Graco 332637F, Reactor 2 Elite Integrated Proportioning System, Repair-Parts Owner's Manual

Repair-Parts
Reactor® 2 Elite Integrated
Proportioning System
332637F
EN
Electric, Heated, Integrated Plural Component Proportioning System With Integrated Generator. For
spraying polyurethane foam and polyurea coatings. For professional use only. Not approved for use in
explosive atmospheres or hazardous locations.
Important Safety Instructions. Read all warnings and instructions in
this manual. Save these instructions.
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
Warnings ............................................................. 3
Important Isocyanate Information........................... 9
Models............................................................... 11
Approvals........................................................... 13
Accessories........................................................ 13
Supplied Manuals ............................................... 14
Related Manuals ................................................ 14
Troubleshooting.................................................. 15
Troubleshoot Errors ..................................... 15
Load Center Diagnostics .............................. 49
Pressure Relief Procedure .................................. 59
Shutdown........................................................... 60
Flushing ............................................................. 63
Repair................................................................ 64
Before Beginning Repair............................... 64
Flush Inlet Strainer Screen ........................... 64
Drain Coolant .............................................. 65
Refill Proportioner Coolant Loop ................... 67
Refill Engine Coolant Loop ........................... 68
Coolant Specifications .................................. 69
Change Pump Lubricant ............................... 69
Remove Pump............................................. 70
Install Pump ................................................ 71
Repair Drive Housing ................................... 72
Repair Electric Motor.................................... 75
Repair Circuit Breaker Module ...................... 76
Replace Load Center Relays and
Fuses ............................................ 78
Replace Load Center ................................... 79
Replace Engine Solenoid Relays .................. 79
Replace Fluid Inlet Sensor............................ 80
Replace Pressure Transducers ..................... 80
Replace Fans .............................................. 81
2
Repair Booster Heater.................................. 83
Repair Heated Hose..................................... 86
Repair Fluid Temperature Sensor
(FTS) ............................................. 88
Replace Heat Exchangers ............................ 91
Replace Power Supply ................................. 94
Replace Circulation Pump ............................ 95
Repair Filter Housing Filter ........................... 96
Remove Fuel Tank....................................... 96
Replace Battery ........................................... 97
Repair Fusible Link Harness ......................... 98
Remove Radiator ....................................... 100
Replace Advanced Display Module
(ADM) .......................................... 100
Replace Engine Control Module.................. 101
Replace Motor Control Module
(MCM) ......................................... 101
Software Update Procedure........................ 102
Replace Temperature Control Module
(TCM) .......................................... 102
Remove Proportioner ................................. 103
Repair Engine............................................ 106
12V Charge Alternator................................ 106
Notes ............................................................. 107
Parts................................................................ 108
Electrical Schematics........................................ 156
Repair and Spare Parts Reference .................... 172
Recommended Rebuild Spare Parts .................. 173
Dimensions ...................................................... 174
Technical Specifications.................................... 177
Notes ............................................................. 180
Graco Extended Warranty for Integrated
Reactor® 2 Components ..................... 181
332637F
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 symbols refer to procedure-specific
risks. When these symbols appear in the body of this manual or on warning labels, refer back to these
Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout
the body of this manual where applicable.
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 Safety Data Sheet (SDS) for handling instructions and to know the specific hazards of
the fluids you are using, including the effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area, always keep work area
well ventilated and always wear appropriate personal protective equipment. See Personal
Protective Equipment warnings in this manual.
• 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
Always wear appropriate personal protective equipment and cover all skin when spraying,
servicing equipment, or when in the work area. Protective equipment helps prevent serious
injury, including long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction;
burns; eye injury and hearing loss. This protective equipment includes but is not limited to:
• A properly fitting respirator, which may include a supplied-air respirator, chemically
impermeable gloves, protective clothing and foot coverings as recommended by the fluid
manufacturer and local regulatory authority.
• Protective eyewear and hearing protection.
332637F
3
Warnings
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from gun, 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.
treatment
•
•
•
•
•
•
Do not spray without tip guard and trigger guard installed.
Engage trigger lock when not spraying.
Do not point gun at anyone or at any part of the body.
Do not put your hand over the spray tip.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Follow the Pressure Relief Procedure when you stop spraying 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.
• 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 power or 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. Do not use pail liners unless
they are antistatic or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock.. Do not use
equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
4
332637F
Warnings
WARNING
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.
PRESSURIZED ALUMINUM PARTS 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.
332637F
5
Warnings
WARNING
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. Alterations or modifications may void agency approvals
and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
6
332637F
Warnings
WARNING
BATTERY HAZARD
The battery may leak, explode, cause burns, or cause an explosion if mishandled.
Data.
• 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
Data.
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.
332637F
7
Warnings
WARNING
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 is heated can become very hot during operation. To avoid
severe burns:
• Do not touch hot fluid or equipment.
CALIFORNIA PROPOSITION 65
The engine exhaust from this product contains a chemical known to the State of California to
cause cancer, birth defects or other reproductive harm.
8
332637F
Important Isocyanate Information
Important Isocyanate Information
Isocyanates (ISO) are catalysts used in two component materials.
Isocyanate Conditions
Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and
atomized particulates.
• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific
hazards and precautions related to isocyanates.
• Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless
you are trained, qualified, and have read and understood the information in this manual and in the fluid
manufacturer’s application instructions and SDS.
• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material, which
could cause off gassing and offensive odors. Equipment must be carefully maintained and adjusted
according to instructions in the manual.
• To prevent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the work
area must wear appropriate respiratory protection. Always wear a properly fitting respirator, which
may include a supplied-air respirator. Ventilate the work area according to instructions in the fluid
manufacturer’s SDS.
• Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local
regulatory authority. Follow all fluid manufacturer recommendations, including those regarding handling
of contaminated clothing. After spraying, wash hands and face before eating or drinking.
• Hazard from exposure to isocyanates continues after spraying. Anyone without appropriate personal
protective equipment must stay out of the work area during application and after application for the time
period specified by the fluid manufacturer. Generally this time period is at least 24 hours.
• Warn others who may enter work area of hazard from exposure to isocyanates. Follow the
recommendations of the fluid manufacturer and local regulatory authority. Posting a placard such as the
following outside the work area is recommended:
332637F
9
Important Isocyanate Information
Self--Ignition
Material Self
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings
and SDS.
Keep Components A and B Separate
Moisture Sensitivity of Isocyanates
Exposure to moisture (such as humidity) will cause
ISO to partially cure, forming small, hard, abrasive
crystals that become suspended in the fluid.
Eventually a film will form on the surface and the ISO
will begin to gel, increasing in viscosity.
NOTICE
Partially cured ISO will reduce performance and
the life of all wetted parts.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere.
Never store ISO in an open container.
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage to equipment. To prevent
cross-contamination:
• Never interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.
Changing Materials
NOTICE
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.
• Keep the ISO pump wet cup or reservoir (if
installed) filled with appropriate lubricant. The
lubricant creates a barrier between the ISO and
the atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may
contain moisture. Always keep solvent
containers closed when not in use.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
NOTE: The amount of film formation and rate of
crystallization varies depending on the blend of ISO,
the humidity, and the temperature.
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.
• 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.
10
332637F
Models
Models
Reactor 2 E-30i Elite
All base systems include fluid inlet pressure and temperature sensors and Graco InSite™. For part numbers,
see Accessories, page 13
�With Air Compressor/Dryer
No Air Compressor/Dryer
Model
E-30i
E-30i with heat
E-30i
E-30i with heat
Base Machine
272079
272080
272089
272090
Maximum Fluid
Working Pressure
psi (MPa, bar)
Approximate Output
per Cycle (A+B) gal.
(liter)
Max Flow Rate lb/min
(kg/min)
Total System Load †
(Watts)
Voltage (phase)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
0.0272 (0.1034)
0.0272 (0.1034)
0.0272 (0.1034)
0.0272 (0.1034)
30 (13.5)
30 (13.5)
30 (13.5)
30 (13.5)
7,400
11,600
13,500
17,700
240 VAC (1)
240 VAC (1)
240 VAC (1)
240 VAC (1)
Available Auxiliary
Current at Volts, 60
Hz*�
Hz*
52 Amps (240)
35 Amps (240)
22 Amps (240)
9 Amps (120)
5 Amps (240)
9 Amps (120)
Fusion AP Package �
AP2079
AH2079
AP2080
AH2080
AP2089
AH2089
AP2090
AH2090
(Gun Part No.)
(246102)
(246102)
(246102)
(246102)
(246102)
(246102)
(246102)
(246102)
CH2079
CS2080
CH2080
CS2089
CH2089
CS2090
CH2090
Fusion CS Package � CS2079
(Gun Part No.)
(CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD)
Probler P2 Package � P22079
PH2079
P22080
PH2080
P22089
PH2089
P22090
PH2090
(Gun Part No.)
(GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2)
Heated Hose
50 ft (15 m)
24Y240 (XtremeWrap)
Heated Whip Hose
10 ft (3 m)
24Y240
24Y240
24Y240
24Y240
24Y240
24Y240
24Y240
24Y240
Qty: 1
Qty: 5
Qty: 1
Qty: 5
Qty: 1
Qty: 5
Qty: 1
Qty: 5
246050
246050
246050
246050
246050
246050
246050
246050
�
Total system watts used by system, based on
maximum heated hose length of 310 ft (94.5 m)
for each unit.
*
Full load amps available for auxiliary equipment
when all bare-system components are operating at
maximum capabilities. Available auxiliary current
is based on 310 ft (94.5 m) of heated hose. An
additional 3.0 amps (240 VAC) of auxiliary current
is available for each 50 ft (15.2 m) section of
heated hose that is not used.
Auxiliary current at 120 VAC is available on line 1
(circuit breaker pin 2), line 2 current at 120 VAC is
used by the air dryer (circuit breaker pin 4).
332637F
�
Available auxiliary current will be less when the
engine is de-rated for site altitude. Reduce the
Available Auxiliary Current in the chart by 2.5
Amps (240 VAC) per 1000 ft (300 m) elevation
increments. If the available auxiliary current is
less than zero, the system configuration may not
support the full load at that altitude.
�
Includes Complete Air Compressor/Dryer Kit
24U176.
See Approvals, page 13.
�
Packages include gun, heated hose, and whip
hose.
11
Models
Reactor 2 E-XP2i Elite
All base systems include fluid inlet pressure and temperature sensors and Graco InSite™. For part numbers,
see Accessories, page 13
Model
No Air Compressor/Dryer
�With Air Compressor/Dryer
E-XP2i with heat
E-XP2i with heat
Base Machine
272081
272091
Maximum Fluid Working Pressure psi
(MPa, bar)
Approximate Output per Cycle (A+B)
gal. (liter)
Max Flow Rate lb/min (kg/min)
3500 (24.1, 241)
3500 (24.1, 241)
0.0272 (0.1034)
0.0272 (0.1034)
30 (13.5)
30 (13.5)
Total System Load † (Watts)
11,600
17,700
Voltage (phase)
240 VAC (1)
240 VAC (1)
Available Auxiliary Current at Volts, 60 35 Amps (240)
Hz*�
Hz*
5 Amps (240)
9 Amps (120)
Fusion AP Package �
AP2081
AP2091
(Gun Part No.)
(246100)
(246100)
Probler P2 Package �
P22081
(GCP2R0)
24Y241
P22091
246055
246055
(Gun Part No.)
Heated Hose
50 ft (15 m)
Heated Whip Hose
10 ft (3 m)
�
Total system watts used by system, based on
maximum heated hose length of 310 ft (94.5 m)
for each unit.
*
Full load amps available for auxiliary equipment
when all bare-system components are operating
at maximum capabilities. Available auxiliary
current is based on 310 ft (94.5 m) of heated hose.
An additional 3.0 amps (240 VAC) of auxiliary
current is available for each 50 ft (15.2 m) section
of heated hose that is not used.
Auxiliary current at 120 VAC is available on line 1
(circuit breaker pin 2), line 2 current at 120 VAC is
used by the air dryer (circuit breaker pin 4).
12
(GCP2R0)
24Y241
�
Available auxiliary current will be less when the
engine is de-rated for site altitude. Reduce the
Available Auxiliary Current in the chart by 2.5
Amps (240 VAC) per 1000 ft (300 m) elevation
increments. If the available auxiliary current is
less than zero, the system configuration may not
support the full load at that altitude.
�
Includes Complete Air Compressor/Dryer Kit
24U176.
See Approvals, page 13.
�
Packages include gun, heated hose, and whip
hose.
332637F
Approvals
Approvals
Note
Intertek approvals apply to proportioning systems
without hoses.
Model
Heated hoses provided with a system or sold
individually are not approved by Intertek.
Accessories
Proportioning System Approvals:
272079
272089
Kit Number
Description
15M483
Remote Display Module Protective
Covers (10 pack)
15V551
ADM Protective Covers (10 pack)
24K207
Fluid Temperature Sensor (FTS)
with RTD
24K333
Fuel Line and Cable Extension Kit
24K336
Hose Rack
24K337
Light Tower Kit
24L911
Pallet Support Kit
24M174
Drum Level Sticks
24U174
Remote Display Module Kit
24U176
Complete Air Compressor Kit
24U177
Feed Pump Shutdown Kit
24U181
Booster Heat Upgrade Kit
9902471
Conforms to ANSI/UL Std. 73
Certified to CAN/CSA Std.
C22.2 No. 68
272080
272081
272090
272091
Cables
121006
150 ft (45 m) cable (for remote
display module)
24N365
RTD Test Cables (to aide resistance
measurements)
24N449
50 ft (15 m) CAN cable (for remote
display module)
9902471
Conforms to ANSI/UL Std. 499
Certified to CAN/CSA Std.
C22.2 No. 88
332637F
13
Supplied Manuals
Supplied Manuals
Related Manuals
The following manuals are shipped with the Reactor.
Refer to these manuals for detailed equipment
information.
The following manuals are for accessories used with
the Reactor.
Manuals are also available at www.graco.com.
Manual
332636
333093
333094
SEBU8311–
02
Description
Reactor 2 Elite Integrated
Proportioning System, Operation
Reactor 2 Elite Integrated
Proportioning System, Startup
Instructions
Reactor 2 Elite Integrated
Proportioning System, Shutdown
Instructions
Perkins® Engine, Repair-Parts
Access at www.perkins.com. Go
to Service and Support/manuals.
Select engine family and type code
“GN”.
Contact Perkins for engine warranty
and service.
-
Mecc Alte Self-Regulating Alternator
Series NPE, Repair-Parts
Access at www.meccalte.com.
Select “meccalte” logo / Download
/ Instruction Manuals. Select NPE
instruction manual on page 5. Go to
Support and enter serial number for
Parts List and Help Videos.
Contact Mecc Alte for warranty and
service
ST
15825–00
33227482
14
Component Manuals in English:
Manuals are available at www.graco.com.
System Manuals
332636
Reactor 2 E-30i and E-XP2i, Operation
Displacement Pump Manual
309577
Electric Reactor Displacement Pump,
Repair-Parts
Feed System Manuals
309572
Heated Hose, Instructions-Parts
309852
Circulation and Return Tube Kit,
Instructions-Parts
309815
Feed Pump Kits, Instructions-Parts
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
332733
Air Compressor and Air Dryer Kit,
Instructions-Parts
332738
Booster Heat Retrofit Kit,
Instructions-Parts
332740
Remote Display Module,
Instructions-Parts
Pallet Support Kit, Instructions-Parts
3A2574
Air Compressor, Operation/Maintenance & Parts list.
3A1903
Access at www.hydrovaneproducts.com. Go to Warranty & Service
tab and select “contact us” to
request manuals.
3A1904
Refrigerated Air Dryer, Instruction
manual
Access from Service
Department (724) 746–1100 or
www.spx.com/en/hankison.
3A1905
3A1906
Hose Rack, Instructions-Parts
Fuel Tank/Battery Move Kit,
Instructions-Parts
Feed Pump Shutdown Kit,
Instructions-Parts
Light Tower Kit, Instructions-Parts
332637F
Troubleshooting
Troubleshooting
Troubleshoot Errors
There are three types of errors that can occur. Errors
are indicated on the display as well as by the light
tower (optional).
Error
Description
Alarms
A parameter critical to
the process has reached
a level requiring the
system to stop. The
alarm needs to be
addressed immediately.
Deviations
A parameter critical
to the process has
reached a level requiring
attention, but not
sufficient enough to
stop the system at this
time.
Advisories
A parameter that is
not immediately critical
to the process. The
advisory needs attention
to prevent more serious
issues in the future.
See Error Codes, page 16 see for causes and
solutions to each error code.
To troubleshoot the error:
2. The QR code screen will be displayed. Scan
the QR code with your mobile device to be sent
directly to online troubleshooting for the active
error code. Otherwise, manually navigate to
help.graco.com and search for the active error.
Note
Press
or
to return to the
previously displayed screen.
3. If no internet connection is available, see Error
Code Troubleshooting in the system repair
manual for causes and solutions for each error
code.
1. Press the soft key next to “Help With This Error”
for help with the active error.
332637F
15
Troubleshooting
Error Codes
Error
A1NM
A4DA
A4DB
A4DH
Type
Description
Cause
Solution
Low Motor Current
Loose/broken
connection.
Check for loose wire terminations at
MCM motor connector.
Bad Motor.
Disconnect motor output connector
from MCM. Confirm less than 8 ohms
resistance between each pair of motor
power leads (M1 to M2, M1 to M3, M2
to M3). If any readings greater than 8
ohms, check motor wiring for damage
and/or loose terminations.
Short circuit in
heater wiring.
Check wiring for touching wires.
Bad heater.
Confirm resistance of heater. Heater
resistance should be 23-26 Ω. If out of
tolerance, replace heater.
Short circuit in
heater wiring.
Check wiring for touching wires.
Bad heater.
Confirm resistance of heater. Heater
resistance should be 23-26 Ω. If out of
tolerance, replace heater.
Short circuit in
hose wiring.
Check continuity of transformer windings.
Normal readings are about 0.2Ω on both
primary and secondary. If reading is 0Ω
replace transformer.
High Current A
High Current B
High Current Hose
Check for shorts between the primary
winding and the support frame or
enclosure.
16
332637F
Troubleshooting
Error
A4NM
Type
Description
Cause
Solution
High Motor Current
Short circuit of
motor wiring.
Check wiring to the motor to ensure no
bare wires are touching and that no wires
are shorted to ground.
Motor will not
rotate.
Remove pump gear housings from motor
and check that motor shaft rotates freely
in direction indicated on motor housing.
Damaged gear
train.
Check pump gear trains for damage and
repair or replace as necessary.
Chemical pump is
stuck.
Repair or replace chemical pump.
A7DA
Unexpected Current
A
Shorted TCM
If error cannot be cleared or regenerates
consistently, replace module.
A7DB
Unexpected Current
B
Shorted TCM
If error cannot be cleared or regenerates
consistently, replace module.
A7DH
Unexpected Current
Hose
Shorted TCM
If error cannot be cleared or regenerates
consistently, replace module.
A8DA
No Current A
Tripped circuit
breaker.
Visually check circuit breaker for a
tripped condition.
Loose/broken
connection.
Check heater wiring for loose wires.
Tripped circuit
breaker.
Visually check circuit breaker for a
tripped condition.
Loose/broken
connection.
Check heater wiring for loose wires.
Tripped circuit
breaker.
Visually check circuit breaker for a
tripped condition.
Loose/broken
connection.
Check heater wiring for loose wires.
A8DB
A8DH
332637F
No Current B
No Current Hose
17
Troubleshooting
Error
CACM
18
Type
Description
Cause
Solution
MCM Communication Error
Module does not
have software.
Insert a system token into the ADM
module and cycle the power. Wait until
the upload is complete before removing
the token.
No 24 VDC supply
to module.
Green light on each module should be
lit. If green light is not lit, check to make
sure each CAN cable connection is tight.
Verify the power supply is outputting 24
VDC. If not, check power supply wiring. If
wiring is okay, replace the power supply.
Loose or broken
CAN cable.
Check the CAN cables running between
GCA modules and tighten of needed. If
the problem still persists move each
cable around the connector and watch
the flashing yellow light on the GCA
modules. If the yellow light stops
flashing, replace the CAN cable.
332637F
Troubleshooting
Error
CACT
DADX
Type
Description
Cause
TCM Communication Module does not
have software.
Error
Pump Runaway
Solution
Insert a system token into the ADM
module and cycle the power. Wait until
the upload is complete before removing
the token.
No 24 VDC supply
to module.
Green light on each module should be
lit. If green light is not lit, check to make
sure each CAN cable connection is tight.
Verify the power supply is outputting 24
VDC. If not, check power supply wiring. If
wiring is okay, replace the power supply.
Loose or broken
CAN cable.
Check the CAN cables running between
GCA modules and tighten of needed. If
the problem still persists move each
cable around the connector and watch
the flashing yellow light on the GCA
modules. If the yellow light stops
flashing, replace the CAN cable.
Flow rate is too
large.
Mix chamber too large for system
selected. Use mix chamber rated for
system.
Ensure the system has chemical and the
feed pumps are operating correctly.
No material in pumps. Verify pumps
are supplying chemical. If necessary,
replace or refill drums.
Inlet ball valves are closed. Open ball
valves.
DE0X
Cycle Switch Error
Faulty or missing
cycle switch.
Check wiring between cycle switch and
MCM.
Missing or out of
place cycle switch
magnet.
Check presence and position of cycle
switch magnet on output crank arm.
EAUX
USB Busy
USB drive has
been inserted to
the ADM.
EVCH
Manual Hose Mode
Enabled
Manual hose mode Install a functioning fluid temperature
has been enabled sensor (FTS) on the hose. Manual hose
in System Setup
mode will automatically turn off.
screen.
EVUX
USB disabled
USB
download/uploads
are disabled.
Enable USB download/uploads on the
Advanced Setup screen before inserting
a USB drive.
F9DX
High Pressure/Flow
Cutback
Mix chamber is
too large for set
pressure.
Reference the pressure flow curves and
select a tip size that is the correct size
for the set pressure.
332637F
Do not remove USB drive until
download/upload is complete.
19
Troubleshooting
Error
Description
Cause
Solution
H1MA
Low Frequency A
Line frequency is
below 55 Hz.
Check frequency. If out of tolerance, see
supplied 120/240V alternator manual for
repair instructions.
H1MB
Low Frequency B
Line frequency is
below 55 Hz.
Check frequency. If out of tolerance, see
supplied 120/240V alternator manual for
repair instructions.
H1MH
Low Frequency Hose Line frequency is
below 55 Hz.
Check frequency. If out of tolerance, see
supplied 120/240V alternator manual for
repair instructions.
20
Type
332637F
Troubleshooting
Error
Type
Description
Cause
Solution
H4MA
High Frequency A
Line frequency is
above 65 Hz.
Check frequency. If out of tolerance, see
supplied 120/240V alternator manual for
repair instructions.
H4MB
High Frequency B
Line frequency is
above 65 Hz.
Check frequency. If out of tolerance, see
supplied 120/240V alternator manual for
repair instructions.
H4MH
High Frequency
Hose
Line frequency is
above 65 Hz.
Check frequency. If out of tolerance, see
supplied 120/240V alternator manual for
repair instructions.
K8NM
Locked Rotor Motor
Motor will not
rotate.
Remove pump gear housings from motor
and check that motor shaft rotates freely
in direction indicated on motor housing.
Damaged gear
train.
Check motor/pump gear trains for
damage and repair or replace as
necessary.
Chemical pump is
stuck.
Repair or replace chemical pump.
L1AX
Low Chemical Level
A
Low material level.
Refill material and update drum level on
ADM Maintenance screen. Alarm can be
disabled on the System Setup screen.
L1BX
Low Chemical Level
B
Low material level.
Refill material and update drum level on
ADM Maintenance screen. Alarm can be
disabled on the System Setup screen.
MMUX
Maintenance Due USB
Insert a USB drive into the ADM and
USB logs have
download all logs.
reached a level
where data loss
will occur if logs are
not downloaded.
332637F
21
Troubleshooting
Error
P0AX
22
Type
Description
Cause
Solution
Pressure Imbalance
A High
Pressure
difference between
A and B material
is greater than the
defined value.
Ensure 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.
Check if heater and PRESSURE
RELIEF/SPRAY valve are plugged.
Clear. Replace rupture disk. Do not
replace with a pipe plug.
Feed system
defective.
Check feed pump and hoses for
blockage. Check that feed pumps have
correct air pressure.
332637F
Troubleshooting
Error
P0BX
P1FA
P1FB
332637F
Type
Description
Cause
Solution
Pressure Imbalance
B High
Pressure
difference between
A and B material
is greater than the
defined value.
Ensure 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.
Check if heater and PRESSURE
RELIEF/SPRAY valve are plugged.
Clear. Replace rupture disk. Do not
replace with a pipe plug.
Feed system
defective.
Check feed pump and hoses for
blockage. Check that feed pumps have
correct air pressure.
Inlet pressure
lower than defined
value.
Ensure that inlet pressure to the pump
is sufficient.
Value defined too
high.
Ensure that the low pressure alarm level
defined on the System Setup screen is
acceptable.
Inlet pressure
lower than defined
value.
Ensure that inlet pressure to the pump
is sufficient.
Value defined too
high.
Ensure that the low pressure alarm level
defined on the System Setup screen is
acceptable.
Low Inlet Pressure A
Low Inlet Pressure B
23
Troubleshooting
Error
P2FA
P2FB
P4AX
P4BX
P6AX
24
Type
Description
Cause
Solution
Low Inlet Pressure A
Inlet pressure
lower than defined
value.
Ensure that inlet pressure to the pump
is sufficient.
Value defined too
high.
Ensure that the low pressure alarm level
defined on the System Setup screen is
acceptable.
Inlet pressure
lower than defined
value.
Ensure that inlet pressure to the pump
is sufficient.
Value defined too
high.
Ensure that the low pressure alarm level
defined on the System Setup screen is
acceptable.
System
pressurized before
allowing heat to
reach setpoint.
Pressure in the hose and pumps will
increase as the system heats up. Turn
on heat and allow all zones to reach the
temperature setpoint before turning on
the pumps.
Bad pressure
transducer.
Verify the ADM pressure reading and the
analog guages at the manifold.
E-XP2i system
configured as
E-30i.
Alarm level is lower for E-30i than for
E-XP2i. Ensure dial on MCM is set to
position "1" for E-XP2i.
System
pressurized before
allowing heat to
reach setpoint.
Pressure in the hose and pumps will
increase as the system heats up. Turn
on heat and allow all zones to reach the
temperature setpoint before turning on
the pumps.
Bad pressure
transducer.
Verify the ADM pressure reading and the
analog guages at the manifold.
E-XP2i system
configured as
E-30i.
Alarm level is lower for E-30i than for
E-XP2i. Ensure dial on MCM is set to
position "1" for E-XP2i.
Loose/bad
connection.
Check to ensure the pressure transducer
is properly installed and all wires are
properly connected.
Bad sensor.
Check if the error follows the transducer.
Disconnect transducer cables from the
MCM (connectors 6 and 7). Reverse
A and B connections and check if
the errors follows. If the error follows
the transducer, replace the pressure
transducer.
Low Inlet Pressure B
High Pressure A
High Pressure B
Pressure Sensor
Error A
332637F
Troubleshooting
Error
P6BX
P6FA
P6FB
P7AX
332637F
Type
Description
Cause
Solution
Pressure Sensor
Error B
Loose/bad
connection.
Check to ensure the pressure transducer
is properly installed and all wires are
properly connected.
Bad sensor.
Check if the error follows the transducer.
Disconnect transducer cables from the
MCM (connectors 6 and 7). Reverse
A and B connections and check if
the errors follows. If the error follows
the transducer, replace the pressure
transducer.
Inlet sensors not
installed.
If inlet sensors are not installed, inlet
sensors should be disabled on the
System Setup screen.
Loose/bad
connection.
Check to ensure inlet sensor is properly
installed and all wires are properly
connected.
Bad sensor.
Check if the error follows the inlet sensor.
Disconnect inlet sensor cables from the
MCM (connectors 8 and 9). Reverse A
and B connections and check if the errors
follows. If the error follows the sensor,
replace the inlet sensor.
Inlet sensors not
installed.
If inlet sensors are not installed, inlet
sensors should be disabled on the
System Setup screen.
Loose/bad
connection.
Check to ensure inlet sensor is properly
installed and all wires are properly
connected.
Bad sensor.
Check if the error follows the inlet sensor.
Disconnect inlet sensor cables from the
MCM (connectors 8 and 9). Reverse A
and B connections and check if the errors
follows. If the error follows the sensor,
replace the inlet sensor.
Pressure
difference between
A and B material
is greater than the
defined value.
Ensure 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
Pressure Sensor
Error Inlet A
Pressure Sensor
Error Inlet B
Pressure Imbalance
A High
25
Troubleshooting
Error
P7BX
T1DE
26
Type
Description
Pressure Imbalance
B High
Low Temperature
Coolant Outlet
Cause
Solution
Fluid leaking from
heater inlet rupture
disk.
Check if heater and PRESSURE
RELIEF/SPRAY valve are plugged.
Clear. Replace rupture disk. Do not
replace with a pipe plug.
Feed system
defective.
Check feed pump and hoses for
blockage. Check that feed pumps have
correct air pressure.
Pressure
difference between
A and B material
is greater than the
defined value.
Ensure 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.
Check if heater and PRESSURE
RELIEF/SPRAY valve are plugged.
Clear. Replace rupture disk. Do not
replace with a pipe plug.
Feed system
defective.
Check feed pump and hoses for
blockage. Check that feed pumps have
correct air pressure.
Radiator fan will
not stop.
Replace fan relay.
Engine thermostat
is stuck closed.
Replace thermostat.
332637F
Troubleshooting
Error
T2AE
332637F
Type
Description
Cause
Solution
Low Temperature
Heat Exchanger A
Coolant circulation
pump not working.
Check for 240 VAC on pump. If there is
the correct voltage, replace circulation
pump.
Air lock in pump
circulation.
Check for coolant flow in sight glass.
No voltage to coil
of valve.
Turn on the manual valve switch (MV),
on the load center, to manually turn on
the solenoids and see if the temperature
rises. If not, check volatge output on
J6 connectoron the load center and
ensure the LEDs are on. Follow Load
Center Diagnostic instructions in system
repair manual. If necessary, replace the
load center board. 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 the
screwdriver sticks, then the coil is good.
Replace the plunger on valve or replace
the complete valve assembly.
27
Troubleshooting
Error
T2BE
T2DA
28
Type
Description
Cause
Solution
Low Temperature
Heat Exchanger B
Coolant circulation
pump not working.
Check for 240 VAC on pump. If there is
the correct voltage, replace circulation
pump.
Air lock in pump
circulation.
Check for coolant flow in sight glass.
No voltage to coil
of valve.
Turn on the manual valve switch (MV),
on the load center, to manually turn on
the solenoids and see if the temperature
rises. If not, check volatge output on
J6 connectoron the load center and
ensure the LEDs are on. Follow Load
Center Diagnostic instructions in system
repair manual. If necessary, replace the
load center board. 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 the
screwdriver sticks, then the coil is good.
Replace the plunger on valve or replace
the complete valve assembly.
Flow is too high at
current setpoint.
Use a smaller mix chamber that is
rated for the unit in use. If recirculating,
decrease flow or decrease temperature
setpoint.
Bad RTD or bad
RTD placement
against heater.
Swap A and B heater output cables and
RTD cables and see if issue follows. If
so, replace RTD.
Bad heater.
Confirm resistance of heater is 23-26.5
Ω. Replace if OL/open loop.
Low Temperature A
332637F
Troubleshooting
Error
T2DB
T2DE
T2DH
T2FA
T2FB
332637F
Type
Description
Cause
Solution
Low Temperature B
Flow is too high at
current setpoint.
Use a smaller mix chamber that is
rated for the unit in use. If recirculating,
decrease flow or decrease temperature
setpoint.
Bad RTD or bad
RTD placement
against heater.
Swap A and B heater output cables and
RTD cables and see if issue follows. If
so, replace RTD.
Bad heater.
Confirm resistance of heater is 23-26.5
Ω. Replace if OL/open loop.
Radiator fan will
not stop.
Replace fan relay.
Engine thermostat
is stuck closed.
Replace thermostat.
Flow is too high at
current setpoint.
Use a smaller mix chamber that is
rated for the unit in use. If recirculating,
decrease flow or decrease temperature
setpoint.
Cold chemical in
unheated portion
of system passed
hose FTS at
startup.
Recirculate heated chemical back to
drum in cold conditions before startup.
Inlet fluid
temperature is
below the defined
level.
Recirculate fluid through heaters until
inlet fluid temperature is above defined
error level.
Inlet fluid
temperature is
below the defined
level.
Recirculate fluid through heaters until
inlet fluid temperature is above defined
error level.
Low Temperature
Coolant Outlet
Low Temperature
Hose
Low Temperature
Inlet A
Low Temperature
Inlet B
Increase the low temperature deviation
level on the System Setup screen.
Increase the low temperature deviation
level on the System Setup screen.
29
Troubleshooting
Error
T3CH
T3CT
T3NM
T3CM
T4AE
30
Type
Description
Cause
Solution
Hose Cutback
Hose current has
been reduced
because hose
has been drawing
current for an
extended period.
Hose setpoint higher than A and B
setpoints. Decrease hose setpoint.
TCM Cutback
Motor Temperature
Cutback
Motor Temperature
Cutback
High Temperature
Heat Exchanger A
Hose FTS is in a colder environment
than the rest of the hose. Expose FTS
to the same environment as the rest of
the hose.
High ambient
temperature.
Ensure ambient temperature is below
120°F(48°C) before using the system.
Enclosure fan not
operating.
Ensure fan in electrical enclosure is
spinning. If it is not, check fan wiring or
replace fan.
Module fan not
operating.
If a TCM fan error (WMI0) has occurred,
fan inside the module is not working
properly. Check TCM fan for debris and
clear with forced air if necessary.
Motor is operating
outside of the
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.
Motor control
temperature is
too high.
Ensure ambient temperature is below
120°F(48°C).
Motor control
temperature is
too high.
Ensure ambient temperature is below
120°F(48°C).
Verify that all fans are working.
Verify that all fans are working.
Manual valve
Open cabinet cover and turn switch to
switch (MV) on
the OFF position.
load center is in the
ON position.
A or B side control
valve solenoid is
stuck in the open
position.
Debris in valve diaphragm or plunger
preventing spring-loaded closed function.
Disconnect connector from valve
solenoid cable. If temperature does not
decrease, rebuild solenoid.
Short on load
center board.
If the blue and red LEDs are on while
heat is off, the load center board is bad.
See Load Center Diagnostics in the
system repair manual.
332637F
Troubleshooting
Error
T4BE
T4CM
T4CT
332637F
Type
Description
Cause
High Temperature
Heat Exchanger B
Manual valve
Open cabinet cover and turn switch to
switch (MV) on
the OFF position.
load center is in the
ON position.
High Temperature
MCM
High Temperature
TCM
Solution
A or B side control
valve solenoid is
stuck in the open
position.
Debris in valve diaphragm or plunger
preventing spring-loaded closed function.
Disconnect connector from valve
solenoid cable. If temperature does not
decrease, rebuild solenoid.
Short on load
center board.
If the blue and red LEDs are on while
heat is off, the load center board is bad.
See Load Center Diagnostics in the
system repair manual.
J6 connector on
load center "Heat
Valves" location is
not centered.
Reconnect J6 connector on load center
in centered location.
High ambient
temperature.
Ensure ambient temperature is below
120°F(48°C) before using the system.
Enclosure fan not
operating.
Ensure fan in electrical enclosure is
spinning. If it is not, check fan wiring or
replace fan.
High ambient
temperature.
Ensure ambient temperature is below
120°F(48°C) before using the system.
Enclosure fan not
operating.
Ensure fan in electrical enclosure is
spinning. If it is not, check fan wiring or
replace fan.
Module fan not
operating.
If a TCM fan error (WMI0) has occurred,
fan inside the module is not working
properly. Check TCM fan for debris and
clear with forced air if necessary.
31
Troubleshooting
Error
T4DA
Type
Description
Cause
Solution
High Temperature A
Bad RTD or bad
RTD placement
against heater.
Swap A and B heater output cables and
RTD cables and see if issue follows. If
so, replace RTD.
Use a smaller mix chamber that is rated
Flow too high
for the unit in use.
for temperature
setpoint, causing
temperature
overshoots when
gun is de-triggered.
T4DB
High Temperature B
Bad RTD or bad
RTD placement
against heater.
Swap A and B heater output cables and
RTD cables and see if issue follows. If
so, replace RTD.
Use a smaller mix chamber that is rated
Flow too high
for the unit in use.
for temperature
setpoint, causing
temperature
overshoots when
gun is de-triggered.
T4DE
T4DH
High Temperature
Coolant Outlet
High Temperature
Hose
Broken fan.
Check fan relay (K4) and fuse (30 Amp
ATO "F3") on load center board. Replace
if needed.
Plugged radiatior.
Replace if needed.
High ambient
temperature.
Ensure ambient temperature is below
120°F(48°C) before using the system.
Hose portion
exposed to an
excessive heat
source, like hot
sun or coiled
hose, can pass
fluid more than
27°F (15°C) over
hose temperature
setting to the FTS.
Shade exposed hose from hot sun or
expose FTS to same environment when
at rest. Uncoil entire hose before heating
to avoid self-heating.
Increase hose setpoint so it is closer to
Setting the A or
A and B setpoints.
B setpoint much
higher than hose
setpoint can cause
fluid more than
27°F (15°C) over
hose temperature
setting to reach the
FTS.
32
332637F
Troubleshooting
Error
T4EA
T4EB
332637F
Type
Description
Cause
Solution
High Temperature
Switch A
Overtemperature
switch sensed a
fluid temperature
above 230°F
(110°C).
Heater was delivered too much power,
causing the overtemperature switch to
open. RTD is not reading properly. After
the heater cools down, replace RTD.
Switch closes and the error can be
cleared when the heater temperature
falls below 190°F (87°C).
Disconnected
or loose
overtemperature
switch
cable/connection.
If heater is not actually over temperature,
check all wiring and connections between
the TCM and the overtemperature
switches.
Overtemperature
switch failed in the
open position.
Replace overtemperature switch.
Overtemperature
switch sensed a
fluid temperature
above 230°F
(110°C).
Heater was delivered too much power,
causing the overtemperature switch to
open. RTD is not reading properly. After
the heater cools down, replace RTD.
Switch closes and the error can be
cleared when the heater temperature
falls below 190°F (87°C).
Disconnected
or loose
overtemperature
switch
cable/connection.
If heater is not actually over temperature,
check all wiring and connections between
the TCM and the overtemperature
switches.
Overtemperature
switch failed in the
open position.
Replace overtemperature switch.
High Temperature
Switch B
33
Troubleshooting
Error
T4NM
T6AE
T6BE
T6DA
34
Type
Description
Cause
Solution
High Temperature
Motor
Cooling fan is not
operating properly.
Check to see that the motor fan is
moving. Measure voltage to fan. There
should be 24 VDC. If no voltage is
measured, check fan wiring.If the fan has
voltage but is not moving, replace fan.
If necessary use an air hose to blow out
around the fan housings and remove any
built-up debris.
Disconnected
or loose motor
temperature cable.
Verify wiring between the motor
temperature sensor and the MCM.
High ambient
temperature.
Ensure ambient temperature is below
120°F(48°C) before using the system.
Bad electric motor.
Replace electric motor.
Disconnected or
loose RTD cable or
connection.
Check all wiring and connection to RTD.
Bad RTD.
Switch the RTD with another and see
if the error message follows the RTD.
Replace RTD if the error follows the RTD.
Disconnected or
loose RTD cable or
connection.
Check all wiring and connection to RTD.
Bad RTD.
Switch the RTD with another and see
if the error message follows the RTD.
Replace RTD if the error follows the RTD.
Disconnected or
loose RTD cable or
connection.
Check all wiring and connection to RTD.
Bad RTD.
Switch the RTD with another and see
if the error message follows the RTD.
Replace RTD if the error follows the RTD.
Sensor Error Heat
Exchanger A
Sensor Error Heat
Exchanger B
Sensor Error A
332637F
Troubleshooting
Error
T6DB
T6DE
Type
Description
Cause
Solution
Sensor Error B
Disconnected or
loose RTD cable or
connection.
Check all wiring and connection to RTD.
Bad RTD.
Switch the RTD with another and see
if the error message follows the RTD.
Replace RTD if the error follows the RTD.
Sensor Error Coolant Disconnected or
loose RTD cable or
Outlet
connection.
Bad RTD.
Check all wiring and connection to RTD.
Switch the RTD with another and see
if the error message follows the RTD.
Replace RTD if the error follows the RTD.
T6DH
Sensor Error Hose
Disconnected or
Expose each hose RTD connection
shorted RTD cable to check and retighten any loose
in hose or bad FTS. connector. Measure hose RTD
cable and FTS continuity. See
Repair Heated Hose, page 86. Order
RTD Test kit 24N365 for measurement.
Disconnect hose RTD and use manual
hose mode to finish job until repair can
be completed.
T6DT
Sensor Error TCM
Shorted RTD cable Expose each hose RTD connection
to check for exposed and shorted
in hose or FTS.
RTD wires. Measure hose RTD
cable and FTS continuity. See
Repair Heated Hose, page 86. Order
RTD Test kit 24N365 for measurement.
Disconnect hose RTD and use manual
hose mode to finish job until repair can
be completed.
Shorted Heater A
or B RTD
332637F
If the error still occurs with the hose FTS
unplugged, one of the heater RTDs is
bad. Unplug the A or B RTD from the
TCM. If unplugging an RTD fixes the
T6DT error, replace the RTD.
35
Troubleshooting
Error
T8AE
Type
Description
Cause
No Temperature
No coolant flow.
Rise Heat Exchanger
A
Solution
Check coolant level. Check for coolant
flow in sight glass. Ensure that circulation
pump has 240 VAC. If not, replace the
circulation pump.
Low chemical
supply
temperature.
Chemical below 32°F(0°C) at startup.
Recirculate cold chemical back to drum
in cold conditions before spraying.
System stored
below 20°F(-7°C)
causing slow
coolant valve
operation.
Ensure ambient temperature is above
20°F(-7°C) .
Bad valve solenoid. Turn on the manual valve switch (MV),
on the load center, and see if the valve
shifts. If not replace solenoid.
Bad load center.
36
Red, blue, and green LEDs should light
up on load center board. If not, replace
load center.
332637F
Troubleshooting
Error
T8BE
Type
Description
Cause
No Temperature
No coolant flow.
Rise Heat Exchanger
B
Solution
Check coolant level. Check for coolant
flow in sight glass.Ensure that circulation
pump has 240 VAC. If not, replace the
circulation pump.
Low chemical
supply
temperature.
Chemical below 32°F(0°C) at startup.
Recirculate cold chemical back to drum
in cold conditions before spraying.
System stored
below 20°F(-7°C)
causing slow
coolant valve
operation.
Ensure ambient temperature is above
20°F(-7°C) .
Bad valve solenoid. Turn on the manual valve switch (MV),
on the load center, and see if the valve
shifts. If not replace solenoid.
T8DA
No Temperature
Rise A
Bad load center.
Red, blue, and green LEDs should light
up on load center board. If not, replace
load center.
J6 connector on
load center "Heat
Valves" location is
not centered.
Reconnect J6 connector on load center
in centered location.
Bad heater rod.
Measure resistance of heater rod, should
be 23-26 Ω. Replace if open.
Bad RTD or bad
RTD placement
against heater.
Swap A and B heater output cables and
RTD cables and see if issue follows. If
so, replace RTD.
Bad valve solenoid. Turn on the manual valve switch (MV),
on the load center, and see if the valve
shifts. If not replace solenoid.
Started spraying
before heater
reached operating
temperature.
332637F
Wait until operating temperature has
been reached before spraying or
recirculating.
37
Troubleshooting
Error
T8DB
Type
Description
Cause
Solution
No Temperature
Rise B
Bad heater rod.
Measure resistance of heater rod, should
be 23-26 Ω. Replace if open.
Bad RTD or bad
RTD placement
against heater.
Swap A and B heater output cables and
RTD cables and see if issue follows. If
so, replace RTD.
Bad valve solenoid. Turn on the manual valve switch (MV),
on the load center, and see if the valve
shifts. If not replace solenoid.
Started spraying
before heater
reached operating
temperature.
Wait until operating temperature has
been reached before spraying or
recirculating.
T8DH
No Temperature
Rise Hose
Started spraying
before heater
reached operating
temperature.
Wait until operating temperature has
been reached before spraying or
recirculating.
V1CM
Low Voltage MCM
Loose/bad
connection or
tripped circuit
breaker.
Check wiring for loose connection or
tripped circuit breaker.
Low generator line
voltage.
Measure voltage across main power
switch (CT01). Voltage should measure
between 195 and 264 VAC.
V1IT
Low Voltage CAN
Bad 24 VDC power Check voltage of power supply. Voltage
supply.
should be 23-25 VDC. If out of tolerance,
replace power supply.
V1MA
Low Voltage A
Loose connection
or tripped circuit
breaker.
Check wiring for loose connection or
tripped circuit breaker.
Low generator line
voltage.
Measure voltage across main power
switch (CT01). Voltage should measure
between 195 and 264 VAC.
High auxilary
inrush current.
Ensure compressor or air drier are set up
to be continuous run and sized according
to the manual.
38
332637F
Troubleshooting
Error
V1MB
V1MH
Type
Description
Cause
Solution
Low Voltage B
Loose connection
or tripped circuit
breaker.
Check wiring for loose connection or
tripped circuit breaker.
Low generator line
voltage.
Measure voltage across main power
switch (CT01). Voltage should measure
between 195 and 264 VAC.
High auxilary
inrush current.
Ensure compressor or air drier are set up
to be continuous run and sized according
to the manual.
Loose connection
or tripped circuit
breaker.
Check wiring for loose connection or
tripped circuit breaker.
Low generator line
voltage.
Measure voltage across main power
switch (CT01). Voltage should measure
between 195 and 264 VAC.
High auxilary
inrush current.
Ensure compressor or air drier are set up
to be continuous run and sized according
to the manual.
Low Voltage Hose
V2IT
Low Voltage CAN
Bad 24 VDC power Check voltage of power supply. Voltage
supply.
should be 23-25 VDC. If out of tolerance,
replace power supply.
V3IT
High Voltage CAN
Bad 24 VDC power Check voltage of power supply. Voltage
supply.
should be 23-25 VDC. If out of tolerance,
replace power supply.
V4CM
High Voltage MCM
Incoming line
voltage is too high.
V4IT
High Voltage CAN
Bad 24 VDC power Check voltage of power supply. Voltage
supply.
should be 23-25 VDC. If out of tolerance,
replace power supply.
332637F
Measure voltage across main power
switch (CT01). Voltage should measure
between 195 and 264 VAC. If voltage is
too high, see supplied alternator manual
for generator specifics and repair.
39
Troubleshooting
Error
Type
Description
Cause
Solution
V4MA
High Voltage A
Incoming line
voltage is too high.
Measure voltage across main power
switch (CT01). Voltage should measure
between 195 and 264 VAC. If voltage is
too high, see supplied alternator manual
for generator specifics and repair.
V4MB
High Voltage B
Incoming line
voltage is too high.
Measure voltage across main power
switch (CT01). Voltage should measure
between 195 and 264 VAC. If voltage is
too high, see supplied alternator manual
for generator specifics and repair.
V4MH
High Voltage Hose
Incoming line
voltage is too high.
Measure voltage across main power
switch (CT01). Voltage should measure
between 195 and 264 VAC. If voltage is
too high, see supplied alternator manual
for generator specifics and repair.
WBC0
Software Version
Error
Incorrect software
version.
Insert a system token into the ADM
module and cycle the power. Wait until
the upload is complete before removing
the token.
WMCE
Load Center Fault
Bad connection
between MCM and
load center board.
Check connection and cables.
Bad load center.
Replace load center.
WMI0
TCM Fan Error
Fan inside TCM
is not operating
properly.
Check for debris in the TCM fan and
clear with forced air if necessary.
WSUX
Configuration Error
USB
A valid
configuration file
can't be found for
the USB.
Inset a system token into the ADM and
cycle power. Wait until the lights on the
USB port stop flashing before removing
token.
WXUD
USB Download Error
Log download
failed.
Backup and reformat the USB drive.
Retry download.
WXUU
USB Upload Error
Custom language
Perform normal USB download and use
file failed to upload. the new disptext.txt file to upload the
custom language.
40
332637F
Troubleshooting
System
See Supplied Manuals, page 14, for air compressor service or warranty contact information.
Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 59.
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
Repair Circuit Breaker Module,
page 76.
Check circuit breaker (CB10). See
Repair Circuit Breaker Module,
page 76.
Electric motor does not operate.
Electric motor runs erratically.
332637F
Loose connections.
Check MCM connections. See
Electrical Schematics, page 156.
Tripped circuit breaker (CB02).
Reset breaker, see Repair Circuit
Breaker Module, page 76. Check
240VAC at output of breaker.
Shorted windings.
Replace motor, see
Repair Electric Motor, page 75.
Failed motor bearings.
Replace motor, see
Repair Electric Motor, page 75.
41
Troubleshooting
Problem
Electric motor cooling fan 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 156.
Fan blade obstructed.
Remove obstruction.
Defective fan.
Replace. See
Replace Motor Fan, page 81.
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 156.
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 dryer cooling fan not running.
Only runs after air reaches a
minimum temperature.
Normal operation.
Air dryer not draining water.
Power not turned on at dryer.
Turn dryer switch ON ( | ).
No air usage.
Check after air flowing.
Pump output low.
Air dryer fault light comes on after
turning dryer power on.
If compressor was running with
Tuff off compressor long enough
dryer off (O), the air temperature is for air temperature to dryer to cool
too high to start dryer.
down. Then turn dryer on ( | ).
Air dryer drain tube is blowing air.
Dryer separator/filter plugged or
drain float not working.
42
Refer to dryer manual to
clean/replace filter element of
bowl float.
332637F
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 67.
Coolant hoses between the
proportioner coolant loop and
engine coolant loop were modified
and created a high point air pocket.
Ensure coolant hoses have a
constant rise in elevation.
Proportioner coolant loop
expansion bottle is empty.
See Refill Proportioner Coolant
Loop, page 67.
Circulation pump stopped running.
Check circuit breaker. Check
voltage.
Bypass control valve does not
open.
Repair or replace valve. See
Replace Control Valve, page 94.
Coolant filter plugged.
Clean or replace filter in filter
housing, see Repair Filter Housing
Filter, page 96 and order replacement filter kit 24T028.
A and B control valves are not
opening fully.
Repair or replace valve. See
Replace Control Valve, page 94.
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 65.
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
Replace Control Valve, page 94.
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
Replace Control Valve, page 94.
Control valve coil not allowing
valve to normally close.
Repair or replace valve coil. See
Replace Control Valve, page 94.
Control valve stuck in open
position.
Repair valve. See
Replace Control Valve, page 94.
Bad load center.
Replace the load
center board. See
Replace Load Center, page 79.
Heat exchanger coolant flow
stopped. No flow in sight glass.
Material slowly heats up.
A or B material cooling down
slower than the other.
332637F
43
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
Remove Radiator, page 100.
Engine thermostat not opening.
Replace engine thermostat.
Coolant level is low in expansion
bottle.
Refill Engine Coolant Loop, page
68.
No coolant flow in engine coolant
loop.
Heat exchanger in the engine
coolant loop is plugged.
Replace heat exchanger. See
Replace Heat Exchangers, page
91.
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.
Coolant level dropping in overflow
bottle but no visible leaks.
Cap not fully tightened.
Push down and tighten cap past
safety latch position.
44
332637F
Troubleshooting
Hose Heat System
Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 59.
2. Turn main power switch OFF.
3. Allow equipment to cool.
Problem
Hose heats but heats slower
than usual or it does not reach
temperature.
Hose does not maintain
temperature while spraying.
Hose temperature exceeds
setpoint.
332637F
Cause
Solution
Ambient temperature is too cold.
Use auxiliary hose heat system.
FTS failed or not installed correctly.
Check FTS, see Check RTD
Cables and FTS, page 86.
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 156.
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.
45
Troubleshooting
Problem
Erratic hose temperature.
Hose does not heat.
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 Repair Fluid Temperature
Sensor (FTS), page 88.
FTS failed.
Check FTS, see Repair Fluid
Temperature Sensor (FTS), page
88.
FTS not installed correctly.
FTS should be installed close to
end of hose in same environment
as gun. Verify FTS installation,
see Repair Fluid Temperature
Sensor (FTS), page 88.
Loose hose electrical connections. Check connections. Repair as
necessary.
46
Circuit breakers tripped.
Reset breakers (CB20 and CB02),
see Repair Circuit Breaker Module,
page 76.
Hose zone not turned on.
Turn on hose heat zone.
A and B temperature setpoints too
low.
Check. Increase if necessary.
Failed TCM.
Remove TCM and install a new
TCM. New module comes with
current software. Update other
modules if necessary. See
software installation instruction
manual.
332637F
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 Power
Connectors, page 86.
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
332637F
Relocate hoses to a warmer area
or increase A and B setpoints.
47
Troubleshooting
Booster Heater
Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 59.
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.
48
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.
Failed heater element.
See
Replace Heater Element, page 83.
Loose RTD connections.
Examine RTD cables connected
to TCM. Confirm RTDs are not
plugged into opposite heat zone.
Reconnect RTD connectors.
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
Replace Heater Element, page 83.
Signal failure from RTD.
See (T4DA, T4DB),
Error Codes, page 16.
332637F
Troubleshooting
Load Center Diagnostics
Reference Replace Load Center Relays and Fuses, page 78, and Electrical Schematics, page 156. The LEDs
on the load center board are helpful diagnostic tools when troubleshooting problems with the engine. Before
referencing the Engine Troubleshooting, page 52, complete the following steps:
1. Identify which LEDs are on and off.
Load Center Component Identification
Figure 1
F3
F4
K1
K2
K3
K4
MV
LED
D1
D2
D3
D4
D10
D12
D14
D23
332637F
Manual Valve Switch ON (engine off)
Figure 2
Radiator Fan Fuse
Load Center Power Fuse
Fuel Relay
Starter Relay
Glow Plug Relay
Radiator Fan Relay
Manual Valve Switch
Related Component
Fuel Shutoff Solenoid
Starter
Glow Plugs
Radiator Fan
A Coolant Valve
B Coolant Valve
Bypass Coolant Valve
Manual Valve Switch
Color
Green
Red
Green
Green
Red
Blue
Green
Red
ON--State Description
ON
Fuel shutoff solenoid on the engine is open.
Starter is cranking.
Glow plugs are heating.
Radiator fan is on.
A-side (red) coolant valve is open.
B-side (blue) coolant valve is open.
Bypass coolant valve is open.
Manual valve switch is in the ON position.
49
Troubleshooting
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.
Table 1 lists a likely order of potential failures in the
load center output-side components.
Table 1 – LEDs Light As Expected
Note
The starter, fuel shutoff solenoid, glow
plugs, and radiator fan operations are
sequenced during startup by the Engine
Control Module.
1
2
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
4. For potential causes and solutions related
to the components in Tables 1 and 2, see
Engine Troubleshooting, page 52.
50
Starter
(D2)
Glow Plugs
(D3)
Engine
Fuel
Shutoff
Solenoid
(FD)
Starter
Solenoid
Relay
(CR6)
Glow Plugs
Solenoid
Relay
(CR7)
3
Engine
Starter
Motor (ES)
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
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.
Radiator
Fan
(D4)
Engine Harness (E) and its connections
Fuel
(D1)
Starter
(D2)
Glow
Plugs
(D3)
Radiator
Fan
(D4)
Battery
Battery cables and its connections
No D2 LED
Disconnect
switch ON
Load
Center
Load Center Fuse F4
Fuse F3
("PWR - ATO 20A")
("FAN ATO 30A")
Fusible Link Harness (C) and its connections
9
Engine Harness (E) and its connections
Engine Control Module Harness (F) and
its connections
Load
Load
Load
Load
Center
Center
Center
Center Fan
Fuel Relay
Starter
Glow
Relay (K4)
(K1)
Relay (K2) Relay (K3)
Load Center Board
10
Engine Control Module
6
7
8
332637F
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.
332637F
51
Troubleshooting
Engine
Contact Perkins for diesel engine service or warranty. See Supplied Manuals, page 14.
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
Replace Battery, page 97.
52
Loose or incorrect wiring
connections.
Verify wiring connections
(including grounds) related
to Engine Control Module.
Check Engine Harness (E),
Engine Control Module Harness
(F), Fusible Link Harness
(C), and battery cables. See
Electrical Schematics, page 156.
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
Replace Load Center Relays and
Fuses, page 78.
Blown fusible link.
Verify continuity through
fusible link harness from
starter to 12V charge alternator. If required, replace
Fusible Link Harness (C). See
Electrical Schematics, page 156.
See Repair Fusible Link Harness,
page 98.
Failed Engine Control Module.
Replace module. See Replace
Engine Control Module, page 101.
Failed Load Center board.
Replace board. See
Replace Load Center, page 79.
332637F
Troubleshooting
Problem
Cause
Solution
Reference Load Center Diagnostics, page 49.
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
Replace Battery, page 97.
332637F
Loose or corroded battery cable
connector.
Verify cable connectors. See
Replace Battery, page 97.
Loose or incorrect wiring
connections.
Verify wiring connections
(including grounds) related to
starter. Check Engine Harness
(E), Engine Control Module
Harness (F), Fusible Link Harness
(C), Disconnect Check Harness
(H), and battery cables. See
Electrical Schematics, page 156.
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
Replace Load Center Relays and
Fuses, page 78.
Failed starter relay.
Replace relay K2 located
on Load Center board. See
Replace Load Center Relays and
Fuses, page 78.
Failed starter solenoid relay.
Replace solenoid relay CR6
located on side of engine. See
Replace Engine Solenoid Relays,
page 79.
Blown fusible link.
Verify continuity through
fusible link harness from
starter to solenoid relay
CR6. If required, replace
Fusible Link Harness (C). See
Electrical Schematics, page 156.
Failed load center board (242).
Replace board. See
Replace Load Center, page 79.
Failed engine control module
(428).
Replace module. See Replace
Engine Control Module, page 101.
Failed engine starter (ES).
Contact local Perkins distributor
for service.
53
Troubleshooting
Problem
Cause
Solution
Reference Load Center Diagnostics, page 49.
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.
Verify wiring connections
(including to grounds) related
to engine fuel shutoff solenoid.
Check Engine Harness (E), Engine
Control Module Harness (F), and
Fusible Link Harness (C). See
Electrical Schematics, page 156.
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
Replace Load Center Relays and
Fuses, page 78.
Solenoid valve rod stuck in
extended position.
Remove valve rod and clean with
WD-40.
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 Replace
Engine Solenoid Relays, page 79.
Failed glow plug solenoid relay.
Replace solenoid relay CR7
located on side of engine. See
Replace Engine Solenoid Relays,
page 79.
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.
54
332637F
Troubleshooting
Problem
Cause
Solution
Reference Load Center Diagnostics, page 49.
Engine shuts down, Engine
Control Module shows no errors.
Loose or incorrect wiring
connections.
Verify wiring connections
(including grounds) related to
engine fuel shutoff solenoid.
Check Engine Harness
(E), and Engine Control
Module Harness (F). See
Electrical Schematics, page 156.
Failed fuel relay.
Replace relay K1 located
on Load Center board. See
Replace Load Center Relays and
Fuses, page 78.
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.
332637F
55
Troubleshooting
Problem
Cause
Solution
Reference Load Center Diagnostics, page 49.
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.
Engine water temperature switch
failed or shorted out.
Check for shorts to
switch wiring. See
Electrical Schematics, page 156.
Loose or incorrect wiring
connections.
Verify wiring connections
(including grounds) related to
radiator fan. Check Engine
Harness (E), and Engine Control
Module Harness (F). See
Electrical Schematics, page 156.
Blown radiator fan fuse.
Determine cause of blown fuse
F3 "FAN - ATO 30A". Repair
issue then replace fuse. See
Replace Load Center Relays and
Fuses, page 78.
Failed radiator fan relay.
Replace relay K4 located
on Load Center board. See
Replace Load Center Relays and
Fuses, page 78.
Obstructed radiator fan.
Remove obstructions.
Failed radiator fan.
Replace fan. See
Replace Radiator Fan, page 82.
Failed engine coolant temperature
sensor.
Replace engine coolant
temperature sensor located
behind radiator connected
to MCM port 3. See
Replace Engine RTD, page 106.
Plugged radiator or coolant
system.
Clean or replace radiator. See
Remove Radiator, page 100.
Contact local Perkins distributor
for service.
56
332637F
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.
Verify wiring connections
(including grounds) related to
oil pressure switch. Check
Engine Harness (E), and Engine
Control Module Harness (F). See
Electrical Schematics, page 156.
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.
Verify wiring connections related
to Engine Control Module, Check
AC Sense Harness (M). See
Electrical Schematics, page 156.
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
332637F
.
57
Troubleshooting
Graco InSite
Problem
No module status LEDs are
illuminated.
Cause
No power to cellular module.
Has not identified GPS location
(green module status LED
flashing).
Still identifying location.
Unable to identify location. In a
location where GPS lock cannot
occur. Buildings and warehouses
often prevent GPS locks.
Has not established cellular
connection (orange module status
LED flashing).
Still establishing cellular
connection.
Unable to establish cellular
connection.
Cannot view data for my unit(s) on
website.
Graco InSite unit has not been
activated.
Reactor temperature data not
displayed on website.
Hose zone temperature data not
displayed on website.
Reactor pressure data not
displayed on website.
Reactor temperature
measurement is not working.
The RTD is not correctly installed
on the hose or is broken.
Reactor pressure measurement is
not working.
58
Solution
Turn Reactor power ON.
Ensure cable is installed between
cellular module and power supply
and MCM.
Wait a few minutes for the unit to
identify the location.
Move system to a location with a
clear view of the sky.
Use extension cable 16X521 and
move cellular module to a location
with a clear view of the sky.
Wait a few minutes for the unit to
establish the connection.
Move system to a location with
cellular service to establish cellular
connection.
Use extension cable 16X521 and
move cellular module to a location
with a clear view of the sky.
Activate unit. See Registering
and Activating the Graco InSite
section.
See System troubleshooting
section.
See RTD repair section.
See System troubleshooting
section.
332637F
Pressure Relief Procedure
Pressure Relief Procedure
Follow the Pressure Relief Procedure
whenever you see this symbol.
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.
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.
5. Engage gun piston safety lock.
The Fusion AP gun is shown.
1. Relieve pressure in gun and perform gun
shutdown procedure. See gun manual.
2. Close gun fluid inlet valves A and B.
Fusion
Fusion
Probler
6. Disconnect gun air line and remove gun fluid
manifold.
Probler
3. Shut off feed pumps and agitator, if used.
332637F
59
Shutdown
Shutdown
Shutdown system to avoid electric shock. All
electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations. 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.
2. Turn off all heat zones.
Immediate Shutdown
NOTICE
To avoid system damage, follow daily shutdown
procedure. Use only for immediate shutdown.
3. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION
.
For immediate shutdown, press:
4. Relieve pressure. See
Pressure Relief Procedure, page 59.
5. Press
to park the Component A Pump. The
park operation is complete when green dot goes
out. Verify the park operation is complete before
moving to next step.
Daily Shutdown
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.
1. Press
60
6. Press
to deactivate the system.
to stop the pumps.
332637F
Shutdown
7. Turn off the air compressor, air dryer, and
breathing air.
8. Close the main air shutoff valve.
9. Turn main power switch OFF. Allow engine
cooling dwell time prior to shutting down the
engine.
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.
NOTICE
Allow engine cooling dwell time, per
manufacturer recommendations, prior to
shutdown. Dwell time will help engine
properly cool down after running at operating
temperature for any period of time. Stopping
the engine immediately after running it at
full load for an extended period of time can
cause the engine to overheat due to the lack of
coolant flow. See engine manual.
10. Press
to stop the engine.
11. Close all fluid supply valves.
332637F
61
Shutdown
12. Engage gun piston safety lock then close fluid
inlet valves A and B.
Fusion
62
Probler
332637F
Flushing
Flushing
To flush feed hoses, pumps, and heaters
separately from heated hoses, set PRESSURE
RELIEF/SPRAY valves (SA, SB) to PRESSURE
RELIEF/CIRCULATION
lines (N).
. Flush through bleed
To avoid fire and explosion:
• Flush equipment only in a well-ventilated area.
• Do not turn on heaters until fluid lines are clear
of solvent.
• 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.
332637F
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 Isocyanate Information.
63
Repair
Repair
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).
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. 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.
1. Flush if necessary. See Flushing, page 63.
2. See Shutdown, page 60.
Flush Inlet Strainer Screen
A
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.
B
C
D
Figure 3
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.
64
332637F
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.
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.
1. Perform Shutdown, page 60.
2. Open the cabinet door on 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.
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.
b. 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.
MV
Proportioner Coolant Loop Drain Valve
Figure 5
LC
c.
To refill coolant loop, see
Refill Proportioner Coolant Loop, page 67.
LC
Figure 4
332637F
65
Repair
5. To drain proportioner coolant loop from filter
housing. Only available on Series B systems.
a. Remove the proportioner coolant loop fill
bottle cap (HF).
b. Remove engine guards as shown. Let the
guards rest on the engine to access the drain
valve.
5 &
+ )
+
7
'
Filter Housing Drain Valve (D)
Figure 6
b. Place the other end of the filter housing drain
tube (T) in a waste container. Open the drain
valve (D).
c.
To refill coolant loop, see
Refill Proportioner Coolant Loop, page 67.
6. To drain engine coolant loop:
a. Remove the engine coolant loop (RC) cap.
Engine Coolant Loop Drain Valve
Figure 7
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 68.
e. Replace engine shrouds. Torque screws to
25 ft-lbs (33.8 N∙m).
66
332637F
Repair
Refill Proportioner Coolant Loop
Purge air from proportioner coolant loop when it is
filled with new coolant or when air enters the coolant
system.
NOTICE
To prevent leaks, do not interchange the two
caps between the radiator and coolant bottle.
The caps have different pressure ratings that
affect the overflow.
Note
It takes about one full warm-up and
cool-down cycle to purge air from coolant.
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 69.
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 69.
NOTICE
Do not refill with drained coolant. Use only fresh,
new coolant to avoid contaminants.
NOTICE
Do not use any “stop leak” additives to prevent
plugged filters and small orifices.
Coolant System Bottles
Figure 8
1. Before refilling coolant loop, perform steps 1–3
from Drain Coolant, page 65. Drain coolant loop
if necessary.
332637F
67
Repair
3. Replace cap and tighten past the safety latch
position.
4. Press start button
control module.
twice on the engine
NOTICE
Do not refill with drained coolant. Use only fresh,
new coolant to avoid contaminants.
NOTICE
5. Turn main power switch on.
Do not use any “stop leak” additives to prevent
plugged filters and small orifices.
1. Perform Shutdown, page 60.
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.
NOTICE
To prevent leaks, do not interchange the two
caps between the radiator and coolant bottle.
The caps have different pressure ratings that
affect the overflow.
2. Remove the engine radiator coolant cap (RC)
and fill until the coolant reaches the bottom of the
neck. See Fig 8, page 67. Replace cap. See
Coolant Specifications, page 69.
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).
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.
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.
12. If necessary, refill or add coolant to the expansion
bottle (HB) cold level indicator line. See Fig 8.
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.
Refill Engine Coolant Loop
Refill the engine coolant loop when the coolant is
below the cold level line at ambient temperature.
8. Press
To avoid burns, do not perform maintenance on
the coolant system until the coolant system has
reached ambient temperature.
to stop the generator.
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.
Only use coolant solutions that are compatible with
the system. See Coolant Specifications, page 69.
68
332637F
Repair
Coolant Specifications
NOTICE
Do not refill with straight water or tap water.
Changing the 50% mix ratio use of tap water will
allow fittings to rust.
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. Do not
use any stop leak products. The additives in these
products will clog the heat exchanger and fluid valves,
decreasing system performance. 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.
To change pump lubricant:
1. Follow Pressure Relief Procedure, page 59.
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.
4. When the reservoir is flushed clean, fill with fresh
lubricant.
5. Thread the reservoir onto the cap assembly and
place it in the bracket.
6. The lubrication system is ready for operation. No
priming is required.
Change Pump 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.
Gel formation is due to moisture absorption by the
pump lubricant. The interval between changes
depends on the environment in which the equipment
is operating. The pump lubrication system minimizes
exposure to moisture, but some contamination is still
possible.
Lubricant discoloration is due to continual seepage of
small amounts of isocyanate past the pump packings
during operation. If the packings are operating
properly, lubricant replacement due to discoloration
should not be necessary more often than every 3 or
4 weeks.
332637F
Pump Lubrication System
Figure 9
69
Repair
Remove Pump
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.
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.
Note
11. Open air compressor bleed valve to relieve
pressure and remove water from tank.
See manual 309577 for pump repair
instructions.
12. Shut off both feed pumps. Close all fluid supply
valves.
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.
13. Route fluid to waste containers or supply tanks.
Turn PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION
7. Close the main air shutoff valve.
. Ensure gauges drop to 0.
8. Turn main power switch off.
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.
70
332637F
Repair
Note
Use drop cloth or rags to protect Reactor
and surrounding areas from spills.
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 expose rod retaining pin. Push
retaining wire clip up. Push pin out. Continue
unscrewing pump.
Pump B
Figure 11
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).
Install Pump
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. 11, page 54 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.
Pump A
Figure 10
4. Reconnect fluid inlet (C) and outlet (D).
5. Go to step 13.
1
Flat side faces up.
Note
2
Lubricate threads with ISO oil or grease.
Steps 6–12 apply to pump A only.
3
Pump top threads must be nearly flush with
bearing face (N).
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.
18. Push retaining wire clip (E) up. Push pin (F)
out. Loosen locknut (G) by hitting firmly with a
non-sparking hammer. Unscrew pump.
332637F
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.
7. Start threading pump into bearing housing (M).
When pin holes align, insert pin. Pull retaining
wire clip down.
8. 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.
71
Repair
9. Connect component A outlet tube loosely at
pump and at heater. Line up tube, then tighten
fittings securely.
10. Tighten star-shaped 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. Secure each tube
with a wire tie between two barbs.
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.
Note
Do not let tubes kink or buckle.
8. Turn main power switch off.
12. Reconnect fluid inlet (C).
13. Purge air and prime the system. See Reactor
operation manual.
Repair Drive Housing
Removal
1. Press
to stop the pumps.
2. Turn off heat zones.
3. Flush pump.
72
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.
332637F
Repair
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. Perform Pressure Relief Procedure, page 59.
13. Remove screws (294) and motor shield (293),
see Fig. 12.
Figure 12
Note
Examine bearing housing (303) and
connecting rod (305). If these parts need
replacing, first remove the pump (315),
see Remove Pump, page 70.
14. Remove cover (74) and screws (75).
15. Remove cycle switch (321) from A side drive
housing. Remove screws (322) and cycle switch
(321).
16. Disconnect pump inlet and outlet lines. Remove
screws (313), washers (314), and bearing
housing (303).
NOTICE
Do not drop gear cluster (304) when removing
drive housing (302). Gear cluster may stay
engaged in motor front end bell (R) or drive
housing.
17. Remove screws (312) and pull drive housing
(302) off motor (301).
Note
The A side drive housing includes
cycle counter switch (321). Switch wire
connects to port #12 on the MCM.
Figure 13
Installation
1. Apply grease liberally to washers (307, 308,
318), all gears, and inside drive housing (302).
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
Drive housing crankshaft must be in line
with crankshaft at other end of motor.
See Fig. 13, page 56.
332637F
73
Repair
4. Push drive housing (302) onto motor (301).
Install screws (312).
Note
If bearing housing (303), connecting rod
(305), or pump (315, 306) were removed,
reassemble rod in housing and install
pump, see Install Pump, page 71 .
5. Install cycle counter switch (3210) and screws
(322).
6. Install bearing housing (303), screws (313), and
washers (314). Pumps must be in phase (both at
same position in stroke).
7. Install cover (74) and screws (75).
8. Install motor shield (293) and screws (294).
Figure 14
74
332637F
Repair
Repair Electric Motor
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 Repair Drive Housing, page 72.
2. Disconnect electric motor (301) power cable from
port #15 on the MCM.
3. Remove screws (294) and motor shield (293).
Rest motor shroud assembly behind the motor
without straining the fan power cable.
Installation
1. Place motor on unit. Thread motor
cables into conduit as before. See
Electrical Schematics, page 156.
2. Fasten motor (301) with screws (268) 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 (268) to
align the motor (301) with side brackets.
3. Install drive housing and pump assemblies, see
Installation, page 73.
4. Disconnect over temperature cable from port
#2 on MCM. Cut tie wraps around harness to
remove cable.
5. Remove four screws (268) holding motor (301) to
bracket. Lift motor off unit.
4. Route motor (301) power cable from motor
through top port into Reactor cart, through back
port out of the Reactor, through cord grip (518),
and into the electrical enclosure. Connect to port
#15 on MCM. Use tie wraps to secure power
cable to other cables on pallet.
5. Install drive housing covers and motor cover.
6. Return to service.
332637F
75
Repair
Repair Circuit Breaker Module
b. Follow Shutdown instructions. See
Shutdown, page 60.
c.
Refer to circuit breaker identification table
and electrical diagrams in Reactor repair
manual.
d. Loosen four screws connecting wires and bus
bar to circuit breaker that will be replaced.
Disconnect wires.
1. See Before Beginning Repair, page 64.
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:
e. Pull locking tab out 1/4 in. (6mm) and pull
circuit breaker away from the din rail. Install
new circuit breaker. Insert wires and tighten
down all screws.
a. Refer to Electrical Schematics, page 156,
and tables on next page.
Circuit Breakers
Figure 15
CB01
CB02
CB03
CB04
CB05
CB06
CB07
CB08
15 A
20 A
40 A
20 A
TB1 2 TB11
30 A
15 A
15 A
5 A
PS1
Ref.
Size
Component
CB04
30 A
Hose Heat
Ref.
Size
Component
CB05
20 A
Motor Control
CB01
5A
Power Supply, Fan,
Coolant Pump
CB06*
40 A
Air Compressor/Open
CB02
15 A
Boost Heat A
CB07*
20 A
Open
CB03
15 A
Boost Heat B
CB08*
15 A
Air Dryer/Open
76
332637F
Repair
Circuit Breakers Inside Alternator Assembly
Figure 17
Circuit Breakers Inside Cabinet
Figure 16
Ref.
Size
Component
CB20
50 A
Heated Hose
332637F
Ref.
Size
Component
CB10
90 A
120/240V Alternator
77
Repair
Replace Load Center Relays and
Fuses
1. Disconnect the negative lug from the negative
post of the battery. See Replace Battery, page 97.
2. Remove the bad relay or fuse from the load
center (242) and install a new relay or fuse. See
Fig. 18.
3. Connect battery cable. See
Replace Battery, page 97.
Relay and Fuse Identification Table
See Load Center Wiring Diagram, page 165.
Repair
Kit
Ref
24L958
K1
K2
K3
K4
Load Center Relay and Fuse Identification
Figure 18
Component
Fuel Relay
Starter Relay
Glow Plug Relay
Fan Relay
Fuse for load center
F3 FAN-ATO - 30A relay K4 and radiator
fan.
Fuse for load center
relays K1, K2, K3
24L959
and their related
F4 PWR-ATO - 20A components; Engine
Control Module
power; and coolant
valve control.
78
332637F
Repair
Replace 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 60.
2. Disconnect the negative lug from the negative
post of the battery. See Replace Battery, page 97
Replace Engine Solenoid Relays
1. Perform Shutdown, page 60.
2. Disconnect the negative lug from the negative
post of the battery. See Replace Battery, page 97.
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 165.
3. Disconnect all connectors. See
Load Center Wiring Diagram, page 165.
4. Remove four nuts (248), and load center (240).
5. Install new load center (240) and
reconnect all connectors. See
Load Center Wiring Diagram, page 165.
6. Connect battery cable. See
Replace Battery, page 97.
Starter (top) and Glow Plug (bottom) Solenoid Relays
Figure 19
332637F
79
Repair
Replace Fluid Inlet Sensor
5. Replace sensor (866).
1. Perform Shutdown, page 60.
Replace Pressure Transducers
2. Perform Pressure Relief Procedure, page 59.
1. Perform Shutdown, page 60.
3. Disconnect inlet sensor cable from the
fluid inlet assembly. Inspect cable for
damage and replace if necessary. See
Electrical Schematics, page 156.
2. Perform Pressure Relief Procedure, page 59.
3. Disconnect transducer cables (455) from #6
and #7 connectors on the MCM. Reverse A
and B connections and check if error code
P6AX or P6BX follows the transducer. See
Error Codes, page 16.
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 #6. Connect B side pressure
transducer cable to MCM port #7.
Figure 20 Fluid Inlet Sensor
4. To replace sensor cable:
a. Open wire bundle and remove sensor cable.
b. Cut any wire ties and disconnect from MCM.
See Electrical Schematics, page 156.
NOTICE
To prevent damage to cable, route and
secure cable in wire bundle and wire ties
as before.
80
332637F
Repair
Replace Fans
Replace Proportioner Module Fan
1. Perform Shutdown, page 60.
2. Remove cabinet panel (70).
Shutdown system to avoid electric shock. To avoid
burns, do not perform maintenance on the fan until
the system has reached ambient temperature.
Replace Motor Fan
3. Refer to Electrical Schematics, page 156. Check
connections of all wires going to terminal blocks
TB21 and TB22. Verify that all screws are tight.
Using an voltmeter, check for 24 volts DC across
TB21(+) and TB22(-). Replace cable (22), if zero
volts are read. If volts are correct and fan doesn’t
spin, replace fan.
1. Perform Shutdown, page 60.
4. Remove fan (212).
2. Remove eight screws (75) and covers (74).
5. Install new fan (212) in reverser order of
disassembly.
3. Remove four screws (294) and cover (293).
4. Refer to Electrical Schematics, page 156. Check
connections of all wires going to terminal blocks
TB21 and TB22. Verify that all screws are tight.
Using an voltmeter, check for 24 volts DC across
TB21(+) and TB22(-). Replace cable (22), if zero
volts are read. If volts are correct and fan doesn’t
spin, replace fan.
5. Remove nuts (292) and fan (212).
6. Install new fan (212) in reverse order.
Figure 22
Figure 21
332637F
81
Repair
Replace Radiator Fan
Replace Electrical Enclosure Fan
1. Perform Shutdown, page 60.
1. Perform Shutdown, page 60.
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 156. Check
connections of all wires going to terminal blocks
TB13, TB14, and power supply PS1. Verify that
all screws are tight. Using an voltmeter, check
for 24 volts DC across TB13(+) and TB14(-).
Replace power supply PS1 (515), if zero volts
are read. If volts are correct and fan doesn’t spin,
replace fan.
4. Install new fan (561) in reverse order of
disassembly so that the fan blows out of the
electrical enclosure.
Figure 23
Figure 24
82
332637F
Repair
Repair Booster Heater
Replace Heater Element
10. Press
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 59.
13. Wait for heater to cool.
14. Remove heater shroud (266).
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.
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,
Replace RTD, page 84.
17. Remove heater element (357) from housing
(351). Be careful not to spill any fluid left in
housing. See Fig. 25.
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.
332637F
19. Install new heater element (357), holding mixer
(359) so it does not block RTD port (P).
20. Reinstall RTD (360), Replace RTD, page 84.
21. Reconnect heater element leadwires to heater
wire connector.
22. Replace heater shroud (266).
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.
83
Repair
Repair Overtemperature Switch
1. Perform Shutdown, page 60.
2. Wait for booster heater to cool.
3. Remove heater shroud.
4. Verify blue wire and brown/black wires
from cable (54) ”HTR-OT” are connected
to overtemperature switch (358). See
Electrical Schematics, page 156.
5. Disconnect overtemperature switch (358) from
cable (54). Test across quick connect terminals
with an ohmmeter.
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 cable to ensure it is not cut or open.
Reconnect the overtemperature switch
and cable. Disconnect the cable from the
overtemperature port on the TCM. Test
from pin 1 to pin 3 and pin 1 o pin 4 on
cable (54) “HTR-OT”. Resistance should be
approximately 0 ohms.
Replace RTD
1. Perform Shutdown, page 60.
2. Wait for heater to cool.
3. Remove heater shroud (266) and heater guards
(299, 300).
4. B Side RTD:
a. Follow “HT- RTD-B" RTD cable (360) and
open split loom about 18 in. (457.2 mm) away
from the heater attachment. Disconnect “HTRTD-B TCM" and “HT-RTD-B” connectors.
See Electrical Schematics, page 156.
b. Visually inspect “HT-RTD-B” connector and
replace extension cable (58) if necessary.
Continue to next step if the extension cable
connector is not damaged.
Note
The cable 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.
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.
c.
5. A side RTD:
a. Follow “HT- RTD-A" RTD cable (360) and
open split loom about 18 in. (457.2 mm) away
from the heater attachment. Disconnect “HTRTD-A TCM" and “HT-RTD-A” connectors.
See Electrical Schematics, page 156.
b. Visually inspect “HT-RTD-A” connector and
replace extension cable (58) if necessary.
Continue to next step if the extension cable
connector is not damaged.
c.
84
Visually inspect “TCM-A HT-RTD-B”
connection to TCM. Continue to next step to
replace RTD (360).
Visually inspect “TCM-A HT-RTD-A”
connection to TCM. Continue to next step to
replace RTD (360).
332637F
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
pipe threads and tighten RTD housing (H)
into adapter (355).
b. Push in RTD (360) so tip contacts heater
element (357).
c.
8. Route wires (S) as before through split loom
and reconnect RTD cable (360) to the B side
extension cable (71) or the A side extension
cable (58).
9. Replace heater shroud and heater guards.
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) when ferrule nut (N) is retightened.
Holding RTD (360) against heater element,
tighten ferrule nut (N) 3/4 turn past
finger-tight.
Figure 25
332637F
85
Repair
Repair Heated Hose
Refer to the heated hose manual 309572 for hose
replacement parts.
Check Hose Heat Power Connectors
1. Perform Shutdown, page 60.
Note
Whip hose must be connected.
2. Disconnect power harness (PM) from hose
termination box terminal block (TB).
Figure 27
4. Using an ohmmeter, check between the
connectors (V). There should be continuity.
5. If hose fails test, retest at each length of hose,
including whip hose, until failure is isolated.
Check RTD Cables and FTS
1. Perform Shutdown, page 60.
2. Disconnect RTD cable (C) at Reactor.
3. Test with an ohmmeter between pins of cable
connector C.
Note
Figure 26
Do not touch outer ring with test probe.
3. For Series A only: Disconnect hose connector
(V) at Reactor.
Pins
Result
3 to 1
approximately 1090
ohms
3 to 4
approximately 1090
ohms
1 to 4
0.2 - 0.4 ohms
2 to any
infinity (open)
4. Retest at each length of hose, including whip
hose, until failure is located.
5. If the FTS is not reading properly at the end of
the hose, connect FTS directly to RTD cable (C)
at the manifold.
86
332637F
Repair
6. If the FTS reads properly at the manifold but
not at the end of the hose, check cable (C)
connections. Verify they are tight.
Figure 29
Heated Hose
Figure 28
332637F
Note
To assist in taking readings, order RTD
Test Kit 24N365. Kit includes two cables:
one cable with a compatible female M8
connector and another cable with a male
M8 connector. Both cables have stripped
wire at the other end for easy test probe
access.
Pins / Wire Color
Result
3 to 1 / brown to blue
approximately 1090
ohms
3 to 4 / blue to black
approximately 1090
ohms
1 to 4 / brown to black
0.2 - 0.4 ohms
2 to any / N/A
infinity (open)
87
Repair
Repair Fluid Temperature Sensor
(FTS)
Installation
The Fluid Temperature Sensor (FTS) is supplied with
the system. Install FTS between main hose and
whip hose. See Heated Hose manual 309572 for
instructions.
Figure 30
Test/Removal
1. Perform Shutdown, page 60.
a. Disconnect air hoses (C,L) and electrical
connectors (D).
b. Disconnect FTS from whip hose (W) and
fluid hoses (A, B).
2. Remove tape and protective covering from FTS.
Disconnect hose cable (F).
c.
Remove ground wire (K) from ground screw
on underside of FTS.
3. If FTS is not reading properly at the end of the
hose, see Check RTD Cables and FTS, page 86.
d. Remove FTS probe (H) from component A
(ISO) side of hose.
4. If FTS fails, replace FTS.
88
332637F
Repair
Transformer Primary Check
1. See Shutdown, page 60.
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.
Transformer Secondary Check
1. See Shutdown, page 60.
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.
5. Start the generator.
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.
6. Turn main power switch on.
7. Press
to turn on hose heat zone.
3. Close the circuit breaker CB20 (906).
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.
Figure 31
4. Confirm main power switch is off before starting
generator.
332637F
Thermal expansion can cause
overpressurization, resulting in equipment
rupture and serious injury, including fluid
injection. Do not pressurize system when
preheating hose.
89
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 TCM “Hose Voltage” and the
hose current. The diagnostic screen will show
if the circuit breaker has been tripped for the
incoming power to the TCM.
Replace Transformer
1. Perform Shutdown, page 60.
2. Open Reactor cabinet.
3. Remove bolts holding transformer (226) to
cabinet floor.
4. Disconnect the transformer wires. See
Reactor Cabinet Wiring Diagram, page 164.
5. Remove transformer (226) from cabinet.
6. Install new transformer (226) in reverse order.
226
90
332637F
Repair
Replace Heat Exchangers
1. If a wall is installed between the generator and
the proportioner, remove the proportioner from
the pallet. See Remove Proportioner, page 103.
2. Perform Flushing, page 63.
3. Perform Shutdown, page 60.
4. Perform Drain Coolant, page 65.
5. For proportioner heat exchangers:
a. Remove fuel tank. See
Remove Fuel Tank, page 96.
Proportioner Heat Exchangers
Figure 32
b. Disconnect both RTD connectors (284). See
Replace Heat Exchanger RTD, page 93.
c.
Disconnect A and B material lines from
swivel fittings (297).
d. Disconnect hose clamps (37, 239) from heat
exchanger assembly (241).
e. Remove four nuts (249) and the heat
exchanger assembly (241). Pull heat
exchanger assembly out of coolant hoses.
f.
332637F
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).
91
Repair
g. Disconnect two swivel fittings (805) and
swivel fittings on heat exchanger outlet (806)
from the heat exchangers (802, 803).
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.
Proportioner Heat Exchangers
Figure 33
h. Remove four nuts (810) and washers (811)
for replacing heat exchangers (802) or (803).
Engine Heat Exchanger
Figure 34
92
332637F
Repair
Replace Heat Exchanger RTD
1. Perform Shutdown, page 60.
2. Remove Reactor cabinet cover.
3. Disconnect RTD from CAN cable.
NOTICE
ISO and RES 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 (272) on RTD sheath
(273).
6. Apply thread sealant to compression fitting pipe
threads (272 and install in heat exchanger.
7. Connect new RTD to extension cable (71).
4. Remove compression fitting (272) from the back
of the heat exchanger with RTD (273) attached.
Figure 35
332637F
93
Repair
Replace Control Valve
Replace 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 60.
1. Perform Shutdown, page 60.
2. Drain coolant from the proportioner coolant loop.
See Drain Coolant, page 65.
2. Disconnect power supply (655) from circuit
breaker CB01 and terminal blocks TB13 through
TB15. See Electrical Schematics, page 156.
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. Insert a flat head screw driver in the mounting
tab on the bottom of the power supply (655) to
remove from the din rail.
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 36
4. Install new power supply (655) in reverse order.
94
332637F
Repair
Replace 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.
To prevent burns, do not perform maintenance on
the coolant system until the coolant system has
reached ambient temperature.
1. Perform Shutdown, page 60.
2. Perform Drain Coolant, page 65.
3. If a wall is installed and the circulation pump can
not be accessed, remove the proportioner. See
Remove Proportioner, page 103.
4. Disconnect pump fittings (234) from swivel fitting
(275).
5. Remove pump cover (C).
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).
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 164.
11. Connect flange fittings (234) to swivel on the
elbow flange fitting (234) and fitting (275).
Figure 37
332637F
95
Repair
Repair Filter Housing Filter
Remove Fuel Tank
1. Drain the proportioner coolant loop. See
Drain Coolant, page 65.
1. Perform Shutdown, page 60 .
2. Remove cap (C) and filter (643) from filter
housing (630).
3. Pull out filter (643). Brush out filter and replace
if necessary.
4. Insert filter (643) into cap (C) and tighten cap into
filter housing (630).
2. Disconnect fuel lines (38, 39). Keep elevated or
plug to prevent siphoning.
3. Remove screws (24) and clamps (30).
4. Slide the fuel tank off the B side of the pallet.
5. Inspect for any damage.
6. Slide fuel tank on to pallet and secure to pallet
with screws (24) and clamps (30). Reconnect
fuel lines (38, 39).
7. Squeeze prime bulb (P) to prime engine. Press
the prime bulb repeatedly until fuel begins to
return to the fuel tank.
Figure 38
96
332637F
Repair
Replace Battery
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.
See Technical Specifications, page 177 for battery
requirements and recommended battery size.
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.
cable is connected to the positive (+) battery
post. Connect black cable to the negative (-)
battery post.
Figure 39
NOTICE
Always connect the red battery cable to battery
positive (+) terminal and the black battery cable
to the battery negative (-) terminal. Failure to
properly connect the battery cable to the battery
will damage the fusible link harness. Do not bypass
the fusible link when damaged. The fusible link
prevents damage to other system components.
4. Reconnect battery cables and cover battery
terminals with plastic caps (PC). Ensure red
332637F
97
Repair
Repair Fusible Link Harness
Follow this procedure to replace fuses
inside the fusible link harness (90). See
Electrical Schematics, page 156, for fusible link
harness connections and wire identification.
4. Remove fusible link harness (90) from engine.
5. Carefully cut open heat shrink encasing the fuse
holder along lines shown.
1. Perform Shutdown, page 60.
2. Disconnect battery from system.
3. Determine which fuse (F8, F9) needs to be
replaced.
a. Cut cable tie (81) and remove red insulator
cap (111) over the positive stud on the
engine starter. Remove the outside nut (106)
and red battery cable (47) . Disconnect
fusible link harness (90) ring terminal from
the engine starter.
b. Using a multimeter, measure continuity
through the harness ring terminals. See
Table 1.
c.
If one of the two wire paths measures “open”,
then the fuse (F8, F9) in that path is blown
and needs to be replaced.
6. Pull away heat shrink. Squeeze the fuse holder
cover and disconnect from base latches. If
latches break off, replace entire fuse holder with
fuse holder (118) shipped loose with the system.
7. Remove two M5 nuts from fuse holder base.
8. Replace blown 60 amp fuse in the fuse holder
base with new fuse (117). New fuse (117) is
shipped loose with the system.
Table 1 Fusible Link Harness Connections
Fuse (117)
Wire No.
Ring Terminal Location
Wire No.
Ring Terminal Location
F8
C010 and C030
Engine starter positive
power lug
C020
12 V charge alternator B+
terminal
C040
C010 and C030
Engine starter positive
power lug
Starter solenoid relay
(CR6)
C050
Glow plug solenoid relay
(CR7)
F9
98
332637F
Repair
9. Replace M5 nuts over fuse and ring terminals.
Torque to 44 in.-lbs (5 N●m).
10. Connect fuse holder cover to fuse holder base.
Wrap entire fuse holder and heat shrink 3–4
times with tape (44).
NOTICE
Ensure tape entirely covers heat shrink.
Failure to seal the cut heat shrink with tape
may allow fluid to contact fusible link and
damage the fusible link.
11. Connect fusible link harness (90) and battery
cable to engine starter with nuts (106). Secure
to solenoid relay bracket with cable ties (81),
shipped loose with system.
13. Insert cable tie (81) through cap insulator (111)
and tighten to the red battery cable (47). Ensure
that the stud is not exposed.
14. Reconnect black battery cable to the negative (-)
battery terminal and the red battery cable to the
positive (+) battery terminal.
NOTICE
Always connect the red battery cable to battery
positive (+) terminal and the black battery cable
to the battery negative (-) terminal. Failure
to properly connect the battery cable to the
battery will damage the fusible link harness.
Do not bypass the fusible link when damaged.
The fusible link prevents damage to other
system components.
12. Snap the cap insulator (111) over the red battery
cable (47). Position the red cap insulator so that
the stud is not exposed.
332637F
99
Repair
Remove Radiator
NOTICE
Do not damage fins on radiator. Damaged radiator
fins will result in poor radiator performance or
cause a coolant leak.
1. Drain the engine coolant loop. Follow
Drain Coolant, page 65.
2. Remove radiator air exhaust duct, if used.
3. Remove screws (17) and back panel (8).
Figure 41
7. Inspect radiator for any obstructions. Replace or
have serviced, if necessary.
8. Install new radiator assembly in reverse order.
9. Follow Refill Engine Coolant Loop, page 68.
Replace 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.
Figure 40
4. Remove eight screws (605), top bracket (604),
and bottom bracket (606).
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).
Figure 42
100
332637F
Repair
Replace Engine Control Module
Replace Motor Control Module (MCM)
1. Perform Shutdown, page 60.
1. Perform Shutdown, page 60.
2. Remove two top screws (17) and loosen the two
side screws to lower the back panel (28).
2. Disconnect connectors from MCM (504).
Disconnect two power cables. See
Electrical Schematics, page 156.
3. Disconnect harness (M) and harness
(F) connectors from the back of the
engine control module (428). See
Engine Control Module Wiring Diagram, page 166
4. Loosen engine control module mounting screws
and remove the engine control module (428).
3. Remove nuts (530) and MCM (504).
4. Set rotary switch. 0= E–30i and 1= E-XP2i.
5. Connect cables to MCM. See
Electrical Schematics, page 156.
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).
Figure 43
332637F
101
Repair
Software Update Procedure
NOTICE
Repair kit GCA modules are shipped
pre-programmed and software loading is not
necessary. If software version upgrade is
necessary, follow the procedure in the manual
provided.
Replace Temperature Control Module
(TCM)
1. Perform Shutdown, page 60.
2. Open electrical enclosure door (501).
3. Disconnect all connectors from the TCM (503).
4. Remove four nuts (530) andTCM (503).
5. Install new TCM module (503). Reassemble
parts in reverse order.
102
332637F
Repair
Remove Proportioner
Only remove the proportioner from the pallet to repair
the heat exchangers or coolant valves between the
proportioner and generator.
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.
1. Perform Shutdown, page 60.
2. Drain the proportioner coolant loop. See
Drain Coolant, page 65.
3. Place an empty pallet in front of the proportioner
(23) and center the pallet cross beam with the
proportioner.
Figure 45
5. Cut the cable tie 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 165. 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
The cable connections will be almost
under the fuel tank mounting location. If
necessary, remove fuel tank or access
the connector from other side of wall.
8. If a wall is installed between the proportioner
(23) and generator continue to step 9. See
Remove Fuel Tank, page 96, if the fuel tank (29)
is mounted on the pallet (1).
Figure 44
4. Loosen the coolant clamps (37) and disconnect
the proportioner coolant outlet and inlet coolant
lines (36).
332637F
103
Repair
9. Loosen the front two mounting screws (24) and
remove the back two mounting screws (24).
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.
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.
11. Place two supports near both sides of the front of
the proportioner (23) . Have one person carefully
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.
Figure 46
104
Figure 47
332637F
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).
332637F
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).
19. Secure all harnesses to pallet and inside cabinet
with cable ties.
105
Repair
Repair Engine
Contact your nearest Perkins distributor for repair
and maintenance.
Replace Engine RTD
1. Perform Shutdown, page 60.
2. Drain the engine coolant loop. See
Drain Coolant, page 65.
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.
Note
To prevent poor heating performance,
use RTD Kit 24L974.
6. Connect new RTD cable (632) to extension cable
(59).
Figure 48
7. Refill the engine coolant loop. See
Refill Engine Coolant Loop, page 68.
Figure 49
12V Charge Alternator
Contact your nearest Perkins distributor for repair
and maintenance.
106
332637F
Notes
Notes
332637F
107
Parts
Parts
Systems
272079, E-30i
272080. E-30i with Booster Heat
272081, E-XP2i with Booster Heat
For systems with an air compressor, see 272089, 272090, and 272091, page 116.
108
332637F
Parts
332637F
109
Parts
110
332637F
Parts
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
332637F
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.
111
Parts
Quantity
Ref
Part
Description
1
24J658
2
- - -
272079
272080
272081
BASE, pallet
1
1
1
GENERATOR, diesel, 22kw; see
22 kW Diesel Generator, page 142
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
20
20
20
6
105324
SCREW, cap, hex hd; 1.2 in (30 mm), M12 x 1.75
4
4
4
7
16U131
GROMMET, tube
1
8
16H898
GUARD, engine, right
1
1
1
9
16H894
GUARD, engine, left
1
1
1
10
125677
ROD, connecting, on/off
1
1
1
11
16X025
DOOR, electrical enclosure
1
1
1
12
16K893
HANDLE, selector, on/off
1
1
1
14�
123656
CABLE, 5pin, male/female (matrix)
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
18
18
18
18�
16W131
CABLE, m12 5p, fem - male, 3.0m
2
2
2
19�
24T051
CABLE, m8 4p (f) to m12 8p (m); 3.0 m
1
1
1
20�
24T198
HARNESS, ac, power, reactor cart
1
1
1
21
125625
TIE, cable, fir tree
5
5
5
22�
24T241
CABLE, power, 24v, integ reactor
1
1
1
- - -
PROPORTIONER, E–30i, (230v, 1ph), see
Proportioners, page 122
1
- - -
PROPORTIONER, E–30i, (4.0kw, 230v, 1ph),
see Proportioners, page 122
- - -
PROPORTIONER, E-xp2i, (4.0kw, 230v, 1ph), see
Proportioners, page 122
23
1
1
24
125626
SCREW, hex hd, flanged; 3 in. (76 mm), 3/8–16
6
6
6
25
16V420
BRACKET, mounting
1
1
1
ENCLOSURE, electrical, see
Electrical Enclosure, page 140
1
1
1
26
- - -
27
24U854
MODULE, GCA, ADM
1
1
1
29
24K390
TANK, fuel, see Fuel Tank, page 150
1
1
1
30
16J889
BRACKET, support, fuel tank
2
2
2
31
24J690
SUPPORT, battery
1
1
1
32
125166
TRAY, battery
1
1
1
33
107251
SCREW, pan hd; 1 in. (25.4 mm), #10–24
4
4
4
112
332637F
Parts
Quantity
Ref
Part
Description
272079
272080
272081
34✖
24M174
STICKS, level, A and B side, 55 gal. (208 l)
1
1
1
35
16K214
HOLDER, cable, tie
4
4
4
36a�
–––
HOSE, coolant, 1 in. ID; 2.66 ft (0.81 m)
1
1
1
36b�
–––
HOSE, coolant, 1 in. ID; 2.92 ft (0.89 m)
1
1
1
CLAMP, hose, dia. 11/16-1-1/2 in.
4
4
4
37�
125370
38
–––
HOSE, fuel, 5/16 in.; 3.33 long
1
1
1
39
–––
HOSE, fuel, 3/16 in.
4
4
4
40�
125163
CLAMP, hose, 7/32-5/8 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
46�
127286
CABLE, cordset, reverse key, .5m
2
2
2
47�� 16K232
CABLE, battery, 30 in. (762 mm), red
1
1
1
48�� 16K233
CABLE, battery, 30 in. (762 mm), black
1
1
1
49�
16K301
HARNESS, dc, diesel, engine
1
1
1
50
125751
CABLE, grounding, braided, engine
1
1
1
51�
16Y518
HARNESS, AC, sense, genset control
1
1
1
52�
125753
CABLE, AC, power, 240v alternator
1
1
1
53�
16K299
HARNESS, dc, disconnect check
1
1
1
54�
24T242
CABLE, over-temp, single reactor
1
1
24U109
CABLE, over-temp, switch short
1
55
16K939
LABEL, safety, system, multi
1
1
1
56
16X154
LABEL, Graco InSite
1
1
1
57�
121002
CABLE, can, female / female 1.5m
1
1
1
58�
125358
CABLE, m8, 4-pin, mf, .5meter, mold
1
1
59�
122837
CABLE, m8, 4-pin, mf, 3m, molded
2
2
2
60�
123652
CABLE, can, male / female 3.5m
1
1
1
61
16W596
LATCH, door
4
4
4
62�
24T199
CABLE, control module, heater
2
2
65
16K362
FOAM, support block
2
2
2
66
16K363
SPACER, fuel tank
2
2
2
67
16H910
GASKET, radiator isolation
1
1
1
69
16W245
DOOR, cabinet
1
1
1
70✖
24K207
KIT, FTS, RTD, single hose; see heated hose manual
1
1
1
71�
125357
CABLE, m8, 4-pin, mf, 1meter, molded
3
4
4
332637F
113
Parts
Quantity
Ref
Part
Description
272079
272080
272081
72
108290
SCREW, mach, binding hd; 1/4 in., #8–32
4
4
4
73
16W216
LABEL, E-30i, elite
1
1
16W217
LABEL, E–XP2i, elite
74�
287292
COVER, drive, plastic
2
2
2
75�
118444
SCREW, mach, slot hex wash hd; 1/2 in. x #10–24
8
8
8
76
190774
BLANK, label, kit
2
2
2
77✖
125871
TIE, cable, 7.50 in.
40
40
40
78
125844
CONDUIT, flexible, non-metalic
7
10.33
10.33
79
16M317
GUARD, engine, top
1
1
1
80
16M319
GUARD, alternator, mount
1
1
1
81
16M321
GUARD, alternator, plate
1
1
1
82✖
333093
QUICK GUIDE, startup
1
1
1
83✖
333094
QUICK GUIDE, shutdown
1
1
1
84
15G280
LABEL, safety, warning, multiple
1
1
1
85�
16K172
HARNESS, dc, link, fusible
1
1
1
86�
125754
CABLE, AC, alternator breaker, blk
1
1
1
87�
125755
CABLE, AC, alternator breaker, red
1
1
1
88�
125822
CABLE, AC, alternator, n to gnd, wh
1
1
1
89
16K297
HARNESS, DC, genset controller
1
1
1
90
- - -
LABEL, cable, self-lam, top level
1
1
1
91
- - -
KIT, label
2
2
2
1
93�
120448
SUPPRESSOR, box snap, ferrite
1
1
1
94�
125835
CLIP, ferrite bead
3
3
3
95�
125839
CLIP, ferrite bead
1
1
1
97
109124
HOSE, coupled, 48 in
1
1
1
98
169970
FITTING, airline; 1/4–18 NPT (m)
3
3
3
99
15V551
SHIELD, membrane, ADM (10 pack)
1
1
1
101
105329
NUT, hex; M8 x 1.25
2
2
2
102
114816
NUT, hex; M6 x 1
3
3
3
103
100186
WASHER, lock, internal tooth
1
1
1
104
15V909
SCREW, 1/2 in. (12 mm), M8 x 1.25
1
1
1
105+ 110911
NUT, hex; M5 x 0.8
1
1
1
106
126054
INSULATOR, cap
1
1
1
109
186494
CLIP, spring
2
2
2
113
169967
FITTING, line air; 1/4–18 NPT (f)
1
1
1
114
332637F
Parts
Quantity
Ref
Part
Description
272079
272080
272081
114✖ 16P405
FUSE, bolt-down, 60A
1
1
1
115✖ 16P406
HOLDER, fuse, bolt-down
1
1
1
116
16W213
LABEL, Reactor
2
2
2
117
16D576
LABEL, made in USA
1
1
1
118
113505
NUT, keps, hex hd
2
2
2
119
16X121
GASKET, door
2
2
2
120
16X122
GASKET, door
2
2
2
121
16X123
GASKET, door
2
2
2
122
16X124
GASKET, door
2
2
2
123
117777
HOLDER, vinyl shop ticket
1
1
1
124✖ 16Y509
CORE, ferrite, snap-on; 0.76 ID
2
2
2
125✖ 16Y516
CORE, ferrite, snap-on; 0.394 ID
1
1
1
Replacement Warning labels, signs, tags, and
cards are available at no cost.
� See Electrical Schematics, page 156.
� Included in Battery Cable Kit 24L962.
� Included in Complete Coolant Hose Kit 24L939.
See Complete Coolant Hose Kit, page 132 .
332637F
✖ Not shown.
� Cover Repair Kit includes four scews.
+
Nut only used on 3–post alternator style. Not
used on connector-style alternator.
115
Parts
272089, E-30i with Air Compressor
272090. E-30i with Booster Heat and Air Compressor
272091, E-XP2i with Booster Heat and Air Compressor
116
332637F
Parts
1
Apply anaerobic sealant to all non-swiveling pipe
threads.
4
Use from safety label (55) or (283).
332637F
117
Parts
Cable Routing
2
3
118
Do not allow cables from starter box to touch
engine. Secure all cables with cable ties (742)
to frame approximately where shown ever 6–12
in. as needed.
Secure with cable ties (742) to pallet tie downs
where shown.
332637F
Parts
4
Parts included with compressor (702b)
11
Discard plug supplied on compressor and install
thermal switch (702h).
5
Coupler supplied with compressor (702b) needs
to be pressed on to (motor (702a) as shown in
detail view.
12
Discard lift ring to install flange.
Discard steel washer on (702g) before assembly.
Torque to 20 ft.-lbs (27 N•m).
13
6
8
Torque to 34 ft.-lbs (46 N•m).
9
Torque to 36 ft.-lbs (43 N•m).
10
Discard key supplied with motor and replace with
key (702j).
332637F
14
Use only Hydrovane Fluid Force Red 2000 or
CompAir CS-300 compressor oil. Fill to top of
fill plug opening. One gallon container, Part No.
17A101, is available as an accessory.
119
Parts
Quantity
Ref
701*
*
Part
272079
272080
272081
Description
272089
1
Reactor, E-30i
Reactor, E-30i with heat
Reactor, E-XP2i with heat
272090
272091
1
1
For parts, see 272079, 272080, and 272081, page 108.
Air Compressor Parts
All air compressor parts are included in the Air Compressor Accessory Kit. See Accessories, page 13.
Ref.
702
Part
16Y567
702a
702b
127364
- - -
702c
702d
702e
107530
16X024
260067
702f
702g
702h
117625
16M826
16Y809
702j
702k
703
704
705
706
707
708
709
16C282
127581
127298
16W780
16W685
16W689
16W843
16W713
24T849
710
711
712
16W577
16W565
24U083
713
112538
714
127108
715
C20679
120
Description
COMPRESSOR,
tankless, 5 hp; includes
702a-702k
MOTOR, 5 hp
COMPRESSOR,
tankless
SCREW, cap, sch, hex
COVER overload switch
FITTING, strain relief,
1/2 npt
NUT, locking
CORD, grip, 3/4 in.
SWITCH, thermal
overload
KEY, square, 1/4
WASHER, bonded seal
DRYER, air
FRAME, air compressor
FRAME, air dryer
BRACKET, clamp
ROD, threaded, 3/8-16
STRAP, frame connector
ENCLOSURE, switch
box
ENCLOSURE, rear
BRACKET, electrical box
STARTER, motor,
reactor
FITTING, elbow, street,
90
FITTING, barbed 5/16 ID
x 1/8 NPT
FITTING, elbow; 1/2–14
npt x 7/8 un
Ref.
716
Part
15E511
717
218093
718
719
113505
112958
720
119865
721
101577
722
125856
723
121488
724
725
113504
17H101
726
730
111218
125644
731
17A346
732
156971
733
734
735
16X520
C19264
512910
1
736
737
16X808
112395
2
738
111194
Qty.
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
Description
FITTING, union, swivel
1/2 x 1/4
HOSE, coupled; 1/2–14
npt, 22 in. (559 mm)
NUT, keps, hex hd; #10
NUT, hex, flanged;
3/8–16
SCREW, mach, hex
serrated; 0.375 in. x
1/4–20
SCREW, cap, hex hd;
0.375 in. x #10–24
SCREW, serrated flange;
0.375 in. x #8-32
SCREW, hex hd,
flanged; 2.75 in. x
3/8–16
NUT, keps, hex hd
TUBE, compressor - air
dryer
CAP, tube, square
FITTING, branch tee, 1/2
npt
HOSE, rubber 5/16 in.; 6
ft (1.8 m)
FITTING, nipple, short;
1/4–18 npt x 1/4–18 npt
VALVE, air, 3-way, din
PLUG, pipe plug 1/4 in.
MUFFLER, polyethylene
1/4 in." npt
BRACKET, motor mount
SCREW, cap, flng hd;
3/4 in. x 3/8–16
SCREW, cap flang hd; 2
in. x 3/8–16
Qty.
1
1
3
12
2
3
3
10
2
1
2
1
1
1
1
1
1
2
4
6
332637F
Parts
Ref.
739
Part
125163
740
741
742
16Y488
106569
261105
Description
CLAMP, hose, 7/32 in. –
5/8 in.
NUT, wire, #14-#6 awg
TAPE, electrical
TIE, cable, 14 in.
Qty.
2
1
10
Ref.
743
744
745
Part
189285
190451
125871
Description
LABEL, hot surface
UNION, adapter
TIE, cable, 7.5 in.
Qty.
1
1
3
Replacement Warning labels, signs, tags, and
cards are available at no cost.
332637F
121
Parts
Proportioners
122
332637F
Parts
332637F
123
Parts
124
332637F
Parts
332637F
125
Parts
126
332637F
Parts
1
2
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).
332637F
3
Safety and warning labels are from label sheet
(283).
4
Fan air flow towards motor.
127
Parts
Quantity
E–30i
Ref
E–30i with
Booster Heat
E-XP2i with
Booster Heat
Description
201
Part
- - -
FRAME
1
1
1
202
16W233
BRACKET, tube guard
1
1
1
203
24T870
MANIFOLD, fluid
1
1
1
204
16W235
BRACKET, tube mount
1
1
1
205
16W608
FITTING, elbow 8jic swivel x 8jicm
2
2
2
206
24V143
KIT, assembly, pair, inlet
1
1
1
207
16W611
FITTING, bulk hd 1/2 nptm x 8 jicm
2
2
2
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
16W609
FITTING, elbow 1/2 nptf x 8 jicm
1
1
1
212
24R756
FAN, cooling, 120 mm, 24 vdc
2
2
2
213
16W610
FITTING, elbow 1/2 nptf x 10 jicm
1
1
1
214
16J758
COVER, heat exchanger
1
1
1
215
16W648
GROMMET, rubber, 1.0 ID x 1.5 OD
1
1
1
216
103181
WASHER, lock ext
4
4
4
217
112125
PLUG, tube
2
2
2
218
116746
FITTING, barbed, plated; 1/8–27 npt
x 1/4 in. I.D. hose
2
2
2
219
191892
FITTING, elbow, street, 90°; 1/8 npt
2
2
2
220
117502
FITTING, reducer #5 x #8 (JIC)
1
1
1
221
117677
FITTING, reducer #6 x #10 (JIC)
1
1
1
222
16X531
BRACKET, reservoir, lube
1
1
1
223
246995
RESERVOIR, bottle, assembly
1
1
1
224
16W183
BRACKET, load center
1
1
1
225
16W043
TUBE, pressure relief
2
2
2
226
15K742
TRANSFORMER, 4090 va, 230/90
1
1
1
227
16H761
BRACKET, mounting, pump
2
2
2
228
186494
CLIP, spring
3
3
3
1
1
2
2
2
229
255716
KIT, heater wire connector
230
261821
CONNECTOR, wire, 6 AWG
128
332637F
Parts
Quantity
E–30i
E–30i with
Booster Heat
E-XP2i with
Booster Heat
Ref
Part
Description
231
24L915
PUMP, centrifugal, circulation
1
1
1
232
24J699
KIT, fitting, pump
1
1
1
233
24K286
KIT, fitting, drain
1
1
1
234
16W191
BRACKET, strainer, left
1
1
1
235
16W193
BRACKET, strainer, right
1
1
1
236
125170
HOSE, formed, 1 in. ID, lower
1
1
1
237�
125371
CLAMP, hose, dia. 3/4-1-3/4 in.
4
4
4
238
24K385
PANEL, air control
1
1
1
239
24K381
EXCHANGER, heat, assembly
1
1
1
240
24L957
BOARD, load center
1
1
1
241
16H880
- - -
COVER, air panel
1
1
1
HOSE, rubber, 5/16 in.
2
2
2
242�
243�
–––
INDICATOR, flow, sight
1
1
1
244
16W184
COVER, fan
1
1
1
245
16X118
MODULE, cellular, GPS
1
1
1
246
125477
FITTING, 1 in. beaded barb x 3/4
nptm
1
1
1
247
112958
NUT, hex, flanged
12
12
12
248
113505
NUT, keps, hex hd
13
13
13
249
117683
SCREW, mach, phil pan hd; 1.5 in. x
#6–32
8
8
8
250
126033
TRIM, edge; 0.33 ft (0.1 m)
1
1
1
251
111800
SCREW, cap, hex hd; 0.625 in. x
5/16–18
4
4
4
252
125943
NUT, serrated flange; 7/16–14
8
8
8
253
125944
SCREW, serrated flange; 2.25 in. x
7/16–14
4
4
4
254
114269
GROMMET, rubber
1
3
3
255
126043
PLUG, cap, 1.25 diameter hole
2
256
126044
PLUG, cap, .75 diameter hole
2
257
24V152
PROPORTIONER, module, E-30i, no heat; see
Dual Zone 4.0 Kw Fluid Heater
1
24V153
1
PROPORTIONER, module, E–XP2i;
see Dual Zone 4.0 Kw Fluid Heater
258-1�
–––
FITTING, A side, inlet, E-30
258-2�
–––
FITTING, A side, inlet, E-XP2
259-3�
–––
FITTING, B side, inlet, E-30
259-4�
–––
FITTING, B side, inlet, E-XP2
1
1
1
1
1
1
1
260
16W206
TUBE, A-side, hose outlet
1
1
1
261
16W207
TUBE, B-side, hose outlet
1
1
1
332637F
129
Parts
Quantity
E–30i
E–30i with
Booster Heat
E-XP2i with
Booster Heat
Ref
Part
Description
262
16W199
TUBE, A-side, inlet
1
1
263
16W202
TUBE, B-side, inlet
1
1
264
24V145
HEATER, assy, 4.0kw, hybrid, 2 zone;
see Dual Zone 4.0 Kw Fluid Heater
1
1
265
104765
PLUG, pipe, headless
2
2
266
16K361
COVER, horizontal heater
1
1
267
121311
FITTING, connector, 3/8–18 npt x 1/2
jic
125643
FITTING, elbow, 3/8 npt x #8 jic
2
2
268
113796
SCREW, flanged, hex hd; 3/4 in. x
1/4–20
24
32
32
269
17H073
MODULE, breaker, hose, int reactor
1
1
1
270�
157785
FITTING, swivel; 3/-14 nps x 3/4–14
npt
1
1
1
271
HARNESS, dc, valve, coolant
1
1
1
272�
16K646
–––
FITTING, compression, 1/8 npt, ss
2
2
2
273�
–––
SENSOR, RTD, 1 kohm, 4 pin, 4.25
in.
2
2
2
2
2
274
125625
TIE, cable, fir tree
9
9
9
275*
24L916
VALVE, solenoid, 3/4 npt, 12 VDC
1
1
1
276
16K312
HOSE, coupled, 26 in. (660 mm)
2
2
2
277
16K311
HOSE, coupled, 18 in. (457 mm)
2
2
2
278
156589
FITTING, union, adapter, 90°; 3/4 nptf
x 3/4 npsm, 1.25 in.
4
4
4
279
FITTING, #12 jic swivel x 3/4 npt(m)
2
2
2
280�
125535
–––
HOSE, coolant, 1 in. ID, bulk; 0.33
ft. (0.1 m)
1
1
1
281
115836
GUARD, finger
1
1
1
282
125857
SCREW, serrated flange, hex hd;
.625 in. #10-24
2
2
2
283
16W612
LABEL, safety
1
1
1
284
198586
CONDUIT, corrugated
1
1
1
287�
261843
FLUID, oxide inhibitor
1
1
1
288�
125871
TIE, cable, 7.50 in.
8
8
8
289
295847
FITTING, elbow, 90°, 3/4 npt
2
2
2
290
260067
FITTING, strain relief, 1/2 npt
1
1
1
291
151395
WASHER, flat
4
4
4
292
127278
NUT, keps, hex; #6–32
4
4
4
293
16W765
COVER, motor
1
1
1
130
332637F
Parts
Quantity
E–30i
E–30i with
Booster Heat
E-XP2i with
Booster Heat
Ref
Part
Description
294
118444
SCREW, mach, slot hex wash hd; 1/2
in. x #10–24
4
4
4
295
194337
WIRE, grounding, door
1
1
1
296
16X129
SCREW, mach, phillips, tooth washer,
.375 in. x #8–32
11
11
11
297
16W201
TUBE, A-side, outlet
1
1
16W204
TUBE, A-side, outlet
16W203
TUBE, B-side, outlet
1
1
298
1
16W205
TUBE, B-side, outlet
299
17A064
GUARD, heater, A-side
1
1
300
17A066
GUARD, heater, B-side
1
1
301
113161
SCREW, flanged, hex hd; 1/2 in x
1/4–20
8
8
8
302
24W204
ENCLOSURE, terminal block
1
1
1
303
17C258
ENCLOSURE, cover
1
1
1
304
189930
LABEL, caution
1
1
1
305
17G461
BRACKET, termination box
1
1
1
Replacement Warning labels, signs, tags, and
cards are available at no cost.
Purchase Relay Repair Kit 24L958; includes
four relays. Purchase Fuse Repair Kit 24L959;
includes two fuses..
* 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.
� Included in Sight Glass Kit 24L921.
332637F
1
� Included in Complete Coolant Hose Kit 24L939.
See Complete Coolant Hose Kit, page 132
� Included in Pump Inlet Assembly Kit. See
Pump Inlet Assembly Kits, page 132.
+ See Electrical Schematics, page 156.
� Not shown.
Series A only.
For series A only order Kit No. 24T059.
131
Parts
Pump Inlet Assembly Kits
Description
Kit
Includes:
E-30i A Side
24L926
258–1
277
279
E-30i B Side
24L927
259–3
277
279
E-XP2i A Side
24L928
258–2
277
279
E-XP2i B Side
24L929
259–4
277
279
1
1
1
Qty:
Complete Coolant Hose Kit, 24L939
Ref
Description
Qty.
Systems
36a
HOSE, coolant, 1 in. ID, 2.66 ft (0.81 m)
1
36b
HOSE, coolant, 1 in. ID, 2.92 ft (0.89 m)
1
37
CLAMP, hose, dia. 11/16-1-1/2 in.
2
40
CLAMP, hose, 7/32-5/8 in.
6
Proportioners, page 122
237
CLAMP, hose, dia. 3/4-1-3/4 in.
4
242
HOSE, rubber, 5/16 in., 1 ft (0.3 m)
2
280
HOSE, coolant, 1 in. ID, 0.33 ft (0.1 m)
1
22 kW Diesel Generator, page 142
562
CLAMP, hose, dia. 3/4–1–3/4 in.
1
Radiator
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
628
HOSE, 1 in. ID; 0.271 ft (0.08 m)
1
629
HOSE, 5/16 in. ID; 1.5 ft (0.5 m)
1
640
HOSE, formed, 1–1/4 upper engine
1
641
CLAMP, hose 7/32 in. - 5/8 in.
4
642
HOSE, formed, 1–1/4 lower engine
1
132
332637F
Parts
Proportioner Module
24V152, Module for E-30i
24V153, Module for EXP2i
1
Torque to 190–120 in-lbs (21–24 N•m).
2
Lubricate threads with ISO oil or grease. Assemble pump cylinders flush to one full thread under-flush of
housing surface.
3
Apply grease to all gear teeth proportionally, motor pinion and drive housing.
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).
7
Flat side faces up.
332637F
133
Parts
Quantity
Ref
Part
Description
24V152
24V153
301
24U051
MOTOR, brushless, double ended, 2 hp
1
1
302+
---
HOUSING, drive, mark vii
2
2
257355
HOUSING, bearing
2
303
245927
HOUSING, bearing
304�
287290
KIT, repair, gear
2
2
305�
241279
KIT, rod, connecting
2
2
245971
PUMP, displacement, B
306
245972
PUMP, displacement, A
1
307�
114699
WASHER, thrust; copper colored
2
2
308�
114672
WASHER, thrust; steel colored
4
4
310�
183169
SPRING, retaining
2
2
311
183210
PIN, str, hdls
2
2
312+
15C753
SCREW, mach, hex wash hd
10
10
313
114666
SCREW, cap, socket head
8
8
314
106115
WASHER, lock (hi-collar)
8
8
246831
PUMP, displacement, A
246832
PUMP, displacement, A
1
193394
NUT, retaining
2
316
193031
NUT, retaining
318+
116192
WASHER, thrust
2
2
320
116618
MAGNET
1
1
321
24T878
SWITCH, reed, m8 4-pin
1
1
322
127301
SCREW, hxhd, thd cut, 4-40 x .375
2
2
325
187437
LABEL, torque
2
2
326
192840
LABEL, warning
2
2
315
Replacement Warning labels, signs, tags, and
cards are available at no cost.
See Pump Repair manual 309577 for repair
kits.
� Spring (310) included in 241279 Connecting
Rod Kit.
Replacement Warning labels, signs, tags, and
cards are available at no cost.
Parts included in Kit xxxxxx (purchase
separately).
*
�
134
2
1
1
2
� Gear Repair Kit includes washers (307) and
(308).
+ Drive Housing Repair Kit includes housing (1),
screws (5), and washer (1) to replace one end.
�
�
�
�
+
332637F
Parts
Dual Zone 4.0 Kw Fluid Heater
24V145
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
Remove tape from probe tip and Orientate sensor as shown. Insert probe until it bottoms on heating element.
Tighten ferrule on sensor probe one turn past finger tight or 16 ft-lbs. (21.6 N•m).
332637F
135
Parts
24V145
Ref
351
352
Part
15M878
15H302
353
121319
354
355
15H304
15H306
356
357
120336
17A092
358
15B137
359
15B135
-
360*
*
136
Description
Qty
BLOCK, horizontal
REDUCER, #14 SAE x
1/2–14 NPT(f)
ADAPTER, 1/2–14 NPT x
#8 JIC
PLUG, 9/16 SAE
ADAPTER, 9/16–18 x
1/8–27 NPT(f)
O-RING, packing
HEATER, immersion,
(2000W, 230V)
SWITCH, over
temperature
MIXER, immersion heater
1
SENSOR, RTD, 1 kohm,
90°, 4 pin, tip
Ref
361
Part
124131
4
362
15M177
366
158683
368
369
124132
15H305
1
370*
-
1
371
372
125644
248187
4
2
2
2
2
Description
Qty
SCREW, machined, pan
hd, 0.375 in. (9.5 mm),
#6–32
INSULATOR, foam,
heater, horizontal
ELBOW, 90°, 1/2–14 NPT
x 1/2–14 NPT
O-RING, fluoroelastomer
PLUG, hollow hex 1-3/16
SAE
COMPRESSION, 1/8
NPT, SST
BRANCH TEE, 1/2 NPT
KIT, rupture disc
assembly
2
1
2
4
2
2
2
2
2
Included in 24L973 Heater RTD Repair Kit.
332637F
Parts
Air Control Panel
2
Apply pipe sealant to all non-swiveling pipe
threads.
Apply anaerobic thread sealant to threads.
3
Torque to 25 +/- 2 ft-lbs (34 N●m)
1
Ref
401
402
Part
16H452
277853
403
117026
404
113331
332637F
Description
BRACKET, air control
BRACKET, mounting,
booth control
SCREW, SHCS, 0.5 in.
(12 mm), M5 x 0.8
VALVE, ball, vented, 1/2 in.
Qty
1
1
2
4
Torque to 10 +/- 2 ft-lbs (14 N●m)
5
See parts illustration for air flow direction.
Ref
405
Part
190451
406
407
158491
155470
408
16H482
1
Description
UNION, adapter, 1/2 NPT
x 1/2 NPSM
NIPPLE, 1/2–14 NPT
SWIVEL, union, 90°,
1/2–14 NPSM x 1/2–14
NPT
MANIFOLD, 1/2 NPT x 1/4
NPT
Qty
1
1
1
1
137
Parts
Ref
409
Part
113796
410
122161
411
124287
412
115841
413
15T498
415
116257
416
417
418
116513
116514
104641
419
156971
Description
Qty
4
SCREW, flanged, hex hd,
0.75 in. (19 mm), 1/4–20
FITTING, air, 1/4 NPT x 3/8
OD
FITTING, adapter, 1/2
npt(m) x #8 JIC(m), ms
FITTING, elbow, 1/4 NPT(f)
x 3/8 OD
FITTING, 90°, swivel, 5/32
OD x 1/8 NPT(f)
GAUGE, pressure, 0–160
psi (0–1 MPa, 0–11 bar)
REGULATOR, air
NUT, regulator, plastic
7
3
Ref
420
421
Part
125539
114558
422
16H531
423
6
424
3
3
3
3
4
BULKHEAD, 1 in. (25.4
mm), 3/4–20 x 1/4–18 NPT
NIPPLE, short, 1/4–18 NPT
426
427
428
429
432
—
—
Description
UNION, Y, 3/8 OD tubing
COUPLER, line, air, 1/4–18
NPT
FITTING, flow control,
1/4–18 NPT
TUBE, nylon, round, black
HOSE, nylon, 250 psi; see
identification table
LABEL, instructions
LABEL, instructions
16K325
16K326
24M665 MODULE, engine controller
125625 TIE, cable, fir tree
16K940 LABEL
Qty
1
4
1
1
9
1
1
1
2
1
4
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
138
4 (101.6)
332637F
Parts
Fluid Manifold
24T870
1
Torque to 355–395 in.-lbs (40–44.6 N●m)
2
Apply sealant (113500) to threads.
3
Valve must be closed with handle position as
shown on drawing.
Ref
451
452
452a
452b
453
454
455
456
457
458
461
Part
255228
247824
158674
247779
102814
162453
Description
MANIFOLD, fluid
KIT, valve, cartridge, drain
O-RING, BUNA-N
SEAL, seat, valve
GAUGE, press, fluid
FITTING, 1/4 NPSM X 1/4
NPT
15M669 SENSOR, pressure, fluid
outlet
247788 HANDLE, red
247789 HANDLE, blue
112309 NUT, hex, jam
124287 FITTING, adapter, 7/8,
1/2–1/4 nptm x #8 JIC
332637F
4
Apply PTFE tape and thread sealant to gauge
threads.
5
Apply grease on valve.
**
Qty
1
2
1
1
2
2
2
1
1
2
Apply PTFE tape or thread sealant to tapered
threads.
Ref
462
Part
121312
Description
463
100840
464
465
111457
189285
ELBOW, male, 3/4 SAE x
1/2 JIC
ELBOW, street, 1/4–18
npt x 1/4–18 npt
O-RING, PTFE
LABEL, hot surface
466
150829
SPRING, compression
Qty
1
1
2
1
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.
139
Parts
Electrical Enclosure
140
332637F
Parts
Electrical Enclosure
Ref.
501
Part
---
502
24T061
503
504
505
506
24U855
24U832
24T060
24R757
507
24R754
508
123143
509
510
511
122313
117666
121612
512
513
514
515
121603
126881
126891
120858
516
120859
✖
Description
ENCLOSURE, electrical,
power
MODULE, BREAKER,
integr reactor
MODULE, TCM
MODULE, MCM
MODULE, disconnect
FAN, COOLING, 80MM,
24VDC
CONNECTOR, power,
male, 2 pin
CONNECTOR, power,
male, 4 pin
BAR, ground, kit
TERMINAL, ground
CONNECTOR, thru, m12,
mxf
GRIP, cord,.51-.71,3/4
BUSHING, strain relief
NUT, bushing
BUSHING, strain relief,
m40 thread
NUT, strain relief, m40
thread
Qty.
1
Ref.
517
Part
127253
1
518
127254
1
1
1
1
519
520
24T174
24R735
521
121000
522
523
524
526
527
528
529
125859
194337
16W456
109466
127278
151395
117683
530
531
532
115942
103473
113505
1
1
1
1
1
1
1
1
1
Description
BUSHING, strain relief,
m50 thread
NUT, strain relief, m50
thread
HARNESS, control box
CABLE, CAN power, m12
fem, pigtail
CABLE, CAN, female /
female 0.5m
WIRE, chassis, ground
WIRE, grounding, door
LABEL, identification
NUT, lock hex
NUT, keps, hex
WASHER, flat
SCREW, mach, phil pan
hd
NUT, hex, flange head
STRAP, tie, wire
NUT, keps, hex hd
Qty.
1
1
1
1
2
1
1
1
2
4
4
4
8
8
7
1
See Electrical Schematics, page 156.
Not shown.
332637F
141
Parts
22kW Diesel Generator
1
Torque to 26 ft-lbs (35.25 N●m)
5
Apply sealant (blue) to threads.
2
Torque to 15 ft-lbs (20 N●m)
6
Torque to 15–20 in.-lbs (1.7–2 N●m)
3
Torque to 100 ft-lbs (135.6 N●m)
7
Apply lubrication to engine end of hose prior to
assembly.
4
Torque to 40 ft-lbs (54 N●m). Parts included with
engine.
142
332637F
Parts
22kW Diesel Generator
Ref
551
552
556
557
558
559
560
562
�
563
564
565
568
569
570
Part
Description
ENGINE, diesel, Perkins
ALTERNATOR, 22 kw,
24R079
diesel engine
16J883 BRACKET, engine mount,
left
16J884 BRACKET, engine mount,
right
125532 SCREW, M14 hex head x
30 mm
16H904 ENCLOSURE, alternator,
front
16H906 ENCLOSURE, alternator,
front
125371 CLAMP, hose, dia.
3/4-1-3/4 in.
125394 ISOLATOR, mount,
radiator, bottom
100079 WASHER, lock, spring
106245 SCREW, cap, sch, 0.625
in. (16 mm) x #8–32
16J799 BRACKET, engine relay
24L963 KIT, relay, solenoid, 12v,
intermittent
113161 SCREW, flanged, hex hd,
1/2 in. x 1/4–20
—
Part
24L965
Description
1
Ref
572
572a
572b
572c
575
125631
10
576
120858
1
577
579
125625
120859
580
581
—
120736
582
583�
115942
584�
586
587
125161
104572
105328
BUSHING, cable, lay-in
strain relief
BUSHING, strain relief,
M40 thread
TIE, cable, fir tree
NUT, strain relief, M40
thread
See Radiator
SCREW, hex flange hd,
M6 x 1
NUT, hex, flange head
MUFFLER, 2 in. (50.8
mm) exhaust
CLAMP, muffler
WASHER, lock spring
SCREW, cap, hex hd, M8
x 1.25
Qty.
1
1
1
1
1
2
8
8
1
2
—
CIRCUIT, breaker, 90A
SCREW
WASHER
NUT
Qty.
1
2
2
2
1
1
4
1
1
2
2
1
1
2
2
4
� Included in Muffler Kit 24L943.
� Included in Complete Coolant Hose Kit 24L939.
See Complete Coolant Hose Kit, page 132.
Replace fuses F6 and F7 located in the junction
box above the 120/240 V alternator. Use Fuse
Replacement Kit 24M723.
332637F
143
Parts
Radiator
See assembly notes on next page.
144
332637F
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 25 in.-lbs (2.8 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
602
16H872
16H910
602a
—
COVER, radiator mount
GASKET, radiator isolation;
see 602a-602c
GASKET, radiator isolation;
14 in. (355.6 mm), 0.63 in.
dia.
GASKET, radiator isolation;
14 in. (355.6 mm), 2 in. dia.
GASKET, radiator isolation;
3 in. (76.2 mm), 2 in. dia.
RADIATOR
BRACKET, top
SCREW, flanged, hex hd;
1/4–20 x 1/2 in. (13 mm)
BRACKET, bottom
FAN, 16 in., 12V
602b
—
602c
—
—
603�
604
16H868
605� 113161
606
607
608
609�
16H870
16H717
16K156
125579
610
16H876
611� 111803
612� 112958
613
16J741
614�
332637F
—
BRACKET, plate
ISOLATOR, mount, radiator,
top
BRACKET, support
SCREW, cap, hex hd;
3/8–16 x 2 in. (50.8 mm)
NUT, hex, flanged
WASHER, nylon, 30% glass
.750 OD
EXCHANGER, heat
Qty
1
1
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).
Part
615� 125356
616� 125139
4
617� 158383
1
618� 125171
—
619*
1
620� 125359
1
1
20
1
1
1
1
1
1
5
621� 16T800
622�
�
623�
��
�
624�
625
626
627
628
4
629
1
125371
125370
—
125204
16H901
125360
Description
FITTING, 1 in. NPT X 1.25
barbed hose
FITTING, barb, beaded
hose
FITTING, union, adapter,
straight
FITTING, modified, union
FITTING, compression, 1/8
NPT, SST
HOSE, formed, 1 1/4 upper
radiator
HOSE, coolant, 1 in. ID; 6
in. (152.4 mm)
CLAMP, hose, dia. 3/4-1-3/4
in.
CLAMP ,hose, dia.
11/16-1-1/2 in.
TANK, aluminum, coolant
BOTTLE, overflow
BRACKET, hose support
HOSE, formed, 1 1/4 lower
radiator
16W156 HOSE, coolant, 1 in. ID;
0.271 ft (0.08 m)
16W155 HOSE, rubber, 5/16 in. 1.5
ft (0.5 m)
Qty
2
2
3
1
1
1
1
4
2
1
2
1
1
1
1
145
Parts
Ref
630�
Part
—
631� 24L967
—
632*
633
634
635
125175
125625
16N580
636
16N581
Description
CAP, radiator; 16 psi (110
kPa, 1.1 bar)
CAP, pressure, coolant,
8-10 psi (55–70 kPa, 0.5–0.7
bar)
SENSOR, RTD 1 K OHM
COUPLING, hose, drain
TIE, cable, fir tree
HOSE, rubber, 5/16 in., 3.33
ft (1 m)
HOSE, rubber, 5/16 in., 1.25
ft (0.4 m)
Qty
1
1
1
1
2
1
Ref
Qty
1
Included in Filter Housing Kit 24T027. Order
24T028 for replacement filter screen (40 mesh).
� Included in Radiator Repair Kit 24L937.
� Included in Coolant Bottle Repair Kit 24L942.
146
Description
637
16M323 GUARD, engine bottom
1
638
16M141 BRACKET, overflow bottle
1
640� 125361 HOSE, formed, 1–1/4 upper 1
engine
641� 125163 CLAMP, hose 7/32 in. 4
5/8in.
642� 125382 HOSE, formed, 1–1/4 lower 1
engine
—
1
643
HOUSING, filter
� included in Heat Exchanger Kit 24L946.
� Included in Radiator Isolator Kit 24L945.
Part
*
Included in RTD Sensor Kit 24L974.
� Included in Complete Coolant Hose Kit 24L939.
See Complete Coolant Hose Kit, page 132.
332637F
Parts
Circuit Breaker Modules
24T061, Din Rail Circuit Breaker Assembly
See Electrical Schematics, page 156.
1
Torque to 5-8 in.-lbs (0.6-1 N●m)
2
Torque to 4-5 in.-lbs (0.5-0.6 N●m)
3
Torque to 23-26 in.-lbs (2.6-3 N●m)
Ref
652
653
Part
120838
24R723
654
24R722
655
656
126453
17A310
657
17A317
658
17A313
659
17A314
332637F
Description
BLOCK, clamp end
BLOCK, terminal, quad M4,
ABB
BLOCK, terminal pe, quad,
ABB
POWER supply, 24V
CIRCUIT, breaker, 2P, 5A,
UL489
CIRCUIT, breaker, 2P, 40A,
UL489
CIRCUIT, breaker, 2P, 15A,
UL489
CIRCUIT, breaker, 2P, 20A,
UL489
Qty
4
2
1
1
1
1
3
Ref
660
Part
17A316
661
662
663
24V851
24V852
127302
664
665
127303
127304
674
127308
Description
CIRCUIT, breaker, 2P, 30A,
UL489
BAR, 18 pos, power buss
BAR, bus, connector
BLOCK, terminal, 12.2 mm,
2 wire
BLOCK, terminal, cover
BLOCK, terminal, jumper, 3
position
BLOCK, terminal
Qty
1
1
2
3
1
1
1
2
147
Parts
17H073, Transformer and Fan Circuit Breaker Module
1
902 903 904 902
905
1
906
2
902
1
901
ti27068a
907
1
Torque to 5-8 in.-lbs (0.6-1 N●m)
2
Torque to 23-26 in.-lbs (2.6-3 N●m)
See Electrical Schematics, page 156.
Ref
901
902
903
904
905
148
Part
- - -
Description
DIN RAIL
125667 TERMINAL, stop, end
126818 BLOCK, terminal 3-wire
126817 COVER, end
125815 TERMINAL, block, feed
thru
Qty
1
3
2
1
2
Ref
906
907
Part
Description
24L960 CIRCUIT, breaker, 50
AMP, 2 pole
- - HARNESS, electric
Qty
1
1
332637F
Parts
24T059, Transformer and Fan Circuit Breaker Module (Series A only)
1
Torque to 5-8 in.-lbs (0.6-1 N●m)
2
Torque to 23-26 in.-lbs (2.6-3 N●m)
See Electrical Schematics, page 156.
Ref
901
902
903
904
905
Part
- --
Description
DIN RAIL
125667 TERMINAL, stop, end
126818 BLOCK, terminal 3-wire
126817 COVER, end
125815 TERMINAL, block, feed
thru
332637F
Qty
1
3
2
1
2
Ref
906
907
908
Part
Description
24L960 CIRCUIT, breaker, 50
AMP, 2 pole
- - WIRE, cu, electrical, 8
AWG, black
- - FERRULE, wire, 8 AWG
Qty
1
8
4
149
Parts
Fuel Tank
24K390
Ref
751
752
753
754
150
Part
125645
125646
125647
Description
TANK, fuel
GROMMET, tank
GROMMET, tank
FITTING, suction, assy
Qty
1
2
1
1
Ref
755
756
758
Part
Description
125648
125649
24L955
FITTING, 3/16 barbed
VALVE, drain
CAP, fuel
Qty
1
1
1
332637F
Parts
Heat Exchanger Assembly
1
2
Ensure flow direction arrows on solenoids
valves (804) are pointing down.
Apply anaerobic pipe sealant to all
non-swiveling fittings before assembling.
Ref
801
Part
16H759
802
24L917
803
24L918
804*
24L916
805
160327
*
Description
BRACKET, heat
exchanger
EXCHANGER, heat, side
A
EXCHANGER, heat, side
B
VALVE, solenoid, 3/4 NPT,
12 VDC
UNION ADAPTER, 90°
Qty
1
Ref
806
Part
24J702
1
807
24J703
1
808
810
811
C20487
112958
16J741
2
2
Description
Qty
KIT, FITTING, outlet, heat 1
exchanger
1
KIT, fitting, inlet, heat
exchanger
NIPPLE, hex
2
8
NUT, hex, flanged
8
WASHER, nylon, 30%
glass, 3/4 OD
Order 125774 Valve Repair Kit to replace all internal valve parts.
Order 125787 Coil Repair Kit to replace coil.
332637F
151
Parts
Fluid Inlet Kit
24V143
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
851
852�
Part
160327
247503
853
854
24U852
24U853
—
855*
856
�
857�
858�
C20203
16V879
555808
Description
UNION ADAPTER, 90°
KIT, manifold, strainer,
inlet
THERMOMETER, dial
GAUGE, pressure, fluid
FILTER, replacement, 20
mesh
GASKET, Y-strainer,
inlet
PLUG, Y-strainer, , inlet
PLUG, pipe
Qty
2
2
2
2
2
Ref
859
Part
15D757
862
863
624545
624545
864
866
118459
24U851
868
16W954
2
2
2
Description
HOUSING, thermometer,
VISCON HP
VALVE, BALL 3/4 NPT
FITTING, tee, 3/4 run x
1/4(f)
FITTING, union, swivel
TRANSDUCER,
pressure, temperature
FITTING, adapter, 3/4
NPT(m) x 3/4 NPT(f)
Qty
2
2
2
4
1
1
Optional 80 mesh filter 255082 (2 pack)
Included in Inlet Filter and Seal Kit 24V020 (20
mesh, 2 pack).
� Included in Manifold Repair Kit 247503.
*
152
332637F
Parts
Switch Box Enclosure
1
Assemble switch blocks as shown.
Ref
701
702
Part
16W575
121618
703
121619
704
705
120493
120494
332637F
Description
ENCLOSURE, front
SWITCH, start, push
button, green
SWITCH, stop, push
button, red
LATCH, mounting
BLOCK, switch, N.O.
Qty
1
1
Ref
706
707
Part
120495
260067
1
708
709
117625
16W614
2
1
Description
BLOCK, switch, N.C.
FITTING, strain relief, 1/2
npt
NUT, locking
LABEL
Qty
1
1
1
1
153
Parts
Motor Starter
1
2
154
Attach ground connector bar aligned vertically to
electrical box with screw and washer.
Labels from sheet (735).
332637F
Parts
3
Torque to 38–42 in.-lbs (4.3–4.7 N•m).
4
Torque to 18–22 in.-lbs (2–2.5 N•m).
5
Torque to 28–32 in.-lbs (3.1–3.6 N•m).
Ref
721
Part
24U081
722
24U082
723
119257
724
725
555582
555629
726
727
16M826
16X009
Description
STARTER, int. reactor,
3 phase
CONTACT, aux, two no
switches
CONNECTOR, bar,
ground
SCREW, soc hd cap, #10
WASHER, #10, external
tooth lock
CORD, grip, 3/4 in.
CABLE, shunt
Qty
1
Ref
728
Part
24U080
1
729
730
24U079
16X011
731
732
733
734
735
24U078
16X012
24U076
16X010
16X422
1
1
1
4
1
Description
CABLE, air compressor
breaker
CABLE, air compressor
CABLE, over
temperature, compressor
CABLE, dryer, breaker
CABLE, power, dryer
CABLE, start-stop
CABLE, pressure vent
LABEL
Qty
1
1
1
1
1
1
1
1
Replacement Warning labels, signs, tags, and
cards are available at no cost.
332637F
155
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
C
(90)
D
System Components
Wiring Diagram
24L964
Engine
Engine, page 167
(280)
16K646
Load Center
Coolant Valves
Load Center, page 165
Coolant Valve Wiring Diagram,
page 165
E
(49)
16K301
Engine
Load center
Engine, page 167
Load Center, page 165
F
(94)
16K297
Load Center
Engine
Engine Control Module
Load Center, page 165
Engine, page 167
Engine Control Module, page 166
H
(53)
16K299
Load Center
Electrical Enclosure
Load Center, page 165
Electrical Enclosure, page 158
K
(52)
125753
Alternator Enclosure
Electrical Enclosure
MCM
Alternator Enclosure, page 168
Electrical Enclosure, page 158
MCM Wiring Diagram, page 160
M
(51)
16Y518
Alternator Enclosure
Engine Control Module
Alternator Enclosure, page 168
Engine Control Module, page 166
N
(54)
125756
Reactor
Electrical Enclosure
MCM
Reactor, page 164
Electrical Enclosure, page 158
P
(519)
24T174
Electrical Enclosure
Electrical Enclosure, page 158
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/Yellow
Monitoring Grounds
Brown
Oil Pressure Switch
Dark Blue
Water Temperature
Black/White
Engine Load Grounds
Orange
Starter
White
Glow Plugs
Gray
Fuel Shutoff Solenoid
(FD)
156
332637F
Electrical Schematics
Wire Label Identification Code
The plastic wire wrap labels applied to many of the cables in the system use a code that indicates both
the near-end and far-end connections made with the labeled wire. The first half of the code describes the
module and port that the near-end of the cable connects to. The second half of the code describes where
the far-end of the cable connects. For example, "MCM-2 MOTOR-OT” denotes that the connector nearest
the label connects to the MCM port #2 (“MCM-2” is MCM port #2) and the far-end connects to the motor
overtemperature sensor (“MOTOR-OT” is Motor Overtemperature Sensor). This code is used throughout the
wiring schematics on the following pages.
Circuit Breaker Identification
Ref.
Size
Component
Ref.
Size
Component
CB01
5A
Power Supply, Fan,
Coolant Circulation Pump
CB07
20 A
Open
CB02
15 A
Boost Heat A
CB08
15 A
CB03
15 A
Boost Heat B
CB20
50 A
CB04
30 A
Hose Heat Primary
CB05
20 A
Motor Control
CB06
40 A
Air Compressor
Air Dryer
Open
Hose Heat Secondary
Open
Available Circuit Breakers
Part
Amps
Part
Amps
17C190
1
17A315
25
17C191
3
17A316
30
17A310
5
17A317
40
17A311
10
17A318
50
17A313
15
17C192
63
17A314
20
332637F
157
5
11
4
10
7
9
6
8
30A
20A
40A
20A
15A
K110 RED
K100 BLK
H100 ORG
H110 ORG
24R735
24T174
BREAKER HARNESS
MOTOR 24U049
15A
22
9
FERRITE
BEAD
16Y509
16
K
FE
B RR
16 EAD ITE
Y5
16
MOTOR 24U049
'TCM-H HT-RTD-H'
H100 ORG
H110 ORG
'24 VDC'
CABLE 16K229
TO LOAD CENTER
CABLE 122837
CABLE 24T241
TO REACTOR BOX
CABLE 24T198
TO CIRC PUMP
TO REACTOR BOX
DOOR
STUD
CORD GRIP
123652
'CAN-1 ADM'
BULKHEAD
121612
BOX
STUD
CORD GRIP
CORD GRIP
127253
127254
24T241
15A
N120 BLK
N130 BLK
FERRITE
BEAD
16Y516
BLK
RED
24
T1
98
122837
5A
N080 BLK
N060 BLK
CB08
NEUTRAL
CB07
GB02
GROUND BAR
122313
K120 WHT
GB01
GROUND TERMINAL
117666
P080 RED
P070 BLK
K110
K100
P060 RED
P050 BLK
P040 RED
P030 BLK
P020 RED
P010 BLK
N080 BLK
N060 BLK
POWER
SUPPLY
PS1
CB06
P080 RED
P090 GRN / YEL
P070 BLK
CAN 121000
CT01
FERRITE
BEAD
16Y516
CB05
16
14
12
13
'MCM-CAN-2 CAN-1'
CAN 121000
FERRITE
BEAD
125839
WHT
BLK
FAN 24U848
121603
15
HOSE
N130 BLK
N120 BLK
'TCM H HT-RTD-H'
'TCM-CAN1 PS1'
'TCM-CAN2 MCM'
P060 RED
P050 BLK
P040 RED
P030 BLK
DISCONNECT
24T060
CB04
MCM
24U832
3
B
'MCM-CAN-1 TCM'
OVER
TEMP
2
A
TCM
24U855
P010 BLK
P020 RED
K120
P100 GRN / YEL
CB03
0
158
CB02
00
'24 VDC'
CB01
12
1
BLK
N1
P110
'C
A
BLU
CIRCUIT BREAKER
DIN RAIL 24T061
CM
'
BRN
DOOR GROUND WIRE
194337
M
P110 GRN / YEL
Electrical Schematics
Electrical Enclosure Wiring Diagram
126881
126891
24T241
GRN / YEL
125859
P110 GRN / YEL
P100 GRN / YEL
P090 GRN / YEL
1 BLK
2 BLK
3 BLK
GRN / YEL
ti23006a
332637F
Electrical Schematics
MCM Cable Routing
Item
End 1
End 2
MCMCAN-1 TCM
MCMCAN-1
MCMCAN-2
CAN-1
MCMCAN-2
TCMCAN-2
Electrical
Enclosure
CAN-1
Bulkhead
Motor
Overtemperature
Switch
MCM-2 MOTOR-OT
MCM Port 2
MCM-3
RTDENGINE
MCM Port 3
MCM-4
HX-RTD-A
MCM Port 4
MCM-5
HX-RTD-B
MCM-6
PRESSURE-A
332637F
MCM Port 5
MCM Port 6
Engine RTD
Sensor
Heat
Exchanger
RTD A
Heat
Exchanger
RTD B
Fluid
Manifold
Pressure
Sensor A
Part
Item
121000
MCM-7
PRESSURE-B
MCM Port 7
MCM-8
INLET-A
MCM Port 8
MCM-9
INLET-B
MCM Port 9
End 1
121000
125357
122837
MCM Port
10
125357
125357
127286
MCM-11
LOAD-CTR
MCM-12
CYCLECNT
MCM-14
INSITE
MCM Port
11
MCM Port
12
MCM Port
14
End 2
Fluid
Manifold
Pressure
Sensor B
Temperature and
Pressure Inlet Sensor A
Temperature and
Pressure Inlet Sensor B
Optional
Feed Pump
Shut Off
Solenoids
Load Center
Fluid Motor
Cycle
Counter
InSite
Module
Part
127286
16W131
16W131
122030
123656
24T878
24T051
159
160
ti23006a
FERRITE
BEAD
125839
'MCM-12 CYCLE-CNT'
'MCM-6 PRESSURE-A'
'MCM-7 PRESSURE-B'
'MCM-8 INLET-A'
'MCM-9 INLET-B'
122837
125357
127286
24T051
24T878
TO REACTOR BOX
TO REACTOR BOX
122837 'RTD-ENGINE MCM'
125357 'MOTOR-OT MCM'
RTD-ENGINE
125357
125357
16W131
24T051
16W131
TO LOAD CENTER
'PRESSURE-A MCM'
123656
PRESSURE-A
FERRITE
BEAD
119253
127286
127286
127286
16W131
16W131
24T878
CORD GRIP
SENSORS
'PRESSURE-B MCM'
16
9
'INSITE MCM'
15
14
8
7
PRESSURE-B
MCM
24U832
11
5
4
6
125753
CORD GRIP
ALTERNATOR
120858
120859
10
3
2
K070 WHT
K010 GRN
CABLE 'K' 125753
TO 120/240 VAC
ALTERNATOR
ELECTRICAL ENCLOSURE
GB01
GROUND TERMINAL
117666
DISCONNECT
24T060
INLET
SENSOR A
24U851
PRESSURE
SENSOR A
15M669
MOTOR-OT
MOTOR
24U051
ENGINE
COOLANT
RTD 24L974
INSITE
16X118
'INLET-A MCM'
12
E-XP2i
1
INLET
SENSOR B
24U851
PRESSURE
SENSOR B
15M669
FLUID MANIFOLD
'INLET-B MCM'
13
E-30i
0
ROTARY SWITCH SETTING
CT01
K050 RED
K030 BLK
MOTOR
CYCLE SWITCH
Electrical Schematics
MCM Wiring Diagram
127253
127254
'MCM-11 LOAD-CTR'
'MCM-14 INSITE'
'MCM-4 HX-RTD-A'
'MCM-5 HX-RTD-B'
'MCM-2 MOTOR-OT'
'MCM-3 RTD-ENGINE'
332637F
332637F
HOSE
TCM
24U855
B
CAN
126881
126891
WHT
BLK
WHT
BLK
24T242
WHT
125357
BLK
BLK
CORD GRIP
SENSORS
261821
24T199
24T242
125357
125358
'HT-A TCM-A'
24T199
HT-RTD-B
'TCM-A HT-A'
BLK
'HT-B TCM-B
16A111
WHT
24T199
HEATER B
RTD A
BLK
BLK
24T199
'TCM-B HT-B'
OT SWITCH 15B137
HT-RTD-A
BLK
125358
FERRITE
BEAD
16Y509
CORD GRIP
MOTOR
BOOST HEAT
RTD B
HEATER A
24L973
A
OVER
TEMP
16A111
24L973
'HT-RTD-A TCM'
ti23006a
BOOST HEATER
24V145
Electrical Schematics
Booster Heater Wiring Diagram
261821
HTR-OT
'HT-RTD-B TCM'
127253
127254
ELECTRICAL ENCLOSURE
'TCM-A HT-RTD-A'
'TCM-B HT-RTD-B'
TCM-OT
161
1
162
5
11
4
10
15
MCM
24U832
3
'MCM-CAN-2 CAN-1'
2
16
14
8
6
13
121000
9
7
12
121000
122030
'CAN-1 MCM'
SPLITTER
124654
BULKHEAD
121612
BULKHEAD
121612
CAN 1
123656
123652
'CAN-1 ADM'
BULKHEAD
121612
CAN 2
SOLENOID
16K335
SOLENOID
16K335
FEED PUMP SHUTOFF
REMOTE DISPLAY
DM 24L952
'ADM-CAN-1 CAN-1'
124003
SPLITTER
125982
123652
ADM 24U854
Electrical Schematics
Optional Remote Display Module and Feed Pump Kit Wiring Diagram
ELECTRICAL ENCLOSURE
ti23006a
Rotary switch
E-30i = 0
E-XP2i = 1
setting:
See Cable Routing Table on page 157.
332637F
Electrical Schematics
Optional Customer Auxiliary Power Wiring Diagram
See Circuit Breaker Identification, page 157, 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.
PS1
POWER
SUPPLY
CB04
30A
CB05
20A
120 VAC AUXILIARY LOAD
CIRCUIT BREAKER DIN RAIL 24T061
L2
CB03
L1
15A
240 VAC
AUXILIARY LOAD
CB02
15A
LINE TO LINE WIRING
CB01
5A
240 VAC AUXILIARY LOAD
CB06
40A
LINE TO NEUTRAL WIRING
CB08
120 VAC
AUXILIARY LOAD
15A
L2
120 VAC
AUXILIARY LOAD
CB07
20A
L1
NEUTRAL
N
NEUTRAL
N
NEUTRAL
ti23006a
332637F
163
1
2
164
N120 BLK
BLK
BLK
BLK
RED
RED
N210 BLK
N220 BLK
TB24
TB23
4
3
2
1
125357
'HX-RTD-B MCM'
WHT
BLK
TO HEATED HOSE POWER
TO HEATED HOSE POWER
TO HEATED HOSE RTD
BLK
BLK
GRN / YEL
N040
N
N080
COOLANT PUMP
24L915
N060
L
TO POWER
DISTRIBUTION
BOX
HARNESS
24T198
CABLE 24T241
24 VDC
COOLANT PUMP JUNCTION BOX
N080- BLK
N060 BLK
N040 GRN / YEL
N130 BLK
N120 BLK
'HT-RTD-H TCM-H'
24T198
CABLE 125357
CABLE 24T241
CABLE 122837
HARNESS 24T198
TO POWER DISTRIBUTION BOX
CORD GRIP
260067
122837
125357
'HX-RTD-A MCM'
'HT-RTD-H TCM-H'
TRANSFORMER
SECONDARY
CABINET FAN
24U847
2
CB20
4
PRIMARY
TB21
N130 BLK
1
3
24L972
24L972
HX-RTD-B
REACTOR ENCLOSURE
TB22
WHT
HOSE BREAKER
DIN RAIL 24T059
MOTOR FAN
24U847
ti27070a
HEAT EXCHANGER RTD B
HEAT EXCHANGER RTD A
HX-RTD-A
Electrical Schematics
Reactor Cabinet Wiring Diagram
2
ELEC ENCL
GND STUD
Torque thin terminal block connections to 5–7
in.–lbs (0.5–0.8 N●m).
Torque large terminal block connections to 13–15
in.–lbs (1.4–1.7 N●m).
332637F
Electrical Schematics
Load Center Wiring Diagram
E630 - BLU
E620 - BRN
E611 - BLK
E150 - WHT
E100 - ORG
E200 - GRY
E190 - TAN
FUSE REPAIR KIT
24L959
(contains two replacement fuses)
HAR NESS, 1236 56
E020 - RED
E220 - PUR
E010 - BLK/WHT
RELAY REPAIR KIT
24L958
(contains four replacement relays)
LOAD CENTER REPAIR KIT
24L957
F0 20
F0 10
F0 30
F0 40
F0 70
F0 80
F1 00
F1 10
F1 20
E190
E200
E100
E150
E611
E620
E630
F120 - BLU
F110 - BRN
F100 - BLK/YEL
F080 - PUR
F070 - WHT
F040 - ORG
F030 - GRY
F010 - BLK/YEL
F020 - RED
TO ENGINE
CONTROL
MODULE
HARNESS ‘F’
16K297
‘L O ADC TR -J4 MCM’
TO ENGINE
HARNESS ‘E’
16K301
1
J2
1
J3
CR4
J4
J6 1
LOAD CENTER
K4
D100 - RED
D11 0 - BLK/WH T
D120 - BLU
D130 - BLK/WHT
D140 - GRY
D150 - BLK/WHT
TO COOLANT VALVES (12 VDC)
HARNESS ‘D’
16K646
K1
J5 1
E02 0
K2
E220
H100 - ORG
K3
H110 - ORG
TO ELECTRICAL ENCLOSURE
HARNESS ‘H’
16K299
E010
1
J1
F3
F4
1
ti23006a
1
Manual Valve Switch:
o — OFF: Automatic Operation
1 – ON: Manual Operation
Coolant Valve (12 VDC) Wiring Diagram
Load Center
J6–6
J6–5
J6–4
J6–3
J6–2
J6–1
332637F
Harness D (16K646)
D150 — BLK/WHT
D140 — GRY
D130 — BLK/WHT
D120 — BLU
D110 — BLK/WHT
D100 — RED
Connection Description
Bypass valve return
Bypass valve signal
B valve return
B valve signal
A valve return
A valve signal
Pin
No.
J18–2
J18–1
J17–2
J17–1
J16–2
J16–1
Coolant Valve Connector
Pin Designations
PIN 2
PIN 1
PIN
UNUSED
165
Electrical Schematics
Engine Control Module Wiring Diagram
TO 120 / 240 VAC
ALTERNATOR
HARNESS 'M', 16Y518
FERRITE
BEAD
125835
RED
BLK
M060
M040
M020
N
24M665, ENGINE CONTROL MODULE
16
F120
F110
F100
F080
F070
F040
F030
F020
F010
F010 BLK / YEL
DSE PIN 16
F020 RED
F030 GRY
TO LOAD CENTER
HARNESS 'F', 16K297
F040 ORG
F070 WHT
F080 PUR
ti23006B
F100 BLK / YEL
F110 BRN
F120 BLU
ti27069a
166
332637F
Electrical Schematics
Engine Wiring Diagram
D+
3 - POST VERSION
FOR ALT. W/ 2 PIN CONNECTOR
B+
E190 - TAN
E020 - RED
12V
CHARGE ALTERNATOR
C020 - RED
E190 - TAN
B+
L
A
E190 - TAN
B
12V
CHARGE ALTERNATOR
FUSIBLE LINK HARNESS ‘C’, 24L964
C020 - RED
F8
+
C010 - RED
-
FUSE, 16P405, FUSE HOLDER, 16P406
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
GLOW PLUGS
GLOW PLUG
SOLENOID RELAY
CR7
“BOTTOM”
E111 - BLK/WHT
E031
TO LOAD CENTER
HARNESS ‘E’
16K301
E031 - BLK/WHT
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
E035
J8
E035 - BLK/WHT
E614
RADIATOR FAN
SINGLE POINT
GROUND
E614 - BLK/YEL
P
E620 - BRN
E611 - BLK/YEL
SP3
E620 - BRN
E612 - BLK/YEL
OIL PRESSURE SWITCH
J10
1
E630 - BLU
T
E630 - BLU
E613 - BLK/YEL
J11
WATER TEMPERATURE
SWITCH
ti24216a
1
2
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.
332637F
3
4
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).
See Repair Fusible Link Harness, page 98, for
fuse or fuse holder repair.
167
Electrical Schematics
ti27082a
Alternator Enclosure Wiring Diagram
ALTERNATOR ENCLOSURE
K080-WHT
125822
M070-WHT
W2
U2
V2
U1
V1
W1
125631
1
TO ENGINE CONTROL
MODULE
M020-BLK
SP11
BLK
F6, 2 AMP
BLK
1
HARNESS 'M',125752
M040-RED
SP12
F7, 2 AMP
BLK
BLK
2
K070-WHT
TO POWER
DISTRIBUTION BOX
K030-BLK
K050 - RED
2
4
1
90 AMP
CB10
3
K020-BLK
125754
K040-RED
125755
HARNESS 'K',16Y518
K010 - GRN
120858
120859
1
F6 and F7 Fuse replacement kit, 24M723.
(contains two fuses)
2
CB10 circuit breaker replacement kit, 24L965.
3.
4
168
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.
Torque all four wire connections to 40–42 in.-lbs
(4.5–4.7 N●m).
332637F
Electrical Schematics
TI23006a
1
2
ELECTRICAL ENCLOSURE
MOTOR STARTER BOX
START STOP BOX
AIR COMPRESSOR
AND MOTOR ASSEMBLY
16Y567
Air Compressor Wiring Diagram
Tighten all power cable connections to 23–25
in.–lbs (2.6–2.8 N●m).
Torque all air compressor wire connections to
30–32 in.–lbs (3.4–3.6 N●m).
332637F
169
CB04
CB05
CB06
CB07
CB08
5A
15A
15A
30A
20A
40A
20A
15A
GND2
GROUND BAR
122313
PD-GND2
24U080
24U078
ELECTRICAL
ENCLOSURE
CABLE 24U080
TO MOTOR STARTER
CABLE 24U078
TO MOTOR STARTER
WHT
BLK
GRN
CB03
PD-GND2
WHT
BLK
GRN
CB02
NEUTRAL
CB01
CORD GRIP
16M862
CORD GRIP
260067
117625
CORD GRIP
16M862
AC-W1-W5
YEL 4
RED 8
CORD GRIP
260067
117625
24U076
CORD GRIP
260067
117625
16X011
BLK
WHT
AC-OT2
AC-OT1
RED
WHT
BLK
SS-4
STOP
SWITCH
SS-2
SS-3
START
SWITCH
SS-1
OVER
TEMPERATURE
SENSOR
AIR COMPRESSOR OVER TEMPERATURE BOX
AIR COMPRESSOR START STOP BOX
CABLE 16X011
TO MOTOR STARTER
CABLE 24U076
TO MOTOR STARTER
CABLE 24U079
TO MOTOR STARTER
GROUND
STUD
AC-GND
AC-W4-W8
WIRE NUT
#6
MOTOR JUNCTION BOX
WIRE NUT
#6
BLU 1
BLK 5
170
BLK
WHT
GRN
ti23338a
24U079
BREAKER DIN RAIL
24T061
Electrical Schematics
Air Compressor Junction Boxes
PD-N
PD-CB8-4
PD-CB6-2
PD-CB6-4
332637F
Electrical Schematics
Motor Starter
CORD GRIP
16M826
BLK
WHT
MS-QD1
MS-QD1
WHT
24U076
RED
BLK
MS-A2
A2
Motor STARTER
WITH BOX
24U081
23
CABLE 16X011
TO COMPRESSOR OVER TEMP SENSOR
MS-23
MS-13
L1
16X012
MS-L1
MS-L2
MS-L3
MS-A1
MS-A1
MS-QD2
GRN
BLK
WHT
A1
16X011
CABLE 24U076
TO COMPRESSOR START STOP BOX
AUXILIARY
CONTACTOR
24U082
L3
L2
CABLE 16X012
TO AIR DRYER
16X009 BLK
13
14
MS-14
MS-24
GROUND BAR
119257
MS-95
95 96
97
98
MS-GND
MS-GND
MS-QD2
24
T2
T3
MS-GND
T1
MS-GND
MS-96
CORD GRIP
16M826
GRN
WHT
BLK
MS-T2
MS-T3
MS-98
MS-T1
24U079
CORD GRIP
16M826
CABLE 24U078
TO ELECTRICAL ENCLOSURE
AIR DRYER POWER
CORD GRIP
16M826
WHT
BLK
24U080
GRN
WHT
BLK
16X010
BLK
GRN
24U078
WHT
MS-98
CABLE 24U079
TO AIR COMPRESSOR
CABLE 24U080
TO ELECTRICAL ENCLOSURE
AIR COMPRESSOR POWER
CABLE 16X010
TO AIR EXHAUST VALVE
ti23006a
332637F
171
Repair and Spare Parts Reference
Repair and Spare Parts Reference
Recommended Common Spare Parts
Ref
Part
Description
Part of Assembly
70
114
24K207
16P405
Systems
Systems
115
16P406
240
24L958
Hose FTS (Fluid Temperature Sensor)
Fusible Link Fuse (Replacement For
Fusible Link Harness)
Fusible Link Fuse Holder (Replacement
For Fusible Link Harness)
Load Center Relay Repair Kit, for load
center (4 Relays)
Load Center Fuse Repair Kit (2 Fuses)
RTD Repair Kit (A or B Heat Exchangers)
Coolant Valve Repair Kit (includes
diaphragm, seals, and plunger)
Coolant Valve Solenoid Coil Repair Kit
Proportioner
Heat Exchanger Assembly
Proportioner
Heat Exchanger Assembly
Proportioner Module
Proportioner Module
Proportioner Module
Proportioner Module
272
273
275
24L959
24L972
125774
125787
315
15C852
15C851
246963
246964
247824
102814
15M669
24L963
24L965
E-30i Pump Repair Kit
E-XP2i Pump Repair Kit
Systems
Proportioner
Proportioner
Proportioner
360
370
619
632
643
855
856
---
24L973
E-XP2i Wet Cup Repair Kit
E-30i Wet Cup Repair Kit
Drain Valve Cartridge
Fluid Pressure Gauge
Pressure Sensor
Engine Solenoid Relay Kit
90 A Circuit Breaker Kit (For Generator
Junction Box)
RTD Repair Kit (Booster Heater)
24L974
RTD Repair Kit (Engine Heat Exchanger)
Radiator
24T028
24V020
Radiator
Fluid Inlet Kit
---
24N365
---
17A101
Coolant Filter Kit (one 40 mesh screen)
Y-Strainer Filter and Gasket Kit, 20 mesh
(2 pack)
Fuse Replacement Kit (For Generator
Junction Box)
RTD Cable Test Kit (To assist measuring
RTDs and RTD cable resistances)
Compressor Oil (1 gallon)
452
453
455
569
572
172
24M723
Fluid Manifold
Fluid Manifold
Fluid Manifold
Diesel Generator
Diesel Generator
Heater
Diesel Generator
Heated Hose and FTS
Air Compressor Systems
332637F
Recommended Rebuild Spare Parts
Recommended Rebuild
Spare Parts
Ref.
Part
Description
Part of Assembly
27
504
212
231
240
275
804
416
423
424
503
506
656
657
658
659
660
906
24U854
24U832
24R756
24L915
24L957
24L916
Advanced Display Module (ADM)
Motor Control Module (MCM)
Cooling Fan, Motor and Lower Cabinet
Coolant Circulation Pump
Load Center Repair Kit
Coolant Valve (complete)
116513
24M650
Air Regulator
System
Proportioner
Proportioner
Proportioner
Proportioner
Proportioner
Heat Exchanger Assembly
Air Control Panel
Air Control Panel
---
24L939
332637F
24U855
24R757
126125
126131
126127
126128
126130
24L960
Air Control Tubing Repair Kit (includes full
length of air control tubing)
Temperature Control Module (TCM)
Cooling Fan, Electrical Enclosure
5A Circuit Breaker
40A Circuit Breaker
15A Circuit Breaker
20A Circuit Breaker
30A Circuit Breaker
50A Circuit Breaker
Complete Coolant Hose Kit (includes all
coolant hoses)
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Enclosure
Enclosure
Enclosure
Enclosure
Enclosure
Enclosure
Enclosure
Transformer and Fan Circuit Breaker
Module
See Complete Coolant Hose Kit in manual
173
Dimensions
Dimensions
Figure 50
174
332637F
Dimensions
Figure 51
Figure 52
332637F
175
Dimensions
Figure 53 Floor Mount Hole Pattern
176
332637F
Technical Specifications
Technical Specifications
Reactor 2 Elite Integrated Proportioning Systems
U.S.
Metric
E-30i
2000 psi
14 MPa, 140 bar
E-XP2i
3500 psi
24.1 MPa, 241 bar
E-30i
150°F
65°C
E-30i with booster heater
180°F
82°C
E-XP2i
180°F
82°C
30 lb/min
13.5 kg/min
2 gpm
7.6 lpm
310 ft
94 m
E-30i
0.0272 gal.
0.1034 liter
E-XP2i
0.0203 gal.
0.0771 liter
300 psi
2.1 Mpa, 20.7 bar
20° to 120°F
-7° to 49°C
Maximum Fluid Working Pressure
Maximum Fluid Temperature
Maximum Output
E-30i
E-XP2i
Maximum Heated Hose Length
Length
Cycle, A and B
Output per Cycle
Maximum Inlet Fluid Pressure
E-30i and E-XP2i
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
Voltage
12 Vdc
Minimum Cold Cranking Amps
800 CCA
Connection Type
Post Style
332637F
177
Technical Specifications
Reactor 2 Elite Integrated Proportioning Systems
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
None
E-30i with booster heat
4000 Watts
E-XP2i
4000 Watts
Rotary Vane Air Compressor
Hydrovane Model V04 (PURS type), continuous run
Part No.
Pressure
025CK10
140 psi
Specifications
Required Features
0.9 MPa, 9.6 bar
16 cfm
Thermal overload switch, Safety Relief Valve
Motor: Baldor
Part No.
Specifications
EL1410–CUS
5 HP, 1735 RPM, 240 V, 1 Phase, OPSB
Required Features
C face, lift rings
Refrigerated Air Dryer
Hankison Model H1T20
Specifications
115VAC, 1 Phase, 60 Hz, 22 scfm at 150 psi (1 MPa, 10.3 bar)
Required Features
Pilot valve unloader
Noise, Sound Pressure measured per ISO-9614–2.
Noise
Sound Pressure measured from
3.1 ft (1 m), at 1500 psi (10 MPa,
103 bar), 2 gpm (7.6 lpm)
91.0 dBA
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
178
332637F
Technical Specifications
Reactor 2 Elite Integrated Proportioning Systems
Size
Maximum Pressure
1/4 NPSM(m), with sst braided tubing
250 psi
1.75 MPa, 17.5 bar
E-30i
1750 lb
794 kg
E–30i with compressor and dryer
2200 lb
998 kg
E-30i with booster heat
1800 lb
816 kg
E–30i with booster heat,
compressor, and dryer
2250 lb
1021 kg
E-XP2i
1800 lb
816 kg
E–XP2i with compressor and dryer
2200 lb
998 kg
Weight
Wetted Parts
Material
332637F
Aluminum, stainless steel, zinc plated carbon steel, brass, carbide,
chrome, chemically resistant o-rings, PTFE, ultra-high molecular weight
polyethylene
179
Notes
Notes
180
332637F
Graco Extended Warranty for Integrated Reactor®
2 Components
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.
Graco Part Number
Description
Warranty Period
24U050
Electric Motor
36 Months or 3 Million Cycles
24U051
Electric Motor
36 Months or 3 Million Cycles
24U831
Motor Control Module
36 Months or 3 Million Cycles
24U832
Motor Control Module
36 Months or 3 Million Cycles
24U855
Heater Control Module
36 Months or 3 Million Cycles
24U854
Advanced Display Module
36 Months or 3 Million Cycles
All other Reactor 2 parts
12 Months
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction,
damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper
maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco
be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures,
accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation,
operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized
Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace
free of charge any defective parts. The equipment will be returned to the original purchaser transportation
prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be
made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS 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 hereunder must be brought within the latter of two (2) years of the date of
sale, or one (1) year the warranty period expires.
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 332637
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision F, August 2015

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