Graco 3A1706B - Reactor E-30i and E-XP2i, Repair-Parts Owner's Manual

Repair-Parts
Reactor® E-30i and
E-XP2i
3A1706B
EN
Electric, Heated, Integrated Plural Component Proportioning System With Integrated Generator.
For spraying polyurethane foam and polyurea coatings. For professional outdoor use only. Not
for use in explosive atmospheres.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these
instructions.
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
Warnings ............................................................. 3
Important Two-Component Material
Information ............................................. 7
Proportioner Models ............................................. 9
Systems............................................................. 10
Accessories........................................................ 11
Supplied Manuals ............................................... 12
Related Manuals ................................................ 12
Troubleshooting.................................................. 13
Error Codes and Troubleshooting.................. 13
Load Center Diagnostics .............................. 34
Repair................................................................ 42
Before Beginning Repair............................... 42
Pressure Relief Procedure............................ 42
Flushing ...................................................... 43
Flush Inlet Strainer Screen ........................... 44
Shutdown .................................................... 45
Drain Coolant .............................................. 46
Refill Proportioner Coolant Loop ................... 47
Refill Engine Coolant Loop ........................... 48
Coolant Specifications .................................. 48
Pump Lubrication System ............................. 49
Pump Removal ............................................ 50
Pump Installation ......................................... 52
Drive Housing .............................................. 52
Motor Brushes ............................................. 55
Electric Motor .............................................. 57
Circuit Breaker Module ................................. 58
2
Relays and Fuses ........................................ 60
Transducers ................................................ 61
Fans ........................................................... 62
Booster Heater ............................................ 64
Heated Hose ............................................... 67
Fluid Temperature Sensor (FTS)................... 68
Heat Exchangers ......................................... 70
Power Supply .............................................. 73
Circulation Pump ......................................... 74
Sight Glass and Filter ................................... 75
Fuel Tank .................................................... 76
Battery ........................................................ 76
Radiator ...................................................... 77
Advanced Display Module (ADM).................. 78
Engine Control Module ................................. 78
Motor Control Module (MCM)........................ 79
High Power Temperature Control Module
(HPTCM) ....................................... 79
Low Power Temperature Control Module
(LPTCM) ........................................ 79
Remove Proportioner ................................... 81
Engine ........................................................ 83
12V Charge Alternator.................................. 83
Parts.................................................................. 84
Electrical Schematics ........................................ 126
Dimensions ...................................................... 141
Technical Specifications.................................... 144
Graco Standard Warranty.................................. 148
3A1706B
Warnings
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 symbol refers to procedure-specific
risks. When these symbols appear in the body of this manual 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.
WARNING
ELECTRIC SHOCK HAZARD
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 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.
TOXIC FLUID OR FUMES
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled, or swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
CARBON MONOXIDE HAZARD
Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing
carbon monoxide can cause death.
• Do not operate in an enclosed area.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the
operating area of the equipment to help protect you from serious injury, including eye injury,
hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
3A1706B
3
Warnings
SKIN INJECTION HAZARD
WARNING
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce
skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get
immediate surgical treatment.
Engage trigger lock when not dispensing.
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.
Follow the Pressure Relief Procedure when you stop dispensing and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
•
•
•
•
•
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:
• Use equipment only in well ventilated area.
• Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is
flammable and can ignite or explode if spilled on hot surface.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
plastic drop cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use
equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
THERMAL EXPANSION HAZARD
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.
4
3A1706B
Warnings
WARNING
PRESSURIZED ALUMINUM HAZARD
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.
PLASTIC PARTS CLEANING SOLVENT HAZARD
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.
• See Technical Data in this and all other equipment instruction manuals. Read fluid and
solvent manufacturer’s MSDSs and recommendations.
EQUIPMENT MISUSE HAZARD
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
system component. See Technical Data in all equipment manuals.
• 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. Turn off all
equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment.
• 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.
3A1706B
5
Warnings
BATTERY HAZARD
WARNING
The battery may leak, explode, cause burns, or cause an explosion if mishandled.
• Only use the battery type specified for use with the equipment. See Technical Data.
• Battery maintenance must only be performed or supervised by personnel knowledgeable of
batteries and the required precautions. Keep unauthorized personnel away from battery.
• When replacing the battery, use the same lead-acid automotive battery, with 800 CCA
minimum, specified for use with the equipment. See Technical Data.
• Do not dispose of battery in fire. The battery is capable of exploding.
• Follow local ordinances and/or regulations for disposal.
• Do not open or mutilate the battery. Released electrolyte has been known to be harmful to
the skin and eyes and to be toxic.
• Remove watches, rings, or other metal objects.
• Only use tools with insulated handles. Do not lay tools or metal parts on top of battery.
MOVING PARTS HAZARD
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, follow the Pressure Relief Procedure and disconnect all power sources.
ENTAGLEMENT HAZARD
Rotating parts can cause serious injury.
•
•
•
•
Keep clear of moving parts.
Do not operate equipment with protective guards or covers removed.
Do not wear loose clothing, jewelry or long hair while operating equipment.
Equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid
severe burns:
• Do not touch hot fluid or equipment.
6
3A1706B
Important Two-Component Material Information
Important Two-Component Material Information
Isocyanate Conditions
Spraying or dispensing materials containing
isocyanates creates potentially harmful mists,
vapors, and atomized particulates.
Read material manufacturer’s warnings and
material MSDS to know specific hazards and
precautions related to isocyanates.
Prevent inhalation of isocyanate mists, vapors,
and atomized particulates by providing sufficient
ventilation in the work area. If sufficient ventilation
is not available, a supplied-air respirator is required
for everyone in the work area.
To prevent contact with isocyanates, appropriate
personal protective equipment, including
chemically impermeable gloves, boots, aprons,
and goggles, is also required for everyone in the
work area.
Material Self-Ignition
Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material MSDS.
Keep Components A and B Separate
Moisture Sensitivity of Isocyanates
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage equipment. To prevent
cross-contamination of the equipment’s wetted
parts, never interchange component A (isocyanate)
and component B (resin) parts.
Isocyanates (ISO) are catalysts used in two
component foam and polyurea coatings. ISO will
react with moisture (such as humidity) to form small,
hard, abrasive crystals, which become suspended in
the fluid. Eventually a film will form on the surface
and the ISO will begin to gel, increasing in viscosity. If
used, this partially cured ISO will reduce performance
and the life of all wetted parts.
The amount of film formation and rate of crystallization
varies depending on the blend of ISO, the humidity,
and the temperature.
To prevent exposing ISO to moisture:
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
• Keep the ISO lube pump 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 ISO pump oil
or grease when reassembling.
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage equipment. To prevent
cross-contamination of the equipment’s wetted
parts, never interchange component A (isocyanate)
and component B (resin) parts.
3A1706B
7
Important Two-Component Material Information
Foam Resins with 245 fa Blowing
Agents
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.
Changing Materials
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.
8
3A1706B
Proportioner Models
Proportioner Models
E-30i Series
Part
Available Auxiliary
Current at 240V, 60
Hz*
259079
50 Amps
259080
32 Amps
259089 
30 Amps
259090 
12 Amps
Voltage
(phase)
240V
(1)
240V
(1)
240V
(1)
240V
(1)
System
Watts†
Booster Max
Heat
Flow
Watts
Rate
lb/min
(kg/min)
7,700
0
30 (13.5)
11,700
4,000
30 (13.5)
7,700
0
30 (13.5)
11,700
4,000
30 (13.5)
Approximate
Output per
Cycle (A+B)
gal. (liter)
Maximum
Fluid Working
Pressure psi
(MPa, bar)
0.0272
(0.1034)
0.0272
(0.1034)
0.0272
(0.1034)
0.0272
(0.1034)
2000
140)
2000
140)
2000
140)
2000
140)
(14,
(14,
(14,
(14,
E-XP2i Series
Part
Available
Auxiliary
Current at
240V, 60
Hz*
Voltage
(phase)
System
Watts†
Booster
Heat
Watts
Max Flow
Rate gpm
(lpm)
259081
32 Amps
240V (1)
11,700
4,000
2.0 (7.6)
259091 
12 Amps
240V (1)
11,700
4,000
2.0 (7.6)
Approximate
Output per
Cycle (A+B)
gal. (liter)
0.0203
(0.0771)
0.0203
(0.0771)
Maximum
Fluid Working
Pressure psi
(MPa, bar)
3500 (24.1, 241)
3500 (24.1, 241)
*
Full load amps available for auxiliary equipment when all bare-system components are operating at
maximum capabilities. Refer to Circuit Breaker Configuration Options in the Operation manual.

Total system watts used by bare system, based on maximum hose length for each unit:
E-30i and E-XP2i series, 310 ft (94.5 m) maximum heated hose length, including whip hose.

Includes Complete Air Compressor Kit 24K335.
See Approvals, page 10.
3A1706B
9
Systems
Approvals
Model
Approvals:
259079
Conforms to ANSI/UL Std. 73 Certified to CAN/CSA Std. C22.2 No. 68
259080
259081
Conforms to ANSI/UL Std. 499 Certified to CAN/CSA Std. C22.2 No. 88
Systems
Remote
Display
Module Kit
Heated Hose
Gun
50 ft (15 m) 10 ft (3 m)
Model
Part
24K240
246050
Fusion™ AP
246101
259080
24K240
246050
Fusion™ AP
246101
259081
24K241
246055
Fusion™ AP
246100
✓
24K394
246050
Fusion™ AP
246101
259080
✓
24K394
246050
Fusion™ AP
246101
AP9181
259081
✓
24K395
246055
Fusion™ AP
246100
CS9079
259079
24K240
246050
Fusion™ CS
CS0101
CS9080
259080
24K240
246050
Fusion™ CS
CS0101
CS9081
259081
24K241
246055
Fusion™ CS
CS0000
CS9179
259079
✓
24K394
246050
Fusion™ CS
CS0101
CS9180
259080
✓
24K394
246050
Fusion™ CS
CS0101
CS9181
259081
✓
24K395
246055
Fusion™ CS
CS0000
P29079
259079
24K240
246050
Probler® P2
GCP2R1
P29080
259080
24K240
246050
Probler® P2
GCP2R1
P29081
259081
24K241
246055
Probler® P2
GCP2R0
P29179
259079
✓
24K394
246050
Probler® P2
GCP2R1
P29180
259080
✓
24K394
246050
Probler® P2
GCP2R1
P29181
259081
✓
24K395
246055
Probler® P2
GCP2R0
Part
Proportioner
AP9079
259079
AP9080
AP9081
AP9179
259079
AP9180
10
3A1706B
Accessories
Systems with Air Compressor
Remote
Air
Display
Compressor
Module Kit
✓
Heated Hose
Gun
50 ft (15 m) 10 ft (3 m)
Model
Part
24K240
246050
Fusion™ AP
246101
✓
24K240
246050
Fusion™ AP
246101
259091
✓
24K241
246055
Fusion™ AP
246100
AP9189
259089
✓
✓
24K394
246050
Fusion™ AP
246101
AP9190
259090
✓
✓
24K394
246050
Fusion™ AP
246101
AP9191
259091
✓
✓
24K395
246055
Fusion™ AP
246100
CS9089
259089
✓
24K240
246050
Fusion™ CS
CS0101
CS9090
259090
✓
24K240
246050
Fusion™ CS
CS0101
CS9091
259091
✓
24K241
246055
Fusion™ CS
CS0000
CS9189
259089
✓
✓
24K394
246050
Fusion™ CS
CS0101
CS9190
259090
✓
✓
24K394
246050
Fusion™ CS
CS0101
CS9191
259091
✓
✓
24K395
246055
Fusion™ CS
CS0000
P29089
259089
✓
24K240
246050
Probler® P2
GCP2R1
P29090
259090
✓
24K240
246050
Probler® P2
GCP2R1
P29091
259091
✓
24K241
246055
Probler® P2
GCP2R0
P29189
259089
✓
✓
24K394
246050
Probler® P2
GCP2R1
P29190
259090
✓
✓
24K394
246050
Probler® P2
GCP2R1
P29191
259091
✓
24K395
246055
Probler® P2
GCP2R0
Part
Proportioner
AP9089
259089
AP9090
259090
AP9091
✓
Accessories
Kit Number
Description
Kit Number
Description
125379
50 ft (15 m) CAN cable (for remote
display module)
24K336
Hose Rack
24K207
Fluid Temperature Sensor (FTS)
with RTD
15V551
ADM Protective Covers (10 pack)
15M483
24K338
Remote Display Module Kit
Remote Display Module Protective
Covers (10 pack)
24K335
Complete Air Compressor Kit
24K334
Feed Pump Shutdown Kit
125970
Air Compressor (without air supply
tank)
24K333
Fuel Line and Cable Extension Kit
24K337
Light Tower Kit
24M490
Air Compressor (mounted 30 gallon
tank)
24M174
Drum Level Sticks
24L911
Pallet Support Kit
24M125
Air Tank (12 gallons, 113.5 liters)
121006
24M178
Air Dryer (desiccant)
150 ft (45 m) cable (for remote
display module)
24M258
Compressor Rack (frame only)
3A1706B
11
Supplied Manuals
Supplied Manuals
Related Manuals
The following manuals are shipped with the Reactor.
Refer to these manuals for detailed equipment
information.
Manuals are available at www.graco.com.
Manuals are also available at www.graco.com.
Manual
Description
3A1705
Reactor E-30i and E-XP2i,
Operation
Reactor E-30i and E-XP2i, Startup
Instructions
Reactor E-30i and E-XP2i,
Shutdown Instructions
Perkins® Engine, Repair-Parts
16K761
16K913
SEBU7992
–
Mecc Alte Self-Regulating Alternator
Series NPE, Repair-Parts
Component manuals in English:
System Manuals
3A1705
Reactor E-30i and E-XP2i, Operation
Displacement Pump Manual
Electric Reactor Displacement Pump,
Repair-Parts
Feed System Manuals
309577
309572
Heated Hose, Instructions-Parts
309852
Circulation and Return Tube Kit,
Instructions-Parts
Feed Pump Kits, Instructions-Parts
309815
309827
Feed Pump Air Supply Kit,
Instructions-Parts
Spray Gun Manuals
309550
Fusion ™ AP Gun
312666
Fusion ™ CS Gun
313213
Probler P2 Gun
Accessory Manuals
3A1902
Compressor Rack, Instructions-Parts
3A1903
Hose Rack, Instructions-Parts
3A1904
Fuel Tank/Battery Move Kit,
Instructions-Parts
Feed Pump Shutdown Kit,
Instructions-Parts
Light Tower Kit, Instructions-Parts
3A1905
3A1906
3A1907
3A2574
12
Remote Display Module,
Instructions-Parts
Pallet Support Kit, Instructions-Parts
3A1706B
Troubleshooting
Troubleshooting
Error Codes and Troubleshooting
Note
Error codes are stored in the error log and
displayed on the Error and Troubleshooting
screens on the ADM.
Error
Error
Type
Name
Cause
Solution
Code
A1N1
Location
MCM
ALARM
No Motor Current
Loose or bad
connection.
Motor brushes
completely worn down.
Bad MCM.
A4CH
Hose
ALARM
High Relay
Current Hose
Wiring problem.
Check wiring between
MCM and motor.
Check motor brushes and
replace if needed.
Replace MCM. See
Motor Control Module
(MCM), page 79.
Check wiring between
HPTCM and contactor.
Look for shorted wire
between HPTCM and
contactor terminals A1 and
A2.
Measure resistance
between A1 and A2
terminals. The resistance
should be about 289Ω.
If contactor is measuring
less than 100Ω, then the
contactor is shorted and
should be replaced.
Shorted contactor.
3A1706B
13
Troubleshooting
Error
Error
Type
Name
Cause
Solution
Code
A4CM
Location
MCM
ALARM
High MCM
Current
MCM is drawing too
much current from the
system.
A4DA
Boost A
ALARM
High Heater
Current
A4DB
Boost B
Short circuit in booster
heater wiring.
Bad heater.
A4DH
Hose
A4NM
MCM
If problem continues
replace MCM. See
Motor Control Module
(MCM), page 79.
Check wiring for touching
wires.
Measure resistance of
heater(s), replace if
needed. See Booster
Heater, page 64.
Check continuity of
transformer windings,
normal reading 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 of the
transformer.
Check wiring to the motor
to ensure no bare wires are
touching and that no wires
are shorted to ground.
Replace motor
Electric Motor, page 57.
Repair or replace
chemical pump. See
Pump Removal, page 50.
Replace Module. See
High Power Temperature
Control Module (HPTCM),
page 79, or Low Power
Temperature Control
Module (LPTCM), page 79.
Replace Module. See
High Power Temperature
Control Module (HPTCM),
page 79, or Low Power
Temperature Control
Module (LPTCM), page 79.
Short circuit in hose
wiring.
ALARM
High Motor
Current
Short circuit of motor
wiring.
Motor will not rotate.
Chemical pump is stuck
A7CH
Hose
ALARM
Unexpected
Relay Current
Shorted Temperature
Control Module.
A7DA
Boost A
ALARM
A7DB
Boost B
Unexpected
Heater Current
Shorted Temperature
Control Module.
A7DH
Hose
14
3A1706B
Troubleshooting
Error
Error
Type
Name
Cause
Solution
Code
A8DA
Location
Boost A
ALARM
No Heater
Current
Tripped circuit breaker.
A8DB
Boost B
A8DH
Hose
Visually check circuit
breaker for a tripped
condition.
Check heater wiring for
loose wires.
CACA
Boost A
CACB
Boost B
Loose/broken
connection.
ALARM
Communication
Error
Module does not have
software or dial is set to
wrong position.
No 24 VDC supply to
module.
CACH Hose
Loose or broken CAN
cable.
CACM MCM
Bad module
CACP
3A1706B
Remote
Display
Module
Bad module
Insert a system token into
the missing GCA module
and cycle the power. Wait
until the red light on the
module to stop flashing
before removing the token.
Verify the dial on the TCMs
are in the correct position:
0 for hose, A for boost A,
B for boost B
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,
replace power supply. See
System Repair manual.
Check the CAN cables
running between GCA
modules and tighten if
needed. If the problem still
persists move each cable
around the connector and
watch the flashing yellow
light on the GCA modules.
If the lights stops replace
the CAN cable.
Replace MCM. See
Motor Control Module
(MCM), page 79.
Replace Remote Display
Module. See Remote
Display Module manual for
instructions.
15
Troubleshooting
Error
Error
Type
Name
Cause
Solution
Code
DADX
Location
MCM
ALARM
Pump Runaway
Flow rate is too large
DE0X
MCM
ALARM
Pump Cycle
Switch Fault
Faulty or missing cycle
switch.
F9DX
MCM
ALARM
Pressure Flow
Cutback
Mix chamber is too large
for the set pressure.
H1MH Hose
ALARM
Low Line
Frequency
Line frequency is below
55 Hz.
H4MH Hose
ALARM
High Line
Frequency
Line frequency is above
65 Hz.
K8NM
ALARM
Locked Rotor
Locked rotor.
Mix chamber too large for
system selected, use mix
chamber rated for system.
Make sure 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.
Check wiring between
cycle switch and MCM port
6.
Reference the pressure
flow curves in the operation
manual and select a tip
size that is the correct size
for the set pressure.
Check frequency. If
out of tolerance, see
supplied 120/240V
alternator manual for
repair instructions.
Check frequency. If
out of tolerance, see
supplied 120/240V
alternator manual for
repair instructions.
Replace motor. See
Electric Motor, page 57.
Repair or replace
pump. See
Pump Removal, page 50.
Fill tanks with material.
MCM
Chemical pump is stuck.
L1AX
L1BX
16
ADM
ALARM
Low Chemical
Level A
Low Chemical
Level B
Tanks low on material.
3A1706B
Troubleshooting
Error
Error
Code
MBN0
Location
MCM
Type
Name
ADVISORY Motor Brush
Wear
MMUX USB
ADVISORY USB Log Full
P4AX
ALARM
MCM
P4BX
P6AX
P6BX
3A1706B
MCM
ALARM
Over Pressure A
Cause
Solution
Brushes have worn
down and need
replacing.
USB logs have reached
a level were data loss
will occur if logs are not
downloaded.
System pressurized
before allowing heat to
reach setpoint.
Replace Brushes. See
Motor Brushes, page 55.
Over Pressure B
Bad pressure
transducer.
Pressure
Transducer Fault
A
Loose/bad connection.
Pressure
Transducer Fault
B
Bad sensor.
Use a USB drive and
download all logs.
Turn on the heat and allow
the hose to reach the
setpoint before turning on
the pumps.
Verify the ADM pressure
reading the analog
gauges at the manifold.
Replace transducers if
they do not match. See
Transducers, page 61.
Check to ensure the
pressure transducer is
properly installed and
all wires are properly
connected.
See if the error follows the
transducer. Disconnect
transducer cable from
#8 and #9 connectors
on MCM. Reverse A
and B connections and
check if the error follows.
If the error follows the
transducer, replace the
pressure transducer. See
Transducers, page 61.
If the error does not
follow, replace MCM. See
Motor Control Module
(MCM), page 79.
17
Troubleshooting
Error
Error
Code
Location
P7AX
MCM
Type
Name
Cause
Solution
ALARM
Pressure
Imbalance A
High
Pressure difference
between A and B
material is greater than
the defined amount.
Ensure the material flow is
equally restricted on both
material lines.
Pressure imbalance is
defined too low.
Ensure that the pressure
imbalance value, on the
System Setup screen, is at
an acceptable maximum
pressure to prevent
unnecessary alarms and
abort dispenses.
Out of material.
Fill tanks with material.
Fluid leaking from
heater inlet rupture disk
(372).
Check if heater
and PRESSURE
RELIEF/SPRAY valve
(SA or SB) are plugged.
Clear. Replace rupture
disk (372) with a new one;
do not replace with a pipe
plug.
Feed system defective.
Check feed pump and
hoses for blockage. Check
that the feed pumps have
the correct air pressure.
Pressure
Imbalance B
High
P7BX
P0AX
MCM
ADVISORY Pressure
Imbalance A
High
See P7AX.
P0BX
MCM
ADVISORY Pressure
Imbalance B
High
See P7BX.
T1DE
Heat
ALARM
Exchanger
18
Low
Temperature
Coolant Outlet
Radiator fan will not
stop.
Replace fan relay. See
Load Center Relays and
Fuses, page 60.
Engine thermostat is
stuck open.
Replace thermostat. See
Perkins distribution.
3A1706B
Troubleshooting
Error
Error
Code
Location
T2AE
Heat
DEVIATION Low
Temperature Hx
Exchanger
A
T2BE
Type
Name
Low
Temperature Hx
B
Cause
Solution
Coolant circulation
pump not working.
Check for 240 VAC on
pump. If there is the
correct voltage, replace
circulation pump. See
Circulation Pump, page 74.
Air lock in circulation
pump.
Check for coolant flow in
sight glass.
No voltage to coil of
valve.
Turn on the manual
valve switch, on the load
center, to manually turn
on the solenoids and
see if the temp rises.
If not, check voltage
output on J6 connector
on the load center and
ensure the LEDs are
on. Follow Load Center
Diagnostics, page 34. If
necessary, replace the
load center board. See
Load Center, page 60.
If voltage is present,
measure the resistance of
the coil, it should be 12.5
Ω, if coil is open replace
coil.
If voltage is present, test
the coil with screwdriver.
The screwdriver should
magnetically stick inside
the coil. If screwdriver
sticks, replace the
plunger on valve or
replace the complete
valve assembly. See
Control Valve, page 73.
3A1706B
19
Troubleshooting
Error
Error
Type
Name
Cause
Solution
Code
Location
T2DA
Boost A
ALARM
Low Chemical
Temperature
Flow is too high at
current setpoint.
Use a smaller mix chamber
that is rated for the unit in
use.
T2DB
Boost B
Bad heater(s)
Confirm resistance of
heater is 23–26.5 ohms.
Replace if OL/open loop.
T2DH
Hose
System stored below
20°F(-7°C).
Ensure system ambient
temperature is above
20°F(-7°C).
T2DE
Heat
ADVISORY Low
Temperature
Exchanger
Coolant Outlet
Radiator fan will not
stop.
Replace fan relay. See
Load Center Relays and
Fuses, page 60.
Engine thermostat is
stuck open.
Replace thermostat. See
Perkins distributor to
replace.
Motor is operating
outside of pressure
flow curve. The system
is running at a lower
setpoint to preserve
motor life.
Run the system at a
lower duty cycle or with
a smaller mix chamber.
See performance charts in
system operation manual.
High Chemical
Temperature Hx
A
Manual override switch
on load center board is
in the on position.
Open cabinet cover and
turn switch to the off
position.
High Chemical
Temperature Hx
B
B side control valve
solenoid is stuck in the
open position.
Disconnect connector from
solenoid. If temperature
does not decrease,
rebuild solenoid. See
Control Valve, page 73.
Short on load center
board. If the blue and
red LEDs are on while
the heat is off, then the
load center board is
bad.
Disconnect connector
from the solenoid. If
temperature does not
decrease, rebuild solenoid.
Follow Load Center
Diagnostics, page 34.
If necessary, replace
load center board. See
Load Center, page 60.
J6 connector on load
center “Heat Valves”
location is not centered.
Reconnect J6 connector
on load center in centered
location.
ALARM
T3NM
MCM
T4AE
Heat
ALARM
Exchanger
T4BE
20
Low Chemical
Temperature
ADVISORY High Motor
Temperature
3A1706B
Troubleshooting
Error
Error
Type
Name
Cause
Solution
Code
Location
T4CA
Boost A
ALARM
LPTCM Over
Temperature
Cooling fan not
operating on power.
If fan is not working check
wiring between CB03 and
fan. If wiring is good,
replace fan. See Electrical
Enclosure Fan, page 63.
T4CB
Boost B
LPTCM Over
Temperature
Overheated module.
T4CH
Hose
HPTCM Over
Temperature
Turn controller off. Wait
a few minutes. If the
condition does not clear or
regenerates consistently,
replace module. See
High Power Temperature
Control Module (HPTCM),
page 79, or Low Power
Temperature Control
Module (LPTCM), page 79.
T4CM
MCM
High ambient
temperature.
Ensure ambient
temperature is below
120°F(48°C) before using
the system.
Overheated Control
Module.
Stop the pumps. Wait
a few minutes. If the
condition does not clear or
regenerates consistently,
replace MCM. See
Motor Control Module
(MCM), page 79.
High Chemical
Temperature
Bad RTD.
Swap A and B heater power
cables and RTDs and see if
issue follows. If so, replace
RTD. See RTD, page 65.
High Chemical
Temperature
Bad Low Power
Temperature Control
Module.
Swap the A and B LPTCMs
and see if the issue follows
the module. If so replace
LPTCM. See Low Power
Temperature Control
Module (LPTCM), page 79.
T4DA
Boost A
T4DB
Boost B
3A1706B
ALARM
ALARM
High MCM
Temperature
21
Troubleshooting
Error
Error
Code
Location
T4DH
Hose
T4DE
T4NM
Type
Name
Cause
Solution
ALARM
High Chemical
Temperature
Bad High Power
Temperature Control
Module.
Replace HPTCM. See
High Power Temperature
Control Module (HPTCM),
page 79.
Heat
ALARM
Exchanger
High
Temperature
Coolant Outlet
Radiator fan not
functioning properly.
Check fan relay (K4) and
fuse (30 Amp ATO “F3”)
on load center board.
Replace if needed. See
Load Center Relays and
Fuses, page 60.
Plugged radiator.
Replace if needed. See
Radiator, page 77.
High ambient
temperature.
Ensure ambient
temperature is below
120°F(48°C) before using
the system.
Cooling fans are not
operating properly.
Ensure ambient
temperature is less than
120°F (48°C).
MCM
ALARM
High Motor
Temperature
Check to see that the fans
are moving. Measure
voltage to fans. There
should be 240 VAC. If no
voltage is measured, check
wiring between fan and
circuit breaker CB03.
If the fans have voltage but
are not moving, replace
fan.
Use an air hose to blow out
around the fan housings
and remove any built-up
debris.
Bad electric motor.
22
Replace motor. See
Electric Motor, page 57.
3A1706B
Troubleshooting
Error
Error
Code
Location
T6AE
Type
Name
Cause
Solution
Heat
ALARM
Exchanger
RTD Fault A
The module is reading
infinite resistance.
Check port on module and
wiring to RTD.
T6BE
Heat
Exchanger
RTD Fault B
Bad RTD.
T6DA
Boost A
RTD Fault A
T6DB
Boost B
RTD Fault B
T6DE
Heat
Exchanger
Coolant Outlet
RTD Fault
Switch the RTD with
another and see if the error
message follows the RTD.
Replace RTD if the error
follows the RTD.
T6DH
Hose
RTD Fault
T8AE
Heat
ALARM
Exchanger
Temperature Not
Rising Hx A
No coolant flow.
Check coolant level.
Check for coolant flow in
sight glass.
Ensure that the circulation
pump has 240 VAC.
If not, replace the
circulation pump. See
Circulation Pump, page 74.
T8BE
3A1706B
Temperature Not
Rising Hx B
No chemical flow.
Set pressure relief/spray
valves to pressure
relief/circulation to heat
faster.
J6 connector on load
center “Heat Valves”
location is not centered.
Reconnect J6 connector
on load center in centered
location.
Bad solenoid.
Turn on the manual
valve switch, on the load
center, and see if the
solenoid shifts. if not
replace solenoid. See
Control Valve, page 73.
Bad load center.
Follow Load Center
Diagnostics, page 34.
If necessary, replace
load center. See
Load Center, page 60.
23
Troubleshooting
Error
Error
Type
Name
Cause
Solution
Code
Location
T8DA
Boost A
ALARM
Temperature Not
Rising
Bad heater rod (boost).
Measure resistance, 23 –
26 Ω, of heater rod, replace
if reading open. See
Heater Element, page 64.
T8DB
Boost B
Bad hose heater.
Measure hose
resistance, replace
if reading open. See
Heater Element, page 64
T8DH
Hose
Started spraying before
engine and hose
reached operating
temperature.
Wait until temperatures
have been reached on
engine and hose before
spraying.
V1CM
MCM
ALARM
Bus Under
Voltage
Tripped circuit breaker.
Visually check circuit
breaker for a tripped
condition.
V1MH
Hose
ALARM
Low Line Voltage
Loose or bad
connection.
Check wiring for loose
wires.
Low generator line
voltage
Measure voltage across
main power switch.
Voltage should measure
between 190 and 264 VAC.
High auxiliary inrush
current.
Ensure compressor or
air drier are setup to be
continuous run and sized
according to manual.
Incoming line voltage is
too high.
Measure voltage across
main power switch.
Voltage should measure
between 190 and 264 VAC.
If voltage is too high, see
supplied alternator manual
for generator specifications
and repair.
Bad Connection
between MCM (Port 10)
and brush wear/over
temperature board.
Check connection and
cables.
Bad brush wear/over
temperature board.
Replace Motor. See
Motor Control Module
(MCM), page 79.
V4CM
MCM
ALARM
Bus Overvoltage
V4MH
HPTCM
ALARM
High Line
Voltage
ALARM
Motor Sensor
Fault
WBNM MCM
24
3A1706B
Troubleshooting
Error
Error
Code
Location
WMCE MCM
Type
Name
Cause
Solution
ALARM
Load Center
Fault
Bad Connection
between MCM (Port
2) and load center
board.
Check connection and
cables.
Bad load center.
Replace load center. See
Load Center, page 60.
WSCX ADM
ADVISORY Invalid CAN
Configuration
Duplicate node on CAN
network.
Verify LPTCM are set to A
and B.
WSUX USB
ADVISORY USB Invalid
Configuration
A valid configuration file
can't be found for the
USB.
Insert a system token
into the ADM and cycle
the power. Wait until the
lights on USB port stop
flashing before Removing
the token.
Bad ADM.
Replace ADM. See
Advanced Display Module
(ADM), page 78.
WXUD ADM
ADVISORY USB Download
Error
Log Download Failed.
Backup and reformat
the USB drive. Retry
download.
WXUU ADM
ADVISORY USB Upload
Error
Custom language file
failed to upload
Perform normal USB
download and use the new
disptext.txt file to upload
the custom language.
WX00
ALARM
The alarm external input
has been driven low.
An active alarm is being
generated by the external
trigger. If the external
alarm is not configured
check for a short in the
wiring going to MCM port
7, pins 1 and 3.
3A1706B
MCM
External Input
25
Troubleshooting
System
Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 42.
2. Turn main power switch OFF.
3. Allow equipment to cool.
Problem
Reactor ADM does not turn on.
Cause
No power.
Solution
Turn main power switch ON.
Turn circuit breakers ON, see
Circuit Breaker Module, page 58.
Check circuit breaker (CB10). See
Circuit Breaker Module, page 58.
Electric motor does not operate.
26
Loose connections.
Check MCM connection 13.
Tripped circuit breaker (CB02).
Reset breaker, see
Circuit Breaker Module, page 58.
Check 240VAC at output of
breaker.
Worn brushes.
Check both sides. Length
must be 0.7 in. (17 mm)
minimum. To replace, see
Motor Brushes, page 55.
Broken or misaligned brush
springs.
Realign or replace, see
Motor Brushes, page 55.
Brushes or springs binding in
brush holder.
Clean brush holder and align
brush leads for free movement.
Shorted armature.
Replace motor, see
Electric Motor, page 57.
Check motor commutator for burn
spots or other damage.
Remove motor. Have motor shop
resurface commutator, if possible.
3A1706B
Troubleshooting
Problem
Electric motor cooling fans not
working.
Cause
Solution
Tripped circuit breaker (CB03).
Reset circuit breaker (CB03).
Check 240VAC at output of
breaker.
Loose wire.
Check. See
Electrical Schematics, page 126.
Fan blade obstructed.
Remove obstruction.
Defective fan.
Replace. See Motor Fan, page 62.
Obstructed fluid hose or gun; fluid
hose ID too small.
Open, clear; use hose with larger
ID.
Worn piston valve or intake valve
in displacement pump.
See pump manual.
Pressure setpoint too high.
Reduce setpoint and output will
increase.
Fluid leak in pump packing nut
area.
Worn throat seals.
Replace. See pump manual.
No pressure on one side.
Fluid leaking from heater inlet
rupture disk (372).
Check if heater and PRESSURE
RELIEF/SPRAY valve (SA or SB)
are plugged. Clear. Replace
rupture disk (372) with a new one;
do not replace with a pipe plug.
Air compressor does not start.
Tripped circuit breaker (CB04).
Reset circuit breaker (CB04).
Not wired correctly.
See
Electrical Schematics, page 126.
Compressor starter overheated
from rapid multiple start and stop
procedures.
Let starter cool down for 2 minutes
then press reset on the air
compressor electrical enclosure
and start.
Air compressor shuts down
randomly.
Loose wire connections.
Check and retighten all wire
connections in the air compressor
electrical enclosure.
Air compressor supply tank does
not drain water.
Pilot air ball valve (1017) is closed.
Open ball valve.
Water drain valve (1016) shuttle
valve is stuck.
Replace drain valve.
Air compressor water drain valve
constantly blows air.
Water drain valve (1016) shuttle
valve is stuck in the center
position.
Close and re-open the pilot air
valve (1017).
Water in air line supplying
proportioner.
Desiccant pellets saturated with
moisture (blue color changed to
pink).
Replace desiccant pellets. Order
desiccant replacement kit 288810.
See manual 309921.
Very high humidity conditions.
Open manual water drain valve
(1016) regularly. See Systems
with Air Compressors, page 92.
Pump output low.
3A1706B
27
Troubleshooting
Coolant System
Problem
Cause
Solution
Proportioner Coolant Loop
Air bubbles in sight glass.
Air trapped in heat exchanger
coolant.
See Refill Proportioner Coolant
Loop, page 47.
Coolant hoses between the
proportioner coolant loop and
engine coolant loop were modified
and created a high point air pocket.
Ensure there is constant elevation
of hoses from proportioner coolant
loop to engine coolant loop.
Proportioner coolant loop
expansion bottle is empty.
See Refill Proportioner Coolant
Loop, page 47.
Circulation pump stopped running.
Check circuit breaker. Check
voltage.
Bypass control valve does not
open.
Repair or replace valve. See
Control Valve, page 73.
Coolant filter plugged.
Clean or replace filter
in sight glass. See
Sight Glass and Filter, page 75.
Order replacement filter kit
24L922.
A and B control valves are not
opening fully.
Repair or replace valve. See
Control Valve, page 73.
System stored below 20°F(-7°C).
Ensure system ambient
temperature is above 20°F(-7°C).
Heat exchanger coolant in sight
glass is a milky color.
Possible material leaking into
coolant.
Drain Proportioner coolant loop.
See Drain Coolant, page 46.
Check for pressurized material
leaks.
A or B material heats up slower
than the other.
Control valve opening too slow.
Repair or replace valve. See
Control Valve, page 73.
System stored below 20°F(-7°C).
Ensure system ambient
temperature is above 20°F(-7°C).
Control valve coil failed.
Repair or replace valve coil. See
Control Valve, page 73.
Control valve coil not allowing
valve to normally close.
Repair or replace valve coil. See
Control Valve, page 73.
Control valve stuck in open
position.
Repair valve. See
Control Valve, page 73.
Bad load center.
Replace the load center board.
See Load Center, page 60.
Heat exchanger coolant flow
stopped. No flow in sight glass.
Material slowly heats up.
A or B material cooling down
slower than the other.
28
3A1706B
Troubleshooting
Problem
Cause
Solution
Engine Coolant Loop
Engine coolant does not reach full
temperature.
Engine temperature normal, but
heat exchanger temperature is low
or slowly increases.
Radiator fan does not shut off.
Check fan relay. Check fan wiring.
Radiator core becoming plugged.
Replace radiator. See
Radiator, page 77.
Engine thermostat not opening.
Replace engine thermostat.
Coolant level is low in expansion
bottle.
Refill Engine Coolant Loop, page
48.
No coolant flow in engine coolant
loop.
Heat exchanger in the engine
coolant loop is plugged.
Replace heat exchanger. See
Heat Exchangers, page 70.
Expansion bottle levels are not
rising when coolant is heating.
Radiator or heat exchanger bottle
cap not opening.
Replace cap.
Coolant level in engine coolant
expansion bottle rises too high
and too fast.
Expansion bottle cap and radiator
cap are switched.
Switch radiator caps. Radiator cap
is marked 16 lbs and expansion
bottle is marked 8 lbs.
Spring loaded gasket inside
radiator cap does not seal.
Replace radiator cap.
Coolant level in proportioner
coolant expansion bottle does not
rise when hot.
Expansion bottle cap and radiator
cap are switched.
Switch radiator caps. Radiator cap
is marked 16 lbs and expansion
bottle is marked 8 lbs.
Coolant level in proportioner
coolant expansion bottle rises too
high and too fast.
Expansion bottle cap stuck open.
Replace expansion bottle cap.
3A1706B
29
Troubleshooting
Hose Heat System
Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 42.
2. Turn main power switch OFF.
3. Allow equipment to cool.
Problem
Cause
Solution
Hose heats but heats slower
than usual or it does not reach
temperature.
Ambient temperature is too cold.
Use auxiliary hose heat system.
FTS failed or not installed correctly.
Check FTS, see Fluid Temperature
Sensor (FTS), page 68.
Hose does not maintain
temperature while spraying.
A and B setpoints too low.
Increase A and B setpoints.
Hose is designed to maintain
temperature, not to increase it.
Ambient temperature is too cold.
Increase A and B setpoints to
increase fluid temperature and
keep it steady.
Flow too high.
Use smaller mix chamber.
Decrease pressure.
Hose was not fully preheated.
Wait for hose to heat to correct
temperature before spraying.
A and/or B heaters are overheating
material.
Check primary heaters for either
a RTD problem or a failed
element attached to RTD, see
Electrical Schematics, page 126.
Faulty FTS connections.
Verify that all FTS connections are
snug and that pins of connectors
are clean. Unplug and re-plug
RTD wires, cleaning off any debris.
Ambient temperature is too high.
Cover hoses or move to a location
with a lower ambient temperature.
Hose temperature exceeds
setpoint.
30
3A1706B
Troubleshooting
Problem
Erratic hose temperature.
Hose does not heat.
3A1706B
Cause
Solution
Faulty FTS connections.
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 not installed correctly.
FTS should be installed close to
end of hose in same environment
as gun. Verify FTS installation,
see Fluid Temperature Sensor
(FTS), page 68.
FTS failed.
Check FTS, see Fluid Temperature
Sensor (FTS), page 68.
FTS not installed correctly.
FTS should be installed close to
end of hose in same environment
as gun. Verify FTS installation,
see Fluid Temperature Sensor
(FTS), page 68.
Loose hose electrical connections.
Check connections. Repair as
necessary.
Circuit breakers tripped.
Reset breakers (CB20
and CB02), see
Circuit Breaker Module, page 58.
Hose zone not turned on.
Turn on hose heat zone.
A and B temperature setpoints too
low.
Check. Increase if necessary.
Failed HPTCM.
Remove HPTCM and install a new
HPTCM. New modules come with
most current software. Update
other modules if necessary. See
software upgrade instruction
manual.
Contactor not functioning.
Verify contactor actuates when
the hose heat zone is turned on.
The button in the middle of the
contactor should pull in. If not,
check electrical connections.
31
Troubleshooting
Problem
Cause
Solution
Hoses near Reactor are warm, but
hoses downstream are cold.
Shorted connection or failed hose
heating element.
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 Heat Connectors,
page 67.
Low hose heat.
A and B temperature setpoints too
low.
Increase A and B setpoints. Hose
designed to maintain temperature,
not increase temperature.
Hose temperature setpoint too
low.
Check. Increase if necessary to
maintain heat.
Flow too high.
Use smaller mix chamber.
Decrease pressure.
Low current; FTS not installed.
Install FTS, see operation manual.
Hose heat zone not turned on long
enough to reach setpoint.
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.
32
3A1706B
Troubleshooting
Booster Heater
Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 42.
2. Turn main power switch OFF.
3. Allow equipment to cool.
Problems
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.
Problem
Booster heater(s) does not heat.
Control of booster heat is
abnormal; high temperature
overshoots (T4DA, T4DB) occurs
intermittently.
3A1706B
Cause
Solution
Heat turned off.
Turn on heat zones.
Temperature control alarm.
Check ADM for error codes.
Signal failure from RTD.
Signal failure from RTD.
Dirty RTD connections.
Examine RTD cables connected
to LPTCMs. 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.
RTD not contacting 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.
Failed heater element.
See Heater Element, page 64.
Signal failure from RTD.
See (T4DA, T4DB), Error Codes
and Troubleshooting, page 13.
33
Troubleshooting
Load Center Diagnostics
Reference Relays and Fuses, page 60, and Load Center Wiring Diagram, page 134. The LEDs on the load
center board are helpful diagnostic tools when troubleshooting problems with the engine. Before referencing
the Engine Troubleshooting, page 37, complete the following steps:
1. Identify which LEDs are on and off.
2. Determine if the LEDs are expected to be in
the state observed. Determine if an unlit LED
should be on by referring to the LED Expected
Operation table.
Note
1
The starter, fuel shutoff solenoid, glow
plugs, and radiator fan operations are
sequenced during startup by the Engine
Control Module.
2
3. If the LEDs light as expected, focus
troubleshooting attention to components listed in
Table 1. If the LEDs do not light as expected, first
focus troubleshooting attention to components
listed in Table 2.
4. For potential causes and solutions related to
the components in Tables 1 and 2, see Engine
Troubleshooting, page 37.
LED Expected Operation
LED
ON State
D1
On when fuel is being fed to the engine –
from shortly before the starter cranks until
the engine is turned off.
On when starter is cranking – from shortly
after the Fuel LED lights (beginning
approximately 8 seconds after the green
start button on the Engine Control Module
is pressed) and until shortly after the
engine turns over.
On when glow plugs are warming the
engine - from when the green start button
is pressed on the Engine Control Module
until shortly after the engine starts and
comes up to speed.
On when radiator fan is running – from
shortly before the starter cranks until
shortly after the main power switch is
turned on, then intermittently thereafter as
required by engine temperature. (If the
main power switch is left off, the fan will
run continuously.)
D2
D3
D4
34
Table 1 lists a likely order of potential failures in the
load center output-side components.
Table 1 – LEDs Light As Expected
Radiator
Glow
Fan
Plugs
(D4)
(D3)
Engine Harness "E" and its connections
Fuel
(D1)
Starter
(D2)
Engine
Fuel
Shutoff
Solenoid
(FD)
Starter
Solenoid
Relay
(CR6)
3
Engine
Starter
Motor
(ES)
Glow
Plugs
Solenoid
Relay
(CR7)
Table 2 indicates a likely order of potential failures in
the load center input-side power, cable, or control
components.
Table 2 – LEDs Do Not Light As Expected
Fuel
(D1)
1
2
3
4
5
6
7
8
9
Glow
Plugs
(D3)
Battery
Starter
(D2)
Radiator
Fan
(D4)
Battery cables and its connections
Load
Center
Fuse F3
Radiator Fan Fuse F4
("FAN
("PWR - ATO 20A")
- ATO
30A")
Fusible Link Harness "C" and its connections
Engine Harness "E" and its connections
Engine Control Module Harness "F"
and its connections
Load
Load
Load
Load
Center
Center
Center
Center
Fan Relay
Glow
Starter
Fuel
(K4)
Relay
Relay
Relay
(K3)
(K2)
(K1)
Load Center Board
Engine Control Module
3A1706B
Troubleshooting
Load Center Component Identification
Figure 1
Manual Valve Switch ON (engine off)
Figure 2
F3
Load Center Power Fuse
F4
Radiator Fan Fuse
K1
Fuel Relay
K2
Starter Relay
K3
Glow Plug Relay
K4
Radiator Fan Relay
MV
Manual Valve Switch
LED
Related Component
Color
D1
Fuel Shutoff Solenoid
Green
Fuel shutoff solenoid on the engine is open.
D2
Red
Starter is cranking.
D3
Starter
Glow Plugs
Green
Glow plugs are heating.
D4
Radiator Fan
Green
D10
A Coolant Valve
Red
Radiator fan is on.
A-side (red) coolant valve is open.
D12
Blue
B-side (blue) coolant valve is open.
D14
B Coolant Valve
Bypass Coolant Valve
Green
Bypass coolant valve is open.
D23
Manual Valve Switch
Red
Manual valve switch is in the ON position.
3A1706B
ON-State Description
35
Troubleshooting
LED
Description
Off
4. Engine starting; glow plugs continue to warm
engine.
On
Flashing
LED Sequence for Engine Startup and Operation
1. After pressing green start button on Engine
Control Module, glow plugs start warming engine.
5. Engine is running; with main power switch off,
the radiator fan runs continuously.
2. Fuel and radiator fan turn on shortly before
engine starting; glow plugs continue to warm
engine.
6. Engine is running; electronics take control of and
cycle the fan and valves beginning shortly after
main power switch is turned on.
3. Engine starting; fuel, fan, and glow plugs
continue to operate.
36
3A1706B
Troubleshooting
Engine
Problem
Engine Control Module does not
power up from sleep mode.
Cause
Discharged or failed battery.
Solution
Verify battery voltage is 11 - 13
volts DC.
Charge or replace battery as
required. See Battery, page 76.
3A1706B
Loose or incorrect wiring
connections.
Refer to schematics, verify wiring
connections (including grounds)
related to Engine Control Module.
Check Engine Harness "E"
(16K301), Engine Control Module
Harness "F" (16K297), Fusible
Link Harness "C" (16K172), and
battery cables. Verify voltage is
11 - 13 volts DC from starter to
ground.
Blown Load Center board fuse.
Determine cause of blown fuse
F4 "PWR - ATO 20A". Repair
issue then replace fuse. See
Relays and Fuses, page 60.
Blown fusible link.
Verify continuity through fusible
link harness from starter to 12V
charge alternator. If required,
replace Fusible Link Harness "C"
(16K172).
Failed Engine Control Module.
Replace module. See
Engine Control Module, page 78.
Failed Load Center board.
Replace board. See
Load Center, page 60.
37
Troubleshooting
Problem
Cause
Solution
Reference Load Center Diagnostics, page 34.
Engine does not turn over.
Main power switch on electrical
enclosure is in the ON position.
Turn switch to OFF position.
Discharged or failed battery.
Verify battery voltage is 11 - 13
volts DC.
Charge or replace battery as
required. See Battery, page 76.
38
Loose or corroded battery cable
connector.
Verify cable connectors. See
Battery, page 76.
Loose or incorrect wiring
connections.
Refer to schematics, verify wiring
connections (including grounds)
related to starter. Check Engine
Harness "E" (16K301), Engine
Control Module Harness "F"
(16K297), Fusible Link Harness
"C" (16K172), Disconnect Check
Harness "H" (16K299), and battery
cables. Verify voltage is 11 - 13
volts DC from starter to ground.
Blown Load Center board fuse.
Determine cause of blown fuse
F4 "PWR - ATO 20A". Repair
issue then replace fuse. See
Relays and Fuses, page 60.
Failed starter relay.
Replace relay K2 located
on Load Center board. See
Relays and Fuses, page 60.
Failed starter solenoid relay.
Replace solenoid relay CR6
located on side of engine. See
Engine Solenoid Relays, page 61.
Blown fusible link.
Verify continuity through fusible
link harness from starter to
solenoid relay CR6. If required,
replace Fusible Link Harness (C),
part no. 16K172.
Failed engine starter (ES).
Contact local Perkins distributor
for service.
3A1706B
Troubleshooting
Problem
Cause
Solution
Reference Load Center Diagnostics, page 34.
Engine turns over, but does not
start.
Low fuel level.
Refill fuel tank.
Lost prime.
Ensure fuel tank is at least half full,
prime with bulb until fuel is flowing
through return line to tank.
Loose or incorrect wiring
connections.
Refer to schematics, verify wiring
connections (including to grounds)
related to engine fuel shutoff
solenoid. Check Engine Harness
"E" (16K301), Engine Control
Module Harness "F" (16K297),
and Fusible Link Harness "C"
(16K172).
Blocked air intake.
Replace air filter.
Blocked exhaust system.
Check that exhaust system is
open (rain cap is free to move, no
exhaust obstructions or plugging).
Remove blockage.
Blocked fuel filter.
Inspect/replace fuel filter.
Failed fuel relay.
Replace relay K1 located
on Load Center board. See
Relays and Fuses, page 60.
Failed engine fuel shutoff solenoid.
Verify engine fuel shutoff solenoid
(FD) related wiring according to
schematics (see Cause "Loose
or incorrect wiring connections",
above).
Contact local Perkins distributor
for service.
Failed glow plug relay.
Replace relay K3 located
on Load Center board. See
Engine Solenoid Relays, page 61.
Failed glow plug solenoid relay.
Replace solenoid relay CR7
located on side of engine. See
Engine Solenoid Relays, page 61.
Failed glow plug assembly.
Verify glow plug related wiring
according to schematics (see
Cause "Loose or incorrect wiring
connections", above).
Contact local Perkins distributor
for service.
3A1706B
39
Troubleshooting
Problem
Cause
Solution
Reference Load Center Diagnostics, page 34.
Engine shuts down, Engine
Control Module shows no errors.
Loose or incorrect wiring
connections.
Refer to schematics, verify wiring
connections (including grounds)
related to engine fuel shutoff
solenoid. Check Engine Harness
"E" (16K301), and Engine Control
Module Harness "F" (16K297).
Failed fuel relay.
Replace relay K1 located
on Load Center board. See
Relays and Fuses, page 60.
Failed engine fuel shutoff solenoid.
Verify engine fuel shutoff solenoid
(FD) related wiring according to
schematics (see Cause "Loose
or incorrect wiring connections",
above).
Contact local Perkins distributor
for service.
Engine shuts down, Engine
Control Module shows High
Coolant Temperature Shutdown
icon.
Low engine coolant level.
Inspect coolant system for leaks.
Repair as necessary and refill
system.
Loose or incorrect wiring
connections.
Refer to schematics, verify wiring
connections (including grounds)
related to radiator fan. Check
Engine Harness "E" (16K301), and
Engine Control Module Harness
"F" (16K297).
Blown radiator fan fuse.
Determine cause of blown fuse
F3 "FAN - ATO 30A". Repair
issue then replace fuse. See
Relays and Fuses, page 60
Failed radiator fan relay.
Replace relay K4 located
on Load Center board. See
Relays and Fuses, page 60.
Obstructed radiator fan.
Remove obstructions.
Failed radiator fan.
Replace fan. See
Radiator Fan, page 63.
Failed engine coolant temperature
sensor.
Replace engine coolant
temperature sensor located
behind radiator connected to MCM
port 5. See Engine RTD, page 83.
Plugged radiator or coolant
system.
Clean or replace radiator. See
Radiator, page 77.
Contact local Perkins distributor
for service.
40
3A1706B
Troubleshooting
Problem
Engine shuts down. Engine
Control Module shows Low Oil
Pressure Shutdown icon.
Cause
Solution
Low oil level.
Check oil level and refill.
Loose or incorrect wiring
connections.
Refer to schematics, verify wiring
connections (including grounds)
related to oil pressure switch.
Check Engine Harness "E"
(16K301), and Engine Control
Module Harness "F" (16K297).
Failed oil pressure switch.
Replace oil pressure switch
Contact local Perkins distributor
for service.
Engine shuts down. Engine
Control Module shows Under
Low fuel level.
Refill fuel tank.
Lost prime.
Ensure fuel tank is at least half full,
prime with bulb until fuel is flowing
through return line to tank.
Blocked air intake.
Replace air filter.
Blocked exhaust system.
Check that exhaust system is
open (rain cap is free to move, no
exhaust obstructions or plugging).
Remove blockage.
Blocked fuel filter.
Replace fuel filter.
Generator overloaded.
Confirm auxiliary electrical loads
wired into the electrical enclosure
by the customer are within the
system's available auxiliary power
limits.
Loose or incorrect wiring
connections.
Refer to schematics, verify wiring
connections related to Engine
Control Module, Check AC Sense
Harness "M" (125752).
Blown voltage sense fuses.
Replace fuses F6 and F7 located
in the junction box above the
120/240 V alternator. Use repair
kit 24M723.
Frequency Shutdown icon
or Generator Low Voltage
Shutdown icon
3A1706B
.
41
Repair
Repair
2. Close gun fluid inlet valves A and B.
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.
Before Beginning Repair
NOTICE
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.
3. Shut off feed pumps and agitator, if used.
4. 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
1. Flush if necessary. See Flushing, page 43.
2. See Shutdown, page 45.
Pressure Relief Procedure
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.
5. Engage gun piston safety lock.
6. Disconnect gun air line and remove gun fluid
manifold.
The Fusion AP gun is shown.
1. Relieve pressure in gun and perform gun
shutdown procedure. See gun manual.
42
3A1706B
Repair
Flushing
• To flush feed hoses, pumps, and heaters
separately from heated hoses, set PRESSURE
RELIEF/SPRAY valves (SA, SB) to PRESSURE
To prevent fire and explosion, flush equipment only
in a well-ventilated area. Do not spray flammable
fluids. Do not turn on heaters while flushing with
flammable solvents.
RELIEF/CIRCULATION
lines (N).
GA
SA
. Flush through bleed
GB
SB
• Flush out old fluid with new fluid, or flush out old
fluid with a compatible solvent before introducing
new fluid.
• Use the lowest possible pressure when flushing.
• All wetted parts are compatible with common
solvents. Use only moisture-free solvents.
• 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 TwoComponent Material Information, page 7.
3A1706B
43
Repair
Flush Inlet Strainer Screen
The inlet strainers filter out particles that can plug the
pump inlet check valves. Inspect the screens daily as
part of the startup routine, and clean as required.
Isocyanate can crystallize from moisture
contamination or from freezing. If the chemicals used
are clean and proper storage, transfer, and operating
procedures are followed, there should be minimal
contamination of the A-side screen.
3. Remove the screen (A) from the strainer
manifold. Thoroughly flush the screen with
compatible solvent and shake it dry. Inspect the
screen. No more than 25% of the mesh should
be restricted. If more than 25% of the mesh is
blocked, replace the screen. Inspect the gasket
(B) and replace as required.
4. Ensure the pipe plug (D) is screwed into the
strainer plug (C). Install the strainer plug with the
screen (A) and gasket (B) in place and tighten.
Do not overtighten. Let the gasket make the seal.
5. Open the fluid inlet valve, ensure that there are
no leaks, and wipe the equipment clean. Proceed
with operation.
Note
Clean the A-side screen only during
daily startup. This minimizes moisture
contamination by immediately flushing
out any isocyanate residue at the start of
dispensing operations.
1. Close the fluid inlet valve at the pump inlet and
shut off the appropriate feed pump. This prevents
material from being pumped while cleaning the
screen.
2. Place a container under the strainer base to catch
drain off when removing the strainer plug (C).
44
A
B
C
D
Figure 3
3A1706B
Repair
Shutdown
NOTICE
8. Turn main power switch off.
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. Press
to stop the pumps.
2. Turn off heat zones.
3. Relieve pressure. See
Pressure Relief Procedure, page 42.
4. Press
to park the Component A Pump.
5. Press
to deactivate the system.
6. Turn off the air compressor, air dryer, and
breathing air.
7. Close the main air shutoff valve.
To prevent electric shock do not remove any
shrouds or open the electrical enclosure door.
240 V is still present in the system until the
engine has stopped.
9. Allow engine dwell time.
NOTICE
Allow engine dwell time, per manufacturer
recommendations, prior to shutdown. Dwell
time will help engine cool down after running at
operating temperature for any period of time.
10. Press
on the engine control module.
11. Open air compressor bleed valve to relieve
pressure and remove water from tank.
12. Close all fluid supply valves.
3A1706B
45
Repair
Drain Coolant
To avoid burns, do not perform maintenance on
the coolant system until the coolant system has
reached ambient temperature.
Drain coolant from the engine and proportioner
coolant loops once a year or if the coolant lines need
to be disconnected, in order to install a wall between
the generator and proportioner.
1. Perform Shutdown, page 45.
LED Component
LED Color
Manual valve switch (MV)
Red
A Side Control Valve
Red
B Side Control Valve
Blue
Bypass Valve
Green
4. To drain proportioner coolant loop:
a. Remove the proportioner coolant loop fill
bottle (HF) cap. See Fig 5.
b.
2. Remove the cabinet door from the front of the
proportioner.
3. Turn on manual valve switch (MV), located on
the load center (LC), to manually open the A
and B heat exchanger control valves and bypass
control valve.
Place the other end of the drain tube in a
waste container. Open the drain valve. Drain
coolant until coolant is no longer visible in
the sight glass.
Note
The 12V battery must be connected to
operate valves. The load center (LC)
LEDs will stay on when the manual valve
switch (MV) is in the on position.
LC
Proportioner Coolant Loop Drain Valve
Figure 5
MV
c.
To refill coolant loop, see
Refill Proportioner Coolant Loop, page 47.
Figure 4
46
3A1706B
Repair
5. To drain engine coolant loop:
a. Remove the engine coolant loop (RC) cap.
See Fig 5.
b.
Remove engine guards as shown. Let the
guards rest on the engine to access the drain
valve.
To avoid burns, do not perform maintenance on
the coolant system until the coolant system has
reached ambient temperature.
Only use coolant solutions that are compatible with
the system. See Coolant Specifications, page 48.
1. Before refilling coolant loop, perform steps 1–3
from Drain Coolant, page 46. Drain coolant loop
if necessary.
2. Remove the caps from the metal proportioner
coolant loop fill bottle (HF) and expansion
bottle (HB). Fill the proportioner coolant loop fill
bottle (HF) to the top and add more coolant to
expansion bottle (HB) until the coolant is at the
cold fill line. See Coolant Specifications, page 48.
RC
HB
HF
EB
Engine Coolant Loop Drain Valve
Figure 6
c.
Place a waste container under the drain
valve. Open the drain valve and drain
coolant.
d. To refill coolant loop, see
Refill Engine Coolant Loop, page 48.
e. Replace engine shrouds. Torque screws to
25 ft-lbs (33.8 N∙m).
Refill Proportioner Coolant Loop
Note
Air needs to be purged from the proportioner
coolant loop when it is filled with new coolant
or when air enters the coolant system. It
takes about one full warm-up and cool-down
cycle to purge air from coolant.
3A1706B
Coolant System Bottles
Figure 7
3. Replace cap.
4. Press start button
control module.
twice on the engine
5. Turn main power switch on.
47
Repair
6. Inspect coolant flow in sight glass (SG) for
bubbles and to verify that the coolant is flowing.
7. Inspect coolant loops for leaking fittings or valves.
8. The coolant has reached operating temperature
when the radiator fan turns on. When the fan
turns on, turn the main power switch off.
of the neck. See Fig 5. Replace cap. See
Coolant Specifications, page 48.
3. Remove the cap from the engine coolant loop
bottle (EB) and fill until the coolant is at the hot
level. Replace cap.
4. Press start button
control module.
twice on the engine
5. Turn main power switch on.
9. Press
to stop the generator.
10. After the coolant system temperature lowers to
ambient temperature, refill or add coolant to the
expansion bottle (HB) cold level indicator line.
11. Turn off manual valve switch (MV) to close the A
and B heat exchanger control valves (VA, VB)
and bypass control valve (VC).
6. Inspect coolant loops for leaking fittings or valves.
7. The coolant has reached operating temperature
when the radiator fan turns on. When the fan
turns on, turn the main power switch off.
Note
When the manual valve switch (MV) is
in the off position, the load center (LC)
LEDs only turn on when the system
opens the valves.
8. Press
to stop the generator.
Refill Engine Coolant Loop
9. Add more coolant to expansion bottle (EB)
after the coolant system temperature lowers to
ambient temperature. Repeat until coolant level
stays at cold level when at ambient temperature.
It may take a few cycles to remove all air out of
coolant system.
Refill the engine coolant loop when the coolant is
below the cold level line at ambient temperature.
Coolant Specifications
12. If necessary, refill or add coolant to the expansion
bottle (HB) cold level indicator line. See Fig 5.
To avoid burns, do not perform maintenance on
the coolant system until the coolant system has
reached ambient temperature.
Only use coolant solutions that are compatible with
the system. See Coolant Specifications, page 48.
Only refill the coolant loops with a solution of 50%
distilled or soft water and 50% green ethylene glycol
antifreeze with a corrosion inhibitor. Do not use
common tap water; it contains chlorides and minerals
which form scale on the coolant system walls. Use
only antifreeze that meets specification ASTM
D3306–89, BS658, or AS 2108. A pre-diluted mix
is recommended, such as PEAK Ready Use 50/50
Pre-Diluted.
1. Perform Shutdown, page 45.
2. Remove the engine radiator coolant cap (RC)
and fill until the coolant reaches the bottom
48
3A1706B
Repair
Pump Lubrication System
4. When the reservoir is flushed clean, fill with fresh
lubricant.
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.
5. Thread the reservoir onto the cap assembly and
place it in the bracket.
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.
6. The lubrication system is ready for operation. No
priming is required.
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 42.
2. Lift the lubricant reservoir (R) out of the bracket
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.
3A1706B
R
Pump Lubrication System
Figure 8
49
Repair
Pump Removal
9. Allow engine dwell time.
NOTICE
Pump rod and connecting rod move during
operation. Moving parts can cause serious injury
such as pinching or amputation. Keep hands and
fingers away from connecting rod during operation.
Note
See manual 309577 for pump repair
instructions.
1. Press
to stop the pumps.
Allow engine dwell time, per manufacturer
recommendations, prior to shutdown. Dwell
time will help engine cool down after running at
operating temperature for any period of time.
10. Press
on the engine control module.
11. Open air compressor bleed valve to relieve
pressure and remove water from tank.
12. Shut off both feed pumps. Close all fluid supply
valves.
2. Turn off heat zones.
3. Flush pump.
4. Press
to park the Component A Pump.
5. Press
to deactivate the system.
6. Turn off the air compressor, air dryer, and
breathing air.
7. Close the main air shutoff valve.
13. 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
8. Turn main power switch off.
SA
GB
SB
To prevent electric shock do not remove any
shrouds or open the electrical enclosure door.
240 V is still present in the system until the
engine has stopped.
50
3A1706B
Repair
Note
Use drop cloth or rags to protect Reactor
and surrounding areas from spills.
18. Push retaining wire clip (E) up. Push pin (F)
out. Loosen locknut (G) by hitting firmly with a
non-sparking hammer. Unscrew pump.
Note
Steps 14–16 apply to pump A. To
disconnect pump B, go to steps 17 and
18.
14. Disconnect fittings at fluid inlet (C) and outlet (D).
Also disconnect steel outlet tube from heater
inlet.
15. Disconnect tubes (T). Remove both tube fittings
(U) from wet-cup.
16. Loosen locknut (G) by hitting firmly with a
non-sparking hammer. Unscrew pump far
enough to separate and push up finger guard
(P), to expose rod retaining pin. Push retaining
wire clip up. Push pin out. Continue unscrewing
pump.
Pump B
Figure 10
1
Flat side faces up.
2
Lubricate threads with ISO oil or grease.
3
Pump top threads must be nearly flush with
bearing face (N).
Pump A
Figure 9
1
Flat side faces up.
2
Lubricate threads with ISO oil or grease.
Pump top threads must be nearly flush with
bearing face (N).
3
Finger guard (P) not used on E-30i model.
4
Note
Steps 17 and 18 apply to pump B.
17. Disconnect fluid inlet (C) and outlet (D). Also
disconnect steel outlet tube from heater inlet.
3A1706B
51
Repair
Pump Installation
Note
Steps 1–5 apply to pump B. To reconnect
pump A, proceed to step 6.
1. Ensure locknut (G) is screwed on pump with flat
side up. Screw pump into bearing housing (M)
until pin holes align. Push pin (F) in. Pull retaining
wire clip (E) down. See Fig. 10, page 51 for view
and assembly notes.
2. Continue screwing pump into housing until fluid
outlet (D) is aligned with steel tube and top
threads are +/- 1/16 in. (2 mm) of bearing face
(N).
3. Tighten locknut (G) by hitting firmly with a
non-sparking hammer.
11. Apply thin film of TSL to barbed fittings. Using
two hands, support tubes (T) while pushing
straight onto barbed fittings. Do not let tubes
kink or buckle. Secure each tube with a wire tie
between two barbs.
12. Reconnect fluid inlet (C).
13. Purge air and prime the system. See Reactor
operation manual.
Drive Housing
Removal
1. Press
to stop the pumps.
2. Turn off heat zones.
4. Reconnect fluid inlet (C) and outlet (D).
3. Flush pump.
5. Go to step 13.
4. Press
to park the Component A Pump.
5. Press
to deactivate the system.
Note
Steps 6–12 apply to pump A only.
6. Ensure star-shaped locknut (G) is screwed on
pump with flat side up. Carefully twist and extend
displacement rod 2 in. (51 mm) above wet-cup.
See Fig. 9, page 51 for view and assembly notes.
7. Start threading pump into bearing housing
(M). Place finger guard (P) over rod when it is
accessible through window of bearing housing.
When pin holes align, insert pin. Pull retaining
wire clip down.
6. Turn off the air compressor, air dryer, and
breathing air.
7. Close the main air shutoff valve.
8. Turn main power switch off.
Note
Finger guard is not used on E-30i model.
8. Seat finger guard (P) on wet-cup. Continue
threading pump into bearing housing (M) until top
threads are +/- 1/16 in. (2 mm) of bearing face
(N). Ensure that barbed fittings at wet-cup flush
ports are accessible.
9. Connect component A outlet tube loosely at
pump and at heater. Line up tube, then tighten
fittings securely.
To prevent electric shock do not remove any
shrouds or open the electrical enclosure door.
240 V is still present in the system until the
engine has stopped.
10. Tighten star-shaped locknut (G) by hitting firmly
with a non-sparking hammer.
52
3A1706B
Repair
9. Allow engine dwell time.
NOTICE
18. Remove screws (312, 319) and washers (314)
and pull drive housing (302) off motor (301).
Note
Allow engine dwell time, per manufacturer
recommendations, prior to shutdown. Dwell
time will help engine cool down after running at
operating temperature for any period of time.
10. Press
The A side drive housing includes cycle
counter switch (321). If replacing this
housing, remove pins (322) and switch.
Reinstall pins and switch on new drive
housing. Switch wire connects to port #6
on the MCM.
on the engine control module.
11. Open air compressor bleed valve to relieve
pressure and remove water from tank.
78
12. Perform Pressure Relief Procedure, page 42.
13. Remove screws (61) and motor shield (56), see
Fig. 11.
Note
Examine bearing housing (303) and
connecting rod (305). If these parts need
replacing, first remove the pump (306),
see Pump Removal, page 50
.
61
77
78
56
14. Remove cover (77) and screws (78).
15. Disconnect cycle counter switch cable from port
#6 on the MCM. Cut zip ties on harness with
counter switch cable inside.
16. Remove front plate (289) and two screws (299).
Remove screws (326), and washers (314) from
inside the mounting bracket
17. Disconnect pump inlet and outlet lines. Remove
screws (313), washers (315), and bearing
housing (303).
61
77
299
292
289
ti18474a
Figure 11
NOTICE
Do not drop gear cluster (204) when removing
drive housing (202). Gear cluster may stay
engaged in motor front end bell (R) or drive
housing.
Figure 12
3A1706B
53
Repair
Installation
4. Push drive housing (302) onto motor (301).
Install screws (312, 319) and washers (314).
1. Apply grease liberally to washers (307, 308,
318), all gears, and inside drive housing (302).
Note
If bearing housing (303), connecting rod
(305), or pump (306) were removed,
reassemble rod in housing and install
pump, see Pump Installation, page 52 .
2. Install one bronze washer (308) in drive housing,
then install steel washers (307, 318) as shown.
3. Install second bronze washer (308) on gear
cluster (304) and insert gear cluster in drive
housing.
Note
5. Route cycle counter switch cable (321) under the
motor fan and inside the conduit. Connect to port
#6 on the MCM and close conduit with tie wraps.
Drive housing crankshaft must be in line
with crankshaft at other end of motor.
See Fig. 12, page 53.
6. Install bearing housing (303), screws (313), and
washers (315). Pumps must be in phase (both at
same position in stroke).
7. Install cover (77) and screws (78).
8. Install motor shield (56) and screws (61) , see
Proportioners.
314
319
321
301
322
318
305
311
308
304
330
302
307
320
313
328
308
314
312
303
327
314
310
315
316
326
331
316
306
Figure 13
54
3A1706B
Repair
Motor Brushes
Brush Removal
9. Remove motor cover, screws. Remove brush
inspection covers, and screws from top and
bottom of motor.
Note
Replace brushes worn to less than 0.7 in. (17
mm). Brushes wear differently on each side
of motor; check both sides. Brush Repair
kit 234037 (includes brushes and springs)
is available.
1. Press
to stop the pumps.
2. Turn off heat zones.
3. Perform Pressure Relief Procedure, page 42.
4. Press
to park the Component A Pump.
5. Press
to deactivate the system.
10. Remove two screws (299) and front plate (289).
See Fig. 19, page 62.
11. Remove two screws (299) from back plate (290).
Rest fan and back plate (290) behind motor. See
Fig. 19, page 62.
12. Push in spring clip (C) to release hooks (H) from
brush holder. Pull out clip and spring (S). Note
spring orientation.
H
6. Turn main power switch off.
C
S
Note
The top brush has a pair of thin wires
for brush wear signal. Unplug at spade
connector provided.
To prevent electric shock do not remove any
shrouds or open the electrical enclosure door.
240 V is still present in the system until the
engine has stopped.
13. Use a screw driver or 5/16 nut driver to loosen
terminal screw (R). Pull away brush lead (L),
being careful motor lead terminal (T) remains in
place. Remove and discard brush (B).
7. Allow engine dwell time.
NOTICE
Allow engine dwell time, per manufacturer
recommendations, prior to shutdown. Dwell
time will help engine cool down after running at
operating temperature for any period of time.
8. Press
on the engine controller.
To prevent electric shock and burns, wait for 5
minutes for stored voltage to discharge.
3A1706B
B
L
T
R
14. Inspect commutator for excessive pitting,
burning, or gouging. Black color on commutator
is normal. Have commutator resurfaced by
qualified motor repair shop if brushes wear too
quickly.
15. Repeat steps 12 and 13 for the other side.
55
Repair
Brush Installation
3. Install spring (S) so it will uncoil onto brush (B),
as shown. Spring will be damaged if installed
backwards.
NOTICE
When installing brushes, follow steps carefully.
Improper installation damages parts beyond use.
Note
Install brush with a pair of thin wires in top of
motor. Plug spade terminal into connector.
1. Install new brush (B) so lead (L) is in long slot
(D) of holder.
D
L
B
S
4. Install spring clip (C) and push in until hooks (H)
catch slots in housing. Incorrect installation may
jam clip.
H
B
2. Slide terminal (L) under terminal screw (R). Make
sure motor lead terminal (T) is still connected at
screw. Tighten screw.
S
C
Do not touch brushes, leads, springs, or brush
holders while equipment is plugged in, to
reduce the risk of electric shock and serious
injury.
B
L
T
R
NOTICE
Do not run pumps dry for more than 30
seconds while checking brushes, to avoid
damaging pumps.
5. Reinstall brush inspection covers and screws.
Reinstall motor cover and screws..
56
3A1706B
Repair
6. Reinstall fan assembly and plates.
7. Test brushes with both pump pins (F)
disconnected. See Fig. 12, page 53.
a. Start engine.
b.
Activate system.
c.
Press circulate
d. Press
6. Remove four screws (273) holding motor (301) to
bracket. Lift motor off unit.
Installation
to enter jog mode.
to start motor.
e. Select J 1 (jog mode). Slowly increase jog
setting to J 6. Inspect brush and commutator
contact area for excessive arcing. Arcs
should not “trail” or circle around commutator
surface. Run motor for 20-30 min at J 6 to
seat brushes.
1. Place motor on unit. Thread motor
cables into conduit as before. See
Electrical Schematics, page 126.
2. Fasten motor with screws (273) until screws
are fully threaded in mounting bracket. Do not
tighten screws until drive housing and pumps are
connected to the motor.
Note
If necessary, loosen screws (273) to
align the motor (301) with side brackets.
Electric Motor
3. Install drive housing and pump assemblies, see
Installation, page 54.
Removal
NOTICE
Be careful not to drop or damage the motor. The
motor is heavy and may require two people to lift.
1. Remove drive housing and pump assemblies.
See Drive Housing, page 52.
2. Disconnect electric motor (301) power cable from
port #13 on the MCM.
3. Remove two screws (299) and motor fan
assembly. Rest the motor fan assembly behind
the motor without straining the fan power cable.
See Fig. 19, page 62.
4. Remove screws (326) and washers (314). Test
brushes with both pump pins (F) disconnected.
See Fig. 13, page 54.
3A1706B
5. Disconnect brushwear/over temperature cable
from port #10 on MCM. Cut tie wraps around
harness to remove cable.
4. Install screws (326) and washers (314). Tighten
screws (273).
5. Route motor (301) power cord from motor
through conduit and connect to port #13 on
MCM. Route brushwear/over temperature cable
up from motor and connect to port #10 on MCM.
Insert cables in conduit and use tie wraps to
secure the conduit together and the pallet.
6. Connect motor fan assembly to motor (301). See
Fig. 19, page 62.
7. Install front bracket.
8. Install drive housing covers and motor cover.
9. Return to service.
57
Repair
Circuit Breaker Module
Ref.
Size
Component
CB01
30 A
High Power Temperature
Control Module (HPTCM)
CB02
20 A
Motor Control Module
(MCM)
1. See Before Beginning Repair, page 42.
CB03
5A
2. Using an ohmmeter, check for continuity across
circuit breaker (left to right). If no continuity, trip
breaker, reset, and retest. If still no continuity,
replace breaker as follows:
Two Motor Fans, Cabinet
Fan, Power Supply, and
Coolant Circulation Pump
CB04
30 A
Auxiliary Power (Air
Compressor)
CB05
10 A
Auxiliary Power
CB06
20 A
Auxiliary Power
a. Refer to Electrical Schematics, page 126,
and tables on next page.
b.
Install new breaker and reconnect wires.
CB07
15 A
E-30i: Auxiliary
CB08
CB07
CB06
CB08
CB05
15 A
E-XP2i and E-30i With
Heat: Low Power
Temperature Control
Module (LPTCM) B
E-30i: Auxiliary
CB04
CB03
E-XP2i and E-30i With
Heat: Low Power
Temperature Control
Module (LPTCM) A
CT01
CB02
CB01
Circuit Breakers
Figure 14
58
3A1706B
Repair
CB20
Circuit Breakers Inside Cabinet
Figure 15
Ref.
Size
Component
CB20
50 A
Heated Hose
CB10
Circuit Breakers Inside Alternator Assembly
Figure 16
3A1706B
Ref.
Size
Component
CB10
90 A
120/240V Alternator
59
Repair
Relays and Fuses
Load Center Relays and Fuses
1. Disconnect the negative lug from the negative
post of the battery. See Battery, page 76.
2. Remove the bad relay or fuse from the load
center (242) and install a new relay or fuse. See
Fig. 17.
3. Connect battery cable. See Battery, page 76.
Relay and Fuse Identification Table
See Load Center Wiring Diagram, page 134.
Repair
Kit
24L958
Ref
Component
K1
Fuel Relay
K2
Starter Relay
K3
Glow Plug Relay
K4
Fan Relay
F3 FAN-ATO - 30A
24M723
F4 PWR-ATO - 20A
Load Center Relay and Fuse Identification
Figure 17
Fuse for load
center relay K4
and radiator fan.
Fuse for load center
relays K1, K2, K3
and their related
components;
Engine Control
Module power;
and coolant valve
control.
Load Center
NOTICE
Before handling board, put on a static conductive
wrist strap to protect against static discharge which
can damage board. Follow instructions provided
with wrist strap.
1. Perform Shutdown, page 45.
2. Disconnect the negative lug from the negative
post of the battery. See Battery, page 76
3. Disconnect all connectors. See
Load Center Wiring Diagram, page 134
4. Remove four bolts (250) and load center (242).
5. Install new load center (242) and
reconnect all connectors. See
Load Center Wiring Diagram, page 134
6. Connect battery cable. See Battery, page 76.
60
3A1706B
Repair
Engine Solenoid Relays
Transducers
1. Perform Shutdown, page 45.
2. Perform Pressure Relief Procedure, page 42.
1. Perform Shutdown, page 45.
2. Disconnect the negative lug from the negative
post of the battery. See Battery, page 76.
3. Remove two bolts (570) and solenoid relay (569).
The starter solenoid relay (CR6) is above the
glow plug solenoid relay (CR7).
4. Disconnect cables from the old relay
and connect to the new relay. See
Load Center Wiring Diagram, page 134.
3. Disconnect transducer cables (455) from #8
and #9 connectors on the MCM. Reverse A
and B connections and check if error code
P6AX or P6BX follows the transducer. See
Error Codes and Troubleshooting, page 13.
4. If transducer fails test, thread cable through top
of cabinet. Note path as cable must be replaced
in same way.
5. Install o-ring (466) on new transducer (455).
6. Install transducer in manifold. Mark end of cable
with tape (red=transducer A, blue=transducer B).
7. Route cable into cabinet and thread into bundle
as before.
8. Connect A side pressure transducer cable
to MCM port #9. Connect B side pressure
transducer cable to MCM port #8.
455
455
466
451
Starter (top) and Glow Plug (bottom) Solenoid Relays
Figure 18
3A1706B
61
Repair
Fans
Proportioner Module Fan
Shutdown system to avoid electric shock. To avoid
burns, do not perform maintenance on the fan until
the system has reached ambient temperature.
1. Perform Shutdown, page 45.
2. Remove cabinet panel (70).
3. See Electrical Schematics, page 126. Using an
ohmmeter, check for continuity across circuit
breaker CB03 (left to right). If no continuity,
trip breaker, reset, and retest. If still no
continuity, replace breaker. For instructions, see
Circuit Breaker Module, page 58.
Motor Fan
4. Remove fan (212).
1. Perform Shutdown, page 45.
2. Remove two screws (299) and front plate (289).
5. Install new fan (212) in reverser order of
disassembly.
3. Remove three screws (299) from back plate
(290).
4. Refer to Electrical Schematics, page 126.
Using an ohmmeter, check for continuity
across circuit breaker CB03 (left to right). If
no continuity, trip breaker, reset, and retest.
If still no continuity, replace breaker. See
Circuit Breaker Module, page 58.
212
5. Remove bolts (251) and fan (212).
6. Install new fan (212) in reverser order.
212
70
251
290
ti18476a
Figure 20
299
299
ti18477a
289
Figure 19
62
3A1706B
Repair
Radiator Fan
Electrical Enclosure Fan
1. Perform Shutdown, page 45.
1. Perform Shutdown, page 45.
2. Remove four screws (605) and disconnect power
cable (PC).
2. Open electrical enclosure door (502). Loosen
four nuts (558) and remove fan (561).
3. Install new fan (605) to radiator bracket (601)
with screws (605).
3. Refer to Electrical Schematics, page 126.
Using an ohmmeter, check for continuity
across circuit breaker (top to bottom). If no
continuity, trip breaker, reset, and retest. If still
no continuity, replace breaker. For instructions,
see Circuit Breaker Module, page 58.
601
4. Install new fan (561) in reverse order of
disassembly so that the fan blows out of the
electrical enclosure.
605
502
607
PC
ti18475a
Figure 21
558
561
ti18479a
Figure 22
3A1706B
63
Repair
Booster Heater
10. Press
Heater Element
on the engine control module.
11. Open air compressor bleed valve to relieve
pressure and remove water from tank.
12. Perform Pressure Relief Procedure, page 42.
13. Wait for heater to cool.
1. Press
to stop the pumps.
2. Turn off heat zones.
3. Flush pump.
4. Press
to park the Component A Pump.
5. Press
to deactivate the system.
6. Turn off the air compressor, air dryer, and
breathing air.
7. Close the main air shutoff valve.
8. Turn main power switch off.
14. Remove heater shroud (271).
15. Disconnect heater element wires from heater
wire connector. Test with ohmmeter.
Total Heater
Wattage
Element
Ohms
4,000
2000
23–26.5
Note
The A-side heater element is located
in the booster heater end nearest the
B-side pump and the B-side heater
element is located near the A-side pump.
16. To remove heater element, first remove RTD
(360) to avoid damage. See step 7, RTD, page 65
17. Remove heater element (357) from housing
(351). Be careful not to spill any fluid left in
housing. See Fig. 23, page 66.
18. Inspect element. It should be relatively smooth
and shiny. If there is a crusted, burnt, ash-like
material adhered to element or sheath shows
pitting marks, replace element.
To prevent electric shock do not remove any
shrouds or open the electrical enclosure door.
240 V is still present in the system until the
engine has stopped.
9. Allow engine dwell time.
NOTICE
Allow engine dwell time, per manufacturer
recommendations, prior to shutdown. Dwell
time will help engine cool down after running at
operating temperature for any period of time.
64
19. Install new heater element (357), holding mixer
(359) so it does not block RTD port (P).
20. Reinstall RTD (360), RTD, page 65.
21. Reconnect heater element leadwires to heater
wire connector.
22. Replace heater shroud (271).
Line Voltage
The heater outputs its rated wattage at 240 VAC.
Low line voltage will reduce power available and the
heater will not perform at full capacity.
3A1706B
Repair
Overtemperature Switch
1. Perform Shutdown, page 45.
2. Wait for booster heater to cool.
3. Remove heater shroud.
4. Open the split loom about 18 in. (457 mm)
away from where the overtemperature switch is
attached to the heater. Verify “J23 TCM-A/B” and
“J23 OVERTEMP-SW” cables are connected. .
See Electrical Schematics, page 126.
5. Disconnect overtemperature switch (358) from
splitter cable. Test across pins 1 and 3 of
connector labeled “J23 OVERTEMP-SW” with
ohmmeter.
6. If switch fails test, remove screws. Discard failed
switch. Apply a thin layer of thermal compound
110009, install new switch in same location on
housing (351), and secure with screws (361).
Reconnect cables.
RTD
1. Perform Shutdown, page 45.
2. Wait for heater to cool.
3. Remove heater shroud.
4. B Side RTD: disconnect RTD cable “TCM-B–2
HT-RTD-B” (360) from B side LPTCM (543). See
Electrical Schematics, page 126.
5. A side RTD:
a. Follow “J24 HT- RTD-A" RTD cable (360) and
open split loom about 18 in. (457.2 mm) away
from the heater attachment. Disconnect “J24
HT- RTD-A" and “J24 TCM-A” connectors.
See Electrical Schematics, page 126.
a. If the resistance is not approximately 0 ohms,
the overtemperature switch needs to be
replaced. Go to step 6.
b.
If the resistance is approximately 0 ohms,
test the splitter cable to ensure it is not cut or
open. Reconnect the overtemperature switch
and splitter. Disconnect the splitter from port
1 on both LPTCMs. Test from pin 1 to 3
at both “TCM-A-1 J23” and “TCM-B-1 J23”.
Resistance should be approximately 0 ohms.
b.
Visually inspect “J24 TCM-A” connector and
replace extension cable (58) if necessary.
Continue to next step if the extension cable
connector is not damaged.
c.
Visually inspect “TCM-A-2 J24” connection
to A side LPTCM. Continue to next step to
replace RTD (360).
Note
The splitter may have failed if one or both
of the readings is above approximately 0
ohms. If the readings is approximately
0 ohms, then there may have been a
bad connector/connection causing the
problem.
3A1706B
65
Repair
6. Loosen ferrule nut (N). Remove RTD (360) from
heater housing (351), then remove RTD housing
(H). Do not remove the adapter (355) unless
necessary. If adapter must be removed, ensure
that mixer (359) is out of the way when replacing
the adapter.
7. Replace RTD (360).
a. Apply PTFE tape and thread sealant to male
threads and tighten RTD housing (H) into
adapter (355).
b.
Push in RTD (360) so tip contacts heater
element (357).
c.
Holding RTD (360) against heater element,
tighten ferrule nut (N) 1/4 turn past tight.
8. Route wires (S) as before through split loom and
reconnect RTD cable (360) to the B side LPTCM
or the A side extension cable (58).
9. Replace heater shroud.
10. 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
element (357).
ti18513a
Figure 23
66
3A1706B
Repair
Heated Hose
FM
Refer to the heated hose manual 309572 for hose
replacement parts.
HA
A
Check Hose Heat Connectors
HB
B
C
1. Perform Shutdown, page 45.
Note
V
Whip hose must be connected.
2. Disconnect hose connector (V) at Reactor, see
Fig. 24.
3. Using an ohmmeter, check between the
connectors (V). There should be continuity.
4. If hose fails test, retest at each length of hose,
including whip hose, until failure is isolated.
Check FTS Cables
1. Perform Shutdown, page 45.
2. Disconnect FTS cable (C) at Reactor.
Heated Hose
Figure 24
3. If the FTS is not reading properly at the end of
the hose, connect FTS directly to RTD cable (C)
at the manifold.
a. If the FTS reads properly at the manifold but
not at the end of the hose, check cable (C)
connections. Verify they are tight.
b.
3A1706B
Bypass one length at a time to isolate the
bad section.
67
Repair
Fluid Temperature Sensor (FTS)
b.
Test/Removal
Disconnect FTS from whip hose (W) and
fluid hoses (A, B).
c.
Remove ground wire (K) from ground screw
on underside of FTS.
1. Perform Shutdown, page 45.
d. Remove FTS probe (H) from component A
(ISO) side of hose.
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, step 3 from Check FTS Cables, page 67.
Installation
4. If FTS fails, replace FTS.
The Fluid Temperature Sensor (FTS) is supplied.
Install FTS between main hose and whip hose. See
Heated Hose manual 309572 for instructions.
a. Disconnect air hoses (C,L) and electrical
connectors (D).
B
D
K
F
W
B
A
L
ti18511a
C
A
Figure 25
68
3A1706B
Repair
Transformer Primary Check
5. Start the generator.
1. See Shutdown, page 45.
2. Locate the two smaller (10 AWG) wires, labeled
1 and 2, coming out of transformer. Trace these
wires back to terminal blocks TB23 and TB24.
Use an ohmmeter to test for continuity between
two wires; there should be continuity.
twice on the engine
Press start button
control module. The controller will automatically
sequence glow plug warming and crank
operations. Allow engine to reach full operating
speed.
Note
Engine will not start if main power switch
is in the on position.
Transformer Secondary Check
6. Turn main power switch on.
1. See Shutdown, page 45.
2. Locate the two larger (6 AWG) wires, labeled 3
and 4, coming out of transformer. Trace these
wires back to circuit breaker CB20 (906). Open
the circuit breaker to turn the color indicator on
the circuit breaker GREEN. Use an ohmmeter to
test for continuity between two transformer wires
in circuit breaker terminals 1 and 3; there should
be continuity.
3. Close the circuit breaker CB20 (906).
7. Press
to turn on hose heat zone.
This equipment is used with heated fluid which
can cause equipment surfaces to become very
hot. To avoid severe burns:
• Do not touch hot fluid or equipment.
• Allow equipment to cool completely before
touching it.
• Wear gloves if fluid temperature exceeds
110°F (43°C).
• Do not turn on hose heat without fluid in
hoses.
ti18544a
Figure 26
4. Confirm main power switch is off before starting
generator.
3A1706B
Thermal expansion can cause
overpressurization, resulting in equipment
rupture and serious injury, including fluid
injection. Do not pressurize system when
preheating hose.
69
Repair
8. To verify voltage on the secondary leads of the
transformer, measure between the terminals 2
and 4 on CB20. This will verify the circuit breaker
is working properly.
Model
Secondary Voltage
310 ft
90 Vac*
210 ft
62 Vac*
* For 240 Vac line voltage.
9. See the Diagnostic Run Screen on the ADM. The
Diagnostic Run Screen displays the incoming
(240 Vac) to the HPTCM (TCM-H) “Hose Voltage”
and the hose current. The diagnostic screen will
show if the circuit breaker has been tripped for
the incoming power to the HPTCM.
Heat Exchangers
1. If a wall is installed between the generator and
the proportioner, remove the proportioner from
the pallet. See Remove Proportioner, page 81.
2. Perform Flushing, page 43.
3. Perform Shutdown, page 45.
4. Perform Drain Coolant, page 46.
5. For proportioner heat exchangers:
a. Remove fuel tank. See Fuel Tank, page 76.
b.
Disconnect both RTD connectors (284). See
Proportioner RTD, page 72.
c.
Disconnect A and B material lines from
swivel fittings (297).
238
37
239
237
249
297
2. Open Reactor cabinet.
ti18490a
Proportioner Heat Exchangers
Figure 27
Replace Transformer
1. Perform Shutdown, page 45.
241
d. Disconnect hose clamps (37, 239) from heat
exchanger assembly (241).
3. Remove bolts holding transformer (226) to
cabinet floor.
e. Remove four nuts (249) and the heat
exchanger assembly (241). Pull heat
exchanger assembly out of coolant hoses.
4. Disconnect the transformer wires. See
Reactor Cabinet Wiring Diagram, page 133
f.
5. Remove transformer (226) from cabinet.
6. Install new transformer (226) in reverse order.
70
Install a new heat exchanger assembly
(241) by following the removal steps in
reverse order. Orient control valves as
shown. Continue to next step to remove heat
exchangers (802) or (803).
3A1706B
Repair
g. Disconnect two swivel fittings (805) and
swivel fittings on heat exchanger outlet (806)
from the heat exchangers (802, 803).
803
802
6. For the engine heat exchanger:
a. Disconnect swivel fittings (617) and (618)
from heat exchanger (614).
b.
Remove nuts (612), washers (613), and heat
exchanger (614). Set expansion bottle and
bracket aside.
c.
Install new heat exchanger (614) in reverse
order by following the removal steps in
reverse order.
811
810
806
805
ti18491a
Proportioner Heat Exchangers
Figure 28
h. Remove four nuts (810) and washers (811)
for replacing heat exchangers (802) or (803).
Engine Heat Exchanger
Figure 29
3A1706B
71
Repair
Proportioner RTD
1. Perform Shutdown, page 45.
2. Remove Reactor cabinet cover.
3. Disconnect RTD from splitter (277).
NOTICE
Chemical will release when either RTD is
removed from the heat exchangers. To prevent
damage to load center and other electronics,
protect all electronics from chemicals released
from the heat exchanger RTD ports.
The RTD probe cannot be removed from the
compression nut.
NOTICE
To ensure accurate temperature readings, only
use RTD Kit 24L972.
5. Tighten compression fitting (283) on RTD sheath
(284).
6. Apply thread sealant to compression fitting pipe
threads (283) and install in heat exchanger.
7. Connect new RTD to splitter (277).
4. Remove compression fitting (283) from the back
of the heat exchanger with RTD (284) attached.
J21-2 HX-RTD-B
J21-1 HX-RTD-A
Figure 30
72
3A1706B
Repair
Control Valve
Power Supply
Follow these instructions to replace a control valve
solenoid coil or remove the component A control
valve, component B control valve, or the bypass
control valve.
1. Perform Shutdown, page 45.
1. Perform Shutdown, page 45.
2. Drain coolant from the proportioner coolant loop.
See Drain Coolant, page 46.
2. Disconnect power supply cables (515)
from HPTCM and terminal blocks. See
Electrical Schematics, page 126.
3. To repair the control valve, remove the four
nuts (VN) and washers (VW). Remove the front
of the control valve, diaphragm, and gaskets.
Purchase Valve Repair Kit 125774. For complete
installation instructions see the Control Valve
Kits manual 3A1932.
3. Remove fan assembly, screws (530), washers
(529), and power supply (515).
4. Install new power supply (515) in reverse order.
4. To remove the solenoid coil (SC), loosen
connector screw and disconnect the coolant
valve harness (D). Remove the nut (SN)
and washer (SW) from coil. Purchase Valve
Coil Replacement Kit 125787. For complete
installation instructions see the Control Valve
Kits manual 3A1932.
Figure 31
3A1706B
24 VDC Power Supply
Figure 32
73
Repair
Circulation Pump
6. Press in tabs to disconnect power wires (W).
7. Remove four outside nuts (254). Hold on to the
pump flanges (234) and remove the circulation
pump (233). Remove four inside nuts (254) to
remove flanges from the pump.
Do not perform maintenance on the coolant system
until the coolant system has reached ambient
temperature.
8. Place o-rings, supplied with the new circulation
pump (233), between the pump and the flange
fittings (234). Insert screws (255) through the
pump and flange fittings (234) and tighten four
nuts on screws (255).
1. Perform Shutdown, page 45.
2. Perform Drain Coolant, page 46.
3. If a wall is installed and the circulation pump can
not be accessed, remove the proportioner. See
Remove Proportioner, page 81.
4. Disconnect pump fittings (234) from swivel fitting
(275).
5. Remove pump cover (C).
254
234
9. Place circulation pump (233) on brackets (223)
so that coolant will flow towards the sight glass.
Install four nuts (254) on screws (255).
10. Connect power wires to pump and replace cover.
See Reactor Cabinet Wiring Diagram, page 133.
11. Connect flange fittings (234) to swivel on the
elbow flange fitting (234) and fitting (275).
233
233
234
C
275
254
275
W
255
Figure 33
74
3A1706B
Repair
Sight Glass and Filter
5. Insert washer (246) and filter (247) in elbow
fitting (248). Connect elbow fitting (248) and
sight glass (245).
Note
To avoid burns, do not perform maintenance on
the coolant system until the coolant system has
reached ambient temperature.
1. Drain the proportioner coolant loop. See
Drain Coolant, page 46.
2. Loosen hose clamp (37) and pull coolant hose
(112) off of elbow fitting (248).
To prevent an air pocket from forming
inside the coolant lines between the
proportioner and generator, ensure there
is a constant rise in elevation. Ensure
elbow fitting is turned 55°. Failure to
have a constant rise in elevation will
reduce heating efficiency.
112
247
37
275
245
245
246
248
Figure 34
3. Remove elbow fitting (248).
4. Pull out filter (247). Inspect washers (246) and
filter. Brush out filter and sight glass (245).
Replace if necessary.
3A1706B
Figure 35
75
Repair
Fuel Tank
Battery
1. Perform Shutdown, page 45 .
2. Disconnect fuel lines (38, 39). Keep elevated or
plug to prevent siphoning.
6. Slide fuel tank on to pallet and secure to pallet.
Reconnect fuel lines (38, 39).
Improper battery installation or maintenance
may result in electric shock, chemical burns,
or explosion. Battery maintenance must only
be performed or supervised by personnel
knowledgeable of batteries and the required
precautions. Keep unauthorized personnel away
from batteries.
7. Squeeze prime bulb (P) to prime engine. Press
the prime bulb repeatedly until fuel begins to
return to the fuel tank.
See Technical Specifications, page 144 for battery
requirements and recommended battery size.
3. Remove screws (24) and clamps (30).
4. Slide the fuel tank off the B side of the pallet.
5. Inspect for any damage.
24
39
P
38
30
1. Remove plastic caps (PC) from battery terminals
and disconnect battery cables from battery.
2. Disconnect strap and remove battery.
3. Place new battery on bracket and secure with
strap.
24
30
4. Reconnect battery cables and cover battery
terminals with plastic caps (PC). Ensure red
cable is connected to the positive (+) battery
post. Connect black cable to the negative (-)
battery post.
PC
ti18485a
Figure 36
Figure 37
76
3A1706B
Repair
Radiator
4. Remove eight screws (605), top bracket (604),
and bottom bracket (606).
NOTICE
Do not damage fins on radiator. Damaged radiator
fins will result in poor radiator performance or
cause a coolant leak.
5. Loosen hose clamps (622) and coolant hose
from radiator (603) inlet and outlet.
6. Carefully swing the bottom of the radiator (603)
away from the engine and lift out of cover (601).
622
1. Drain the engine coolant loop. Follow
Drain Coolant, page 46.
603
2. Remove radiator air exhaust duct, if used.
604
3. Remove screws (17) and back panel (8).
605
606
622
10
601
ti1848aa
Figure 39
7. Inspect radiator for any obstructions. Replace or
have serviced, if necessary.
8
8. Install new radiator assembly in reverse order.
9. Follow Refill Engine Coolant Loop, page 48.
17
ti18480a
Figure 38
3A1706B
77
Repair
Advanced Display Module (ADM)
1.
Loosen screw in bracket (402). Lift up on
bracket (402) and remove ADM (27).
2. Disconnect CAN cable (57).
3. Inspect ADM for damage. Replace if necessary.
Engine Control Module
1. Perform Shutdown, page 45.
2. Remove two top screws (17) and loosen the two
side screws to lower the back panel (28).
3. Disconnect harness “M” and harness
“F” connectors from the back of the
engine control module (428). See
Engine Control Module Wiring Diagram, page 136
4. Loosen engine control module mounting screws
and remove the engine control module (428).
5. Install new engine control module (428) in air
control panel. Secure clips in place and tighten
mounting screws.
6. Connect all wire harnesses and close the back
panel with two screws (17).
428
17
ti18516a
Figure 40
28
ti18484a
Figure 41
78
3A1706B
Repair
Motor Control Module (MCM)
See Fig. 42, page 80.
2. Remove hole plug, screw (551), and washer
(554) from the back side of the electrical
enclosure.
1. Perform Shutdown, page 45.
3. Open electrical enclosure door (502).
2. Remove four screws (73, 74) and two guards
(68).
4. Disconnect all connectors from the HPTCM (542)
inside and outside the power distribution box.
3. Disconnect connectors from MCM (205).
Disconnect two power cables. See
Electrical Schematics, page 126.
5. Remove screw (551) and washer (554) from
mounting bracket (536).
4. Loosen top two bolts (258) and remove five lower
screws (258) and washers (256, 257) . Two
mounting locations use lock tooth washer (282).
5. Lift the MCM (205) out of bracket.
6. Install two screws (258) and washers (256, 257)
in top of new MCM (205).
7. Slide MCM (205) in bracket and allow the MCM
to rest on the top two screws (258).
6. Install new HPTCM module (542). Reassemble
parts in reverse order.
Low Power Temperature Control
Module (LPTCM)
See Fig. 43, page 80.
1. Perform Shutdown, page 45.
8. Install mounting screws (258) and washers (256,
257). Only two mounting locations use lock tooth
washer (282).
2. Open electrical enclosure door (502).
9. Ensure rotary switch is set to proper position for
E-30i or E-XP2i system. 0= E–30i and 1= E-XP2i.
4. Loosen mounting bolts on LPTCM (543) and
disconnect module from base (544).
10. Connect connectors to MCM. See
Electrical Schematics, page 126.
High Power Temperature Control
Module (HPTCM)
3. Disconnect all connectors from the LPTCM (543)
inside and outside the power distribution box.
Note
Loosen nuts (528) to slide the back
electrical panel to the left to remove
module or base mounting bolts.
See Fig. 44, page 80.
5. If the base needs to be replaced, disconnect
CAN cables, remove four mounting screws (458),
and remove ground screw in base (544).
1. Perform Shutdown, page 45.
6. Reassemble parts in reverse order.
3A1706B
79
Repair
258
205
73
554
68
74
68
282
551
502
258
257
256
ti18478a
MCM Repair
Figure 42
542
528
544
458
554
ti18482a
543
551
HPTCM Repair
Figure 44
ti18483a
LPTCM Repair
Figure 43
80
3A1706B
Repair
Remove Proportioner
Only remove the proportioner from the pallet to repair
the heat exchangers or coolant valves between the
proportioner and generator.
112
113
The back of the proportioner could slide off of
the pallet and support brackets during removal
and installation. Never remove the proportioner
from the system pallet alone. Always use two or
more people and supports remove and install the
proportioner from the pallet.
37
T
1. Perform Shutdown, page 45.
2. Drain the proportioner coolant loop. See
Drain Coolant, page 46.
3. Place an empty pallet in front of the proportioner
(23) and center the pallet cross beam with the
proportioner.
ti18487a
Figure 46
5. Cut the cable tie (T) that secures the wire
harnesses behind the A side of the proportioner
(23) to the pallet (1).
6. Disconnect engine wire harness E connectors
(49) from J1 and J2 from the load center (242).
See Load Center Wiring Diagram, page 134. Cut
engine harness cable ties inside the proportioner
cabinet and pull out the backside of the cabinet.
7. Disconnect the engine coolant temperature cable
(59).
Note
ti18486a
The cable connections will be almost
under the fuel tank mounting location. If
necessary, remove fuel tank or access
from other side of wall.
8. If a wall is installed between the proportioner
(23) and generator continue to step 9. See
Fuel Tank, page 76, if the fuel tank (29) is
mounted on the pallet (1).
Figure 45
4. Loosen the coolant clamps (37) and disconnect
the proportioner coolant outlet and inlet coolant
lines (112, 113).
3A1706B
81
Repair
9. Loosen the front two mounting screws (24) and
remove the back two mounting screws (24).
NOTICE
The back of the proportioner could slide off of
the pallet and support brackets during removal
and installation. To prevent damage to the
proportioner, always use two or more people
and supports.
10. Use 6 in. x 6 in. x 11 in. pieces of wood (S1, S2,
S3, and S4) to support the proportioner during
the removal and installation process.
tip the proportioner forward and the other person
center the four supports under both sides of the
proportioner frame.
12. Have one person hold the proportioner in place
and the other remove the two front mounting
screws (24).
NOTICE
Do not strain wire harness between
proportioner and electrical enclosure to prevent
damage to connectors.
13. Carefully slide the proportioner (23) off the pallet
support brackets and on to the wood supports.
Continue to slide the proportioner off the front of
the pallet until there is enough space to service
the backside components.
14. Secure the proportioner frame to the empty pallet
you positioned on the floor with c-clamps.
ti18488a
ti18489a
24
Figure 47
Figure 48
11. Place two supports near both sides of the front of
the proportioner (23) . Have one person carefully
82
3A1706B
Repair
15. The proportioner is ready for servicing.
16. To install the proportioner (23) on the pallet (1),
ensure the wood proportioner frame supports,
inside the proportioner pallet (1), are aligned with
both sides of the proportioner frame.
17. Guide cables behind the proportioner (23) when
sliding the proportioner back to the mounting
position. Secure the proportioner frame to the
pallet with four mounting screws (924). Torque to
40 ft-lbs (54 N•m).
18. Route the engine wire harness E connectors (49)
through the back of the proportioner (23) and
connect wire harness connectors to J1 and J2
connectors on the load center (242). Reconnect
engine coolant temperature cable (59).
632
619
19. Secure all harnesses to pallet and inside cabinet
with cable ties.
Engine
Contact your nearest Perkins distributor for repair
and maintenance.
ti18545a
Figure 49
Engine RTD
30
5
1. Perform Shutdown, page 45.
2. Drain the engine coolant loop. See
Drain Coolant, page 46.
3. Disconnect RTD cable (632) from extension
cable (59).
4. Remove compression fitting (619) and RTD (632)
from the fitting. The RTD probe (632) cannot be
removed from the compression nut (619).
5. Apply anaerobic sealant to compression fitting
threads (619) and install in fitting at a 30° angle.
ti18546a
Note
To prevent poor heating performance,
use RTD Kit 24L974.
Figure 50
6. Connect new RTD cable (632) to extension cable
(59).
12V Charge Alternator
7. Refill the engine coolant loop. See
Refill Engine Coolant Loop, page 48.
Contact your nearest Perkins distributor for repair
and maintenance.
3A1706B
83
Parts
Parts
Systems
259079, E-30i
259080. E-30i with Booster Heat
259081, E-XP2i with Booster Heat
For systems with an air compressor, see 259089, 259090, and 259091, page 92.
ti18533a
84
3A1706B
Parts
3A1706B
85
Parts
40
17
8
83
17
9
85
17
21
84
107
5
17
106
45
50
ti18535a
107
110
109
111
81
108
47
90
201
86
45
48
3A1706B
Parts
81
38
38
38
3
Apply anaerobic sealant to all non-swiveling pipe
threads.
Apply lubrication to all push—on hoses prior to
assembly.
4
Torque to 25 ft-lbs (33.8 N●m).
5
Torque to 40 ft-lbs (54 N●m).
6
Torque to 15–20 in.-lbs (1.7–2 N●m).
2
3A1706B
7
9
10
Torque to 25 in-lbs (2.8 N●m).
Safety and warning labels are from label sheet
(55).
Bundle fuel lines above engine, inside flexible
plastic split conduit, with cable ties (81) to avoid
direct contact.
87
Parts
Quantity
Ref
Part
Description
1
24J658
2
—
259079
259080
259081
BASE, pallet
1
1
1
GENERATOR, diesel, 22kw, see
22kW Diesel Generator, page 116
1
1
1
3
16H732
SUPPORT, generator
1
1
1
4
24L953
KIT, isolator (4 pack)
1
1
1
5
111192
SCREW, cap flange hd; 0.875 in. (22 mm), 3/8–16
22
22
22
6
105324
SCREW, cap, hex hd; 1.2 in (30 mm), M12 x 1.75
4
4
4
8
16H898
GUARD, engine, right
1
1
1
9
16H894
GUARD, engine, left
1
1
1
16
115942
NUT, hex, flange head; 1/4–20
4
4
4
17
113161
SCREW, flanged, hex hd; 0.5 in. (13 mm), 1/4–20
34
34
34
21
125625
TIE, cable, fir tree
5
5
5
—
PROPORTIONER, E–30i, (230v, 1ph), see
Proportioners, page 96
1
—
PROPORTIONER, E–30i, (4.0kw, 230v, 1ph), see
Proportioners, page 96
—
PROPORTIONER, E-xp2i, (4.0kw, 230v, 1ph), see
Proportioners, page 96
23
1
1
24
125626
SCREW, hex hd, flanged; 3 in. (76 mm), 3/8–16
6
6
6
25
16H456
BRACKET, mounting
1
1
1
1
1
26
—
ENCLOSURE, electrical, heat, see
Electrical Enclosure, page 113
—
ENCLOSURE, electrical, non-heat, see
Electrical Enclosure, page 113
1
27
24L948
MODULE, ADM
1
1
1
28
16H880
COVER, air panel
1
1
1
29
24K390
TANK, fuel, see Fuel Tank, page 123
1
1
1
30
16J889
BRACKET, support, fuel tank
2
2
2
88
3A1706B
Parts
Quantity
Ref
Part
Description
259079
259080
259081
31
24J690
SUPPORT, battery
1
1
1
32
125166
TRAY, battery
1
1
1
33
15D256
SCREW, cap, socket hd; 0.75 in. (19 mm), #10–24
4
4
4
34✖
24M174
STICKS, level, A and B side, 55 gal. (208 l)
1
1
1
35
16K214
HOLDER, cable, tie
4
4
4
36
16N585
HOSE, FUEL, 5/16 in., 0.33 ft (0.1 m)
1
1
1
37
125370
CLAMP, hose, dia. 11/16-1-1/2 in.
4
4
4
38
16N584
HOSE, FUEL, 5/16 in., 3 ft (1 m)
1
1
1
39
16N583
HOSE, fuel, 3/16 in.; 4 ft (1.2 m)
1
1
1
40
125163
CLAMP, hose, 7/32 in.-5/8 in.
6
6
6
43✖
206995
FLUID, TSL™, 1 qt.
2
2
2
44✖
106569
TAPE, electrical
1
1
1
45
100639
WASHER, lock
3
3
3
CABLE, battery, 30 in. (762 mm), red
1
1
1
CABLE, battery, 30 in. (762 mm), black
1
1
1
47

—
48

—
49
16K301
HARNESS E, DC, diesel, engine
1
1
1
50
125751
CABLE, grounding, braided, engine
1
1
1
51
125752
HARNESS M, AC, sense, genset control
1
1
1
52
125753
CABLE, AC, power, 240v alternator
1
1
1
53
16K299
HARNESS H, DC, disconnect check
1
1
1
54
125756
HARNESS N, AC, power, reactor cart
1
1
1
55▲
16K939
LABEL, identification
1
1
1
56
16K398
SHIELD, motor, E-30i
1
1
1
57
121002
CABLE, CAN, female / female, 5 ft (1.5 m)
1
1
1
58
125358
CABLE, M8, 4-pin, mf, 1.6 ft (0.5 m), molded
1
1
59
122837
CABLE, M8, 4-pin, mf, 9.8 ft (3 m), molded
2
2
2
60
123652
CABLE, CAN, male / female, 11.4 ft (3.5 m)
1
1
1
61
115492
SCREW, slot hex wash hd; 0.375 in. (9.5 mm), 8–32
8
8
8
62
125762
CABLE, volex, 16 AWG, male, 76 in. (1930 mm)
2
2
65
16K362
FOAM, support block
2
2
3A1706B
2
89
Parts
Quantity
Ref
Part
Description
259079
259080
259081
66
16K363
SPACER, fuel tank
2
2
2
67
16H910
GASKET, radiator isolation
1
1
1
68
16K765
GUARD, MCM cables
2
2
2
70
246976
COVER, assembly (main cabinet)
1
1
1
71✖
24K207
KIT, FTS, RTD, single hose; see heated hose manual
1
1
1
72
125760
HARNESS, splitter, parallel, M8-3
1
1
76
16M127
LABEL, integrated reactor, E-30i
76
16M128
LABEL, integrated reactor, E-XP2i
77
193546
COVER, drive
2
2
2
78
114818
SCREW, self-tap, fil hd; 1.25 in. (31.75 mm), 8–32
8
8
8
79
16M207
COVER, electrical, side, panel
1
1
1
81✖
125871
TIE, cable, 7.50 in.
33
33
33
83
16M317
GUARD, engine, top
1
1
1
84
16M319
GUARD, alternator, mount
1
1
1
85
16M321
GUARD, alternator, plate
1
1
1
87✖
16K761
INSTRUCTIONS, startup; not shown
1
1
1
88✖
16K913
INSTRUCTIONS, shutdown; not shown
1
1
1
89▲
15G280
LABEL, warning
1
1
1
90
24L964
HARNESS, DC, link, fusible
1
1
1
91
125754
CABLE, AC, alternator breaker, black
1
1
1
92
125755
CABLE, AC, alternator breaker, red
1
1
1
93
125822
CABLE, AC, alternator, neutral to ground
1
1
1
94
16K297
HARNESS F, DC, genset controller
1
1
1
95✖
16M399
LABEL, cable, self-laminate, top level
1
1
1
90
1
1
1
3A1706B
Parts
Quantity
Ref
Part
Description
259079
259080
259081
96✖
552069
LABEL, metallized
2
2
2
98
120448
SUPPRESSOR, box snap, ferrite
1
1
1
99
125835
CLIP, ferrite bead
3
3
3
100 125839
CLIP, ferrite bead
1
1
1
102
109124
HOSE, coupled, 48 in. (1219.2 mm), 1/4–18 NPT
1
1
1
103
169967
FITTING, line air; 1/4–18 NPT
4
4
4
104
15V551
SHIELD, membrane, ADM (10 pack)
1
1
1
106
105329
NUT, hex; M8 x 1.25
2
2
2
107
114816
NUT, hex; M6 x 1
3
3
3
108
100186
WASHER, lock, internal tooth
1
1
1
109
15V909
SCREW,1/2 in. (12 mm), M8 x 1.25
1
1
1
110
110911
NUT, hex; M5 x 0.8
1
1
1
111
126054
INSULATOR, cap
1
1
1
112 16N577
HOSE, coolant, 1 in. ID, 2.66 ft (0.81 m)
1
1
1
113 16N578
HOSE, coolant, 1 in. ID, 2.92 ft (0.89 m)
1
1
1
▲ Replacement Warning labels, signs, tags, and
cards are available at no cost.
 See Electrical Schematics, page 126.
 Included in Battery Cable Kit 24L962.
3A1706B
 Included in Complete Coolant Hose Kit 24L939.
See Complete Coolant Hose Kit, page 105 .
✖ Not shown.
91
Parts
259089, E-30i with Air Compressor
259090. E-30i with Booster Heat and Air Compressor
259091, E-XP2i with Booster Heat and Air Compressor
1037
1007
1041
1028
1044 1010
1029
1013
1010
1003
1008
1035
1032
1045
1046
1011
1009
1002
ti18541a
1035
1034
1002
1001
1010
1005
1009
1009
1010
11
1011
Apply anaerobic sealant to all non-swivel pipe threads.
92
3A1706B
Parts
1004a
1004b
1004
1041
1012
1039
1033
1024
1006
1011
1038
1015
1017
1040
1030
1038
1015 1016 1031
1017
1015
ti18542a
1026
Apply anaerobic sealant to all non-swivel pipe threads.
3A1706B
93
Parts
1036
25 in. (635 mm)
24
1024
1036
48 in.
(1219 mm)
36
9 in. (228.6 mm)
ti18626a
1023
1036 48 in.
(1219 mm)
94
3A1706B
Parts
Quantity
Ref
Part
1014* 259079
Description
259089
Reactor, E-30i
259080
Reactor, E-30i with heat
259081
Reactor, E-XP2i with heat
259090
259091
1
1
1
For parts, see 259079, 259080, and 259081, page 84.
*
Air Compressor Parts
All air compressor parts are included in the Air Compressor Accessory Kit. See Accessories, page 11.
Part
Ref
Description
Part
Description
Qty
1
1029 109570
STRAIGHT, nipple, hex.
3/8
SCREW, cap, hex hd; 1.18
in. (30 mm), M12 x 1.75
WASHER, plain
1030 16N177
BULKHEAD, brass, 3/8
1
1
1031 115671
1
1
1032* 111218
CONNECTOR, male; 1/4
OD x 1/8 NPT 9(f)
CAP, tube, square
Qty
Ref
1026 297436
1001* 24M147
RACK, compressor, rear
1
1002* 24M146
RACK, compressor, front
1
1003* 24M145
RACK, compressor, top
1
1004 24M125
TANK, ASM, 12 gal, air
receiver (includes 1004a
and 1004b)
VALVE, safety relief, 200
psi (1.4 MPa, 14 bar)
VALVE, check, 1/2 m x f
1
GUSSET, compressor,
support, side
BRACKET, air tank/dryer
1
1033 24M636
1
1034 16M827
1004a 125967
1004b 16N185
1005* 16K133
1006* 24M150
1007 125970
COMPRESSOR, air, 5 HP
1
1008 24L953
KIT, isolator (4 pack)
1
1009* 121488
SCREW, hex hd, flanged;
2.75 in. (70 mm), 3/8–16
SCREW, cap flange hd;
.875 in. (22 mm), 3/8–16
NUT, hex, flanged; 3/8–16
28
1010* 111192
1011* 112958
1012 112785
15
39
4
1016 125991
SCREW, hex hd, flanged;
1.5 in. (38 mm), 3/8–16
ADAPTER, elbow, 3/4–14
NPTF X 1/–142 NPSM
PROPORTIONER, see
table for part number
CONNECTOR, male, 1/4
NPT (f)
VALVE, drain, automatic
1
1017 15B565
VALVE, ball
2
1023 214656
HOSE, coupled, 61209,10
ft (3 m)
HOSE, coupled; 1/2–14
NPT
1
1013 120375
1014
—
1015 125428
1024 218093
*
1
1028 105324
2
4
4
SYSTEM, desiccant air
dryer; see manual 309921
HARNESS, wire, 3 pole,
8/3
CORD, grip, 3/4 in.
1
KIT, tube, nylon, rd; 1/4 in.
OD, 16 ft (4.8 m)
1037 16M960 NUT, compression, with
sleeve; 1/4 OD
1038 126017 BOLT, U, 1/2-13, 4 OD
pipe
1039 113796 SCREW, flanged, hex hd
1
1035 16M826
1036 24M675
1
2
1
1
2
1040 115942
NUT, hex, flange head
1041 114109
ELBOW, male, swivel
2
SCREW, cap, flange hd;
1.25 in. (31.75 mm),
1/2–13
NUT, hex, flanged; 1/2–13
4
PLATE, compressor,
adapter
FITTING, bushing adapter,
3/8–18 NPT (m) x 1/4–18
NPT (f)
FITTING, tee, male
branch, 1/4–18 NPT
2
1044*111195
3
4
1045*112731
1046*16N165
1047 126109
1048 126110
2
2
1
1
Included in Compressor Frame Kit 24M258.
 Parts for adapting to the mounting feet of the optional Quincy PTL5–5B air compressor.
3A1706B
95
Parts
Proportioners
E-30i
E–30i with Booster Heat
E-XP2i with Booster Heat
218
201
219
240
272
206
206
262
265
224
253
203
220
272
232
273
221
215
225
263
219
264
223
228
266
222
ti18404a
218
299
265
270
96
3A1706B
Parts
258
257
256
217
205
296
249
204
294
244
257
258
254
256
273
282
280
280
296
297 295
227
233
273
234
285
286
238
239
255
241
241
247
249
235
237
ti18406a
285 275 245
3A1706B
246
246
248
97
Parts
271
273
272
269
273
266
272
267
268
265
ti18405a
98
3A1706B
Parts
292
302
287
212
251
291
290
293
273
288
202
299
299
300
215
209
299
208
292
289
210
273
249
ti18407a
3A1706B
99
Parts
285
274
211
285
212
251
208
209
250
250
284
226
214
283
273
ti18408a
242
250
1
2
3
100
Apply anaerobic polyacrylate pipe sealant to all
non-swiveling pipe threads.
Apply grease to tube fitting threads. Torque to
43 ft-lbs (58 N•m).
Safety and warning labels are from label sheet
(279).
3A1706B
Parts
Quantity
Ref
Part
—
201
E-30i
E–30i
with
Booster
Heat
E-XP2i
with
Booster
Heat
FRAME
1
1
1
Description
202
16H758
SUPPORT, motor
1
1
1
203
24K382
MANIFOLD, fluid; see Fluid Manifold, page 112
1
1
1
204
24J710
BRACKET, MCM
1
1
1
205
24L949
KIT, module, MCM
1
1
1
206
24L934
KIT, assembly, pair, inlet; see Fluid Inlet Kit, page 125
1
1
1
208
15H189
BOOT, wire feed through
2
2
2
209
15G816
COVER, plate, wire way
2
2
2
210
15B456
GASKET, manifold
1
1
1
211
15B360
GASKET, fan
1
1
1
212
115834
FAN, cooling
2
2
2
214
16J758
COVER, heat exchanger
1
1
1
215
16K357
STRAP, motor
2
2
2
217
112125
PLUG, tube
2
2
2
218
116746
FITTING, barbed, plated; 1/4 hose ID, 1–8–27 NPT
2
2
2
219
191892
FITTING, elbow, street, 90°, 1/8 NPT
2
2
2
220
117502
FITTING, reducer #5 JIC x #8 JIC
1
1
1
221
117677
FITTING, reducer #6 JIC x #10 JIC
1
1
1
222
297216
BRACKET, reservoir, lube
1
1
1
223
258707
RESERVOIR, bottle, assembly
1
1
1
224
205447
COUPLING, hose
2
2
2
TUBE, PTFE
6
6
6
—
225
226
15K742
TRANSFORMER, 4090 VA, 230/90 VAC
1
1
1
227
16H761
BRACKET, mounting, pump
2
2
2
228
186494
CLIP, spring
7
7
7
230
255716
KIT, heater wire connector
1
1
232
261821
CONNECTOR, wire, 6 AWG
1
1
1
233
24L915
KIT, pump, centrifugal, circulation
1
1
1
234
24J699
KIT, fitting, pump
1
1
1
235
24K286
KIT, fitting, drain
1
1
1
3A1706B
101
Parts
Quantity
E-30i
E–30i
with
Booster
Heat
E-XP2i
with
Booster
Heat
HOSE, coolant, 1 in. ID, 4 in. (101.6 mm)
1
1
1
125170
HOSE, formed, 1 in. ID lower
1
1
1
125371
CLAMP, hose, dia. 3/4–1–3/4 in.
4
4
4
—
PANEL, air control; see Air Control Panel, page 110
1
1
1
—
EXCHANGER, heat, assembly; see
Heat Exchanger Assembly, page 124
1
1
1
242★ 24L957
KIT, load center
1
1
1
243
125871
TIE, cable, 7.5 in. (190.5 mm)
4
4
4
244
16N582
HOSE, rubber, 5/16 in., 2 ft (0.6 m)
1
1
1
245

—
1
1
1
246

—
2
2
2
247

—
1
1
1
Ref
Part
Description
237
16N576
238
239
240
241
INDICATOR, flow, sight
WASHER, plain
STRAINER
248
125477
FITTING, 1 in. beaded barb x 3/4–14 NPT(m)
1
1
1
249
112958
NUT, hex, flanged, 3/8–16
16
16
16
250
113505
NUT, keps, hex hd
14
14
14
251
125858
SCREW, serrated flange, 2 in. (51 mm), 6–32
8
8
8
253
111800
SCREW, cap, hex hd, 0.625 in. (16 mm), 5/16–18
4
4
4
254
125943
NUT, serrated flange, hex hd, 7/16–14
8
8
8
255
125944
SCREW, serrated flanged, hex hd, 2.25 in. (57 mm),
7/16–14
4
4
4
256
110755
WASHER, plain
7
7
7
257
100016
WASHER, lock
7
7
7
258
121112
SCREW, cap, socket head, 0.625 in. (16 mm), 1/4–20
7
7
7
262
24L924
PROPORTIONER, module, E–30i; see
Proportioner Module, page 106
1
1
24L925
PROPORTIONER, module, E-XP2i; see
Proportioner Module, page 106
102
1
3A1706B
Parts
Quantity
Ref
Part
263–1

—
263–3

—
264–2

—
264–4

—
265
Description
KIT, A-side, inlet, E–30i
E-30i
E–30i
with
Booster
Heat
1
1
KIT, A-side, inlet, E-XP2i
KIT, B-side, inlet, E–30i
1
1
1
KIT, B-side, inlet, E-XP2i
16K227
TUBE, A-side, outlet
16K224
TUBE, A-side, outlet
16K229
TUBE, B-side, outlet
16K225
TUBE, B-side, outlet
267
16K226
268
E-XP2i
with
Booster
Heat
1
1
1
1
1
TUBE, A-side, inlet
1
1
16K228
TUBE, B-side, inlet
1
1
269
24L936
HEATER, assy, 4.0kw, hybrid, 2 zone; see
Dual Zone 4.0 Kw Fluid Heater, page 108
1
1
270
104765
PLUG, pipe headless
2
2
271
16K361
COVER, horizontal heater
1
1
272
121311
FITTING, connector, 3/8–18 NPT x #8 JIC
125643
FITTING, elbow, 3/8 NPT x #8 JIC
2
2
273
113796
SCREW, flanged, hex hd, 0.75 in. (19 mm), 1/4–20
22
24
24
274
24J721
MODULE, fan/transformer breaker
1
1
1
275
157785
FITTING, swivel, 3/4–14 NPS x 3/4–14 NPT
1
1
1
277+
125806
CABLE, splitter, M8, 4-pin, ffm 1.5m
1
1
1
278+
123656
CABLE, 5 pin, male/female
1
1
1
279
▲
16K894
LABEL, identification
1
1
1
280+
16K646
HARNESS, DC, valve, coolant
1
1
1
281+
16M660
LABEL, cable
1
1
1
282
558685
WASHER, 1/4 external tooth lock
2
2
2
2
2
2
2
2
2
266
283

—
284

—
3A1706B
FITTING, compression, 1/8 NPT, sst
SENSOR, RTD, 1 kohm, 4pin, 4.25in
1
1
2
2
103
Parts
Quantity
E-30i
E–30i
with
Booster
Heat
E-XP2i
with
Booster
Heat
TIE, cable, fir tree
7
7
7
24L916
VALVE, solenoid, 3/4 NPT, 12 VDC
1
1
1
287
121172
GRIP, cord, .39-.56, 1/2
2
2
2
288
16K385
SHIELD, airflow, side
1
1
1
289
16K386
SHIELD, airflow, front
1
1
1
290
16K387
SHIELD, airflow, back
1
1
1
291
16K388
COVER, back fan
1
1
1
292
16K390
FOAM, airflow shield, border
1
1
1
293
115492
SCREW, mach, slot hex washer hd, 0.375 in. (9.5
mm), 8–32
2
2
2
294
16K312
HOSE, coupled, 26 in. (660 mm), 3/4–14 NPT
2
2
2
295

16K311
HOSE, coupled, 18 in. (457 mm), 3/4–14 NPT
2
2
2
296
156589
FITTING, union, adapter, 90°
4
4
4
297

125535
FITTING, #12 JIC swivel x 3/4 NPT(m)
2
2
2
299
125856
SCREW, 8-32, serrated flange
11
11
11
300
125857
SCREW, 10-24, serrated flange
2
2
2
Ref
Part
Description
285
125625
286
▲ Replacement Warning labels, signs, tags, and
cards are available at no cost.
★ Includes four 30 Amp 12 vdc relays. Purchase
Relay Repair Kit 24L958. Includes two fuses.
Purchase Fuse Repair Kit 24L959.
* Order 125774 Valve Repair Kit to replace all
internal valve parts. Order 125787 Coil Repair
Kit to replace coil.
 Included in RTD Repair Kit 24L972.
104
 Included in Sight Glass Kit 24L921.
 Included in Five Pack Repair Kit 24L922.
 Included in Complete Coolant Hose Kit 24L939.
See Complete Coolant Hose Kit, page 105
 Included in Pump Inlet Assembly Kit. See
Pump Inlet Assembly Kits, page 105.
+ See Electrical Schematics, page 126.
3A1706B
Parts
Pump Inlet Assembly Kits
Description
Kit
Includes:
E-30i A Side
24L926
263–1
295
297
E-30i B Side
24L927
263–3
295
297
E-XP2i A Side
24L928
263–2
295
297
E-XP2i B Side
24L929
263–4
295
297
1
1
1
Qty:
Complete Coolant Hose Kit, 24L939
Ref
Description
Qty.
Systems, page 84
112
HOSE, coolant, 1 in. ID, 2.66 ft (0.81 m)
1
113
HOSE, coolant, 1 in. ID, 2.92 ft (0.89 m)
1
Proportioners, page 96
244
HOSE, rubber, 5/16 in., 1 ft (0.3 m)
1
298
HOSE, coolant, 1 in. ID, 0.33 ft (.1 m)
1
22 kW Diesel Generator, page 116
562
CLAMP, hose, dia. 3/4–1–3/4 in.
1
Radiator, page 118
620
HOSE, formed, 1–1/4 upper radiator
1
621
HOSE, coolant, 1 in. ID; 6 in. (152.4 mm)
1
622
CLAMP, hose, dia. 3/4–1–3/4 in.
4
623
CLAMP, hose, dia. 11/16–1–1/2 in.
2
627
HOSE, formed, 1–1/4 lower radiator
1
640
HOSE, formed, 1–1/4 upper engine
1
641
CLAMP, hose 7/32 in. - 5/8in.
4
642
HOSE, formed, 1–1/4 lower engine
1
3A1706B
105
Parts
Proportioner Module
24L924, Module for E-30i
24L925, Module for EXP2i
314
319
321
301
322
318
305
311
308
304
327
314
310
315
316
330
302
320
313
328
308
314
312
303
307
326
331
316
306
1
2
Flat side faces up.
Lubricate threads with ISO oil or grease. Assemble pump cylinders flush to one full thread under-flush of
housing surface.
3
Torque to 115–135 in-lbs (13–15 N•m).
4
Torque to 20–30 ft-lbs (27–40.6 N•m).
5
Crankshaft must be in line with crankshaft at other end of motor.
6
Torque to 70–80 ft-lbs (95–108 N•m).
106
3A1706B
Parts
Quantity
Ref
Part
Description
24L924
24L925
301
24L923
MOTOR, electric
1
1
302
245969
HOUSING, drive
2
2
303
240724
HOUSING, bearing
245795
HOUSING, bearing
2
304
243951
GEAR, combination
2
2
305
241278
ROD, connecting
2
2
306
245971
PUMP, displacement, B
245972
PUMP, displacement, B
1
307
114699
WASHER, thrust (steel)
2
2
308
114672
WASHER, thrust (copper)
4
4
310
183169
SPRING, retaining
2
2
311
183210
PIN
2
2
312
114686
SCREW, cap, socket hd; 5/16–18 x 3–1/4 in. (83 mm)
4
4
313
114666
SCREW, cap, socket hd; 3/8–16 x 2–1/4 in. (57 mm)
8
8
314
104008
WASHER, lock, spring
12
12
315
106115
WASHER, lock (hi-collar)
8
8
316
193031
NUT, retaining
193394
NUT, retaining
2
318
116192
WASHER, thrust
2
2
319
101864
SCREW, cap, socket hd; 5/16–18 x 1 in. (25 mm)
4
4
320
116618
MAGNET
1
1
321
125757
SWITCH, reed, M8-4pin cable
1
1
322
116838
PIN, spring
2
2
326
102962
SCREW, cap socket hd; 5/16–18 x 1–1/4 in. (31 mm)
4
4
327
104765
PLUG, pipe headless
2
2
328
246831
PUMP, displacement, A
246832
PUMP, displacement, A
329
15C588
GUARD, finger; not shown
330▲
192840
LABEL, warning
2
2
331
187437
LABEL, torque
2
2
2
1
2
1
1
1
▲ Replacement Danger and Warning labels, tags, and cards are available at no cost.
3A1706B
107
Parts
Dual Zone 4.0 Kw Fluid Heater
24L936
351
359
362
357
368
369
358
372
366
370
371
361
353
356
353
352
354
360
1
Torque to 120 ft-lbs (163 N•m).
2
Torque to 23 ft-lbs (31 N•m).
3
Apply thermal paste.
4
Apply pipe sealant and PTFE tape to all non-swiveling threads and threads without o-rings.
5
Apply lithium grease lubricant to o-rings before assembling in block (1).
6
108
ti18170a
355
Remove tape from probe tip and Orientate sensor as shown. Insert probe until it bottoms on heating element.
Tighten ferrule on sensor probe 1/4 turn past finger tight.
3A1706B
Parts
24L936
Ref
Part
Description
Qty
351
15M878
BLOCK, horizontal
352
15H302
REDUCER, #14 SAE x 1/2–14 NPT(f)
1
353
121319
ADAPTER, 1/2–14 NPT x #8 JIC
354
15H304
PLUG, 9/16 SAE
355
15H306
ADAPTER, thermocouple, 9/16–18 x 1/8–27 NPT(f)
356
120336
O-RING, packing
357
16A111
HEATER, immersion, (2000W,230V)
358
123408
HARNESS, M8 x thermal switch, 3-PIN
359
15B135
360* -
MIXER, immersion heater
361
124131
SCREW, machined, pan hd, 0.375 in. (9.5 mm), #6–32
362
15M177
INSULATOR, foam, heater, horizontal
366
158683
ELBOW, 90°, 1/2–14 NPT x 1/2–14 NPT
368
124132
O-RING, fluoroelastomer
369
SENSOR, RTD, 1 kohm, 90 deg, 4 pin, tip
15H305
370* -
COMPRESSION, 1/8 NPT, SST
371
125644
BRANCH TEE, 1/2 NPT
372
248177
HOUSING, rupture, disc
*
PLUG, hollow hex 1-3/16 SAE
4
4
2
2
2
2
1
2
2
2
1
2
4
2
2
2
2
Included in 24L973 Heater RTD Repair Kit.
3A1706B
109
Parts
Air Control Panel
417
415
428
426
418
410
432
419
421
401
427
422
402
412
429
415
403
413
409
410
0
424-5
420
416
424-7 424-6
424-3
424-2
412
404
407
405
406
408
411
ti18341a
423
424-8
424-1
424-4
110
3A1706B
Parts
2
Apply pipe sealant to all non-swiveling pipe
threads.
Apply anaerobic pipe sealant to threads.
3
Torque to 25 +/- 2 ft-lbs (34 N●m)
1
4
Torque to 10 +/- 2 ft-lbs (14 N●m)
5
See parts illustration for air flow direction.
Ref
Part
Description
Qty
Ref
Part
Description
Qty
401
16H452
BRACKET, air control
1
415
116257
3
402
277853
1
416
116513
3
403
117026
417
116514
NUT, regulator, plastic
3
404
113331
418
104641
190451
419
156971
406
158491
BULKHEAD, 1 in. (25.4
mm), 3/4–20 x 1/4–18 NPT
NIPPLE, short, 1/4–18
NPT
UNION, Y, 3/8 OD tubing
4
405
BRACKET, mounting,
booth control
SCREW, SHCS, 0.5 in.
(12 mm), M5 x 0.8
VALVE, ball, vented, 1/2
in.
UNION, adapter, 1/2 NPT
x 1/2 NPSM
NIPPLE, 1/2–14 NPT
GAUGE, pressure, 0–160
psi (0–1 MPa, 0–11 bar)
REGULATOR, air
407
155470
408
16H482
409
113796
410
122161
411
198171
412
115841
413
15T498
▲
★
SWIVEL, union, 90°,
1/2–14 NPSM x 1/2–14
NPT
MANIFOLD, 1/2 NPT x 1/4
NPT
SCREW, flanged, hex hd,
0.75 in. (19 mm), 1/4–20
FITTING, air, 1/4 NPT x
3/8 OD
FITTING, elbow, 1/8 NPT
x 5/32 OD
FITTING, elbow, 1/4
NPT(f) x 3/8 OD
FITTING, 90°, swivel, 5/32
OD x 1/8 NPT(f)
2
1
1
1
1
1
4
7
3
6
3
420
125539
421
114558
422
16H531
423
★
424
★
426
427
—
COUPLER, line, air,
1/4–18 NPT
FITTING, flow control,
1/4–18 NPT
TUBE, nylon, round, black
4
1
4
1
1
9
16K325
HOSE, nylon, 250 psi; see
identification table
LABEL, instructions
1
16K326
LABEL, instructions
1
428
24M665
1
429
125625
MODULE, engine
controller
TIE, cable, fir tree
2
LABEL, safety
1
—
432▲ 16K940
Replacement Warning labels, signs, tags, and cards are available at no cost.
Included in Tubing Repair Kit 24M650.
424 Identification Table
Ref
Length
in. (mm)
Qty.
424–1 11 (279.4)
1
424–2 13.5 (342.9)
1
424–3 16.5 (419.1)
1
424–4 16 (406.4)
1
424–5 16.5 (419.1)
1
424–6 15 (381)
1
424–7 6.5 (165.1)
1
424–8 5.5 (139.7)
1
423
3
4 (101.6)
3A1706B
111
Parts
Fluid Manifold
24K382
458
456
457
468
453
452
464
455
467
468
1
455
465
466
454
1
452
462
451
463
1
Torque to 355–395 in.-lbs (40–44.6 N●m)
2
Apply sealant (113500) to threads.
464
454
465
3
**
Valve must be closed with handle position as
shown on drawing.
Apply PTFE tape or thread sealant to tapered
threads.
Ref
Part
Description
Qty
Ref
Part
Description
451
255228
MANIFOLD, fluid
1
464
121309
2
452★ 255071
VALVE, drain valve
2
452a★158674
O-RING, BUNA-N
1
465
100840
452b★247779
SEAL, seat, valve
1
466
111457
ADAPTER, #8 SAE x #8
JIC
ELBOW, street, 1/4–18
NPT
O-RING, PTFE
453
102814
GAUGE, press, fluid
2
467▲ 189285
LABEL, caution
1
454
162453
2
468
SPRING, compression
2
455
15M669
2
▲
456
15J915
FITTING, 1/4 NPSM X 1/4
NPT
SENSOR, pressure, fluid
outlet
HANDLE, red
1
★
457
15J916
HANDLE, blue
1
458
112309
NUT, hex, jam
2
462
117556
NIPPLE, #8 JIC x 1/2 NPT
1
463
117557
NIPPLE, #10 JIC x 1/2
NPT
1
112
150829
Qty
2
2
Replacement Warning labels, signs, tags,
and cards are available at no cost.
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.
3A1706B
Parts
Electrical Enclosure
Electrical Enclosure with Heat
Electrical Enclosure without Heat
551
517
551 564 562
556 501
544
554
550
541
529
527
530
526
566
555
528
516
565
531
502
551
558
532
506b
512
561
554
525
503
519
510
551
509
514
504
506c
566
506a
553
547
573
552
537
567
506d
3A1706B
508
543
542
529 546
536
549
522
515
113
Parts
Electrical Enclosure with Heat
Electrical Enclosure without Heat
Quantity
With
Heat
Without
Heat
Ref
Part
Description
501
257155
ENCLOSURE, medium
1
1
502
16H766
DOOR, enclosure, electric
1
1
503
16K893
HANDLE, selector, on/off
1
1
504
122315
LATCH, quarter turn
2
2
506
15V932
GASKET, hphm (includes 506a-506d)
1
1
507
15X754
BRACKET, mounting, electrical
1
1
508
101682
SCREW, cap, sch, 0.625 in. (16 mm), 1/4–20
4
4
509
100016
WASHER, lock
4
4
510
100015
NUT, hex mscr, 1/4–20
4
4
512▲
16K930
LABEL, identification
1
1
514
122313
BAR, ground, kit
1
1
515
123374
POWER SUPPLY, 24 VDC, 2.5 A, 60 W
1
1
516
16M049
PANEL, side
1
1
517
24L947
MODULE, disconnect breaker
1
1
519
121612
CONNECTOR, thru, M12, m x f
1
1
522
120859
NUT, strain relief, M40 thread
1
1
523✖
125789
CABLE, can, female / female 0.5m
2
1
525
24J728
MODULE, din rail assy
1
1
526
100023
WASHER, flat
4
4
527
100133
WASHER, lock, 3/8
4
4
528
100307
NUT, hex, 3/8–16
4
4
529
157021
WASHER, lock, int
4
4
530
100035
SCREW, mach, pan hd, 0.3125 in. (8 mm) #8–32
4
4
531
112905
WASHER, plain
6
6
532
112788
SCREW, cap, socket hd, 0.375 in. (9.5 mm), #8–32
6
6
536
15R535
BRACKET, mounting, GCA high power
1
1
537
15U651
BRACKET, high power, GCA
1
1
538✖
15W902 CABLE, M8, male / ferrules
1
1
114
3A1706B
Parts
Quantity
With
Heat
Without
Heat
Ref
Part
Description
541
194337
WIRE, grounding, door
1
1
542
24L950
MODULE, HPTCM
1
1
543
24L951
MODULE, LPTCM
2
544
289697
MODULE, GCA, cube, base
2
546
125683
CONDUIT
1
1
547
117831
SCREW, mach., pan hd, 1/2 in. (13 mm), #6–32
4
4
548✖
125684
HARNESS, wire, hphm
1
1
549
120858
BUSHING, strain relief, M40 thread
1
1
550
100166
NUT, full hex
2
2
551
103833
SCREW, mach, crbh, 0.375 in. (9.5 mm), #10–32
7
7
552
117666
TERMINAL, ground
1
1
553
121603
GRIP, cord, .51-.71, 3/4
2
2
554
C38163
WASHER, lock, ext. tooth
4
4
555
15V933
GASKET, lphm
2
556
115322
WASHER, lock, external, 4mm
10
557
277674
ENCLOSURE, cube door
2
558
111280
NUT, locking
4
559✖
121597
CABLE, can, 90 female/90 female, .
1
560
120094
SCREW, pan hd, phillips, zinc, 2 in. (51 mm), #8–32
4
4
561
125784
FAN, 3x3, 230 V
1
1
562
114417
SCREW, self tap, pan hd, 8–32 x 0.625 in. (16 mm)
8
563✖
16K800
HARNESS, AC, fan, cooling box
1
564
121070
SCREW, machine, #8 x1.375
2
565
125677
ROD, connecting, on/off
1
1
566
100639
WASHER, lock
2
2
567
125859
WIRE, chassis, ground
1
1
568✖
15Y824
WIRE, chassis, ground
1
1
569✖
16K799
CABLE, volex, female, 16 AWG
2
573
121171
GRIP, cord, 0.35–0.63, 3/4 NPT
1
✖
▲
10
4
1
1
See Electrical Schematics, page 126.
Not shown.
Replacement Warning labels, signs, tags, and cards are available at no cost.
3A1706B
115
Parts
22kW Diesel Generator
580
585
583
557
558
587
584
586
572a
572b
560
565
575
582
564
563
559
576
577
572b
579
581
ti18176a
568
558
551, 552
569
558
556
570
1
Torque to 26 ft-lbs (35.25 N●m)
7
Apply sealant (blue) to threads.
2
Torque to 15 ft-lbs (20 N●m)
8
Torque to 15 ft-lbs (20 N●m)
3
Torque to 100 ft-lbs (135.6 N●m)
9
Torque to 15–20 in.-lbs (1.7–2 N●m)
4
Torque to 40 ft-lbs (54 N●m)
10
Apply lubrication to engine end of hose prior to
assembly.
6
Apply sealant (red) to threads.
116
3A1706B
Parts
22kW Diesel Generator
Part
Ref
551
—
552
—
556
16J883
557
16J884
558
125532
559
16H904
560
16H906
562

563
125371
125394
564
100079
565
106245
568
16J799
569
24L963
570
113161
Description
Qty.
Ref
Part
Description
Qty.
ENGINE, diesel, Perkins
1
572
24L965
CIRCUIT, breaker, 90A
1
ALTERNATOR, 22 kw,
diesel engine
BRACKET, engine mount,
left
BRACKET, engine mount,
right
SCREW, M14 hex head x
30 mm
ENCLOSURE, alternator,
front
ENCLOSURE, alternator,
front
CLAMP, hose, dia.
3/4-1-3/4 in.
ISOLATOR, mount,
radiator, bottom
WASHER, lock, spring
1
572a
SCREW
2
572b
WASHER
2
572c
NUT
2
BUSHING, cable, lay-in
strain relief
BUSHING, strain relief,
M40 thread
TIE, cable, fir tree
1
NUT, strain relief, M40
thread
See Radiator, page 118
1
1
1
575
125631
10
576
120858
1
577
125625
579
120859
580
581
—
120736
2
582
115942
8
583
SCREW, cap, sch, 0.625
in. (16 mm) x #8–32
BRACKET, engine relay
8
1
KIT, relay, solenoid, 12v,
intermittent
SCREW, flanged, hex hd,
1/2 in. x 1/4–20
2
1
1
4
1
4
1
SCREW, hex flange hd,
M6 x 1
NUT, hex, flange head
2
1
584 125161
MUFFLER, 2 in. (50.8
mm) exhaust
MUFFLER, clamp
1
585 125685
CAP, exhaust
1
586
104572
WASHER, lock spring
2
587
105328
SCREW, cap, hex hd, M8
x 1.25
2
—
2
 Included in Muffler Kit 24L943.
 Included in Complete Coolant Hose Kit 24L939.
See Complete Coolant Hose Kit, page 105.
3A1706B
117
Parts
Radiator
See assembly notes on next page.
622
22
616 617
17
615
613
632
620
619
618
623
614
615
617
621
622
616
640
602a
602c
605
630
604
638
603
625
605
605
641
625
635
636
607
605
631
612
634
612
624
605
606
602b
622
601
608
633
626
605
605
637
118
609
9
627
642
611
610
3A1706B
Parts
1
Apply pipe sealant to all non-swiveling pipe
threads.
8
Secure adhesive side of gasket to parts opposing
radiator, not radiator.
2
Torque to 25 +/- 2 ft-lbs (34 N●m).
9
See parts list for length.
3
Torque to 10 +/- 2 ft-lbs (14 N●m).
10
Torque to 23 +/- 2 ft-lbs (31 N●m).
4
Torque to 40 +/- 2 ft-lbs (54 N●m).
11
5
Torque to 15–20 in.-lbs (1.7–2 N●m).
12
6
7
Install rubber hose onto bead barb fitting to 0.13
in. (3.3 mm) maximum from hex.
Locate and install edge of hose clamp 0.38 in.
(9.6 mm) maximum from the end of rubber hose.
Ref
Part
Description
601
16H872
COVER, radiator mount
1
614
602
16H910
GASKET, radiator isolation;
see 602a-602c
1
602a
—
GASKET, radiator isolation;
14 in. (355.6 mm), 0.63 in.
dia.
4
602b
—
GASKET, radiator isolation;
14 in. (355.6 mm), 2 in. dia.
1
602c
—
GASKET, radiator isolation;
3 in. (76.2 mm), 2 in. dia.
1
603
—
RADIATOR
1
BRACKET, top
1
SCREW, flanged, hex hd;
1/4–20 x 1/2 in. (13 mm)
604
16H868
605 113161
Qty
Qty
615 125356
FITTING, 1 in. NPT X 1.25
barbed hose
2
616 125139
FITTING, barb, beaded
hose
2
617 158383
FITTING, union, adapter,
straight
3
618 125171
FITTING, modified, union
1
FITTING, compression, 1/8
NPT, SST
1
620 125359
HOSE, formed, 1 1/4 upper
radiator
1
20
621 16N579
HOSE, coolant, 1 in. ID; 6
in. (152.4 mm)
1
622 125371

CLAMP, hose, dia.
3/4-1-3/4 in.
4
623 125370

CLAMP ,hose, dia.
11/16-1-1/2 in.
2
TANK, aluminum, coolant
1
16H870
BRACKET, bottom
1
16H717
FAN, 16 in., 12V
1
608
16K156
BRACKET, plate
1
609 125579
ISOLATOR, mount, radiator,
top
1
610
BRACKET, support
1
611 111803
SCREW, cap, hex hd;
3/8–16 x 2 in. (50.8 mm)
1
612 112958
NUT, hex, flanged
5
613
WASHER, nylon, 30% glass
.750 OD
4
3A1706B
—
Description
1
607
16J741
Part
EXCHANGER, heat
606
16H876
Ref
Apply lubrication to all press-on hoses prior to
assembly.
Loosen all four nuts to approximately 0.18 in.
(4.5 mm) from mounting plate. Place bracket
(638) over nuts and slide down under flange of
nuts until it stops. Re-torque nuts to 25 ft-lbs
(33.8 N●m).
619*
624
—
—
625
125204
BOTTLE, overflow
2
626
16H901
BRACKET, hose support
1
627
125360
HOSE, formed, 1 1/4 lower
radiator
1
119
Parts
Ref
Part
Description
Qty
Ref
Part
Description
Qty
630 24L940
CAP, radiator; 16 psi (110
kPa, 1.1 bar)
1
636
16N581
HOSE, rubber, 5/16 in., 1.25
ft (0.4 m)
1
631 24L967
CAP, pressure, coolant,
8-10 psi (55–70 kPa,
0.5–0.7 bar)
1
637
16M323
GUARD, engine bottom
1
638
16M141
BRACKET, overflow bottle
1
640 125361
HOSE, formed, 1–1/4 upper
engine
1
641 125163
CLAMP, hose 7/32 in. 5/8in.
4
642 125382
HOSE, formed, 1–1/4 lower
engine
632*
—
SENSOR, RTD 1 K OHM
1
633
125175
COUPLING, hose, drain
1
634
125625
TIE, cable, fir tree
2
635
16N580
HOSE, rubber, 5/16 in., 3.33
ft (1 m)
1
1
 included in Heat Exchanger Kit 24L946.
*
 Included in Radiator Repair Kit 24L937.
 Included in Complete Coolant Hose Kit 24L939.
 Included in Coolant Bottle Repair Kit 24L942.
Included in RTD Sensor Kit 24L974.
See Complete Coolant Hose Kit, page 105.
 Included in Radiator Isolator Kit 24L945.
120
3A1706B
Parts
Circuit Breaker Modules
24J728, Din Rail Circuit Breaker Assembly
See Electrical Schematics, page 126.
674
659
673
661
662
663
652
651 652
653
654
655
656
654
657 655 675 658 658 676 671
660
671
ti18510a
Ref
Part
Description
Qty
Ref
Part
Description
Qty
651
125666
1
662
125671
125667
2
663
125672
653
126015
RELAY, contactor
1
654
126130
2
671
126767
655
126128
673
–
656
126125
674
–
657
126126
658
126127
675
–
659
125668
CIRCUIT, breaker, 2P,
30A, UL489
CIRCUIT, breaker, 2P,
20A, UL489
CIRCUIT, breaker, 2P,
5A, UL489
CIRCUIT, breaker, 2P,
10A, UL489
CIRCUIT, breaker, 2P,
15A, UL489
BAR,18 pos, power buss
660
125669
BAR, bus, connector
2
676
–
661
125670
TERMINAL, block, end
cover
1
TERMINAL, block, three
wire
TERMINAL, block, bridge
jumper
TERMINAL, block, three
wire ground
WIRE, black , 10 AWG,
UL 1015, 14 in. (355.6
mm). K130
WIRE, red , 10 AWG, UL
1015, 14 in. (355.6 mm).
K140
WIRE, black , 16 AWG,
UL 1015, 14 in. (355.6
mm). K150
WIRE, red , 16 AWG, UL
1015, 14 in. (355.6 mm).
K160
4
652
RAIL, DIN, 18 in. (457.2
mm)
TERMINAL, stop, end
3A1706B
2
1
1
2
1
2
2
2
2
2
2
121
Parts
24J721, Transformer and Fan Circuit Breaker Module
See Electrical Schematics, page 126.
ti18514a
Ref
Part
Description
Qty
Ref
Part
Description
Qty
901
514014
RAIL, mount
1
906
24L960
1
902
125667
TERMINAL, stop, end
2
903
125816
2
907
125767
904
125814
908
—
905
125815
TERMINAL, block, 2 level,
4 conduct
TERMINAL, block, end
cap
TERMINAL, block, feed
thru
909
—
KIT, circuit, breaker, 50
amp, 2 pole
CIRCUIT, block, three
wire ground
WIRE, cu, electrical, 8
AWG, black
FERRULE, wire, 8 AWG
122
1
2
1
2
4
3A1706B
Parts
Fuel Tank
24K390
754
758
757
752
755
752
751
Description
Qty
751
Part
-
TANK, fuel
1
752
125645
GROMMET, tank
753
125646
GROMMET, tank
754
125647
FITTING, suction, 5/16
barbed
Ref
3A1706B
753
756
Ref
755
Part
Description
Qty
125648
FITTING, 3/16 barbed
1
2
756
125649
VALVE, drain
1
1
757
125651
TUBE, suction
1
1
758
24L955
CAP, fuel
1
123
Parts
Heat Exchanger Assembly
803
802
811
810
806
807
801
808
804
805
1
2
ti18492a
Ensure flow direction arrows on solenoids
valves (804) are pointing down.
Apply anaerobic pipe sealant to all
non-swiveling fittings before assembling.
Ref
Part
Description
Qty
Ref
Part
Description
Qty
801
16H759
BRACKET, heat exchanger
1
807
24J703
1
802
24L917
EXCHANGER, heat, side A
1
803
24L918
EXCHANGER, heat, side B
1
808
C20487
KIT, fitting, inlet, heat
exchanger
NIPPLE, hex
804* 24L916
VALVE, solenoid, 3/4 NPT,
12 VDC
UNION ADAPTER, 90°
2
810
112958
NUT, hex, flanged
8
811
16J741
WASHER, nylon, 30%
glass, 3/4 OD
8
805
160327
806
24J702
*
Order 125774 Valve Repair Kit to replace all internal valve parts.
Order 125787 Coil Repair Kit to replace coil.
124
KIT, FITTING, outlet, heat
exchanger
2
2
1
3A1706B
Parts
Fluid Inlet Kit
24L934
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.
Ref
Part
Description
Qty
Ref
Part
Description
Qty
851
160327
UNION ADAPTER, 90°
2
858
15H199
PLUG, strainer, WYE, inlet
2
853
15J119
2
859
104813
PLUG, pipe
2
854
102124
MANIFOLD, strainer,
WYE, inlet
THERMOMETER, dial
860
15D757
2
855
120300
GAUGE, pressure, fluid
2
863
109077
HOUSING, thermometer,
VISCON HP
VALVE, BALL 3/4 NPT
856
180199
FILTER, replacement
2
864
160032
857
15H200
GASKET, strainer, WYE,
inlet
2
865
157785
3A1706B
2
NIPPLE, 1–1/4 in. x 2 in.
3/4 NPT
FITTING, swivel
2
2
4
125
Electrical Schematics
Electrical Schematics
Harness IdentificatioN
All wire harnesses are identified by a letter. The first letter on each wire in a wire harness corresponds with the
wire harness. Use the table below to identify the wire harness, system component connections, and wiring
diagram page number(s). The wiring diagram will show every wire included.
Harness
Identifier
Ref
Part
D
(280)
E
System Components
Wiring Diagram
16K646
Load Center
Coolant Valves
Load Center, page 134
Coolant Valve Wiring Diagram,
page 134
(49)
16K301
Engine
Load center
Engine, page 137
Load Center, page 134
F
(94)
16K297
Load Center
Engine
Engine Control Module
Load Center, page 134
Engine, page 137
Engine Control Module, page 136
H
(53)
16K299
Load Center
Electrical Enclosure
Load Center, page 134
Electrical Enclosure, page 128
K
(52)
125753
Alternator Enclosure
Electrical Enclosure
Alternator Enclosure, page 138
Electrical Enclosure, page 128
M
(51)
125752
Alternator Enclosure
Engine Control Module
Alternator Enclosure, page 138
Engine Control Module, page 136
N
(54)
125756
Reactor
Electrical Enclosure
MCM
Reactor, page 133
Electrical Enclosure, page 128
Engine Harness Wire Color Code
This table refers to Engine Harness E (49), Engine Control Module Harness F (94), and Disconnect Check
Harness H (53).
Color
Purpose
Color
Purpose
Red
Battery Positive (Lines
Always Energized)
Violet
Radiator Fan
Black/White
Engine Load Grounds
Black/Yellow
Monitoring Grounds
Orange
Starter
Brown
Oil Pressure Switch
White
Glow Plugs
Dark Blue
Water Temperature
Gray
Fuel Shutoff Solenoid
(FD)
126
3A1706B
Electrical Schematics
Circuit Breaker Identification
Ref.
Size
Component
CB01
30 A
High Power Temperature
Control Module (HPTCM)
CB02
20 A
Motor Control Module
(MCM)
CB03
5A
Two Motor Fans, Cabinet
Fan, Power Supply, and
Coolant Circulation Pump
CB04
30 A
Auxiliary Power (Air
Compressor)
CB05
10 A
Auxiliary Power
Ref.
Size
Component
CB06
20 A
Auxiliary Power
CB07
15 A
E-XP2i and E-30i With
Heat: Low Power
Temperature Control
Module (LPTCM) A
E-30i: Auxiliary
CB08
15 A
E-XP2i and E-30i With
Heat: Low Power
Temperature Control
Module (LPTCM) B
E-30i: Auxiliary
Available Circuit Breakers
Part
Amps
Part
Amps
126123
1
126129
25
126124
3
126130
30
126125
5
126131
40
126126
10
24L960
50
126127
15
123668
63
126128
20
3A1706B
127
Electrical Schematics
Electrical Enclosure Wiring Diagram
K110 - RED
K120
WHT
K100 - BLK
Disconnect Ass’y, 24J722
SW01
TB01
TB02
H110 - ORG
ENCLOSURE BOUNDARY
K070 - WHT
K050 - RED
K030 - BLK
K010 - GRN
H100 - O RG
CT01
TO 120/240VAC ALTERNATOR
POWER CABLE ‘K’, 125753
K070 - WHT
K050 - RED
K030 - BLK
Circuit Breaker Ass’y,
24J728
GRN
BLU
BRN
H100 - ORG
TO LOAD CENTER
H110 - ORG
HARNESS ‘H’, 16K299
16K800
GND { TB17
TB18
FAN - BLK
L2 { TB15
N080 - BLK
L1 { TB13
N060 - BLK
TB16
FAN - BLK
CB0 7
CB08
TB14
N080 - BLK
C B06
N060 - BLK
N030 - BLK
TO REACTOR PROPORTIONER
N020 - BLK
HARNESS ‘N’, 125756
C B04 TB11 T B12 C B05
N010 - GRN/YEL
N040 - G RN /YEL
K110 - RED
POWER SUPPLY, 123374
K100 - BLK
1
C B03
HPTCM, 255774
HOSE RTD EXT
122837
‘TCM-H-2 RTD-HOSE’
‘TCM-H-6 PSU’
CB0 2
N030 - BLK
FERRITE
BEAD
125839
‘TCM-H-6 CAN-1’
N020 - BLK
‘TCM-H-4 CONTACT’
CB01
15W902
125684
BRN
BLU
N12 0
BLK
N1 30
BLK
CT02
GB01
Ground Terminal,
117666
1
‘CAN-1 MCM’
‘CAN-1 TCM-H’
CAN, 123652
BULKHEAD,
121612
GRN/YEL
125859
GRN/YEL
15Y824 GRN/YEL
N010 - GRN/YEL
N040 - GRN/YEL
K010-GRN
CAN, 125789
GB02
Ground Bar
122313
Rotary switch set to “0”.
See Circuit Breaker Identification, page 127, for
circuit breaker identification table.
128
3A1706B
Electrical Schematics
Outside Electrical Enclosure With Optional Heater Wiring Diagram
TCM-A
256270
255716
TCM-A-3 HTR-A
BLAC K
BLACK
125762
WHITE
TCM-A-2 J24
125358
BLACK
J24 HT-RTD-A
J24 TCM-A
255716
TCM-A-1 J23
124262
16A111
HEATER A
Electrical
Enclosure
125760
J23 TCM-A/B
BOOSTER HEATER, 24K380
J23 OVERTEMP-SW
RTD ‘A’
123408
OT SWITCH
HEATER B
RTD ‘B’
124262
TCM-B
256270
TCM-B-3 HTR-B
16A111
BLAC K
BLACK
125762
BLACK
WHITE
TCM-B-2 HT-RTD-B
2x 255716
TCM-B-1 J23
Heater viewed from the back of the proportioner.
3A1706B
129
Electrical Schematics
Optional Booster Heater Wiring Diagram
ENCLOSURE BOUNDARY
2
LPTCM, 256270
‘TCM-A-CAN TCM-H’
‘TCM-A-5 PWR’
16K799
CIRCUIT BREAKER
{
L2 {
L1 {
GRN
3
LPTCM, 256270
‘TCM-B-CAN TCM-A’
GRN
WHT
B LK
WHT
BLK
16K799
‘TCM-B-5 PWR’
‘TCM-B-CAN PSU’
CB0 7
C B 08
GND
TB18
TB17
TB16
TB15
TB14
TB13
‘TCM-A-CAN TCM-B’
C A N , 1 21 59 7
C AN , 12 5 78 9
GRN
WHT
B LK
1
C B 06
POWER
SUPPLY, 123374
HPTCM, 255774
C B 04 TB 11 T B 12 C B 05
‘TCM-H-6 TCM-A’
CB0 2
C B 03
‘TCM-H-6 CAN-1’
C B 01
To MCM
CAN, 125789
‘CAN-1 TCM-H’
‘CAN-1 MCM’
CAN, 123652
BULKHEAD, 121612
CT02
1
Rotary switch set to “0”.
2
Rotary switch set to “A”.
3
Rotary switch set to “B”.
130
3A1706B
Electrical Schematics
Optional Remote Display Module Wiring Diagram
ENCLOSURE BOUNDARY
HPTCM, 255774
C AN , 12 57 89
‘TCM-H-6 CAN-1’
SPLITTER, 124654
‘CAN-1 TCM-H’
‘CAN 1’
‘CAN-1 MCM’
To MCM
CAN, 123652
BULKHEAD, 121612
‘CAN 2’
CAN, 121000
To Remote Display
CAN, 123652
BULKHEAD, 121612
3A1706B
131
Electrical Schematics
Optional Customer Auxiliary Power Wiring Diagram
See Circuit Breaker Identification, page 127, for circuit breaker identification table and other available circuit breakers.
Before making any changes to the standard auxiliary circuit breaker configuration, refer to Circuit Breaker Configuration
Options in the Reactor Operation Manual.
240 VAC AUXILIARY LOAD
L2
L1
240VAC
AUXILIARY LOAD
240 VAC
LINE - LINE
120 VAC AUXILIARY LOAD
L2
L1
120 VAC
LINE - NEUTRAL
120VAC
AUXILIARY LOAD
CT01
L1
L2
N EU T RA L NE UT R AL
120 VAC
NEUTRALS
120 VAC
LINE - NEUTRAL
120VAC
AUXILIARY LOAD
TB18
TB17
TB16
TB15
TB14
TB13
CB01
CB0 2
C B03
C B04 TB11 T B12 C B05
C B06
CB0 7
CB08
MAIN POWER DISCONNECT
CT02
132
3A1706B
Electrical Schematics
Reactor Cabinet Wiring Diagram
N120 - BLK
N130 - BLK
N040 - GRN/YEL
N060 - BLK
N080 - BLK
N060- -GRN/YEL
BLK
N050
N070 - BLK
N090 - BLK
TO ELECTRICAL ENCLOSURE
HARNESS ‘N’, 125756
4
COOLANT PUMP
125174
3
DETAIL A
L N
N050
N070
N090
TOP
VIEW
PRIMARY
SECONDARY
}
N220 - BLK
N210 - BLK
REACTOR HEATED HOSE
1
3
CABINET COOLING FAN
115834
2
4
MOTOR COOLING FAN
126002
CB20
TB25
TB21
TB22
TB24
TB23
TRANSFORMER,
15K742
DETAIL A
CIRCUIT BREAKER AND TERMINAL BLOCK DESIGNATION
3A1706B
133
Electrical Schematics
Load Center Wiring Diagram
H A R NE SS , 1236 56
E020 - RED
E220 - PUR
E010 - BLK/WHT
RELAY REPAIR KIT
24L958
(contains four replacement relays)
LOAD CENTER REPAIR KIT
24L957
F 0 10
F 0 20
F 0 30
F 0 40
F 0 70
F 0 80
F 1 00
F 1 10
F 1 20
E 190
E 200
E 100
E 150
E 611
E 620
E 630
F120 - BLU
F110 - BRN
F100 - BLK/YEL
F080 - PUR
F070 - WHT
F040 - ORG
F030 - GRY
F020 - RED
F010 - BLK/YEL
TO ENGINE
CONTROL
MODULE
HARNESS ‘F’
16K297
‘L O ADC TR -J4 MCM’
E630 - BLU
E620 - BRN
E611 - BLK
E150 - WHT
E100 - ORG
E200 - GRY
E190 - TAN
TO ENGINE
HARNESS ‘E’
16K301
1
J2
1
J3
&5
J4
J6 1
LOAD CENTER
.
D150 - BLK/WHT
D140 - GRY
D130 - BLK/WHT
D120 - BLU
D 11 0 - B LK /W H T
D100 - RED
TO COOLANT VALVES
HARNESS ‘D’
16K646
.
J5 1
E 02 0
.
E220
H100 - ORG
.
H110 - ORG
TO ELECTRICAL ENCLOSURE
HARNESS ‘H’
16K299
E010
1
J1
1
1
Manual Valve Switch:
0 — Auto
1 – Manual Override
Coolant Valve Wiring Diagram
134
Harness D (16K646)
J6–1
D150 — BLK/WHT
Connection Description
Bypass valve return
J6–2
D140 — GRY
Bypass valve signal
J18–1
J6–3
D130 — BLK/WHT
J17–2
J6–4
D120 — BLU
B valve return
B valve signal
J6–5
D110 — BLK/WHT
D100 — RED
A valve return
A valve signal
J16–2
J6–6
Load Center
Coolant Valve Coil Terminal
J18–2
PIN 2
PIN 1
J17–1
J16–1
3A1706B
Electrical Schematics
Reactor Wiring Diagram
ADM
24E451
FERRITE
BEAD
120448
ADM -CAN MC M
CABLE, 121002
1
MCM-1 ADM-CAN
MCM-9 PRESSURE-A
MCM-10 MTR SENSE
MCM-8 PRESSURE-B
MCM-1 CAN-1
MCM-2 LOADCTR
RED
BLK
S P LIT T E R , 1 2580 6
MCM-3 J21
TO MOTOR
24K393
MCM-6 PUMP-CYCLE
MCM-5 J22
J22 MC M
J21 M CM
1 22 83 7
1 2
R T D , 12 42 33
15 V 83 7
R T D , 12 42 33
J22 ENGINE RTD
J21-2 HX-RTD-B
J21-1 HX-RTD-A
MCM
257396
ENGINE COOLANT
TEMPERATURE
A&B
HEAT EXCHANGERS RTD
TO ELECTRICAL ENCLOSURE
HARNESS ‘N’, 125756
1
N010 - GRN/YEL
N020 - BLK
-N030
G R N-/Y
EL
BLK
Rotary switch
E-30i = 0
E-XP2i = 1
setting:
See Cable Routing Table on next page.
3A1706B
135
Electrical Schematics
Reactor Cable Routing
Item
MCM-1
ADM-CAN
MCM-10
MTR
SENSE
MCM-1
CAN-1
MCM-2
LOADCTR
End 1
End 2
Part
MCM-1
ADM-CAN
121002
MCM-10
MOTOR
24K393
MCM-1
MCM-2
ELECT.
ENCL
LOAD
CENTER
Item
MCM-8
PRESSURE
B
MCM-9
PRESSURE
A
HARNESS
‘N’
123652
123656
MCM-3J21
MCM-3
J21
125806
MCM-5J22
MCM–5
J22
122837
MCM-6
PUMP —
CYCLE
MCM-6
PUMP
CYCLE
SWITCH
125757
TO MOTOR
End 1
End 2
Part
MCM-8
B
PRESSURE
15M669
MCM-9
A
PRESSURE
15M669
MCM-12
ELECT.
ENCL.
125756
MCM-13
MOTOR
24K393
Engine Control Module Wiring Diagram
TO 120/240VAC
ALTERNATOR
HARNESS ‘M’, 125752
FERRITE
BEAD
125835
M06 0 - W HT
M040 - RED
M020 - BLK
M0 60
M0 40
M0 20
24L966, ENGINE CONTROL MODULE
136
F 12 0
F 11 0
F 10 0
HARNESS ‘F’, 16K297
F 08 0
F 07 0
F 0 40
F 03 0
F 02 0
F 01 0
TO LOAD CENTER
F010 - BLK/YEL
F020 - RED
F030 - GRY
F040 - GRN
F070 - WHT
F080 - PUR
F100 - BLK/YEL
F110 - BRN
F120 - BLU
3A1706B
Electrical Schematics
Engine Wiring Diagram
D+
E190 - TAN
E190 - TAN
E020 - RED
E020 - RED
FUSIBLE LINK HARNESS ‘C’, 16K172
B+
12V
CHARGE ALTERNATOR
C020 - RED
F8
C010 - RED
F9
C030 - RED
+
-
C040 - RED
C050 - RED
ENGINE
STARTER
ES
E140 - ORG
E100 - ORG
STARTER
SOLENOID RELAY
CR6
“TOP”
E100 - ORG
E112 - BLK/WHT
C050 - RED
E180 - WHT
E150 - WHT
E150 - WHT
SP4
3
E010 - BLK/WHT
E111 - BLK/WHT
E031
TO LOAD CENTER
HARNESS ‘E’
16K301
E031 - BLK/WHT
GLOW PLUGS
GLOW PLUG
SOLENOID RELAY
CR7
“BOTTOM”
SP2
2
E033 - BLK/WHT
E033
E200 - GRY
FD
FUEL SHUTOFF
SOLENOID
E200 - GRY
E032 - BLK/WHT
J7
SP1
1
E220 - PUR
E220 - PUR
E034 - BLK/WHT
E614
E035
J8
E035 - BLK/WHT
RADIATOR FAN
SINGLE POINT
GROUND
E614 - BLK/YEL
P
E620 - BRN
E611 - BLK/YEL
SP3
E620 - BRN
E612 - BLK/YEL
E630 - BLU
OIL PRESSURE SWITCH
J10
1
T
E630 - BLU
E613 - BLK/YEL
J11
1
2
3
WATER TEMPERATURE
SWITCH
Splice located inside the 3/4 in. loom above the
starter.
Splice located inside the 3/4 in. loom above
the panel holding CR6 and CR7, near the white
cable tie.
Splice located inside the 3/4 in. loom bottom of
the loop, under CR6 and CR7, approximately 6
in. from the main trunk, Engine Harness “E”.
3A1706B
137
Electrical Schematics
Alternator Enclosure Wiring Diagram
ALTERNATOR ENCLOSURE
K080 - WHT
125822
M060 - WHT
M070 - WHT
W2
U2
V2
U1
V1
W1
125631
1
TO ENGINE CONTROL
MODULE
M020 - BLK
BLK
BLK
F6, 2 AMP
M060 - WHT
HARNESS ‘M’, 125752
M040 - RED
TO ELECTRICAL
ENCLOSURE
K070 - WHT
1
SP12
BLK
F7, 2 AMP
BLK
2
K030 - BLK
HARNESS ‘K’, 125753
SP11
K 05 0 - R E D
90 AMP
CB10
K020 - BLK
125754
K040 - RED
125755
K010 - GRN
120858
120859
1
F6 and F7 Fuse replacement kit, 24M723.
(contains two fuses)
2
CB10 circuit breaker replacement kit, 24L965.
3.
138
Two ferrite beads (125835), not shown, are
located on two bundles of wires from the
alternator to the circuit board. These are installed
to eliminate electrical interferences and are
needed to ensure proper operations.
3A1706B
Electrical Schematics
Air Compressor Wiring Diagram
ELECTRICAL ENCLOSURE BOUNDARY
CIRCUIT BREAKER
ASS’Y, 24J728
AIR COMPRESSOR ELECTRICAL ENCLOSURE
GND { TB17
TB18
L2 { TB15
TB16
WHT
BLK
1/L1
3/L2
5/L3
2/T1
4/T2
6/T3
C B04 TB11 T B12 C B05
C B06
CB0 7
CB08
L1 {
BLK
TB14
TB13
BLK
BLK
BLK
TO AIR
COMPRESSOR
GRN
C B03
WHT
GRN
CB01
CB0 2
BLK
POWER CABLE, 16M827
CORD GRIP,
16M826
CT02
CORD GRIP,
16M826
GRN
GB02
Ground Bar
122313
3A1706B
139
Electrical Schematics
140
3A1706B
Dimensions
Dimensions
Top View
Figure 51
Side View
Figure 52
3A1706B
141
Dimensions
Top View: System with Compressor and Hose Rack
Accessories
Figure 53
Side View: System with Compressor and Hose Rack
Accessories
Figure 55
Front View
Figure 54
142
3A1706B
Dimensions
Pallet Mounting Dimensions
Figure 56
3A1706B
143
Technical Specifications
Technical Specifications
E-30i Models
U.S.
Metric
2000 psi
14 MPa, 140 bar
E-30i
140°F
60°C
E-30i with booster heater
180°F
82°C
30 lb/min
13.5 kg/min
310 ft
94 m
0.0272 gal.
0.1034 liter
20° to 120°F
-7° to 49°C
Maximum Fluid Working Pressure
Pressure
Maximum Fluid Temperature
Maximum Output
Output
Maximum Heated Hose Length
Length
Output per Cycle
A and B
Operating Ambient Temperature Range
Temperature
Auxiliary Power Available
Voltage
120 Vac or 240 Vac, 60 Hz
Engine
Model
Perkins 404–22G, 2.2 L, 29 HP
Alternator
Model
Mecc Alte 22 kW, 240 V, 1 PH, 60 Hz, pancake style
Battery Requirements
12 Vdc
Voltage
Minimum Cold Cranking Amps
800 CCA
Connection Type
Post Style
Recommended Battery Size
34
BC Group Number
Length
10.25 in.
260 mm
Width
6.81 in.
173 mm
Height
7.88 in.
200 mm
Booster Heater Power
E-30i
E-30i with booster heat
144
None
4000 Watts
3A1706B
Technical Specifications
Recommended Air Compressors
Champion® BR-5, Base Mount
5 HP, 240 V, 1 Phase, 60 Hz
Specifications
Required Features
Belt guard aftercooler
Pilot valve unloader
Quincy PLT5–5B, Base Mount
5 HP, 240 V, 1 Phase, 60 Hz
Specifications
Required Features
Belt guard aftercooler
Pilot valve unloader
Champion® HR5-3, 30 Gallon Tank Mount
Specifications
5 HP, 240 V, 1 Phase, 60 Hz
Required Features
Pilot valve unloader
Noise
91.0 dBA
Sound Pressure measured from
3.1 ft (1 m), at 1500 psi (10 MPa,
103 bar), 2 gpm (7.6 lpm)
Fluid Inlets
Component A (ISO) and
Component B (RES)
3/4 NPT(f) with 3/4 NPSM(f) union
Fluid Outlets
Component A (ISO)
#8 (1/2 in.) JIC, with #5 (5/16 in.) JIC adapter
Component B (RES)
#10 (5/8 in.) JIC, with #6 (3/8 in.) JIC adapter
Fluid Circulation Ports
Size
Maximum Pressure
1/4 NPSM(m), with plastic tubing
250 psi
1.75 MPa, 17.5 bar
E-30i
1750 lb
794 kg
E-30i with booster heat
1800 lb
816 kg
E–30i with compressor
2250 lb
1020 kg
E–30i with booster heat and
compressor
2300 lb
1043 kg
Weight
Wetted Parts
Material
3A1706B
Aluminum, stainless steel, zinc plated carbon steel, brass,
carbide, chrome, chemically resistant o-rings, PTFE, ultra-high
molecular weight polyethylene
145
Technical Specifications
E-XP2i Models
U.S.
Metric
3500 psi
24.1 MPa, 241 bar
180°F
82°C
2 gpm
7.6 lpm
310 ft
94 m
0.0203 gal.
0.0771 liter
20° to 120°F
-7° to 49°C
Maximum Fluid Working Pressure
Pressure
Maximum Fluid Temperature
E-XP2i
Maximum Output
Output
Maximum Heated Hose Length
Length
Output per Cycle
A and B
Operating Ambient Temperature Range
Temperature
Auxiliary Power Available
120 Vac or 240 Vac, 60 Hz
Voltage
Engine
Model
Perkins 404–22G, 2.2 L, 29 HP
Alternator
Model
Mecc Alte 22 kW, 240 V, 1 PH, 60 Hz, pancake style
Battery Requirements
Voltage
12 Vdc
Minimum Cold Cranking Amps
800 CCA
Connection Type
Post Style
Recommended Battery Size
34
BC Group Number
Length
10.25 in.
260 mm
Width
6.81 in.
173 mm
Height
7.88 in.
200 mm
Booster Heater Power
Wattage
146
4000 Watts
3A1706B
Technical Specifications
Recommended Air Compressors
Champion® BR-5, Base Mount
5 HP, 240 V, 1 Phase, 60 Hz
Specifications
Required Features
Belt guard aftercooler
Pilot valve unloader
Quincy PLT5–5B, Base Mount
5 HP, 240 V, 1 Phase, 60 Hz
Specifications
Required Features
Belt guard aftercooler
Pilot valve unloader
Champion® HR5-3, 30 Gallon Tank Mount
Specifications
5 HP, 240 V, 1 Phase, 60 Hz
Required Features
Pilot valve unloader
Noise
91.0 dBA
Sound Pressure measured from
3.1 ft (1 m), at 2000 psi (14 MPa,
138 bar), 1.0 gpm (3.8 lpm)
Fluid Inlets
Component A (ISO) and
Component B (RES)
3/4 NPT(f) with 3/4 NPSM(f) union
Fluid Outlets
Component A (ISO)
#8 (1/2 in.) JIC, with #5 (5/16 in.) JIC adapter
Component B (RES)
#10 (5/8 in.) JIC, with #6 (3/8 in.) JIC adapter
Fluid Circulation Ports
Size
Maximum Pressure
1/4 NPSM(m), with plastic tubing
250 psi
1.75 MPa, 17.5 bar
E-XP2i
1800 lb
816 kg
E-XP2i with compressor
2500 lb
1043 kg
Weight
Wetted Parts
Material
3A1706B
Aluminum, stainless steel, zinc plated carbon steel, brass,
carbide, chrome, chemically resistant o-rings, PTFE, ultra-high
molecular weight polyethylene
147
Graco Standard Warranty
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.
With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of
twelve months 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.
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 WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS
FOR A PARTICULAR PURPOSE.
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 MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT,
MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. 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.
FOR GRACO CANADA CUSTOMERS
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.
Graco Information
For the latest information about Graco products, visit www.graco.com.
To place an order, contact your Graco Distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original Instructions. This manual contains English. MM 3A1706
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2012, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revised 02/2012

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