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

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

Repair-Parts

Electric,

For spraying approved for

Important instructions

332637L

EN

PROVEN QUALITY. LEADING TECHNOLOGY.

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

Important Isocyanate Information .................... 8

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

Approvals ...................................................... 12

Accessories.................................................... 12

Supplied Manuals........................................... 13

Related Manuals ............................................ 13

Troubleshooting ............................................ 14

Troubleshoot Errors ................................ 14

Load Center Diagnostics.......................... 49

Pressure Relief Procedure............................... 59

Shutdown ...................................................... 60

Flushing ........................................................ 62

Repair............................................................ 63

Before Beginning Repair .......................... 63

Flush Inlet Strainer Screen ....................... 63

Drain Coolant .......................................... 64

Refill Proportioner Coolant Loop.............. 66

Refill Engine Coolant Loop....................... 67

Coolant Specifications ............................. 67

Change Pump Lubricant........................... 68

Repair Drive Housing............................... 72

Repair Electric Motor ............................... 74

Repair Circuit Breaker Module.................. 75

Replace Load Center Relays and

Fuses .......................................... 77

Replace Load Center ................................ 78

Replace Engine Solenoid Relays ............... 78

Replace Fluid Inlet Sensor ........................ 79

Replace Pressure Transducers ................. 79

Replace Fans ........................................... 80

Repair Booster Heater .............................. 82

Repair Heated Hose ................................. 85

Repair Fluid Temperature Sensor

(FTS) ........................................... 88

Replace Heat Exchangers......................... 91

Replace Power Supply .............................. 93

Replace Circulation Pump ........................ 94

Repair Filter Housing Filter ...................... 95

Remove Fuel Tank ................................... 96

Replace Battery........................................ 96

Repair Fusible Link Harness ..................... 97

Remove Radiator ..................................... 98

Replace Advanced Display Module

(ADM) ......................................... 99

Replace Engine Control Module ............... 99

Replace Motor Control Module

(MCM) ......................................... 99

Software Update Procedure.................... 100

Replace Temperature Control Module

(TCM)........................................ 100

Remove Proportioner ............................. 101

Repair Engine ........................................ 103

Optional Accessories Installation and

Repair....................................... 104

Notes ......................................................... 111

Parts ............................................................ 112

Electrical Schematics.................................... 159

Repair and Spare Parts Reference ................. 178

Recommended Rebuild Spare Parts .............. 179

Dimensions ................................................. 180

Technical Specifications ............................... 183

Notes ......................................................... 186

Graco Extended Warranty for Integrated

Reactor® 2 Components.................. 187

2 332637L

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

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

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing 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

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

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

Exhaust contains poisonous carbon monoxide, which is colorless and odorless.

Breathing carbon monoxide can cause death.

• Do not operate in an enclosed area.

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.

332637L 3

4

Warnings

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

• 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.

checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

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.

• 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.

equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

332637L

332637L

Warnings

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

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

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

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

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

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

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

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

and solvent manufacturer’s MSDSs and recommendations.

5

Warnings

6

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

• 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.

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.

The battery may leak, explode, cause burns, or cause an explosion if mishandled.

• Battery maintenance must only be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from battery.

• When replacing the battery, use the same lead-acid automotive battery, with 800

CCA minimum, specified for use with the equipment. See Technical

• 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 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 sources.

332637L

332637L

Warnings

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 surfaces and fluid that is heated can become very hot during operation.

To avoid severe burns:

• Do not touch hot fluid or equipment.

The engine exhaust from this product contains a chemical known to the State of

California to cause cancer, birth defects or other reproductive harm.

7

Important Isocyanate Information

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

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:

8 332637L

Important Isocyanate Information

Self -Ignition

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.

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

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

Never component B wetted parts.

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

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

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never container.

• 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: crystallization varies depending on the blend of

ISO, the humidity, and the temperature.

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

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

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

• When changing between epoxies and urethanes or polyureas, disassemble and clean all fluid components and change hoses. Epoxies often have amines on the

B (hardener) side. Polyureas often have amines on the B (resin) side.

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

332637L 9

Models

2 EE -30i

All base systems include fluid inlet pressure and temperature sensors and Graco InSite ™ . For part numbers, see .

Maximum

Working Pressure psi (MPa,

Pressure

EE -

272079

EE -

272080

EE u With

272089

EE -

272090

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)

Output

(A+B) gal.

30 (13.5) 30 (13.5) 30 (13.5) 30 (13.5)

Total

7,400 11,600 13,500 17,700

240 VAC (1)

52 Amps (240)

240 VAC (1)

35 Amps (240)

Current

Hz* H

(Gun Part No.)

AP2079

(246102)

(Gun Part No.)

CS2079

(CS02RD)

(Gun Part No.)

P22079

(GCP2R2)

24Y240

50

24Y240 (Xtreme-Wrap) Qty:

Heated ft

246050

=

*

AH2079

(246102)

CH2079

(CS02RD)

PH2079

(GCP2R2)

24Y240

AP2080

(246102)

CS2080

(CS02RD)

P22080

(GCP2R2)

24Y240

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

CB08, line 1 (circuit breaker pin 2), line 2 current at 120 VAC is used by the air dryer

(circuit breaker pin 4).

AH2080

(246102)

CH2080

(CS02RD)

PH2080

(GCP2R2)

24Y240

H u l

6

240 VAC (1)

22 Amps (240)

9 Amps (120)

AP2089

(246102)

CS2089

(CS02RD)

P22089

(GCP2R2)

24Y240

246050

AH2089

(246102)

CH2089

(CS02RD)

PH2089

(GCP2R2)

24Y240

240 VAC (1)

5 Amps (240)

9 Amps (120)

AP2090

(246102)

CS2090

(CS02RD)

P22090

(GCP2R2)

24Y240

246050

AH2090

(246102)

CH2090

(CS02RD)

PH2090

(GCP2R2)

24Y240

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.

Refer to Circuit Breaker Configuration Options in your Reactor operation manual.

See .

Packages include gun, heated hose, and whip hose.

10 332637L

Models

2 EE -XP2i

All base systems include fluid inlet pressure and temperature sensors and Graco InSite ™ . For part numbers, see .

Maximum

Pressure psi

EE -

272081

3500 (24.1, 241)

EE u With

272091

3500 (24.1, 241)

0.0203 (0.0771) 0.0203 (0.0771)

Available

Volts, 60 Hz* H gal/min (l/min) 2.0 (7.6)

11,600

240 VAC (1)

35 Amps (240)

2.0 (7.6)

17,700

240 VAC (1)

5 Amps (240)

9 Amps (120)

(Gun Part No.)

(Gun Part No.)

AP2081

(246100)

P22081

(GCP2R0)

24Y241 Xtreme-Wrap

Heated

10

=

*

246055

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).

H u l

6

AP2091

(246100)

P22091

(GCP2R0)

24Y241 Xtreme-Wrap

246055

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.

Refer to Circuit Breaker Configuration Options in your Reactor operation manual.

See .

Packages include gun, heated hose, and whip hose.

332637L 11

Approvals

Intertek approvals apply to proportioning systems without hoses.

272079

272080

272081

272089

272090

272091

Conforms to UL Std. 499 Certified to CAN/CSA Std. C22.2 No. 88

Kit Number Description

15M483

15V551

24K207

Remote Display Module

Protective Covers (10 pack)

ADM Protective Covers (10 pack)

Fluid Temperature Sensor (FTS) with RTD

24K333

24K336

24K337

24L911

24M174

Fuel Line and Cable Extension Kit

Hose Rack

Light Tower Kit

Pallet Support Kit

24U174

24U176

24U177

24U181

Drum Level Sticks

Remote Display Module Kit

Complete Air Compressor Kit

Feed Pump Shutdown Kit

Booster Heat Upgrade Kit

121006

24N365

24N449

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

RTD Test Cables (to aide resistance measurements)

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

12 332637L

Supplied Manuals

The following manuals are shipped with the

Reactor. Refer to these manuals for detailed equipment information.

Manuals are also available at www.graco.com

.

332636

333093

333094

SEBU8311–

02

-

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.

ST

15825–00

Contact Mecc Alte for warranty and service

Air Compressor, Operation/Maintenance & Parts list.

Access at www.hydrovaneproducts.com. Go to Warranty &

Service tab and select “contact us” to request manuals.

Air Compressor Motor

Contact Baldor for warranty and service. Locate a Baldor

Authorized Service Center at www.baldor.com.

33227482 Refrigerated Air Dryer,

Instruction manual

Access from Service

Department (724) 746–1100 or www.spx.com/en/hankison.

The following manuals are for accessories used with the Reactor.

Manuals are available at www.graco.com

.

332636 Reactor 2 E-30i and E-XP2i,

Operation

309577 Electric Reactor Displacement

Pump, Repair-Parts

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

309550 Fusion ™ AP Gun

312666 Fusion ™ CS Gun

313213 Probler ® P2 Gun

332738 Booster Heat Retrofit Kit,

Instructions-Parts

332740 Remote Display Module,

Instructions-Parts

3A2574

Pallet Support Kit, Instructions-

Parts

3A1903 Hose Rack, Instructions-Parts

3A1904

3A1905

Fuel Tank/Battery Move Kit,

Instructions-Parts

Feed Pump Shutdown Kit,

Instructions-Parts

3A1906 Light Tower Kit, Instructions-Parts

332637L 13

Troubleshooting

To troubleshoot the error:

1. Press the soft key next to “Help With This

Error” for help with the active error.

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

Reactor 2 App manual for instructions.

There are three types of errors that can occur.

Errors are indicated on the display as well as by the light tower (optional).

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.

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

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

A parameter that is not immediately critical to the process.

The advisory needs attention to prevent more serious issues in the future.

See

Error Codes

for causes and solutions to each error code.

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.

14 332637L

Troubleshooting

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

See help.graco.com for more detail on troubleshooting error codes.

A1NM

A4DA

A4DB

Low Motor Current Loose or broken connection.

High Current A

Bad motor.

Fluid is not in system.

Verify the following:

• Power connector is tightly connected at MCM port #15.

Confirm wiring is not pulling connector out of proper position.

• Cable insulation or wire is not cut or frayed.

• Wires are tightly torqued in power connector terminals. Test by pulling on individual wires in power connector.

• Cable not damaged at strain relief on motor case.

Disconnect motor power connector at

MCM port #15. Measure resistances at motor power connector.

Must read 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 and previous step

(“Loose/broken power connection or motor cable”) was verified, then motor may need replacement.

Verify the following:

• Fluid is in the pumps.

• The inlet valves are open.

Check wiring for touching wires.

Short circuit in heater wiring.

Bad heater.

High Current B

Confirm resistance of heater. Heater resistance should be 23-26 Ω. If out of tolerance, replace heater.

Check wiring for touching wires.

Short circuit in heater wiring.

Bad heater.

Confirm resistance of heater. Heater resistance should be 23-26 Ω. If out of tolerance, replace heater.

332637L 15

A7DA

A7DB

A7DH

A8DA

Troubleshooting

A4DH

A4NM

A8DB

A8DH

High Current Hose

High Motor Current

Unexpected

Current A

Unexpected

Current B

Unexpected

Current Hose

No Current A

Supply voltage and/or frequency fluctuation may be affecting hose current control.

Generator may be overloaded.

Measure voltage and frequency at system disconnect switch and confirm that they are stable.

Software bug.

Short circuit of motor wiring.

Motor will not rotate.

Damaged gear train.

Chemical pump is stuck

Shorted TCM

Shorted TCM

Shorted TCM

Use continuous-run compressor with head-unloader.

Turn off unnecessary loads connected to generator.

A bug identified in software can cause nuisance triggering of this error, especially when running at high pressure and low flow rates. Upgrade system to the latest system software.

Check wiring to the motor to ensure no bare wires are touching and that no wires are shorted to ground.

Remove pump gear housings from motor and check that motor shaft rotates freely in the direction indicated on the motor housing.

Check pump gear trains for damage and repair or replace as necessary.

Repair or replace chemical pump.

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

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

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

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

No Current B

No Current Hose

Tripped circuit breaker.

Loose/broken connection.

Tripped circuit breaker.

Loose/broken connection.

Tripped circuit breaker.

Loose/broken connection.

Visually check circuit breaker for a tripped condition.

Check hose wiring for loose wires.

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

16 332637L

CACM

Troubleshooting

MCM Communication Error

Module does not have software.

Dial set to wrong position.

No 24 VDC supply to module.

Loose or broken

CAN cable.

Software mismatch between modules.

Insert a software upgrade token into the ADM and cycle the power.

Make certain to wait until the upload is complete before removing the token.

For more information on loading software, refer to the module programming manual 3A1244.

Ensure the MCM dial is set to the correct position.

• E-30i: dial position = 0

• E-XP2i: dial position = 1

• Green light on each module should be lit.

If green light is not lit, check to make sure each CAN cable connection is not cross threaded and is tight.

• Verify the power supply is outputting 24 V dc. If not, check power supply wiring. If wiring is okay, replace the power supply.

Check the CAN cables running between GCA modules.

Check for cross threading and tighten if needed. If the problem still persists, grasp the cable near the connector, move it around, and watch the flashing yellow light on the GCA modules. If the yellow light stops flashing, replace the CAN cable.

Installing a new module in the system, or swapping in a module from another system, may cause a software mismatch.

Update software in all modules by following the procedure in your system's manual.

Make certain to wait until the upload is complete before removing the token.

For more information on loading software, also refer to the module programming manual by searching for "3A1244" at www.graco.com.

332637L 17

Troubleshooting

CACT TCM Communication Error

Cross threaded

CAN cable.

Software mismatch between modules.

No 24 VDC supply to module.

Module does not have software.

Loose or broken

CAN cable.

CAN cables carry 24 V dc power and communicaton between modules.

A cross threaded CAN cable connector may cause problems with communication and/or power to modules. Carefully check for cross threaded CAN connections on the

TCM and on other modules.

Installing a new module in the system, or swapping in a module from another system, may cause a software mismatch. Update software in all modules by following the procedure in your system's manual.

Make certain to wait until the upload is complete before removing the token.

For more information on loading software, refer to the module programming manual 3A1244.

• Green light on each module should be lit.

If green light is not lit, check to make sure each CAN cable connection is not cross threaded and is tight.

• Verify the power supply is outputting 24 V dc. If not, check power supply wiring. If wiring is okay, replace the power supply

Insert a software upgrade token into the ADM and cycle the power.

Make certain to wait until the upload is complete before removing the token.

For more information on loading software, refer to the module programming manual by searching for "3A1244" at www.graco.com.

Check the CAN cables running between GCA modules.

Check for cross threading and tighten if needed. If the problem still persists, grasp the cable near the connector, move it around, and watch the flashing yellow light on the GCA modules. If the yellow light stops flashing, replace the CAN cable.

18 332637L

EAUX

EVCH

EVUX

DADX

DE0X

Troubleshooting

Pump Runaway

Cycle Switch Error

USB Busy

Manual Hose Mode

Enabled

USB disabled

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.

Check wiring between cycle switch and MCM, Port 12.

Switch is disconnected or cabled is damaged.

Switch is faulty.

Missing or out of place cycle switch magnet.

USB drive has been inserted into the ADM.

Manual hose mode has been enabled in

System Setup screen.

USB download/uploads are disabled.

Measure resistance between pin 3 and 4, Normally switch is open, and resistance is very high (open circuit).

With cycle switch magnet near switch

(contacts closed), normal resistance is less than 1 ohm.

Check presence and position of cycle switch magnet on output crank arm.

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

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

Enable USB download/uploads on the Advanced Setup screen before inserting a USB drive.

332637L 19

Troubleshooting

F9DX

H1MA

H1MB

H1MH

High Pressure/Flow

Cutback

Low Frequency A

Low Frequency B

Low Frequency

Hose

Machine is operating above pressure/flow rating.

Motor or motor control temperature is too high.

Line frequency is below 55 Hz.

Line frequency is below 55 Hz.

Line frequency is below 55 Hz.

• Mix chamber is too large for set pressure

• Set pressure is too high for given mix chamber

See operation manual for

Performance Charts.

NOTE:

Module (ADM) software 16N725

(all versions) and 17A157 (version

1.01.001 only).

• For these specific software realeases, the causes for the codes

F9DX, T3NM and T3CM were combined and all triggered the code F9DX. ADM software more recent than 17A517 1.01.001 splits these three codes apart.

• For all causes/solutions, see T3NM and/or T3CM.

Check frequency. If out of tolerance, see supplied 120/240V alternator manual for repair instructions.

Check frequency. If out of tolerance, see supplied 120/240V alternator manual for repair instructions.

Check frequency. If out of tolerance, see supplied 120/240V alternator manual for repair instructions.

20 332637L

H4MA

H4MB

H4MH

K8NM

L1AX

L1BX

MMUX

Troubleshooting

High Frequency A

High Frequency B

High Frequency

Hose

Locked Rotor Motor

Line frequency is above 65 Hz.

Line frequency is above 65 Hz.

Line frequency is above 65 Hz.

Software bug.

Chemical pump is stuck.

Damaged gear train.

Motor will not rotate.

Check frequency. If out of tolerance, see supplied 120/240V alternator manual for repair instructions.

Check frequency. If out of tolerance, see supplied 120/240V alternator manual for repair instructions.

Check frequency. If out of tolerance, see supplied 120/240V alternator manual for repair instructions.

A bug exists in older motor control software that may falsely trigger this error code when there is neither a locked rotor, nor mechanical issues or damage to the proportioner motor.

Upgrade sofrware to system version

2.01.001 (Motor Control Module

2.01.001) or greater.

Repair or replace chemical pump.

Low Chemical Level

A

Low Chemical Level

B

Maintenance Due -

USB

Low material level.

Low material level.

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

Check pump gear trains for damage and repair or replace as necessary.

Remove pump gear housings from motor and check that motor shaft rotates freely in direction indicated on motor housing.

Refill material and update drum level on ADM Maintenance screen.

Alarm can be disabled on the System

Setup screen.

Refill material and update drum level on ADM Maintenance screen.

Alarm can be disabled on the System

Setup screen.

Insert a USB drive into the ADM and download all logs.

332637L 21

Troubleshooting

P0AX

P0BX

P1FA

P1FB

22

Pressure Imbalance

A High

Pressure Imbalance

B High

Low Inlet Pressure

A

Low Inlet Pressure

B

Pressure difference between A and

B material is greater than the defined value.

Pressure imbalance is defined too low.

Ensure material flow is equally restricted on both material lines.

Out of material.

Fill tanks with material

Feed system defective.

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

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.

Pressure difference between A and

B material is greater than the defined value.

Pressure imbalance is defined too low.

Ensure material flow is equally restricted on both material lines.

Ensure that the pressure imbalance value, on the System Setup screen, is at an acceptable maximum pressure to prevent unnecessary alarms and abort dispenses.

Out of material.

Fill tanks with material

Feed system defective.

Ensure that the pressure imbalance value, on the System Setup screen, is at an acceptable maximum pressure to prevent unnecessary alarms and abort dispenses.

Fluid leaking from heater inlet rupture disk.

Inlet pressure lower than defined value.

Value defined too high.

Inlet pressure lower than defined value.

Value defined too high.

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

Check if heater and PRESSURE

RELIEF/SPRAY valve are plugged.

Clear. Replace rupture disk. Do not replace with a pipe plug.

Ensure that inlet pressure to the pump is sufficient.

Ensure that the low pressure alarm level defined on the System Setup screen is acceptable.

Ensure that inlet pressure to the pump is sufficient.

Ensure that the low pressure alarm level defined on the System Setup screen is acceptable.

332637L

P2FA

P2FB

P4AX

P4BX

P6AX

Troubleshooting

Low Inlet Pressure

A

Low Inlet Pressure

B

High Pressure A

High Pressure B

Pressure Sensor

Error A

System pressurized before allowing heat to reach setpoint.

Bad pressure transducer.

E-XP2i system configured as

E-30i.

System pressurized before allowing heat to reach setpoint.

Bad pressure transducer.

E-XP2i system configured as

E-30i.

Loose/bad connection.

Inlet pressure lower than defined value.

Value defined too high.

Inlet pressure lower than defined value.

Value defined too high.

Ensure that inlet pressure to the pump is sufficient.

Ensure that the low pressure alarm level defined on the System Setup screen is acceptable.

Ensure that inlet pressure to the pump is sufficient.

Bad sensor.

Ensure that the low pressure alarm level defined on the System Setup screen is acceptable.

Pressure in the hose and pumps will increase as the system heats up.

Turn on heat and allow all zones to reach the temperature setpoint before turning on the pumps.

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

Alarm level is lower for E-30i than for

E-XP2i. Ensure dial on MCM is set to position "1" for E-XP2i.

Pressure in the hose and pumps will increase as the system heats up.

Turn on heat and allow all zones to reach the temperature setpoint before turning on the pumps.

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

Alarm level is lower for E-30i than for

E-XP2i. Ensure dial on MCM is set to position "1" for E-XP2i.

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

Check if the error follows the transducer. Disconnect transducer cables from the 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.

332637L 23

Troubleshooting

P6BX

P6FA

P6FB

Pressure Sensor

Error B

Pressure Sensor

Error Inlet A

Pressure Sensor

Error Inlet B

Loose/bad connection.

Bad sensor.

Inlet sensors not installed.

Loose/bad connection.

Bad sensor.

Inlet sensors not installed.

Loose/bad connection.

Bad sensor.

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

Check if the error follows the transducer. Disconnect transducer cables from the 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.

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

System Setup screen.

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

Check if the error follows the inlet sensor. Disconnect inlet sensor cables from the 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.

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

System Setup screen.

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

Check if the error follows the inlet sensor. Disconnect inlet sensor cables from the 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.

24 332637L

P7AX

P7BX

T1DE

Troubleshooting

Pressure Imbalance

A High

Pressure Imbalance

B High

Low Temperature

Coolant Outlet

Pressure difference between A and

B material is greater than the defined value.

Pressure imbalance is defined too low.

Ensure material flow is equally restricted on both material lines.

Out of material.

Fill tanks with material

Feed system defective.

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

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.

Pressure difference between A and

B material is greater than the defined value.

Pressure imbalance is defined too low.

Ensure material flow is equally restricted on both material lines.

Ensure that the pressure imbalance value, on the System Setup screen, is at an acceptable maximum pressure to prevent unnecessary alarms and abort dispenses.

Out of material.

Fill tanks with material

Feed system defective.

Ensure that the pressure imbalance value, on the System Setup screen, is at an acceptable maximum pressure to prevent unnecessary alarms and abort dispenses.

Fluid leaking from heater inlet rupture disk.

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

Check if heater and PRESSURE

RELIEF/SPRAY valve are plugged.

Clear. Replace rupture disk. Do not replace with a pipe plug.

Replace fan relay.

Radiator fan will not stop.

Engine thermostat is stuck closed.

Replace thermostat.

332637L 25

Troubleshooting

T2AE

T2BE

Low Temperature

Heat Exchanger A

Low Temperature

Heat Exchanger B

Coolant circulation pump not working.

Air lock in pump circulation.

No voltage to coil of valve.

Check for 240 VAC on pump. If there is the correct voltage, replace circulation pump.

Check for coolant flow in sight glass.

Coolant circulation pump not working.

Air lock in pump circulation.

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.

Check for 240 VAC on pump. If there is the correct voltage, replace circulation pump.

Check for coolant flow in sight glass.

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.

26 332637L

T2DA

T2DB

T2DE

T2DH

T2FA

332637L

Troubleshooting

Low Temperature A

Low Temperature B

Low Temperature

Coolant Outlet

Low Temperature

Hose

Low Temperature

Inlet A

Flow is too high at current setpoint.

Bad RTD or bad

RTD placement against heater.

Loose heater wires or connector.

Bad heater element.

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

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

Check for loose heater element wires or loose green connector at TCM.

Flow is too high at current setpoint.

Bad RTD or bad

RTD placement against heater.

Loose heater wires or connector.

Bad heater element.

Confirm resistance of heater. Heater resistance should be 23–26 ohms. If out of tolerance, replace the heater element.

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

If recirculating, decrease flow or decrease temperature setpoint.

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

Check for loose heater element wires or loose green connector at TCM

Confirm resistance of heater. Heater resistance should be 23-26 Ω. If out of tolerance, replace heater element.

Replace fan relay.

Radiator fan will not stop.

Engine thermostat is stuck closed.

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

Flow is too high at current setpoint.

Replace thermostat.

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

Inlet fluid temperature is below the defined level.

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

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

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

27

Troubleshooting

T2FB

T3CH

T3CT

T3NM

Low Temperature

Inlet B

Hose Cutback

TCM Cutback

Motor Temperature

Cutback

Inlet fluid temperature is below the defined level.

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

High ambient temperature.

Enclosure fan not operating.

Module fan not operating.

Cooling fan on back of motor not operating properly.

Ambient temperature is too high.

Machine is operating above pressure/flow rating.

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

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

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

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

Ensure ambient temperature is below

120° F(48° C) before using the system.

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

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

Verify the following:

• Ensure fan is always running when machine is powered on.

• Ensure fan is blowing air toward the motor (inward).

• Ensure fan is clean and moves freely. Remove any obstructions in front of fan grille.

• Ensure no hot air (from other heat sources) is being directed toward the fan.

Ensure system ambient temperature is below 120° F(48° C).

• Mix chamber is too large for set pressure

• Set pressure is too high for given mix chamber preserve motor life. If the motor gets too hot this advisory automatically reduces the pressure setpoint to allow the motor to cool. To avoid this advisory, run the system at a lower duty cycle or with a smaller mix chamber.

28 332637L

T3CM

T4AE

T4BE

T4CM

T4CT

332637L

Troubleshooting

Motor Temperature

Cutback

High Temperature

Heat Exchanger A

High Temperature

Heat Exchanger B

High Temperature

MCM

High Temperature

TCM

Motor control temperature is too high.

Ensure ambient temperature is below

120° F (48° C) before using the system.

Verify that all fans are working.

Open cabinet cover and turn switch to the OFF position.

Manual valve switch (MV) on load center is in the ON position.

A or B side control valve solenoid is stuck in the open position.

Short on load center board.

High ambient temperature.

Enclosure fan not operating.

Module fan not operating.

Debris in valve diaphragm or plunger preventing spring-loaded closed function. Disconnect connector from valve solenoid cable. If temperature does not decrease, rebuild solenoid.

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.

Open cabinet cover and turn switch to the OFF position.

Manual valve switch (MV) on load center is in the ON position.

A or B side control valve solenoid is stuck in the open position.

Short on load center board.

J6 connector on load center "Heat

Valves" location is not centered.

High ambient temperature.

Enclosure fan not operating.

Debris in valve diaphragm or plunger preventing spring-loaded closed function. Disconnect connector from valve solenoid cable. If temperature does not decrease, rebuild solenoid.

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.

Reconnect J6 connector on load center in centered location.

Ensure ambient temperature is below

120°F(48°C) before using the system.

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

Ensure ambient temperature is below

120°F(48°C) before using the system.

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

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

29

Troubleshooting

T4DA

T4DB

T4DE

High Temperature

A

High Temperature

B

High Temperature

Coolant Outlet

Bad RTD or bad

RTD placement against heater.

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

Bad RTD or bad

RTD placement against heater.

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

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

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

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

High ambient temperature.

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

Broken fan, fan relay, or blown fan fuse.

Ensure ambient temperature is below

120° F (49° C) before using the system.

Check fan relay (K4) and fuse (30

Amp ATO "F3") on load center board.

Replace if needed.

Water pump belt failure.

Check engine water belt pump.

Replace if needed.

Plugged radiator.

Replace if needed.

30 332637L

T4DH

Troubleshooting

High Temperature

Hose

Fluid is overheated in portions of hose exposed to an excessive heat source, like hot sunlight. When spraying begins, overheated fluid passes over the

FTS, triggering this alarm.

Trigger point is

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

Coiled hose creates excessive heat in a portion of the hose.

When spraying begins, the overheated fluid passes over the

FTS.

Fluid hose insulation missing from over FTS, leading to erratic hose temperature control.

Shade exposed hose from hot sun or expose FTS to same environment when at rest.

Uncoil entire hose before heating.

Multiple sections of hose piled or wrapped creates self-heating and leads to this problem.

• Hose temperature is measured in the A-side (red) fluid hose approximately 18 in. (0.5 m) back toward the proportioner from the

FTS fittings.

• Confirm that insulation is intact over, at minimum, the last 6 ft

(2 m) of the A-side hose. If not, replace missing insulation over the individual hoses. (Wrapping replacement insulation over the whole hose bundle is not sufficient for proper hose temperature control.)

• Replacement insulation is available from Graco or a hardware store.

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

Setting the A or B setpoint much higher than hose setpoint can cause fluid more than 27°

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

332637L 31

Troubleshooting

T4EA

T4EB

High Temperature

Switch A

High Temperature

Switch B

Cold ambient temperature is causing hose to heat.

Overtemperature switch sensed a fluid temperature above 230°F

(110°C).

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

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

Heater was delivered too much power, causing the overtemperature switch to open. RTD is not reading properly. After the heater cools down, replace RTD. Switch closes and the error can be cleared when the heater temperature falls below

190°F (87°C).

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

Disconnected or loose overtemperature switch cable/connection.

Overtemperature switch failed in the open position.

Overtemperature switch sensed a fluid temperature above 230°F

(110°C).

Disconnected or loose overtemperature switch cable/connection.

Overtemperature switch failed in the open position.

Replace overtemperature switch.

Heater was delivered too much power, causing the overtemperature switch to open. RTD is not reading properly. After the heater cools down, replace RTD. Switch closes and the error can be cleared when the heater temperature falls below

190°F (87°C).

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

Replace overtemperature switch.

32 332637L

T4NM

Troubleshooting

High Temperature

Motor

High amount temperature.

Cooling fan is not operating properly.

Ensure ambient temperature is below

120° F (49° C) before using the system.

• 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.

Verify wiring between the motor temperature sensor and the module.

Disconnected or loose motor temperature cable.

Failed motor temperature sensor.

Measure resistance between pins

1 and 3 on motor temperature cable connector.

Readings vary depending on temperature, but at room temperature (72°F/22°C), the resistance should be approximately

1500 to 2500 ohms. An open circuit reading indicates a possible wire break. Replace motor.

T6AE

T6BE

332637L

Sensor Error Heat

Exchanger A

Sensor Error Heat

Exchanger B

Disconnected or loose RTD cable or connection.

Bad RTD.

Check all wiring and connection to

RTD.

Disconnected or loose RTD cable or connection.

Bad RTD.

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

Replace RTD if the error follows the

RTD.

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.

33

Troubleshooting

T6DA

T6DB

T6DE

T6DH

T6DT

Sensor Error A Disconnected or loose RTD cable or 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.

Check all wiring and connection to

RTD.

Sensor Error B Disconnected or loose RTD cable or connection.

Bad RTD.

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

Replace RTD if the error follows the

RTD.

Check all wiring and connection to

RTD.

Sensor Error

Coolant Outlet

Disconnected or loose RTD cable or connection.

Bad RTD.

Sensor Error Hose

Sensor Error TCM

Disconnected or shorted RTD cable in hose or bad FTS.

Shorted RTD cable in hose or FTS.

Shorted Heater A or B RTD

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

Replace RTD if the error follows the

RTD.

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

Test kit 24N365 for measurement.

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

Expose each hose RTD connection to check for exposed and shorted

RTD wires. Measure hose RTD cable and FTS continuity. See . Order RTD

Test kit 24N365 for measurement.

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

If the error still occurs with the hose

FTS unplugged, one of the heater

RTDs is bad. Unplug the A or B RTD from the TCM. If unplugging an RTD fixes the T6DT error, replace the RTD.

34 332637L

T6NM

Troubleshooting

Sensor error motor

MCM

Disconnected or loose motor temperature cable.

Failed motor temperature sensor.

Verify wiring between the motor temperature sensor and the module.

Measure resistance between pins

1 and 3 on motor temperature cable connector.

Readings vary depending on temperature, but at room temperature (72° F / 22° C), the resistance should be approximately

1500 to 2500 ohms. An open circuit reading indicates a possible wire break. Replace motor.

T8AE No Temperature

Rise Heat

Exchanger A

No coolant flow.

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.

Red, blue, and green LEDs should light up on load center board. If not, replace load center.

332637L 35

Troubleshooting

T8BE

T8DA

No Temperature

Rise Heat

Exchanger B

No Temperature

Rise A

No coolant flow.

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.

System stored below 20°F(-7°C) causing slow coolant valve operation.

Chemical below 32°F(0°C) at startup.

Recirculate cold chemical back to drum in cold conditions before spraying.

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.

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 RTD or band

RTD placement against heater.

Loose heater wires or connector.

Bad heater element.

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

Check for loose heater element wires or loose green connector at TCM.

Bad valve solenoid.

Confirm resistance of heater. Heater resistance should be 23-26 Ω. If out of tolerance, replace heater element.

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.

36 332637L

T8DB

T8DH

V1CM

V1IT

V1MA

332637L

Troubleshooting

No Temperature

Rise B

No Temperature

Rise Hose

Low Voltage MCM

Low Voltage CAN

Low Voltage A

Bad RTD or bad

RTD placement against heater.

Loose heater wires or connector.

Bad heater element.

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

Check for loose heater element wires or loose green connector at TCM.

Bad valve solenoid.

Confirm resistance of heater. Heater resistance should be 23-26 Ω. If out of tolerance, replace heater element.

Turn on the manual valve switch (MV), on the load center, and see if the valve shifts. If not replace solenoid.

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

Started spraying before heater reached operating temperature.

Started spraying before heater reached operating temperature.

Loose/bad connection or tripped circuit breaker.

Low generator line voltage.

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

Check wiring for loose connection or tripped circuit breaker.

Mis-adjusted

24 VDC power supply.

Measure voltage across main power switch (CT01). Voltage should measure between 195 and 264 VAC.

Measure voltage of power supply.

Voltage should be 23-25 VDC. If out of tolerance, adjust output voltage to approximately 24 VDC.

Reference schematics in repair manual. Trace all CAN cables and check all connections.

Short circuit or intermittent connection in wiring.

Bad 24 VDC power supply.

Loose connection or tripped circuit breaker.

Low generator line voltage.

If voltage can not be adjusted back into tolerance range, replace power supply.

Check wiring for loose connection or tripped circuit breaker.

High auxilary inrush current.

Measure voltage across main power switch (CT01). Voltage should measure between 195 and 264 VAC.

Ensure compressor or air drier are set up to be continuous run and sized according to the manual.

37

Troubleshooting

V1MB

V1MH

V2IT

V3IT

V4CM

V4IT

Low Voltage B

Low Voltage Hose

Low Voltage CAN

High Voltage CAN

High Voltage MCM

High Voltage CAN

Loose connection or tripped circuit breaker.

Low generator line voltage.

High auxilary inrush current.

Loose connection or tripped circuit breaker.

Low generator line voltage.

Check wiring for loose connection or tripped circuit breaker.

Measure voltage across main power switch (CT01). Voltage should measure between 195 and 264 VAC.

Ensure compressor or air drier are set up to be continuous run and sized according to the manual.

Check wiring for loose connection or tripped circuit breaker.

High auxilary inrush current.

Mis-adjusted

24 VDC power supply.

Short circuit or intermittent connection in wiring.

Bad 24 VDC power supply.

Measure voltage across main power switch (CT01). Voltage should measure between 195 and 264 VAC.

Ensure compressor or air drier are set up to be continuous run and sized according to the manual.

Measure voltage of power supply.

Voltage should be 23-25 VDC. If out of tolerance, adjust output voltage to approximately 24 VDC.

Reference schematics in repair manual. Trace all CAN cables and check all connections.

Mis-adjusted

24 VDC power supply.

Bad 24 VDC power supply.

Incoming line voltage is too high.

Mis-adjusted

24 VDC power supply.

Bad 24 VDC power supply.

If voltage can not be adjusted back into tolerance range, replace power supply.

Measure voltage of power supply.

Voltage should be 23-25 VDC. If out of tolerance, adjust output voltage to approximately 24 VDC.

If voltage can not be adjusted back into tolerance range, replace power supply.

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.

Measure voltage of power supply.

Voltage should be 23-25 VDC. If out of tolerance, adjust output voltage to approximately 24 VDC.

If voltage can not be adjusted back into tolerance range, replace power supply.

38 332637L

V4MA

V4MB

V4MH

WBC0

WMCE

WMI0

WSUX

WXUD

WXUU

Troubleshooting

High Voltage A

High Voltage B

High Voltage Hose

Software Version

Error

Load Center Fault

TCM Fan Error

Configuration Error

USB

USB Download

Error

USB Upload Error

Incoming line voltage is too high.

Incoming line voltage is too high.

Incoming line voltage is too high.

Incorrect software version.

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.

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.

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.

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

MCM does not have line voltage.

If V1CM also exists, see troubleshooting for V1CM. The software version cannot be read if the MCM does not have line voltage.

Check connection and cables.

Bad connection between MCM and load center board.

Bad load center.

Replace load center.

Fan inside TCM is not operating properly.

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

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.

Log download failed.

Custom language file failed to upload.

Backup and reformat the USB drive.

Retry download.

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

332637L 39

Troubleshooting

See

Supplied Manuals, page 13 , 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.

Reactor ADM does not turn on.

No power.

Turn main power switch ON.

Turn circuit breakers ON, see

Circuit Breaker Modules .

Check circuit breaker (CB10). See

Circuit Breaker Modules .

Electric motor does not operate.

Electric motor runs erratically.

Loose connections.

Tripped circuit breaker (CB02).

Reset breaker.

See

Circuit Breaker Modules

. Check

240VAC at output of breaker.

Shorted windings.

Check MCM connections. See

Circuit Breaker Modules .

Replace motor.

See

Repair Electric Motor, page 74 .

Software bug.

Failed motor bearings.

Update system to fastest version of software. Insert an upgrade token into the ADM and cycle the power.

Wait until the upload is complete before removing the token.

Replace motor, see

Repair Electric Motor, page 74 .

40 332637L

Troubleshooting

Electric motor cooling fan not working.

Tripped circuit breaker (CB03).

Reset circuit breaker (CB03). Check

240VAC at output of breaker.

Loose wire.

Check the fan.

See

Electrical Schematics, page 159 .

Fan blade obstructed.

Remove obstruction.

Defective fan.

Replace the fan.

See

Replace Motor Fan, page 80

.

Open, clear; use hose with larger ID.

Pump output low.

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

Worn piston valve or intake valve in displacement pump.

Pressure setpoint too high.

See pump manual.

Reduce setpoint and output will increase.

Replace. See pump manual.

Fluid leak in pump packing nut area.

Worn throat seals.

No pressure on one side.

Air compressor does not start.

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.

Tripped circuit breaker (CB04).

Reset circuit breaker (CB04).

Not wired correctly.

Compressor starter overheated from rapid multiple start and stop procedures.

See

Electrical Schematics, page 159 .

Let starter cool down for 2 minutes then press reset on the air compressor electrical enclosure and start.

332637L 41

Troubleshooting

Air compressor shuts down during operation.

Air dryer cooling fan not running.

Air dryer not draining water.

Air dryer fault light comes on after turning dryer power on.

Air dryer drain tube is blowing air.

Compressor oil over temperature switch triggering shutdown.

Motor current draw greater than

24 amps, triggering shutdown.

Check continuity of overtemperature switch and cabling.

Switch is normally closed.

Oil temperature range during normal operation is 170°–190° F

(77°–88° C). Compressor oil over temperature switch opens at oil temperature of approximately

230° F (110° C). Maintain ambient temperature below system ambient temperature limit of 120° F (49° C).

Reset motor starter.

If repeatedly shutting down, manually spin the compressor fan blades with the compressor powered off. The compressor should turn freely. If it does not, separate the compressor from the motor and determine whether the compressor or motor is at fault.

Repair or replace the faulty part.

See

Supplied Manuals, page 13

for compressor and compressor motor warranty and service information.

If repeatedly shutting down and the compressor turns freely, measure the current draw of the compressor motor. After 20 minutes of operation at maximum pressure

(130–140 psi), measure current on the black wire in harness 24U079.

Normal readings are less than

23.3 A when operating at full load. If current draw is greater than approximately 27 A, replace the capacitors on the compressor motor. See

Replace Compressor

Motor Capacitors, page 109

.

Normal operation.

Only runs after air reaches a minimum temperature.

Power not turned on at dryer.

No air usage.

If compressor was running with dryer off (O), the air temperature is too high to start dryer.

Dryer separator/filter plugged or drain float not working.

Turn dryer switch ON ( | ).

Check after air flowing.

Turn off compressor long enough for air temperature to dryer to cool down. Then turn dryer on ( | ).

Refer to dryer manual to clean/replace filter element of bowl float. See

Supplied Manuals, page 13 .

42 332637L

Troubleshooting

Air bubbles in sight glass.

Heat exchanger coolant flow stopped. No flow in sight glass.

Material slowly heats up.

Heat exchanger coolant in sight glass is a milky color.

A or B material heats up slower than the other.

A or B material cooling down slower than the other.

Air trapped in heat exchanger coolant.

Coolant hoses between the proportioner coolant loop and engine coolant loop were modified and created a high point air pocket.

Proportioner coolant loop expansion bottle is empty.

Circulation pump stopped running.

See

Refill Proportioner Coolant

Loop, page 66

.

Ensure coolant hoses have a constant rise in elevation.

See

Refill Proportioner Coolant

Loop, page 66

.

Check circuit breaker. Check voltage.

Repair or replace valve. See

Replace Control Valve, page 93

.

Bypass control valve does not open.

Coolant filter plugged.

Clean or replace filter in filter housing, see

Repair Filter

Housing Filter, page 95

and order replacement filter kit

24T028.

Repair or replace valve. See

Replace Control Valve, page 93

.

A and B control valves are not opening fully.

System stored below 20°F(-7°C).

Ensure system ambient temperature is above

20°F(-7°C).

Possible material leaking into coolant.

Drain Proportioner coolant loop.

See

Drain Coolant, page 64

.

Check for pressurized material leaks.

Control valve opening too slow.

Repair or replace valve. See .

System stored below 20°F(-7°C).

Ensure system ambient temperature is above

20°F(-7°C).

Control valve coil failed.

Control valve coil not allowing valve to normally close.

Repair or replace valve coil. See

Repair or replace valve coil. See

Control valve stuck in open position.

Bad load center.

Repair valve. See

Replace the load center board.

See

Load Center Diagnostics, page 49 .

332637L 43

Troubleshooting

Engine coolant does not reach full temperature.

Engine temperature normal, but heat exchanger temperature is low or slowly increases.

Expansion bottle levels are not rising when coolant is heating.

Coolant level in engine coolant expansion bottle rises too high and too fast.

Coolant level in proportioner coolant expansion bottle does not rise when hot.

Coolant level in proportioner coolant expansion bottle rises too high and too fast.

Coolant level dropping in overflow bottle but no visible leaks.

Radiator fan does not shut off.

Check fan relay. Check fan wiring.

Radiator core becoming plugged.

Replace radiator. See

Radiator .

Engine thermostat not opening.

Replace engine thermostat.

Coolant level is low in expansion bottle.

See

Refill Engine Coolant Loop, page 67 .

No coolant flow in engine coolant loop.

Heat exchanger in the engine coolant loop is plugged.

Radiator or heat exchanger bottle cap not opening.

Expansion bottle cap and radiator cap are switched.

Replace heat exchanger. See

Heat Exchanger Assembly

Replace cap.

Switch radiator caps. Radiator cap is marked 16 lbs and expansion bottle is marked 8 lbs.

Replace radiator cap.

.

Spring loaded gasket inside radiator cap does not seal.

Expansion bottle cap and radiator cap are switched.

Expansion bottle cap stuck open.

Switch radiator caps. Radiator cap is marked 16 lbs and expansion bottle is marked 8 lbs.

Replace expansion bottle cap.

Cap not fully tightened.

Push down and tighten cap past safety latch position.

44 332637L

Troubleshooting

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.

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

Hose does not maintain temperature while spraying.

Hose temperature exceeds setpoint.

Ambient temperature is too cold.

FTS failed or not installed correctly.

A and B setpoints too low.

Ambient temperature is too cold.

Flow too high.

Hose was not fully preheated.

A and/or B heaters are overheating material.

Faulty FTS connections.

Ambient temperature is too high.

Use auxiliary hose heat system.

Check FTS. See

Check RTD

Cables and FTS, page 86

.

Increase A and B setpoints.

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

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

Use smaller mix chamber.

Decrease pressure.

Wait for hose to heat to correct temperature before spraying.

Check primary heaters for either a RTD problem or a failed element attached to RTD.

See

Electrical Schematics, page

159

.

Verify that all FTS connections are snug and that pins of connectors are clean. Unplug and re-plug RTD wires, cleaning off any debris.

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

332637L 45

Troubleshooting

Erratic hose temperature.

Hose does not heat.

Faulty FTS connections.

FTS not installed correctly.

FTS failed.

FTS not installed correctly.

Loose hose electrical connections.

Circuit breakers tripped.

Verify that all FTS connections are snug and that pins of connectors are clean. Unplug and re-plug FTS wires along length of hose, cleaning off any debris.

FTS should be installed close to end of hose in same environment as gun.

Verify FTS installation, see

Repair Fluid Temperature

Sensor (FTS), page 88 .

Check FTS, see

Repair Fluid

Temperature Sensor (FTS), page 88 ..

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 .

Check connections. Repair as necessary.

Reset breakers (CB20 and

CB02), see

Repair Circuit

Breaker Module, page 75

.

Turn on hose heat zone.

Check. Increase if necessary.

Hose zone not turned on.

A and B temperature setpoints too low.

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.

46 332637L

Troubleshooting

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

Low hose heat.

Shorted connection or failed hose heating element.

A and B temperature setpoints too low.

With power off, check the hose resistance with and without the whip hose attached. With the whip hose attached, the reading should be less than

3 ohm. Without the whip hose attached, the reading should be OL (open loop).

See

Check Hose Heat Power

Connectors, page 85 .

Increase A and B setpoints.

Hose designed to maintain temperature, not increase temperature.

Check. Increase if necessary to maintain heat.

Hose temperature setpoint too low.

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.

Loose hose electrical connections.

Allow hose to heat up, or preheat fluid.

Check connections. Repair as necessary.

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

332637L 47

Troubleshooting

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.

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.

Booster heater(s) does not heat.

Heat turned off.

Temperature control alarm.

Signal failure from RTD.

Failed heater element.

Loose RTD connections.

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

RTD not contacting heater element.

Failed heater element.

Signal failure from RTD.

Turn on heat zones.

Check ADM for error codes.

Error

Codes table (see

Error Codes

).

See

Replace Heater Element, page 82 .

Examine RTD cables connected to TCM. Confirm RTDs are not plugged into opposite heat zone. Reconnect RTD connectors.

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

Holding RTD tip against heater element, tighten ferrule nut

1/4 turn past tight.

See

Replace Heater Element, page 82 .

See (T4DA, T4DB),

Error Codes

.

48 332637L

Troubleshooting

Reference

Replace Load Center Relays and Fuses, page 77 , and

Electrical Schematics, page 159 . The

LEDs on the load center board are helpful diagnostic tools when troubleshooting problems with the engine. Before referencing the

Engine , complete the following steps:

1. Identify which LEDs are on and off.

Load Center Component Identification

Figure 1

Radiator Fan Fuse F3

F4

K1

K2

K3

K4

MV

Load Center Power Fuse

Fuel Relay

Starter Relay

Glow Plug Relay

Radiator Fan Relay

Manual Valve Switch

LED Related

D1 Fuel Shutoff Solenoid

D2

D3

Starter

Glow Plugs

D4 Radiator Fan

D10 A Coolant Valve

D12 B Coolant Valve

D14 Bypass Coolant Valve

D23 Manual Valve Switch

Green

Red

Green

Green

Red

Blue

Green

Red

Manual Valve Switch ON (engine off)

Figure 2

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.

332637L 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.

Note

The starter, fuel shutoff solenoid, glow plugs, and radiator fan operations are sequenced during startup by the Engine Control

Module.

LED ON

D1

D2

D3

D4

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.)

3. If the LEDs light as expected, focus troubleshooting attention to components listed in Table 1. If the LEDs do not light as expected, first focus troubleshooting attention to components listed in Table 2.

4. For potential causes and solutions related to the components in Tables 1 and 2, see

Engine .

Table 1 lists a likely order of potential failures in the load center output-side components.

Glow

Plugs

Radiator

Fan

1 Engine Harness (E) and its connections

2 Engine

Fuel

3

Shutoff

Solenoid

(FD)

Starter

Solenoid

Relay

(CR6)

Glow

Plugs

Solenoid

Relay

(CR7)

Engine

Starter

Motor

(ES)

Table 2 indicates a likely order of potential failures in the load center input-side power, cable, or control components.

5

6

7

1

2

3

4

8

9

10

Fuel

(D1)

Starter

(D2)

Plugs

(D3)

Battery

Fan

(D4)

Battery cables and its connections

No D2

LED Disconnect switch

ON

Load Center Fuse F4

("PWR - ATO 20A")

Load

Center

Fuse F3

("FAN

- ATO

30A")

Fusible Link Harness (C) and its connections

Engine Harness (E) and its connections

Engine Control Module Harness (F) and its connections

Load

Center

Fuel

Relay

(K1)

Load

Center

Starter

Relay

(K2)

Load

Center

Glow

Relay

(K3)

Load

Center

Fan

Relay

(K4)

Load Center Board

Engine Control Module

50 332637L

LED Description

Off

On

Flashing

1. After pressing green start button on Engine

Control Module, glow plugs start warming engine.

Troubleshooting

4. Engine just started; glow plugs continue to warm 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 shortly after main power switch is turned on. Heat zones are off.

3. Engine starting; fuel, fan, and glow plugs continue to operate.

7. Engine is running; with heat zones on, A and

B valves cycled by electronics.

332637L 51

Troubleshooting

Contact Perkins for diesel engine service or warranty. See

Supplied Manuals, page 13

.

Engine Control Module does not power up from sleep mode.

Discharged or failed battery.

Loose or incorrect wiring connections.

Verify battery voltage is 11 -

13 volts DC.

Charge or replace battery as required. See

Replace Battery, page 96 .

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 159 . 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 77

.

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 159 . See

Repair Fusible Link Harness, page 97 .

Failed Engine Control Module.

Replace module. See

Replace Engine Control Module, page 99 .

Failed Load Center board.

Replace board.

See

Replace Load Center, page 78

.

52 332637L

Troubleshooting

Reference

Load Center Diagnostics, page 49 .

Engine does not turn over.

Main power switch on electrical enclosure is in the ON position.

Discharged or failed battery.

Turn switch to OFF position.

Verify battery voltage is 11 -

13 volts DC.

Charge or replace battery as required. See

Replace Battery, page 96 .

Verify cable connectors. See

Replace Battery, page 96 .

Loose or corroded battery cable connector.

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

159

. 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 77

.

Failed starter relay.

Replace relay K2 located on Load Center board. See

Replace Load Center Relays and

Fuses, page 77

.

Failed starter solenoid relay.

Replace solenoid relay CR6 located on side of engine.

See

Replace Engine Solenoid

Relays, page 78

.

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 159

.

Failed load center board (242).

Replace board.

See

Replace Load Center Relays and

Fuses, page 77

.

Failed engine control module

(428).

Replace module. See

Replace Engine Control Module, page 99 .

Failed engine starter (ES).

Contact local Perkins distributor for service.

332637L 53

Troubleshooting

Reference

Load Center Diagnostics, page 49 .

Engine turns over, but does not start.

Low fuel level.

Lost prime.

Loose or incorrect wiring connections.

Blocked air intake.

Blocked exhaust system.

Blocked fuel filter.

Failed fuel relay.

Solenoid valve rod stuck in extended position.

Failed engine fuel shutoff solenoid.

Failed glow plug relay.

Refill fuel tank.

Ensure fuel tank is at least half full, prime with bulb until fuel is flowing through return line to tank.

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 159 .

Replace air filter.

Check that exhaust system is open (rain cap is free to move, no exhaust obstructions or plugging). Remove blockage.

Inspect/replace fuel filter.

Replace relay K1 located on Load Center board. See

Replace Load Center Relays and

Fuses, page 77

.

Remove valve rod and clean with WD-40.

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.

Replace relay K3 located on

Load Center board. See .

Failed glow plug solenoid relay.

Replace solenoid relay CR7 located on side of engine.

See

Replace Engine Solenoid

Relays, page 78

.

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 332637L

Troubleshooting

Reference

Load Center Diagnostics, page 49 .

Engine shuts down, Engine

Control Module shows no errors.

Loose or incorrect wiring connections.

Failed fuel relay.

Failed engine fuel shutoff solenoid.

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 159 .

Replace relay K1 located on Load Center board. See

Replace Load Center Relays and

Fuses, page 77

.

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.

332637L 55

Troubleshooting

Reference

Load Center Diagnostics, page 49 .

Engine shuts down, Engine

Control Module shows High

Coolant Temperature Shutdown icon.

Low engine coolant level.

Engine water temperature switch failed or shorted out.

Loose or incorrect wiring connections.

Blown radiator fan fuse.

Failed radiator fan relay.

Obstructed radiator fan.

Failed radiator fan.

Failed engine coolant temperature sensor.

Plugged radiator or coolant system.

Inspect coolant system for leaks. Repair as necessary and refill system.

Check for shorts to switch wiring. See

Electrical

Schematics, page 159

.

Verify wiring connections

(including grounds) related to radiator fan. Check Engine

Harness (E), and Engine Control Module Harness (F). See

Electrical Schematics, page

159

.

Determine cause of blown fuse

F3 "FAN - ATO 30A". Repair issue then replace fuse. See

Replace Load Center Relays and

Fuses, page 77

.

Replace relay K4 located on Load Center board. See

Replace Load Center Relays and

Fuses, page 77

.

Remove obstructions.

Replace fan.

See

Replace Radiator Fan, page 81 .

Replace engine coolant temperature sensor located behind radiator connected to MCM port 3.

See

Replace Engine RTD, page 103 .

Clean or replace radiator. See

Remove Radiator, page 98 .

Contact local Perkins distributor for service.

56 332637L

Troubleshooting

Engine shuts down. Engine

Control Module shows Low Oil

Pressure Shutdown icon.

Engine shuts down. Engine

Control Module shows Under

Frequency Shutdown icon or Generator Low Voltage

Shutdown icon .

Low oil level.

Loose or incorrect wiring connections.

Failed oil pressure switch.

Low fuel level.

Lost prime.

Blocked air intake.

Blocked exhaust system.

Blocked fuel filter.

Generator overloaded.

Loose or incorrect wiring connections.

Blown voltage sense fuses.

Check oil level and refill.

Verify wiring connections

(including grounds) related to oil pressure switch. Check

Engine Harness (E), and Engine

Control Module Harness (F).

See

Electrical Schematics, page

159

.

Replace oil pressure switch

Contact local Perkins distributor for service.

Refill fuel tank.

Ensure fuel tank is at least half full, prime with bulb until fuel is flowing through return line to tank.

Replace air filter.

Check that exhaust system is open (rain cap is free to move, no exhaust obstructions or plugging). Remove blockage.

Replace fuel filter.

Confirm auxiliary electrical loads wired into the electrical enclosure by the customer are within the system's available auxiliary power limits.

Verify wiring connections related to Engine Control Module,

Check AC Sense Harness (M).

See

Electrical Schematics, page

159

.

Replace fuses F6 and F7 located in the junction box above the

120/240 V alternator. Use repair kit 24M723.

332637L 57

Troubleshooting

No module status LEDs are illuminated.

Has not identified GPS location

(green module status LED flashing).

Has not established cellular connection (orange module status LED flashing).

Cannot view data for my unit(s) on website.

Reactor temperature data not displayed on website.

Hose zone temperature data not displayed on website.

Reactor pressure data not displayed on website.

No power to cellular module.

Still identifying location.

Unable to identify location.

In a location where GPS lock cannot occur. Buildings and warehouses often prevent GPS locks.

Still establishing cellular connection.

Unable to establish cellular connection.

Graco InSite unit has not been activated.

Reactor temperature measurement is not working.

The RTD is not correctly installed on the hose or is broken.

Reactor pressure measurement is not working.

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.

58 332637L

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

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.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

The Fusion AP gun is shown.

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

2. Close gun fluid inlet valves A and B.

5. Engage gun piston safety lock.

6. Disconnect gun air line and remove gun fluid manifold.

3. Shut off feed pumps and agitator, if used.

332637L 59

Shutdown

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

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.

1. Press to stop the pumps.

2. Turn off all heat zones.

To avoid system damage, follow daily shutdown procedure. Use only for immediate shutdown.

For immediate shutdown, press:

3. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION .

Stop Auto Start ti30478a

4. Relieve pressure.

See

Pressure Relief Procedure, page 59 .

60 332637L

Shutdown

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.

9. Turn main power switch OFF. Allow engine cooling dwell time prior to shutting down the engine.

6. Press to deactivate the system.

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

8. Close the main air shutoff valve.

To prevent electric shock do not remove any shrouds or open the electrical enclosure door. 240 V is still present in the system until the engine has stopped.

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.

Stop Auto Start ti30478a

332637L 61

Flushing

11. Close all fluid supply valves.

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

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.

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 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 .

62 332637L

Repair

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.

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

1. Flush if necessary. See

Flushing, page 62 .

2. See

Shutdown, page 60

.

Note

Clean the A-side screen only during daily startup. This minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing operations.

1. Close the fluid inlet valve at the pump inlet and shut off the appropriate feed pump.

This prevents material from being pumped while cleaning the screen.

2. Place a container under the strainer base to catch drain off when removing the strainer plug (C).

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.

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.

Figure 3

A

B

C

D

332637L 63

Repair

To avoid burns, do not perform maintenance on the coolant system until the coolant system has reached ambient temperature.

Drain coolant from the engine and proportioner coolant loops once a year or if the coolant lines need to be disconnected, in order to install a wall between the generator and proportioner.

1. Perform

Shutdown, page 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.

4. To drain proportioner coolant loop: a. Remove the proportioner coolant loop fill bottle (HF) cap.

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.

Proportioner Coolant Loop Drain Valve

Figure 5 c. To refill coolant loop, see

Refill

Proportioner Coolant Loop, page 66

.

MV

LC

L C

Figure 4

Manual valve switch

(MV)

A Side Control Valve

B Side Control Valve

Bypass Valve

Red

Red

Blue

Green

64 332637L

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).

55 &&

++ ))

++

Repair

6. To drain engine coolant loop: a. Remove the engine coolant loop (RC) cap.

b. Remove engine guards as shown. Let the guards rest on the engine to access the drain valve.

77

''

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 Engine Coolant Loop, page 67 .

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 67 .

e. Replace engine shrouds. Torque screws to 25 ft-lb (33.8 N∙m).

332637L 65

Repair

Purge air from proportioner coolant loop when it is filled with new coolant or when air enters the coolant system.

cool-down cycle to purge air from coolant.

3. Replace cap and tighten past the safety latch position.

4. Press start button control module.

twice on the engine

5. Turn main power switch on.

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 67

.

6. Inspect coolant flow in sight glass (SG) for bubbles and verify that 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 fan turns on, turn main power switch off.

Do not refill with drained coolant. Use only fresh, new coolant to avoid contaminants.

Do not use any “stop leak” additives to prevent plugged filters and small orifices.

1. Before refilling coolant loop, perform steps

1–3 from

Drain Coolant, page 64

. Drain

coolant loop if necessary.

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 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 67 .

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).

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

.

66

Figure 8

332637L

Repair

5. Turn main power switch on.

Refill the engine coolant loop when the coolant is below the cold level line at ambient temperature.

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 67

.

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.

Do not refill with drained coolant. Use only fresh, new coolant to avoid contaminants.

8. Press 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.

Do not use any “stop leak” additives to prevent plugged filters and small orifices.

1. Perform

Shutdown, page 60 .

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 . Replace cap. See

Coolant Specifications, page 67 .

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

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.

332637L 67

Repair

Check the condition of the ISO pump lubricant daily. Change the lubricant if it becomes a gel, its color darkens, or it becomes diluted with isocyanate.

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

Lubricant discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during operation. If the packings are operating properly, lubricant replacement due to discoloration should not be necessary more often than every 3 or 4 weeks.

To change pump lubricant:

1. Follow

Pressure Relief Procedure, page 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. Manually prime the ISO pump. Plug the small vent hole (H) between the tube grommets while squeezing the bottle to force the lubricant up the feed tube. Repeat until the fluid level reaches the ISO pump to force the air out.

Pump Lubrication System

Figure 9

7. Verify that the ISO pump is operating correctly by feeling the pulsation in the return tube during normal proportioner pump operation.

8. Ensure the vent hole stays open.

68 332637L

Repair

Pump rod and connecting rod move during operation. Moving parts can cause serious injury such as pinching or amputation. Keep hands and fingers away from connecting rod during operation.

Note

See manual 309577 for pump repair instructions.

1. Press to stop the pumps.

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.

10. Press on the engine control module.

11. Open air compressor bleed valve to relieve pressure and remove water from tank.

12. Shut off both feed pumps. Close all fluid supply valves.

13. Route fluid to waste containers or supply tanks. Turn PRESSURE RELIEF/SPRAY valves

(SA, SB) to PRESSURE RELIEF/CIRCULATION

. Ensure gauges drop to 0.

8. Turn main power switch off.

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.

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.

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.

332637L 69

Repair

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.

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.

Pump A

Figure 10

1

2

3

Flat side faces up.

Lubricate threads with ISO oil or grease.

Pump top threads must be nearly flush with bearing face (N).

Note

Steps 17 and 18 apply to pump B.

Pump B

Figure 11

1

2

3

Flat side faces up.

Lubricate threads with ISO oil or grease.

Pump top threads must be nearly flush with bearing face (N).

70 332637L

Repair

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.

4. Reconnect fluid inlet (C) and outlet (D).

5. Go to step 13.

Note

Steps 6–12 apply to pump A only.

6. Ensure star-shaped locknut (G) is screwed on pump with flat side up. Carefully twist and extend displacement rod 2 in. (51 mm) above wet-cup.

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.

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.

Note

Do not let tubes kink or buckle.

12. Reconnect fluid inlet (C).

13. Purge air and prime the system. See Reactor operation manual.

332637L 71

Repair

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.

13. Remove screws (294) and motor shield

(293), see

Fig. 12 .

Note

Examine bearing housing (303) and connecting rod (305). If these parts need replacing, first remove the pump (315), see .

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).

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.

9. Allow engine dwell time.

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.

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 .

Figure 12

72 332637L

Repair

Figure 13

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 .

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.

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

332637L 73

Repair

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.

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.

1. Place motor on unit. Thread motor cables into conduit as before. See

Electrical Schematics, page 159

.

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. 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.

74 332637L

1. See

Before Beginning Repair, page 63

.

Circuit Breakers

CB01

CB02

CB03

CB04

CB05

CB06

CB07

5 A

15 A

15 A

30 A

20 A

40 A

20 A

Power Supply, Fan, Coolant Pump

Boost Heat A

Boost Heat B

Hose Heat

Motor Control

Air Compressor/Open

Open

Repair

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: a. Refer to

Electrical Schematics, page 159

, and tables on next page.

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.

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.

P S 1

CB08 15 A Air Dryer/Open

332637L 75

Repair

Circuit Breakers Inside Cabinet

Figure 15

CB20 50 A Heated Hose

Circuit Breakers Inside Alternator Assembly

Figure 16

CB10 90 A 120/240V Alternator

76 332637L

Repair

1. Disconnect the negative lug from the negative post of the battery. See

Replace Battery, page 96 .

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 96 .

Load Center Relay and Fuse Identification

Figure 17

See

Electrical Schematics, page 159 .

Repair

Kit

24L958

24L959

K1

K2

K3

K4

F3 FAN-ATO -

30A

F4 PWR-ATO -

20A

Fuel Relay

Starter Relay

Glow Plug Relay

Fan Relay

Fuse for load center relay K4 and radiator fan.

Fuse for load center relays

K1, K2, K3 and their related components;

Engine Control

Module power; and coolant valve control.

332637L 77

Repair

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 96

3. Disconnect all connectors. See

Electrical Schematics, page 159

.

4. Remove four nuts (248), and load center

(240).

5. Install new load center (240) and reconnect all connectors. See

Electrical Schematics, page 159

.

6. Connect battery cable.

See

Replace Battery, page 96 .

1. Perform

Shutdown, page 60 .

2. Disconnect the negative lug from the negative post of the battery. See

Replace Battery, page 96 .

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

Electrical Schematics, page 159

.

Starter (top) and Glow Plug (bottom) Solenoid

Relays

Figure 18

78 332637L

Repair

5. Replace sensor (866).

1. Perform

Shutdown, page 60 .

2. Perform

Pressure Relief Procedure, page 59 .

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

Electrical Schematics, page 159

.

1. Perform

Shutdown, page 60 .

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

.

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 19 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 159 .

To prevent damage to cable, route and secure cable in wire bundle and wire ties as before.

332637L 79

Repair

Shutdown system to avoid electric shock. To avoid burns, do not perform maintenance on the fan until the system has reached ambient temperature.

1. Perform

Shutdown, page 60 .

2. Remove eight screws (75) and covers (74).

3. Remove four screws (294) and cover (293).

4. Refer to

Electrical Schematics, page 159 .

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.

1. Perform

Shutdown, page 60 .

2. Remove cabinet panel (70).

3. Refer to

Electrical Schematics, page 159 .

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.

4. Remove fan (212).

5. Install new fan (212) in reverser order of disassembly.

Figure 21

Figure 20

80 332637L

Repair

1. Perform

Shutdown, page 60 .

2. Remove four screws (605) and disconnect power cable (PC).

3. Install new fan (605) to radiator bracket

(601) with screws (605).

1. Perform

Shutdown, page 60 .

2. Open electrical enclosure door (502). Loosen four nuts (558) and remove fan (561).

3. Refer to

Electrical Schematics, page 159

.

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 22

Figure 23

332637L 81

Repair

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.

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.

12. Perform

Pressure Relief Procedure, page 59 .

13. Wait for heater to cool.

14. Remove heater shroud (266).

15. Disconnect heater element wires from heater wire connector. Test with ohmmeter.

Total

Wattage

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 83 .

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.

19. Install new heater element (357), holding mixer (359) so it does not block RTD port (P).

20. Reinstall RTD (360).

21. Reconnect heater element leadwires to heater wire connector.

22. Replace heater shroud (266).

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.

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.

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 159

.

82 332637L

Repair

5. Disconnect overtemperature switch (358) from cable (54). Test across quick connect terminals with an ohmmeter.

ohms, the overtemperature switch needs to be replaced. Go to step 6.

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.

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.

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 “HT- RTD-B

TCM" and “HT-RTD-B” connectors. See

Electrical Schematics, page 159 .

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.

c. Visually inspect “TCM-A HT-RTD-B” connection to TCM. Continue to next step to replace RTD (360).

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 “HT- RTD-A

TCM" and “HT-RTD-A” connectors. See

Electrical Schematics, page 159 .

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. Visually inspect “TCM-A HT-RTD-A” connection to TCM. Continue to next step to replace RTD (360).

332637L 83

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. Holding RTD (360) against heater element, tighten ferrule nut (N) 3/4 turn past finger-tight.

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.

Figure 24

84 332637L

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

Repair

3. For Series A only: Disconnect hose connector

(V) at Reactor.

1. Perform

Shutdown, page 60 .

2. Disconnect power harness (PM) from hose termination box terminal block (TB).

Figure 26

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.

Figure 25

332637L 85

Repair

1. Perform

Shutdown, page 60 .

2. Disconnect RTD cable (C) at Reactor.

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

probe.

3 to 1

3 to 4

1 to 4

2 to any

See

RTD Resistance vs. Temperature, page 87

.

See

RTD Resistance vs. Temperature, page 87

.

0.2 - 0.4 ohms 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.

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 28

Note

To assist in taking readings, order

RTD Test Kit 24N365. Kit includes two cables: one cable with a compatible female M8 connector and another cable with a male M8 connector. Both cables have stripped wire at the other end for easy test probe access.

3 to 1 / brown to blue

See

RTD Resistance vs. Temperature, page 87

.

3 to 4 / blue to black See

RTD Resistance vs. Temperature, page 87

.

0.2 - 0.4 ohms 1 to 4 / brown to black

2 to any / N/A infinity (open)

86

Heated Hose

Figure 27

332637L

332637L

843

882

922

961

1000

1039

1078

1117

1155

1194

1232

1271

1309

1347

1385

-40 (-40)

-30 (-22)

-20 (-4)

-10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

40 (104)

50 (122)

60 (140)

70 (158)

80 (176)

90 (194)

100 (212)

Repair

87

Repair

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

309572 for instructions.

Figure 29

1. Perform

Shutdown, page 60 .

2. Remove tape and protective covering from

FTS. Disconnect hose cable (F).

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

Check RTD Cables and FTS, page 86 .

4. If FTS fails, replace FTS.

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

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

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

d. Remove FTS probe (H) from component

A (ISO) side of hose.

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.

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.

88 332637L

3. Close the circuit breaker CB20 (906).

7. Press to turn on hose heat zone.

Repair

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 30

4. Confirm main power switch is off before starting generator.

5. Start the generator.

Press start button twice on the engine 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.

Thermal expansion can cause overpressurization, resulting in equipment rupture and serious injury, including fluid injection. Do not pressurize system when preheating hose.

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.

310 ft

210 ft

* For 240 Vac line voltage.

90 Vac*

62 Vac*

332637L 89

Repair

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.

1. Perform

Shutdown, page 60 .

2. Open Reactor cabinet.

3. Remove bolts holding transformer (226) to cabinet floor.

4. Disconnect the transformer wires. See

Electrical Schematics, page 159

.

5. Remove transformer (226) from cabinet.

6. Install new transformer (226) in reverse order.

226

90 332637L

Repair

1. If a wall is installed between the generator and the proportioner, remove the proportioner from the pallet. See

Remove Proportioner, page 101 .

2. Perform

Flushing, page 62 .

3. Perform

Shutdown, page 60 .

4. Perform

Drain Coolant, page 64

.

a. Remove fuel tank. See

Fuel Tank

.

b. Disconnect both RTD connectors (284).

See

Replace RTD, page 83 .

c. Disconnect A and B material lines from swivel fittings (297).

Proportioner Heat Exchangers

Figure 31 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.

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).

g. Disconnect two swivel fittings (805) and swivel fittings on heat exchanger outlet

(806) from the heat exchangers (802,

803).

Proportioner Heat Exchangers

Figure 32 h. Remove four nuts (810) and washers

(811) for replacing heat exchangers

(802) or (803).

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.

Engine Heat Exchanger

Figure 33

332637L 91

Repair

1. Perform

Shutdown, page 60 .

2. Remove Reactor cabinet cover.

3. Disconnect RTD from CAN cable.

4. Remove compression fitting (272) from the back of the heat exchanger with RTD (273) attached. The RTD probe cannot be removed from the compression nut.

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.

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).

Figure 34

92 332637L

Repair

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 .

2. Drain coolant from the proportioner coolant loop. See

Drain Coolant, page 64 .

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.

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.

1. Perform

Shutdown, page 60 .

2. Disconnect power supply (655) from circuit breaker CB01 and terminal blocks TB13 through TB15. See

Electrical Schematics, page 159

.

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. Install new power supply (655) in reverse order.

332637L 93

Figure 35

94

Repair

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 64

.

3. If a wall is installed and the circulation pump can not be accessed, remove the proportioner. See

Remove Proportioner, page 101 .

4. Disconnect pump fittings (234) from swivel fitting (275).

5. Remove pump cover (C).

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.

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

Electrical Schematics, page 159 .

11. Connect flange fittings (234) to swivel on the elbow flange fitting (234) and fitting (275).

332637L

1. Drain the proportioner coolant loop. See

Drain Coolant, page 64

.

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).

Repair

332637L 95

Repair

1. Perform

Shutdown, page 60 .

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.

See Technical Specifications, page 183

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.

4. Reconnect battery cables and cover battery terminals with plastic caps (PC). Ensure red cable is connected to the positive (+) battery post. Connect black cable to the negative

(-) battery post.

Figure 36

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.

96

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.

332637L

Repair

Follow this procedure to replace fuses inside the fusible link harness (90). See

Electrical Schematics, page 159 , for fusible link

harness connections and wire identification.

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.

4. Remove fusible link harness (90) from engine.

5. Carefully cut open heat shrink encasing the fuse holder along lines shown.

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.

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.

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.

Fuse (117) Wire

F8 C010 and C030

F9 C010 and C030

Engine starter positive power lug

Engine starter positive power lug

C020

C040

C050

12 V charge alternator

B+ terminal

Starter solenoid relay

(CR6)

Glow plug solenoid relay

(CR7)

332637L 97

Repair

9. Replace M5 nuts over fuse and ring terminals. Torque to 44 in-lb (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).

3. Remove screws (17) and back panel (8).

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.

12. Snap the cap insulator (111) over the red battery cable (47). Position the red cap insulator so that the stud is not exposed.

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.

Figure 37

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).

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.

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 64

.

2. Remove radiator air exhaust duct, if used.

Figure 38

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 67 .

98 332637L

Repair

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.

4. Update software by inserting an upgrade token into ADM (27) and cycling system power. Wait until the update is complete before removing the token and restarting the system.

Figure 40

Figure 39

1. Perform

Shutdown, page 60 .

2. Remove two top screws (17) and loosen the two side screws to lower the back panel (28).

3. Disconnect harness (M) and harness

(F) connectors from the back of the engine control module (428). See

Electrical Enclosure

4. Loosen engine control module mounting screws and remove the engine control module (428).

5. Install new engine control module (428) in air control panel. Secure clips in place and tighten mounting screws.

6. Connect all wire harnesses and close the back panel with two screws (17).

1. Perform

Shutdown, page 60 .

2. Disconnect connectors from MCM (504).

Disconnect two power cables. See

Electrical Schematics, page 159

.

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 159

.

332637L 99

Repair

Repair kit GCA modules are shipped pre-programmed. Upgrade token part number 17E206. If software version upgrade is necessary, follow the procedure in the manual provided.

6. Update software by inserting an upgrade token into ADM and cycling system power.

Wait until update is complete before removing the token and restarting the system.

1. Perform

Shutdown, page 60 .

2. Open electrical enclosure door (501).

3. Disconnect all connectors from the TCM

(503).

4. Remove four nuts (530) and TCM (503).

5. Install new TCM module (503). Reassemble parts in reverse order.

100 332637L

Repair

Only remove the proportioner from the pallet to repair the heat exchangers or coolant valves between the proportioner and generator.

4. Loosen the coolant clamps (37) and disconnect the proportioner coolant outlet and inlet coolant lines (36).

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 64

.

3. Place an empty pallet in front of the proportioner (23) and center the pallet cross beam with the proportioner.

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

Electrical Schematics, page 159 .

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).

9. Loosen the front two mounting screws (24) and remove the back two mounting screws

(24).

332637L

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.

101

Repair

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.

14. Secure the proportioner frame to the empty pallet you positioned on the floor with c-clamps.

Figure 41

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).

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.

Figure 42

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 (24). Torque to 40 ft-lb (54 N•m).

18. Route the engine wire harness E connectors

(49) through the back of the proportioner

(23) and connect wire harness connectors to J1 and J2 connectors on the load center (242). Reconnect engine coolant temperature cable (59).

19. Secure all harnesses to pallet and inside cabinet with cable ties.

102 332637L

Repair

Contact your nearest Perkins distributor for repair and maintenance.

1. Perform

Shutdown, page 60 .

2. Drain the engine coolant loop. See

Drain Coolant, page 64

.

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).

7. Refill the engine coolant loop. See

Refill Engine Coolant Loop, page 67

.

Figure 43

Figure 44

Contact your nearest Perkins distributor for repair and maintenance.

332637L 103

Repair

6. Install two motor brackets (736) with screws

(738) on top of frame (704).

For the steps below, see

Parts, page 112

to view callouts.

1. Install air compressor frame (704) and air dryer frames (705) on a pallet with screws

(723). Leave nuts and bolts loose.

NOTE: to gain access to the frame mounting screws.

2. Remove two existing nuts (719) from the system and secure frame (705) to the system with nuts (719). Torque to 40 ft-lb (54

N•m).

to gain alignment.

3. Connect air compressor frame (704) and air dryer frame (705) with strap (708).

4. Tighten all bolts and nuts.

5. Install end caps (726).

Use lifting device to prevent personal injury when lifting the compressor. Do not overlap lifting straps over tubing or other fragile components.

7. Lift air compressor on top of brackets (736) and secure to brackets with screws (737).

8. Install motor starter (712) to bracket (711) with screws (721) and nuts (718). Attach to air compressor frame (704) with screws

(738).

9. Install switch box enclosure (709) on air control panel with screws (720).

104 332637L

Repair

1. Turn off the 120/240 VAC alternator circuit breaker CB10 (572).

3. Connect the compressor over-temperature cable from the motor starter (712) to the compressor over-temperature switch in the enclosure (702d).

CABLE 16X011

TO MOTOR STARTER

AIR COMPRESSOR OVER TEMPERATURE BOX

CORD GRIP

260067

117625

AC-OT1

16X011

BLK

WHT

AC-OT2

2. Connect the compressor power cable from the motor starter (712) to the air compressor motor power junction box

(MJ). Remove the junction box cover from the air compressor motor. Insert wires in the cable end marked “AIR-CMP MTR-STR” from the starter box (712) through strain relief and connect with wire nuts (740). See

Electrical Schematics, page 159 . Reassemble

the cover.

MOTOR JUNCTION BOX

740

WIRE NUT

#6

WIRE NUT

#6

AC-W1

AC-W5

AC-W4-W8

AC-GND ti23259a

OVER

TEMPERATURE

SENSOR

16Y809

127581

4. Connect the motor starter cable to the start/stop switch enclosure (709).

CABLE 24U076

TO MOTOR STARTER AIR COMPRESSOR START STOP BOX

CORD GRIP

260067

117625

SS-1

STOP

SWITCH

SS-3

START

SWITCH

24U076

RED

WHT

BLK

SS-2

SS-4 ti23416a

5. Connect the motor starter cable to the air dryer connector. See

Electrical Schematics, page 159

.

6. Route power cables from the motor starter and air compressor towards the

Cable

Parts, page 112

.

GROUND

STUD

WIRE NUT

#6

CORD GRIP

16M862

CABLE 24U079

TO MOTOR STARTER ti31519a

332637L 105

Repair

7. Use a screwdriver to punch out two 3/4 in.

knockouts. Install cord grips (702g) at the bottom hole and (746) in the upper hole.

TI23260b

ELECTRICAL ENCLOSURE

14. Turn on the 120/240 VAC alternator circuit breaker CB10 (572).

PP

KK

JJ

8. Loosen the nut on the cord grips (702g,

746). Insert power cable (712h) through the lower cord grip (702g) and cable (712m) through the upper cord grip (746).

9. Connect the black and white wire from cable

(712h) CB06 and the green wire to the ground bus bar GB02 inside the electrical enclosure.

ti23263b

1. Apply thread sealant to threads of elbow fitting (715) and install in the air compressor outlet.

2. Connect tube (725) and fittings (715) to the air dryer inlet and air compressor outlet.

3. Connect hose (717) to the system air inlet fitting and fitting (744).

ELECTRICAL

ENCLOSURE

PP

CORD GRIP

121171

NEUTRAL

WHT

BLK

GRN

24U078

KK

PD-GND2

GND2

GROUND BAR

122313

PD-GND2

WHT

BLK

GRN

24U080

CABLE 24U078

TO MOTOR STARTER

CABLE 24U080

TO MOTOR STARTER

CORD GRIP

16M826

10. Connect cable (712m) black wire to CB08 and white wire to Neutral. Connect the green wire to the ground bus bar, GB02 inside the electrical enclosure.

11. Tighten the nut on the cord grips (702g,

746).

12. Route all cables along proper routes. See

Cable

Dryer

Routing Air Compressor and Air

Dryer section in

Parts, page 112 . Use wire

ties (742) to hold against frames.

13. Turn on CB06 and CB08.

For the steps below, see to view callouts.

1. Connect air dryer outlet fittings and dump valve (716, 730, 732–735, 744) and install onto the dryer as shown.

2. Lift air dryer onto frame (705) and align with the fan facing the engine. Install a nut

(719) on the bottom of each threaded rod to the end of the thread. Thread rods (707) through the nuts in bracket (705) and secure with the nuts pre-installed on the rod.

3. Connect clamp bracket (706) to rods (707) with nuts (719).

4. Connect elbow fitting (713), barbed fitting

(714) and rubber hose (731) to the fitting.

Secure hose (731) with clamp (739) and route the hose to the drain pail.

106 332637L

Repair

5. Remove the wire schematic label from the inside of the compressor motor starter box cover. Replace it with the label (16X422) provided in the kit.

The following procedure must be carried out by properly trained service personnel. Due to stored energy in the motor capacitors (702m,

702n), this procedure exposes the service personnel to potential shock, arcing, or flying metal debris from arcing. Proper personal protection equipment is required, including, but not limited to, eye protection, face shield, and hand protection.

For installation of Compressor Motor Wiring

Upgrade Kit (25M556) used for updating wiring to the compressor motor.

series A through series C (marked on system serial number label). Systems of series D and following already contain the wiring update described in this section.

1. See

Before Beginning Repair, page 63

.

2. Perform

Shutdown, page 60 .

3. Complete steps 1 - 8 from

Replace

Compressor Motor Capacitors, page 109

to properly discharge the motor capacitors

(702m, 702n).

Voltage may be present on both the compressor motor’s capacitors (702m,

702n) and its wiring. To prevent electric shock or arcing, complete the steps described below to properly discharge the motor capacitors before proceeding with repair. .

4. Open the compressor motor starter box

(712). With a DC voltmeter, measure the voltage between T1–T2, T1–T3, and T2–T3 on the overload relay (MR) to verify that the motor capacitor (702m, 702n) voltage has discharged to less than 5 VDC. If it has not, repeat step 3.

6. Remove and discard the black jumper wire labeled “16X009” from the compressor starter box. Refer to the Motor Starter diagram in

Electrical Schematics, page 159

to identify the location of wiring and harnesses.

7. Open the compressor motor junction box

(MJ). Remove and discard the old harness labeled “24U079”, connected between the compressor starter box (712) and the motor junction box (MJ).

8. Install the jumper wire: a. Insert the end labeled “MS-L3” into L3 terminal of motor starter (MS) and torque to 38–42 in-lb.

b. Loosen adjacent terminal L2 of motor starter (MS). Insert both jumper wire ends labeled “MS-L2” along with existing wire labeled “MS-L2” that is part of harness

24U080 into terminal L2 of motor starter

(MS) and torque to 38–42 in-lb.

9. Install updated harness 24U079 (containing red wire) into compressor motor starter box

(712) through the strain relief. Reference

Compressor

Electrical Schematics, page 159

) to match labeled wires to correct terminals.

a. Insert and tighten the green wire labeled

“MS-GND” into ground bus bar (723).

Torque to 28–32 in-lb.

b. Insert and tighten black, white, and red wires into associated terminals of the overload relay (MR). Torque to 38–42 in-lb.

c. Tighten strain relief.

332637L 107

Repair

10. Install the opposite end of updated harness 24U079 into the motor junction box through the strain relief. Refer to Compressor Motor Junction box in

Electrical Schematics, page 159

to match labeled wires to the correct terminals.

a. Connect the green wire labeled “AC-GND” to the ground stud in the motor junction box (MJ).

b. Use the provided wire nuts to join the following:

• White wire labeled “AC-W1” with the blue motor wire labeled “1”.

• Black wire labeled “AC-W4–W8” with both the yellow motor wire labeled “4” and the red motor wire labeled “8”.

• Red wire labeled “AC-W5” with the black motor wire labeled “5”.

c. Tug on wires in wire nuts to confirm they are secure. Wrap tightly with electrical tape.

d. Tighten the strain relief.

11. Reinstall the compressor motor junction box cover and the compressor motor starter box cover.

12. Secure the harnesses with provided cable ties. Cables should not touch the engine or

Parts, page 112

) for routing details.

13. Ensure no wires are loose.

14. Turn on main circuit breaker CB10 (572) located on engine (2).

15. Reconnect red battery cable (47) to positive terminal of engine battery.

Verification: compressor. Run for 20 minutes at full load (130–140 psi). Check current on the black wire harness 24U079 (see

Electrical Schematics, page 159

). Current measured should be less than 23.3 A.

Nominal current is approximately 19–21 A.

108 332637L

Repair

5. Wait a minimum of five hours after completing the Shutdown procedure for motor capacitors (702m, 703n) to partially self-discharge.

6. Remove six bolts (MB) that secure the cover on the motor capacitor housing (CH).

The following procedure must be carried out by properly trained service personnel. Due to stored energy in the motor capacitors, this procedure exposes the service personnel to potential shock, arcing, or flying metal debris from arcing. Proper personal protection equipment is required, including, but not limited to, eye protection, face shield, and hand protection.

For installation of Capacitor Repair Kit (25M541) used for replacing start and run capacitors in the compressor motor.

be used to repair motors with serial number

“F170818XXXX” or later. For repair of motors with serial number “F170817XXXX” or earlier, order motor replacement kit 25M727.

1. See

Before Beginning Repair, page 63

.

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.

2. Perform

Shutdown, page 60 .

3. Disconnect black battery cable (48) from negative terminal of the engine battery to prevent starting of engine (2).

4. Turn off main circuit breaker CB10 (572) located on engine (2).

7. With a DC voltmeter, measure the voltage across the terminals of each capacitor

(702m, 702n) to verify that the voltage has discharged to below 50 VDC (refer to section in

Electrical Schematics, page 159 ).

If it has not, wait until the measured voltage is below 50 VDC before proceeding with repair.

8. After all capacitor voltages measure below

50 VDC and while wearing proper personal protection equipment, use an insulated handle screwdriver to short across the two contacts on the end of each capacitor (702m,

702n) to complete discharging. Hold for 10 seconds on each set of contacts.

9. Remove bolt and capacitor retaining bracket from inside motor capacitor housing (CH).

Voltage may be present on both the compressor motor’s capacitors (702m,

702n) and its wiring. To prevent electric shock or arcing, wait long enough for the voltage on the motor capacitors to self-discharge to below 50 Vdc before proceeding with repair.

332637L 109

Repair

10. Replace capacitors (702m, 702n): a. Disconnect wires and remove old capacitors (702m, 702n).

b. Connect new capacitors (702m,

702n). Refer to Compressor

Diagram

Motor

Electrical Schematics, page 159 , for

proper wiring configuration. Refer to

Capacitor Identification wiring is configured correctly.

polarized; wiring may be connected to either terminal as long as the final wiring configuring matches the wiring diagrams.

11. Arrange capacitor (702m, 702n) into motor capacitor housing (CH) and secure them in place using retaining bracket and bolt.

12. Use six bolts (MB) to secure cover on motor capacitor housing (CH).

13. Turn on main circuit breaker CB10 (572) located on engine (2).

14. Reconnect black battery cable (48) to negative terminal of engine battery.

702n

702m

Description Rating

Start

Capacitor

Run

Capacitor

216–25

9 µF

60 µF

Qty.

Notes

2

1

Smaller diameter

Larger diameter

110 332637L

Notes

332637L 111

Parts

272079, EE -

272080. EE -

272081, EE -XP2i

For systems with an air compressor, see 272089, 272090, and 272091 .

112 332637L

Parts

332637L 113

Parts

114 332637L

Parts

4

5

2

3

6

Apply anaerobic sealant to all non-swiveling pipe threads.

Apply lubrication to all push—on hoses prior to assembly.

Torque to 25 ft-lb (33.8 N●m).

Torque to 40 ft-lb (54 N●m).

Torque to 15–20 in-lb (1.7–2 N●m).

7

9

10

11

Torque to 25 in-lb (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.

Included with generator (2).

332637L 115

Parts

31

32

33

34

24

25

26

27

29

30

7

8

5

6

3

4

Ref Part

1

2

24J658 BASE, pallet

- - GENERATOR, diesel, 22kw; see

22kW Diesel Generator

16H732 SUPPORT, generator

24L953 KIT, isolator (4 pack)

111192

105324

SCREW, cap flange hd; 0.875 in. (22 mm), 3/8–16

SCREW, cap, hex hd; 1.2 in (30 mm), M12 x 1.75

16U131 GROMMET, tube

16H898 GUARD, engine, right

272079 272080 272081

1

1

1

1

1

1

1

1

1

1

20

4

1

1

20

4

1

20

4

1

1

1

1

1

1

1

1

1

1

1

1 9

10

11

12

16H894 GUARD, engine, left

125677 ROD, connecting, on/off

16X025 DOOR, electrical enclosure

16K893 HANDLE, selector, on/off

14l 123656 CABLE, 5pin, male/female (matrix)

16 115942 NUT, hex, flange head; 1/4–20

17 113161 SCREW, flanged, hex hd; 0.5 in. (13 mm), 1/4–20

18l 16W131 CABLE, m12 5p, fem - male, 3.0m

19l 24T051 CABLE, m8 4p (f) to m12 8p (m); 3.0 m

20l 24T198 HARNESS, ac, power, reactor cart

21 125625 TIE, cable, fir tree

22l 24T241 CABLE, power, 24v, integ reactor

23 - - PROPORTIONER, E–30i, (230v, 1ph), see

Proportioners

- - -

PROPORTIONER, E–30i, (4.0kw, 230v, 1ph), see

Proportioners

1

1

4

18

2

1

1

5

1

1

1

1

4

18

2

1

1

5

1

1

1

1

4

18

2

1

1

5

1

- - -

PROPORTIONER, E-xp2i, (4.0kw, 230v, 1ph), see

Proportioners

125626 SCREW, hex hd, flanged; 3 in. (76 mm), 3/8–16

16V420 BRACKET, mounting

- - ENCLOSURE, electrical, see

Electrical Enclosure

24U854 MODULE, GCA, ADM

24K390 TANK, fuel, see

Fuel Tank

16J889 BRACKET, support, fuel tank

24J690 SUPPORT, battery

125166 TRAY, battery

107251 SCREW, pan hd; 1 in. (25.4 mm), #10–24

24M174 STICKS, level, A and B side, 55 gal. (208 l)

6

1

1

1

1

2

1

1

4

1

6

1

1

1

1

2

1

1

4

1

1

1

1

1

2

4

1

1

1

6

1

116 332637L

Parts

Ref Part

35

36aQ

36bQ

16K214 HOLDER, cable, tie

– – –

HOSE, coolant, 1 in. ID; 2.66 ft (0.81 m)

– – –

HOSE, coolant, 1 in. ID; 2.92 ft (0.89 m)

37Q 125370 CLAMP, hose, dia. 11/16-1-1/2 in.

38 – – – HOSE, fuel, 5/16 in.; 3.33 long

39 – – –

HOSE, fuel, 3/16 in.

40Q 125163 CLAMP, hose, 7/32-5/8 in.

43 206995 FLUID, TSL ™ , 1 qt.

44

45

106569 TAPE, electrical

100639 WASHER, lock

46l 127286 CABLE, cordset, reverse key, .5m

47lv 16K232 CABLE, battery, 30 in. (762 mm), red

48lv 16K233 CABLE, battery, 30 in. (762 mm), black

49l 16K301 HARNESS, dc, diesel, engine

50 125751 CABLE, grounding, braided, engine

51l† 17L263 HARNESS, AC, sense, genset control

52l 125753 CABLE, AC, power, 240v alternator

53l 16K299 HARNESS, dc, disconnect check

54l 24T242 CABLE, over-temp, single reactor

24U109 CABLE, over-temp, switch short

55▲ 16K939 LABEL, safety, system, multi

56 16X154 LABEL, Graco InSite

57l 121002 CABLE, can, female / female 1.5m

58l 125358 CABLE, m8, 4-pin, mf, .5meter, mold

59l 122837 CABLE, m8, 4-pin, mf, 3m, molded

60l 123652 CABLE, can, male / female 3.5m

61 16W596 LATCH, door

62l 24T199 CABLE, control module, heater

65 16K362 FOAM, support block

66

67

69

16K363 SPACER, fuel tank

16H910 GASKET, radiator isolation

16W245 DOOR, cabinet

70 24K207 KIT, FTS, RTD, single hose; see heated hose manual

71l 125357 CABLE, m8, 4-pin, mf, 1meter, molded

1

1

2

2

1

3

1

1

1

1

1

1

1

3

2

272079 272080 272081

4

1

4

1

4

1

1

4

1

4

6

2

1

1

4

1

4

6

2

1

1

4

1

4

6

2

1

3

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3

2

1

1

1

1

2

1

4 4

2

2

1

1

1

1

1

4

2

2

1

1

1

1

1

1

1

2

2

1

4

1

1

2

2

1

4

332637L 117

Parts

Ref Part

72

73

108290 SCREW, mach, binding hd; 1/4 in., #8–32

16W216 LABEL, E-30i, elite

16W217 LABEL, E–XP2i, elite

79

80

81

74u 287292 COVER, drive, plastic

75u 118444 SCREW, mach, slot hex wash hd; 1/2 in. x #10–24

76

77

190774

125871

BLANK, label, kit

TIE, cable, 7.50 in.

16M317 GUARD, engine, top

16M319 GUARD, alternator, mount

16M321 GUARD, alternator, plate

82

83

333093

333094

QUICK GUIDE, startup

QUICK GUIDE, shutdown

84▲ 15G280 LABEL, safety, warning, multiple

85l 16K172 HARNESS, dc, link, fusible

86l 125754 CABLE, AC, alternator breaker, blk

87l 125755 CABLE, AC, alternator breaker, red

88l 125822 CABLE, AC, alternator, n to gnd, wh

89‡ 17L264 HARNESS, DC, genset controller

90

91

- - LABEL, cable, self-lam, top level

- - KIT, label

93l 120448 SUPPRESSOR, box snap, ferrite

94l 125835 CLIP, ferrite bead

95l 125839 CLIP, ferrite bead

97 109124 HOSE, coupled, 48 in

98

99

169970 FITTING, airline; 1/4–18 NPT (m)

15V551 SHIELD, membrane, ADM (10 pack)

101 105329 NUT, hex; M8 x 1.25

102 114816 NUT, hex; M6 x 1

103 100186 WASHER, lock, internal tooth

104 15V909 SCREW, 1/2 in. (12 mm), M8 x 1.25

105+ 110911 NUT, hex; M5 x 0.8

106 126054 INSULATOR, cap

109 186494 CLIP, spring

113 169967 FITTING, line air; 1/4–18 NPT (f)

3

1

2

1

1

3

1

2

1

1

1

3

1

1

1

2

1

1

1

1

1

1

1

1

272079 272080 272081

4

1

4

1

4

2 2

1

2

1

1

1

8

2

40

8

2

40

1

1

1

1

1

1

8

2

40

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3

1

2

1

1

3

1

2

1

1

1

3

1

1

1

2

1

3

1

2

1

1

3

1

2

1

1

1

3

1

1

1

2

1

118 332637L

Parts

Ref Part

114 16P405 FUSE, bolt-down, 60A

115 16P406 HOLDER, fuse, bolt-down

116 16W213 LABEL, Reactor

117 16D576 LABEL, made in USA

118 113505 NUT, keps, hex hd

119 16X121 GASKET, door

120 16X122 GASKET, door

121 16X123 GASKET, door

122 16X124 GASKET, door

123 117777 HOLDER, vinyl shop ticket

124 16Y509 CORE, ferrite, snap-on; 0.76 ID

125 16Y516 CORE, ferrite, snap-on; 0.394 ID u

+ l v

Q

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

See

Electrical Schematics, page 159 .

Included in Battery Cable Kit 24L962.

Included in Complete Coolant Hose Kit

24L939. See

Proportioners

.

Not shown.

Cover Repair Kit includes four screws.

Nut only used on 3–post alternator style.

Not used on connector-style alternator.

2

1

2

2

1

272079 272080 272081

1

1

1

1

1

1

2

1

2

2

2

2

1

2

2

2

2

1

2

2

2

2

2

1

2

1

2

1

2

2

1

† 17L263 for system series “C” and following.

For reference, harness 16Y518 was for system series “A” and “B” only. For replacement of 16Y518, purchase kit

24M665.

‡ 17L264 for system series “C” and following.

For reference, harness 16K297 was for system series “A” and “B” only. For replacement of 16K297, purchase kit

24M665.

332637L 119

Parts

120 332637L

Parts

332637L 121

Parts

122 332637L

Parts

332637L 123

Parts

124 332637L

Parts

1

2

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

Apply grease to tube fitting threads. Torque to 43 ft-lb (58 N•m).

3

4

Safety and warning labels are from label sheet (283).

Fan air flow towards motor.

332637L 125

Parts

216

217

218

219

220

221

222

223

224

225

226

227

228

229

230○

208

209

210

211

212

213

214

215

201

202

203

204

205

206

207

- - FRAME

16W233 BRACKET, tube guard

24T870 MANIFOLD, fluid

16W235 BRACKET, tube mount

16W608 FITTING, elbow 8jic swivel x 8jicm

24V143 KIT, assembly, pair, inlet

16W611 FITTING, bulk hd 1/2 nptm x 8 jicm

15H189 BOOT, wire feed through

15G816 COVER, plate, wire way

15B456 GASKET, manifold

16W609 FITTING, elbow 1/2 nptf x 8 jicm

24R756 FAN, cooling, 120 mm, 24 vdc

16W610 FITTING, elbow 1/2 nptf x 10 jicm

16J758 COVER, heat exchanger

16W648 GROMMET, rubber, 1.0 ID x 1.5

OD

103181 WASHER, lock ext

112125 PLUG, tube

116746 FITTING, barbed, plated; 1/8–27 npt x 1/4 in. I.D. hose

191892 FITTING, elbow, street, 90°; 1/8 npt

117502 FITTING, reducer #5 x #8 (JIC)

117677 FITTING, reducer #6 x #10 (JIC)

16X531 BRACKET, reservoir, lube

246995 RESERVOIR, bottle, assembly

16W183 BRACKET, load center

16W043 TUBE, pressure relief

15K742 TRANSFORMER, 4090 va, 230/90

16H761 BRACKET, mounting, pump

186494 CLIP, spring

255716 KIT, heater wire connector

261821 CONNECTOR, wire, 6 AWG

2

1

1

1

2

2

2

1

1

1

1

1

2

1

1

4

2

2

2

2

3

2

1

1

1

1

1

1

2

E–30i

Booster

1

1

2

1

1

1

2

1

1

1

2

2

2

1

1

4

2

2

2

2

3

2

1

1

2

1

1

1

1

1

EE XP2i

Booster with

Booster Heat

1

1

2

1

1

1

2

1

1

1

2

2

2

1

1

4

2

2

2

2

3

2

1

1

2

1

1

1

1

1

126 332637L

Parts

239

240◊

241

242Q

243l

244

245

246

231

232

233

234

235

236

237Q

238

247

248

249

250

251

252

253

254

255

256

257

258-1v

258-2v

259-3v

259-4v

260

261

24L915 PUMP, centrifugal, circulation

24J699 KIT, fitting, pump

24K286 KIT, fitting, drain

16W191 BRACKET, strainer, left

16W193 BRACKET, strainer, right

125170 HOSE, formed, 1 in. ID, lower

125371 CLAMP, hose, dia. 3/4-1-3/4 in.

24K385 PANEL, air control

24K381 EXCHANGER, heat, assembly

24L957 BOARD, load center

16H880 COVER, air panel

- - HOSE, rubber, 5/16 in.

– – –

INDICATOR, flow, sight

16W184 COVER, fan

16X118 MODULE, cellular, GPS

125477 FITTING, 1 in. beaded barb x 3/4 nptm

112958 NUT, hex, flanged

113505 NUT, keps, hex hd

117683 SCREW, mach, phil pan hd; 1.5 in.

x #6–32

126033 TRIM, edge; 0.33 ft (0.1 m)

111800 SCREW, cap, hex hd; 0.625 in. x

5/16–18

125943 NUT, serrated flange; 7/16–14

125944 SCREW, serrated flange; 2.25 in.

x 7/16–14

114269 GROMMET, rubber

126043 PLUG, cap, 1.25 diameter hole

126044 PLUG, cap, .75 diameter hole

24V152 PROPORTIONER, module,

E-30i, no heat; see

Dual Zone 4.0 Kw Fluid Heater

24V153 PROPORTIONER, module, E–XP2i; see

Dual Zone 4.0 Kw Fluid Heater

– – –

FITTING, A side, inlet, E-30

– – –

FITTING, A side, inlet, E-XP2

– – –

FITTING, B side, inlet, E-30

– – – FITTING, B side, inlet, E-XP2

16W206 TUBE, A-side, hose outlet

16W207 TUBE, B-side, hose outlet

332637L

1

1

1

1

12

13

8

1

4

1

1

1

2

1

1

1

4

1

1

1

1

1

1

1

1

8

4

1

2

2

1

EE XP2i

Booster with

1

1

1

1

1

2

1

1

4

1

1

1

1

1

1

1

12

13

8

1

4

8

4

3

E–30i

Booster

1

1

1

1

1

2

1

1

4

1

1

1

1

1

1

1

1

4

12

13

8

8

4

3

1

1

1

1

1

1

1

1

1

1

127

Parts

262

263

264

265

266

267

268

269■

270l

271

272u

273u

274

275*

276

277

278

279

280Q

281

282

283▲

284

2876

2886

289

290

291

292

293

16W199 TUBE, A-side, inlet

16W202 TUBE, B-side, inlet

24V145 HEATER, assy, 4.0kw, hybrid, 2 zone; see

Dual Zone 4.0 Kw Fluid Heater

104765 PLUG, pipe, headless

16K361 COVER, horizontal heater

121311 FITTING, connector, 3/8–18 npt x

1/2 jic

125643 FITTING, elbow, 3/8 npt x #8 jic

113796 SCREW, flanged, hex hd; 3/4 in. x

1/4–20

17H073 MODULE, breaker, hose, int reactor

157785 FITTING, swivel; 3/-14 nps x

3/4–14 npt

16K646 HARNESS, dc, valve, coolant

– – – FITTING, compression, 1/8 npt, ss

– – –

SENSOR, RTD, 1 kohm, 4 pin, 4.25

in.

125625 TIE, cable, fir tree

24L916 VALVE, solenoid, 3/4 npt, 12 VDC

16K312 HOSE, coupled, 26 in. (660 mm)

16K311 HOSE, coupled, 18 in. (457 mm)

156589 FITTING, union, adapter, 90°; 3/4 nptf x 3/4 npsm, 1.25 in.

125535 FITTING, #12 jic swivel x 3/4 npt(m)

– – –

HOSE, coolant, 1 in. ID, bulk; 0.33

ft. (0.1 m)

115836 GUARD, finger

125857 SCREW, serrated flange, hex hd;

.625 in. #10-24

16W612 LABEL, safety

198586 CONDUIT, corrugated

261843 FLUID, oxide inhibitor

125871 TIE, cable, 7.50 in.

295847 FITTING, elbow, 90°, 3/4 npt

260067 FITTING, strain relief, 1/2 npt

151395 WASHER, flat

127278 NUT, keps, hex; #6–32

16W765 COVER, motor

2

2

24

1

2

2

9

1

4

1

1

2

2

2

2

4

4

2

1

1

1

8

1

1

1

1

EE XP2i

Booster with

1

1

1

2

1

2

32

1

2

2

9

1

4

1

1

2

2

2

2

4

4

2

1

1

1

8

1

1

1

1

E–30i

Booster

1

1

1

2

1

2

32

1

2

2

9

1

4

1

1

2

2

2

2

4

4

2

1

1

1

8

1

1

1

1

128 332637L

Parts

294

295

296

297

298

299

300

921

922

923

924▲

925

118444 SCREW, mach, slot hex wash hd;

1/2 in. x #10–24

194337 WIRE, grounding, door

16X129 SCREW, mach, phillips, tooth washer, .375 in. x #8–32

16W201 TUBE, A-side, outlet

16W204 TUBE, A-side, outlet

16W203 TUBE, B-side, outlet

16W205 TUBE, B-side, outlet

17A064 GUARD, heater, A-side

17A066 GUARD, heater, B-side

113161 SCREW, flanged, hex hd; 1/2 in x

1/4–20

24W204 ENCLOSURE, terminal block

25A234 ENCLOSURE, cover

189930 LABEL, caution

17G461 BRACKET, termination box l u

*

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.

4

1

11

1

1

8

1

1

1

1

E–30i

Booster

4

1

11

1

1

8

1

1

1

1

1

1

EE XP2i

Booster with

4

1

11

1

1

8

1

1

1

1

1

1

+

6

Q v

Included in Complete Coolant Hose Kit

24L939. See

Proportioners

Included in Pump Inlet Assembly Kit. See

Proportioners

.

See

Electrical Schematics, page 159 .

Not shown.

Series A only.

For series A only order Kit No. 24T059.

332637L 129

Parts

E-30i A Side

E-30i B Side

E-XP2i A Side

E-XP2i B Side

24L926

24L927

24L928

24L929

Ref Description

36a HOSE, coolant, 1 in. ID, 2.66 ft (0.81 m)

36b HOSE, coolant, 1 in. ID, 2.92 ft (0.89 m)

37 CLAMP, hose, dia. 11/16-1-1/2 in.

40 CLAMP, hose, 7/32-5/8 in.

237 CLAMP, hose, dia. 3/4-1-3/4 in.

242 HOSE, rubber, 5/16 in., 1 ft (0.3 m)

280 HOSE, coolant, 1 in. ID, 0.33 ft (0.1 m)

562 CLAMP, hose, dia. 3/4–1–3/4 in.

620 HOSE, formed, 1–1/4 upper radiator

621 HOSE, coolant, 1 in. ID; 6 in. (152.4 mm)

622 CLAMP, hose, dia. 3/4–1–3/4 in.

623 CLAMP, hose, dia. 11/16–1–1/2 in.

627 HOSE, formed, 1–1/4 lower radiator

628 HOSE, 1 in. ID; 0.271 ft (0.08 m)

629 HOSE, 5/16 in. ID; 1.5 ft (0.5 m)

640 HOSE, formed, 1–1/4 upper engine

641 CLAMP, hose 7/32 in. - 5/8 in.

642 HOSE, formed, 1–1/4 lower engine

258–1

259–3

258–2

259–4

1

277

277

277

277

1

279

279

279

279

1

1

2

1

1

1

1

4

4

1

1

1

4

2

1

1

1

2

6

130 332637L

for EE -30i

Parts

1

2

3

6

7

4

5

Torque to 190–210 in-lb (21–24 N•m).

Lubricate threads with ISO oil or grease. Assemble pump cylinders flush to one full thread under-flush of housing surface.

Apply grease to all gear teeth proportionally, motor pinion and drive housing.

Torque to 20–30 ft-lb (27–40.6 N•m).

Crankshaft must be in line with crankshaft at other end of motor.

Torque to 70–80 ft-lb (95–108 N•m).

Flat side faces up.

332637L 131

Parts

316

318+

320

321

322

325

326▲

306◊

307u

308u

310l

311

312+

313

314

24U051

17W869

245927

257355

287290

241279

245971

245972

114699

114672

183169

183210

15C753

114666

106115

246831

246832

193394

193031

116192

116618

24T878

127301

187437

192840 l

301

302+

303

304u

305l

315◊

◊ u

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

See Pump Repair manual 309577 for repair kits.

MOTOR, brushless, double ended, 2 hp

KIT, repair, drive housing

HOUSING, bearing

HOUSING, bearing

KIT, repair, gear

KIT, rod, connecting

PUMP, displacement, B

PUMP, displacement, A

WASHER, thrust; copper colored

WASHER, thrust; steel colored

SPRING, retaining

PIN, str, hdls

SCREW, mach, hex wash hd

SCREW, cap, socket head

WASHER, lock (hi-collar)

PUMP, displacement, A

PUMP, displacement, A

NUT, retaining

NUT, retaining

WASHER, thrust

MAGNET

SWITCH, reed, m8 4-pin

SCREW, hxhd, thd cut, 4-40 x .375

LABEL, torque

LABEL, warning

2

2

1

2

2

1

4

2

2

1

2

24V152 24V153

1

2

1

2

2

2

2 2

1

2

2

10

8

8

2

4

2

2

10

8

8

1

1

2

2

2

1

2

2

2

1

+

Drive Housing Repair Kit includes housing

(1), screws (5), and washer (1) to replace one end. See

Repair and Spare Parts

Reference, page 178

.

Spring (310) included in 241279

Connecting Rod Kit.

Gear Repair Kit includes washers (307) and

(308).

132 332637L

Parts

3

4

1

2

5

6

Torque to 120 ft-lb (163 N•m).

Torque to 23 ft-lb (31 N•m).

Apply thermal paste.

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

Apply lithium grease lubricant to o-rings before assembling in block (1).

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-lb. (21.6 N•m).

332637L 133

Parts

351

352

353

354

355

356

357

358

359

360*

*

15M878 BLOCK, horizontal

15H302 REDUCER, #14 SAE x

1/2–14 NPT(f)

121319 ADAPTER, 1/2–14

NPT x #8 JIC

15H304 PLUG, 9/16 SAE

15H306 ADAPTER, 9/16–18 x 1/8–27 NPT(f)

120336 O-RING, packing

17A092 HEATER, immersion,

(2000W, 230V)

15B137 SWITCH, over temperature

15B135

- - -

MIXER, immersion heater

SENSOR, RTD, 1 kohm, 90°, 4 pin, tip

1

2

2

Included in 24L973 Heater RTD Repair

Kit.

1

4

2

2

4

2

1

361

362

366

368

369

370*

371

372

124131 SCREW, machined, pan hd, 0.375 in.

(9.5 mm), #6–32

15M177 INSULATOR, foam, heater, horizontal

158683 ELBOW, 90°, 1/2–14

NPT x 1/2–14 NPT

124132 O-RING, fluoroelastomer

15H305 PLUG, hollow hex

1-3/16 SAE

- - COMPRESSION, 1/8

NPT, SST

125644 BRANCH TEE, 1/2

NPT

248187 KIT, rupture disc assembly

2

2

2

2

4

2

1

2

134 332637L

Parts

1

2

3

Apply pipe sealant to all non-swiveling pipe threads.

Apply anaerobic thread sealant to threads.

Torque to 25 +/- 2 ft-lb (34 N●m)

4

5

Torque to 10 +/- 2 ft-lb (14 N●m)

See parts illustration for air flow direction.

332637L 135

Parts

401

402

403

404

405

406

407

408

409

410

411

412

413

415

H

16H452 BRACKET, air control

277853 BRACKET, mounting, booth control

117026 SCREW, SHCS, 0.5

in. (12 mm), M5 x

0.8

113331 VALVE, ball, vented,

1/2 in.

190451 UNION, adapter,

1/2 NPT x 1/2

NPSM

158491 NIPPLE, 1/2–14 NPT

155470 SWIVEL, union, 90°,

1/2–14 NPSM x

1/2–14 NPT

16H482 MANIFOLD, 1/2

NPT x 1/4 NPT

113796 SCREW, flanged, hex hd, 0.75 in.

(19 mm), 1/4–20

122161 FITTING, air, 1/4

NPT x 3/8 OD

124287 FITTING, adapter,

1/2 npt(m) x #8

JIC(m), ms

115841 FITTING, elbow,

1/4 NPT(f) x 3/8

OD

15T498 FITTING, 90°, swivel, 5/32 OD x 1/8 NPT(f)

116257 GAUGE, pressure,

0–160 psi (0–1 MPa,

0–11 bar)

Included in Tubing Repair Kit 24M650.

1

1

2

1

1

1

1

1

4

7

3

6

3

3

416

417

418

419

420

421

422

429

432

423

H

424

H

426

427

428

116513 REGULATOR, air

116514 NUT, regulator, plastic

104641 BULKHEAD, 1 in.

(25.4 mm), 3/4–20 x 1/4–18 NPT

156971 NIPPLE, short,

1/4–18 NPT

125539 UNION, Y, 3/8 OD tubing

114558 COUPLER, line, air,

1/4–18 NPT

16H531 FITTING, flow control, 1/4–18

NPT

- - -

- - -

TUBE, nylon, round, black

HOSE, nylon,

250 psi; see identification table

16K325 LABEL, instructions

16K326 LABEL, instructions

25A854 MODULE, engine controller (system series “C” and following)

24M665 MODULE, engine controller (system series “A” and “B” only)

125625 TIE, cable, fir tree

16K940 LABEL

1

2

1

4

1

4

1

3

3

4

1

9

1

1

1

136 332637L

Length

(mm)

424–1 11 (279.4)

424–2 13.5 (342.9)

424–3 16.5 (419.1)

424–4 16 (406.4)

424–5 16.5 (419.1)

424–6 15 (381)

424–7 6.5 (165.1)

424–8 5.5 (139.7)

423 4 (101.6)

Fluid

24T870

1

1

1

1

1

3

1

1

1

Parts

1

2

3

Torque to 355–395 in-lb (40–44.6 N●m)

Apply sealant (113500) to threads.

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

4

5

**

Apply PTFE tape and thread sealant to gauge threads.

Apply grease on valve.

Apply PTFE tape or thread sealant to tapered threads.

332637L 137

Parts

451

452 †*+

452a

452b

453

454

455

456 †*

457 †+

458 †*+

461

462

255228

247824

158674

247779

102814

162453

15M669

247788

247789

112309

124287

121312

MANIFOLD, fluid

KIT, valve, cartridge, drain

O-RING, BUNA-N

SEAL, seat, valve

GAUGE, press, fluid

FITTING, 1/4 NPSM

X 1/4 NPT

SENSOR, pressure, fluid outlet

HANDLE, red

HANDLE, blue

NUT, hex, jam

FITTING, adapter,

7/8, 1/2–1/4 nptm x #8 JIC

ELBOW, male, 3/4

SAE x 1/2 JIC

1

1

2

2

1

2

2

1

1

2

463

464

100840

111457

ELBOW, street,

1/4–18 npt x

1/4–18 npt

O-RING, PTFE

1

2

465

466 †*+

189285 LABEL, hot surface

150829 SPRING, compression

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

1

2

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.

1

138 332637L

Parts

332637L 139

Parts

501

502

503

504

505

506

507

508

509

510

511

512

513

514

515

516

- - -

24T061

24U855

26D472

24T060

24R757

24R754

123143

122313

117666

121612

121603

126881

126891

120858

120859

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

See

Electrical Enclosure .

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

518

519

520

521

522

523

524

526

527

528

529

530

531

532

517 127253

127254

24T174

24R735

121000

125859

194337

16W456

109466

127278

151395

117683

115942

103473

113505

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

1

1

1

1

2

1

1

1

2

4

4

4

8

8

7

140 332637L

Parts

3

4

1

2

Torque to 26 ft-lb (35.25 N●m)

Torque to 15 ft-lb (20 N●m)

Torque to 100 ft-lb (135.6 N●m)

Torque to 40 ft-lb (54 N●m). Parts included with engine.

5

6

7

Apply sealant (blue) to threads.

Torque to 15–20 in.-lb (1.7–2 N●m)

Apply lubrication to engine end of hose prior to assembly.

332637L 141

Parts

551

552

556

557

558

559

560

562

Q

563

564

565

568

569

570

- - -

24R079

ENGINE, diesel,

Perkins

ALTERNATOR, 22 kw, diesel engine

16J883

16J884

BRACKET, engine mount, left

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 n

Q

Included in Muffler Kit 24L943.

Included in Complete Coolant Hose Kit

24L939. See

Proportioners .

Replace fuses F6 and F7 located in the junction box above the 120/240 V alternator. Use Fuse Replacement Kit

24M723.

1

1

1

1

10

1

1

1

2

8

8

1

2

4

572

572a

572b

572c

575

576

577

579

580

581

582

583n

584n

586

587

24L965

- - -

- - -

- - -

CIRCUIT, breaker,

90A

SCREW

WASHER

NUT

125631 BUSHING, cable, lay-in strain relief

120858 BUSHING, strain relief, M40 thread

125625 TIE, cable, fir tree

120859 NUT, strain relief,

M40 thread

- - -

See

Radiator

120736 SCREW, hex flange hd, M6 x 1

115942

- - -

NUT, hex, flange head

MUFFLER, 2 in. (50.8 mm) exhaust

125161 CLAMP, muffler

104572 WASHER, lock spring

105328 SCREW, cap, hex hd, M8 x 1.25

1

1

4

1

2

2

2

1

2

1

1

2

1

2

2

142 332637L

See assembly notes on next page.

Parts

332637L 143

Parts

5

6

7

3

4

1

2

Apply pipe sealant to all non-swiveling pipe threads.

Torque to 25 +/- 2 ft-lb (34 N●m).

Torque to 10 +/- 2 ft-lb (14 N●m).

Torque to 40 +/- 2 ft-lb (54 N●m).

Torque to 15–20 in-lb (1.7–2 N●m).

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.

601

602

602a

602b

602c

603v

604

605l

606

607

608

609n

610

611n

612n

613

614u

615u

616u

617u

618u

619*

620Q

16H872

16H910

- - -

- - -

- - -

112958

16J741

- - -

125356

125139

158383

125171

- - -

- - -

16H868

113161

16H870

16H717

16K156

125579

16H876

111803

125359

COVER, radiator mount

GASKET, radiator isolation; see 602a-602c

GASKET, radiator isolation;

14 in. (355.6 mm), 0.63 in.

GASKET, radiator isolation;

14 in. (355.6 mm), 2 in.

GASKET, radiator isolation;

3 in. (76.2 mm), 2 in. dia.

RADIATOR

BRACKET, top

FITTING, union, adapter, straight

FITTING, modified, union

FITTING, compression, 1/8

NPT, SST

HOSE, formed, 1 1/4 upper radiator

1

1

4

1

1

1

1

SCREW, flanged, hex hd;

1/4–20 x 1/2 in. (13 mm)

BRACKET, bottom

FAN, 16 in., 12V

20

1

BRACKET, plate

ISOLATOR, mount, radiator

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 1

FITTING, 1 in. NPT X 1.25

barbed hose

2

FITTING, barb, beaded hose 2

5

4

1

1

1

1

1

3

1

1

1 u

Included in Heat Exchanger Kit 24L946.

v

Included in Radiator Repair Kit 24L937.

l Included in Coolant Bottle Repair Kit 24L942.

n

Included in Radiator Isolator Kit 24L945.

10

11

8

9

12

Secure adhesive side of gasket to parts opposing radiator, not radiator.

See parts list for length.

Torque to 25 in-lb (2.8 N●m).

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-lb

(33.8 N●m).

621Q

622u

Q

623u vl

Q

624l

625

626

627

628 ◊

629 ◊

630v

631l

632*

633

634

635

636

637

638

640Q

641Q

642Q

643 ◊

16T800

125371

125370

- - -

125204

16H901

125360

16W156

16W155

- - -

24L967

- - -

125175

125625

16N580

16N581

16M323

16M141

125361

125163

125382

- - -

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.

1

4

2

TANK, aluminum, coolant

BOTTLE, overflow

BRACKET, hose support

HOSE, formed, 1 1/4 lower radiator

HOSE, coolant, 1 in. ID;

0.271 ft (0.08 m)

HOSE, rubber, 5/16 in. 1.5

ft (0.5 m)

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

1

1

1

1

1

1

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)

GUARD, engine bottom

1

1

BRACKET, overflow bottle

HOSE, formed, 1–1/4 upper engine

CLAMP, hose 7/32 in. -

5/8in.

HOSE, formed, 1–1/4 lower engine

HOUSING, filter

1

1

1

4

1

1

1

2

1

2

1

◊ Included in Filter Housing Kit 24T027. Order 24T028 for replacement filter screen (40 mesh).

* Included in RTD Sensor Kit 24L974.

Q Included in Complete Coolant Hose Kit 24L939. See

Complete Coolant Hose Kit .

144 332637L

Parts

See

Electrical Schematics, page 159 .

1

2

3

Torque to 5-8 in-lb (0.6-1 N●m)

Torque to 4-5 in-lb (0.5-0.6 N●m)

Torque to 23-26 in-lb (2.6-3 N●m)

Ref Part

652 120838 BLOCK, clamp end

653 24R723 BLOCK, terminal, quad

M4, ABB

654 24R722 BLOCK, terminal pe, quad, ABB

655 126453 POWER supply, 24V

656 17A310 CIRCUIT, breaker, 2P, 5A,

UL489

657 17A317 CIRCUIT, breaker, 2P,

40A, UL489

658 17A313 CIRCUIT, breaker, 2P,

15A, UL489

659 17A314 CIRCUIT, breaker, 2P,

20A, UL489

1

3

1

1

4

2

1

2

Ref Part

660 17A316 CIRCUIT, breaker, 2P,

30A, UL489

661 24V851 BAR, 18 pos, power buss

662 24V852 BAR, bus, connector

663 127302 BLOCK, terminal, 12.2

mm, 2 wire

664 127303 BLOCK, terminal, cover

665 127304 BLOCK, terminal, jumper,

3 position

674 127308 BLOCK, terminal

1

1

2

3

1

1

1

332637L 145

Parts

1

902 903 904 902

905

1

906

2

902

1

901 ti27068a

907

1

Torque to 5-8 in-lb (0.6-1 N●m)

Torque to 23-26 in-lb (2.6-3 N●m)

2

See

Electrical Schematics, page 159 .

Ref Part

901

- - DIN RAIL

902 125667 TERMINAL, stop, end

903 126818 BLOCK, terminal 3-wire

904 126817 COVER, end

1

3

2

1

Ref Part

905 125815 TERMINAL, block, feed thru

906 24L960 CIRCUIT, breaker, 50

AMP, 2 pole

907

- - -

HARNESS, electric

2

1

1

146 332637L

Parts

1

Torque to 5-8 in-lb (0.6-1 N●m)

Torque to 23-26 in-lb (2.6-3 N●m)

2

See

Electrical Schematics, page 159 .

Ref Part

901 - - DIN RAIL

902 125667 TERMINAL, stop, end

903 126818 BLOCK, terminal 3-wire

904 126817 COVER, end

905 125815 TERMINAL, block, feed thru

2

1

2

1

3

Ref Part

906 24L960 CIRCUIT, breaker, 50

AMP, 2 pole

907

- - -

WIRE, cu, electrical, 8

AWG, black

908 - - FERRULE, wire, 8 AWG

1

8

4

332637L 147

Parts

751

752

753

754

- - -

125645

125646

125647

TANK, fuel 1

GROMMET, tank 2

GROMMET, tank 1

FITTING, suction, assy

1

755

756

758

125648

125649

24L955

FITTING, 3/16 barbed

VALVE, drain

CAP, fuel

1

1

1

148 332637L

Parts

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 Part Description

801 16H759 BRACKET, heat exchanger

802 24L917 EXCHANGER, heat, side

A

803 24L918 EXCHANGER, heat, side

B

804* 24L916 VALVE, solenoid, 3/4

NPT, 12 VDC

805 160327 UNION ADAPTER, 90°

1

1

2

2

Qty

1

*

Ref Part Description

806 24J702 KIT, FITTING, outlet, heat exchanger

807 24J703 KIT, fitting, inlet, heat exchanger

808 C20487 NIPPLE, hex

810 112958 NUT, hex, flanged

811 16J741 WASHER, nylon, 30% glass, 3/4 OD

Order 125774 Valve Repair Kit to replace all internal valve parts.

2

8

8

Qty

1

1

332637L 149

Parts

1

2

Apply sealant to all tapered pipe threads.

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

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

851

852u

853

854

855*H

856Hu

857u

858u

160327

247503

24U852

24U853

- - -

128061

16V879

555808

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

*

H u

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.

2

2

2

2

2

2

2

2

859

862

863

864

866

868

150

15D757

109071

624545

118459

24U851

16W954

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)

2

2

2

4

1

1

332637L

272089, EE -

272090. EE -

272091, EE -XP2i

Parts

1

2

3

Apply anaerobic sealant to all non-swiveling pipe threads.

Torque to 40 ft-lb (54 N•m).

See

Motor Starter

for component parts.

332637L 151

Parts

1

4

5

Apply anaerobic sealant to all non-swiveling pipe threads.

Use from safety label (55) or (283).

See for

Switch Box Enclosure

for component parts.

152 332637L

Parts

2

3

4

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.

Coil extra cable and use cable tie (742) to attach to underside of air dryer (703).

332637L 153

Parts

4

5

9

10

6

8

Parts included with compressor (702b)

Coupler supplied with compressor (702b) needs to be pressed on to (motor (702a) as shown in detail view.

Torque to 20 ft-lbs (27 N•m).

Torque to 34 ft-lbs (46 N•m).

Torque to 36 ft-lbs (43 N•m).

Discard key supplied with motor and replace with key (702j).

701*

*

272079

272080

272081

Reactor, E-30i

Reactor, E-30i with heat

Reactor, E-XP2i with heat

1

For parts, see 272079, 272080, and 272081 .

11

12

13

14

Discard plug supplied on compressor and install thermal switch (702h).

Discard lift ring to install flange.

Discard steel washer on (702g) before assembly.

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.

1

1

154 332637L

Parts

All air compressor parts are included in the Air Compressor Accessory Kit. See

Accessories, page 12 .

702

702n†

703

704

705

706

707

708

709‡

710

711

712*

713

714

702a

702b

702c

702d

702e

702f

702g

702h

702j

702k

702m†

715

716

717

16Y567 COMPRESSOR, tankless, 5 hp; includes 702a-702k

25M727 MOTOR, 5 hp

- - -

COMPRESSOR, tankless

107530 SCREW, cap, sch, hex

1

1

16X024 COVER overload switch

260067 FITTING, strain relief, 1/2 npt

117625 NUT, locking

16M826 CORD, grip, 3/4 in.

16Y809 SWITCH, thermal overload

16C282 KEY, square, 1/4

127581 WASHER, bonded seal

- - -

CAPACITOR, run

- - -

CAPACITOR, start

127298 DRYER, air

16W780

16W685

FRAME, air compressor

FRAME, air dryer

16W689 BRACKET, clamp

16W843 ROD, threaded, 3/8-16

16W713 STRAP, frame connector

24T849

16W577

ENCLOSURE, switch box

ENCLOSURE, rear

16W565 BRACKET, electrical box

24U083 STARTER, motor, reactor

1

112538 FITTING, elbow, street, 90

127108 FITTING, barbed 5/16 ID x 1/8

NPT

1

C20679 FITTING, elbow; 1/2–14 npt x

7/8 un

2

15E511 FITTING, union, swivel 1/2 x 1/4 1

218093 HOSE, coupled; 1/2–14 npt, 22 in. (559 mm)

1

1

1

1

1

4

1

1

1

1

2

1

1

1

1

1

1

1

1

1

2

1

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

‡ See

Switch Box Enclosure

for component parts.

738

739

740

741

742

743▲

744

745

746

733

734

735

736

737

723

724

725

726

730

731

732

718

719

720

721

722

113505 NUT, keps, hex hd; #10

112958 NUT, hex, flanged; 3/8–16

119865 SCREW, mach, hex serrated;

0.375 in. x 1/4–20

101577 SCREW, cap, hex hd; 0.375 in. x

#10–24

125856 SCREW, serrated flange; 0.375

in. x #8-32

121488 SCREW, hex hd, flanged; 2.75 in.

x 3/8–16

113504 NUT, keps, hex hd

17H101 TUBE, compressor - air dryer

111218 CAP, tube, square

125644 FITTING, branch tee, 1/2 npt

17A346 HOSE, rubber 5/16 in.; 6 ft (1.8

m)

156971 FITTING, nipple, short; 1/4–18 npt x 1/4–18 npt

16X520 VALVE, air, 3-way, din

C19264 PLUG, pipe plug 1/4 in.

512910 MUFFLER, polyethylene 1/4 in.

npt

16X808 BRACKET, motor mount

112395 SCREW, cap, flng hd; 3/4 in. x

3/8–16

111194 SCREW, cap flang hd; 2 in. x

3/8–16

125163 CLAMP, hose, 7/32 in. – 5/8 in.

16Y488 NUT, wire, #14-#6 awg

106569 TAPE, electrical

261105 TIE, cable, 14 in.

189285 LABEL, hot surface

190451 UNION, adapter

125871 TIE, cable, 7.5 in.

121171 GRIP, cord, .35-.63, 3/4

3

12

2

3

3

10

1

2

4

6

2

1

10

1

1

3

1

1

1

1

2

1

2

1

1

* See

Motor Starter

for component parts.

† Not shown. Located inside the top corner of (702a). Included in Compressor Motor

Repair Kit 25M541.

332637L 155

Parts

e

1

Assemble switch blocks as shown.

709a 16W575 ENCLOSURE, front

709b 121618 SWITCH, start, push button, green

709c 121619 SWITCH, stop, push button, red

709d 120493 LATCH, mounting

709e 120494 BLOCK, switch, N.O.

1

2

1

1

1

709f 120495 BLOCK, switch, N.C.

709g 260067 FITTING, strain relief,

1/2 npt

709h 117625 NUT, locking

709j 16W614 LABEL

1

1

1

1

156 332637L

Parts

1

2

Attach ground connector bar aligned vertically to electrical box with screw and washer.

Labels from sheet (712s).

332637L 157

Parts

Diagram depicts wiring configuration for system series “D” and following. See for system series

“A” through “C” wiring configuration.

3

4

5

Torque to 38–42 in-lb (4.3–4.7 N•m).

Torque to 18–22 in-lb (2–2.5 N•m).

Torque to 28–32 in-lb (3.1–3.6 N•m).

702g 16M826 CORD, grip, 3/4 in.

712a 24U081 STARTER, int.

reactor, 3 phase

712b 24U082 CONTACT, aux, two no switches

712c 119257 CONNECTOR, bar, ground

712d 555582 SCREW, soc hd cap,

#10

712e 555629 WASHER, #10, external tooth lock

712g 16X009 CABLE, shunt

712h* 24U080 CABLE, air compressor breaker

*

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

Order 24U080 for system series “D” and following. If system series is “C” or earlier, order kit 25M556 along with 24U080.

Order 24U079 for system series “D” and following. If system series is “C” or earlier, order kit 25M556.

4

1

1

1

1

1

1

1

712j† 24U079 CABLE, air compressor

712k 16X011 CABLE, over temperature, compressor

712m 24U078 CABLE, dryer, breaker

712n 16X012 CABLE, power, dryer

712p 24U076 CABLE, start-stop

712r 16X010 CABLE, pressure vent

712s▲ 16X422 LABEL

1

1

1

1

1

1

1

158 332637L

Electrical Schematics

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

C

D

E

(90)

(280)

(49)

24L964

16K646

16K301

Engine

Load Center

Coolant Valves

Engine

Load center

Engine, page 171

Load Center, page 168

Coolant Valve Wiring Diagram, page 168

Engine, page 171

Load Center, page 168

F

H

(94)

(53)

17L264†

16K299

Load Center

Engine Control Module

Load Center

Electrical Enclosure

Load Center, page 168

Engine Control Module, page

169

Load Center, page 168

Electrical Enclosure, page 161

K

M

(52)

(51)

125753

17L263‡

Alternator Enclosure

Electrical Enclosure

Disconnect

Alternator Enclosure

Engine Control Module

Alternator Enclosure, page 172

Electrical Enclosure, page 161

MCM Wiring Diagram, page

163

Alternator Enclosure, page 172

Engine Control Module, page

169

Reactor, page 167

Electrical Enclosure, page 161

N (54) 125756

Reactor

Electrical Enclosure

MCM

(519) 24T174 Electrical Enclosure P

Electrical Enclosure, page 161

† 17L264 for system series “C” and following. For reference, this harness was 16K297 for system series “A” and “B” only. For replacement of 16K297, purchase kit 24M665.

‡ 17L263 for system series “C” and following. For reference, this harness was 16Y518 for system series “A” and “B” only. For replacement of 16Y518, purchase kit 24M665.

This table refers to Engine Harness E (49), Engine Control Module Harness F (94), and Disconnect

Check Harness H (53).

Red

Black/White

Orange

White

Gray

Battery Positive (Lines

Always Energized)

Engine Load Grounds

Starter

Glow Plugs

Fuel Shutoff Solenoid

(FD)

Violet

Black/Yellow

Brown

Dark Blue

Radiator Fan

Monitoring Grounds

Oil Pressure Switch

Water Temperature

332637L 159

Electrical Schematics

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.

CB01 5 A

CB02

CB03

CB04

CB05

15 A

15 A

30 A

20 A

Power Supply, Fan,

Coolant Circulation

Pump

Boost Heat A

Boost Heat B

Hose Heat Primary

Motor Control

CB06

CB07

CB08

CB20

40 A

20 A

15 A

50 A

Air Compressor

Open

Open

Air Dryer

Open

Hose Heat Secondary

17C190

17C191

17A310

17A311

17A313

17A314

1

3

5

10

15

20

17A315

17A316

17A317

17A318

17C192

25

30

40

50

63

160 332637L

Electrical Schematics

332637L 161

Electrical Schematics

MCM-

CAN-1

TCM

MCM-

CAN-2

CAN-1

MCM-2

MO-

TOR-OT

MCM-6

PRES-

SURE-A

MCM-7

PRES-

SURE-B

MCM-

CAN-1

MCM-

CAN-2

MCM Port

2

MCM Port

6

MCM Port

7

TCM-

CAN-2

Electrical

Enclosure

CAN-1

Bulkhead

Motor

Overtemperature

Switch

Fluid

Manifold

Pressure

Sensor A

Fluid

Manifold

Pressure

Sensor B

121000

121000

125357

127286

127286

MCM-8

INLET-A

MCM-9

INLET-B

MCM-12

CYCLE-

CNT

MCM-14

INSITE

MCM Port

8

MCM Port

9

MCM Port

12

MCM Port

14

Temperature and

Pressure

Inlet Sensor A

Temperature and

Pressure

Inlet Sensor B

Fluid

Motor

Cycle

Counter

InSite

Module

16W131

16W131

24T878

24T051

162 332637L

Electrical Schematics

332637L 163

Electrical Schematics

'HT-RTD-A TCM'

BLK

BLK

261821

BLK

WHT

HTR-OT

24L973 HT-RTD-B

BLK

BLK

261821

BLK

WHT

ELECTRICAL ENCLOSURE

'HT-RTD-B TCM'

126881

126891

127253

127254

TCM

24U855

'TCM-B HT-RTD-B'

'TCM-A HT-RTD-A'

TCM-OT

WHT

BLK

WHT

BLK ti23006a

164 332637L

Electrical Schematics

1

Rotary setting:

E-30i = 0 E-XP2i = 1

See Cable Routing Table on page 157.

332637L 165

Electrical Schematics

See

Circuit Breaker Identification, page 160 , for circuit breaker identification table and other available circuit

breakers. Before making any changes to the standard auxiliary circuit breaker configuration, refer to Circuit

Breaker Configuration Options in the Reactor Operation Manual.

240 VAC AUXILIARY LOAD

240 VAC

AUXILIARY LOAD

LINE TO LINE WIRING

L1

L2

PS1

POWER

SUPPLY ti23006a

166

120 VAC AUXILIARY LOAD

LINE TO NEUTRAL WIRING

120 VAC

AUXILIARY LOAD

120 VAC

AUXILIARY LOAD

L1

L2

N

N

NEUTRAL

NEUTRAL

NEUTRAL

332637L

Electrical Schematics

2

REACTOR ENCLOSURE

PRIMARY

SECONDARY

WHT

BLK

N130 BLK

N120 BLK

BLK

RED

BLK

RED ti27070b

1

2

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).

332637L

ELEC ENCL

GND STUD

167

Electrical Schematics

TO ENGINE

HARNESS ‘E’

16K301

TO ENGINE

CONTROL

MODULE

HARNESS ‘F’

17L264

E630 - BLU

E620 - BRN

E611 - BLK

E150 - WHT

E100 - ORG

E200 - GRY

E190 - TAN

E020 - RED

E220 - PUR

E010 - BLK/WHT

F120 - BLU

F110 - BRN

F100 - BLK/YEL

F080 - PUR

F070 - WHT

F040 - ORG

F030 - GRY

F010 - BLK/YEL

F020 - RED

FUSE REPAIR KIT

24L959

(contains two replacement fuses)

RELAY REPAIR KIT

24L958

(contains four replacement relays)

LOAD CENTER REPAIR KIT

24L957

1

J3

CR4

1

J2

LOAD CENTER

K4 K1

E02 0

E220

E010

1 J1 F3 F4 ti30468a

* 17L264 for system series “C” and following.

For reference, this harness was 16K297 for system series “A” and “B” only. For replacement of 16K297.

1

Manual Valve Switch:

o

— OFF: Automatic Operation

1 – ON: Manual Operation

K2 K3

J5 1

1

J4

J6 1

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

H100 - ORG

H110 - ORG

TO ELECTRICAL ENCLOSURE

HARNESS ‘H’

16K299

168

J6–6

J6–5

J6–4

J6–3

J6–2

J6–1

D (16K646) Connection

D150 — BLK/WHT

D140 — GRY

D130 — BLK/WHT

D120 — BLU

D110 — BLK/WHT

D100 — RED

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

PIN 2

Connector

Designations

PIN 1

PIN

UNUSED

332637L

Electrical Schematics

TO 120 / 240 VAC

ALTERNATOR

HARNESS 'M', 17L263

FERRITE

BEAD

125835

RED

BLK

1

21 24

25A854, ENGINE

CONTROL MODULE

9 10 20

DSE PIN 20

TO LOAD CENTER

HARNESS 'F', 17L264

F010 BLK / YEL

F020 RED

F030 GRY

F040 GRN

F070 WHT

F080 PUR

F100 BLK / YEL

F110 BRN

F120 BLU

332637L 169

Electrical Schematics

TO 120 / 240 VAC

ALTERNATOR

1

HARNESS 'M', 16Y518

FERRITE

BEAD

125835

RED

BLK

TO LOAD CENTER

HARNESS 'F', 16K297 1

F010 BLK / YEL

F020 RED

F030 GRY

F040 ORG

F070 WHT

F080 PUR

F100 BLK / YEL

F110 BRN

F120 BLU

1

For replacement, purchase kit 24M665.

N

24M665, ENGINE CONTROL MODULE

16

DSE PIN 16 ti27069b

170 332637L

Electrical Schematics

D+ B+

FOR ALT. W/ 2 PIN CONNECTOR

3 - POST VERSION

E190 - TAN

E020 - RED

12V

CHARGE ALTERNATOR

C020 - RED

E190 - TAN E190 - TAN

A

B

FUSIBLE LINK HARNESS ‘C’, 24L964

C020 - RED

L

B+

12V

CHARGE ALTERNATOR

F8

FUSE, 16P405, FUSE HOLDER, 16P406

F9

C010 - RED

C030 - RED

+ -

TO LOAD CENTER

HARNESS ‘E’

16K301

E100 - ORG

E150 - WHT

E010 - BLK/WHT

E200 - GRY

E220 - PUR

E620 - BRN

E611 - BLK/YEL

E630 - BLU

C040 - RED

C050 - RED

E100 - ORG

E112 - BLK/WHT

C050 - RED

3

SP4

E031 - BLK/WHT

E150 - WHT

E111 - BLK/WHT

2

SP2

E200 - GRY

E032 - BLK/WHT

E033 - BLK/WHT

1

SP1

E220 - PUR

E034 - BLK/WHT

J7

E140 - ORG

ENGINE

STARTER

ES

STARTER

SOLENOID RELAY

CR6

“TOP”

E180 - WHT

GLOW PLUG

SOLENOID RELAY

CR7

“BOTTOM”

GLOW PLUGS

FD

FUEL SHUTOFF

SOLENOID

J8

E035 - BLK/WHT

RADIATOR FAN

SINGLE POINT

GROUND

E614 - BLK/YEL

P

E620 - BRN

E612 - BLK/YEL

OIL PRESSURE SWITCH

1

SP3

J10

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.

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 , for fuse or fuse holder repair.

332637L 171

Electrical Schematics

ALTERNATOR ENCLOSURE

125631

TO ENGINE CONTROL

MODULE

HARNESS 'M',17L263

5

M020-BLK

M040-RED

M070-WHT

W2 U2 V2

SP11

SP12

BLK

BLK

U1

1

F6, 2 AMP

F7, 2 AMP

1

BLK

BLK

V1 W1

K080-WHT

125822

TO POWER

DISTRIBUTION BOX

HARNESS 'K',125753

K070-WHT

K030-BLK

K050 - RED

K010 - GRN

2

4

90 AMP

CB10

2

1

3

K020-BLK

125754

K040-RED

125755

120858 120859

1

3.

2

F6 and F7 Fuse replacement kit, 24M723.

(contains two fuses)

CB10 circuit breaker replacement kit,

24L965.

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.

4

5

Torque all four wire connections to 40–42 in-lb (4.5–4.7 N●m).

17L263 for system series “C” and following.

For reference, this harness was 16Y518 for system series “A” and “B” only. For replacement of 16Y518, purchase kit

24M665.

172 332637L

Electrical Schematics

CB01 CB02 CB03 CB04

5A 15A 15A 30A

CB05 CB06 CB07 CB08

20A 40A 20A 15A ti31518a

1

2

PD-CB6-4

PD-CB6-2

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).

PD-N

PD-CB8-4

332637L 173

Electrical Schematics

MOTOR JUNCTION BOX

WIRE NUT

#6

WIRE NUT

#6

740

WIRE NUT

#6

CORD GRIP

16M862 ti31519a

AC-W1

AC-W5

AC-W4-W8

AC-GND

GROUND

STUD

CABLE 24U079

TO MOTOR STARTER

MOTOR JUNCTION BOX

WIRE NUT

#6

WIRE NUT

#6

AC-W1-W5 AC-W4-W8

AC-GND

GROUND

STUD

CABLE 24U079

TO MOTOR STARTER

CORD GRIP

16M862 ti32255a

174 332637L

Electrical Schematics

1

2

Start capacitor – smaller diameter.

Run capacitor – larger diameter.

332637L 175

Electrical Schematics

CORD GRIP

16M826

MS-QD1 MS-QD1

MS-A2

A1

MS-23

23

MS-13

13

L1 L2

MS-L3

A2

MS-L1

MS-L2

L3

Motor STARTER

WITH BOX

24U081

AUXILIARY

CONTACTOR

24U082

BLK

WHT

16X011

WHT

RED

BLK

GRN

BLK

WHT

24U076

16X012

CABLE 16X011

TO COMPRESSOR OVER TEMP SENSOR

CABLE 24U076

TO COMPRESSOR START STOP BOX

CABLE 16X012

TO AIR DRYER

MS-14

MS-24

24

14

95 96 97 98

MS-96

MS-98

MS-98

T1

MS-T1

T2 T3

MS-T3

MS-T2

OVERLOAD

RELAY

GROUND BAR

119257

GRN

RED

BLK

WHT

24U079

CORD GRIP

16M826

CORD GRIP

16M826

CORD GRIP

16M826

1

2

CABLE 24U078

TO ELECTRICAL ENCLOSURE

AIR DRYER POWER

CABLE 16X010

TO AIR EXHAUST VALVE

Order 24U079 for system series “D” and following. If system series is “C” or earlier, order replacement kit 25M556.

Order 24U080 for system series “D” and following. If system series is “C” or earlier, order replacement kit 25M556 along with

24U080.

1

CABLE 24U079

TO AIR COMPRESSOR

CABLE 24U080

2

TO ELECTRICAL ENCLOSURE

AIR COMPRESSOR POWER ti31522a

176 332637L

CORD GRIP

16M826

MS-QD1 MS-QD1

MS-A2

A1

MS-23

23

MS-13

13

L1 L2 L3

MS-L1

MS-L2

MS-L3

A2

Motor STARTER

WITH BOX

24U081

AUXILIARY

CONTACTOR

24U082

BLK

WHT

16X011

WHT

RED

BLK

GRN

BLK

WHT

24U076

16X012

CABLE 16X011

TO COMPRESSOR OVER TEMP SENSOR

CABLE 24U076

TO COMPRESSOR START STOP BOX

CABLE 16X012

TO AIR DRYER

MS-14

MS-24

24

14

95 96 97 98

MS-96

MS-98

MS-98

T1

MS-T1

T2 T3

MS-T2

MS-T3

GROUND BAR

119257

GRN

WHT

BLK

24U079

CORD GRIP

16M826

CORD GRIP

16M826

CORD GRIP

16M826

1

2

CABLE 24U078

TO ELECTRICAL ENCLOSURE

AIR DRYER POWER

CABLE 16X010

TO AIR EXHAUST VALVE

Order 24U079 for system series “D” and following. If system series is “C” or earlier, order replacement kit 25M556.

Order 24U080 for system series “D” and following. If system series is “C” or earlier, order replacement kit 25M556 along with

24U080.

1

CABLE 24U079

TO AIR COMPRESSOR

CABLE 24U080

2

TO ELECTRICAL ENCLOSURE

AIR COMPRESSOR POWER ti31521a

Electrical Schematics

332637L 177

Repair and Spare Parts Reference

70

114

115

240

272

273

275

302

312

318

315

712j

- - -

855

856

- - -

- - -

452

453

455

569

572

360

370

619

632

643

702m

702n

24K207

16P405

16P406

24L958

24L959

24L972

125774

125787

17W869

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

KIT, repair, drive housing

Systems

Systems

Systems

Proportioner

Proportioner

Proportioner

Proportioner

Heat Exchanger Assembly

Proportioner

Heat Exchanger Assembly

Proportioner Module

15C852

15C851

246963

246964

247824

102814

15M669

24L963

24L965

24L973

24L974

24T028

25M541

25M556

17A101

24V020

24M723

24N365

E-30i Pump Repair Kit

E-XP2i Pump Repair Kit

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)

RTD Repair Kit (Engine Heat Exchanger)

Coolant Filter Kit (one 40 mesh screen)

Compressor Motor Capacitor Repair Kit.

NOTE: motors. See

Replace Compressor Motor

Capacitors, page 109 .

Compressor Motor Wiring Upgrade Kit

Compressor Oil (1 gallon)

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)

Proportioner Module

Proportioner Module

Proportioner Module

Proportioner Module

Fluid Manifold

Fluid Manifold

Fluid Manifold

Diesel Generator

Diesel Generator

Heater

Radiator

Radiator

Air Compressor Systems

Air Compressor Systems

Air Compressor Systems

Fluid Inlet Kit

Diesel Generator

Heated Hose and FTS

178 332637L

Recommended Rebuild Spare Parts

27

504

212

231

240

275

804

416

423

424

503

506

656

657

658

659

660

906

- - -

24U85

4

Advanced Display Module (ADM) System

24U83

2

Motor Control Module (MCM) Proportioner

24R756 Cooling Fan, Motor and Lower Cabinet Proportioner

24L915 Coolant Circulation Pump Proportioner

24L957 Load Center Repair Kit

24L916 Coolant Valve (complete)

Proportioner

Proportioner

Heat Exchanger Assembly

Air Control Panel 116513 Air Regulator

24M65

0

Air Control Tubing Repair Kit (includes full length of air control tubing)

24U85

5

Temperature Control Module (TCM)

24R757 Cooling Fan, Electrical Enclosure

Air Control Panel

Electrical Enclosure

Electrical Enclosure

126125 5A Circuit Breaker

126131 40A Circuit Breaker

126127 15A Circuit Breaker

126128 20A Circuit Breaker

126130 30A Circuit Breaker

24L960 50A Circuit Breaker

24L939 Complete Coolant Hose Kit (includes all coolant hoses)

Electrical Enclosure

Electrical Enclosure

Electrical Enclosure

Electrical Enclosure

Electrical Enclosure

Transformer and Fan Circuit Breaker

Module

See Complete Coolant Hose Kit in manual

332637L 179

Dimensions

Figure 45

180 332637L

Dimensions

Figure 46

332637L 181

Dimensions

Figure 47 Floor Mount Hole Pattern

182 332637L

Technical Specifications

E-30i

E-XP2i

E-30i

E-30i with booster heater

E-XP2i

E-30i

E-XP2i

Length

E-30i

E-XP2i

E-30i and E-XP2i

Temperature

Voltage

Model

Model

Voltage

Minimum Cold Cranking Amps

Connection Type

2000 psi

3500 psi

150°F

180°F

180°F

14 MPa, 140 bar

24.1 MPa, 241 bar

65°C

82°C

82°C

30 lb/min

2 gpm

310 ft

13.5 kg/min

7.6 lpm

94 m

0.0272 gal.

0.0203 gal.

300 psi

0.1034 liter

0.0771 liter

2.1 Mpa, 20.7 bar

-7° to 49°C 20° to 120°F

120 Vac or 240 Vac, 60 Hz

Perkins 404–22G, 2.2 L, 29 HP

Mecc Alte 22 kW, 240 V, 1 PH, 60 Hz, pancake style

12 Vdc

800 CCA

Post Style

332637L 183

Technical Specifications

BC Group Number

Length

Width

Height

E-30i

E-30i with booster heat

E-XP2i

10.25 in.

6.81 in.

7.88 in.

34

None

4000 Watts

4000 Watts

260 mm

173 mm

200 mm

Part No.

Pressure

Specifications

Required Features

025CK10

140 psi 0.9 MPa, 9.6 bar

16 cfm

Thermal overload switch, Safety Relief Valve

Part No.

Specifications

Required Features

EL1410–CUS

5 HP, 1735 RPM, 240 V, 1 Phase, OPSB

C face, lift rings

Hankison Model H1T20

Specifications

Required Features

Sound Pressure measured from

3.1 ft (1 m), at 1500 psi (10

MPa, 103 bar), 2 gpm (7.6 lpm)

Component A (ISO) and

Component B (RES)

115VAC, 1 Phase, 60 Hz, 22 scfm at 150 psi (1 MPa, 10.3 bar)

Pilot valve unloader

91.0 dBA

3/4 NPT(f) with 3/4 NPSM(f) union

Component A (ISO)

Component B (RES)

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

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

184 332637L

Technical Specifications

Size

Maximum Pressure

E-30i

E–30i with compressor and dryer

E-30i with booster heat

E–30i with booster heat, compressor, and dryer

E-XP2i

E–XP2i with compressor and dryer

Material

1/4 NPSM(m), with sst braided tubing

250 psi

1750 lb

2200 lb

1800 lb

2250 lb

1800 lb

2200 lb

1.75 MPa, 17.5 bar

794 kg

998 kg

816 kg

1021 kg

816 kg

998 kg

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

332637L 185

Notes

186 332637L

Integrated Reactor

®

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.

24U050

24U051

26D472

24U855

24U854

All other Reactor 2 parts

Electric Motor

Electric Motor

Motor Control Module

Heater Control Module

Advanced Display Module

36 Months or 3 Million Cycles

36 Months or 3 Million Cycles

36 Months or 3 Million Cycles

36 Months or 3 Million Cycles

36 Months or 3 Million Cycles

12 Months

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

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified,

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

THIS

INCLUDING

FOR

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above.

The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty 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

AND

MATERIALS 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.

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

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 www.graco.com

Revision L – December 2022

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