage A

Low Voltage B

Low Voltage Hose

Bad RTD or bad

RTD placement against heater.

Bad heater element.

Loose heater wires.

Started spraying before heater reached operating temperature.

Started spraying before heater reached operating temperature.

Bad 24 VDC power supply.

Bad 24 VDC power supply.

Loose connection or tripped circuit breaker.

Low incoming line voltage.

Loose connection or tripped circuit breaker.

Low incoming line voltage.

Loose connection or tripped circuit breaker.

Low incoming line voltage.

Swap A and B heater output cables and RTD cables and see if issue follows. If so, replace RTD.

Confirm resistance of heater. Heater resistance should be 9-12 Ω for 10 kW systems, 6-8 Ω for 15 kW systems, 4–6 Ω for 20 kW systems. If out of tolerance, replace heater element.

Check for loose heater element wires.

Wait until operating temperature has been reached before spraying or recirculating.

Wait until operating temperature has been reached before spraying or recirculating.

Check voltage of power supply. Voltage should be 23-25 VDC. If out of tolerance, replace power supply.

Check voltage of power supply. Voltage should be 23-25 VDC. If out of tolerance, replace power supply.

Check wiring for loose connection or tripped circuit breaker.

Measure voltage at circuit breaker and ensure voltage is greater than 195 VAC.

Check wiring for loose connection or tripped circuit breaker.

Measure voltage at circuit breaker and ensure voltage is greater than 195 VAC.

Check wiring for loose connection or tripped circuit breaker.

Measure voltage at circuit breaker and ensure voltage is greater than 195 VAC.

334946D

V3IT TCM

V3MA TCM

V3MB TCM

V3MH TCM

V4IT TCM

V4MA TCM

V4MB TCM

V4MH TCM

WMI0 TCM

WSUX USB

Troubleshooting

High Voltage CAN

High Voltage A

High Voltage B

High Voltage Hose

High Voltage CAN

High Voltage A

High Voltage B

High Voltage Hose

TCM Fan Error

Configuration Error

USB

Bad 24 VDC power supply.

Incoming line voltage is too high.

Incoming line voltage is too high.

Incoming line voltage is too high.

Bad 24 VDC power supply.

Incoming line voltage is too high.

Incoming line voltage is too high.

Incoming line voltage is too high.

Fan inside TCM is not operating properly.

A valid configuration file can't be found for the USB.

Check voltage of power supply. Voltage should be 23-25 VDC. If out of tolerance, replace power supply.

Ensure incoming system power is wired properly.

Verify voltage at each circuit breaker is between 195 and

264 VAC.

Ensure incoming system power is wired properly.

Verify voltage at each circuit breaker is between 195 and

264 VAC.

Ensure incoming system power is wired properly.

Verify voltage at each circuit breaker is between 195 and

264 VAC.

Check voltage of power supply. Voltage should be 23-25 VDC. If out of tolerance, replace power supply.

Ensure incoming system power is wired properly.

Verify voltage at each circuit breaker is between 195 and

264 VAC.

Ensure incoming system power is wired properly.

Verify voltage at each circuit breaker is between 195 and

264 VAC.

Ensure incoming system power is wired properly.

Verify voltage at each circuit breaker is between 195 and

264 VAC.

Check for debris in the TCM fan and clear with forced air if necessary.

Inset a system token into the ADM and cycle power.

Wait until the lights on the

USB port stop flashing before removing token.

334946D 33

Troubleshooting

WXUD ADM

WXUU ADM

USB Download Error Log download failed.

USB Upload Error Custom language file failed to upload.

Backup and reformat the

USB drive. Retry download.

Perform normal USB download and use the new disptext.txt file to upload the custom language.

34 334946D

Troubleshooting

2.

Turn main power OFF.

3.

Allow equipment to cool.

Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and controls are properly set and wiring is correct before assuming there is a problem.

Note

Motor startup is delayed a maximum of 5 seconds from the last time the motor was turned off to reduce the chance of the motor overheating.

Before performing any troubleshooting procedures:

1.

Follow

Pressure Relief Procedure, page 46 .

Electric motor will not start or stops during operation.

Loose connections and/or contactor

(CT01) is not closing.

Check wiring between the following components:

• HCM and contactor CT01

Damaged HCM.

• HCM and fuses F11/F12

Replace HCM.

Loose connections and/or contactor

(CT01) is closing.

Check wiring between the following components:

Circuit breaker tripped.

• motor junction box and CB12

• CB12

• contact CT01 and main disconnect switch (or terminal blocks TB06 and TB09)

Reset CB12 within the electrical enclosure after confirming wiring is correct and its insulation is intact.

334946D 35

Troubleshooting

Hydraulic pump does not develop pressure. Low or zero pressure with screeching noise.

Pump is not primed or lost its prime.

Check electric motor rotation. Both motor and hydraulic pump must rotate counterclockwise when viewed from shaft end. If rotation is incorrect, reverse leads L1 and

Screeching noise is characteristic of cavitation and is normal at initial startup for a maximum of 30 seconds.

Hydraulic fluid is too hot.

Electric motor operating in wrong direction for 3 Phase system.

Drive belt loose or broken.

Operation manual.

Check dipstick to ensure that hydraulic reservoir is properly filled

(see Operation manual).

Check that inlet fitting is fully tight, to ensure no air is leaking into the pump inlet.

To prime pump, run unit at lowest pressure setting and slowly increase pressure. In some cases it may be necessary to remove motor cover and drive belt to allow for manual (counterclockwise) rotation of hydraulic pump. Turn fan pulley by hand. Verify oil flow by removing oil filter to see flow into filter manifold. Reinstall oil filter. Do

NOT operate unit without a properly installed oil filter.

If noise continues longer than 30 seconds, press to shut off the motor. Check that the inlet fittings are tight and that the pump has not lost its prime.

Ensure that the reservoir is properly serviced. Improve ventilation to allow more efficient heat dissipation.

Motor must operate counterclockwise from pully end.

Check drive belt condition. Replace if broken.

36 334946D

Troubleshooting

1.

Follow

Pressure Relief Procedure, page 46 .

2.

Turn main power OFF.

3.

Allow equipment to cool.

Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and controls are properly set and wiring is correct before assuming there is a problem.

Before performing any troubleshooting procedures:

Proportioning pump does not hold pressure when stalled.

Material Imbalance. See

Pressure/Material Imbalance, page 38 .

Pump piston or intake valve leaking. 1.

Observe gauges to determine which pump is losing pressure.

Restriction at the gun.

Inadequate flow from pump; cavitation.

2.

Determine in which direction the pump has stalled by observing which directional icon is displayed on the ADM

Home screen. See Table 1.

3.

Repair the valve. See pump manual.

Clean the gun; see your separate gun manual.

Increase fluid supply to proportioning pump:

Pressure relief/circulation valve leaking back to supply.

• Use 2:1 supply pump

• Use minimum 3/4 in. (19 mm) ID supply hose, as short as practical

Fluid is too thick. Consult your material supplier for the recommended fluid temperature to maintain a viscosity of 250 to 1500 centipoise.

Clean inlet strainer screen.

Worn pump inlet valve ball/seat or gasket. Replace pump.

Remove return line and determine if flow is present while in SPRAY mode.

334946D 37

Troubleshooting

Pumps do not reverse direction or pumps do not move.

Erratic pump movement.

Pump output low.

Fluid leak at pump rod seal.

No pressure on one side.

Loose reversing proximity switch.

See

Pumps Do Not Reverse

Direction, page 39

.

Loose piston packing bolt.

See

Pumps Do Not Reverse

Direction, page 39

.

Faulty directional valve.

Pump cavitation.

See

Pumps Do Not Reverse

Direction, page 39

.

Feed pump pressure is too low.

Adjust pressure to maintain 100 psi

(0.7 MPa, 7 bar) minimum.

Fluid is too thick. Consult your material supplier for recommended fluid temperature to maintain a viscosity of 250 to 1500 centipoise.

Loose reversing proximity switch.

See

Pumps Do Not Reverse

Direction, page 39

.

Faulty directional valve.

Replace directional valve.

Obstructed fluid hose or gun; fluid hose ID too small.

Worn piston valve or intake valve in displacement pump.

Inadequate feed pump pressure.

Open fluid hose to clear obstruction, or use hose with larger ID.

See pump manual.

Check feed pump pressure and adjust to 100 psi (0.7 MPa, 7 bar) minimum.

Replace. See pump manual.

Worn throat seals.

Fluid leaking from pump outlet rupture disk.

Inadequate feed pump pressure.

Check if heater and PRESSURE

RELIEF/SPRAY valve (SA or SB) are plugged. Clear. Replace rupture disk with a new one; do not replace with a pipe plug.

Check feed pump pressure and adjust to 100 psi (0.7 MPa, 7 bar) minimum.

Note

Table 1 is related to troubleshooting problem,

“Proportioning pump does not hold pressure when stalled.”

B-side pump piston valve is dirty or damaged.

A-side pump inlet valve is dirty or damaged.

B-side pump inlet valve is dirty or damaged.

A-side pump piston valve is dirty or damaged.

To determine which component is out of balance, check the color of some sprayed material.

Two-component materials are usually a mix of light and dark fluids, so the under-proportioned component can often be readily determined.

When you have determined which component is under-proportioned, spray off-target, focusing on the pressure gauge for that component.

For example:

if component B is under-proportioned, focus on the B-side pressure gauge. If the B gauge reads considerably higher than the A gauge, the problem is at the gun. If the B gauge reads considerably lower than the A gauge, the problem is at the pump.

38 334946D

Troubleshooting

For proportioning pumps to reverse direction, the proximity switches (211) must sense the switching plate (319) to reverse the directional valve (207).

Voltage is still present inside the directional valve. Improper testing of the proximity switch connections inside the directional valve may cause injury or electric shock. Check the proximity switch connections as instructed.

Measure voltage across correct terminals. See

Electrical Schematics, page 95

.

The switching plate moves from side to side during operation. Keep hands away from the switching plate, while checking the functionality of the directional valve, to prevent pinching hands.

1.

Check the functionality of each proximity switch

(211).

a.

Remove the front cover.

b.

With the motor powered off, confirm that the indicating lights on the body of each proximity switch (211) turns on when a metallic item, such as the shaft of a screwdriver, is placed on the face of each switch.

c.

If the indicating lights turn on, the proximity switches, its wiring, and the HCM are likely operating correctly; proceed to step 2. If the indicating lights do not turn on, proceed to step 6.

2.

Confirm the proximity switches (211), switch bracket (209), and switching plate (319) are firmly mounted and not damaged.

3.

Check distance between the proximity switches

(211) and the switching plate (319).

a.

Park the pump.

b.

Confirm that the proximity switch (211) nearest the A-side of the pump is backed out

0.5 to 1.5 turns from being in contact with the switching plate (319).

c.

Disconnect the cable from the proximity switch (211) nearest the B-side of the pump.

Operate the pump until the switching plate

(319) is located above the B-side proximity switch, then turn off the motor/pump.

d.

Confirm that the proximity switch (211) nearest the B-side of the pump is backed out

0.5 to 1.5 turns from being in contact with the switching plate (319).

e.

Reconnect the cable to the B-side proximity switch (219).

4.

Check functionality of the directional valve (207).

a.

Confirm that the directional valve cable is connected properly from HCM port 15 to the directional valve body (207) and is not damaged. Inspect wiring inside the cover of the directional valve. See

Electrical Schematics, page 95

.

b.

During operation, the direction indicator lights on the directional valve body (207) should switch on based on the valve that is open.

334946D 39

Troubleshooting

c.

Turn on the motor and stall the pumps at the lowest pressure setting (compensator knob turned fully counter-clockwise). The pump will travel in either the A or B direction until the pressure setting is reached.

d.

Identify the solenoid that is operating by viewing the direction indicator lights on the cover of the directional valve (207). Measure voltage across the associated terminals to determine if proper voltage is reaching the valve (approximately 200 to 240 VAC). See

Electrical Schematics, page 95 , and the table

below, to identify the proper terminals to measure across.

e.

Trigger each proximity switch (211) with the shaft of a screwdriver, confirming each solenoid within the directional valve (207) operates as described in table below.

f.

If one or both sides are not operating properly, according to the table, first reconfirm wiring to directional valve (207) per

Electrical Schematics, page 95 , then replace

directional valve (207).

5.

If you have determined that the cause is none of the previous possible causes, check for a loose piston packing retaining bolt. This causes the piston to contact the inner face of the pump inlet flange before the switching plate activates the proximity switch. Shut down the unit and disassemble the appropriate pump for repair.

6.

Check for loose or faulty proximity switch cable or connections. Confirm the connections to the proximity switches are tight and internally free from oil and other contaminates.

7.

Swap the cables to the proximity switches to see if the problem follows the switch or is in the cable.

Replace either the failed switch or the cable.

8.

Replace the HCM. See

Replace HCM, page 65 .

ADM indicates

Indicator light on directional valve cover

Last proximity switch triggered

Terminals in directional valve energized

Left arrow, labeled “b”

Right side proximity switch

Terminals associated with red and orange wires

Right arrow, labeled “a”

Left side proximity switch

Terminals associated with black and white wires

Note

For diagnostic purposes, it is possible to manually override the directional valve by using a small screwdriver to depress the button in the center of either directional valve end cap. Depressing the button in the right end cap should cause the pump to travel to the right. Depressing the left button should cause the pump to travel to the left.

40 334946D

Troubleshooting

Before performing any troubleshooting procedures:

1.

Follow

Pressure Relief Procedure, page 46 .

2.

Turn main power switch OFF.

3.

Allow equipment to cool.

Hose heats but heats slower than usual or it does not reach temperature.

Hose does not maintain temperature while spraying.

Ambient temperature is too cold.

FTS failed or not installed correctly.

Check FTS, see

Check RTD

Cables and FTS, page 59

.

Low supply voltage.

Verify line voltage. Low line voltage significantly reduces power available to the hose heat system, affecting longer hose lengths.

A and B setpoints too low.

Relocate hoses to a warmer area or recirculate heated fluid through the hose.

Ambient temperature is too cold.

Increase A and B setpoints.

Hose is designed to maintain temperature, not to increase it.

Increase A and B setpoints to increase fluid temperature and keep it steady.

Flow too high.

Hose was not fully preheated.

Low supply voltage.

Use smaller mix chamber.

Decrease pressure.

Wait for hose to heat to correct temperature before spraying.

Verify line voltage. Low line voltage significantly reduces power available to the hose heat system, affecting longer hose lengths.

334946D 41

Troubleshooting

Hose temperature exceeds setpoint.

Erratic hose temperature.

Hose does not heat.

A and/or B heaters are overheating material.

Faulty FTS connections.

Ambient temperature is too high.

Check primary heaters for either an RTD problem or a failed element attached to RTD, see

Electrical Schematics, page 95

.

Verify that all FTS connections are snug and that pins of connectors are clean. Unplug and re-plug

RTD wires, cleaning off any debris.

Cover hoses or move to a location with a lower ambient temperature.

Replace damaged insulation.

Hose insulation over the FTS location is damaged.

Faulty FTS connections.

FTS not installed correctly.

FTS failed.

Verify that all FTS connections are snug and that pins of connectors are clean. Unplug and re-plug

FTS wires along length of hose, cleaning off any debris.

FTS should be installed close to end of hose in same environment as gun. Verify FTS installation, see

Repair Fluid Temperature

Sensor (FTS), page 61 .

Check FTS, see

Repair Fluid

Temperature Sensor (FTS), page

61

.

FTS not installed correctly.

FTS should be installed close to end of hose in same environment as gun. Verify FTS installation, see

Repair Fluid Temperature

Sensor (FTS), page 61 .

Loose hose electrical connections.

Check connections. Repair as necessary.

Circuit breakers tripped.

Hose zone not turned on.

Reset breakers (CB11 and/or

CB15), see

Repair Circuit Breaker

Module, page 62

.

Turn on hose heat zone.

A and B temperature setpoints too low.

Check. Increase if necessary.

42 334946D

Troubleshooting

Hoses near Reactor are warm, but hoses downstream are cold.

Low hose heat.

Shorted connection or failed hose heating element.

A and B temperature setpoints too low.

With power off, check the hose resistance with and without the whip hose attached. With the whip hose attached, the reading should be less than 3 ohm. Without the whip hose attached, the reading should be OL (open loop). See

Check Hose Wires, page 59 .

Increase A and B setpoints. Hose designed to maintain temperature, not increase temperature.

Hose temperature setpoint too low.

Flow too high.

Low current; FTS not installed.

Hose heat zone not turned on long enough to reach setpoint.

Check. Increase if necessary to maintain heat.

Use smaller mix chamber.

Decrease pressure.

Install FTS, see operation manual.

Allow hose to heat up, or preheat fluid.

Loose hose electrical connections.

Check connections. Repair as necessary.

Ambient temperature is to low Relocate hoses to a warmer area or increase A and B setpoints.

334946D 43

Troubleshooting

Primary Heater(s) does not heat.

Control of primary heat is abnormal; high temperature overshoots (T4DA, T4DB) occurs intermittently.

Before performing any troubleshooting procedures:

1.

Follow

Pressure Relief Procedure, page 46 .

2.

Turn main power switch OFF.

3.

Allow equipment to cool.

Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and controls are properly set and wiring is correct before assuming there is a problem.

Heat turned off.

Temperature control alarm.

Signal failure from RTD.

Dirty RTD connections.

RTD not contacting heater element.

Failed heater element.

Signal failure from RTD.

Turn on heat zones.

Check ADM for error codes.

Check ADM for error codes.

Confirm RTD cabling is properly connected and not damaged.

Replace RTD.

Examine RTD cables connected to TCM. Confirm RTDs are not plugged into opposite heat zone. Unplug and re-plug RTD connectors. Unplug and re-plug

RTD connectors. Ensure RTD tip contacts the heater element.

Loosen ferrule nut, push in RTD so tip contacts heater element.

Holding RTD tip against heater element, tighten ferrule nut 1/4 turn past tight.

See

Replace Heater Element, page 57 .

See (T6DA, T6DB),

Error Codes

.

44 334946D

Troubleshooting

Before performing any troubleshooting procedures:

1.

Relieve Pressure. See

Pressure Relief Procedure, page 46 .

2.

Turn main power switch OFF.

3.

Allow equipment to cool.

Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs.

The material ratio is significantly offset from 1 : 1.

The ADM displays low inlet pressure alarms, but the inlet pressure reading appears correct..

The material flow and ratio are not displayed on the ADM.

The flow meter repeatedly disables itself.

The k-factor entered in the ADM is incorrect.

Cavitation is reducing the pump performance.

Air is trapped in the system, between the feed pumps and the heated hose.

While spraying, the inlet pressure drops below 30 psi.

The flow meter is disabled.

The inlet sensors are disabled.

Update the k-factor. See

Replace Flow Meter .

Increase the feed pump pressure.

Install a larger feed pump.

Clean the y-strainer filter.

Install a smaller mix chamber in the spray gun.

Condition the material in the drums to the ambient temperature of the proportioner.

Re-route the feed hoses to a lower height.

Purge air from the system. Refer to your ratio monitor manual for instructions.

Place the heated hose on flat ground. Spray material into a waste container until all air has left the system.

Increase the feed pump pressure.

Install a larger feed pump.

Install a smaller mix chamber in the spray gun.

Enable the flow meter on System

Screen 1.

Enable the inlet sensors. Inlet sensors must be enabled for the flow meter to function.

334946D 45

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

4.

Close gun fluid inlet valves A and B.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the

Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

The Fusion AP gun is shown.

1.

Press to stop the pumps.

2.

Turn off all heat zones.

5.

Shut off feed pumps and agitator, if used.

6.

Route fluid to waste containers or supply tanks.

Turn PRESSURE RELIEF/SPRAY valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION

. Ensure gauges drop to 0.

GA GB

SA SB

7.

Engage gun piston safety lock.

3.

Relieve pressure in gun and perform gun shutdown procedure. See gun manual.

8.

Disconnect gun air line and remove gun fluid manifold.

46 334946D

Shutdown

Proper system setup, startup, and shutdown procedures are critical to electrical equipment reliability. The following procedures ensure steady voltage. Failure to follow these procedures will cause voltage fluctuations that can damage electrical equipment and void the warranty.

6.

Turn off the air compressor, air dryer, and breathing air.

7.

Turn main power switch OFF.

1.

Press to stop the pumps.

2.

Turn off all heat zones.

3.

Relieve pressure.

See

Pressure Relief Procedure, page 46 .

To prevent electric shock do not remove any covers or open the electrical enclosure door while the power is ON.

8.

Close all fluid supply valves.

4.

Press to park the Component A and

Component B pumps. The park operation is complete when green dot goes out. Verify the park operation is complete before moving to next step.

9.

Set PRESSURE RELIEF/SPRAY valves to

SPRAY to seal out moisture from the drain line.

10. Engage gun piston safety lock then close fluid inlet valves A and B.

5.

Press to deactivate the system.

334946D 47

Flushing

To avoid fire and explosion:

• Flush equipment only in a well-ventilated area.

• Ensure main power is off and heater is cool before flushing.

• Do not turn on heater until fluid lines are clear of solevent.

To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE

RELIEF/SPRAY valves (SA, SB) to PRESSURE

RELIEF/CIRCULATION lines (N).

GA GB

. Flush through bleed

SA SB

To flush entire system, circulate through gun fluid manifold (with manifold removed from gun).

To prevent moisture from reacting with isocyanate, always leave the system filled with a moisture-free plasticizer or oil. Do not use water. Never leave the system dry. See

Important Two-

Component Material Information, page 7 .

48 334946D

Repairing this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. Be sure to shut off all power to equipment before repairing.

Repair

3.

Disconnect the B (Resin) side pump inlet line, the inlet y-strainer, and hard tube (57). Remove the pin (213) from the clevis (317) to disconnect the pump from the hydraulic cylinder (201). Remove the four screws (203) holding the pump to the spacers (313) of the cylinder. Take the pump assembly to a workbench.

Proper system setup, startup, and shutdown procedures are critical to electrical equipment reliability. The following procedures ensure steady voltage. Failure to follow these procedures will cause voltage fluctuations that can damage electrical equipment and void the warranty.

1.

Flush if necessary. See

Flushing, page 48 .

2.

See

Shutdown, page 47

.

Torque to 200 in.-lb (22.6 N•m).

1

4.

Disconnect the A (ISO) side pump inlet line, the inlet y-strainer, and hard tube (55). Use the pin extractor tool (101) to remove the pin (213), which disconnects the pump from the hydraulic cylinder

(201). Remove the four screws (203) holding the pump to the spacers (313) of the cylinder. Take the pump assembly to a workbench.

1.

Follow

Before Beginning Repair, page 49

.

2.

Turn both Pressure Relief/Spray valve (SA, SB) to Pressure Relif/Circulation. Route fluid to waste containers or supply tanks. Ensure gauges (GA,

GB) drop to 0 psi.

GA GB

SA SB

Note

Use drop cloth or rags to protect the

Reactor and surrounding area from spills.

Torque to 200 in.-lb (22.6 N•m).

1

5.

See pump manual for repair instructions.

6.

Reconnect the pump in the reverse order. Torque the screws to 200 in.-lb (22.6 N•m)

334946D 49

Repair

1.

Perform

Shutdown, page 47 .

2.

Perform

Pressure Relief Procedure, page 46 .

3.

Disconnect the flow meter cable.

4.

Disconnect the heated hose from the flow meter.

Remove the flow meter.

5.

Remove four screws (VS) and remove the top cover (PL).

9.

Reinstall the gears.

a.

Place the gear with the magnets (MG) on the left pin of the housing.

6.

Remove eight screws (MS) and remove the metal cap (SD).

7.

Remove gears (GS) from the housing (HG).

8.

Clean the gears and the fluid section of the housing with compatible solvent.

must be installed on the left side or the meter will not function. Install the gears as shown.

b.

Position the gears perpendicular (90°) to each other and install the rounded bottom

(RB) of the gear into the housing.

stay engaged and rotate together once installed. Reinstall the gears if they do not stay engaged or rotate together.

10. Reinstall the flow meter. Reconnect the heated hose and flow meter cable.

50 334946D

Repair

8.

The lubrication system is ready for operation. No priming is required.

Check the condition of the ISO pump lubricant daily.

Change the lubricant if it becomes a gel, its color darkens, or it becomes diluted with isocyanate.

Gel formation is due to moisture absorption by the pump lubricant. The interval between changes depends on the environment in which the equipment is operating. The pump lubrication system minimizes exposure to moisture, but some contamination is still possible.

Lubricant discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during operation. If the packings are operating properly, lubricant replacement due to discoloration should not be necessary more often than every 3 or

4 weeks.

To change pump lubricant:

1.

Follow

Pressure Relief Procedure, page 46 .

2.

Lift the lubricant reservoir (LR) out of the bracket

(RB) and remove the container from the cap.

Holding the cap over a suitable container, remove the check valve and allow the lubricant to drain.

Reattach the check valve to the inlet hose.

3.

Drain the reservoir and flush it with clean lubricant.

4.

When the reservoir is flushed clean, fill with fresh lubricant.

5.

Thread the reservoir onto the cap assembly and place it in the bracket.

6.

Push the larger diameter supply (ST) tube approximately 1/3 of the way into the reservoir.

7.

Push the smaller diameter return tube (RT) into the reservoir until it reaches the bottom.

the reservoir to ensure that isocyanate crystals will settle to the bottom and not be siphoned into the supply tube and returned to the pump.

Figure 1 Pump Lubrication System

Note

Change break-in oil in a new system after the first 250 hours of operation or within 3 months, whichever comes first.

0 to 90°F

(-17 to 32°C)

90°F and above

(32°C and above)

1000 hours or 12 months, whichever comes first

500 hours or 6 months, whichever comes first

1.

Follow

Pressure Relief Procedure, page 46 .

2.

Allow hydraulic fluid to cool.

334946D 51

Repair

3.

Place a pan under the reservoir drain plug (16f) to catch oil.

4.

Remove the drain plug (16f).

5.

Place a rag around base of oil filter (119) to prevent oil from spilling. Unscrew filter 1/4-3/4 turn to break air lock in filter. Wait five minutes to allow oil in filter to drain back into reservoir.

Unscrew filter and remove.

6.

Reinstall drain plug (16f).

7.

Replace filter (119): a.

Coat filter seal with fresh oil.

b.

Screw filter on snug, then an additional 1/4 turn.

8.

Refill reservoir with approved hydraulic fluid. See

Table 3.

9.

Proceed with normal operation.

Note

Upon starting motor, hydraulic pump may make a screeching noise until primed. If this noise continues for more than 30 seconds, switch off motor control.

Citgo

Amsoil

BP Oil International

Carl Bechem GmbH

Castrol

Chevron

Exxon

A/W ISO Grade 46

AWI ISO Grade 46

(synthetic*)

Energol® HLP-HM, ISO

Grade 46

Staroil HVI 46

Hyspin AWS 46

Rykon® AW, ISO 46

Mobil

Shell

Texaco

Humble Hydraulic H,

ISO Grade 46

Mobil DTE 25, ISO

Grade 46

Shell Tellus, ISO Grade

46

Texaco AW Hydraulic,

ISO Grade 46

* Note: Do not mix mineral-based and synthetic hydraulic oils. Completely drain oil from reservoir and pump prior to converting between oils.

If the approved oils are not available in your area, use an alternative hydraulic oil meeting the following requirements: anti-wear, anti-foaming, oxidation stability, corrosion protection, and water separation.

52 334946D

Repair

5.

Remove motor and belt covers (123, 131, 132).

Lift cover (132) and loosen the blue bracket (131) fasteners. Lift the blue bracket (133) off of the fasteners and set aside. Remove the belt covers

(131, 132).

To prevent dropping the electric motor, two people may be required to remove the motor from the system.

1.

Follow

Shutdown, page 47 .

2.

Open electrical enclosure. Disconnect the

A side heater connector from the TCM. See

Electrical Schematics, page 95 . Close the

electrical enclosure door.

3.

Remove mounting bolts from the bottom frame and move the system away from the wall.

Figure 3 Motor and Belt Covers

Figure 2

4.

Remove upper bolts (3). Tilt the electrical enclosure down to gain access to the motor cover.

Figure 4 Heater and Belt Covers

334946D 53

Repair

6.

Remove the belt (51). See

Replace Belt, page 55

.

Remove the two pulley screws (48) and the belt tensioning assembly from the motor.

To prevent damage to cables, do not crush or strain any cables near the point where the frame halves hinge.

9.

Note or label the wire connections. See the

Electrical Schematics, page 95

and the diagram inside the motor junction box cover. The motor must operate counter-clockwise when looking at the output shaft.

10. Remove the motor.

Figure 5 Motor and Belt Assembly

7.

Remove the electric motor junction box cover

8.

(43).

Disconnect the motor cables. See

Electrical Schematics, page 95 .

1.

Place the motor on the unit.

2.

Fasten the motor with bolts.

3.

Connect the wires, using wire nuts. See

Electrical Schematics, page 95 , and the diagram

inside the motor junction box.

Note

For 3–Phase Motors, the motor must rotate counterclockwise when viewed from the shaft end. If rotation is incorrect, reverse power leads L1 and L2. Follow the system operation manual.

4.

Replace bracket (133) and the belt and heater covers (131, 132, 134).

5.

Raise electrical enclosure into the vertical position and ensure wires are not pinched between the frame halves. Replace and tighten bolts (3).

6.

Open electrical enclosure. Connect the A side heater connector the TCM.

7.

Secure the system to original mounting location.

8.

Return to service.

54 334946D

1.

Follow

Shutdown, page 47 .

2.

Remove the heater cover (134) and the belt cover fasteners (19).

To prevent damage to the overtemperature switch, carefully remove the covers.

3.

Lift cover (132) and loosen the blue bracket (131) fasteners. Lift the blue bracket (133) off of the fasteners and set aside. Remove the belt covers

(131, 132).

4.

Remove the belt.

5.

Install the new belt and replace the covers.

Repair

334946D 55

Repair

See Fluid Inlet Sensor Kit 17F837 manual 3A3009.

1.

Flush. See

Flushing, page 48

.

2.

See

Shutdown, page 47

.

3.

Disconnect inlet sensor cable from the fluid inlet assembly. Inspect cable for damage and replace if necessary. See

Electrical Schematics, page 95

.

1.

Flush. See

Flushing, page 48

.

2.

See

Shutdown, page 47

.

3.

Disconnect transducer cables (405) from #6 and

#7 connectors on the HCM.

4.

Remove wire ties constraining transducer cable and remove cable from cabinet.

5.

Install o-ring (406) on new transducer (405).

6.

Install transducer in manifold. Mark end of cable with tape (red=transducer A, blue=transducer B).

7.

Route new cable into cabinet and thread into bundle as before. Attach cable ties to bundle as before.

8.

Connect A side pressure transducer cable to HCM port #6. Connect B side pressure transducer cable to HCM port #7.

Figure 6 Fluid Inlet Sensor

4.

To replace sensor cable: a.

Cut any wire ties and disconnect from HCM.

See

Electrical Schematics, page 95

.

To prevent damage to cable, secure cable with wire ties.

5.

Replace sensor and secure with wire ties.

56 334946D

Repair

1.

Follow

Before Beginning Repair, page 49

.

2.

Wait for heaters to cool.

3.

Remove heater cover.

4.

Disconnect heater element wires from heater wire connector inside the electrical enclosure.

See

Electrical Schematics, page 95

. Test with an ohmmeter.

Element Ohms

H-30

H-30,

H-40,

H-XP2

H-40,

H-50,

H-XP3

10 kW

15 kW

20 kW

2,550

2,550

2,550

18–21

18–21

18–21

5.

If the RTD is on the heater element, remove the RTD (512) to avoid damage. See

Replace RTD, page 58 .

6.

Use a wrench to remove the heater element

(508). Inspect element. It should be relatively smooth and shiny. Replace element if there is a crusted, burnt ash-like material adhered to the element, or if the sheath shows pitting marks.

7.

Install the new heater element (508), holding the mixer (510) so it does not block the RTD port.

Torque to 120 ft-lb (163 N•m).

8.

Install the RTD (512), if removed earlier. See

Replace RTD, page 58 .

9.

Reconnect the wires inside the electrical enclosure.

1.

Perform

Shutdown, page 47 .

2.

Wait for heaters to cool.

3.

Disconnect overtemperature switches (509) from cable (88). Test across spade terminals with ohmmeter.

a.

If the resistance is not approximately 0 ohms, the overtemperature switch (509) needs to be replaced. Go to step 5.

b.

If the resistance is approximately 0 ohms, inspect cable (88) to ensure it is not cut or open. Reconnect the overtemperature switch

(509) and cable (88). Disconnect cable from the TCM. Test from pin 1 to 3 and 1 to 4. If the resistance is not approximately 0, and switches are 0, replace cable in place or original cable.

4.

If the switch fails the test, remove the screws.

Discard the failed switch. Apply a thin layer of thermal compound 110009, install a new switch

(509) in the same location on housing (501).

Secure with screws (513) and reconnect cables

(88).

The heater outputs its rated wattage at 230 VAC.

Low line voltage will reduce power available and the heater will not perform at full capacity.

334946D 57

Repair

1.

Perform

Shutdown, page 47 .

2.

Wait for heater to cool.

3.

Remove heater covers.

4.

Cut cable ties around the woven wrap with the

RTD cable (512).

5.

Disconnect RTD cable (512) from TCM (453).

6.

Loosen ferrule nut (N). Remove RTD (512) from heater housing (501), then remove RTD housing

(H). Do not remove the adapter (206) unless necessary. If adapter must be removed, ensure that mixer (510) is out of the way when replacing the adapter.

7.

Remove RTD cable (512) from woven wrap.

8.

Replace RTD cable (512).

a.

Apply PTFE tape and thread sealant to male pipe threads and tighten RTD housing (H) into adapter (506).

b.

Push in RTD (512) so tip contacts heater element (508).

c.

Holding RTD (512) against heater element, tighten ferrule nut (N) 3/4 turn past finger-tight.

9.

Route wires (S) as before through woven wrap and reconnect RTD cable (512) to the TCM.

10. Replace heater covers.

11. Follow startup instructions in the operation manual. Turn on A and B heat simultaneously to test. Temperatures should rise at same rate.

If one is low, loosen ferrule nut (N) and tighten

RTD housing (H) to ensure RTD tip contacts the heater element (212) when ferrule nut (N) is retightened.

ti26526a

Figure 7

58 334946D

Repair

Refer to the heated hose manual 309572 for hose replacement parts.

1.

Perform

Shutdown, page 47 .

Note

Whip hose must be connected.

2.

Remove cover (CV).

3.

Disconnect system wires from the Reactor.

4.

Disconnect hose wires (HW) from terminal block

(TB), see Fig 3.

5.

Using an ohmmeter, check between the hose wires (HW). There should be continuity.

6.

If hose fails test, retest at each length of hose from the system out to the gun, including whip hose, until failure is isolated.

7.

Reconnect wires and install cover (CV).

4.

Retest at each length of hose, including whip hose, until failure is located.

5.

If the FTS is not reading properly at the end of the hose, connect FTS directly to RTD cable (C) at the manifold.

6.

If the FTS reads properly at the manifold but not at the end of the hose, check cable (C) connections. Verify they are tight.

1.

Perform

Shutdown, page 47 .

2.

Disconnect RTD cable (C) at Reactor (SC).

3.

Test with an ohmmeter between pins of M8 cable connector C.

Note

Do not touch outer ring with test probe while measuring resistance.

3 to 1

3 to 4

1 to 4

2 to any

See

RTD Resistance vs. Temperature, page 60 page 60

.

.

See

RTD Resistance vs. Temperature,

0.2 - 0.4 ohms at the

FTS (each 50 ft cable adds 2.5 ohms) infinity (open)

Heated Hose

Figure 8

Note

To assist in taking readings, order RTD

Test Kit 24N365. Kit includes two cables: one cable with a compatible female M8 connector and another cable with a male

M8 connector. Both cables have stripped wire at the other end for easy test probe access.

3 to 1 / brown to blue See

RTD Resistance vs. Temperature, page 60

.

3 to 4 / blue to black See

RTD Resistance vs. Temperature, page 60

.

1 to 4 / brown to black 0.2 - 0.4 ohms at the

FTS (each 50 ft cable adds 2.5 ohms)

2 to any / N/A infinity (open)

334946D 59

Repair

1155

1194

1232

1271

1309

1347

1385

843

882

922

961

1000

1039

1078

1117

-40 (-40)

-30 (-22)

-20 (-4)

-10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

40 (104)

50 (122)

60 (140)

70 (158)

80 (176)

90 (194)

100 (212)

60 334946D

Repair

The Fluid Temperature Sensor (FTS) is supplied with the system. Install FTS between main hose and whip hose. See Heated Hose manual 309572 for instructions.

B

D

K

H

F

B W

A

L ti18511a

C

A

Figure 9

1.

Perform

Shutdown, page 47 .

2.

Remove tape and protective covering from FTS.

Disconnect hose cable (F).

3.

If FTS is not reading properly at the end of the hose, see

Check RTD Cables and FTS, page 59

.

4.

If FTS fails, replace FTS.

a.

Disconnect air hoses (C,L) and electrical connectors (D).

b.

Disconnect FTS from whip hose (W) and fluid hoses (A, B).

c.

Remove ground wire (K) from ground screw on underside of FTS.

d.

Remove FTS probe (H) from component A

(ISO) side of hose.

334946D 61

Repair

1.

Follow

Before Beginning Repair, page 49

.

2.

Using an ohmmeter, check for continuity across the circuit breaker (top to bottom). If no continuity, trip the breaker, reset, and retest. If there still is no continuity, replace the breaker as follows: a.

Refer to

Electrical Schematics, page 95

.

b.

Refer to the circuit breaker identification table and electrical diagrams.

c.

Loosen the screws connecting the wires to the circuit breaker that will be replaced.

Disconnect wires.

d.

Pull the locking tab out 1/4 in. (6 mm) and pull circuit breaker away from the din rail.

Install the new circuit breaker. Insert wires and tighten down all screws.

853 (CB11) 50A, 1 pole

859 (CB12) 20A, 3 pole

854 (CB13) 60A, 2 pole

854 (CB14) 60A, 2 pole

855 (CB15) 40A, 2 pole

Heated Hose

Motor

Heater A

Heater B

Transformer

Primary

17A319

17G724

17G723

17G723

17A317

853 (CB11) 50A, 1 pole Heated

Hose

854 (CB12) 20A, 2 pole Motor

855 (CB13) 40A, 2 pole Heater A

855 (CB14) 40A, 2 pole Heater B

855 (CB15) 40A, 2 pole Transformer Primary

17A319

17A314

17A317

17A317

17A317

62 334946D

Repair

See

Electrical Schematics, page 95 .

1.

Check wires and transformer: a.

See

Shutdown, page 47

.

b.

Shut off CB15.

c.

Use an ohmmeter to test for continuity between terminals 2 and 4 of CB15. If there is no continuity, check transformer and wiring between CB15 and TB31 located behind the lower cover. Go to step 2.

2.

Check transformer and TB31: a.

See

Shutdown, page 47

.

b.

Remove the lower cover.

c.

Locate the two smaller (10 AWG) wires, labeled 1 and 2, coming out of transformer.

Trace these wires back to terminal blocks

TB31.

d.

Use an ohmmeter to test for continuity between two wires; there should be continuity.

See

Electrical Schematics, page 95 .

1.

Check wires and transformer: a.

See

Shutdown, page 47

.

b.

Disconnect 7 pin green connector from TCM.

c.

Use an ohmmeter to test for continuity between terminals 6 and 7 on the TCM 7 pin green connector. There should be continuity.

If there is no continuity, check transformer and wiring.

d.

Leave 7 pin green connector disconnected from TCM.

2.

Check transformer: a.

Remove lower cover.

b.

Locate the two larger (6 AWG) wires, labeled

3 and 4, coming out of transformer. Trace these wires back to TB31. Use an ohmmeter to test for continuity between two transformer wires in terminal block TB31; there should be continuity.

c.

Reconnect the 7 pin green connector to the

TCM.

d.

Apply incoming power to system.

e.

To verify voltage on the secondary leads of the transformer, measure between the transformer leads labeled 3 and 4 at TB31.

Verify the transformer output voltage is approximately 37.5% of the system supply voltage for H-30 and H-XP2 systems or approximately 50% of system supply voltage for H-40, H-50, and H-XP3. For example, with a 240 VAC system supply voltage the transformer output voltage for an H-30 or H-XP2 would be (.375 x 240V), or approximately 90V; for an H-40, H-50, or H-XP3 it would be (.50 x 240V), or approximately 120V.

f.

See the Diagnostic Run Screen on the ADM.

The Diagnostic Run Screen displays the transformer output voltage (approximately

90 or 120 VAC) under “Hose Voltage”. The diagnostic screen will show a Hose Voltage of “0” volts if the circuit breaker has been tripped for the incoming power to the TCM.

Note

The Diagnostic Run Screen is disabled by default and must be enabled in the Setup screens.

See the Operation manual for instructions.

334946D 63

Repair

Note

Wire on both the circuit breaker and power supply are interchangeable.

1.

Perform

Shutdown, page 47 .

2.

Disconnect input and output cables from both sides of the power supply (805). See

Electrical Schematics, page 95 .

3.

Insert a flat head screw driver in the mounting tab on the bottom of the power supply (805) to remove from the din rail.

4.

Install new power supply (805) in reverse order.

Figure 11 Surge Protector

1.

Follow

Before Beginning Repair, page 49

.

2.

Open the electrical enclosure and disconnect all cables from the TCM (602).

3.

Remove the nuts (610) and TCM (602).

Figure 10 24 VDC Power Supply

1.

Loosen connections on terminals 1 and 3 on

CB13. See

Electrical Schematics, page 95

.

2.

Loosen connections on input to power supply (805) on N and L connections. See

Electrical Schematics, page 95 .

3.

Remove two screws (612), washers (611), and surge protector (705) from enclosure.

4.

Install new surge protector (705) in reverse order.

Figure 12 Replace TCM

64 334946D

Repair

1.

Follow

Before Beginning Repair, page 49

.

2.

Open the electrical enclosure and disconnect all cables from the HCM (603).

3.

Remove the nuts (610) and HCM (603).

4.

Set rotary switch.

1.

Loosen four screws (70) on inside of electrical enclosure door (61). Lift up and pull out to remove ADM (88).

2.

Disconnect CAN cable (475).

3.

Inspect ADM (88) for damage. Replace if necessary.

Figure 13 Replace HCM

0 = Reactor 2, H-30

1 = Reactor 2, H-40

2 = Reactor 2, H-50

3 = Reactor 2, H-XP2

4 = Reactor 2, H-XP3

Figure 14

334946D 65

Parts

17H131

17H132

17H143

17H144

17H145

17H146

17H153

17H156

17H162

17H174

17H176

H-30

H-30

H-40

H-40

H-40

H-40

H-50

H-50

H-XP2

H-XP3

H-XP3 see

Proportioner

17H031

17H032

17H043

17H044

17H045

17H046

17H053

17H056

17H062

17H074

17H076

17F838

17F838

17F838

17F838

17F838

17F838

17F838

17F838

17F838

17F838

17F838

66 334946D

Parts

1.

3

Apply anaerobic pipe sealant to all non-swiveling pipe threads.

Ensure that the fan (9) direction arrow points away from the mounting panel.

4

5

Install pulley (45) flush with motor shaft (43).

Install pulley (44) overhung on pump shaft (27) by .18 +/- .03 in. On models 17H031, 17H032, and 17H074: Install pulley (49) .49 +/- .03 in.

from pump shaft (27) end.

334946D 67

Parts

1.

4

5

Apply anaerobic pipe sealant to all non-swiveling pipe threads.

Labels are from warning label (629) included in the Electrical Enclosure. See

Electrical Enclosure, page 86 .

Apply single component thixotropic anaerobic sealant to threads..

68 334946D

Parts

1.

6

7

Apply anaerobic pipe sealant to all non-swiveling pipe threads.

Apply high viscosity anaerobic sealant to threads.

Fill reservoir (16) with hydraulic oil.

334946D 69

Parts

1.

4

5

Apply anaerobic pipe sealant to all non-swiveling pipe threads.

Labels are from warning label (629) included in the Electrical Enclosure. See

Electrical Enclosure, page 86 .

Apply single component thixotropic anaerobic sealant to threads.

70 334946D

Ref.

1

2

34

35

36

31*

32

33

37

38

27

27a

28*

29*

30

22

23

24

25

26

19

20

21

16g

17

18

16b

16c

16d

16e

16f

12

13

14

15

16

16a

7

8

9

10

11

3

4

5

6

- - -

247812

111800

247826

247778

247771

247777

247770

25D893

255032

255021

117556

17G621

113796

- - -

17G646

17G647

127277

112731

17G618

17G617

17G619

115836

24U847

103181

117683

17G680

- - -

15H512

- - -

110792

115764

120804

247793

15G784

121321

15T895

17G624

15H524

119789

112567

247829

17G611

247855

129375

- - -

- - -

CART

HEATER, 7.5kw, 1 zone, rtd

HEATER, assy, 10.2kw, 2 zone, rtd

BOLT, carriage, 1/2-13 x 3.5 l

NUT, hex, flanged

BRACKET, 10kw, hanger

BRACKET, 10kw, shroud

BRACKET, 10kw, guard

GUARD, finger

FAN, cooling, 120mm, 24vdc

WASHER, lock ext

SCREW, mach, phil pan hd

BLOCK, terminal, 6 pole

SCREW, 3/4 in, #6–32

TRANSFORMER, 4090va, 230/90

SCREW, cap, hex hd

RESERVOIR, assembly, hydraulic

HOUSING, inlet

GASKET, inlet

TUBE, inlet

TUBE, return

FILTER, inlet

PLUG

FITTING, straight

FITTING, nipple, #8 jic x 1/2 npt

BRACKET, retaining, tank

SCREW, flanged, hex hd

ADAPTER, hydraulic gauge

TUBE, gauge, pressure

ACCUMULATOR, pressure, 1/4 npt

FITTING, elbow, street, 45 deg

GAUGE, pressure, fluid

COOLER, hydraulic, complete

BRACKET, mntg, pump, hyd, lf

PUMP, hydraulic

KEY, square

KNOB, compensator

KNOB, lock, compensator

LABEL, control

SCREW, set, 1/4-20 sst

FITTING, elbow, male, 90 deg

FITTING, elbow, 90

FITTING, elbow, 1/2 npt x 1 jic

HOSE, inlet, coupled

HOSE, coupled

FITTING, elbow, sae x jic

HOSE, hydraulic supply

334946D

Parts

1

2

4

4

1

1

1

1

1

1

1

1

36

1

1

1

1

1

1

1

1

2

1

20

1

1

4

4

1

2

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

36

1

1

1

1

1

1

1

1

2

1

20

1

1

4

4

1

2

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

34

1

1

1

1

1

1

1

1

1

1

2

1

20

4

4

1

1

2

2

2

1

1

8

8

4

4

1

2

71

Parts

56

57

53

54

55

43

43a

44

45

45a

46

Ref.

39

40

41

42

50

51

52

47

48

49

58

78

80

82

75

76

77

72

73

74

69

70

71

63♯

64

65♯

66♯

67

68

59

60

61♯

62♯

17G668

295731

118459

113161

- - -

24W204

17C258

172953

16X129

- - -

- - -

- - -

17G616

17G600

17G615

17G601

17G613

17G603

17G614

17G604

117677

117502

24U845

24R754

127290

- - -

15H207

247853

111802

15E410

120087

803889

25D458

25D460

15B456

- - -

117464

112161

112586

110996

247816

120710

113802

15H256

- - -

17G645

17G599

17D775

114269

CLAMP, hose, micro 1.75 max dia.

SCREW, mach, hex, wshr hd

SCREW, cap, hex hd

NUT, hex, flange head

MOTOR, 230 vac, 4.0 hp

KEY, square, .25

SCREW, hex hd, flanged

PULLEY, drive, vee

SCREW, cup point, 5/16–18

BRACKET, tensioner

ADJUSTER, belt, tensioner

SCREW, cap, hex hd

PULLEY, fan

SCREW, set, 1/4 x 1/2

BELT, ax46

KIT, pump, hydrl, w/iso and resin, 80

KIT, pump, hydrl, w/iso and resin, 140

GASKET, manifold

MANIFOLD, fluid

TUBE, fluid, iso, heater, in, 10kw

TUBE, fluid, iso, heater, inlet

TUBE, fluid, iso, heater, out, 10kw

TUBE, fluid, iso, heater, outlet

TUBE, fluid, res, heater, inlet, 10kw

TUBE, fluid, res, heater, inlet

TUBE, fluid, res, heater, outlet, 10kw

TUBE, fluid, res, heater, outlet

FITTING, reducer #6 x #10 (jic)

FITTING, reducer #5 x #8 (jic)

TUBE, pressure relief

CONNECTOR, power, male, 2 pin

CABLE, 4-pin, mf, 1.3m, molded

SLEEVE, wire, .50 id

NUT, wire, gray

NUT, wire

FITTING, union, swivel, 3/4"

SCREW, flange, hex hd

GROMMET

ENCLOSURE, terminal block

ENCLOSURE, cover

LABEL, designation

SCREW, mach, phillips, tooth wash

BUSHING, strain relief, 1/2 npt

NUT, strain relief, 1/2 npt

BUSHING, strain relief

TIE, cable, fir tree

COVER, access

LABEL, safety, elec encl, lf

GROMMET, rubber

72

1

1

1

1

1

1

1

2

17

1

1

1

8

1

2

2

1

1

1

3

2

2

1

1

1

2

2

1

1

2

1

1

4

1

2

1

1

1

1

1

1

2

1

1

334946D

1

1

1

1

1

1

1

2

17

1

1

1

8

1

2

2

1

1

1

3

2

2

1

1

1

2

2

1

1

1

4

1

2

1

2

1

1

1

1

1

2

1

1

1

1

1

1

1

1

2

1

1

1

4

1

2

1

2

1

1

1

1

1

2

1

1

1

1

1

2

2

1

2

2

1

3

8

1

1

17

1

1

1

1

1

2

128

129

130

131

132

133

134

123

124

125

126♯

127

113

118

119

120

121

122

105

106

107

109

110

94

95

96

97

98♯

99♯

100▲

101

102

103

104

91

92

93

88♯

89♯

90♯

Ref.

83

86

87

88♯

135

136♦

137♦

117284

296731

206995

116915

247792

15Y118

106569

125871

17G649

- - -

16W654

16U530

15D906

16Y839

296607

24K207

C19843

255716

C20487

114027

- - -

16W766

17G671

17G644

17G623

17G651

17G620

17G652

17G679

17G622

17G610

●17G608

17G609

●17G607

- - -

- - -

- - -

- - -

- - -

24T242

17G687

17G684

17G685

121309

24U846

- - -

- - -

111218

- - -

SCREW, mach, serrated hex head; 1/4 in, #10–32

GROMMET, 3/4 hole x 3/32 thick

GROMMET

CABLE, over-temp, single reactor

HARNESS, overtemp, reactor, dual

HARNESS, heater, A, 64 in.

HARNESS, heater, B , 72 in.

FITTING, adapter, sae-orb x jic

BRIDGE, plug-in jumper, ut35

CAP, 9/16-18 jic cap-aluminum

CAP, 1/2-20 jic cap-aluminum

CAP, tube, square

ENVELOPE, packing, self-adhesive

INSULATOR, foam, heater

MODULE, sys srg prot

SUPPRESSOR, round snap ferrite .260

LABEL, notice, jumper

TOOL, clevis pin extractor

KIT, fts, rtd, single hose

SCREW, cap, sockethead

KIT, heater wire connector

FITTING, nipple, hex

WASHER, flat

RIVET, pop, 5/32 dia.

GRILL, fan guard

RESERVOIR, lube hose assembly

FLUID, tsl, 1 qt.

CAP, breather filler

FILTER, oil, 18-23 psi bypass

LABEL, made in the usa

TAPE, electrical

TIE, cable, 7.50 inch

COVER, motor

ENCLOSURE, electrical, 230v

COVER, control, box

CABLE, motor, ot switch

KIT, assembly, pair, inlet

COVER, transformer

COVER, main

BRACKET, connector, hose

COVER, belt, upper

COVER, belt, lower

BRACKET, retaining, tank, shroud

COVER, 10kw, left

COVER, heater, right

COVER, 10kw, right

COVER, heater, left

BAR, 55 gal chem. meas. B side

BAR, 55 gal chem. meas. A side

334946D

Parts

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

22

2

8

8

1

1

1

8

1

1

1

2

4

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

2

1

22

1

1

1

1

1

1

1

1

2

8

8

1

1

1

1

1

1

1

1

4

1

1

2

1

1

1

2

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

22

2

8

8

1

1

1

8

1

1

1

2

4

1

1

2

1

73

Parts

156

157●

158

159

160

161

162

171

Ref.

138♯

139

140

141

142

143

146

148

154♯

155

*

17G686

15V551

24U854

16W596

127296

- - -

119865

- - -

17B856

C19208

111714

- - -

+ +

+ +

17R703

17Y983

25E540

17B524

HARNESS, heater, B

SHIELD, membrane, adm (10 pack)

MODULE, adm

LATCH, door

SCREW, mchn, pnh, w/ext tooth wash

SPACER, nylon, 1/4 in. od

SCREW, mach, hex serrated

LABEL, A/B

TERMINAL BLOCK

WASHER, lock

SCREW

WASHER, flat, nylon

METER, flow, ISO

METER, flow, RES

CABLE, GCA, M12–5P, m/f, 0.3 m

CABLE, GCA, M12–5P, m/f, 0.2 m

CONNECTOR, splitter

HOSE, hydraulic supply

Replacement Warning labels, signs, tags, and cards are available at no cost.

Parts included in Compensator Knob Assembly Kit

17G606. Purchase separately.

Parts included in Drum Level Stick Kit 24M174.

Purchase separately.

1

1

2

4

4

4

1

1

1

1

2

1

1

1

1

1

4

1

4

4

1

1

2

4

1

1

1

1

2

1

1

● Parts included with Heater Cover Kits (134, 135).

Purchase separately.

♯ See

Electrical Schematics, page 95

.

+ + Included in kit 25N930.

1

1

1

4

4

1

4

1

2

4

1

1

1

74 334946D

Parts

15

16

16a

16b

16c

16d

16e

16f

16g

17

18

19

20

21

22

3

4

8

9

10

11

12

13

14

23

24

25

26

27

27a

28*

29*

30

31*

Ref

1

2

- - -

CART

17G646 HEATER, 7.5kw, 1 zone, rtd

17G648 HEATER, assy, 10.2kw, 1 zone, rtd

127277 BOLT, carriage, 1/2-13 x

3.5 l

112731 NUT, hex, flanged

115836 GUARD, finger

24U847 FAN, cooling, 120mm,

24vdc

103181 WASHER, lock ext

117683 SCREW, mach, phil pan hd

17G680 BLOCK, terminal, 6 pole

- - -

SCREW, 3/4 in, #6–32

247786 TRANSFORMER, 5400va

(410ft, 125m)

111800 SCREW, cap, hex hd

247826 RESERVOIR, assembly, hydraulic

247778 HOUSING, inlet

247771 GASKET, inlet

247777 TUBE, inlet

247770 TUBE, return

25D893 FILTER, inlet

255032 PLUG

255021 FITTING, straight

117556 FITTING, nipple, #8 jic x

1/2 npt

17G621 BRACKET, retaining, tank

113796 SCREW, flanged, hex hd

- - -

ADAPTER, hydraulic gage

17G624 TUBE, gauge, pressure

15H524 ACCUMULATOR, pressure, 1/4 npt

119789 FITTING, elbow, street, 45°

112567 GAUGE, pressure, fluid

247829 COOLER, hydraulic, complete

17G612 BRACKET, mntg, pump, hyd

255019 PUMP, hydraulic

129375 KEY, square

- - -

KNOB, compensator

- - -

KNOB, lock, compensator

15H512 LABEL, control

- - -

SCREW, set, 1/4-20 sst

1

1

1

1

1

1

1

1

1

20

1

1

36

1

1

1

1

1

1

1

1

2

4

4

4

4

2

1

1

1

1

1

1

1

1

2

1

1

20

1

1

1

1

1

1

1

1

1

1

36

1

1

1

1

1

1

2

4

4

2

1

1

2

4

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

20

1

1

36

1

1

1

1

1

1

1

1

2

4

4

4

4

2

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

20

1

1

36

1

1

1

1

1

1

2

4

4

2

1

1

2

4

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

20

1

1

36

1

1

1

1

1

1

2

4

4

2

1

1

2

4

4

1

1

1

1

1

1

1

1

1

20

1

1

1

1

1

1

1

1

1

1

36

1

1

1

1

1

1

2

4

4

2

1

1

2

4

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

20

1

1

36

1

1

1

1

1

1

2

4

4

2

1

1

2

4

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

20

1

1

36

1

1

1

1

1

1

2

4

4

2

1

1

2

4

4

1

1

1

1

1

1

1

334946D 75

Parts

60

61

62♯

63♯

64

65♯

66♯

67

68

69

53

54

55

56

57

58

59

Ref

34

35

36

37

38

39

43

47

48

49

50

51

52

43a

44

45

45a

46

255020 FITTING, elbow, 1-1/16 sae x 1/2 tube

247793 HOSE, inlet, coupled

15G784 HOSE, coupled

121320 FITTING, elbow, sae x jic

15T895 HOSE, hydraulic supply

117464 CLAMP, hose, micro 1.75

max dia.

.

247785 MOTOR, 7.5hp, 3ph,

230V/400V

120710 KEY, square, .25

113802 SCREW, hex hd, flanged

15H256 PULLEY, drive, vee

– – –

SCREW, set, cup, 5/16–18

15H207 BRACKET, tensioner

247853 ADJUSTER, belt, tensioner

111802 SCREW, cap, hex hd

247856 PULLEY, fan

120087 SCREW, set, 1/4 x 1/2

803889 BELT, ax46

25D458 KIT, pump, hydrl, w/iso and resin, 80

25D459 KIT, pump, hydrl, w/iso and resin, 120

25D460 KIT, pump, hydrl, w/iso and resin, 140

15B456 GASKET, manifold

- - -

MANIFOLD, fluid

17G600 TUBE, fluid, iso, heater, inlet

17G601 TUBE, fluid, iso, heater, outlet

17G603 TUBE, fluid, res, heater, inlet

17G604 TUBE, fluid, res, heater, outlet

117677 FITTING, reducer #6 x #10

(jic)

117502 FITTING, reducer #5 x #8

(jic)

24U845 TUBE, pressure relief

24R754 CONNECTOR, power, male, 2 pin

127290 CABLE, 4-pin, mf, 1.3m,

- - molded

SLEEVE, wire, .50 id

17G668 NUT, wire, gray

295731 NUT, wire

118459 FITTING, union, swivel, 3/4 in.

113161 SCREW, flange, hex hd

- - -

GROMMET

1

1

2

1

1

1

2

1

1

4

1

2

1

1

1

1

1

1

1

2

1

1

2

2

3

2

2

1

1

1

1

1

1

1

1

1

1

2

1

1

2

2

3

2

2

1

1

1

1

1

1

1

1

1

2

1

1

1

2

1

1

4

1

2

1

1

1

1

1

1

1

1

2

1

1

2

2

3

2

2

1

1

1

1

1

1

1

1

1

2

1

1

1

2

1

1

4

1

2

1

1

1

1

1

1

1

1

2

1

1

2

2

3

2

2

1

1

1

1

1

1

1

1

1

2

1

1

1

2

1

1

4

1

2

1

1

1

1

1

1

1

2

1

1

2

2

3

2

2

1

1

1

1

1

1

1

1

1

1

2

1

1

2

2

3

2

2

1

1

1

1

1

1

1

1

1

1

2

1

1

1

2

1

1

4

1

2

1

1

1

1

1

1

1

2

1

1

1

2

1

1

4

1

2

1

1

1

1

1

1

1

2

1

1

1

2

1

1

4

1

2

1

1

1

1

1

1

1

1

2

1

1

1

2

1

1

4

1

2

1

1

1

1

1

1

1

1

2

1

1

2

2

3

2

2

1

1

1

1

1

1

1

1

1

2

1

1

2

2

3

2

2

1

1

1

1

1

1

1

1

76 334946D

Parts

84

85

88♯

91

75

76

77

78

80

82

83

Ref

70

71

72

73

74

93

94

101

102

103

105

106

107

109

110

95

97

98♯

99♯

113

118

119

120

121

122

123

124

1

1

2

17

1

1

1

2

2

2

1

1

1

1

8

2

1

1

2

1

1

1

1

22

1

1

1

2

8

1

1

1

1

1

2

8

8

1

24W204 ENCLOSURE, terminal block

17C258 ENCLOSURE, cover

172953 LABEL, designation

16X129 SCREW, mach, phillips, tooth wash

- - -

BUSHING, strain relief, 1/2 npt

- - -

NUT, strain relief, 1/2 npt

- - -

BUSHING, strain relief

17G645 TIE, cable, fir tree

17G599 COVER, access

17D776 LABEL, safety, ele encl

114269 GROMMET, rubber

- - -

SCREW, mach, serrated hex head; 1/4 in, #10–32

125943 NUT, serrated flange

101032 BOLT, machine

17G687 HARNESS, overtemp, reactor, dual

121309 FITTING, adapter, sae-orb x jic

- - -

CAP, 9/16-18 jic cap-aluminum

- - -

CAP, 1/2-20 jic cap-aluminum

111218 CAP, tube, square

16W654 INSULATOR, foam, heater

16U530 MODULE, sys srg prot

15D906 SUPPRESSOR, round snap ferrite .260

296607 TOOL, clevis pin extractor

24K207 KIT, fts, rtd, single hose

C19843 SCREW, cap, sockethead

C20487 FITTING, nipple, hex

114027 WASHER, flat

- - -

RIVET, pop, 5/32 dia.

117284 GRILL, fan guard

296731 RESERVOIR, lube hose assy

206995 FLUID, tsl, 1 qt.

116915 CAP, breather filler

247792 FILTER, oil, 18-23 psi bypass

15Y118 LABEL, made in the usa

106569 TAPE, electrical

125871 TIE, cable, 7.50 inch

17G649 COVER, motor

- - -

ENCLOSURE, electrical, hf, 230v

334946D

1

1

2

17

1

1

1

2

2

2

1

1

1

1

8

2

1

1

2

1

1

22

1

1

1

1

1

2

8

1

1

1

1

1

2

8

8

1

1

1

2

17

1

1

1

2

2

2

1

1

1

1

8

2

1

1

2

1

1

1

1

22

1

1

1

2

8

1

1

1

1

1

2

8

8

1

1

1

2

17

1

1

1

2

2

2

1

1

1

1

8

2

1

1

2

1

1

1

1

22

1

1

1

2

8

1

1

1

1

1

2

8

8

1

1

1

2

17

1

1

1

2

2

2

1

1

1

1

8

2

1

1

2

1

1

22

1

1

1

1

1

2

8

1

1

1

1

1

2

8

8

1

1

1

2

17

1

1

1

2

2

2

1

1

1

1

8

2

1

1

2

1

1

1

1

22

1

1

1

2

8

1

1

1

1

1

2

8

8

1

1

1

2

17

1

1

1

2

2

2

1

1

1

1

8

2

1

1

2

1

1

1

1

22

1

1

1

2

8

1

1

1

1

1

2

8

8

1

1

1

2

17

1

1

1

2

2

2

1

1

1

1

8

2

1

1

2

1

1

1

1

22

1

1

1

2

8

1

1

1

1

1

2

8

8

1

77

Parts

160

161

162

171

Ref

125

126♯

127

128

129

130

131

132

133

134

135

136♦

137♦

138♯

139

140

141

142

143

144

145

146

148

154♯

155

156

157●

158

*

16W766 COVER, control, box

17G671 CABLE, motor, ot switch

17G644 KIT, assembly, pair, inlet

17G623 COVER, transformer

17G651 COVER, main

17G620 BRACKET, connector, hose

17G652 COVER, belt, upper

17G679 COVER, belt, lower

17G622 BRACKET, retaining, tank, shroud

17G608 COVER, heater, right

17G607 COVER, heater, left

- - -

- - -

BAR, 55 gal chem. meas.

B side

BAR, 55 gal chem. meas.

A side

17G686 HARNESS, heater, B

15V551 SHIELD, membrane, adm

(10 pack)

24U854 MODULE, adm

16W596 LATCH, door

127296 SCREW, mchn, pnh, w/ext tooth wash

- - -

SPACER, nylon, 1/4 in. od

15G782 HOSE, coupled

116793 FITTING

119865 SCREW, mach, hex serrated

- - -

LABEL, A/B

17B856 TERMINAL BLOCK

C19208 WASHER, lock

111714 SCREW

- - -

WASHER, flat, nylon

+ + METER , flow, ISO

+ + METER, flow, RES

17R703 CABLE, GCA, M12–5P, m/f,

0.3 m

17Y983 CABLE, GCA, M12–5P, m/f,

2.0 m

25E540 CONNECTOR, splitter

17B524 HOSE, hydraulic, supply

1

1

1

1

1

4

1

1

1

1

1

2

1

1

4

4

1

1

1

2

4

1

1

1

1

1

1

1

1

1

1

1

1

Replacement Warning labels, signs, tags, and cards are available at no cost.

Parts included in Compensator Knob Assembly Kit

17G606. Purchase separately.

Parts included in Drum Level Stick Kit 24M174.

Purchase separately.

1

1

1

1

1

4

1

1

1

1

1

2

1

1

4

4

1

1

1

2

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

1

1

1

1

1

2

1

1

4

4

1

1

1

2

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

1

1

1

1

1

2

1

1

4

4

1

1

1

2

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

1

1

1

1

1

2

1

1

4

4

1

1

1

2

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

1

1

1

1

1

2

1

1

4

4

1

1

1

2

4

1

1

1

1

1

1

1

1

1

1

1

1

1

● Parts included with Heater Cover Kits (134, 135).

Purchase separately.

♯ See

Electrical Schematics, page 95 .

+ + Included in kit 25N930.

1

1

1

4

4

1

1

1

2

4

1

1

1

1

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

4

1

1

1

2

4

1

1

1

1

4

1

1

1

1

1

1

1

1

1

1

1

1

1

78 334946D

Parts

1

3.

2

4

Torque to 200 in-lb (22.6 N●m).

Pin (213) to be clocked horizontal as shown.

Apply sst pipe sealant to all non-swiveling pipe threads.

Remove cover from directional valve (207) and attach solenoid harness wires (225). See

Electrical Schematics, page 95 .

5

6

7

Fully seat pin (213) with a hammer and punch.

Thread in proximity switch (211) all the way until it contacts the clocking plate, then back off a

1/4–1/2 turn.

Apply grease to o-rings (204, 216) before assembly.

334946D 79

Parts

203

204

205

206

207

208

209

210

211

201

202

17G499 CYLINDER, hydraulic, with spacers

17G597 PUMP, proportioner,

#120 (H-40 only)

17G598 PUMP, proportioner,

#140 (H-50, H-30 only)

17G596 PUMP, proportioner ,# 80

(H-XP2, H-XP3 only)

295824 SCREW, cap, sh, 5/16 x

3

112793 PACKING, o-ring

17G531 MANIFOLD, hydraulic

113467 SCREW, cap, socket hd

120299 VALVE, directional, hydraulic

C19986 SCREW, cap, socket, hd

- - -

BRACKET, proximity switch

111800 SCREW, cap, hex hd

17G605 SENSOR, proximity, switch

8

3

1

4

1

2

2

4

1

1

2

2

2

220

221

225

226

213

214

215

216

218

219

228

230

296653 PIN, clevis

121312 FITTING, elbow, sae x jic

295225 PLUG, pipe, flush

106258 PACKING, o-ring

- - -

CYLINDER, lube

(included in kit 261863)

295829 FITTING, plug, 3/8 mpt x

.343 lg

295826 FITTING, elbow, 90, 1/4 mpt x 3/8 in.

295397 FITTING, elbow, 3/8 mpt x 1/2 in.

17G690 HARNESS, valve, solenoid, hr2

121319 FITTING, adapter, npt x jic

121309 FITTING, adapter, sae-orb x jic

17G669 CABLE, gca, m12 (m), m12( f/f), 2 m, s/r/r

1

1

1

1

2

1

6

2

2

2

1

1

80 334946D

Parts

1

4.

3

Torque spacers (313, 314) and rod (315) to 200 in-lb (22.5 N•m).

Torque to 40 +/- 5 ft-lb (345 +/- 54 N•m)

Apply grease to all soft parts before assembly.

301

302

295029 PLATE, retainer

295030 CYLINDER

303* 295031 BUSHING, rod

304 296642 PISTON, cylinder, hydraulic

305* 295640 O-RING

306* 295641 SEAL, u-cup

307* 295642 RING, back-up

308* 296643 RING, wear

309* 158776 PACKING, o-ring

310* 295644 RING, back-up

311* 295645 WIPER, rod

312* 295646 SEAL, shaft

2

1

2

1

2

2

2

2

2

1

2

2

313

314

315

316

317

318

319

320

321

322

295032 SPACER, proportioner

261502 SPACER, reversing switch

295034 ROD, tie

295035 BLOCK, port

261864 CLEVIS, hex

17G527 BUSHING, clocking

17G529 PLATE, clocking, driver

- - -

ADAPTER, lube, cylinder

(included in kit 261863)

177156 PACKING, o-ring

295852 NUT, jam, baffle

*

Parts are also included in Hydraulic Cylinder Repair Kit 296785. Purchase separately.

4

2

2

1

1

1

7

1

1

1

334946D 81

Parts

82

1

2

3

Torque to 355–395 in.-lbs (40–44.6 N●m)

Apply sealant (113500) to threads.

Valve must be closed with handle position as shown on drawing.

4

**

5

Apply PTFE tape and thread sealant to gauge threads.

Apply grease on valve.

Apply PTFE tape or thread sealant to tapered threads.

334946D

Parts

401† 255228 MANIFOLD, fluid

402◊ 247824 KIT, valve, cartridge, drain

402a◊ 158674 O-RING, BUNA-N

402b◊ 247779 SEAL, seat, valve

403

404

405

406

102814 GAUGE, press, fluid

162453 FITTING, 1/4 NPSM X 1/4

NPT

15M669 SENSOR, pressure, fluid outlet

247788 HANDLE, red

407

408

411‡

412

247789 HANDLE, blue

112309 NUT, hex, jam

17Y236 FITTING, 3/4 ORB x #8

JIC

117556 FITTING, 1/2 NPT x #8

JIC

121312 FITTING, elbow, 3/4 SAE x 1/2 JIC

100840 FITTING, elbow, street 413

414 111457 O-RING, PTFE

415▲ 189285 LABEL, caution

2

1

1

2

1

1

1

1

2

2

2

1

1

2

2

1

416

419‡

150829 SPRING, compression

17Y235 FITTING, 3/4 ORB x #10

JIC

117557 FITTING, 1/2 NPT x #10

JIC

Replacement Warning labels, signs, tags, and cards are available at no cost.

2

1

1

Part included in the following complete valve kits:

ISO Valve Kit (left/red) handle 255149.

Resin Valve Kit (right/blue handle) 255150.

Valve Set Kit (both handles and grease gun)

255148.

Part includes replacement ORB fittings (part

411 and 419).

To order a replacement part, verify the type of fitting used with your fluid manifold (1/2

NPT or 3/4 ORB fitting).

334946D 83

Parts

1

2

4.

3

Torque to 120 ft-lb (163 N•m).

Torque to 23 ft-lb (31 N•m).

Apply thermal paste.

Apply pipe sealant and PTFE tape to all non-swiveling threads and threads without o-rings.

84

5

6

8

Apply lithium grease lubricant to o-rings before assembling in block (501).

Orientate sensor as shown. Insert probe until it bottoms on heating element. Tighten ferrule on sensor probe one turn past finger tight or 180 in-lb (20.3 N•m).

Orient rupture disc housing (514) with exhaust hole pointing away from fitting (508).

334946D

Parts

4.

3

1

2

Torque to 120 ft-lb (163 N•m).

Torque to 23 ft-lb (31 N•m).

Apply thermal paste.

Apply pipe sealant and PTFE tape to all non-swiveling threads and threads without o-rings.

5

6

8

Apply lithium grease lubricant to o-rings before assembling in block (501).

Orientate sensor as shown. Insert probe until it bottoms on heating element. Tighten ferrule on sensor probe one turn past finger tight or 180 in-lb (20.3 N•m).

Orient rupture disc housing (514) with exhaust hole pointing away from fitting (505).

505

506

507

508

509

510

511

512

513

514

515

516

501

502

503

504

- - -

HEATER, housing

124132 O-RING

15H305 FITTING, plug holow hex 1-3/16 sae

15H302 FITTING, 1/2–14 npt(f) x 3/16–12 UN-2A

121309 FITTING, adapter, sae-orb x jic

121319 FITTING, adapter, npt x JIC

15H304 FITTING, plug 9/16 sae

15H306 ADAPTER, thermocouple, 9/16 x 1/8

120336 O-RING, packing

16A110 HEATER, immersion, (2550w, 230v)

15B137 SWITCH, over temperature

15B135 MIXER, immersion heater

123325 FITTING, compression, 1/8npt, ss

124262 SENSOR, rtd, 1kohm, 90deg, 4pin, tip

- - -

SCREW, mach, pnh, .375 in, #6–32

247520 HOUSING, rupture disc

248187 HOUSING, rupture disc

15R873 FITTING, tee, 1/2–14 npt(m) x 1/2–14 npt(f) x 1/2–14 npt(f)

15M177 INSULATOR, foam, heater

3

1

1

3

1

3

17G646 17G648 17G647

1

3

1

4

1

4

5 4

4

2 2

3

1

1

4

1

4

2

2

4

2

4

1

4

2

1

1

1

2

1

1

1

2

2

2

2

1

1

334946D 85

Parts

86

1

2

Install disconnect switch (609) so that up is

ON and left is OFF.

Mount fans (604, 632) with arrows pointing towards the panel.

334946D

613

614

615

616

608

609

610

611

612

601

602

603

604

605

606

607

617

618

619

620

621*

622*

637

638

639

638

639

627*

628

629

630

631

632

633

634

635

636

623*

- - -

24U855

24Y263

24U848

24R736

ENCLOSURE, electrical

MODULE, TCM

MODULE, HCM

FAN, cooling, 80mm, 24vdc

SWITCH, disconnect, door mounted

17G653 BAR, ground, kit

255047 BUSHING, strain relief, m40 thread

255048

123967

NUT, strain relief, m40 thread

KNOB, operator disconnect

NUT, hex, flange head 115942

103181

- - -

WASHER, lock ext

SCREW, mach, pnh, .375 in, #6–32

WIRE, grounding, door 194337

113505

111218

114269

- - -

NUT, keps, hex hd

CAP, tube, square

GROMMET, rubber

127278

GROMMET, 1.75 id x .12 groove

NUT, keps, hex

16W925 GASKET, enclosure, foam

16W926 GASKET, enclosure, foam

24R735

127068

- - -

CABLE, can power, m12 fem, pigtail

CABLE, can, female/female 1.0m

- - -

KIT, din rail and harness module

KIT, din rail and harness module, 400V

- - KIT, din rail and harness module, 230V

17G689 HARNESS, hcm ground

17G670 CONNECTOR, 9 pin, sprg cg, retain screw

16X049 LABEL, safety

17G625 SPACER, hex, mf, 1/4-20, 2.5 in.

- - BRACKET, fan, adapter, hcm

17G650 FAN, 120 mm, 24 vdc, 158 cfm

115836 GUARD, finger

151395

117723

WASHER, flat

SCREW, mach, x rec, panhd

109466

17D776

17D775

117666

115942

117666

115942

NUT, lock, hex

LABEL, electrical enclosure; not shown

LABEL, electrical enclosure; not shown

TERMINAL, ground

NUT, hex, flange head

TERMINAL, ground

NUT, hex, flange head

1

1

1

2

1

1

1

1

1

▲ Replacement Warning labels, signs, tags, and cards are available at no cost.

* See

Electrical Schematics, page 95

.

2

1

1

6

8

2

1

1

2

1

1

1

1

1

1

1

1

2

1

2

2

2

4

334946D

1

1

4

1

1

1

1

1

2

1

4

4

1

1

1

1

2

1

1

6

8

2

1

1

2

1

1

1

1

1

1

1

2

2

2

8

1

2

1

1

1

4

1

1

1

1

2

1

4

4

1

1

1

1

2

1

1

6

8

2

1

1

2

1

1

1

1

1

1

1

2

2

2

8

1

2

Parts

87

Parts

701* 17G691 HARNESS, breaker module

702* 17G692 HARNESS, hose out

703◊ - - -

704● - - -

MODULE, din rail, power supply

MODULE, din rail, circuit breakers

705 16U530 MODULE, system surge protector

709* 17G693 HARNESS, motor, low flow, 4 HP

*

See

Electrical Schematics, page 95

.

See

H-30, H-XP2 Power Supply and Terminal Block Module, page 89

.

See

H-30, H-XP2 System Circuit Breaker Module, page 89 .

1

1

1

1

1

1

88 334946D

Parts

801

802

803

804

805

806

807

- - RAIL, mount, 18 mm slot

255045 BLOCK, clamp end

24R722 BLOCK, terminal PE, quad, AB

24R723 BLOCK, terminal, quad

M4, AB

126453 POWER SUPPLY, 24V

255022 RELAY, contactor, 65A,

3p

24R724 BLOCK, terminal, UT35

2

1

1

6

1

3

1

851

852

853

854

855

856

857

858

- - -

RAIL, mount, 18 mm slot

255045 BLOCK, clamp end

17A319 CIRCUIT, breaker, 1P,

50A, UL1077, AB

17A314 CIRCUIT, breaker, 2P,

20A, UL489, AB

17A317 CIRCUIT, breaker, 2P,

40A, UL489, AB

17G667 FUSE, 2.5 amp, 250V, time-lag

255043 HOLDER, fuse terminal block, 5 x 20 mm

- - -

COVER, end, fuse block

1

3

1

2

1

2

2

1

334946D 89

Parts

701* 17G691 HARNESS, breaker module

702* 17G692 HARNESS, hose out

703 � - - MODULE, din rail, power supply

704● - - MODULE, din rail, circuit breakers

705 16U530 MODULE, system surge protector

709* 17G688 HARNESS, motor, 7.5 HP

*

See

Electrical Schematics, page 95

.

See

H-30, H-XP2 Power Supply and Terminal Block Module, page 89

.

See

H-30, H-XP2 System Circuit Breaker Module, page 89 .

1

1

1

1

1

1

1

1

1

1

1

1

90 334946D

Parts

Ref.

Part

1

1a

1b

– – – –

ASSEMBLY, transducer; includes 1a and 1b

624545 FITTING, nipple, pipe

2

24U851 TRANSDUCER, includes foam

16W130 CABLE, M12 5p, f x m,

2.0 m

3 125871 TIE, cable, 7.5 in.

2

2

2

2

8

334946D 91

Parts

1

2

Apply sealant to all tapered pipe threads. Apply sealant to female threads. Apply to at least the first four threads and approximately 1/4 turn wide.

Apply thermal paste to the stem of dial before assembling into housing.

WWLL DD

92 334946D

609‡

610

613

614

615

601

602

603‡

604

160327

118459

247503

24U852

FITTING, union adapter, 90°

FITTING, union, swivel, 3/4 in.

MANIFOLD, strainer, inlet

THERMOMETER, dial

605

606†

24U853 GAUGE, press, fluid

- - -

FILTER, replacement

607†‡ 128061 PACKING, o-ring

608‡ 16V879 CAP, filter

616

617

618

555808

15D757

109077

624545

PLUG, 1/4mp w/ hex hd

HOUSING, thermometer, Viscon HP

VALVE, ball 3/4 npt

C20487 FITTING, nipple, hex

24U851 TRANSDUCER, pressure, temperature (includes foam)

158586 FITTING, bushing

158383 FITTING, union adapter

FITTING, tee 3/4m run x 1/4f

*

Optional 80 mesh filter 255082 (2 pack)

Included in 24V020 Inlet Filter and Seal Kit, 20 mesh (2 pack).

Included in 247503 Manifold Repair Kit.

Parts

2

1

2

2

2

24U320 25N920

2 2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

334946D 93

Parts

801

802

803

804

805

806

- - -

RAIL, mount, 18 mm slot

255045 BLOCK, clamp end

24R722 BLOCK, terminal PE, quad, AB

24R723 BLOCK, terminal, quad

M4, AB

126453 POWER SUPPLY, 24V

255022 RELAY, contactor, 65A,

3p

2

1

1

1

3

1

851

852

853

854

855

856

857

858

859

- - -

RAIL, mount, 18 mm slot

255045 BLOCK, clamp end

17A319 CIRCUIT, breaker, 1P,

50A, UL1077, AB

17G723 CIRCUIT, breaker, 2P,

60A, UL489, AB

17A317 CIRCUIT, breaker, 2P,

40A, UL489, AB

17G667 FUSE, 2.5 amp, 250V, time-lag

255043 HOLDER, fuse terminal block, 5 x 20 mm

- - -

COVER, end, fuse block

17G724 CIRCUIT, breaker, 3P,

20A, UL489, AB

2

1

1

2

1

2

2

1

1

94 334946D

Electrical Schematics

See

System Din Rail and Harness Module Kits, page 88 , for additional part numbers.

To HCM To HCM

80mm

Enclosure

Fan

1

24R757

3

1

2

POWER

SUPPLY

CT01

TB04 TB05 TB06 TB07 TB08 TB09

TB01

TB02

TB03

To TB31

24R725

Jumper

5

16U530 4

3

CB11 CB12 CB13 CB14 CB15

HOSE MOTOR A HEAT B HEAT TRANS PE ti26606b

1

Torque to 6–8 in-lb (0.7– 0.9 N•m)

2

Torque to 28–33 in-lb (3.1– 3.8 N•m)

3

Torque to 23–26 in-lb (2.6–2.9 N•m)

334946D

17D775

4

Torque to 3–5 in-lb (0.3–0.6 N•m)

5

Connect customer-supplied ground wire.

95

Electrical Schematics

See

System Din Rail and Harness Module Kits, page

88

, for additional part numbers.

To HCM

80mm

Enclosure

Fan

To HCM

24R757

1

2

1

120mm

Enclosure

Fan

POWER

SUPPLY

CT01

To TB31

17G650

TB01

TB02

TB03 ti26609a

16U530

3

CB11

CB12 CB13 CB14 CB15

HOSE MOTOR A HEAT B HEAT TRANS

1

Torque to 6–8 in-lb (0.7– 0.9 N•m).

2

Torque to 23–26 in-lb (2.6–2.9 N•m).

3

Torque to 3–5 in-lb (0.3– 0.6 N•m).

2

24R736

Disconnect

96 334946D

Electrical Schematics

See

System Din Rail and Harness Module Kits, page

88

, for additional part numbers.

To HCM

80mm

Enclosure

Fan

1

To HCM

24R757

2

1

120mm

Enclosure

Fan

POWER

SUPPLY

CT01

17G650

TB01

TB02

TB03

To TB31 ti26610a

16U530

3

CB11 CB12 CB13 CB14 CB15

HOSE MOTOR A HEAT B HEAT TRANS

1

Torque to 6–8 in-lb (0.7– 0.9 N•m).

2

Torque to 23–26 in-lb (2.6–2.9 N•m).

3

Torque to 3–5 in-lb (0.3–0.6 N•m).

2

24R736

Disconnect

334946D 97

Electrical Schematics

To TCM

127068

1

24Y263

HCM

24R735

To Power Supply

B Pressure Transducer

A Pressure Transducer

B Inlet Pressure /

Temperature Transducer

A Inlet Pressure /

Temperature Transducer

16W130

16W130 ti26608b

A Inlet

B Inlet

2

1 9

ORANGE WHITE

1

7

G

6

8

9

17G690

To CT01

Ground

Bar 17G653

PE

1

7

G

6

6

7

RED

BLACK

GREEN

3

CB11 CB12 CB13 CB14 CB15

HOSE MOTOR A HEAT B HEAT TRANS

For 3 phase Motor: 17G688 / For Single phase Motor: 17G693

1

See for setting the rotary switch position.

2

3

Connect the blue and brown wires to the motor over-temperature wires inside the motor junction box.

Three pole version of CB12 shown. H-30 and H-XP2 uses a two pole version of CB12.

98 334946D

Electrical Schematics

CB11 CB12 CB13 CB14 CB15

HOSE MOTOR A HEAT B HEAT TRANS

To Ground Bar

Transformer Fan

24R756 RED

3

B RTD

B HEATER

Overtemperature Switchs

17G687 (15kW, 20kW),

24T242 (10 kW)

A HEATER

A RTD

2

TB21 / 17B856

24U855

TCM

1

127068

127068

To ADM

To HCM

To TB03

10kW - 17G685

15k, 20kW - 17G686

To TB02

To Hose

RTD

To Heated

Hose

To Ground

Bar

24W204

Hose Transformer

TB31

17D780

4

1

2

Locate near TCM.

Direct connect heater elements to TCM for 15kW and 20kW systems. Harness 17G684 and spice connectors (255716) used for 10kW systems.

3

4 ti26607B

Terminal block TB21 only used in 15kW and 20kW systems. Use splice connectors 255716 for 10kW systems.

Torque to 35–45 in.-lb. (4–5 N•m).

334946D 99

Hydraulic Reactor 2 Repair Spare Parts Reference

--

--

402

403

405

511,

512

--

202

202

202

202

202

202

906,

907

261854 H-XP2 and H-XP3 Cylinder Seal Kit

261852 H-40 Cylinder Seal Kit

247581 H-30 and H-50 Cylinder Seal Kit

261847 H-XP2 and H-XP3 Piston Seal Kit

261845 H-40 Piston Seal Kit

247579 H-30 and H-50 Piston Seal Kit

24V020 Y-Strainer Filter and Gasket Kit

(pack of two each)

247824 Drain Valve Cartridge

102814 Fluid Pressure Gauge

15M669 Pressure Sensor

24L973 RTD Repair Kit

24K207 Hose FTS

24N450 RTD Cable (50 ft. replacement)

24N365 RTD Cable Test Kit (To assist measuring

RTDs and RTD cable resistances)

Hose

Hose

Hose

Pump

Pump

Pump

Pump

Pump

Pump

Y-Strainer

Fluid Manifold

Fluid Manifold

Fluid Manifold

Heater

100 334946D

Technical Specifications

Models H-30, H-40, and H-50

Models H-XP2 and H-XP3

H-30

H-40, H-50

H-XP2

H-XP3

Model H-40

Models H-30 and H-50

Models H-XP2 and H-XP3

Component A (ISO)

Component B (RES)

Component A (ISO)

Component B (RES)

1/4 npsm(m)

Model H-30

Model H-XP2

Model H-50

Model H-40

Model H-XP3

Model H-40

Models H-30 and H-50

Models H-XP2 and H-XP3

334946D

2000 psi

3500 psi

700 psi

600 psi

1200 psi

850 psi

13.8 MPa, 138 bar

24.1 MPa, 241 bar

4.8 MPa, 48 bar

4.1 MPa, 41 bar

8.2 MPa, 82 bar

5.8 MPa, 58 bar

3/4 npt(f), 300 psi maximum

3/4 npt(f), 300 psi maximum

1.91 : 1

1.64 : 1

2.79 : 1

3/4 npt(f), 2.07 MPa, 20.7

bar maximum

3/4 npt(f), 2.07 MPa, 20.7

bar maximum

#8 1/2 in. JIC, with #5 5/16 in. JIC adapter

#10 5/8 in. JIC, with #6 3/8 in. JIC adapter

250 psi 1.75 MPa, 17.5 bar

190° F

28 lb/min (60 Hz)

1.5 gpm (60 Hz)

52 lb/min (60 Hz)

45 lb/min (60 Hz)

2.8 gpm (60 Hz)

0.063 gal.

0.074 gal.

0.042 gal.

88° C

13 kg/min (60 Hz)

5.7 liter/min (60 Hz)

24 kg/min (60 Hz)

20 kg/min (60 Hz)

10.6 liter/min (60 Hz)

0.24 liter

0.28 liter

0.16 liter

101

Technical Specifications

200–240V nominal, 1 phase

(H-30, H-XP2 only)

200–240V nominal, 3 phase

350–415V nominal, 3 phase

See the Models listing in the manual.

See the Models listing in the manual.

195–264 VAC, 50/60 Hz

195–264 VAC, 50/60 Hz

338–457 VAC, 50/60 Hz

3.5 gal.

13.6 liters

Citgo, A/W Hydraulic Oil, ISO Grade 46

90.2 dB(A)

82.6 dB(A)

H-40, H-50, H-XP3,

H-30, 10 kW

H-30, H-XP2, 15 kW

600 lb

544 lb

556 lb

272 kg

247 kg

252 kg

Aluminum, stainless steel, zinc-plated carbon steel, brass, carbide, chrome, fluoroelastomer, PTFE, ultra-high molecular weight polyethylene, chemically resistant o-rings

All other brand names or marks are used for identification purposes and are trademarks of their respective owners.

102 334946D

Notes

334946D 103

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use.

Graco will, for a period as defined in the table below from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

24U854

24Y263

24U855

Advanced Display Module 36 Months or 2 Million Cycles (whichever comes first)

Hydraulic Control Module 36 Months or 2 Million Cycles (whichever comes first)

Temperature Control

Module

All Other Parts

36 Months or 2 Million Cycles (whichever comes first)

12 Months

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized

Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS

INCLUDING

FOR

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available.

Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO

AND

MATERIALS

These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en

Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

For the latest information about Graco products, visit www.graco.com.

For patent information, see www.graco.com/patents.

To

Phone:

All written and visual data contained in this document reflects the latest product information available at the time of publication.

GRACO

Copyright

Graco reserves the right to make changes at any time without notice.

Original Instructions.

This manual contains English.

MM 334946

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

Graco www.graco.com

Revision D, February 2019

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