Graco 311075U User Manual

Instructions - Parts List

For spraying or dispensing 1:1 mix ratio materials, including epoxies,
polyurethane foam, polyurea coatings, and joint fill materials.
For professional use only.
Not approved for use in European explosive atmosphere locations.

Important Safety Instructions

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

311075U

EN

See page 4 for a list of models and maximum working pressures.

Heated
Package, with

Fusion™ Gun

Nonheated Package, MD2 Cold Spray Gun

WLD

WLD

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Foam Self-ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 9

Keep Components A and B Separate . . . . . . . . . 10

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . 10

Component Identification . . . . . . . . . . . . . . . . . . . 11

Controls and Indicators . . . . . . . . . . . . . . . . . . . . 13

Motor/Pump Control Function Knob . . . . . . . . . 13

STATUS Indicator . . . . . . . . . . . . . . . . . . . . . . . 13

Motor Power Switch/Circuit Breaker . . . . . . . . . 14

Heater Power Switch/Circuit Breaker . . . . . . . . 14

Heater Temperature Controls . . . . . . . . . . . . . . 14

Fluid Temperature Sensors and Displays . . . . . 14

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Startup of Heated Units . . . . . . . . . . . . . . . . . . . . . 22

Heatup Guidelines . . . . . . . . . . . . . . . . . . . . . . 23

Heat Management Tips . . . . . . . . . . . . . . . . . . . 23

Heating Foam Resins with 245 fa Blowing Agents

24

Spraying/Dispensing . . . . . . . . . . . . . . . . . . . . . . . 25

Pause (Heated Units) . . . . . . . . . . . . . . . . . . . . . . . 26

Refilling Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 27

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . 34

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Before Beginning Repair . . . . . . . . . . . . . . . . . . 39

Removing Supply Tanks . . . . . . . . . . . . . . . . . . 39

Recirc/Spray Valves . . . . . . . . . . . . . . . . . . . . . 40

Displacement Pump . . . . . . . . . . . . . . . . . . . . . 41

Control Module . . . . . . . . . . . . . . . . . . . . . . . . . 43

Fluid Heaters (if supplied) . . . . . . . . . . . . . . . . . 48

Pressure Transducers . . . . . . . . . . . . . . . . . . . . 48

Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Cycle Counter Switch Replacement . . . . . . . . . 50

Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Suggested Spare Replacement Parts . . . . . . . . . 68

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 72

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 72

2 311075U

Related Manuals

Related Manuals

The following manuals are for Reactor E-10 components and accessories. Some are supplied with your package,
depending on its configuration. Manuals are also available at www.graco.com.

68

Displacement Pump

Part No. Description

311076 Instruction-Parts Manual (English)

Fluid Heater

Part No. Description

311210 Instruction-Parts Manual (English)

Fusion Air Purge Spray Gun

Part No. Description

309550 Instruction-Parts Manual (English)

Systems

Maximum

Working

Pressure,

psi

Part

AP9570 2000

AP9571 2000

AP9572 2000

CS9570 2000

CS9571 2000

CS9572 2000

249806 2000

249808 2000

24R984 2000

24R985 2000

(MPa, bar)

(14, 140)

(14, 140)

(14, 140)

(14, 140)

(14, 140)

(14, 140)

(14, 140)

(14, 140)

(14, 140)

(14, 140)

Proportioner
(see page 4)

249570 249499 Fusion Air Purge 249810

249571 249499 Fusion Air Purge 249810

249572 249499 Fusion Air Purge 249810

249570 249499 Fusion CS CS22WD

249571 249499 Fusion CS CS22WD

249572 249499 Fusion CS CS22WD

249576 249633 MD2 Gun 255325

249577 249633 MD2 Gun 255325

249576 24R823 2K Manual 24R021

249577 24R823 2K Manual 24R021

Fusion Mechanical Purge Spray Gun

Part No. Description

309856 Instruction-Parts Manual (English)

Fusion CS Spray Gun

Part No. Description

312666 Instruction-Parts Manual (English)

MD2 Dispense Valve

Part No. Description

312185 Instruction-Parts Manual (English)
3A2910 MD2 Cold Spray and Joint Fill Kits

2K Manual Dispense Valve

Part No. Description

332198 Instruction-Parts Manual (English)

Unheated

Hose

35 ft (10.6 m)

(English)

Gun

Model Part

311075U 3

Models

Models

The model no., series letter, and serial no. are located on the back of the Reactor E-10. For faster
assistance, please have that information ready before calling Customer Service.

Maximum

Working
Bare
Proportioner
Part, Series Volts

* Electrical

Connection Application

Pressure,

psi

(MPa, bar) Approvals

249570, A 120 V 15 A cord

(motor)

15 A cord

(heaters)

249571, A 240 V 10 A cord

(motor)

10 A cord

(heaters)

249572, A 240 V 20 A cord

(motor and

heaters)

249576, A 120 V 15 A cord

(motor only)

249577, A 240 V 10 A cord

(motor only)

• Polyurethane Foam

• Hot Polyureas

• Polyurethane Foam

• Hot Polyureas

• Polyurethane Foam

• Hot Polyureas

• Self-leveling Joint Fillers

• Cold Polyureas

• Self-leveling Joint Fillers

• Cold Polyureas

2000

(14, 140)

2000

(14, 140)

2000

(14, 140)

2000

(14, 140)

2000

(14, 140)

9902471

Conforms to ANSI/UL

Std. 499 Certified to

CAN/CSA Std.

C22.2 No. 88

9902471

Conforms to ANSI/UL

Std. 73 Certified to

CAN/CSA Std.

C22.2 No. 68

* See page 16 for detailed electrical requirements.

4 311075U

Warnings

Warnings

The following general warnings are for the setup, use, grounding, maintenance, and repair of this
equipment. Additional, more specific warnings may be found throughout the body of this manual
where applicable. Symbols appearing in the body of the manual refer to these general warnings.

When these symbols appear throughout the manual, refer back to these pages for a description
of the specific hazard.

WARNING

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Use only grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on sprayer and extension cords.

• Do not expose to rain. Store indoors.

TOXIC FLUID OR FUMES HAZARD

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

• Read MSDSs to know the specific hazards of the fluids you are using.

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

• Always wear chemically impermeable gloves when spraying, dispensing, or
cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or
when in the operating area of the equipment to help protect you from serious injury,
including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equip­ment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

311075U 5

Warnings

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin.
This may look like just a cut, but it is a serious injury that can result in amputation.

Get immediate surgical treatment.

• Engage trigger lock when not spraying.

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

• Do not put your hand over the spray tip.

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

• Follow the Pressure Relief Procedure when you stop spraying and before

cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or
explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

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

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

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

• Ground all equipment in work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do
not use equipment until you identify and correct the problem.

• Keep a fire extinguisher in the work area.

THERMAL EXPANSION HAZARD

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

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

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

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocar­bon solvents or fluids containing such solvents in pressurized aluminum equipment.
Such use can cause serious chemical reaction and equipment rupture, and result in
death, serious injury, and property damage.

6 311075U

Warnings

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• This equipment is for professional use only.

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

Turn off all equipment and follow the Pressure Relief Procedure in this manual
when equipment is not in use.

• Do not exceed the maximum working pressure or temperature rating of the low-

est rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See

Technical Data in all equipment manuals. Read fluid and solvent manufac­turer’s warnings. For complete information about your material, request MSDS
from distributor or retailer.

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

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your Graco 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.

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

• Comply with all applicable safety regulations.

MOVING PARTS HAZARD

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

• Keep clear of moving parts.

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

• Pressurized equipment can start without warning. Before checking, moving, or
servicing equipment, follow the Pressure Relief Procedure in this manual. Dis-
connect power or air supply.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation.
To avoid severe burns, do not touch hot fluid or equipment. Wait until equip­ment/fluid has cooled completely.

311075U 7

Overview

Overview

The Reactor E-10 is a portable, electric-pow­ered, 1:1 mix ratio proportioner, for use with a
wide variety of coatings, foams, sealants, and
adhesives. Materials must be self-leveling and
pourable, and may be applied with impinge­ment mix spray guns, disposable mixer guns,
or flush-type mix manifolds.

Reactor E-10 is gravity-fed from 7 gal. (26.5
liter) supply tanks mounted on the unit. The
tanks are translucent to allow monitoring of
fluid level.

Severe duty, positive displacement reciprocat­ing piston pumps meter fluid flow to the gun for
mixing and applying. When set to recirculation
mode, Reactor E-10 will circulate fluids back to
the supply tanks.

Heated models include separate thermostati­cally controlled heaters for each fluid, and an
insulated hose bundle with circulation return
hoses. This allows the hoses and gun to be
preheated to the desired temperature before
spraying. Digital displays show the tempera­tures of the two fluids.

Reactor E-10 has two recirculation speeds,
slow and fast, and an adjustable pressure out­put.

Slow Recirculation

• Slow circulation results in a higher tem­perature transfer in the heater, so hoses
and gun heat up quicker.

• Good for touchup or low flow spraying, up
to moderate temperature.

• Not used to circulate full tanks up to tem­perature.

• Use with 245 fa blowing agent foams, to
minimize heat returned to tank and reduce
frothing.

Fast Recirculation

• Use to support higher flow rates or higher
temperatures by preheating the tanks.

• Agitates fluid within tanks, to avoid heating
only the fluid at the top of the tank.

• Use for flushing.

An electronic processor controls the motor,
monitors fluid pressures, and alerts the opera­tor if errors occur. See STATUS Indicator,
page 13, for further information.

8 311075U

Pressure Adjust

Automatically maintains selected pressure out­put for dispensing or spraying.

Isocyanate Hazard

Isocyanate Hazard

Spraying materials containing isocyanates
creates potentially harmful mists, vapors, and
atomized particulates.

Read material manufacturer’s warnings and
material MSDS to know specific hazards and
precautions related to isocyanates.

Prevent inhalation of isocyanate mists,
vapors, and atomized particulates by provid­ing sufficient ventilation in the work area. If
sufficient ventilation is not available, a sup­plied-air respirator is required for everyone in
the work area.

To prevent contact with isocyanates, appro­priate personal protective equipment, includ­ing chemically impermeable gloves, boots,
aprons, and goggles, is also required for
everyone in the work area.

form small, hard, abrasive crystals, which
become suspended in the fluid. Eventually a
film will form on the surface and the ISO will
begin to gel, increasing in viscosity. If used,
this partially cured ISO will reduce perfor­mance and the life of all wetted parts.

The amount of film formation and rate of
crystallization varies depending on the
blend of ISO, the humidity, and the tem­perature.

To prevent exposing ISO to moisture:

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

• Keep the felt washers in the pump
wet-cups saturated with Graco ISO pump
oil, Part No. 217374. The lubricant creates
a barrier between the ISO and the atmo­sphere.

• Use moisture-proof hoses specifically
designed for ISO, such as those supplied
with your system (see page 63).

Foam Self-ignition

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

Moisture Sensitivity of

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

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

• Always park pumps when you shutdown,
see page 27.

• Always lubricate threaded parts with Part
No. 217374 ISO pump oil or grease when
reassembling.

Isocyanates

Isocyanates (ISO) are catalysts used in two
component foam and polyurea coatings. ISO
will react with moisture (such as humidity) to

311075U 9

Keep Components A and B Separate

Keep Components A
and B Separate

NOTICE

To prevent cross-contamination of the equip­ment’s wetted parts, never interchange com-
ponent A (isocyanate) and component B
(resin) parts.

Changing Materials

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

• Always clean the fluid inlet strainers after
flushing, see page 28.

• Check with your material manufacturer for
chemical compatibility.

• Most materials use ISO on the A side, but
some use ISO on the B side.

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

10 311075U

Component Identification

Key for FIG. 1

Component Identification

A Supply Tank A
B Supply Tank B
C Pump A
D Pump B
E Heater A
F Heater B
G Fluid Pressure Gauges
H Recirc/Spray and Overpressure Relief Valves
J Control Panel; see F

IG

. 3, page 13
K Electric Motor and Drive Housings
L Insulated Hose Bundle

(includes circulation return hoses)

U

N

P

E

H

A

M Fusion Air Purge Spray Gun
N Desiccant Dryer (mounts on supply tank A)
P Recirculation Tubes
Q Air Line Inlet (quick-disconnect fitting)
R Outlet Hose Connections
S Return Hose Connections
T Fluid Temperature Sensors
U Hose Rack and Control Shield
V Fluid Inlet Ball Valves (1 on each side)
W Fluid Inlet Strainers (1 on each side)
X Power Cord
Y Air Filter/Moisture Separator

J

P

B

F

T

S

K

WLD

M

G

T

R

C

Q

Y

L

D

FIG. 1: Component Identification, Heated Packages (Part No. AP9572 Shown)

X

V

W

311075U 11

Component Identification

Key for FIG. 2

A Supply Tank A
B Supply Tank B
C Pump A
D Pump B
G Fluid Pressure Gauges
H Recirc/Spray and Overpressure Relief Valves
J Control Panel; see F

IG

. 3, page 13
K Electric Motor and Drive Housings
L Hose Bundle
M MD2 Cold Spray Gun (with disposable static

mixer) or 2K Manual Gun

U

N

A

P

N Desiccant Dryer (mounts on supply tank A)
P Recirculation Tubes
Q Air Line Inlet (quick-disconnect fitting)
R Outlet Hose Connections
U Hose Rack and Control Shield
V Fluid Inlet Ball Valves (1 on each side)
W Fluid Inlet Strainers (1 on each side)
X Power Cord
Z Air Filter/Moisture Separator

J

P

B

H

G

R

C

L

M

Q

Z

D

K

V

W

WLD

FIG. 2: Component Identification, Nonheated Packages (Part No. 249808 Shown)

X

12 311075U

Controls and Indicators

ST

Controls and Indicators

CF

TD TD

FIG. 3. Controls and Indicators (heated unit shown)

Motor/Pump Control

• Indicator (ST) blinking: If error occurs, STA-

Function Knob

Use knob (CF) to select desired function.

Icon Setting Function

Stop/Park Stops motor and auto-

matically parks pumps.

Slow
Recirc

Fast Recirc Fast recirculation

Pressure
Adjust

STATUS Indicator

• Indicator (ST) steady on: Motor Power
switch is turned on and control board is
working.

Slow recirculation
speed.

speed.
Adjusts fluid pressure

to gun in spray mode.

Code
No. Code Name

1 Pressure imbalance between A and B

2 Unable to maintain pressure setpoint
3 Pressure transducer A failure
4 Pressure transducer B failure
5 Excessive current draw
6 High motor temperature
7 No cycle counter switch input

MP

HP

TI7016a

TUS indicator will blink 1 to 7 times to indi­cate status code, pause, then repeat. See
T

ABLE

1 for a brief description of status
codes. For more detailed information and
corrective action, see page 31.

Table 1

(see also the label on back of the control

sides

: Status Codes

enclosure)

The default is to shut down if a status
code indication occurs. Codes 1 and 2
may be set to disable automatic shut­down if desired; see page 32. The other
codes are not settable.

311075U 13

Controls and Indicators

Motor Power Switch/Circuit Breaker

Switch (MP) turns power on to control board
and function knob. The switch includes a 20 A
circuit breaker.

Heater Power Switch/Circuit Breaker

See FIG. 3. Switch (HP) turns power on to
heater thermostats. The switch includes a 20 A
circuit breaker. Present on heated units only.

Heater Temperature Controls

See FIG. 4. Control knobs (HC) set tempera­ture of component A and B heaters. Indicator
lights (HL) turn on when thermostats are heat­ing, and off when heater reaches setpoint.
Present on heated units only.

Fluid Temperature Sensors and Displays

See FIG. 3. Fluid temperature sensors (T)
monitor actual temperature of component A
and B fluid going to spray gun. Temperatures
are then displayed (TD). Present on heated
units only.

Unit is shipped set to °F. To change to °C, see
page 43.

HL

HL

HC

E

T

IG

. 4. Heater Temperature Controls

F

14 311075U

HC

F

T

TI6984b

Setup

Setup

1.

2.

Improper wiring may cause electric shock or
other serious injury if work is not performed
properly. Have a qualified electrician perform
any electrical work. Be sure your installation
complies with all National, State and Local
safety and fire codes.

Locate Reactor E-10

a.

b.

Locate Reactor E-10 on a level
surface.

Do not expose Reactor E-10 to
rain.

Electrical requirements

a.

b.

c.

d.

Reactor E-10: grounded through
power cord.

Generator (if used): follow your
local code. Start and stop gener-

ator with power cord(s) discon­nected.

Spray gun: grounded through the
supplied fluid hoses, connected

to a properly grounded Reactor
E-10. Do not operate without at
least one grounded fluid hose.

Object being sprayed: follow your
local code.

Connect Reactor E-10 to the correct power
source for your model. See T
with two power cords must be connected to
two separate, dedicated circuits. See FIG. 5.

Some models include cord adapters (55, 56)
for use outside North America. Connect the
appropriate adapter to the unit’s power cord
before connecting to your power source.

3.

The equipment must be grounded. Grounding
reduces the risk of static and electric shock by
providing an escape wire for the electrical cur­rent due to static build up or in the event of a
short circuit.

Ground system

ABLE

2. Models

e.

f.

Solvent pails used when flushing:
follow your local code. Use only

metal pails, which are conduc­tive, placed on a grounded sur­face. Do not place pail on a
nonconductive surface, such as
paper, plastic, or cardboard,
which interrupts grounding conti­nuity.

To maintain grounding continuity
when flushing or relieving pres-

sure, hold a metal part of spray

gun firmly to the side of a
grounded metal pail, then trigger
gun.

311075U 15

Setup

Table 2: Electrical Requirements

Model Required Power Source Power Cord Connector

120 V, 1 phase, 50/60 Hz, two
15 ft (4.5 m) power cords,
Heated

240 V, 1 phase, 50/60 Hz, two
15 ft (4.5 m) power cords,
Heated

240 V, 1 phase, 50/60 Hz, one
15 ft (4.5 m) power cord,
Heated

120 V, 1 phase, 50/60 Hz, one
15 ft (4.5 m) power cord, Non­heated

240 V, 1 phase, 50/60 Hz, one
15 ft (4.5 m) power cord, Non­heated

Table 3: Extension Cord Requirements

Two separate, dedicated cir­cuits rated at minimum of 15
A each

Two separate, dedicated cir­cuits rated at minimum of 10
A each

Single dedicated circuit rated
at minimum of 16 A

Single dedicated circuit rated
at minimum of 15 A

Single dedicated circuit rated
at minimum of 8 A

Two NEMA 5-15T

Two IEC 320, with
two local adapters:

Euro CEE74 Adapter

Australia/China Adapter

One NEMA 6-20P

One NEMA 5-15T

One NEMA 6-20P

Required Wire Size

Model

Nonheated and two cord heated

Up to 50 ft (15 m) Up to 100 ft (30 m)

AWG 14 AWG 12

models
Single cord heated model AWG 12 AWG 10

Cords must be 3-conductor grounded, rated for your
environment.

16 311075U

To avoid electric shock, always unplug both cords
before servicing Reactor E-10.

1

Ensure no other high amp loads are connected
while running Reactor E-10.

2

To verify separate circuits, plug in Reactor E-10
or a worklight and cycle breakers on and off.

1

Heater Power

Setup

2

1

Motor Power

FIG. 5. Use Two Separate Circuits for Two Cord Models

4.

5.

Connect fluid hoses

Connect fluid supply hoses to outlet
hose connections (R, FIG. 6). Red hoses
for component A (ISO), blue for compo­nent B (RES). Fittings are sized to pre­vent connection errors. Connect other
end of hoses to A and B inputs of gun.

Heated units only: connect recirculation
hoses from gun recirculation ports to
connections (S).

Connect gun air hose

For air operated guns only: Connect gun
air hose to the gun air input and to the
air filter outlet (Z). If you are using more
than one hose bundle, join the air hoses
with the nipple (305) provided with the
hose bundle.

6.

7.

Connect main air supply

Connect the main air supply to the quick
disconnect fitting (Q) on the unit. Air
supply hose must be at least 5/16 in. (8
mm) ID up to 50 ft (15 m) or 3/8 in. (10
mm) ID up to 100 ft (30 m).

Air Filter/Moisture Separator (Z) is
equipped with an automatic moisture
drain.

Flush before first use

The Reactor E-10 is tested with a plasti­cizer oil at the factory. Flush out the oil
with a compatible solvent before spray­ing. See page 29.

TI7061a

On heated units with Fusion guns, con­nect the supplied ball valve and
quick-disconnect coupler to the gun air
hose, then connect the coupler to the
gun air fitting.

311075U 17

Setup

Heated Units

A (ISO)

B (RES)

AIR

S

R

Q

Z

WLD

B (RES)

Nonheated Units

A (ISO)

AIR

Q

R

Z

WLD

FIG. 6. Hose Connections

18 311075U

Setup

8.

Fill wet-cups

Keep the felt washers in the pump
wet-cups saturated with Graco ISO
pump oil, Part No. 217374. The lubri­cant creates a barrier between the ISO
and the atmosphere.

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 wet-cup during

operation. Shut off Motor Power

before filling wet-cup.

9.

To prevent cross-contamination of fluids and
equipment parts, never interchange compo­nent A (isocyanate) and component B (resin)
parts or containers.

Have at least two 5 gal. (19 liter) pails to
transfer fluid from drums to supply tanks.
Label one pail “A” and the other “B”, using
the red and blue labels provided. Always
doublecheck which material you have before
pouring it in the supply tanks. Pouring is eas­ier if pails are not filled to the top.

Fill fluid tanks

NOTICE

Fill wet-cups through slots

in plate, or loosen screws

and swing plate aside.

TI6985a

Open only one supply tank at a time, to avoid
splashing material from one tank into the
other when filling.

Using a drill and mixing blade, mix filled or
separated materials in the pail before add­ing to the tanks. Material left in the tanks
overnight may need to be remixed in the
tanks.

311075U 19

Setup

a.

Desiccant filter is blue when fresh, and
turns pink when saturated. Be sure
shipping plugs are removed from open­ings on desiccant filter.

b.

Lift hose rack. Remove tank A
cover and pour ISO into tank A

(red side, with desiccant filter in
cover). Replace cover .

Remove tank B cover and pour
resin into tank B (blue side).
Replace cover .

1

1

TI7017a

10.

Purge air and flush fluid from
lines

a.

b.

Remove both recirculation tubes
(P) from the tanks and secure

each one in a dedicated waste
container.

P

TI7022a

Set function knob to Stop/Park

1

.

Add thin coating of grease lubricant to tank o-ring if lid is difficult

to assemble to tank.

TI7018a

c.

d.

.

Plug in power cord(s). See T
2, page 16.

Open both pump fluid inlet valves
(V, shown in open position).

V

ABLE

TI7019a

20 311075U

Setup

e.

f.

g.

Turn on Motor Power.

Set Recirc/Spray valves to
Recirc.

Set function knob to Slow Recirc

or Fast Recirc .

OR

h.

i.

j.

For heated units, continue with Startup of
Heated Units, page 22.

When clean fluids exit both recir­culation tubes (P), set function

knob to Stop/Park .

Replace recirculation tubes in
supply tanks.

On nonheated units, purge the
hoses through the gun without a

static mixer installed.

Nonheated units are ready to spray/dis­pense. Go to Spraying/Dispensing, page

25.

311075U 21

Startup of Heated Units

Startup of Heated Units

Some models heat the fluid, which can
cause equipment surfaces to become very
hot. To avoid severe burns:

• Do not operate Reactor E-10 without all
covers and shrouds in place.

• 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).

1.

2.

Perform Setup, pages 15-21.

Set function knob to Slow Recirc or

Fast Recirc . See Heatup Guide-
lines, page 23, then continue with steps

3-6.

3.

4.

5.

6.

Turn on Heater Power.

Temporarily set heater control knobs to
maximum setting.

Circulate through heaters until tempera­ture readouts display desired tempera-

ture. See T

Adjust heater control knobs as neces­sary for a stable spray temperature.

ABLE

4 below.

OR

Table 4: Heatup Time Guidelines for starting a cold machine with 5 gal. (19 l) per side (see

Notes below)

Fluid Spray Target

Temperature

125°F (52°C) 20 minutes 25 minutes
150°F (65°C) 40 minutes 50 minutes

Use fast circulation until temperature is within 20°F (11°C) of target,
then use slow circulation to reach final temperature.

Different fluids will absorb heat at different rates. When refilling a warm
machine, heatup times will be less.

22 311075U

35 ft (10.7 m) Hose

(1 bundle)

70 ft (21 m) Hose

(2 bundles)

Startup of Heated Units

Heatup Guidelines

The fluids must be circulated from the
pumps through the heaters, hoses, and
back to the tanks to ensure warm fluids
are supplied to the gun.

Slow Recirculation

• Slow Recirc results in a higher temperature
transfer in the heater, so hoses and gun
heat up quicker.

• Good for touchup or low flow spraying, up
to moderate temperature.

• Not used to circulate full tanks up to tem­perature.

• Use with 245 fa blowing agent foams, to
minimize heat returned to tank and reduce
frothing.

Fast Recirculation

Heat Management Tips

• Heaters perform better with lower flow
rates or smaller mix modules.

• Triggering the gun for short periods helps
maintain efficient heat transfer, keeping
material at the desired temperature. Trig­gering the gun for a long period does not
allow enough heating time, and cold mate­rial will enter the hose.

• If temperature displays fall below accept­able limits, set function knob to Slow Recirc

and circulate again to bring tempera-

tures back up.

• Each 35 ft (10.7 m) hose bundle adds
about 5 minutes to heatup time, with most
materials. Water-based materials take lon­ger to heat up. Maximum recommended
hose length is 105 ft (32 m).

• Fast Recirc keeps heaters on fulltime to
bring fluid tanks up to temperature. The
higher your usage rate, the more heat
needed in the tanks before spraying.

• For normal usage rates: Use Fast

Recirc to get tanks to approximately
50°F (28°C) below desired spray tem­perature, then use Slow Recirc to raise
hose and gun to desired temperature.

• For higher flow rates or continuous

spraying: Use Fast Recirc to bring tem­perature of tanks to approximately 20°F
(11°C) below desired spray tempera­ture, then use Slow Recirc to raise hose
and gun to desired temperature.

• Volume in tanks: Use only what you

need. For example, 2.5 gal. (10 l) in
each tank will heat up almost twice as
fast as 5 gal. (20 l).

• Mixes fluid within tanks, to avoid heating
only the fluid at the top of the tank.

• Use for flushing.

• Use Fast Recirc until tanks are warm to

the touch, then use Slow Recirc until
displays read desired temperature.

• For a quicker start, do initial heatup circula­tion with the tanks 1/4 to 1/3 filled, then add
more material.

311075U 23

Startup of Heated Units

Heating Foam Resins with 245 fa Blowing Agents

New foam blowing agents will froth at tempera­tures above 90°F (33°C) when not under pres­sure, especially if agitated.

Never fill the 7 gal. (26 l) supply tanks beyond
the 5 gal. (19 l) line on the tanks, to leave room
for some frothing.

At High Ambient Temperature (above
75°F/24°C)

• Pour resins slowly to avoid frothing.

• Only use Slow Recirc , to avoid heating
and agitating the tank. If temperature

doesn’t keep up, set function knob to

c. Fill tanks, page 19.

d. Set Recirc/Spray valves to Recirc.

e. Set function knob to Slow Recirc .

f. Turn on Heater Power.

At Cool Ambient Temperature (below
75°F/24°C)

• Use Fast Recirc to heat tanks to
75-90°F. (24-32°C), then use Slow Recirc

Stop/Park , then set to Slow Recirc

again.

• When you stop to refill the tanks, avoid boil­ing off fluid in the heaters by following
these steps:

a. Shut off Heater Power.

b. Leave hoses under pressure.

to raise hose and gun to desired spray

temperature.

• If the top of the resin in tank starts frothing,

do not use Fast Recirc any more.

24 311075U

Spraying/Dispensing

I

Spraying/Dispensing

Use lower pressures for joint filling
applications.

1.

For air operated guns only: Air is sup­plied to spray gun with gun piston safety
lock or trigger safety lock engaged and
gun fluid manifold valves A and B
closed (if present).
If using 2K Manual Dispense Valve, see
dispense valve instruction manual.

ti10442a

Fusion MD2

Set function knob to Stop/Park .

4.

Check fluid pressure gauges to ensure
proper pressure balance. If imbalanced,

reduce pressure of higher component
by slightly turning Recirc/Spray valve
for that component toward Recirc, until
gauges show balanced pressures. The
pressure imbalance alarm (Status Code

1) is inactive for 10 sec after entering
spray pressure mode, to allow time to
balance pressures.

n this example, B side
pressure is higher, so
use the B side valve to
balance pressures.

Watch gauges for 10 sec to be sure
pressure holds on both sides and
pumps are not moving.

2.

3.

311075U 25

Set Recirc/Spray valves to Spray.

Turn function knob to Pressure Adjust

. Keep turning to the right until fluid

pressure gauges show desired pres­sure.

5.

Open gun fluid manifold valves A and B
(impingement mix guns only).

On impingement guns, never open fluid
manifold valves or trigger gun if pres­sures are imbalanced.

Pause (Heated Units)

6.

7.

Disengage piston safety lock or trigger
safety lock.

ti10441a

Fusion MD2

Test spray onto cardboard or plastic
sheet. Verify that material fully cures in

the required length of time, and is the
correct color. Adjust pressure and tem­perature to get desired results. Equip­ment is ready to spray.

3.

4.

Set Recirc/Spray valves to Recirc until
temperature readouts come back up.

If you stop spraying for more than 2 min­utes when using an impingement mix

gun, close gun fluid valves A and B.

Doing this will keep the internal parts of
the gun cleaner and prevent crossover.

Refilling Tanks

Pause (Heated Units)

To bring the hose and gun back to
spray temperature after a brief break,
use the following procedure.

1.

2.

Engage piston safety lock or trigger
safety lock.

ti10442a

Fusion

Set function knob to Slow Recirc .

MD2

Material can be added to the tanks at any time.
See page 19.

If you are operating at high tempera­tures or flow rates, follow instructions
under Pause (Heated Units) to bring
tanks up to temperature.

NOTICE

To prevent cross-contamination of fluids and
equipment parts, never interchange component
A (isocyanate) and component B (resin) parts or
containers.

Have at least two 5 gal. (19 liter) pails to transfer
fluid from drums to supply tanks. Label one pail
“A” and the other “B”, using the red and blue
labels provided. Always doublecheck which
material you have before pouring it in the supply
tanks. Pouring is easier if pails are not filled to
the top.

Open only one supply tank at a time, to avoid
splashing material from one tank into the other
when filling.

26 311075U

Pressure Relief Procedure

Pressure Relief
Procedure

1.

2.

Engage piston safety lock or trigger
safety lock.

Fusion

Set function knob to Stop/Park .

MD2

ti10442a

Shutdown

For longer breaks (more than 10 min­utes), use the following procedure. If
you will be shut down for more than 3
days, first see Flushing, page 29.

1.

2.

Follow all steps of Pressure Relief Pro­cedure, at left.

If using an impingement mix gun, close
gun fluid valves A and B. Doing this will

keep the internal parts of the gun
cleaner and prevent crossover.

3.

Turn Recirc/Spray valves to Recirc.
Fluid will be dumped to supply tanks.

Pumps will move to the bottom of their
stroke. Ensure gauges drop to 0.

3.

4.

5.

Shut off Heater Power (heated units
only).

Shut off Motor Power.

Refer to your separate gun manual and
perform the Shutdown procedure.

311075U 27

Maintenance

Maintenance

• Check pump wet-cups fluid level daily,
page 19.

• Do not overtighten packing nut/wet-cup.
Throat u-cup is not adjustable.

• Keep component A from exposure to mois­ture in atmosphere, to prevent crystalliza­tion.

• Wipe supply tank lid o-ring and inner rim
daily to prevent ISO crystallization. Keep
film of grease on o-ring and inside of lid.

• Check desiccant filter weekly. Filter is blue
when fresh, and turns pink when saturated.

• Remove plug (X) and clean fluid inlet
strainer (51a) as needed. Always clean the
fluid inlet strainers after flushing.

• Generally, flush if you will shutdown for
more than three days. Flush more often if
material is moisture sensitive and humidity
is high in the storage area, or if material
may separate or settle out over time.

• If using an impingement mix gun, close gun
fluid valves A and B when not spraying.
Doing this will keep the internal parts of the
gun cleaner and prevent crossover. Clean
gun mix chamber ports and check valve
screens regularly. See gun manual.

• If using an Fusion Air Purge impingement
mix gun, always grease the gun after use
until purge air carries grease mist out the
front of the gun. Use Part No. 117773
Grease. See gun manual 309550.

51a

X

TI7021a

28 311075U

Flushing

Flushing

Flush equipment only in a well-ventilated
area. Do not spray flammable fluids. Do not
turn on heaters while flushing with flammable
solvents.

• Generally, flush if you will be shut down for
more than 3 days. Flush more often if
material is moisture sensitive and humidity
is high in the storage area, or if material
may separate or settle out over time.

• 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.

2.

3.

4.

Set function knob to Stop/Park .

Shut off Heater Power (heated units
only). Allow system to cool.

Remove recirculation tubes (31) from
supply tanks and place in original con-

tainers or waste containers.

31

• Always leave some type of fluid in system.
Do not use water.

• For long term storage, flush out the solvent
with a storage fluid such as Bayer Mesa­moll plasticizer or, at minimum, clean motor
oil.

1.

Engage piston safety lock or trigger
safety lock. Close fluid valves A and B.

Leave air on.

ti10442a

Fusion

MD2

5.

6.

TI7022a

Turn Recirc/Spray valves to Recirc.

Set function knob to Fast Recirc .
Pump material from supply tanks until

no more comes out.

311075U 29

Flushing

7.

8.

9.

Set function knob to Stop/Park .

Wipe out any remaining material from
the supply tanks. Fill each supply tank

with 1-2 gal. (3.8-7.6 l) of solvent recom­mended by your material manufacturer.

Set function knob to Fast Recirc .
Pump solvent through system to waste

containers.

To flush gun, refer to gun instruction
manual.

Purge Gun Hoses (Nonheated
Units Only)

Disconnect hoses from gun and secure
back into the tanks for thorough clean­ing with solvent.

• Turn Recirc/Spray valve A to Spray.

• Open gun into waste container A.

• Set function knob to Slow Recirc

until hose is flushed.

• Set function knob to Stop/Park

10.

11.

When nearly clear solvent comes from
recirculation tubes, set function knob to

Stop/Park . Return recirculation
tubes to supply tanks.

Set function knob to Fast Recirc .
Circulate solvent through system for

10-20 minutes to ensure thorough
cleaning.

12.

13.

14.

.

• Repeat for B side.

Set function knob to Stop/Park .

Solvent flushing is a two step process.
Go back to step 4, drain solvent, and

flush again with fresh solvent.

Leave unit filled with solvent, plasticizer,
clean motor oil, or refill supply tanks with

new material and reprime.

Never leave the unit dry unless it has
been disassembled and cleaned. If fluid
residue dries in the pumps, the ball
checks may stick the next time you use
the unit.

30 311075U

Troubleshooting

I

Troubleshooting

Status Codes

Determine the status code by counting the
number of times the status indicator (ST)
blinks.

ST

TI7016a

Status Code 1: Pressure Imbalance

The unit does not check for pressure
imbalance at setpoints less than 250 psi
(1.75 MPa, 17.5 bar).

n this example, B side
pressure is higher, so
use the B side valve to
balance pressures.

Turn Recirc/Spray valve only enough to
balance pressure. If turned completely, all
pressure will bleed off.

3. Check fluid inlet strainers (51a, page 28)
and fluid filters at gun.

4. Clean or change restrictor at mixer mani­fold if using disposable mixer gun kit.

Status Code 2: Pressure Deviation
from Setpoint

The unit does not check for pressure
deviation at setpoint less than 400 psi
(2.8 MPa, 28 bar).

The unit does not check for pressure
imbalance for 10 sec after entering pres­sure mode.

Unit senses pressure imbalance between
components A and B, and warns or shuts
down, depending on settings of DIP switches 1
and 2. To turn off automatic shutdown and/or
tighten pressure tolerances for status code 1,
see Status Code 1 and 2 Settings.

1. Check fluid supply of lower pressure com­ponent and refill if necessary.

2. Reduce pressure of higher component by
slightly turning Recirc/Spray valve for that
component toward Recirc, until gauges
show balanced pressures.

Unit senses pressure deviation from setpoint,
and warns or shuts down, depending on set­tings of DIP switches 3 and 4. If equipment
cannot maintain enough pressure for a good
mix with an impingement mix gun, try using a
smaller mix chamber or nozzle.

To turn off automatic shutdown and/or tighten
pressure tolerances for status code 2, see Sta-
tus Code 1 and 2 Settings.

311075U 31

Troubleshooting

ON

Status Code 1 and 2 Settings

OFF

1. Locate switch SW2 on the control board,
page 47.

2. Set the four DIP switches to the desired
positions. See FIG. 7 and T

ABLE

5 on page

F

IG

. 7. DIP Switch (SW2) Settings

32.

Table 5: Status Code 1 and 2 Settings

DIP Switch and Function Left

DIP Switch 1

If selected, causes shutdown or displays a warning if the
pressure imbalance exceeds selection made in DIP
Switch 2

DIP Switch 2

If selected, causes shutdown if A and B pressure imbal­ance is greater than

If selected, causes warning if A and B pressure imbal­ance is greater than

DIP Switch 3

If selected, causes shutdown or displays a warning due to
deviation of pressure from setpoint exceeds selection
made in DIP Switch 4

WARNING SHUTDOWN

500 psi (3.5 MPa, 35
bar)
(60% if < 800 psi [5.6
MPa, 56 bar] running)

300 psi (2.1 MPa, 21
bar)
(50% if < 800 psi [5.6
MPa, 56 bar] running)

WARNING SHUTDOWN

1

2

3

4

TI7023a

1
2
3
4

(Default)

TI7024a

Right (default
setting)

800 psi (5.6 MPa, 56
bar)
(70% if < 800 psi [5.6
MPa, 56 bar] running)

500 psi (3.5 MPa, 35
bar)
(60% if < 800 psi [5.6
MPa, 56 bar] running)

DIP Switch 4

Causes warning if deviation of pressure from setpoint is
greater than

Status Code 3: Transducer A Failure

1. Check transducer A electrical connection
(J3) at board, page 47.

2. Reverse A and B transducer electrical con­nections at board, page 47. If error moves
to transducer B (Status Code 4), replace
transducer A, page 48.

300 psi (2.1 MPa, 21
bar)
(25% if < 800 psi [5.6
MPa, 56 bar])

500 psi (3.5 MPa, 35
bar)
(40% if < 800 psi [5.6
MPa, 56 bar])

Status Code 4: Transducer B Failure

1. Check transducer B electrical connection
(J8) at board, page 47.

2. Reverse A and B transducer electrical con­nections at board, page 47. If error moves
to transducer A (Status Code 3), replace
transducer B, page 48.

32 311075U

Troubleshooting

Status Code 5: Excessive Current
Draw

Shut off unit and contact distributor before
resuming operation.

1. Locked rotor; motor unable to turn. Replace
motor, page 51.

2. Short on control board. Replace board,
page 46.

3. Worn or hung up motor brush causing arc­ing of brush at commutator. Replace
brushes, page 52.

Status Code 6: High Motor
Temperature

Motor is running too hot.

1. Motor temperature too high. Reduce pres­sure duty cycle, gun tip size, or move
Reactor E-10 to a cooler location. Allow 1
hour for cooling.

2. Check fan operation. Clean fan and motor
housing.

Status Code 7: No Cycle Counter
Switch Input

Have not received input from cycle counter
switch for 10 seconds after selecting Recirc
mode.

1. Check cycle counter switch connection to
board (J10, pins 5, 6), page 47.

2. Check that magnet (224) and cycle counter
switch (223) are in place under B side
motor end cover (227). Replace if neces­sary.

311075U 33

Troubleshooting

Troubleshooting Chart

PROBLEM CAUSE SOLUTION

Reactor E-10 does not operate. No power. Plug in power cord.

Cycle Motor Power off ,

then on to reset breaker.

Motor does not operate. Power turned on with function

knob set to a run position.

Loose connection on control
board.

Worn brushes. Check both sides. Replace

Broken or misaligned brush
springs.

Brushes or springs binding in
brush holder.

Shorted armature. Replace motor, page 51.
Check motor commutator for burn

spots, black pitting, or other dam­age.

Failed control board. Replace board. See page 46.

Fan not working. Loose fan cable. Check that cable is connected at

Defective fan. Test and replace if necessary,

Pump output low. Plugged fluid inlet strainer. Clear, see page 28.

Plugged disposable mixer. Clean or replace.
Leaking or plugged piston valve

or intake valve in displacement
pump.

One side doesn’t come up to
pressure in spray mode.

Dirty or damaged Recirc/Spray
valve.

Plugged fluid inlet strainer. Clear, see page 28.
Pump intake valve plugged or

stuck open.
Material is too viscous to pump

with unheated unit.

Set function knob to Stop/Park

, then select desired func-

tion.
Check connection at J11 (120 V)

or J4 (240 V). See page 46.

brushes worn to less than 1/2 in.
(13 mm), see page 52.

Realign or replace, page 52.

Clean brush holder and align
brush leads for free movement.

Remove motor. Have motor shop
resurface commutator, or replace
motor, page 51.

fan and at J9 on control board.
See pages 52 and 46.

page 52.

Check valves. See pump manual.

Clean or repair, page 40.

Clean pump intake valve. See
page 41.

Warm material before adding to
tanks.

34 311075U

PROBLEM CAUSE SOLUTION

Troubleshooting

Pressure is higher on one side
when setting pressure with func-

Pump intake valve partially
plugged.

tion knob.

Air in hose. Fluid is compressible. Purge air from hose.
Unequal size hoses or unequal

hose construction.

Pressures are not balanced when

Unequal viscosities. Change temperature setting to
running, but pressure is gener­ated and holds on both strokes.

Restriction on one side. Clean mix module or restrictor at

Fluid leak in pump packing nut

Worn throat seals. Replace. See pump manual.
area.

Pressure doesn’t hold when

Leaking Recirc/Spray valve. Repair, page 40.
stalled against gun in spray
mode.

Leaking piston valve or intake

valve in displacement pump.

Leaking gun shutoff. Repair. See gun manual.
Pressure is higher on B side

during startup of recirculation,
especially in High Recirc mode.

This is normal. Component B is

typically higher viscosity than

component A until the material is

heated during recirculation.
Resin froths and overflows tank

after refilling hot equipment.

Agitation from pouring. Hot mate-

rial in heaters and hoses froths

when not under pressure.
One gauge shows half as many

Loss of pressure on downstoke. Intake valve is leaking or not clos­pulses as the other when pumps
are cycling.

Loss of pressure on upstoke. Piston valve is leaking or not clos-

Status indicator (red LED) not lit. Motor Power switch off.

Clean pump intake valve. See
page 41.

Use matching hoses, or balance
pressures before spraying.

balance viscosities.

Change restrictor at mix point to
balance back pressure.

mix manifold.
Clean gun check valve screens.

Repair. See pump manual.

No action required.

Turn heaters off before refilling.
Leave hoses pressurized. See
page 24.

ing. Clean or replace valve; see
page 41.

ing. Clean or replace valve or
packings; see page 41.

Cycle Motor Power off ,

then on to reset breaker.

Loose indicator cable. Check that cable is connected at

J10 pins 1 (red) and 2 (black) on
control board. See page 46.

Failed control board. Replace board. See page 46.

311075U 35

Troubleshooting

PROBLEM CAUSE SOLUTION

A side rich; lack of B side. A side gauge is low. B side restriction downstream of

gauge. Check gun check valve
screen, mix module, or mix mani­fold restrictor.

B side gauge is low. B side material supply problem.

Check B side inlet strainer and
pump intake valve.

B side rich; lack of A side. A side gauge is low. A side material supply problem.

Check A side inlet strainer and
pump intake valve.

B side gauge is low. A side restriction downstream of

gauge. Check gun check valve
screen, mix module, or mix mani­fold restrictor.

No temperature display (heated
units only).

Loose display cables on control
board.

Failed control board (displays get
power from control board).

Check cable connections to each
display, page 46.

Remove access panel. Check if
board LED is lighted. If not,
replace board, page 46.

Inadequate power to control
board.

Check that power supply meets
requirements.

Loose power cable. Check cable connections, page

46.

Motor Power switch circuit
breaker tripped.

Display is powered from Motor
Power circuit breaker. Cycle

Motor Power off , then on

to reset breaker.

Wrong temperature displayed. °F/°C switch in wrong position. Set switch, see page 43.
Temperature displays do not

match at ambient temperature.

Displays need calibration. Turn calibration screw on back of

displays to correct reading, see
page 43.

36 311075U

PROBLEM CAUSE SOLUTION

Troubleshooting

No heat, and heater indicator light
is off.

No heat, but heater indicator light
is on.

Heater on one side shuts off early
or continuously during recircula­tion.

Heater Power shut off, or circuit

breaker tripped.

Cycle Heater Power off ,

then on to reset circuit

breaker.

Bad thermostat. With power on, check for continu-

ity at clicks of heater control knob.
To replace thermostat, see

311210.

Bad overtemperature sensor (this

is a high temperature limit fuse

and must be replaced if blown).

With power on, check for continu­ity at overtemperature sensor. To
replace sensor, see 311210.

Loose heater cable connections. Check connections at Heater

Power switch. See F

IG

. 12, page

47.

Bad heater cartridge. Check for continuity at heater car-

tridge connections: 16-18.6 ohms
for 120 V, 64-75 ohms for 240 V.

Y-strainer is plugged on that side. Clean or replace strainer, page

28.

Fluid inlet valve (52) closed. Open valve.

311075U 37

Troubleshooting

38 311075U

Repair

Before Beginning Repair Removing Supply Tanks

Displacement pump repair and parts
information is included in manual
311076, which is supplied with your
unit.

Repairing this equipment requires access to
parts which may cause electric shock or
other serious injury if work is not performed
properly. Have a qualified electrician connect
power and ground to main power switch ter­minals, see page 15. Be sure to shut off all
power to the equipment before repairing.

1. Flush if possible, see page 29. If not possi­ble, clean all parts with solvent immediately
after removal, to prevent isocyanate from
crystallizing due to moisture in the atmo­sphere.

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

2. Close both fluid inlet ball valves (52).

Repair

52

2. Set function knob to Stop/Park .

3. Shut off Motor Power. Disconnect power
supply.

4. Shut off Heater Power. Allow equipment to
cool before repairing.

5. Relieve pressure, page 27.

50

51

TI7020a

Use dropcloth or rags to protect Reactor
E-10 and surrounding area from spills.

3. Open filter drain plug on Y-strainer (51).

4. Disconnect swivel elbow (50) at pump fluid
inlet.

5. Remove screws (4) holding tank to cart
frame.

6. Pivot top of tank to side and lift it and fluid
inlet fittings off cart.

311075U 39

Repair

Recirc/Spray Valves

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

Heated Models Nonheated Models

505

504

503

506

503a
503b

2

1

3

3

2. See FIG. 8. Disassemble Recirc/Spray
valves. Clean and inspect all parts for dam­age. Ensure that the seat (503a) and gas­ket (503b) are positioned inside each valve
cartridge (503).

3. Apply PTFE pipe sealant to all tapered pipe
threads before reassembling.

4. Reassemble in reverse order, following all
notes in FIG. 8.

505

504

503

506

503a
503b

2

1

3

3

508

509510

FIG. 8. Recirc/Spray Valves

507

501

502

507

TI6977a TI6982a

1

Torque to 250 in-lb (28 N•m).

2

Use blue threadlocker on valve cartridge threads into manifold.

3

Part of item 503.

510

511

501

502

508

509

40 311075U

Repair

Displacement Pump

Displacement pump repair and parts
information is included in manual
311076, which is supplied with your
unit.

Use dropcloth or rags to protect
Reactor E-10 and surrounding area
from spills.

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

2. Close both fluid inlet ball valves (52). Open
filter drain plug on Y-strainer (51).

To Remove Intake Valve Only

If pump is not generating any pressure,
the intake ball check may be stuck closed
with dried material.

If the pump is not generating pressure on
the downstroke, intake ball check may be
stuck open.

Either of these conditions can be serviced
with the pump in place.

3. Disconnect fluid inlet (C) and swing it aside.

4. Remove intake valve by hitting ears (E)
firmly right-to-left with a non-sparking ham­mer. Unscrew from pump. See manual
311076 for repair and parts.

51

52

TI7020a

311075U 41

Repair

To Remove Entire Pump Assembly

5. Disconnect fluid inlet (C) and outlet (D)
lines. Also disconnect steel outlet tube (16)
from heater inlet.

6. Remove pump rod cover (222). Push clip
up in back and push pin (217) out. Loosen
locknut (218) by hitting firmly right-to-left
with a non-sparking hammer. Unscrew
pump. See manual 311076 for pump repair
and parts.

7. Install pump in reverse order of disassem­bly, following all notes in FIG. 9. Clean
strainer (51). Reconnect fluid inlet (C) and
outlet (D) lines.

217

2

16

222

D

E

C

2

8. Tighten fluid outlet fitting (D), then tighten
locknut (218) by hitting firmly with a
non-sparking hammer.

9. Open fluid inlet valve (52). Set function

knob to Slow Recirc . Purge air and
prime. See page 20.

51

1

Flat side faces up. Tighten by hitting
firmly with non-sparking hammer.

2

Lubricate threads with ISO oil or grease.

FIG. 9. Displacement Pump

218

1

2

TI7025a

42 311075U

Repair

Control Module

Change Display Temperature Units
(°F/°C)

Unit is shipped with temperature displays set
to °F.

1. Shut off Motor Power. Disconnect power
supply.

2. Remove access cover (39) from back of
control module.

Replace Temperature Display and
Sensor (Heated Units Only)

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

2. Remove temperature sensor (424):

a. Remove snap ring (66d) in thermowell

housing (66e). See FIG. 10.

b. Pull sensor (424) and spacer (66g) out

of thermowell housing.

c. Work sensor and wire out of cable

channel between tanks. It may be eas­ier to remove one tank. See page 39.

3. See FIG. 11. Locate slide switch (FC) at
right edge of each temperature display
board. Unit is shipped set to °F (down). To
change to °C, move both switches to up
position.

Calibrate Temperature Displays

1. Remove access cover (39) from back of
control module.

IG

2. See F
at upper right corner of each temperature
display board. Turn screw slightly to correct
temperature display.

Temperature displays do not read lower
than 50°F (10°C).

. 11. Locate calibration screw (CS)

3. Remove access cover (39) from back of
control module.

4. Disconnect temperature display power
cable from J14 or J15 at bottom left of con­trol board (406).

5. Remove four screws from rear panel studs
and remove temperature display (403) from
front plate (401).

6. Remove screw and nut (409) holding dis­play to plate (403).

7. Pull sensor cable through split in bushing
(411).

311075U 43

Repair

8. Reassemble in reverse order. Mount tem­perature display so Heater Power switch off
(0) position is at left when facing control
panel.

66e

424

66g

66d

TI7067b

FIG. 10. Temperature Sensor

(P) faces up. Install knob on shaft so slot
(S) engages alignment pin in knob. Push
knob onto shaft against detent spring
before tightening setscrews (416a).

7. Reconnect potentiometer wires to J2 as
shown in FIG. 12.

Replace Function
Knob/Potentiometer

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

2. Remove access cover (39) from back of
control module.

3. Disconnect potentiometer wires from J2 on
control board (406). See FIG. 12.

4. See FIG. 11. Remove two setscrews (416a)
and pull function knob (416) off potentiome­ter (404) shaft.

5. Remove nut (N, part of 404) and detent
plate (415).

6. Install new potentiometer (404) in reverse
order. Position potentiometer so slot (S) is
horizontal. Position knob (416) so pointer

44 311075U

Detail of Function Knob/Potentiometer

415

N

P

404

Repair

TI7076a

409

*424

*403

416a

FC

CS

416

*402

416a

421

424*

CS

FC

S

405

401

410

402

404

408

407

412

411

410*

413

* These items are not included on the nonheated display.

416a

416

416a

N
415

417

406

TI6979a

FIG. 11. Control Module (Heated Model Shown)

311075U 45

Repair

Control Board

Power Bootup Check

There is one red LED (D11) on the
board. Power must be on to check. See
FIG. 12 for location. Function is:

• Startup: 1 blink for 60 Hz, 2 blinks for
50 Hz.

• Motor running: LED on.

• Motor not running: LED off.

• Status code (motor not running):
LED blinks status code.

Control Board Replacement

Table 6: Control Board Connectors

(see FIG. 12)

Board

Jack Pin Description

J1 n/a Main power from breaker
J2 n/a Function knob
J3 n/a Transducer A
J4 n/a Motor power (230 V units)
J7 1, 2 Motor thermal overload signal
J8 n/a Transducer B
J9 n/a Fan

J10 1, 2 Status indicator

3, 4 Not used
5, 6 Cycle switch signal

7-8 Jumpered

9-10 Jumpered
J11 n/a Motor power (120 V)
J14 n/a B temperature display
J15 n/a A temperature display

Check motor before replacing board.
See Electric Motor, page 51.

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

2. Remove access cover (39) at back of con­trol module to expose control board (406).

3. Disconnect all cables and connectors from
board. Remove two jumper wires (413)
from J10 pins 7-8 and 9-10.

4. Remove screws (408) and remove board
from control module.

5. Install new board in reverse order.

Apply thermal compound between the
square steel piece on the back of the
board and the main aluminum plate.
Order Part No. 110009 Thermal Com­pound.

46 311075U

Repair

Motor

Cycle

Counter

Black Twin Flat Cable

Fa

Status

Indicator

Black Sheath

Red

Black

LINE

P1

Yellow

Yellow

Red

Black

Jumper

Jumper

Heated Models

P1

P2

Motor Power

On/Off

(20 A

Breaker)

Single Cord Models Only

LINE

Heater Power
On/Off
(20 A
Breaker)

P2

Heater

A

Heater

J1

J9

B

J11 (120 V

J4

J11

Board)

J7

BOARD

CONTROL

not used

1
2

3
4
5

J10

6
7
8
9
10

J15J14

1
2
3
4

D11

ONOFF

SW2 (see page
32 to adjust

not used

Black

White

Red

J3J8

Function

Knob

J2

Black Sheath

2 pin red connectors2 pin red connectors

Gray SheathGray Sheath

Pressure Transducer A

Calibration

Screw

°C

Temperature

Display B

°F

Temperature
Sensor B

Calibration

Screw

°C

Temperature

Display A

Gray Sheath

°F

Temperature
Sensor A

Black Phone Cable and Plug

Pressure Transducer B

Heated Models

FIG. 12. Control Module Wiring Connections

311075U 47

Repair

Fluid Heaters (if supplied) Pressure Transducers

Fluid heater repair and parts
information is included in manual
311210, which is supplied with heated
units.

1. See Before Beginning Repair, page 39.

To replace a pressure transducer, see
at right.

Relieve pressure, page 27.

2. Remove access cover (39) at back of con­trol module to expose control board (406).

3. Disconnect transducer cables from J3 and

IG

J8 at board; see F

. 12, page 47. Reverse
A and B connections and check if status
code follows the bad transducer, page 32.

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

2. Control section of heater can be repaired in
place. Remove heater to clean fluid section.
See manual 311210 for heater repair and
parts.

6058

4. Reconnect good transducer to proper con­nector. Disconnect failed transducer from
board, and unscrew from base of fluid
heater (heated units) or transducer mani­fold (nonheated units).

5. Install o-ring (60) on new transducer (58),
F

IG

. 13.

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

7. Route cable through channel to control
module.

8. Connect transducer cable at board; see
FIG. 12, page 47.

6058

TI7026a

Heated Units

Nonheated Units

TI7027a

FIG. 13. Transducers

48 311075U

Repair

Drive Housing

Removal

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

2. Remove screws (207) and end covers
(221, 227), FIG. 14.

Examine connecting rod (216). If rod
needs replacing, first remove the pump
(219), page 41.

NOTICE

Do not drop gear reducer (214) and crank­shaft (210) when removing drive housing
(215). These parts may stay engaged in
motor end bell (MB) or may pull away with
drive housing.

3. Disconnect pump inlet and outlet lines.
Remove screws (220) and pull drive hous­ing (215) off motor (201) Connecting rod
(216) will disengage from crankshaft (210).

B side crankshaft (210) includes the
cycle counter magnet (224). When
reassembling, be sure to install crank­shaft with magnet on B side.

If replacing crankshaft, remove magnet
(224). Reinstall magnet in center of off­set shaft on new crankshaft. Position
shaft in Park position.

2. Install bronze bearings (211, 213) in drive
housing (215), as shown.

3. Install bronze bearings (209, 211) and steel
washer (208) on crankshaft (210). Install
bronze bearing (213) and steel washer
(212) on gear reducer (214).

4. Install gear reducer (214) and crankshaft
(210) into motor end bell (MB).

Crankshaft (210) must be in line with
crankshaft at other end of motor. Pumps
will move up and down together.

If connecting rod (216) or pump (219)
were removed, reassemble rod in hous­ing and install pump, page 41.

5. Push drive housing (215) onto motor (201).
Install screws (220).

4. Examine crankshaft (210), gear reducer
(214), thrust washers (208, 212), and bear­ings (209, 211, 213).

6. Install drive housing covers (221 on A side,
227 on B side) and screws (207). Pumps
must be in phase (both at same position in
stroke).

Installation

1. Apply grease liberally to washers (208,

212), bearings (209, 211, 213), gear
reducer (214), crankshaft (210), and inside
drive housing (215). Grease is supplied
with replacement parts kits.

311075U 49

Repair

Cycle Counter Switch Replacement

B side drive housing cover (227) includes the cycle counter
switch (223), mounted in the cover. When reassembling, be
sure to install cover with switch on B side.

223

0.6 in. (15.2 mm)
from inside edge

1.0 in. (25.4 mm)
from inside bottom
edge

TI7028a

206

207

221

201

212

(steel)

1

Crankshaft must be in line with crankshaft at other end of motor,
so pumps move up and down in unison.

213

(bronze)

MB

208
(steel)

214

209
(bronze)

210

224

213
(bronze)

211
(bronze)

1

216

215

220

227

207

219

TI7029a

FIG. 14. Drive Housing

50 311075U

Electric Motor

Repair

Test Motor

If motor is not locked up by pumps, it can be
tested using a 9 V battery. Open recirculating
valves, disconnect J4 or J11 from control
board, see FIG. 12, page 47. Touch jumpers
from battery to motor connections. Motor
should turn slowly and smoothly.

Removal

If replacing a component with electrical
cabling, remove one supply tank, page

39.

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

e. Thread motor power switch harness out

bottom of control module and cable
channel, to free motor.

NOTICE

Motor is heavy. Two people may be required
to lift.

5. Remove screws holding motor to bracket.
Lift motor off unit.

Installation

1. If replacing motor, install fan assembly and
fan mount threaded bushing on new motor.

2. Place motor and fan on unit. Thread motor
switch harness into control module.

3. Fasten motor with screws underneath. Do
not tighten yet.

2. Remove four screws (207) and shroud
(206). See FIG. 14.

3. Remove drive housing/pump assemblies,
page 49.

4. Disconnect motor cables as follows:

a. Find control board at back of control

IG

module, see F

b. Unplug motor power connector from J4

(240 V units) or J11 (120 V units).

c. Unplug motor temp switch harness from

connector J7.

d. Unplug cable (37) from fan (202). See

F

IG

. 15.

. 12, page 47.

4. Plug 3-pin connector J7 to board.

5. Plug Motor Power switch harness to con­nector J4 (240 V units) or J11 (120 V units).

6. Install drive housing/pump assemblies,
page 49. Reconnect inlet assemblies to
pumps.

7. Tighten motor mounting screws.

8. Return to service.

311075U 51

Repair

Motor Brushes

Replace brushes worn to less than 1/2
in. (13 mm). Brushes wear differently
on each side of motor; check both
sides. Brush Repair Kit 287735 is
available; kit includes instruction sheet

406582.

Motor commutator should be smooth.
If not, resurface commutator or
replace motor.

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

2. See instruction sheet 406582, included
with Brush Repair Kit 287735. Remove old
brushes and install new ones supplied in
kit.

202

37

TI7030a

FIG. 15. Fan

Fan

1. Disconnect fan cable (37) from fan (202).
With Motor Power on, test cable connector
for line voltage (120 V or 240 V).

2. If voltage is correct, fan is defective.
Remove screws holding fan to shield (206).
Install new fan in reverse order.

3. If voltage is not correct, check fan cable
connection at J9 on control board; see F
12, page 47.

IG

.

52 311075U

Repair

311075U 53

Parts

Parts

Part No. AP9570 or CS9570, 120 V, 15 A, Heated Package
Part No. AP9571 or CS9571, 240 V, 10 A, Heated Package
Part No. AP9572 or CS9572, 240 V, 20 A, Heated Package

61

61

101

103

WLD

102

Proportioner Description 101 102 103

AP9570 120 V, 15 A, Heated

Package

CS9570 CS22WD

AP9571 240 V, 10 A, Heated

Package

CS9571 CS22WD

AP9572 240 V, 20 A, Heated

Package

CS9572 CS22WD

249570

see page 56

249571

see page 56

249572

see page 56

249499

see page 63

249499

see page 63

249499

see page 63

249810

see 309550

see 312666

249810

see 309550

see 312666

249810

see 309550

see 312666

54 311075U

Part No. 249806, 120 V, 15 A, Nonheated Package, MD2
Part No. 249808, 240 V, 10 A, Nonheated Package, MD2
Part No. 24R984, 120 V, 15 A, Nonheated Package, 2K Dispense
Part No. 24R985, 240 V, 10 A, Nonheated Package, 2K Dispense

61

255325

103

24R021

103

Parts

61

101

Ref. Part Description

101 249576 PROPORTIONER, nonheated, 120 V, 15 A;

see page 60; 249806 only

249577

PROPORTIONER, heated, 240 V, 10 A;
see page 60; 249808 only

102

249633 HOSE BUNDLE, non-insulated; see

page 63

24R823

103 255325

HOSE BUNDLE; see page 63
GUN, MD2 Cold Spray; see 312185 and

3A2910

24R021 VALVE, dispense, 2K 11

102

249633

WLD

102

24R823

Quantity

249806 249808 24R984 24R985

1 1

1 1

11

11

11

311075U 55

Parts

Part No. 249570, 120 V, 15 A, Heated Proportioner
Part No. 249571, 240 V, 10 A, Heated Proportioner

Part No. 249572, 240 V, 20 A, Heated Proportioner

57

56

55

41

30

31

26

34

31

41

39

41

40▲

5

66c

12

8

11

2

32

2a

66

66b

66h

41

33

66f

1 (Ref)

58

60

18

6

11

17

16

47

38

4

1 (Ref)

46

49

44

1

36

35

45

7

8

2

2a

1 (Ref)

15

14

62

53*

28

27

63

64

56 311075U

65

29

13

51*

50*

50*

54*

52*

Heated Proportioners

Ref. Part Description Qty

1 24R382 CART; see page 67 1
2 24L000 TANK, with lid and outlet fitting;

LDPE; includes item 2a
2a 15F895 . O-RING, lid, tank 1
4 111800 SCREW, cap, hex hd; 5/16-18 x

5/8 in. (16 mm)
5 24K984 DRYER, desiccant 1
6 24K976 MUFFLER, vent 1
7 101044 WASHER, plain; 1/2 in. (13 mm) 1
8 119973 LANYARD; 14 in. (356 mm); sst 2
11 119993 PLUG 2
12 287655 PROPORTIONER, bare, 120 V;

Model 249570; see page 62

287656 PROPORTIONER, bare, 240 V;

Models 249571 and 249572;

see page 62
13 117493 SCREW, machine, hex washer

hd; 1/4-20 x 1-1/2 in. (38 mm)
14 116393 ADAPTER; 1/4 npt (m x f) 2
15 556765 ELBOW; 1/4 npt(m) x 3/8 JIC 2
16 24K998 TUBE, fluid 2
17 24L007 HEATER, fluid, 120 V; Model

249570; includes items 58 and

60; see 311210

24L008 HEATER, fluid, 240 V; Models

249571 and 249572; includes

items 58 and 60; see 311210
18 167002 INSULATOR, heat 4
26 116704 ADAPTER, B side;

3/8 JIC x 1/4 npt(m)
27 104641 BULKHEAD FITTING 1
28 169970 FITTING, air line; 1/4 npt(m) 1
29 162453 NIPPLE; 1/4 npt x 1/4 npsm 1
30 24L009 MANIFOLD, recirculation, with

valves; see page 66
31 15V421 TUBE, recirculation; 3/8 (10

mm) OD; sst
32 249629 HOSE, component A (ISO); 1/4

in. (6 mm) ID; thermoplastic

hose with moisture guard; 1/4

npsm(f) x 48 in. (1219 mm)
33 249630 HOSE, component B (RES); 1/4

in. (6 mm) ID; thermoplastic

hose; 1/4 npsm(f) x 48 in. (1219

mm)
34 24L004 DISPLAY, heated, 120 V; Model

249570; see page 64

24L005 DISPLAY, heated, 240 V;

Models 249571 and 249572;

see page 64
35 117623 NUT, cap; 3/8-16 4

12

Ref. Part Description Qty

36 24K995 CORD, 120 V; Model 249570 2

2

24K997 CORD, 240 V; Model 249571 2

24K996 CORD, 240 V; Model 249572 1
37 15G458 CABLE, fan; see page 62 1
38 CONDUIT, flexible; non-metallic 1
39 15G385 COVER, access, display 1
40▲ 15G280 LABEL, warning 1
41 108296 SCREW, machine, hex washer

hd; 1/4-20 x 5/8 in. (16 mm)

43 217374 LUBRICANT, ISO pump; not

shown

44 BOLT; 10-24 x 1 in. (25 mm) 2

1

45 15G119 GUARD, splash 1
46 15G461 RACK, hose 1

1

47 PLUG 4
48 109510 STRAP, bungee; 25 in. (635

4

mm)
49 WASHER, flat; 1/4 in.; nylon 4
50* 160327 ELBOW, swivel; 3/4 npt(m) x

3/4 npsm(f)
51* 101078 Y-STRAINER; includes item

2

51a
51a 180199 . ELEMENT, 20 mesh; not

shown

52* 119882 VALVE, ball; 3/4 npt (fbe),

2

t-handle
53* C20487 NIPPLE; 3/4 npt 2
54* 157785 UNION, swivel; 3/4 npt(m) x 3/4

2

npsm(f)
55 242001 ADAPTER, cord; Europe; Model

249571 only
56 242005 ADAPTER, cord; Australia;

Model 249571 only
57 195551 RETAINER, plug, adapter;

1

Model 249571 only
58 24K999 TRANSDUCER, pressure;

2

included with item 17
60 111457 O-RING; ptfe; included with item 172

1

61 15G476 LABEL, components A and B;

see page 54
62 119992 NIPPLE, pump inlet; 3/4 npt 2

1

63 157350 NIPPLE; 1/4 npt x 3/8 npt 1
64 24K977 AIR FILTER/SEPARATOR, with

3/8 npt auto drain; includes item

1

64a 114228 . ELEMENT, 5 micron; polypro-

1

65 100176 BUSHING; 3/8 npt(m) x

2a

pylene; not shown

1/4 npt(f)

Parts

10

1

2

2

2

1

2

2

2

2

2

2

2

1

1

1

311075U 57

Parts

Ref. Part Description Qty

66 24E555 KIT, temperature sensor 2
66a 121063 O-RING, fluroroelastomer 1
66b‡ 123787 FITTING, elbow, 45°; 3/8 jic x

1/4-18 npt

66c‡ 123788 FITTING, elbow, 45°; 5/16 jic x

1/4-18 npt
66d 555561 RING, retaining, 3/8 1
66e 16C785 HOUSING, thermowell 1
66f 16C786 MANIFOLD, fluid 1
66g 16C787 SPACER, sensor 1
66h 113641 GAUGE, pressure, fluid; sst 1

*

Included in 287718 Pump Inlet Kit (one side).

‡ 24E555 Kit includes “A” and “B” side adapters.

Install required fittings as needed.

▲ Replacement Danger and Warning labels, tags,

and cards are available at no cost.

1

1

58 311075U

Parts

311075U 59

Parts

Part No. 249576, 120 V, Nonheated Proportioner
Part No. 249577, 240 V, Nonheated Proportioner

57

56

55

30

26

31

32

8

5

11

2a

2

33

30 (Ref)

11

16

34

31

38

47

36

45

35

7

8

6

2

2a

1 (Ref)

4

41

39

41

40▲

1 (Ref)

46

49

44

1

60

58

15

59

23

12

29

62

53*

28

27

63

64

65

60 311075U

13

29

51*

50*

50*

54*

52*

Nonheated Proportioners

Ref. Part Description Qty

1 24R382 CART; see page 67 1
2 24L000 TANK, with lid and outlet fitting;

LDPE; includes item 2a
2a 15F895 . O-RING, lid, tank 1
4 111800 SCREW, cap, hex hd; 5/16-18 x

5/8 in. (16 mm)
5 24K984 DRYER, desiccant 1
6 24K976 MUFFLER, vent 1
7 101044 WASHER, plain; 1/2 in. (13 mm) 1
8 119973 LANYARD; 14 in. (356 mm); sst 2
11 119993 PLUG 2
12 287655 PROPORTIONER, bare, 120 V;

Model 249576; see page 62

287656 PROPORTIONER, bare, 240 V;

Model 249577; see page 62
13 117493 SCREW, machine, hex washer

hd; 1/4-20 x 1-1/2 in. (38 mm)
15 116702 UNION; 1/4 npt(m) x 3/8 JIC 2
16 15V420 TUBE, fluid 2
23 126960 ELBOW, swivel; 1/4 npt(m) x

1/4 npsm(f)
25 119998 ADAPTER, A side;

1/2 JIC x 1/4 npt(m)
26 116704 ADAPTER, B side;

3/8 JIC x 1/4 npt(m)
27 104641 BULKHEAD FITTING 1
28 169970 FITTING, air line; 1/4 npt(m) 1
29 C20479 NIPPLE; 1/4 npt x 1/4 npsm 3
30 287755 MANIFOLD, recirculation, with

valves; see page 66
31 15V421 TUBE, recirculation; 3/8 (10

mm) OD; sst
32 249629 HOSE, component A (ISO); 1/4

in. (6 mm) ID; thermoplastic

hose with moisture guard; 1/4

npsm(f) x 48 in. (1219 mm)
33 249630 HOSE, component B (RES); 1/4

in. (6 mm) ID; thermoplastic

hose; 1/4 npsm(f) x 48 in. (1219

mm)
34 249537 DISPLAY, nonheated, 120 V;

Model 249576; see page 65

249538 DISPLAY, nonheated, 240 V;

Model 249577; see page 65
35 117623 NUT, cap; 3/8-16 4

36

24K995 CORD, 120 V; Model 249576 1

24K997 CORD, 240 V; Model 249577 1
37 15G458 CABLE, fan; see page 62 1
38 CONDUIT, flexible; non-metallic 1
39 15G385 COVER, access, display 1
40▲ 15G280 LABEL, warning 1

12

Ref. Part Description Qty

41 108296 SCREW, machine, hex washer

2

hd; 1/4-20 x 5/8 in. (16 mm)

43 217374 LUBRICANT, ISO pump; not

shown
44 BOLT; 10-24 x 1 in. (25 mm) 2
45 15G119 GUARD, splash 1
46 15G461 RACK, hose 1
47 PLUG 4
48 109510 STRAP, bungee; 25 in. (635

mm)
49 WASHER, flat; 1/4 in.; nylon 4
50* 160327 ELBOW, swivel; 3/4 npt(m) x

1

3/4 npsm(f)
51* 101078 Y-STRAINER; includes item

1

51a
51a 180199 . ELEMENT, 20 mesh; not

4

shown

52* 119882 VALVE, ball; 3/4 npt (fbe),

t-handle

2

53* C20487 NIPPLE; 3/4 npt 2
54* 157785 UNION, swivel; 3/4 npt(m) x 3/4

1

npsm(f)
55 242001 ADAPTER, cord; Europe; Model

3

249577 only
56 242005 ADAPTER, cord; Australia;

Model 249577 only
57 195551 RETAINER, plug, adapter;

Model 249577 only

1

58 24K999 TRANSDUCER, pressure 2
59 15G292 MANIFOLD, pressure trans-

2

ducer
60 111457 O-RING; ptfe 2

1

61 15G476 LABEL, components A and B;

see page 55
62 119992 NIPPLE; 3/4 npt 2
63 157350 NIPPLE; 1/4 npt x 3/8 npt 1
64 24K977 AIR FILTER/SEPARATOR, with

1

3/8 npt auto drain; includes item

2a
64a 114228 . ELEMENT, 5 micron; polypro-

1

pylene; not shown

65 100176 BUSHING; 3/8 npt(m) x 1/4

1

* Included in 287718 Pump Inlet Kit (one side).

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

npt(f)

Parts

6

1

2

2

2

1

2

2

1

1

1

2

2

1

1

1

311075U 61

Parts

Part No. 287655, 120 V Bare Proportioner
Part No. 287656, 240 V Bare Proportioner

207

206

207

201 (Ref)

203

205

‡221

210*209*208*

†212

201

†213

†214

◆216

†213

218

219

Ref. Part Description Qty

201 24E355 MOTOR, electric; 120 V 1

24E356 MOTOR, electric; 240 V

202 24K985 FAN, cooling; 120 V 1

24K986 FAN, cooling; 240 V 1
203 115836 GUARD, finger 1
204 RIVET, blind; 5/32 x 3/8 grip 1
205 SCREW, machine, slotted hd;

8-32 x 2 in. (51 mm)
206 24L003 SHIELD, proportioner 1
207‡ 115492 SCREW, machine, hex washer

12

hd; 8-32 x 3/8 in. (10 mm)
208* 116074 WASHER, thrust; steel 2
209* 107434 BEARING, thrust; bronze 2
210* 248231 CRANKSHAFT KIT 2
211* 180131 BEARING, thrust; bronze 2
212† 116073 WASHER, thrust; steel 2
213† 116079 BEARING, thrust; bronze 4
214† 287057 GEAR REDUCER KIT 2
215‡ 287055 DRIVE HOUSING KIT 2
216◆ 287053 CONNECTING ROD KIT 2
217◆ 196762 PIN, straight 2
218 195150 NUT, jam, pump 2

204
202

224

211*

215‡

220‡

217◆

223

227

220‡

207‡

37

207‡

222‡

Ref. Part Description Qty

219 24L006 PUMP, displacement; see

311076

220‡ 117493 SCREW, machine, hex washer

hd; 1/4-20 x 1-1/2 in. (38 mm)
221‡ 15B254 COVER, drive housing, A side 1
222‡ 15B589 COVER, pump rod 2
223 117770 SWITCH, reed, w/cable 1

3

224 24K982 MAGNET 1
227 249854 COVER, drive housing, B side;

includes item 223 and 228
228 115711 TAPE, mounting, reed switch;

not shown

* Included in 248231 Crankshaft Kit.

† Included in 287057 Gear Reducer Kit.

‡ Included in 287055 Drive Housing Kit.

◆ Included in 287053 Connecting Rod Kit.

TI6978a

2

8

1

1

62 311075U

Part No. 249499, Insulated Hose Bundle with recirculation lines

Parts

301

302 (Ref)

302

303 (Ref)

305 303

Ref. Part Description Qty

Ref. Part Description Qty

301 249508 HOSE, fluid (component A), mois-

ture guard; 1/4 in. (6 mm) ID; no. 5
JIC fittings (mxf); 35 ft (10.7 m)

302 249509 HOSE, fluid (component B); 1/4 in.

303 15G342 HOSE, air; 1/4 in. (6 mm) ID; 1/4

2

304 buy

locally

305 156971 NIPPLE; 1/4 npt; for joining air line

2
(6 mm) ID; no. 6 JIC fittings (mxf);
35 ft (10.7 m)

Part No. 249633, Non-insulated Hose Bundle without recirculation lines

301

304

npsm (fbe); 35 ft (10.7 m)
TUBE, foam, insulated; 1-3/8 in.

(35 mm) ID; 31 ft (9.5 m)

to another hose bundle

302 (Ref)

TI6991a

1

1

1

302
305

303

TI6992a

Ref. Part Description Qty

Ref. Part Description Qty

301 249508 HOSE, fluid (component A), mois-

ture guard; 1/4 in. (6 mm) ID; no. 5
JIC fittings (mxf); 35 ft (10.7 m)

302 249509 HOSE, fluid (component B); 1/4 in.

303 15G342 HOSE, air; 1/4 in. (6 mm) ID; 1/4

1

npsm (fbe); 35 ft (10.7 m)

305 156971 NIPPLE; 1/4 npt; for joining air line

to another hose bundle

1
(6 mm) ID; no. 6 JIC fittings (mxf);
35 ft (10.7 m)

Part No. 24R823, 1/4 in. (6 mm) ID x 35 ft (10.7 m) Non-insulated Hose Bundle without Recirculation Lines and
Air Hose

Ref. Part Description Qty

301 249508 HOSE, fluid (component A); 1/4 in. (6 mm) ID, 35 ft (10.7 m), 1/2-20 UNF, moisture guard,

1

static dissipative

302 249509 HOSE, fluid (component B); 1/4 in. (6 mm) ID, 35 ft (10.7 m), 9/16-18 UNF, moisture guard,

1

static dissipative

1

1

311075U 63

Parts

Part No. 24L004, 120 V Heated Display
Part No. 24L005, 240 V Heated Display

409

403

402

421

401

404 402

414

408

407

405 416a

416

416a

404 (Ref)

415

417

406

410

410

424

Ref. Part Description Qty

401 15F984 PLATE 1
402 24K983 SWITCH, motor or heater

power, with circuit breaker

403 15G386 MODULE, display, tempera-

ture; includes (1) item 402 and

(2) item 424
404 24L002 POTENTIOMETER 1
405 119930 INDICATOR, status, LED 1
406 24G886 BOARD, control; 120 V units

only

24G887 BOARD, control; 240 V units

only
407 15G230 CABLE, harness 1
408 107156 SCREW, machine, pan hd 7
409 113505 NUT, keps, hex hd 10
410 119898 BULKHEAD FITTING, cable 2

411

412

413

Ref. Part Description Qty

411 101765 GROMMET 1
412 116773 CONNECTOR, plug 1

2

413 15C866 WIRE, jumper 2
414 15G279 LABEL, display 1

1

415 15G053 PLATE, detent 1
416 24L001 KNOB, function; includes item

416a

416a 101118 . SCREW, set; no. 10 x 1/4 in.

1

(6 mm)
417 15G454 LABEL, startup, heated 1
421 15G384 ENCLOSURE 1

1

424 24K981 DISPLAY, temperature, with

sensor

425 DUAL TERMINAL; not shown 2

TI6979a

1

2

2

64 311075U

Part No. 249537, 120 V Nonheated Display
Part No. 249538, 240 V Nonheated Display

403 405

Parts

421

409

410

401

404

423

414

411

402

408

407

412

416a

416

416a

404 (Ref)
415

417

406

Ref. Part Description Qty

401 15F984 PLATE 1
402 24K983 SWITCH, motor power, with cir-

cuit breaker
403 15G408 COVER, display 1
404 24L002 POTENTIOMETER 1
405 119930 INDICATOR, status, LED 1
406 24G886 BOARD, control; 120 V units

only

24G887 BOARD, control; 240 V units

413

Ref. Part Description Qty

414 15G279 LABEL, display 1
415 15G053 PLATE, detent 1

1

416 24L001 KNOB, function; includes item

416a

416a 101118 . SCREW, set; no. 10 x 1/4 in.

(6 mm)

417 15G281 LABEL, startup, unheated 1

1

421 15G384 ENCLOSURE 1
423 PLUG 1

1

TI6983a

only
407 15G230 CABLE, harness 1
408 107156 SCREW, machine, pan hd 7
409 113505 NUT, keps, hex hd 10
410 119897 BULKHEAD FITTING, cable 1
411 101765 GROMMET 1
412 116773 CONNECTOR, plug 1
413 WIRE, jumper 2

311075U 65

1

2

Parts

Part No. 24L009 Recirculation Manifold, Heated Models

505

Ref. Part Description Qty

501 24K993 MANIFOLD, recirculation 1

504

502 111763 ELBOW; 1/4 npt (mbe) 2
503 239914 VALVE, recirc/spray; includes

503

503a 15E022 . SEAT 1
503b 111699 . GASKET 1
504 224807 BASE, valve 2
505 187625 HANDLE, valve, drain 2

▲512

506

503a
503b

506 111600 PIN, grooved 2

501

508

502

507 100721 PLUG, pipe; 1/4 npt(m) 2
508 100840 ELBOW, street; 1/4 npt(m) x 1/4

509 116704 ADAPTER; 3/8 JIC x 1/4 npt(m) 1
510 119998 ADAPTER; 5/16 JIC x 1/4

512▲ 189285 LABEL, warning 1

507

▲ Replacement Danger and Warning labels, tags,

and cards are available at no cost.

509510

TI6977a

Part No. 287755 Recirculation Manifold, Nonheated Models

2

items 503a, 503b

2

npsm(f)

1

npt(m)

507

510

511

506

508

509

505

504

503

503a
503b

501

502

TI6982a

Ref. Part Description Qty

501 24K993 MANIFOLD, recirculation 1
502 111763 ELBOW; 1/4 npt (mbe) 4
503 239914 VALVE, recirc/spray; includes

items 503a, 503b
503a 15E022 . SEAT 1
503b 111699 . GASKET 1
504 224807 BASE, valve 2
505 187625 HANDLE, valve, drain 2
506 111600 PIN, grooved 2
507 113641 GAUGE, pressure, fluid 2
508 116504 TEE; 1/4 npt(m) x 1/4 npt(f) run;

1/4 npt(f) branch
509 116704 ADAPTER; 3/8 JIC x 1/4 npt(m) 1
510 119998 ADAPTER; 5/16 JIC x 1/4

npt(m)
511 556765 ELBOW, tube; 1/4 npt(m) x 3/8

in. (10 mm) OD tube

2

2

1

2

66 311075U

Part No. 249582, Cart

Parts

612

611

607

609

608

603

602

602

612

610

Ref. Part Description Qty

602 154636 WASHER, flat 4
603 116411 SPRING 2
604 116477 WASHER, flat; nylon 4
605 116478 WHEEL, pneumatic 2
606 101242 RING, retaining 2
607 GRIP, handle 2
608 24U760 BRACKET, tank mount 1
609 24U761 BRACKET, crossbar 1
610 24U762 BRACKET, motor mount 1
611 24T150 GUSSET 1
612 110996 NUT, hex, flange head 18

WLD

604

605

604

606

311075U 67

Suggested Spare Replacement Parts

Suggested Spare Replacement Parts

Keep the following spare parts on hand to reduce downtime.

All Units Heated Units Only

Part Description

24K984 DRYER, desiccant
15F895 O-RING, lid, tank
24K983 SWITCH, motor or heater power, with cir-

cuit breaker
113641 GAUGE, pressure, fluid; sst
101078 Y-STRAINER; includes 180199 element
180199 ELEMENT, Y-strainer, 20 mesh
114228 ELEMENT, air filter, 5 micron; polypropyl-

ene
239914 VALVE, recirc/spray; includes seat and

gasket
24L002 POTENTIOMETER, control knob
24G886 BOARD, control; 120 V units only
24G887 BOARD, control; 240 V units only
24K999 TRANSDUCER, pressure
24L006 PUMP, displacement; fits either side
287718 INLET KIT, tank to pump
249855 REPAIR KIT, displacement pump;

includes seals, balls, bearings, intake

valve seat)

Part Description

24K981 DISPLAY, temperature, with sensor
24K980 FUSE, heater over-temperature
24K978 THERMOSTAT, heater
24K989 HEATER ELEMENT; 120 V units only
24K990 HEATER ELEMENT; 240 V units only

Accessories

Part Description

249815 GUN, Fusion MP with 4-hose manifold
255325 GUN, MD2 Cold Spray
24P765 KIT, Joint Fill Extension

68 311075U

Dimensions

Dimensions

All Models

LQPP

LQPP

ti6974b

LQPP

311075U 69

Technical Data

Technical Data

Maximum fluid working
pressure

Electrical requirements Model AP9570, CS9570: 120 Vac, 1 phase, 50/60 Hz, 3500 W;

Generator Size (for Reac­tor E-10 only)

Maximum Fluid Tempera­ture

Maximum Ambient Tem­perature

2000 psi (14 MPa, 140 bar)

requires two separate, dedicated 15 A circuits

Model AP9571, CS9571: 240 Vac, 1 phase, 50/60 Hz, 3800 W;
requires two separate, dedicated 10 A circuits

Model AP9572, CS9572: 240 Vac, 1 phase, 50/60 Hz, 3800 W;
requires a single dedicated 16 A circuit

Model 249806, 24R984: 120 Vac, 1 phase, 50/60 Hz, 1800 W;
requires a single dedicated 15 A circuit

Model 249808, 24R985: 240 Vac, 1 phase, 50/60 Hz, 1800 W;
requires a single dedicated
8 A circuit

Heated: 5000 W minimum

Nonheated: 2500 W minimum

160°F (71°C)

110°F (43°C)

Maximum Output 12 lb/min (5.4 kg/min) at 340 cycles/min

Output per Cycle (A and B).00352 gal. (.0133 liter)

Overpressure Relief Recirc/Spray valves automatically relieve excessive fluid pressure

back to supply tanks

Heater Power 120V models: 850 W each; 1700 W total

240V models: 1000 W each; 2000 W total

Sound Pressure 78.7 dB(A) in fast circulation mode

84.5 dB(A) at 2000 psi (14 MPa, 140 bar), 0.72 gpm (2.7 lpm)

Sound Power, per ISO
9614-2

88.6 dB(A) in fast circulation mode

94.4 dB(A) at 2000 psi (14 MPa, 140 bar), 0.72 gpm (2.7 lpm)

70 311075U

Tank Capacity 7 gal. (26.5 liters) each (nominal)

Fluid Outlets Component A (ISO): -5 JIC male

Component B (RES): -6 JIC male

Fluid Circulation Returns Component A (ISO): -5 JIC male

Component B (RES): -6 JIC male

Air Inlet 1/4 in. quick-disconnect industrial type pin fitting

Air Outlet 1/4 npsm(m)

Technical Data

Gun Compressed Air

Fusion Gun (purge air and operating air): 4 scfm (0.112 m3/min)

Requirements

MD2 Gun with disposable mixer kit: 14 scfm (0.392 m3/min), with air
spray valve fully open

3

MD2 Gun with joint fill kit: 2 scfm (.056 m

/min)

Hose Markings A Side: Red

B Side: Blue

Weight (empty) approximately 160 lb (72 kg), depending on model

Wetted Parts Aluminum, stainless steel, carbon steel, brass, carbide, chrome,

chemically resistant o-rings, PTFE, ultra-high molecular weight poly­ethylene

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

311075U 71

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.

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

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

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.

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

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

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

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: [phone] or Toll Free: 1-800-328-0211 Fax: [phone]

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

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2005, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

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 311075

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised July 2014