Graco 332637C User Manual

Repair-Parts

Reactor® 2 Elite Integrated

Proportioning System

Electric, Heated, Integrated Plural Component Proportioning System With Integrated Generator. For spraying polyurethane foam and polyurea coatings. For professional use only. Not approved for use in explosive atmospheres or hazardous locations.

Important Safety Instructions. Read all warnings and instructions in this manual. Save these instructions.

332637C

PROVEN QUALITY. LEADING TECHNOLOGY.

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

Important Isocyanate Information........................... 9

Models............................................................... 11

Approvals........................................................... 13

Accessories........................................................13

Supplied Manuals............................................... 14

Related Manuals ................................................ 14

Troubleshooting.................................................. 15

Troubleshoot Errors ..................................... 15

Load Center Diagnostics .............................. 50

Pressure Relief Procedure .................................. 60

Shutdown........................................................... 61

Flushing............................................................. 64

Repair................................................................ 65

Before Beginning Repair...............................65

Flush Inlet Strainer Screen ...........................65

Drain Coolant .............................................. 66

Reﬁll Proportioner Coolant Loop ................... 68

Reﬁll Engine Coolant Loop ........................... 69

Coolant Speciﬁcations.................................. 70

Change Pump Lubricant............................... 70

Remove Pump............................................. 71

Install Pump ................................................ 72

Repair Drive Housing ................................... 73

Repair Electric Motor.................................... 76

Repair Circuit Breaker Module ...................... 77

Replace Load Center Relays and

Fuses ............................................ 79

Replace Load Center ................................... 80

Replace Engine Solenoid Relays ..................80

Replace Fluid Inlet Sensor............................81

Replace Pressure Transducers ..................... 81

Replace Fans .............................................. 82

Repair Booster Heater.................................. 84

Repair Heated Hose.....................................87

Repair Flui d Temperature Sensor

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

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

Replace Power Supply ................................. 94

Replace Circulation Pump ............................ 95

Repair Filter Housing Filter ........................... 96

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

Replace Battery ........................................... 97

Repair Fusible Link Harness.........................98

Remove Radiator....................................... 100

Replace Advanced Display Module

(ADM).......................................... 100

Replace Engine Control Module .................. 101

Replace Motor Control Module

(MCM) ......................................... 101

Replace Temperature Control Module

(TCM) .......................................... 101

Remove Proportioner ................................. 102

Repair Engine ............................................ 105

12V Charge Alternator................................ 105

Notes ............................................................. 106

Parts................................................................ 107

Electrical Schematics........................................ 154

Repair and Spare Parts Reference .................... 170

Recommended Rebuild Spare Parts .................. 171

Dimensions...................................................... 172

Technical Speciﬁcations.................................... 175

Notes ............................................................. 178

Graco Extended Warranty for Integrated

Reactor® 2 Components ..................... 179

332637C

Warnings

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

WARNING

ELECTRIC SHOCK HAZARD

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

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

• Connect only to grounded power source.

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

TOXIC FLUID OR FUMES

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

• Read MSDSs to know the s pec i ﬁc hazards of the ﬂuids you are using.

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

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

CARBON MONOXIDE HAZARD

Exhaust contains poisonou s carbon monoxi de , which is colorless and odorless. Breathing carbon monoxide can cause death.

• Donotoperateinanenclosedarea.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipmen t when in the work area to help prevent serious inj ury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eyewear, and hearing protectio n.

• Respirators, protective clothing, and gloves as recommended by the ﬂuid and solvent manufacturer.

332637C 3

Warnings

WARNING

SKIN INJECTION HAZARD

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

treatment

• Do not s pra y without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part o f 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 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

Pressure Relief Procedure

when you stop spray i ng an d be fore c l ean ing , ch eck ing ,

Get immediate surgical

Flammable fumes, such as solvent and paint fumes, in 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 u npl ug power cords, or turn power or light switches on or off when ﬂammable fumes are present.

• Ground all equipment in the work area. See

• Use only grounded hoses.

• Hold gun ﬁrmly to side of grounded pail when triggering into pail. Do not use pail liners unle ss they are antistatic or conductive.

•

Stop operation immediately

equipment u nti l you identify and correct the problem.

• Keep a working ﬁre extinguisher in the work area.

if static sparking occurs or you feel a shock.Do not use

Grounding

work area

instructions.

canigniteorexplode.Tohelp

332637C

Warnings

WARNING

THERMAL EXPANSION HAZARD

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

• Openavalvetorelievetheﬂuidexpansionduringheating.

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

PRESSURIZED ALUMINUM PARTS HAZARD

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

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

• Many other ﬂuids may contain chemicals that can react with aluminum . Contac t y ou r mate rial supplier for compatibility.

PLASTIC

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

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

•See solvent manufacturer’s MSDSs and recommendations.

PARTS CLEANING SOLVENT HAZARD

Technical Data

in this and all other equipment instruction ma nua ls . Read ﬂuid and

332637C 5

Warnings

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

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

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See

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

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

• Turn off all equip ment and follow the

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

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

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

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

• Route hoses and cab les away from trafﬁc areas, s ha rp edges, moving parts, and hot su rfac es .

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

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

Technical Data

Pressure Relief Procedure

in all equipment manuals.

when equipment is not in use.

6 332637C

WARNING

BATTERY HAZARD

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

Warnings

• Only use the battery type speciﬁed for use with the equipment. See

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

• When replacing the battery, use the same lead-acid automotive battery, with 800 CCA minimum, speciﬁed for use with the equipment. See

• Do not dispose of battery in ﬁre. The battery is capable of exploding.

• Follow local ordinances and/or regulations for disposal.

• Donotopenormutilatethebattery. Releasedelectrolytehasbeenknowntobeharmfulto theskinandeyesandtobetoxic.

• Remove watches, rings, or other metal objects.

• Only use tools with insulated handles. Do not lay tools or metal parts on top of battery.

MOVING PARTS HAZARD

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

• Keep clear of moving parts.

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

• Pressurized equipment can start without warning. Be fore checking, m ov ing, or servicing equipment, fol low the

Pressure Relief Procedure

Technical Data

and disconnect all power sources.

Technical Data

332637C

Warnings

WARNING

ENTAGLEMENT HAZARD

Rotating parts can cause serious injury.

• Keep clear of moving parts.

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

• Do not wear l oo se clothing, jewelry or long hair while operating equipment.

• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the

BURN HAZARD

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

• Do not touch hot ﬂuid or equipment.

CALIFORNIA PROPOSITION 65

The engine exhaust from this product contains a chemical known to the State of California to cause cancer, birth defects or other reproductive harm.

Pressure Relief Procedure

and disconnect all power sources.

8 332637C

Important Isocyanate Information

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

Important Isocyanate Information

Isocyanate Conditions

Spraying or dispensing materials containing isocyanates creates potentially harmful mis ts, vapors, and atomized particulates.

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

Prevent i nh ala tio n of isocy ana te mists, vapors, and atomized particulates by providing sufﬁcient ventilation in the work area. If sufﬁc i ent 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, in cluding chemically impermeable gloves, boots , aprons, and goggles, is also required for everyone in the work area.

Keep Components A and B Separate

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

•

Never

interchange component A and component

B wetted parts.

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

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause ISO to partially cure; forming small, hard, abrasiv e 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

Material Self-Ignition

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

NOTICE

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

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

Never

store ISO in an open container.

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

• Use only moisture-proof hoses compatible with ISO.

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

• Always lubricate threaded parts with an appropriate lubrica nt when reassembling.

332637C 9

Important Isocyanate Information

Foam Resins with 245 fa Blowing Agents

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

Changing Materials

NOTICE

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

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

• Always clean the ﬂuid inlet strainers after ﬂushing.

• Check with your materi al manufacturer for chemical compatibility.

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

10 332637C

Models

Reactor 2 E-30i Elite

All base systems include ﬂuid inlet pressure and temperature sensors and Graco InSite™. For part numbers, see Accessories, page 13

Model

Base Machine Maximum Fluid

Working Pressure psi (MPa, bar)

Approximate Output per Cycle (A+B) gal. (liter)

Max Flow Rate lb/min (kg/min)

Total System Load † (Watts)

Voltage (phase) Available Auxiliary

Current at Volts, 60 Hz*



No Air Compressor/Dryer

E-30i E-30i with heat E-30i E-30i with heat

272079 272080 272089 272090 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138)

0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034)

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

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

240 VAC (1) 240 VAC (1) 240 VAC (1) 240 VAC (1) 52 Amps (240) 35 Amps (240) 22 Amps (240)

9 Amps (120)



With Air Compressor/Dryer

5 Amps (240) 9 Amps (120)

Fusion AP Package

(Gun Part No.)

Fusion CS Package

(Gun Part No.)

Probler P2 Package

(Gun Part No.)

Heated Hose 50 ft (15 m)

Heated Whip Hose 10 ft (3 m)



Total system watts used by system, based on maximum heated hose length of 310 ft (94.5 m) for each unit.

* Full load amps available for auxiliary equipment

when all bare-system components are operating at maximum capabilities. Available auxiliary current is based on 310 ft (94.5 m) of heated hose. An additional 3.0 amps (240 VAC) of auxiliary current is available for each 50 ft (15.2 m) section of heated hose that is not used.

liary current at 120 VAC is available on line 1

Auxi

rcuit breaker pin 2), line 2 current at 120 VAC is

(ci

d by the air dryer (circuit breaker pin 4).

use



AP2079

(246102)



CS2079

(CS02RD)

P22079



(GCP2R2)

24K240 24K240 24K240 24K240

24Y240 24Y240 24Y240 24Y240

AP2080

(246102)

CS2080

(CS02RD)

P22080

(GCP2R2)

AP2089

(246102)

CS2089

(CS02RD)

P22089

(GCP2R2)



Available auxiliary current will be less when the engine is de-rated for site altitude. Reduce the Available Auxiliary Current in the chart by 2.5 Amps (240 VAC) per 1000 ft (300 m) elevation increments. If the available auxiliary current is less than zero, the system conﬁguration may not support the full load at that altitude.



Includes Complete Air Compressor/Dryer Kit 24U176.

See Approvals, page 13.



Packages include gun, heated hose, and whip hose.

AP2090

(246102)

CS2090

(CS02RD)

P22090

(GCP2R2)

332637C

Models

Reactor 2 E-XP2i Elite

All base systems include ﬂuid inlet pressure and temperature sensors and Graco InSite™. For part numbers, see Accessories, page 13

Model

Base Machine Maximum Fluid Working Pressure psi

(MPa, bar) Approximate Output per Cycle (A+B)

gal. (liter) MaxFlowRatelb/min(kg/min)

Total System Load † (Watts) Voltage (phase) Available Auxiliary Current at Volts, 60

Hz*



No Air Compressor/Dryer

E-XP2i with heat E-XP2i with heat

272081 272091 3500 (24.1, 241) 3500 (24.1, 241)

0.0272 (0.1034) 0.0272 (0.1034)

30 (13.5) 30 (13.5) 11,600 17,700 240 VAC (1) 240 VAC (1) 35 Amps (240) 5 Amps (240)



With Air Compressor/Dryer

9 Amps (120)

Fusion AP Package

(Gun Part No.)

Probler

(Gun Par

Heated H 50 ft (15

Heated 10 ft (3

P2 Package

t No.)

ose

Whip Hose m)



Total sy maximum for each

* Full load amps available for auxiliary equipment

when all bare-sys tem components are operating at maximum capabilities. Available auxiliary current is based on 310 ft (94.5 m) of heated hose. An additional 3.0 amps (240 VAC) of auxiliary current is available for each 50 ft (15.2 m) section of heated hose that is not used.

Auxiliary current at 120 VAC is available on line 1 (circuit breaker pin 2), line 2 current at 120 VAC is used by the air dryer (circuit breaker pin 4).



stem watts used by system, based on

heated hose length of 310 ft (94.5 m)

unit.

AP2081

(246101)

P22081 (GCP2R1)

24Y241 24Y241

246055 246055

AP2091

(246101)

P22091

(GCP2R1)







ble auxiliary current will be less when the

Availa

is de-rated for site altitude. Reduce the

engine

ble Auxiliary Current in the chart by 2.5

Availa Amps (2 increm less th suppor

Includes Complete Air Compressor/Dryer Kit 24U176.

See Approvals, page 13. Packages include gun, heated hose, and whip

hose.

40 VAC) per 1000 ft (300 m) elevation

ents. If the available auxiliary current is

an zero, the system conﬁguration may not

t the full load at that altitude.

332637C

Approvals

Intertek approvals apply to proportioning systems without hoses.

Model

272079 272089

272080 272081 272090 272091

Proportioning System Approvals:

9902471

Conforms to ANSI/UL Std. 73

Certiﬁed to CAN/CSA Std.

C22.2 No. 68

Note

Heated hoses provided with a system or sold individually are not approved by Intertek.

Accessories

Kit Number Description

15M483 Remote Display Module Protective

Covers (10 pack) 15V551 24K207

24K333 Fuel Line and Cable Extension Kit 24K336 Hose Rack 24K337 Light Tower Kit 24L911 24M174 Drum Level Sticks 24U174 Remote Display Module Kit 24U176 24U177

Cables

ADM Protective Covers (10 pack)

Fluid Temperature Sensor (FTS)

with RTD

Pallet Support Kit

Complete Air Compressor Kit

Feed Pump Shutdown Kit

9902471

rms to ANSI/UL Std. 499

Confo

ﬁed to CAN/CSA Std.

Certi

C22.2

No. 88

121006 150 ft (45 m) cable (for remote

display module) 24N365

24N449

RTD Test Cables (to aide resistance

measurements)

50ft(15m)CANcable(forremote

display module)

332637C 13

Supplied Manuals

The following m anu al s are shipped with the Reac to r. Refer to these manuals for detailed equi pm ent information.

Manuals are also available at www.graco.com.

Manual Description

332636 Reactor 2 Elite Integrated

Proportioning System, Operation

333093 Reactor 2 Elite Integrated

Proportioning System, Startup Instructions

333094 Reactor 2 Elite Integrated

Proportioning System, Shutdown Instructions

SEBU8311–02Perkins® Engine, Repair-Parts

Access at www.perkins.com. Go to Service and Support/manuals. Select engine family and type code “GN”.

Contact Perkins for engine warranty and service.

ST 15825–00

33227482

Mecc Alte Self-Regulating Alternator Series NPE, Repair-Parts

Access at www.meccalte.com. Select “meccalte” logo / Download / Instruction Manuals. Select NPE instruction manual on page 5. Go to Support and enter serial number for Parts List and Help Videos.

Contact Mecc Alte for warranty and service

Air Compressor, Operation/Mainte- nance & Parts list.

Access at www.hydrovaneprod- ucts.com. Go to Warranty & Service tab and select “contact us” to request manuals.

Refrigerated Air Dryer, Instruction manual Access from S e rvice Department (724) 746–1100 or www.spx.com/en/hank i son.

Related Manuals

The following manuals are for accessories used with the Re ac tor.

Component Manuals in English:

Manuals are available at www.graco.com.

System Manuals

332636

Displacement Pump Manual

309577 Electric Reactor Displacement Pump,

Feed System Manuals

309572 Heated Hose, Instructions-Parts 309852

309815 Feed Pump Kits, Instructions-Parts 309827

Spray Gun Manuals

309550 Fusion ™ AP Gun 312666 Fusion ™ CS Gun 313213 Probler®P2 Gun

Accessory Manuals

332733 Air Compressor and Air Dryer Kit,

332738

332740 Remote Display Module,

3A2574 3A1903 Hose Rack, Instructions-Parts

3A1904

3A1905

3A1906

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

Repair-Parts

Circulation and Return Tube Kit, Instructions-Parts

Feed Pump Air Supply Kit, Instructions-Parts

Instructions-Parts Booster Heat R etroﬁt Kit, Instructions-Parts

Instructions-Parts Pallet Support Kit, Instructions-Parts

Fuel Tank/Battery Move Kit, Instructions-Parts Feed Pump Shutdown Kit, Instructions-Parts Light Tower Kit, Instructions-Parts

332637C

Troubleshooting

Troubleshoot Errors

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

Error Description Alarms

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

Troubleshooting

2. TheQRcodescreenwillbedisplayed. Scan the QR code with your mobile device to be sent directly to online troubleshooting for the active error code. Otherwise, manually navigate to

help.graco.com and search for the active error.

Deviations

Advisories

See Error Codes, page 16 see for causes and solutions to each error code.

To troublesh oot the error:

1. Press the s oft key next to “Help With This Error” forhelpwiththeactiveerror.

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

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

3. If no i Code T manu code

Note

Press previ

nternet connection is available, see Error

roubleshooting in the system repair

al for causes and solutions for each error

or to return to the

ously displayed screen.

332637C 15

Troubleshooting

Error Codes

Error Location Type Description Cause Solution

A1NM

A4DA Heater A

A4DB Heater B High Current B

MCM

Low Motor Current

High Current A

Loose/broken connection.

Bad Motor. Disconnect motor output

Short circuit in heater wiring.

Bad heater.

Short circuit in heater wiring.

Bad heater.

Check for loose wire terminations at MCM motor connector.

connector from MCM. Conﬁrm less than 8 ohms resistance between each pair of motor power leads (M1toM2,M1toM3,M2to M3). If any readings greater than 8 ohms, check motor wiring for damage and/or loose terminations.

Check wiring for touching wires.

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

Check wiring for touching wires.

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

A4DH Hose

High Current Hose Short circuit in

hose wiring.

Check continuity of transformer windings. Normal readings are about

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

Check for shorts between the p rimary windin g and the support frame or enclosure.

16 332637C

Troubleshooting

Error Location Type Description

A4NM

A7DA Heater A

A7DB Heater B

A7DH Hose

MCM

High Motor Current

Unexpected CurrentAShorted TCM If error cannot be cleared

Unexpected CurrentBShorted TCM If error cannot be cleared

Unexpected Current Hose

Cause Solution

Short circuit of motor wiring.

Motor will not rotate.

Damaged gear train.

Chemical pump is stuck.

Shorted TCM If error cannot be cleared

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

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

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

Repair or replace chemical pump.

or regenerates consistently, replace module.

A8DA Heater A

A8DB Heater B

A8DH Hose

No Current A

No Current B

No Current Hose

Tripped circuit breaker.

Loose/broken connection.

Tripped circuit breaker.

Loose/broken connection.

Tripped circuit breaker.

Loose/broken connection.

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

332637C

Troubleshooting

Error Location Type Description

CACM MCM MCM Communica-

tion Error

Cause Solution

Module does not have software.

No 24 VDC supply to module.

Loose or broken CAN cable.

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

Greenlightoneachmodule should be lit. If green light is notlit,checktomakesure each CAN cable connection is tight. Verify the power supply is outputting 24 VDC. If not, check power supply wiring. If wiring is okay, replace the power supply.

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

18 332637C

Troubleshooting

Error Location Type Description

CACT TCM TCM Communication

Error

Cause Solution

Module does not have software.

No 24 VDC supply to module.

Loose or broken CAN cable.

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

Greenlightoneachmodule should be lit. If green light is not lit, check to make sure each CAN cable connection is tight. Verify the power supply is outputting 24 VDC. If not, check powe r supply wiring. If wiring is okay, replace the power supply.

DADX MCM Pump Runaway Flow rate is too

large.

DE0X

EAUX ADM

MCM

Cycle Switch Error

USB Busy USB drive has

Faulty or missing cycle switch.

Missing or out of place cycle switch magnet.

been inserted to the ADM.

Mix ch am ber too large for system selected. Use mix chamber rated for system.

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

No material in pumps. Verify pumps are supplying chemical. If necessary, replace or reﬁll drums.

Inlet ball valves are closed. Open ball valves.

Check wiring between cycle switch and MCM.

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

Do not remove USB drive

until download/upload

is complete.

332637C 19

Troubleshooting

Error Location Type Description

EVCH

EVUX ADM

F9DX

H1MA Heater A Low Frequency A

H1MB Heater B Low Frequency B Line frequency is

ADM

MCM

Manual Hose Mode Enabled

USB disabled USB

High Pressure/Flow Cutback

Cause Solution

Manual hose mode has been enabled in System Setup screen.

download/uploads are disabled.

Mix chamber is too large for set pressure.

Line frequency is below 55 Hz.

below 55 Hz.

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

Enable USB download/up- loadsontheAdvanced Setupscreenbeforeinsert- ing a USB drive.

Reference the pressure ﬂow curves and select a tip size that is the correct size for the set pressure.

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

H1MH Hose Low Frequency Hose

Line frequency is below 55 Hz.

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

20 332637C

Troubleshooting

Error Location Type Description

H4MA Heater A High Frequency A

H4MB Heater B High Frequency B

H4MH Hose High Frequency

Hose

K8NM

MCM

Locked Rotor Motor

Cause Solution

Line frequency is above65Hz.

Motor will not rotate.

Damaged gear train.

Chemical pump is stuck.

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

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

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

Repair or replace chemical pump.

L1AX ADM

L1BX ADM

MMUX

USB

Low Chemical Level A

Low Chemical Level B

Maintenance Due - USB

Low material level.

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

Reﬁll material and update drum level on ADM Maintenance screen. Alarm can be disabled on the System Setup screen.

InsertaUSBdriveintothe ADM and download all logs.

332637C

Troubleshooting

Error Location Type Description

P0AX

MCM

Pressure Imbalance AHigh

Cause Solution

Pressure difference between AandBmaterial is greater than the deﬁned value.

Pressure imbalance is deﬁned too low.

Out of material. Fill tanks with material Fluid leaking from

heater inlet ruptu re disk.

Feed system defective.

Ensure material ﬂow is equally restricted on both material lines.

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

Check if he ate r and PRESSURE RELIEF/SPRAY valve are plugged. Clear. Replace rupture disk. Do not replace withapipeplug.

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

332637C

Troubleshooting

Error Location Type Description

P0BX

MCM

Pressure Imbalance BHigh

Cause Solution

Pressure difference between AandBmaterial is greater than the deﬁned value.

Pressure imbalance is deﬁned too low.

Out of material. Fill tanks with material Fluid leaking from

heater inlet rupture disk.

Feed system defective.

Ensure material ﬂow is equally restricted on both material lines.

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

Check if heater and PRESSURE RELIEF/SPRAY valve are plugged. Clear. Replace rupture disk. Do not replace withapipeplug.

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

P1FA

P1FB

MCM

Low Inlet Pressure A

Low Inlet Pressure B

Inlet pressure lower than deﬁned value.

Value deﬁned too high.

Inlet pressure lower than deﬁned value.

Value deﬁned too high.

Ensure that inlet pressure to the pump i s sufﬁcient.

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

Ensure that inlet pressure to the pump i s sufﬁcient.

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

332637C 23

Troubleshooting

Error Location Type Description

P2FA

P2FB MCM Low Inlet Pressure B

P4AX

MCM

Low Inlet Pressure A

High Pressure A

Cause Solution

Inlet pressure lower than deﬁned value.

Value deﬁned too high.

Inlet pressure lower than deﬁned value.

Value deﬁned too high.

System pressurized before allowing heat to reach setpoint.

Ensure that inlet pressure to the pump is sufﬁcient.

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

Ensure that inlet pressure to the pump is sufﬁcient.

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

Pressureinthehoseand pumps wil l increase as the system h eats up. Turn on heat and allow all zones to reach the temperature setpoint before turning on the pump s.

P4BX

MCM

High Pressure B

Bad pressure transducer.

E-XP2i system conﬁgured as E-30i.

System pressurized before allowing heat to reach setpoint.

Bad pressure transducer.

E-XP2i system conﬁgured as E-30i.

Verify the ADM pressure readingandtheanalog guages at th e manifold.

Alarm level is lower for E-30i than for E-XP2i. Ensure dial on MCM is set to position "1" for E-XP2i.

Pressureinthehoseand pumps wil l increase as the system h eats up. Turn on heat and allow all zones to reach the temperature setpoint before turning on the pump s.

Verify the ADM pressure readingandtheanalog guages at th e manifold.

Alarm level is lower for E-30i than for E-XP2i. Ensure dial on MCM is set to position "1" for E-XP2i.

332637C

Troubleshooting

Error Location Type Description

P6AX

P6BX

MCM

Pressure Sensor Error A

Pressure Sensor Error B

Cause Solution

Loose/bad connection.

Bad sensor.

Loose/bad connection.

Bad sensor.

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

Check if the error follows the transducer. Disconnect transducer cables from the MCM (connectors 6 and7). ReverseAandB connections and check if the errors follows. If the error follows the trans du ce r, replace the pressure transducer.

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

P6FA MCM Pressure Sensor

Error Inlet A

332637C 25

Inlet sensors not installed.

Loose/bad connection.

Bad sensor.

If inlet sensors are not installed, inlet sensors should be disabled on the System Setup screen.

Checktoensureinlet sensor is properly installed and all wires are properly connected.

Check if the error follows the inlet sensor. Disconnect inlet sensor cables from the MCM (connectors 8 and9). ReverseAandB connections and check if the errors follows. If the error follows the sensor, replace the inlet sensor.

Troubleshooting

Error Location Type Description

P6FB

P7AX

MCM

Pressure Sensor Error Inlet B

Pressure Imbalance AHigh

Cause Solution

Inlet sensors not installed.

Loose/bad connection.

Bad sensor.

Pressure difference between AandBmaterial is greater than the deﬁned value.

If inlet sensors are not installed, inlet sensors should be disabled on the System Setup screen.

Check to ens ure i nl et sensor is properly installed and all wires are properly connected.

Check if the error follows the inlet sensor. Disconnect inlet sensor cables from the MCM (connectors 8 and9). ReverseAandB connections and check if the errors follo ws . If the error follows the sensor, replace the inlet sensor.

Ensure material ﬂow is equally restricted on both material lines.

Pressure imbalance is deﬁned too low.

Out of material. Fluid leaking from

heater inlet ruptu re disk.

Feed system defective.

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

Fill tanks with material Check if he ate r

and PRESSURE RELIEF/SPRAY valve are plugged. Clear. Replace rupture disk. Do not replace withapipeplug.

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

26 332637C

Troubleshooting

Error Location Type Description

P7BX

MCM

Pressure Imbalance BHigh

Cause Solution

Pressure difference between AandBmaterial is greater than the deﬁned value.

Pressure imbalance is deﬁned too low.

Out of material. Fill tanks with material Fluid leaking from

heater inlet rupture disk.

Feed system defective.

Ensure material ﬂow is equally restricted on both material lines.

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

Check if heater and PRESSURE RELIEF/SPRAY valve are plugged. Clear. Replace rupture disk. Do not replace withapipeplug.

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

T1DE Engine

Heat Exchanger

Low Temperature Coolant Outlet

Radiator fan will not stop.

Engine thermostat is stuck closed.

Replace fan relay.

Replace thermostat.

332637C

Troubleshooting

Error Location Type Description

T2AE Heat Ex. A Low Temperature

Heat Exchanger A

Cause Solution

Coolant circulation pump not working.

Air lock in pump circulation.

Novoltagetocoil of valve.

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

Check for coolan t ﬂow in sight glass.

Turn on the manual valve switch(MV),ontheload center, to manually turn on the solenoids and see if the temperature rises. If not, check volatge output on J6 connectorontheloadcenter andensuretheLEDs are on. Follow Load Center Diagnostic instructions in system repair manual. If necessary, replace the load center board. If voltage is present, measure the resistance of the coil, it should be 12.5 Ω. If coil is open replace coil. If voltage is present, test the coil with screwdriver. The screwdriver should magnetically stick inside the coil . If the screwdriver sticks, then the coil is good. Replace the plunger on valve or replace the complete valve assembly.

28 332637C

Troubleshooting

Error Location Type Description

T2BE Heat Ex. B Low Temperature

Heat Exchanger B

Cause Solution

Coolant circulation pump not working.

Air lock in pump circulation.

Novoltagetocoil of valve.

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

Check for coolant ﬂow in sight glass.

Turn on the manual valve switch (MV), on the load center, to manually turn on the solenoids and see if the temperature rises. If not, check volatge output on J6 connectorontheloadcenter and ensure the LEDs are on. Follow Load Center Diagnostic instructions in system repair manual. If necessary, replace the load center board. If voltage is present, measure the resistance of the coil, it should be 12.5 Ω. If coil is open replace coil. If voltage is present, test the coil with screwdriver. The screwdriver should magnetically stick inside the coil. If the screwdriver sticks, then the coil is good. Rep lac e the plunger on valve or replace the complete valve assembly.

T2DA Heater A Low Temperature A

332637C 29

Flow is too high at current setpoint.

Bad RTD or bad RTD placement against heater.

Bad heater.

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

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

Conﬁrmresistance of heater is 23-26.5 Ω. Repl ace if OL/open loop.

Troubleshooting

Error Location Type Description

T2DB Heater B Low Temperature B

Low Temperature

Exchanger

T2DH Hose Low Temperature

Coolant Outlet

Hose

Cause Solution

Flow is too high at current setpoint.

Bad RTD or bad RTD placement against heat er.

Bad heater.

Radiator fan will not stop.

Engine thermostat is stuck closed.

Flow is too high at current setpoint.

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

Swap A an d B heater o utpu t cables and RTD cables and see if issue follows. If so, replace RTD.

Conﬁrmresistance of heater is 23-26.5 Ω. Replace if OL/open loop.

Replace fan relay.T2DE Heat

Replace thermostat.

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

T2FA MCM Low Temperature

Inlet A

T2FB

MCM

Low Temperature Inlet B

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

Inlet ﬂuid temperature is below the deﬁned level.

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

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

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

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

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

30 332637C

Troubleshooting

Error Location Type Description

T3CH

T3CT TCM TCM Cutback

Hose

Hose Cutback

Cause Solution

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

High ambient temperature.

Enclosure fan not operating.

Module fan not operating.

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

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

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

Ensurefaninelectrical enclosure is spinning. If it is not, check fan wiring or replace fan.

If a TCM fan error (WMI0) has occurred, fan inside themoduleisnotworking properly. Check TCM fan for debris and clear with forced air if necessary.

T3NM

T4AE Heat Ex. A High Temperature

MCM

MCM Cutback

Heat Exchanger A

Motor is operating outside of the pressure ﬂow curve.

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

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

Short on load center board.

The system is running at a lower setpoint to preserve motor life. Run the system at a lower duty cycle or with a smaller mix chamber.

Open cabinet cover and turn switch to the OFF position.

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

IftheblueandredLEDsare on while heat is off, the load center board is bad. See Load Center Diagnostics in the system repair manual.

332637C 31

Troubleshooting

Error Location Type Description

T4BE Heat Ex. B High Temperature

Heat Exchanger B

Cause Solution

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

A or B side control valvesolenoidis stuckintheopen position.

Short on load center board.

J6 connector on load center "Heat Valves" location is not centered.

Open cabinet cover and turn switch to the OFF position.

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

If the blue and red LEDs are on while heat is off, the load center board is bad. See Load Center Diagnostics in the system repa ir manual.

Reconnect J6 connector on load center in centered location.

T4CM MCM

T4CT TCM High Temperature

High Temperature MCM

TCM

High ambient temperature.

Enclosure fan not operating.

High ambient temperature.

Enclosure fan not operating.

Module fan not operating.

Ensure ambient temperature is below 120°F(48°C) before using the sy ste m.

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

Ensure ambient temperature is below 120°F(48°C) before using the sy ste m.

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

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

32 332637C

Troubleshooting

Error Location Type Description

T4DA Heater A High Temperature A

T4DB Heater B High Temperature B

T4DE Heat

Exchanger

High Temperature Coolant Outlet

Cause Solution

Bad RTD or bad RTD placement against heater.

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

Bad RTD or bad RTD placement against heater.

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

Broken fan. Check fan relay (K4) and

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

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

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

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

fuse (30 Amp ATO "F3") on load center board. Replace if needed.

T4DH Hose High Temperature

Hose

Plugged radiatior. High ambient

temperature.

Hose portion exposed to an excessive heat source, like hot sun or coiled hose, can pass ﬂuid more than 27°F (15°C) over hose temperature setting to the FTS.

Setting the A or B setpoint much higher than hos e setpoint can cause ﬂuid more than 27°F (15°C) over hose temperature setting to reach the FTS.

Replace if needed. Ensure ambient

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

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

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

332637C 33

Troubleshooting

Error Location Type Description

T4EA Heater A High Temperature

Switch A

T4EB Heater B High Temperature

Switch B

Cause Solution

Overtemperature switch sensed a ﬂuid temperature above 230°F (110°C).

Broken or loose overtemperature switch cable/connection.

Overtemperature switch failed in the open position.

Overtemperature switch sensed a ﬂuid temperature above 230°F (110°C).

Heater was delivered too much power, causing the overtemperature switch to open. RTD is not reading properly. After the heater cools down, replace RTD. Switch closes and the error canbeclearedwhenthe heater temperature falls below 190°F (87°C).

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

Replace overtemperature switch.

Broken or loose overtemperature switch cable/connection.

Overtemperature switch failed in the open position.

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

Replace overtemperature switch.

34 332637C

Troubleshooting

Error Location Type Description

T4NM

T6AE Heat Ex. A

MCM

High Temperature Motor

Sensor Error Heat Exchanger A

Cause Solution

Cooling fan is not operating properly.

Broken or loose motor temperature cable.

High ambient temperature.

Bad electric motor. Replace electric motor. Broken or loose

RTD cable or connection.

Check to see that the motor fan is moving. Measure voltagetofan.Thereshould be 24 VDC. If no voltage is measured, check fan wiring.If the fan has voltage but is not moving, replace fan. If necessary use an air hose to blow out around the fan hous i ngs and re mov e any built-up debris.

Verify wiring between the motor temperature sensor andtheMCM.

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

Check all wiring and connection to RTD.

T6BE Heat Ex. B

T6DA Heater A

Sensor Error Heat Exchanger B

Sensor Error A

Bad RTD.

Broken or loose RTD cable or connection.

Bad RTD.

Disconnected or loose RTD cable or connection.

Bad RTD.

Switch the RTD with another and see if the error messagefollowstheRTD. Replace RTD if the error follows the RTD.

Check all wiring and connection to RTD.

Switch the RTD with another and see if the error messagefollowstheRTD. Replace RTD if the error follows the RTD.

Check all wiring and connection to RTD.

Switch the RTD with another and see if the error messagefollowstheRTD. Replace RTD if the error follows the RTD.

332637C 35

Troubleshooting

Error Location Type Description

T6DB Heater B

T6DE Engine

Heat Exchanger

T6DH Hose

Sensor Error B

Sensor Error Coolant Outlet

Sensor Error Hose

Cause Solution

Disconnected or loose RTD cable or connection.

Bad RTD.

Disconnected or loose RTD cable or connection.

Bad RTD.

Disconnected or shorted RTD cable in hose or bad FTS .

Check all wiring and connection to RTD.

Switch the RTD with another and see if the error messagefollowstheRTD. ReplaceRTDiftheerror follows th e RTD.

Check all wiring and connection to RTD.

Switch the RTD with another and see if the error messagefollowstheRTD. ReplaceRTDiftheerror follows th e RTD.

Expose each hose RTD connection to check and retighten any loose c on- nector. Measure hose RTD cable and FTS continuity. See Repair Heated Hose,

page 87.OrderRTDTest

kit 24N365 for measure- ment. Di sconnect hose RTD and use manual hose mode to ﬁnish job until repaircanbecompleted.

T6DT

TCM

Sensor Error TCM

Shorted RTD cable in hose or FTS.

Shorted Heater A or B RTD

Expose each hose RTD connection to check for exposed and shorted RTD wires. Measure hose RTD cable and FTS continuity. See Repair Heated Hose,

page 87.OrderRTDTest

kit 24N365 for measure- ment. Di sconnect hose RTD and use manual hose mode to ﬁnish job until repaircanbecompleted.

If the error still occurs with the ho se FTS unpl ug ged , one of the heater RTDs is bad. Unplug th e A or B RTD from the TCM. If unplugging an RTD ﬁxes the T6DT error, replace the RTD.

36 332637C

Troubleshooting

Error Location Type Description

T8AE Heat Ex. A No Temperature

Rise Heat Ex ch ang er A

Cause Solution

No coolant ﬂow. Check coolant lev el.

Check for coolant ﬂow in sight glass. Ensure that circulation pump has 240 VAC. If not, re pla ce the circulation pump.

Low ch emi cal supply temperature.

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

Bad valve solenoid. Turn on the manual valve

Chemical below 32°F(0°C) at startup. Recirculate cold chemical back to drum in cold conditions before spraying.

Ensure ambient temperature is above 20°F(-7°C) .

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

Bad load center. Red, blue, and green LEDs

should light up on load center board. If not, replace load center.

332637C 37

Troubleshooting

Error Location Type Description

T8BE Heat Ex. B No Temperature

Rise Heat Exchanger B

Cause Solution

No coolant ﬂow. Check coolant level.

Check for coolant ﬂow in sight glass.Ensure that circulation pump has 240 VAC. If not, replace the circulation pump.

Low chemical supply temperature.

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

Bad valvesolenoid. Turn on the manual valve

Chemical below 32°F(0°C) at startup. Recirculate cold chemical back to drum in cold conditions before spraying.

Ensure ambient temperature is above 20°F(-7°C) .

switch(MV),ontheload center, and see if the valve shifts. If not replace solenoid.

T8DA Heater A No Temperature

Rise A

Bad load center. Red, blue, and green LEDs

should light up on load center board. If not, replace load center.

J6 connector on load center "Heat Valves" location is not centered.

Bad heater rod.

Bad RTD or bad RTD placement against heat er.

Bad valvesolenoid. Turn on the manual valve

Started spraying before heater reached operating temperature.

Reconnect J6 connector on load center in centered location.

Measure resistance of heater rod, should b e 2 3-26 Ω. Replace if open.

Swap A an d B heater o utpu t cables and RTD cables and see if issue follows. If so, replace RTD.

switch(MV),ontheload center, and see if the valve shifts. If not replace solenoid.

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

38 332637C

Troubleshooting

Error Location Type Description

T8DB Heater B No Temperature

Rise B

T8DH Hose No Temperature

Rise Hose

V1CM MCM Low Voltage MCM

Cause Solution

Bad heater rod.

Bad RTD or bad RTD placement against heater.

Bad valve solenoid. Turn on the manual valve

Started spraying before heater reached operating temperature.

Loose/bad connection or tripped circuit breaker.

Measure resistance of heater rod, should be 23-26 Ω. Replace if open.

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

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

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

Check wiring for loose connection or tripped circuit breaker.

Low generator line voltage.

V1IT TCM Low Voltage CAN Bad 24 VDC power

supply.

V1MA

TCM

Low Voltage A

Loose connection or tripped circuit breaker.

Low generator line voltage.

High auxilary inrush current.

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

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

Check wiring for loose connection or tripped circuit breaker.

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

Ensure compressor or air drier are set up to be continuous run and sized accordingtothemanual.

332637C 39

Troubleshooting

Error Location Type Description

V1MB

V1MH

TCM

Low Voltage B

Low Voltage Hose

Cause Solution

Loose connection or tripped circuit breaker.

Low generator line voltage.

High auxilary inrush current.

Loose connection or tripped circuit breaker.

Low generator line voltage.

High auxilary inrush current.

Check wiring for loose connection or tripped circuit breaker.

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

Ensure compressor or air drier are set up to be continuous run and sized accordingtothemanual.

Check wiring for loose connection or tripped circuit breaker.

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

Ensure compressor or air drier are set up to be continuous run and sized accordingtothemanual.

V2IT TCM Low Voltage CAN Bad 24 VDC power

supply.

V3IT

V4CM MCM High Voltage MCM

V4IT

TCM

High Voltage CAN Bad 24 VDC power

supply.

Incoming line voltage is too high.

High Voltage CAN Bad 24 VDC power

supply.

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

Measure voltage across main power switch (CT01). Voltage should measure between 195 and 264 VAC. If voltage is too high, see supplied alternator manual for generator speciﬁcs and repair.

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

40 332637C

Troubleshooting

Error Location Type Description

V4MA

V4MB

V4MH TCM High Voltage Hose Incoming line

TCM

High Voltage A Incoming line

High Voltage B Incoming line

Cause Solution

voltage is too high.

Measure voltage across main power switch (CT01). Voltage should measure between 195 and 264 VAC. If voltage is too high, see supplied alternator manual for generator speciﬁcs and repair.

WBC0 MCM Software Version

Error

WMCE MCM Load Center Fault

WMI0

WSUX USB Conﬁguration Error

WXUD ADM

WXUU ADM USB Upload Error Custom language

TCM

TCM Fan Error Fan inside TCM

USB

USB Download Error

Incorrect software version.

Bad connection between MCM and load center board.

Bad load center. Replace load center.

is not operating properly.

Avalid conﬁguration ﬁle can't be found for the USB.

Log download failed.

ﬁlefailedtoupload.

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

Check connection and cables.

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

Inset a system token into the ADM and cycle power. Wait unti l the lights on the USB port stop ﬂashing before removing token.

Backup and reformat the USB drive. Retry download.

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

332637C

Troubleshooting

System

See Supplied Manuals, page 14, for air compressor service or warranty contact information.

Before performing any troubleshooting procedures:

1. Relieve Pressure. See Pressure Relief Procedure, page 60.

2. Turn main power switch OFF.

3. Allow equipment to cool.

Problem Cause Solution

Reactor ADM does not turn on. No power.

Turn main power switch ON. Turn circuit breakers ON, see

Repair Circuit Breaker Module, page 77.

Check circuit breaker (CB10). See

Repair Circuit Breaker Module, page 77.

Electric motor does not operate.

Electric motor runs erratically. Failed motor bearings. Replace motor, see

Loose co nne cti on s. Check MCM connections. See

Electrical Schematics, page 154.

Tripped circuit breaker (CB02). Reset breaker, see Repair Circuit

Breaker Module, page 77.Check

240VAC at output of breaker.

Shorted windings. Replace motor, see

Repair Electric Motor, page 76.

332637C

Problem Cause Solution

Electric motor cooling fan not working.

Pump output low.

Fluidleakinpumppackingnut area.

No pressure on one side. Fluid leaking from heater inlet

Air compressor does not start.

Air dryer cooling fan not running. Only runs after hot air ﬂow. Normal operation. Air dryer not draining water.

Tripped circuit breaker (CB03). Reset circuit breaker (CB03).

Check 240VAC at output of breaker.

Loose wire.

Fan blade obstructed. Remove obstruction. Defective fan. Replace. See

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

Worn piston valve or intake valve in displacement pump.

Pressure setpoint too high. Reduce setpoint and output will

Worn throat seals.

rupture disk (372).

Tripped circuit breaker (CB04). Reset circuit breaker (CB04). Not wired correctly. See

Compressor starter overheated from rapid multiple start and stop procedures.

Power not turned on at dryer. No air usage. Check after air ﬂowing.

Check. See

Electrical Sch em ati cs , page 154.

Replace Motor Fan, page 82.

Open, clear; use hose with larger ID.

See pump manual.

increase. Replace. See pump manual.

Check if heater and PRESSURE RELIEF/SPRAY valve (SA or SB) are plugged. Clear. Replace rupture disk (372) with a new one; do not replace with a pipe plug.

Electrical Sch em ati cs , page 154.

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

TurndryerswitchON(|).

Troubleshooting

332637C 43

Troubleshooting

Coolant System

Problem Cause Solution

Proportioner Coolant Loop

Air bubbles in sight glass .

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

Material slo wly heats up.

Heat ex ch ang er coolant in sight glass is a milky color.

A or B material heats up slower than the other.

A or B material cooling down slower than the other.

Air trapped in heat exchanger coolant.

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

Proportioner coolant loop expansion bottle is empty.

Circulation pump stopped running. Check circuit breaker. Check

Bypass control valve does not open.

Coolant ﬁlter plugged. Clean or repla ce ﬁlter in ﬁlter

A and B control valves are not opening fully.

System stored below 20°F(-7°C).

Possible material leaking into coolant.

Control valve opening too slow. Repair or replace valve. See

System stored below 20°F(-7°C). Ensure system ambient

Control valve coil failed. Repair or replace valve coil. See

Control valve coil not allowing valve to normally close.

Control valve stuck in open position.

Bad load center. Replac e the load

See Reﬁll Proportioner Coolant

Loop, page 68.

Ensure coolant hoses have a constant rise in elevation.

See Reﬁll Proportioner Coolant

Loop, page 68.

voltage. Repair or replace valve. See

Replace Control Valve, page 94.

housing, see Repair Filter Housing

Filter, page 96 and order replace-

ment ﬁlter kit 24T028. Repair or replace valve. See

Replace Control Valve, page 94.

Ensure system ambient temperature is above 20°F(-7°C).

Drain Proportioner coolant loop. See Drain Coolant, page 66. Check for pressurized material leaks.

Replace Control Valve, page 94.

temperature is above 20°F(-7°C).

Replace Control Valve, page 94.

Repair or replace valve coil. See

Replace Control Valve, page 94.

Repair valve. See

Replace Control Valve, page 94.

center board. See

Replace Load Center, page 80.

332637C

Problem Cause Solution

Engine Coolant Loop

Engine coolant does not reach full temperature.

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

Expansion bottle levels are not rising when coolant is heating.

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

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

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

Coolant level dropping in overﬂow bottle but no visible leaks.

Troubleshooting

Radiator fan does not shut off. Check fan relay. Check fan wiring. Radiator core becoming plugged.

Engine thermostat not opening. Replace engine thermostat. Coolant level is low in expansion

bottle. No coolant ﬂow in engine coolant

loop. Heat exchanger in the engine

coolant loop is plugged.

Radiator or heat exchanger bottle cap not opening.

Expansion bottle cap and radiator cap are switched.

Spring loaded gasket inside radiator cap does not seal.

Expansion bottle cap and radiator cap are switched.

Expansion bottle cap stuck open. Replace expansion bottle cap.

Cap not fully tightened.

Replace radiator. See

Remove Radiator, page 100.

Reﬁll Engine Coolant Loop, page

69.

Replace heat exchanger. See

Replace Heat Exchangers, page

91.

Replace cap.

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

Replace radiator cap.

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

Push down and tighten cap past safety latch position.

332637C 45

Troubleshooting

Hose Heat System

Before performing any troubleshooting procedures:

1. Relieve Pressure. See Pressure Relief Procedure, page 60.

2. Turn main power switch OFF.

3. Allow equipment to cool.

Problem Cause Solution

Ambient temperature is too cold. Use auxiliary hose heat system.Hose heats but heats slower than usual or it do es not reach temperature.

FTS failed or not installed correctly. Chec k FTS, see Check RTD

Cables and FTS, page 87.

Hose does not maintain temperature while spraying.

Hose temperature exceeds setpoint.

A and B setpoints too low. Increase A and B setpoints.

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

Ambient temperature is too cold. Increase A and B setpoints to

increase ﬂuid temperature and keep it steady.

Flow too high. Use smaller mix chamber.

Decrease pressure.

Hose was not fully preheated. Wait for hose to heat to correct

temperature before spraying.

A and/or B heaters are overheating

material.

Faulty FTS connections. Verify that all FTS conn ec tio ns are

Ambient temperature is too high.

Chec k primary heaters for eithe r a RTD problem or a failed element attached to RTD, see

Electrical Schematics, page 154.

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

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

46 332637C

Troubleshooting

Problem

Erratic hose temperature.

Hose does not heat.

Cause Solution

Faulty FTS connections. Verify that all FTS connections are

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

FTS not installed correctly. FTS should be installed close to

end of hose in same environment as gun. Verify FTS installation, see Repair Fluid Temperature

Sensor (FTS), page 88.

FTS failed. Check FTS, see Repair Fluid

Temperature Sensor (FTS), page

88.

FTS not installed correctly. FTS should be installed close to

end of hose in same environment as gun. Verify FTS installation, see Repair Fluid Temperature

Sensor (FTS), page 88.

Loose hose electrica l co nne cti on s. Check connections. Repair as

necessary.

Circuit breakers tripped. Reset breakers (CB20 and CB02),

see Repair Circuit Breaker Module,

page 77.

Hose zone not turned on. Turn on hose heat zone. A and B temperature setpoints too

low. Failed TCM. Remove TCM and install a new

Check. Increase if necessary.

TCM. New module comes with

current software. Update other

modules if necessary. See

software installation instruction

manual.

332637C

Troubleshooting

Problem

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

Low hose heat.

Cause Solution

Shorted connection or failed hose heating element.

A and B temperature setpoints too low.

Hose temperature setpoint too low.

Flow too high. Use smaller mix chamber.

Low current; FTS not installed. Install FTS, see operation manual. Hose heat zone not turned on long

enough to reach setpoint. Loose hose electrical connections.

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

Check Hose Hea t Connectors, page 87.

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

Check. Increase if necessary to maintain heat.

Decrease pressure.

Allowhosetoheatup,orpreheat ﬂuid.

Check connections. Repair as necessary.

Ambient temperature is to low Relocate hoses to a warmer area

or increase A and B setpoints.

48 332637C

Troubleshooting

Booster Heater

Before performi ng any trouble sh ooti ng procedures:

1. Relieve Pressure. See Pressure Relief Procedure, page 60.

2. Turn main power switch OFF.

3. Allow equipment to cool.

Problems

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

Problem

Booster heater(s) does not heat.

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

Cause Solution

Heat turned off. Temperature control alarm. Signal failure from RTD. Signal failure from RTD. Failed heater element.

Loose RTD connections. Examine RTD cables connected

RTD not contacting heater element.

Failed heater element.

Signal failure from RTD. See (T4DA, T4DB), Error Codes.

Turn on heat zones.

Check ADM for error codes.

See

Replace Heater Element, page 84.

to TCM. Conﬁrm RTDs are not

plugged into opposite heat zone.

Reconnect RTD connectors.

Loosen ferrule nut, push in RTD

so tip contacts heater element.

Holding RTD tip against heater

element, tighten ferrule nut 1/4

turn past tight.

See

Replace Heater Element, page 84.

332637C 49

Troubleshooting

Load Center Diagnostics

Reference Replace Load Center Re lays and Fuses, page 79,andElectric al Schematics, page 154.TheLEDs on the load center board are helpfu l diagnostic tools wh en troubleshooting problems with the engine. Before referencing the Engine Troubleshoot ing , page 53, complete the following steps:

1. Identify which LEDs are on and off.

Load Center Component Identiﬁcation Figure 1

F3 Radiator Fan Fuse F4 K1 Fuel Relay K2 K3 K4 Radiator Fan Relay MV

LED

D1 D2 D3 D4 Radiator Fan D10 D12 D14 D23

Load Ce

Starte Glow Pl

Manua

Related Component

Fuel Shutoff Solenoid Green Starter Glow Plugs

A Coolant Valve B Coolant Valve Bypass Coolant Valve Manual Valve Switch

nter Power Fuse

r Relay

ug Relay

lValveSwitch

Manual Valve Switch ON (engine off) Figure 2

Color

Red Green Green Radiator fan is on. Red Blue Green Red

ON-State Description

Fuel shutoff solenoid on the engine is open. Starter is cranking. Glow plugs are heating.

A-side (red) coolant valve is open. B-side (blue) coolant valve is open. Bypass coolant valve is open.

al valve switch is in the ON position.

Manu

50 332637C

Troubleshooting

2. Determine if the LEDs are expected to be in the state observed. Determine if an unlit LED should be on by referring to the LED Expected Operation table.

Note

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

LED Expected Operation

LED

D4 On when radiator fan is running – from

ON State

On when fuel is being fed to the engine – from shortly before the starter cranks until the engine is turned off.

On when starter is cranking – from shortly after the Fuel LED lights (beginning approximately 8 seconds after the green start button on the Engine Control Module is pressed) and until shortly after the engine turns over.

On when glow plugs are warming the engine - from when the green start button is pressed on the Engine Control Module until shortly after the engine starts and comes up to speed.

shortly before the starter cranks until shortly after the main power switch is turned on, then intermittently thereafter as required by engine temperature. (If the main power switch is left off, the fan will run continuously.)

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

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

Engine Trouble sh ooti ng , page 53.

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

Table1–LEDsLightAsExpected

Fuel (D1)

1 2 Engine

3 Engine

Engine Harne

Fuel

Shutoff

Solenoid

(FD)

Starter

(D2)

ss (E) and its connections

Starter

Solenoid

Relay (CR6)

Starter

Motor (ES)

Glow Plugs

(D3)

Glow Plugs

Solenoid

Relay (CR7)

Radiator

Fan

(D4)

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

Table 2 – LEDs Do Not Light As Expected

Fuel (D1)

1 2

5 6

9 Load Center Board

Load Center Fuse F4

Fusible Link Harness (C) and its connections

Engine Harness (E) and its connections

Engine Control Module Harness (F) and

Load

Center

Fuel Relay

(K1)

Starter

(D2)

Battery

Battery cables and its connections

No D2 LED Disconnect

switch ON

("PWR - ATO 20A")

its connections

Load Center Starter

Relay (K2)

Engine Control Module

Glow

Plugs

(D3)

Load

Center

Glow

Relay (K3)

Radiator

Fan

(D4)

Load

Center

Fuse F3

("FAN -

ATO 30A")

Load

Center Fan

Relay (K4)

332637C 51

Troubleshooting

LED

LED Sequence for Engine Startup and Operation

1. AfterpressinggreenstartbuttononEngine

2. Fuel and radiator fan turn on shortly before

Description

Off On

Flashing

Control Module, glow plugs start warming engine.

engine starting; glow plugs continue to warm engine.

4. Engine starting; glow plugs continue to warm engine.

5. Engine is running; with main power switch off, the radiator fan runs continuou sl y .

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

6. Engine is running; electronics take control of and cycle the fan and valves beginning shortly after main power switch is turned on.

52 332637C

Engine

Contact Perkins for diesel engine service or warranty. See Supplied Manuals, page 14.

Troubleshooting

Problem

Engine Control Module does not power up from sleep mode.

Cause Solution

Discharged or failed battery.

Loose or incorrect wiring connections.

Blown Load Center board fuse. Determine cause of blown fuse

Blown fusible link. Verify continuity through

Verify battery voltage is 11 - 13 volts DC.

Charge or replace bat- tery as required. See

Replace Battery, page 97.

Verify wiring connections (including grounds) related to Engine Control Module. Check Engine Harness (E), Engine Control Module Harness (F), Fusible Link Harness (C), and battery cables. See

Electrical Schematics, pag e 154.

Verifyvoltageis11-13voltsDC from starter to ground.

F4 "PWR - ATO 20A". Repair issue then replace fuse. See

Replace Load Center Relays and Fuses, page 79.

fusible link harness from starter to 12V charge alter- nator. If required, replace Fusible Link Harness (C). See

Electrical Schematics, pag e 154.

See Repair Fusible Link Harness,

page 98.

Failed Engine Control Module. Replace module. See Replace

Engine Control Module, page 101.

Failed Load Center board. Replace board. See

Replace Load Center, page 80.

332637C 53

Troubleshooting

Problem

Reference Load Center Diagnostics, page 50. Engine does not turn over.

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

Discharged or failed battery.

Loose or corroded battery cable connector.

Loose or incorrect wiring connections.

Blown Load Center board fuse. Determine cause of blown fuse

Cause Solution

Turn switch to OFF position.

Verify battery voltage is 11 - 13 volts DC.

Charge or replace bat- tery as required. See

Replace Battery, page 97.

Verify cable connectors. See

Replace Battery, page 97.

Verify wiring connections (including grounds) related to starter. Check Engine Harness (E), Engine Control Module Harness (F), Fusible Link Harness (C), Disconnect Check Harness (H), and battery cables. See

Electrical Schematics, page 154.

Verify voltage is 11 - 13 volts DC from starter to ground.

F4 "PWR - ATO 20A". Repair issue then replace fuse. See

Replace Load Center Relays and Fuses, page 79.

Failed starter relay. Replace relay K2 located

on Load Center board. See

Replace Load Center Relays and Fuses, page 79.

Failed starter solenoid relay. Replace solenoid relay CR6

locatedonsideofengine. See

Replace Engine Solenoid Relays, page 80.

Blown fus ib le link. Verify contin uit y through

fusible link harness from starter to solenoid relay CR6. If required, replace Fusible Link Harness (C). See

Electrical Schematics, page 154.

Failed load center board (242). Replace board. See

Replace Load Center, page 80.

Failed engine control module (428).

Failed engine starter (ES). Contact local Perkins distributor

Replace module. See Replace

Engine Control Module, page 101.

for service.

54 332637C

Troubleshooting

Problem

Reference Load Center Diagnostics, page 50. Engine turns over, but does not

start.

Low fuel level. Reﬁll fuel tank. Lost prime.

Loose or incorrect wiring connections.

Blocked air intake. Replace air ﬁlter. Blocked exhaust system.

Blocked fuel ﬁlter. Inspect/replace fuel ﬁlter. Failed fuel relay.

Cause Solution

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

Verify wiring connections (including to grounds) related to engine fuel shutoff solenoid. Check Engine Harness (E), Engine Control Module Harness (F), and Fusible Link Harness (C). See

Electrical Sch em ati cs , page 154.

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

Replace relay K1 located on Load Center board. See

Replace Load Center Relays and Fuses, page 79.

Solenoid valve rod stuck in extended position.

Failed engine fuel shutoff solenoid.

Failed glow plug relay. Replace relay K3 located on

Failed glow plug solenoid relay.

Failed glow plug assembly.

Remove valve rod and clean with WD-40.

Verify engine fuel shutoff solenoid (FD) related wiring according to schematics (see Cause "Loose or incorrect wiring connections", above).

Contact local Perkins distributor for service.

Load Center board. See Replace

Engine Solenoid Relays, page 80.

Replace solenoid relay CR7 locatedonsideofengine. See

Replace Engine Solenoid Relays, page 80.

Verify glow plug related wiring accordingtoschematics(see Cause "Loose or incorrect wiring connections", above).

Contact local Perkins distributor for service.

332637C 55

Troubleshooting

Problem

Reference Load Center Diagnostics, page 50. Engine shuts down, Engine

Control Module sh ows no errors.

Loose or incorrect wiring connections.

Failed fuel relay.

Failed engine fuel shutoff solenoid.

Cause Solution

Verify wiring connections (including grounds) related to engine fuel shutoff solenoid . Check Engine Harness (E), and Engine Control Module Harness (F). See

Electrical Schematics, page 154.

Replace relay K1 located on Load Center board. See

Replace Load Center Relays and Fuses, page 79.

Verify engine fuel shutoff solenoid (FD) related wiring according to schematics (see Cause "Loose or incorrect wiring connections", above).

Contact local Perkins distributor for service.

56 332637C

Troubleshooting

Problem

Reference Load Center Diagnostics, page 50. Engine shuts down, Engine

Control Module shows High Coolant Temperature Shutdown icon.

Low engine coolant level.

Engine water temperature switch failed or shorted out.

Loose or incorrect wiring connections.

Blown radiator fan fuse. Determine cause of blown fuse

Failed radiator fan relay.

Cause Solution

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

Check for shorts to switch wiring. See

Electrical Sch em ati cs , page 154.

Verify wiring connections (including grounds) related to radiator fan. Check Engine Harness (E), and Engine Control Module Harness (F). See

Electrical Sch em ati cs , page 154.

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

Replace Load Center Relays and Fuses, page 79.

Replace relay K4 located on Load Center board. See

Replace Load Center Relays and

Fuses, page 79.

Obstructed radiator fan. Remove obstructions. Failed radiator fan. Replace fan. See

Replace Radiator Fan, page 83.

Failed engine coolant temperature sensor.

Plugged radiator or coolant system.

Replaceenginecoolant

temperature sensor located

behind radiator connected

to MCM port 3. See

ReplaceEngineRTD,page105.

Clean or replace radiator. See

Remove Radiator, page 100.

Contact local Perkins distributor

for service.

332637C 57

Troubleshooting

Problem

Engine shuts down. Engine Control Module sh ows Low Oil Pressure Shutdown icon.

Engine shuts down. Engine Control Module shows Under

Frequency Sh utd own icon or Generator Low Voltage

Shutdown icon

Cause Solution

Low oil level. Loose or incorrect wiring

connections.

Failed oil pressure switch.

Low fuel level. Reﬁll fuel tank. Lost prime.

Blocked air intake. Blocked exhaust system.

Blocked fuel ﬁlter. Replace fuel ﬁlter.

Check oil level and reﬁll. Verify wiring connections

(including grounds) related to oil pressure switch. Check Engine Harness (E), and Engine Control Module Harness (F). See

Electrical Schematics, page 154.

Replace oil pressure switch Contact local Perkins distributor

for service.

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

Replace air ﬁlter. Check that exhaust system is

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

Generator overloaded. Conﬁrm auxiliary electrical loads

wiredintotheelectricalenclosure by the customer are within the system's available auxiliary power limits.

Loose or incorrect wiring connections.

Blown voltage sense fuses. Replace fuses F6 and F7 located

Verify wiring connections related to Engine Control Module, Check AC Sense Harness (M). See

Electrical Schematics, page 154.

in the junction box above the 120/240 V alternator. Use repair kit 24M723.

58 332637C

Graco InSite

Troubleshooting

Problem

No module status LEDs are illuminated.

Has not identiﬁed GPS location (green module s tatus LED ﬂashing). Unable to identify location. In a

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

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

Reactor temperature data not displayed on website. Hose zone temperature data not displayed on website. Reactor pressure data not displayed on website.

No power to cellular module.

Still identifying location. Wait a few minutes for the unit to

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

Still establishing cellular connection. Unable to establish cellular connection.

Graco InSite unit has not been activated.

Reactor temperature measurement is not working. The RTD is not correctly installed onthehoseorisbroken. Reactor pressure measurement is not working.

Cause Solution

Turn Reactor power ON.

Ensure cable is installed between

cellular module and power supply

and MCM.

identify th e location.

Move system to a location with a

clear view of the sky .

Useextensioncable16X521and

move cellular module to a location

with a clear view of the sky.

Wait a few minutes for the unit to

establish the connection.

Move system to a location with

cellular service to establish cellular

connection.

Useextensioncable16X521and

move cellular module to a location

with a clear view of the sky.

Activate unit. See Registering

andActivatingtheGracoInSite

section.

See System troubleshooti ng

section.

See RTD repair section.

See System troubleshooti ng

section.

332637C 59

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

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

The Fusion AP gun is shown.

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

2. Close gun ﬂuid inlet valves A and B.

4. Route ﬂuid to waste containers or supply tanks. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION

. Ensure gauges drop to 0.

5. Engage gun piston safety lock.

Fusion Probler

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

Fusion Probler

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

60 332637C

Shutdown

Shutdown system to avoid electric shock. All electrical wiring must be done by a qualiﬁed electrician and comply with all local codes and regulations. To hel p prevent serious injury from pressurized ﬂuid, such as skin injection, splashing ﬂuidandmovingparts,followthePressureRelief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

Immediate Shutdown

NOTICE

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

For immediate shutdown, press :

2. Turn off all heat zones.

3. Set PRESSURE RELIEF/SPRAY valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION

4. Relieve pressure. See

Pressure Relief Procedure, page 60.

Daily Shutdown

NOTICE

Proper system setup, s ta rtup, and shutdown procedures are critical to electrical equipment reliability. The following procedures ensure steady voltage. Failure to follow these proc edu res will cause voltage ﬂuctuations that can damage electrical equi pm ent and void the warranty.

1. Press to stop the pumps.

5. Press

park operation is complete when green dot goes out. Verify the park operation is com pl ete before moving to next step.

6. Press to deactivate the system.

to park the Component A Pump. The

332637C 61

Shutdown

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

8. Closethem

ain air shutoff valve.

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

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

NOTICE

Allow engine cooling dwell time, per manufacturer recommendations, prior to shutdown. Dwell time will help engine properly cool down after running at operating temperature for any period of time. Stopping the engine immediately after running it at full load for an extended period of time can causetheenginetooverheatduetothelackof coolant ﬂow. See engine manual.

10. Press to stop the engine.

11. Close all ﬂuid supply valves.

62 332637C

Shutdown

12. Engage gun piston safety lock then close ﬂuid

inlet valves A and B.

Fusion Probler

332637C 63

Flushing

To avoid ﬁre and explosion:

• Flush equipment only in a well-ventilated area.

• Do not turn on heaters until ﬂuid lines are clear of solvent.

• Flush out old ﬂuid with new ﬂuid, or ﬂush out old ﬂuid with a compatible solvent before introducing new ﬂuid.

• Use the lowest possible pressure when ﬂushing.

• All wetted parts are compatible with common solvents. Use only moisture-free solvents.

To ﬂush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE

RELIEF/CIRCULATION lines (N).

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

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

Important Isocyanate Information, page 9.

. Flush through bleed

64 332637C

Repair

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

Before Beginning Repair

NOTICE

1. Close the ﬂuid inlet valve at the pump inlet and shut off the appropriate feed pump. This prevents material from being pumped while cleaning the screen.

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

3. Remove the screen (A) from the strainer manifold. Thoroughly ﬂush the screen with compatible solvent and shake it dry. Inspect the screen. No more than 25% of the mesh should be restricted . If mo re than 25% of the mesh is blocked, replace the screen. Inspect the gasket (B) and replace as required.

4. Ensurethepipeplug(D)isscrewedintothe strainer plug (C). Install the strainer plug with the screen (A) and gasket (B) in place and tighten. Do not overtighten. Let the gasket make the seal.

5. Open the ﬂuid inlet valve, ensure that there are no leaks, and wipe the equipment clean. Proceed with operation.

1. Flush if necessary. See Flushing, page 64.

2. See Shutdown, page 61.

Flush Inlet Strainer Screen

The inlet strainers ﬁlter out particles that can plug the pump inlet check valves. Inspect the screens daily as part of the startup routine, and clean as req ui red.

Isocyanate can crystalli ze from moisture contamination or from freezing. If the chemicals used are clean and proper storage, transfer, and operating procedures are followed, there should be minimal contamination of the A-side screen.

Note

CleantheA-sidescreenonlyduring daily startup. This minimizes moisture contamination by immediately ﬂushing out any isocyanate residue at the start of dispensing operations.

Figure 3

332637C 65

Repair

Drain Coolant

LED Component LED Color

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

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

1. Perform Shutdown, page 61.

2. Open the cabinet door on the front of the proportioner.

3. Turn on manual valve switch (MV), located on the load center (LC), to manually open the A and B heat exchanger control valves and bypass control valve.

Note

The 12V battery must be connected to operate valves. The load ce nter (LC) LEDs will stay on when the manual valve switch (MV) is in the on position.

Manualvalveswitch(MV) A Side Control Valve B Side Control Valve Bypass Valve

4. To drain proportioner coolant loop:

a. Remove the proportioner coolant loop ﬁll

bottle (HF) cap.

b. Placetheotherendofthedraintubeina

waste container. Open the drain valve. Drain coolant until coolant is no longer visible in the sight glass.

Red Red Blue Green

Figure 4

66 332637C

Proportioner Coolant Loop Drain Valve Figure 5

c. To reﬁll coolant loop, s ee

Reﬁll Proportioner Coolant Loop, page 68.

Repair

5. To drain proportioner coolant loop from ﬁlter

housing. Only available on Series B systems.

a. Remove the proportioner coolant loop ﬁll

bottle cap (HF).

Filter Housing Drain Valve (D) Figure 6

b. Remove engine guards as shown. Let the

guards rest on the engine to access the drain valve.

b. Place the other end of the ﬁlter housing drain

tube (T) in a waste container. Open the drain valve (D).

c. To reﬁll coolant loop, see

Reﬁll Proportioner Coolant Loop, page 68.

6. To drain engine coolant loop:

a. Remove the engine coolant loo p (RC) cap.

Engine Coolant Loop Drain Valve Figure 7

c. Place a waste container under the drain

valve. O pen the drain valve and drain coolant.

d. To reﬁll coolant loop, see

Reﬁll Engine Coolant Loop, page 69.

e. Replace engine shrouds. Torque screws to

25 ft-lbs (33.8 N∙m).

332637C 67

Repair

Reﬁll Proportioner Coolant Loop

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

Note

It takes about one full warm-up and cool-down cycle to purge air from coolant.

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

Only use coolant solutions that are compatible with the system. See Coolant Speciﬁcations, page 70.

NOTICE

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

NOTICE

To prevent leaks, do not interchange the two caps between the radiator and coolant bottle. The caps have different pressure ratings that affect the overﬂow.

2. Remove the caps from the metal proportioner coolant loop ﬁll bottle (HF) and expansion bottle (HB). Fill the proportioner coolant loop ﬁ ll bottle (HF) to the top and add more coolant to expansion bottle (HB) until the coolant is at the cold ﬁll line. See Coolant Speciﬁcations, page 70.

NOTICE

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

1. Before reﬁlling coolant loop, perform steps 1–3 from Drain Coolant, page 66. Drain coolant loop if necessary.

Coolant System Bottles Figure 8

68 332637C

Repair

3. Replace cap and tighten past the safety latch

position.

4. Press start button

control module.

5. Turn main power switch on.

6. Inspect coolant ﬂow i n sight glass (SG) for

bubbles and to verify that the coolant is ﬂowing.

7. Inspect coolant loops for leaking ﬁttings or valves.

8. The coolant has reached operating temperature

when the radiator fan turns on. When the fan turns on, turn the main power sw itc h off.

9. Press to stop the generato r.

10. After the coolant sy s tem temperature lowers to

ambient temperature, reﬁll or add coolant to the expansion bottle (HB) cold level indicator line.

11. Turn off manual valve switch (MV) to close the A

and B heat exchanger control valves (VA, VB) and bypass control valve (VC).

twiceontheengine

Only use coolant solutions that are compatible with the system. See Coolant Speciﬁcations, page 70.

NOTICE

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

NOTICE

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

1. Perform Shutdown, page 61.

NOTICE

To prevent leaks, do not interchange the two caps between the radiator and coolant bottle. The caps have different pressure ratings that affect the overﬂow.

2. Removetheengineradiatorcoolantcap(RC) and ﬁll until the coolant reaches the bottom of the neck. See Fig 8. Replace cap. See

Coolant Speciﬁcations, page 70.

3. Remove th e cap from the engine coolant loop bottle (EB) and ﬁll until the coolant is at the hot level. Replace cap.

4. Press start button control module.

twiceontheengine

Note

When the manual valve switch (MV) is in the off position, the load center (LC) LEDs only turn on when the system opens the valves.

12. If necessary, reﬁll or add coolant to the expansion bottle (HB) cold level indicator line. See Fig 8.

Reﬁll Engine Coolant Loop

Reﬁll the engine coolant loop when the coolant is below the cold level line at ambien t t emp eratu re.

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

5. Turn main power switch on.

6. Inspect coolant loops for leaking ﬁttings or valves.

7. The coolant has reached operating temperature when the radiator fan turns on. When the fan turns on, turn the main power switc h off.

8. Press to stop the generator.

9. Add more coolant to expansion bottle (EB) after the coolant system temperature lowers to ambient temperature. Repeat until coolant level stays at cold level when at ambient temperature. It may take a few cycles to remove all air out of coolant system.

332637C 69

Repair

Coolant Speciﬁcations

NOTICE

Do not reﬁll with straight water or tap water. Changing the 50% mix rat io use of tap water will allow ﬁttings to rust.

Only reﬁll the coolant loops with a solution of 50% distilled or soft water and 50% green ethylene g lycol antifreeze with a corrosion inhibitor. Do not use common tap water; it contains chlorides and minerals which form scale on the coolant system walls. Do not use any stop leak products. The additives in these products will cl og the heat exc han ger and ﬂuid valv es , decreasing system performance. Use only antifreeze that meets speciﬁcation ASTM D3306–89, BS658, or AS 2108. A pre-diluted mix is recommended, such as PEAK Ready Use 50/50 Pre-Diluted.

Change Pump Lubricant

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

To change pump lubricant:

1. Follow Pressure Relief Procedure, page 60.

2. Lift the lubricant reservoir (R) out of the bracket and remove th e container from the cap . Holding the cap over a suitable c ont ain er, remove the check valve and allow the lubricant to drain. Reattach the check valve to the inlet hose .

3. Drain the reservoir and ﬂush it with clean lubricant.

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

5. Thread the reserv oir onto the cap asse mbl y and placeitinthebracket.

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

Gel forma tio n is due to moisture abs orpti on by the pump lubricant. The interval between changes depends on th e environment in which th e equipment is operating. The p ump lubrication system mi ni miz es exposure to moisture, but some contamination is still possible.

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

Pump Lubrication System Figure 9

70 332637C

Repair

Remove Pump

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

Note

See manual 309577 for pump repair instructions.

1. Press

2. Turn off he

3. Flush pump

4. Press

5. Press

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

7. Close the main air shutoff valve.

op the pumps.

to st

at zones.

to park the Component A Pump.

to deactivate the system.

9. Allow engine dwell time.

NOTICE

Allow engine dwell time, per manufacturer recommendations, prior to shutdown. Dwell time will help engine cool down after running at operating temperature for any period of time.

10. Press on the engine control module.

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

12. Shut off both feed pump s. Close all ﬂui d supply valves.

13. Route ﬂuid to waste containers or supply tanks. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION

8. Turn main power switch off.

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

. Ensure gauges drop to 0.

332637C

Repair

Note

Use drop cloth or rags to protect Reactor and surrounding areas from spills.

Note

Steps 14–16 apply to pump A. To disconnect pump B, go to steps 17 and

18.

14. Disconnect ﬁttings at ﬂuid inlet (C) and outlet (D). Also disconnect s te el outlet tube from heater inlet.

15. Disconnect tubes (T). Remove both tube ﬁttings (U) from wet-cup.

16. Loosen lockn ut (G) by hitting ﬁrmly w ith a non-sparking hammer. Uns crew pump far enough to expose rod retaining pin. Push retaining wire clip up. Push pin out. Continue unscrewing pump.

Pump B Figure 11

Flat side faces up.

Lubricate threads with ISO oil or grease.

Pump top threads must be nearly ﬂush with

bearing face (N).

Install Pump

Pump A Figure 10

Flat side faces up.

Lubricate threads with ISO oil or grease.

Pump top threads must be nearly ﬂush with

bearing face (N).

Note

Steps 17 and 18 apply to pump B.

Note

Steps 1–5 apply to pump B. To reconnect pump A, proceed to step 6.

1. Ensure locknut (G) is screwed on pump with ﬂat side up. Screw pump into bearing housing (M) until pin holes align. Push pin (F) in. Pull retaining wire clip (E) down. See Fig. 11, page 54 for view and assembly notes.

2. Continue screwing pump into housing until ﬂuid outlet (D) is aligned with steel tube and top threads are +/- 1/16 in. (2 mm) of bearing face (N).

3. Tighten locknut (G) by hitting ﬁrmly with a non-sparking hammer.

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

5. Go to step 13.

Note

Steps 6–12 apply to pump A only.

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

17. Disconnect ﬂuid inlet (C) and ou tlet (D). Also disconnect s tee l outlet tube from heater inl et.

18.Pushretainingwireclip(E)up. Pushpin(F) out. Loosen locknut (G) by hitting ﬁrmly with a non-sparking h amm er. Unscrew pump.

7. Start threading pump into bearing housing (M). When pin holes align, insert pin. Pull retaining wire clip down.

8. Continue th readi ng pump into bearing housing (M) until top threads are +/- 1/16 in. (2 mm) of

332637C

Repair

bearing face (N). Ensure that barbed ﬁttings at wet-cup ﬂush ports are accessible.

9. Connect component A outlet tube lo osely at pump and at heater. Line up tube, then tighten ﬁttings securely.

10. Tighten star-shaped locknut (G) by hitting ﬁrmly with a non-sparking hammer.

11. Apply thin ﬁlm of TSL to barbed ﬁttings. Using two hands, s upp ort tubes (T) while pushing straight onto barbed ﬁttings. Secure each tube withawiretiebetweentwobarbs.

Note

Do not let tubes kink or buckle.

12. Reconnect ﬂuid inlet (C).

13. Purge air and prime the system. See Reac tor operation manual.

Repair Drive Housing

Removal

1. Press to stop the pumps.

2. Turn off heat zones.

3. Flush pump.

4. Press

5. Press

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

7. Close the main air shutoff valve.

8. Turn main power switch off.

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

to park the Component A Pump.

to deactivate the system.

332637C 73

Repair

9. Allow engine dwell time.

NOTICE

Allow engine dwell time, per manufacturer recommendations, prior to shutdown. Dwell time will help engine cool down afte r running at operating temperature for any period of time.

10. Press on the engine control module.

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

12. Perform Pressure Relief Procedure, page 60.

13. Remove screws (294) and motor shield (293), see Fig. 12.

Note

Examine bearing housing (303) and connecting rod (305). If these pa rts nee d replacing, ﬁrst remove the pump (315), see Remove Pump, page 71.

Figure 12

14. Remove cover (74) and screws (75).

15. Remove cycle switch (321) from A side drive housing. Remov e screws (322) and cycle switch (321).

16. Disconnect pump inlet and outlet lines. Remove screws (313), washers (314), and beari ng housing (303).

NOTICE

Do not drop gear cluster (304) when removing drive housing (302). Gear cluster may stay engaged in motor front end bell (R) or drive housing.

17. Remove screws (312) and pull drive housing (302)offmotor(301).

Note

The A side drive housing includes cycle counter switch (321). Switch wire connects to port #12 on the MCM.

Figure 13

Installation

1. Apply grease liberally to washers (307, 308,

318), all gears, and inside drive housing (302).

2. Install one bronze washer (308) in drive housing, then install steel washers (307, 318) as shown.

3. Install second bronze washer (308) on gear cluster (304) and insert gear cluster in drive housing.

Note

Drive housing crankshaft must be in line with crankshaft at other end of motor. See Fig. 13, page 56.

332637C

Repair

4. Push drive housing (302) onto motor (301). Install screws (312).

Note

If bearing housing (303), connecting rod (305), or pump (315, 306) were removed, reassemblerodinhousingandinstall pump, see Install Pump, page 72 .

5. Install cycle counter switch (3210) and screws (322).

6. Install bearing housing (303), screws (313), and washers (314). Pumps must be in phase (both at same position in stroke).

7. Install cover (74) and screws (75).

8. Install motor shield (293) and screws (294).

ure 14

Fig

332637C 75

Repair

Repair Electric Motor

Removal

NOTICE

Be careful not to drop or damage the motor. The motor is heavy and may require two people to lift.

1. Remove drive housing and pump assemblies. See Repair Drive Housing, page 73.

2. Disconnect electric motor (301) power cable from port#15ontheMCM.

3. Remove screws (294) and motor shield (293). Rest motor shroud assembly behind the motor without strain ing the fan power ca bl e.

Installation

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

Electrical Schematics, page 154.

4. Disconnect over temperature cable from port #2 on MCM. Cut tie wraps around harness to remove cable.

5. Remove four screws (268) holding motor (301) to bracket. Lift motor off unit.

2. Fasten motor (301) with screws (268) until screws are fully threaded in mounting bracket. Do not tighten screws until drive housing and pumpsareconnectedtothemotor.

Note

If necessary, loosen screws (268) to align the motor (301) wi th side brackets.

3. Install driv e housing and pump assemblies, se e

Installation, page 74.

4. Route motor (301) power cable from motor through top port into Reactor cart, through back port out of the Reactor, through cord grip (518), and into the electrical enclosure. Connect to port #15onMCM.Usetiewrapstosecurepower cable to other cables on pallet.

5. Install drive housing covers and motor cover.

6. Return to service.

76 332637C

Repair

Repair Circuit Breaker Module

1. See Before Beginning Repair, page 65.

2. Using an ohmmeter, check for continuity across circuit breaker (left to right). If no continuity, trip breaker, reset, and retest. If still no continuity, replace breaker as follows:

a. Refer to Electrical Schematics, page 154,

and tables on next page.

PS1

b. Follow Shutdown instructions. See

Shutdown, page 61.

c. Refer to circuit breaker identiﬁcation table

and electrical diagrams in Reactor repair manual.

d. Loosen four screws connecting wires and bus

bar to circuit breaker that will be replaced. Disconnect wires.

e. Pull locking tab out 1/4 in. (6mm) and pull

circuit breaker away from the din rail. Install new circuit breaker. Insert wires a nd tighten down all screws.

1 A 5

A 5 1

A 30

A 0 2

A2 40

A 0

A 5 1

4 0 B C

B11T T

2 1 B

05 B C

7 0 B C

08 B C

Circuit Breakers Figure 15

Ref. Size Component

CB01

Power Supply, Fan,

Coolant Pump CB02 CB03

15 A Boost Heat A 15 A Boost Heat B

332637C

Ref. Size Component

CB04

30 A Hose Heat CB05 20 A Motor Control CB06* CB07* CB08* 1

40 A

20 A

Air Compressor/Open Open Air Dryer/Open

Repair

Circuit Breakers Inside Cabinet Figure 16

Ref. Size Component

Circuit Breakers Inside Alternator Assembly Figure 17

Ref. Size Component

CB10

90 A 120/240V Alternator

CB20

50 A Heated Hose

78 332637C

Replace Load Center Relays and Fuses

1. Disconnect the negative lug from the negative post of the battery. See ReplaceBattery, page97.

2. Remove the bad relay or fuse from the load center (242) and install a new relay or fuse. See

Fig. 18.

3. Connect battery cable. See

Replace Battery, page 97.

Repair

Relay and Fuse Identiﬁcation Table

See Load Center Wiring Diagram, page 163.

Repair

Kit

24L958

24L959

Ref

K1 K2 K3 K4

F3 FAN-ATO - 30A

F4 PWR-ATO - 20A

Component

Fuel Relay Starter Relay Glow Plug Relay Fan Relay Fuse for load center

relay K4 and radiator fan.

Fuse for load center relays K1, K2, K3 and their related components; Engine Control Module power; and coolant valve control.

Load Center Relay and Fuse Identiﬁcation Figure 18

332637C 79

Repair

Replace Load Center

NOTICE

Before handling board, put on a static conductive wrist strap to protect against st atic discharge which can damage board. Follow instructions provided with wrist strap.

1. Perform Shutdown, page 61.

2. Disconnect the negative lug from the negative post of the battery. See Replace Battery, page 9 7

3. Disconnect all connectors. See

Load Center Wiring Diagram, page 163.

4. Remove four nuts (248), and load center (240).

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

Load Center Wiring Diagram, page 163.

Replace Engine Solenoid Relays

1. Perform Shutdown, page 61.

2. Disconnect the negative lug from the negative post of the battery. See Replace Battery, page 97.

3. Remove two bolts (570) and solenoid relay (569). The starte r solenoid relay (CR6) i s above th e glow plug solenoid relay (CR7).

4. Disconnect cables from the old relay andconnecttothenewrelay. See

Load Center Wiring Diagram, page 163.

6. Connect battery cable. See

Replace Battery, page 97.

Starter (top) and Glow Plug (bottom) Solenoid Relays Figure 19

80 332637C

Repair

Replace Fluid Inlet Sensor

1. Perform Shutdo wn, page 61.

2. Perform Pressure Relief Procedure, page 60.

3. Disconnect inl et sensor cable from the

ﬂuid inlet assembly. Inspect cable for damage and replace if necessary. See

Electrical Schematics, page 154.



5. Replace sensor (866).

Replace Pressure Transducers

1. Perform Shutdown, page 61.

2. Perform Pressure Relief Procedure, page 60.

3. Disconnect transducer cables (455) from #6 and #7 connectors on the MCM. Reverse A and B connections and chec k if error code P6A X or P6BX follows the transducer. See Error Codes.

4. If transducer fails test, thread cable through to p of cabinet. Note path as cable must be replaced in same way.

5. Install o-ring (466) on new transducer (455).

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

7. Route cable into cabinet and thread into bundle as before.

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

Figure 20 Fluid Inlet Sensor

4. To replace sensor cable:

a. Open wire bundle and remove sensor cable. b. Cut any wire ties and disconnect from MCM.

See Electrical Schematics, page 154.

NOTICE

To prevent damage to cable, route and securecableinwirebundleandwireties as before.

332637C 81

Repair

Replace Fans

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

Replace Motor Fan

1. Perform Shutdown, page 61.

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

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

4. Refer to Electrical Schematics, page 154.Check connections of all wires going to terminal blocks TB21 and TB22. Verify that all screws are tight. Using an voltmeter, check for 24 volts DC across TB21(+) and TB22(-). Replace cable (22), if zero volts are read. If volts are correct and fan doe sn’t spin, replace fan.

Replace Proportioner Module Fan

1. Perform Shutdown, page 61.

2. Remove cabinet panel (70).

3. Refer to Electrical Schematics, page 154.Check connections of all wires going to terminal blocks TB21 and TB 22. Verify that al l screws are tight. Using an voltmeter, check for 24 volts DC across TB21(+) and TB22(-). Replace cable (22), if zero volts are read. If volts are correct and fan doesn’t spin, replace fan.

4. Remove fan (212).

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

5. Remove nuts (292) and fan (212).

6. Install new fan (212) in reverse order.

Figure 21

Figure 22

82 332637C

Repair

Replace Radiator Fan

1. Perform Shutdo wn, page 61.

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

3. Install new fan (605) to radiator bracket (601) with screws (605).

Replace Electrical Enclosure Fan

1. Perform Shutdown, page 61.

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

3. Refer to Electrical Schematics, page 154.Check connections of all wires going to terminal blocks TB13, TB14, and power supply P S1 . Verify that all screws are tight. Using an voltmeter, chec k for 24 volts DC across TB13(+) and TB14(-). Replace power supply PS1 (515), if zero volts are read. If volts are correct and fan doesn’t spin, replace fan.

4. Install new fan (561) in reverse order of disassembly so that the fan blows out o f the electrical enclosure.

Figure 23

Figure 24

332637C 83

Repair

Repair Booster Heater

Replace Heater Element

1. Press to stop the pumps.

2. Turn off heat zones.

3. Flush pump.

4. Press

5. Press

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

7. Close the main air shut off valve.

8. Turn main power switch off.

to park the Component A Pump.

to deactivate the system.

10. Press on the engine control module.

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

12. Perform Pressure Relief Procedure, page 60.

13. Wait for heater to cool.

14. Remove heater shroud (266).

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

Total Heater Wattage

4,000 2000 23–26.5

Note

The A-side heater element is located in the booster heater end nearest the B-sidepumpandtheB-sideheater element is located near the A-side pump.

16. To remove heater element, ﬁrst remove RTD (360) to avoid damage. See step 7,

ReplaceRTD,page85.

Element Ohms

To prevent electric shock do not remove any shrouds or open the electrical enclosure door. 240 V is stil l present i n the sys tem until th e engine h as stopped.

9. Allow engine dwell time.

NOTICE

Allow engine dwell time, per manufacturer recommendations, prior to shutdown. Dwell time will help engine cool down afte r running at operating temperature for any period of time.

17. Remove heater element (357) from housing (351). Be careful not to spill any ﬂuid left in housing. See Fig. 25.

18. Inspect element. It should be relatively smooth and shiny. If there is a crusted, burnt, ash-like material adhered to element or sheath shows pitting marks, replace element.

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

20. Reinstall RTD (360), Replace RTD, page 85.

21. Reconnect heater element leadwires to heater wire connector.

22. Replace heater shroud (266).

Line Voltage

The heater outputs its rated wattage at 240 VAC. Low line voltage will reduce power available and the heater will not perform at ful l capacity.

84 332637C

Repair Overtemperature Switch

1. Perform Shutdo wn, page 61.

2. Wait for booster heater to cool.

3. Remove heater shroud.

4. Verify blue wire and brown/black wires from cable (54) ”HTR-OT” are connec ted to overtemperature switch (358). See

Electrical Schematics, page 154.

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

Repair

a. If the resistance

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

b. If the resistanceisapproximately 0 ohms,

test the cable to ensure it is not cut or open. Reconnect the overtemperature switch and cable. Disconnect the cable from the overtemperature port on the TCM. Test from pin 1 to pin 3 and pin 1 o pin 4 on cable (54) “HTR-OT”. Resistance should be approximately 0 ohms.

Note

The cable may have failed if one or b oth of the readings is above approximately 0 ohms. If the read ings is approximately 0 ohms, then there may have been a bad connector/connection causing the problem.

6. If switch fails test, remove screws. Discard failed switch. Apply a thin layer of thermal compound 110009, install new switch in same location on housing (351), and secure with screws (361). Reconnect cables.

is not

approximately 0 ohms,

Replace RTD

1. Perform Shutdown, page 61.

2. Wait for heater to cool.

3. Remove heater shroud (266) and heater guards (299, 300).

4. B Side RTD: a. Follow “HT- RTD-B" RTD cable (360) and

open split loom about 18 in. (457.2 mm) away from the heater attachment. Disconnect “HT- RTD-B TCM" and “HT-RTD-B” connectors. See Electrical Schematics, page 154.

b. Visually inspect “HT-RTD-B” connector and

replace extension cable (58) if necessary. Continue to next step if the extension cable connector is not damaged.

c. Visually inspect “TCM-A HT-RTD-B”

connection to TCM. Continue to next step to replace RTD (360).

5. A side RTD: a. Follow “HT- RTD-A" RTD cable (360) and

open split loom about 18 in. (457.2 mm) away from the heater attachment. Disconnect “HT- RTD-A TCM" and “HT-RTD-A” connectors. See Electrical Schematics, page 154.

b. Visually inspect “HT-RTD-A” connector and

replace extension cable (58) if necessary. Continue to next step if the extension cable connector is not damaged.

c. Visually inspect “TCM-A HT-RTD-A”

connection to TCM. Continue to next step to replace RTD (360).

332637C 85

Repair

6. Loosen ferrule nut (N). Remove RTD (360) from heater housing (351), then remove RTD housin g (H). Do not remov e the ada pte r (355) unles s necessary. If adapter must be removed, ensure that mixer (359) is out of the way when replacing the adapter.

7. Replace RTD (360).

a. Apply PTFE tap e and thread sealant to mal e

pipe threads and tighten RTD housing (H) into adapter (355).

b. Push in RTD (360) so tip contacts heater

element (357).

c. Holding RTD (360) against heater element,

tighten ferrule nut (N) 3/4 turn past ﬁnger-tight.

8. Route wires (S) as before through split loom and reconnect RTD cable (360) to the B side extension cable (71) or th e A s id e extension cable (58).

9. Replace heater shroud and heater guards.

10. Follow startup instructions in the operation manual. Turn on A and B heat simultaneously to test. Temperatures should rise at same rate. If one is low, loosen ferrule nut (N) and tighten RTD housing (H) to ensure RTD tip contacts element (357) when ferrule nut (N) is retightened.

Figure 25

86 332637C

Repair

Repair Heated Hose

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

Check Hose Heat Connectors

1. Perform Shutdo wn, page 61.

Note

Whip hose must be connected.

2. Disconnect hose connector (V) at Reactor, see

Fig. 26.

3. Using an ohmmeter, check bet ween the connectors (V). Th ere should be continuity .

4. If hose fails test, retest at each length of hose, including whip hose, until failure is isolated.

Check RTD Cables and FTS

1. Perform Shutdo wn, page 61.

2. Disconnect RTD cable (C) at Reactor.

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

Note

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

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

Heated Hose Figure 26

Do not touch outer ring with test probe.

Pins Result

3 to 1 approximately 1090

ohms

3 to 4 approximately 1090

ohms 1to4 0.2-0.4ohms 2toany

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

inﬁnity (open)

Note

To assist in taking readings, order RTD Test Kit 24N365. Kit includes two cables: one cable with a compatible female M8 connector and an oth er c abl e w ith a male M8 connector. Both cables have stripped wire at the other end for easy test probe access.

Pins / Wire Color

3 to 1 / brown to blue approximately 1090

3 to 4 / blue to black approximately 1090

1 to 4 / brown to bla ck 0.2 - 0.4 ohms 2 to any / N/A inﬁnity (open)

Result

ohms

332637C 87

Repair

Repair Fluid Temperature Sensor (FTS)

Installation

The Fluid Temperature Sen so r (FTS) is s up pli ed with the system. Instal l FTS between main hose and whip hose. See Heated Hose manual 309572 for instructions.

Figure 27

Test/Removal

1. Perform Shutdown, page 61.

2. Remove tape and protective covering from FTS. Disconnect hose cable (F).

3. If FTS is not reading properly at the end of the hose, see Check RTD Cables and FTS, page 87.

4. If FTS fails, replace FTS.

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

connectors (D).

b. Disconnect FTS from whip hose (W) and

ﬂuid h os es (A, B).

c. Remove ground wire (K) from ground screw

on underside of FTS.

d. Remove FTS probe (H) from component A

(ISO) side of hose.

88 332637C

Repair

Transformer Primary Check

1. See Shutdown, page 61.

2. Locate the two smaller (10 AWG) wires, labeled

1 and 2, c omi ng out of transformer. Trace these wires back to terminal blocks TB23 and TB24. Use an ohmmeter to test for continuity between two wires; there should be continuity.

Transformer Secondary Check

1. See Shutdown, page 61.

2. Locate the two larger (6 A WG ) wires, labeled 3

and 4, coming out of transformer. Trace these wires back to circuit breaker CB20 (906). Open the circuit breaker to turn the color indicator on the circuit breaker GREEN. Use an ohmmeter to test for continuity between two transformer wires in circuit breaker terminals 1 and 3; there should be continuity.

3. Close the circuit breaker CB20 (906).

5. Start the generator.

Press start button control module. The controller will automatically sequence glow plug warming and crank operations. Allow engine to reach full operating speed.

Note

Engine will not start if main power switch is in the on position.

6. Turn main power switch on.

7. Press to turn on hose heat zone.

Thisequipmentisusedwithheatedﬂuidwhich can cause equipment surfaces to become very hot. To avoid severe burns:

twiceontheengine

Figure 28

4. Conﬁrm main power switch is off before starting

generator.

• Do not touch hot ﬂuid or equipment.

• Allow equipment to cool completely before touching it.

• Wear gloves if ﬂuid temperature exceeds 110°F (43°C).

• Do not turn on hose heat without ﬂuid in hoses.

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

332637C 89

Repair

8. To verify voltage on the secondary leads of the transformer, measure between the terminals 2 and 4 on CB20. This will verify the circuit breaker is working properly.

Model

310 ft 90 Vac* 210 ft 62 Vac*

* For 240 Vac line voltage.

9. See the Diagnostic Run Screen on the ADM. The Diagnostic Run Screen displays the incoming (240 Vac) to the TCM “Hose Voltage” and the hose current. The diagnostic screen will show if th e circuit breaker has been trippe d for the incoming power to the TCM.

Secondary Voltage

Replace Transformer

1. Perform Shutdown, page 61.

2. Open Reactor cabinet.

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

4. Disconnect the transformer wires. See

Reactor Cabinet Wiring Diagram, page 162.

5. Remove transformer (226) from cabinet.

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

226

90 332637C

Replace Heat Exchangers

1. If a wall is installed between the generator and the proportioner, remove the proportioner from the pallet. See Remove Proportioner, page 102.

2. Perform Flush ing , page 64.

3. Perform Shutdo wn, page 61.

4. Perform Drain Coolant, page 66.

For proportioner heat exchangers:

a. Remove fuel tank. See

Remove Fuel Tank, page 96.

b. Disconnect both RTD connectors (284). See

Replace Heat Exchanger RTD, page 93.

c. Disconnect A and B material lines from

swivel ﬁttings (297).

Repair

Proportioner Heat Exchangers Figure 29

d. Disconnect hose clamps (37, 239) from heat

exchanger assembly (241).

e. Remove four nuts (249) and the heat

exchanger assembly (241). Pull heat exchanger assembly out of coolant hoses.

f. Install a new hea t exchanger assembly

(241) by following the removal steps in reverse order. Orient control valves as shown. Continue to next step to remove heat exchangers (802) or (803).

332637C 91

Repair

g. Disconnect two swivel ﬁttings (805) and

swivel ﬁttings on heat exchanger outlet (806) from the heat exchangers (802, 803).

For the engine heat exchanger:

a. Disconnect swivel ﬁttings (617) and (618)

from heat exchanger (614).

b. Remove nuts (612), washers (613), and heat

exchanger (614). Set expansion bottle and bracket aside.

c. Install new heat exchanger (614) in reverse

order by following the removal steps in reverse order.

Proportioner Hea t Exchangers Figure 30

h. Remove four nuts (810) and washers (811)

for replacing heat exchangers (802) or (803).

Engine Heat Exchanger Figure 31

92 332637C

Repair

Replace Heat Exchanger RTD

1. Perform Shutdo wn, page 61.

2. Remove Reactor cabinet cover.

3. Disconnect RTD from CAN cable.

NOTICE

ISO and RES will release when either RTD is removed from the heat exchangers. To prev ent damage to load center and other electronics, protect all elec troni cs from chemicals releas ed from the heat exchanger RTD ports.

4. Remove compression ﬁtting (272) from the b ack of the heat exchanger with RTD (273) attached.

The RTD probe cannot be removed from the compression nut.

NOTICE

To ensure accurate temperature readings, only use RTD Kit 24L972.

5. Tighten compression ﬁtting (272) on RTD sheath (273).

6. Apply thread sealant to compression ﬁtting pipe threads (272 and install in heat exchanger.

7. Connect new RTD to extension cable (71).

Figure 32

332637C 93

Repair

Replace Control Valve

Follow thes e instructions to replace a c ont rol valve solenoid coil or remove the component A control valve, component B control valve, or the bypass control valve.

1. Perform Shutdown, page 61.

2. Drain coolant from the proportioner coolant loop. See Drain Coolant, page 66.

3. To re pai r the control valve, remove the four nuts (VN) and washers (VW). Remove the front of the control valve, diaphragm, and gaskets. Purchase Valve Repair Kit 125774. For complete installation instructions see the Control Valve Kits manual 3A1932.

4. To remove the solenoid coil (SC), loo se n connector screw and disconnect the coolant valve harness (D). Remove the nut (SN) and washer (SW) from coil. Purchase Valve Coil Replacement Kit 125787. For complete installation instructions see the Control Valve Kits manual 3A1932.

Replace Power Supply

1. Perform Shutdown, page 61.

2. Disconnect power supply (655) from circuit breaker CB01 and terminal blocks TB13 through TB15. See Electrical Schematics, page 154.

3. Insert a ﬂat head screw driver in the mounting tab on the bottom of the power supply (655) to remove from the din rail.

Figure 33

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

94 332637C

Repair

Replace Circulation Pump

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

1. Perform Shutdo wn, page 61.

2. Perform Drain Coolant, page 66.

3. If a wall is installed and the ci rcul ati on pump can not be accessed, remove the proportioner. See

Remove Proportioner, page 102.

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

5. Remove pump cover (C).

6. Press in tabs to disconnect power wires (W).

7. Remove four outside nuts (254). Hold on to the pump ﬂanges (234) and remove the circulation pump (233). Remove four inside nuts (254) to remove ﬂanges from the pump.

8. Place o-rings, supplied with the new circulation pump (233), between the pump and the ﬂange ﬁttings (234). Insert screws (255) through the pump and ﬂange ﬁttings (234) and tighten four nuts on screws (255).

9. Place circulation pump (233) on brackets (223) so that coolant will ﬂow towards the sight glass. Install four nuts (254) on screws (255).

10. Connect power wires to pump and replace c over. See Reactor Cabinet Wiring Diagram, page 162.

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

Figure 34

332637C 95

Repair

Repair Filter Housing Filter

1. Drain the proportioner coolant loop. See

Drain Coolant, page 66.

2. Remove cap (C) and ﬁlter (643) from ﬁlter housing (630).

3. Pull out ﬁlter (643). Brush out ﬁlter and replace if necessary.

4. Insert ﬁlter (643) into cap (C) and t igh ten c ap i nto ﬁlter housing (630).

Remove Fuel Tank

1. Perform Shutdown, page 61 .

2. Disconnect fuel lines (38, 39). Keep elevated or plug to prevent siphoni ng.

3. Remove screws (24) and clamps (30).

4. Slide the fuel tank off the B side of the pallet.

5. Inspect for any damage.

6. Slide fuel tank on to pallet and secure to pallet with screws (24) and clamps (30). Reconnect fuel lines (38, 39).

7. Squeeze prime bulb (P) to prime engine. Press the pri me bulb repeatedly until fuel begins to return to the fuel tank.

Figure 35

96 332637C

Repair

Replace Battery

Improper battery installation or maintenance may result in electric shock, chemical burns, or explosion. Battery maintenance must only be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorize d personnel away from batteries.

See Technical Speciﬁcations, page 175 for battery requirements and recommended battery size.

1. Remove plastic caps (PC) from battery term inals and disconnect battery cables from battery.

2. Disconnect strap and remove battery.

3. Place new battery on bracket and secure with strap.

4. Reconnect battery cables and cover battery terminals with plastic caps (PC). Ensure red

cableisconnectedtothepositive(+)battery post. Connect black c ab le to the negative (-) battery post.

Figure 36

NOTICE

Always connect the red battery cable to battery positive (+) terminal and the black battery cable to the battery negative (-) terminal. Failure to properly connect the battery cable to the battery will damage th e fusible link harness. Do not by pas s the fusible link when damaged. The fusible link prevents damage to other system components.

332637C 97

Repair

Repair Fusible Link Harness

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

Electrical Schematics, page 154, for fusible link

harness conn ec tio ns and wire identiﬁcat ion .

1. Perform Shutdown, page 61.

2. Disconnect battery from system.

3. Determine which fuse (F8, F9) needs to be replaced.

a. Cut cable tie (81) and remove red insulator

cap (111) over the positive stud on the engine starter. Remove the outside nut (106) and red battery cable (47) . Disconnect fusible link harness (90) ring terminal from the engine starter.

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

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

6. Pull away heat shrink. Squeeze the fuse holder cover and disconnect from base latches. If latches break off, replace entire fuse holder with fuse holder (118) shipped loose with the system.

b. Using a multimeter, measure continuity

through the harness ring terminals. See Table 1.

c. I f one of the two wire paths measures “open”,

then the fuse (F8, F9) in that path is blown and needs to be replaced.

Table 1 Fusible Link Harness Connections

Fuse (117) Wire No. Ring Terminal Location Wire No. Ring Terminal Location

C010 and C030

Engine starter positive power lug

7. Remove two M5 nuts from fuse holder base.

8. Replaceblown60ampfuseinthefuseholder base with new fuse (117). New fuse (117) is shipped loose with the system.

C020

C040

C050

12 V charge alternator B+ terminal

Starter solenoid relay (CR6)

Glow plug solenoid relay (CR7)

98 332637C

Repair

9. Replace M5 nuts over fuse and ring terminals. Torque to 44 in.-lbs (5 N●m).

10. Connect fuse holder c over to fuse holder base. Wrap entire fuse holder and heat shrink 3–4 times with tape (44).

NOTICE

Ensure tape entirely covers heat sh rink. Failure to seal the cut heat shrink with tape may allow ﬂuid to contact fusible link and damage the fusible link.

11. Connect fusible link harness (90) and battery cable to engine starter with nuts (106). Secure to solenoid relay bracket with cable ties (81), shipped loose with system.

12. Snap th e c ap insulator (111) over the red b atte ry cable (47). Position the red cap insulator so that the stud is not exposed.

13. Insert cable tie (81) through cap insulator (111) andtightentotheredbatterycable(47).Ensure that the stud is not exposed.

14. Reconnect black battery cable to the negative (-) battery terminal and the red battery cable to the positive (+) battery terminal.

NOTICE

Always connect the red battery cable to battery positive (+) termi nal and the black ba ttery cable to the battery negative (-) terminal. Failure to properly connect the battery cable to the battery will damage the fusible link harness. Do not bypass the fusible link whe n damaged. The fus i ble link prevents damage to other system components.

332637C 99

Repair

Remove Radiator

NOTICE

Do not damage ﬁns on radiator. Damaged radiator ﬁns will result in poor radiator performance or cause a coolant leak.

1. Drain the engine coolant loop. Follow

Drain Coolant, page 66.

2. Remove radiator air exhaust duct, if used.

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

Figure 38

7. Inspect radiator for any obstructions. Replace or have serviced, if necessary.

Figure 37

4. Remove eight screws (605), top bracket (604), and bottom bracket (606).

5. Loosen hose clamps (622) and coolant hose from radiator (603) inlet and outlet.

8. Install new radiator assembly in reverse order.

9. Follow Reﬁll Engine Coolant Loop, page 69.

Replace Advanced Display Module (ADM)

1. Loosen screw in bracket (402). Lift up on bracket (402) and remove ADM (27).

2. Disconnect CAN cable (57).

3. Inspect ADM for damage. Replace if necessary.

6. Carefully swing the bottom of the radiator (603) away from the engi ne and lift out of cover (601).

Figure 39

100 332637C

Graco 332637C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Warnings

Important Isocyanate Information

Isocyanate Conditions

Keep Components A and B Separate

Moisture Sensitivity of Isocyanates

Material Self-Ignition

Foam Resins with 245 fa Blowing Agents

Changing Materials

Models

Reactor 2 E-30i Elite

Reactor 2 E-XP2i Elite

Approvals

Accessories

Supplied Manuals

Related Manuals

Component Manuals in English:

Troubleshooting

Troubleshoot Errors

Error Codes

System

Coolant System

Hose Heat System

Booster Heater

Load Center Diagnostics

Engine

Graco InSite

Pressure Relief Procedure

Shutdown

Flushing

Repair

Before Beginning Repair

Flush Inlet Strainer Screen

Drain Coolant

Change Pump Lubricant

Remove Pump

Install Pump

Repair Drive Housing

Removal

Installation

Repair Electric Motor

Removal

Installation

Repair Circuit Breaker Module

Replace Load Center Relays and Fuses

Replace Load Center

Replace Engine Solenoid Relays

Replace Fluid Inlet Sensor

Replace Pressure Transducers

Replace Fans

Replace Motor Fan

Replace Proportioner Module Fan

Replace Radiator Fan

Replace Electrical Enclosure Fan

Repair Booster Heater

Replace Heater Element

Repair Overtemperature Switch

Replace RTD

Repair Heated Hose

Check Hose Heat Connectors

Check RTD Cables and FTS

Repair Fluid Temperature Sensor (FTS)

Installation

Test/Removal

Transformer Primary Check

Transformer Secondary Check

Replace Transformer

Replace Heat Exchangers

Replace Heat Exchanger RTD

Replace Control Valve

Replace Power Supply

Replace Circulation Pump

Repair Filter Housing Filter

Remove Fuel Tank

Replace Battery

Repair Fusible Link Harness