Graco Reactor E-30i Repair Parts Download Page 36 | Manualshive

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Troubleshooting

Booster Heater

Before performing anytroubleshooting procedures:
1. Relieve Pressure. See

Pressure Relief Procedure, page 46

.

2. Turn main power switch OFF.
3. Allow equipment to cool.
Problems
Trythe recommended solutions in the order given for each problem, to avoid unnecessaryrepairs. Also,

determine that all circuit breakers, switches, and controls are properlyset and wiring is correct before

assuming there is a problem.

Problem

Cause

Solution

Heat turned off.

Turn on heat zones.

Temperature control alarm.

Check ADM for error codes.

Booster heater(s) does not heat.

Signal failure from RTD.

Signal failure from RTD.

DirtyRTD connections.

Examine RTD cables connected

to LPTCMs. Conﬁrm RTDs are

not plugged into opposite heat

zone. Unplug and re-plug RTD

connectors. Unplug and re-plug

RTD connectors. Ensure RTD tip

contacts the heater element.

RTD not contacting heater

element.

Loosen ferrule nut, push in RTD

so tip contacts heater element.

Holding RTD tip against heater

element, tighten ferrule nut 1/4

turn past tight.

Failed heater element.

See

Replace Heater Element, page 68

.

Control of booster heat is

abnormal; high temperature

overshoots (T4DA, T4DB) occurs

intermittently.

Signal failure from RTD.

See (T4DA, T4DB),

Error Codes

and Troubleshooting, page 14

.

36

3A1706K

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Summary of Contents for Reactor E-30i

Page 1: ...r spraying polyurethane foam and polyurea coatings For professional use only Not for use in explosive atmospheres or hazardous locations Important Safety Instructions Read all warnings and instructions in this manual Save these instructions PROVEN QUALITY LEADING TECHNOLOGY All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 2: ...es 64 Replace Transducers 65 Replace Fans 66 Repair Booster Heater 68 Repair Heated Hose 71 Repair Fluid Temperature Sensor FTS 72 Replace Heat Exchangers 74 Replace Power Supply 77 Replace Circulation Pump 78 Repair Sight Glass Filter 79 Repair Filter Housing Filter 80 Remove Fuel Tank 81 Replace Battery 81 Repair Fusible Link Harness 82 Remove Radiator 84 Repair Advanced Display Module ADM 85 Re...

Page 3: ...ith all local codes and regulations TOXIC FLUID OR FUMES Toxic ﬂuids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed Read MSDSs to know the speciﬁc hazards of the ﬂuids you are using Store hazardous ﬂuid in approved containers and dispose of it according to applicable guidelines CARBON MONOXIDE HAZARD Exhaust contains poisonous carbon monoxide whi...

Page 4: ...t off engine and let it cool Fuel is ﬂammable and can ignite or explode if spilled on hot surface Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn light switches on or off when ﬂammable fumes are present Groun...

Page 5: ...ate the unit when fatigued or under the inﬂuence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use ﬂuids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read ﬂuid and solvent manufacturer s warnings For complete information...

Page 6: ...h insulated handles Do not lay tools or metal parts on top of battery MOVING PARTS HAZARD Moving parts can pinch cut or amputate ﬁngers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all ...

Page 7: ...arts Moisture Sensitivity of Isocyanates Cross contamination can result in cured material in ﬂuid lines which could cause serious injury or damage equipment To prevent cross contamination of the equipment s wetted parts never interchange component A isocyanate and component B resin parts Isocyanates ISO are catalysts used in two component foam and polyurea coatings ISO will react with moisture suc...

Page 8: ...ires special attention to avoid equipment damage and downtime When changing materials ﬂush the equipment multiple times to ensure it is thoroughly clean Always clean the ﬂuid inlet strainers after ﬂushing Check with your material manufacturer for chemical compatibility When changing between epoxies and urethanes or polyureas disassemble and clean all ﬂuid components and change hoses Epoxies often ...

Page 9: ... 259081 32 Amps 240 V 1 11 700 2 0 7 6 0 0203 0 0771 3500 24 1 241 259091 12 Amps 240 V 1 16 700 2 0 7 6 0 0203 0 0771 3500 24 1 241 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 ...

Page 10: ...ovals Model Approvals 259079 Conforms to ANSI UL Std 73 Certiﬁed to CAN CSA Std C22 2 No 68 259080 259081 Conforms to ANSI UL Std 499 Certiﬁed to CAN CSA Std C22 2 No 88 10 3A1706K All manuals and user guides at all guides com ...

Page 11: ...sion CS CS0101 CS9080 2000 13 8 138 259080 24K240 246050 Fusion CS CS0101 CS9081 3500 24 1 241 259081 24K241 246055 Fusion CS CS0000 CS9179 2000 13 8 138 259079 24K394 246050 Fusion CS CS0101 CS9180 2000 13 8 138 259080 24K394 246050 Fusion CS CS0101 CS9181 3500 24 1 241 259081 24K395 246055 Fusion CS CS0000 P29079 2000 13 8 138 259079 24K240 246050 Probler P2 GCP2R1 P29080 2000 13 8 138 259080 24...

Page 12: ...er P2 GCP2R1 P29090 2000 13 8 138 259090 24K240 246050 Probler P2 GCP2R1 P29091 3500 24 1 241 259091 24K241 246055 Probler P2 GCP2R0 P29189 2000 13 8 138 259089 24K394 246050 Probler P2 GCP2R1 P29190 2000 13 8 138 259090 24K394 246050 Probler P2 GCP2R1 P29191 3500 24 1 241 259091 24K395 246055 Probler P2 GCP2R0 Accessories Kit Number Description 24N449 50 ft 15 m CAN cable for remote display modul...

Page 13: ...on Air Compressor Operation Maintenance Parts list For warranty and service call Gardner Denver Customer Serivce 866 276 3440 or Champion 815 875 3321 Related Manuals Manuals are available at www graco com Component manuals in English System Manuals 3A1705 Reactor E 30i and E XP2i Operation Displacement Pump Manual 309577 Electric Reactor Displacement Pump Repair Parts Feed System Manuals 309572 H...

Page 14: ... requiring attention but not sufﬁcient enough to stop the system at this time Advisories are indicated by This condition indicates a parameter that is not immediately critical to the process The advisory needs attention to prevent more serious issues in the future Error Code Error Location Type Name Cause Solution Loose or bad motor or wire connection Check for tight motor wire termination in gree...

Page 15: ...g too much current from the system If problem continues replace MCM See Replace Motor Control Module MCM page 86 Short circuit in booster heater wiring Check wiring for touching wires A4DA A4DB Boost A Boost B ALARM High Heater Current Bad heater Measure resistance of heater s replace if needed See Repair Booster Heater page 68 Check continuity of transformer windings normal reading are about 0 2Ω...

Page 16: ...ce Module See Replace Low Power Temperature Control Module LPTCM page 86 Turned off main power switch with heaters and motor ON Turn off heat and motor power at ADM before turning off the main power switch Turned on hose circuit breaker with hose heat on Turn on circuit breaker with hose heat off Failed to power off after loading software Power off after software downloaded A7DH Hose ALARM Unexpec...

Page 17: ...DC If not replace power supply See System Repair manual Loose or broken CAN cable Check the CAN cables running between GCA modules and tighten if needed If the problem still persists move each cable around the connector and watch the ﬂashing yellow light on the GCA modules If the lights stops replace the CAN cable CACA CACB CACH CACM CACP Boost A Boost B Hose MCM Remote Display Module ALARM Commun...

Page 18: ... set pressure Reference the pressure ﬂow curves in the operation manual and select a tip size that is the correct size for the set pressure H1MH Hose ALARM Low Line Frequency Line frequency is below 55 Hz Check frequency If out of tolerance see supplied 120 240V alternator manual for repair instructions H4MH Hose ALARM High Line Frequency Line frequency is above 65 Hz Check frequency If out of tol...

Page 19: ...ansducer Verify the ADM pressure reading the analog gauges at the manifold Replace transducers if they do not match See Replace Transducers page 65 Loose bad connection Check to ensure the pressure transducer is properly installed and all wires are properly connected P6AX P6BX MCM ALARM Pressure Transducer Fault A Pressure Transducer Fault B Bad sensor Check if the error follows the transducer Dis...

Page 20: ...ter and PRESSURE RELIEF SPRAY valve SA or SB are plugged Clear Replace rupture disk 372 Do not replace with a pipe plug P7AX P7BX MCM ALARM Pressure Imbalance A High P7AX Pressure Imbalance B High P7BX Feed system defective Check feed pump and hoses for blockage Check that the feed pumps have the correct air pressure P0AX MCM ADVISORY Pressure Imbalance A High See P7AX P0BX MCM ADVISORY Pressure I...

Page 21: ...ow Temperature Hx A Low Temperature Hx B No voltage to coil of valve Turn on the manual valve switch on the load center to manually turn on the solenoids and see if the temperature rises If not check voltage output on J6 connector on the load center 242 and ensure the LEDs are on See Load Center page 143 Follow Load Center Diagnostics page 37 If necessary replace the load center board See Replace ...

Page 22: ...a smaller mix chamber See performance charts in system operation manual Manual override switch on load center board is in the on position Open cabinet cover and turn switch to the off position A or B side control valve solenoid is stuck in the open position Debris in valve diaphragm or plunger preventing spring loaded closed function Disconnect connector from solenoid coil If temperature does not ...

Page 23: ...utes If the condition does not clear or regenerates consis tently replace MCM See Replace Motor Control Module MCM page 86 Bad RTD or bad RTD placement against heater rod Swap A and B heater power cables and RTD cables and see if issue follows If so replace RTD See Replace RTD page 69 T4DA T4DB Boost A Boost B ALARM High Chemical Temperature Bad Low Power Temperature Control Module Swap the A and ...

Page 24: ...e Replace HPTCM See Replace High Power Temperature Control Module HPTCM page 86 Cooling fans are not operating properly Ensure ambient temperature is less than 120 F 48 C Check to see that the fans are moving Measure voltage to fans There should be 240 VAC If no voltage is measured check wiring between fan and circuit breaker CB03 If the fans have voltage but are not moving replace fan Use an air ...

Page 25: ...sage follows the RTD Replace RTD if the error follows the RTD T6DH Hose ALARM RTD Cable or FTS Fault Broken RTD cable in hose or bad FTS Expose each hose RTD connection to check and retighten any loose con nector Measure hose RTD cable and FTS continuity See Check RTD Cables and FTS page 71 Order RTD Test Kit 24N365 for measurement See Temporary Manual Hose Temperature Control instructions in the ...

Page 26: ...ss Ensure that the circulation pump has 240 VAC If not replace the circulation pump See Replace Circulation Pump page 78 T8AE only J6 connector on load center Heat Valves location is not centered Reconnect J6 connector on load center in centered location Bad valve solenoid coil Turn on the manual valve switch on the load center and see if the solenoid shifts For coolant valve LED identiﬁcation see...

Page 27: ... manual for repair Started spraying before engine and hose reached operating temperature Wait until operating temperatures have been reached on engine and hose before spraying T8DH Hose ALARM Temperature Not Rising Low chemical supply temperature Recirculate heated chemical back to drum in cold conditions before spraying Chemical below 32 F 0 C at startup V1CM MCM ALARM Bus Under Voltage Tripped M...

Page 28: ... 64 WSCX ADM ADVISORY Invalid CAN Conﬁguration Duplicate node on CAN network Verify LPTCM are set to A and B A valid conﬁguration ﬁle can t be found for the USB Insert a system token into the ADM and cycle the power Wait until the lights on USB port stop ﬂashing before removing the token WSUX USB ADVISORY USB Invalid Conﬁguration Bad ADM Replace ADM See Repair Advanced Display Module ADM page 85 W...

Page 29: ... 62 Loose connections Check MCM connection 13 Tripped circuit breaker CB02 Reset breaker see Repair Circuit Breaker Module page 62 Check 240VAC at output of breaker Worn brushes Check both sides Length must be 0 7 in 17 mm minimum To replace see Repair Motor Brushes page 59 Broken or misaligned brush springs Realign or replace see Repair Motor Brushes page 59 Brushes or springs binding in brush ho...

Page 30: ... Not wired correctly See Electrical Schematics page 134 Air compressor does not start Compressor starter overheated from rapid multiple start and stop procedures Let starter cool down for 2 minutes then press reset on the air compressor electrical enclosure and start Air compressor shuts down randomly Loose wire connections Check and retighten all wire connections in the air compressor electrical ...

Page 31: ...t ﬁlter kit 24T028 A and B control valves are not opening fully Repair or replace valve See Replace Control Valve page 77 Material slowly heats up System stored below 20 F 7 C Ensure system ambient temperature is above 20 F 7 C Heat exchanger coolant in sight glass is a milky color Possible material leaking into coolant Drain Proportioner coolant loop See Drain Coolant page 50 Check for pressurize...

Page 32: ...exchanger bottle cap not opening Replace cap Expansion bottle cap and radiator cap are switched Switch radiator caps Radiator cap is marked 16 lbs and expansion bottle is marked 8 lbs Coolant level in engine coolant expansion bottle rises too high and too fast Spring loaded gasket inside radiator cap does not seal Replace radiator cap Coolant level in proportioner coolant expansion bottle does not...

Page 33: ... cold Increase A and B setpoints to increase ﬂuid temperature and keep it steady Flow too high Use smaller mix chamber Decrease pressure Hose does not maintain temperature while spraying Hose was not fully preheated Wait for hose to heat to correct temperature before spraying A and or B heaters are overheating material Check primary heaters for either a RTD problem or a failed element attached to ...

Page 34: ...gun Verify FTS installation see Repair Fluid Temperature Sensor FTS page 72 Loose hose electrical connections Check connections Repair as necessary Circuit breakers tripped Reset breakers CB20 and CB02 see RepairCircuitBreakerModule page 62 Hose zone not turned on Turn on hose heat zone A and B temperature setpoints too low Check Increase if necessary Failed HPTCM Remove HPTCM and install a new HP...

Page 35: ...s too low Increase A and B setpoints Hose designed to maintain temperature not increase temperature Hose temperature setpoint too low Check Increase if necessary to maintain heat Flow too high Use smaller mix chamber Decrease pressure Low current FTS not installed Install FTS see operation manual Hose heat zone not turned on long enough to reach setpoint Allow hose to heat up or preheat ﬂuid Loose...

Page 36: ...not heat Signal failure from RTD Signal failure from RTD Dirty RTD connections Examine RTD cables connected to LPTCMs Conﬁrm RTDs are not plugged into opposite heat zone Unplug and re plug RTD connectors Unplug and re plug RTD connectors Ensure RTD tip contacts the heater element RTD not contacting heater element Loosen ferrule nut push in RTD so tip contacts heater element Holding RTD tip against...

Page 37: ...ly after the engine turns over D3 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 D4 On when radiator fan is running from shortly before the starter cranks until shortly after the main power switch is turned on then intermittently thereafter as required by engine temperatu...

Page 38: ...D1 Fuel Shutoff Solenoid Green Fuel shutoff solenoid on the engine is open D2 Starter Red Starter is cranking D3 Glow Plugs Green Glow plugs are heating D4 Radiator Fan Green Radiator fan is on D10 A Coolant Valve Red A side red coolant valve is open D12 B Coolant Valve Blue B side blue coolant valve is open D14 Bypass Coolant Valve Green Bypass coolant valve is open D23 Manual Valve Switch Red Ma...

Page 39: ...arm engine 3 Engine starting fuel fan and glow plugs continue to operate 4 Engine starting glow plugs continue to warm engine 5 Engine is running with main power switch off the radiator fan runs continuously 6 Engine is running electronics take control of and cycle the fan and valves beginning shortly after main power switch is turned on 7 Ensure engine is running proportioner idle before any heat...

Page 40: ...Identiﬁcation page 134 Verify voltage is 11 13 volts DC from starter to ground Blown Load Center board fuse Determine cause of blown fuse F4 PWR ATO 20A Repair issue then replace fuse See Replace Relays and Fuses page 64 Blown fusible link Verify continuity through fusible link harness from starter to 12V charge alter nator If required replace Fusible Link Harness C See Harness Identiﬁcation page ...

Page 41: ...C from starter to ground Blown Load Center board fuse Determine cause of blown fuse F4 PWR ATO 20A Repair issue then replace fuse See Replace Relays and Fuses page 64 Failed starter relay Replace relay K2 located on Load Center board See Replace Relays and Fuses page 64 Failed starter solenoid relay Replace solenoid relay CR6 located on side of engine See Replace Engine Solenoid Relays page 65 Blo...

Page 42: ...led fuel relay Replace relay K1 located on Load Center board See Replace Relays and Fuses page 64 Solenoid valve rod stuck in extended position 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 Failed engine fuel shutoff solenoid Contact local Perkins distributor for service Fail...

Page 43: ... Harness F See Harness Identiﬁcation page 134 Failed fuel relay Replace relay K1 located on Load Center board See Replace Relays and Fuses page 64 Verify engine fuel shutoff solenoid FD related wiring according to schematics see Cause Loose or incorrect wiring connections above Engine shuts down Engine Control Module shows no errors Failed engine fuel shutoff solenoid Contact local Perkins distrib...

Page 44: ...use of blown fuse F3 FAN ATO 30A Repair issue then replace fuse See Replace Relays and Fuses page 64 Failed radiator fan relay Replace relay K4 located on Load Center board See Replace Relays and Fuses page 64 Obstructed radiator fan Remove obstructions Failed radiator fan Replace fan See Replace Radiator Fan page 67 Failed engine coolant temperature sensor Replace engine coolant temperature senso...

Page 45: ...r intake Replace air ﬁlter Blocked exhaust system Check that exhaust system is open rain cap is free to move no exhaust obstructions or plugging Remove blockage Blocked fuel ﬁlter Replace fuel ﬁlter Generator overloaded Conﬁrm auxiliary electrical loads wired into the electrical enclosure by the customer are within the system s available auxiliary power limits Loose or incorrect wiring connections...

Page 46: ...f Procedure This equipment stays pressurized until pressure is manually relieved To help prevent serious injury from pressurized ﬂuid such as skin injection splashing ﬂuid and moving parts follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment The Fusion AP gun is shown 1 Relieve pressure in gun and perform gun shutdown procedure See gun man...

Page 47: ...mon 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 Flush through bleed 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 p...

Page 48: ...and shut off the appropriate feed pump This prevents material from being pumped while cleaning the screen 2 Place a container under the strainer base to catch drain off when removing the strainer plug C 3 Remove the screen A from the strainer manifold Thoroughly ﬂush the screen with compatible solvent and shake it dry Inspect the screen No more than 25 of the mesh should be restricted If more than...

Page 49: ...the air compressor air dryer and breathing air 7 Close the main air shutoff valve 8 Turn main power switch off To prevent electric shock do not remove any shrouds or open the electrical enclosure door 240 V is still present in the system until the engine has stopped 9 Allow engine dwell time NOTICE Allow engine dwell time per manufacturer recommendations prior to shutdown Dwell time will help engi...

Page 50: ...n Figure 4 LED Component LED Color Manual valve switch MV Red A Side Control Valve Red B Side Control Valve Blue Bypass Valve Green 4 To drain proportioner coolant loop a Remove the proportioner coolant loop ﬁll bottle HF cap See Fig 8 b Place the other end of the drain tube in a waste container Open the drain valve Drain coolant until coolant is no longer visible in the sight glass Proportioner C...

Page 51: ...nt system has reached ambient temperature Only use coolant solutions that are compatible with the system See Coolant Speciﬁcations page 53 1 Before reﬁlling coolant loop perform steps 1 3 from Drain Coolant page 50 Drain coolant loop if necessary 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 ﬁl...

Page 52: ...system has reached ambient temperature Only use coolant solutions that are compatible with the system See Coolant Speciﬁcations page 53 1 Perform Shutdown page 49 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 NOTICE Do not interchange the two caps between the radiator a...

Page 53: ...mp lubricant The interval between changes depends on the environment in which the equipment is operating The pump lubrication system minimizes exposure to moisture but some contamination is still possible Lubricant discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during operation If the packings are operating properly lubricant replacement due to disc...

Page 54: ...ic shock do not remove any shrouds or open the electrical enclosure door 240 V is still present in the system until the engine has stopped 9 Allow engine dwell time NOTICE Allow engine dwell time per manufacturer recommendations prior to shutdown Dwell time will help engine cool down after running at operating temperature for any period of time 10 Press on the engine control module 11 Open air com...

Page 55: ...retaining wire clip up Push pin out Continue unscrewing pump Pump A Figure 10 1 Flat side faces up 2 Lubricate threads with ISO oil or grease 3 Pump top threads must be nearly ﬂush with bearing face N 4 Finger guard P not used on E 30i model Note Steps 17 and 18 apply to pump B 17 Disconnect ﬂuid inlet C and outlet D Also disconnect steel outlet tube from heater inlet 18 Push retaining wire clip E...

Page 56: ...0i model 8 Seat ﬁnger guard P on wet cup Continue threading pump into bearing housing M until top threads are 1 16 in 2 mm of bearing face N Ensure that barbed ﬁttings at wet cup ﬂush ports are accessible 9 Connect component A outlet tube loosely at pump and at heater Line up tube then tighten ﬁttings securely 10 Tighten star shaped locknut G by hitting ﬁrmly with a non sparking hammer 11 Apply th...

Page 57: ...le counter switch cable from port 6 on the MCM Cut zip ties on harness with counter switch cable inside 16 Remove front plate 289 and two screws 299 Remove screws 326 and washers 314 from inside the mounting bracket 17 Disconnect pump inlet and outlet lines Remove screws 313 washers 315 and bearing housing 303 NOTICE Do not drop gear cluster 304 when removing drive housing 302 Gear cluster may sta...

Page 58: ...sing 302 onto motor 301 Install screws 312 319 and washers 314 Note If bearing housing 303 connecting rod 305 or pump 306 were removed reassemble rod in housing and install pump see Install Pump page 56 5 Route cycle counter switch cable 321 under the motor fan and inside the conduit Connect to port 6 on the MCM and close conduit with tie wraps 6 Install bearing housing 303 screws 313 and washers ...

Page 59: ...ectric shock and burns wait for 5 minutes for stored voltage to discharge 9 Remove motor cover screws Remove brush inspection covers and screws from top and bottom of motor 10 Remove two screws 299 and front plate 289 See Fig 20 page 65 11 Remove two screws 299 from back plate 290 Rest fan and back plate 290 behind motor See Fig 20 page 65 12 Push in spring clip C to release hooks H from brush hol...

Page 60: ...B T R L 3 Install spring S so it will uncoil onto brush B as shown Spring will be damaged if installed backwards B S 4 Install spring clip C and push in until hooks H catch slots in housing Incorrect installation may jam clip S C H Do not touch brushes leads springs or brush holders while equipment is plugged in to reduce the risk of electric shock and serious injury NOTICE Do not run pumps dry fo...

Page 61: ... 57 5 Disconnect brushwear over temperature cable from port 10 on MCM Cut tie wraps around harness to remove cable 6 Remove four screws 273 holding motor 301 to bracket Lift motor off unit Installation 1 Place motor on unit Thread motor cables into conduit as before See Electrical Schematics page 134 2 Fasten motor with screws 273 until screws are fully threaded in mounting bracket Do not tighten ...

Page 62: ... Circuit Breakers Figure 15 Ref Size Component CB01 30 A High Power Temperature Control Module HPTCM CB02 20 A Motor Control Module MCM CB03 5 A Two Motor Fans Cabinet Fan Power Supply and Coolant Circulation Pump CB04 30 A Auxiliary Power Air Compressor CB05 10 A Auxiliary Power CB06 20 A Auxiliary Power E XP2i and E 30i With Heat Low Power Temperature Control Module LPTCM A CB07 15 A E 30i Auxil...

Page 63: ...Inside Cabinet Figure 16 Ref Size Component CB20 50 A Heated Hose Circuit Breakers Inside Alternator Assembly Figure 17 Ref Size Component CB10 90 A 120 240V Alternator 3A1706K 63 All manuals and user guides at all guides com ...

Page 64: ... relays K1 K2 K3 and their related components Engine Control Module power and coolant valve control Load Center Relay and Fuse Identiﬁcation Figure 18 Replace Load Center NOTICE Before handling board put on a static conductive wrist strap to protect against static discharge which can damage board Follow instructions provided with wrist strap 1 Perform Shutdown page 49 2 Disconnect the negative lug...

Page 65: ...e Relief Procedure page 46 3 Disconnect transducer cables 455 from 8 and 9 connectors on the MCM Reverse A and B connections and check if error code P6AX or P6BX follows the transducer See Error Codes and Troubleshooting page 14 4 If transducer fails test thread cable through top of cabinet Note path as cable must be replaced in same way 5 Install o ring 466 on new transducer 455 6 Install transdu...

Page 66: ... still no continuity replace breaker See Repair Circuit Breaker Module page 62 5 Remove bolts 251 and fan 212 6 Install new fan 212 in reverser order Figure 20 Replace Proportioner Module Fan 1 Perform Shutdown page 49 2 Remove cabinet panel 70 3 See Electrical Schematics page 134 Using an ohmmeter check for continuity across circuit breaker CB03 left to right If no continuity trip breaker reset a...

Page 67: ...2 Loosen four nuts 558 and remove fan 561 3 Refer to Electrical Schematics page 134 Using an ohmmeter check for continuity across circuit breaker top to bottom If no continuity trip breaker reset and retest If still no continuity replace breaker For instructions see Repair Circuit Breaker Module page 62 4 Install new fan 561 in reverse order of disassembly so that the fan blows out of the electric...

Page 68: ...Disconnect heater element wires from heater wire connector Test with ohmmeter Total Heater Wattage Element Ohms 4 000 2000 23 26 5 Note The A side heater element is located in the booster heater end nearest the B side pump and the B side heater element is located near the A side pump 16 To remove heater element ﬁrst remove RTD 360 to avoid damage See step 7 Replace RTD page 69 17 Remove heater ele...

Page 69: ...ve failed if one or both of the readings is above approximately 0 ohms If the readings is approximately 0 ohms then there may have been a bad connector connection causing the problem 6 If switch fails test remove screws Discard failed switch Apply a thin layer of thermal compound 110009 install new switch in same location on housing 351 and secure with screws 361 Reconnect cables Replace RTD 1 Per...

Page 70: ...o tip contacts heater element 357 c Holding RTD 360 against heater element tighten ferrule nut N 1 4 turn past tight 8 Route wires S as before through split loom and reconnect RTD cable 360 to the B side LPTCM or the A side extension cable 58 9 Replace heater shroud 10 Follow startup instructions in the operation manual Turn on A and B heat simultaneously to test Temperatures should rise at same r...

Page 71: ... 4 0 2 0 4 ohms 2 to any inﬁnity open 4 Retest at each length of hose including whip hose until failure is located 5 If the FTS is not reading properly at the end of the hose connect FTS directly to RTD cable C at the manifold 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 25 Note To assist in taking rea...

Page 72: ...ve 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 71 4 If FTS fails replace FTS a Disconnect air hoses C L and electrical connectors D b Disconnect FTS from whip hose W and ﬂuid hoses A B c Remove ground wire K from ground screw on underside of FTS d Remove FTS probe H from component A ISO side...

Page 73: ...4 Conﬁrm main power switch is off before starting generator 5 Start the generator Press start button twice on the engine control module The controller will automatically sequence glow plug warming and crank operations Allow engine to reach full operating speed Note Engine will not start if main power switch is in the on position 6 Turn main power switch on 7 Press to turn on hose heat zone This eq...

Page 74: ...all new transformer 226 in reverse order 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 88 2 Perform Flushing page 47 3 Perform Shutdown page 49 4 Perform Drain Coolant page 50 5 For proportioner heat exchangers a Remove fuel tank See Remove Fuel Tank page 81 b Disconnect both RTD conn...

Page 75: ...placing heat exchangers 802 or 803 6 For the engine heat exchanger a Disconnect swivel ﬁttings 617 and 618 from heat exchanger 614 b Remove nuts 612 washers 613 and heat exchanger 614 Set expansion bottle and bracket aside c Install new heat exchanger 614 in reverse order by following the removal steps in reverse order Engine Heat Exchanger Figure 30 3A1706K 75 All manuals and user guides at all g...

Page 76: ... the heat exchanger RTD ports 4 Remove compression ﬁtting 283 from the back of the heat exchanger with RTD 284 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 283 on RTD sheath 284 6 Apply thread sealant to compression ﬁtting pipe threads 283 and install in heat exchanger 7 Connect...

Page 77: ...n instructions see the Control Valve Kits manual 3A1932 4 To remove the solenoid coil SC loosen connector screw and disconnect the coolant valve harness D Remove the nut SN and washer SW from coil Purchase Valve Coil Replacement Kit 125787 For complete installation instructions see the Control Valve Kits manual 3A1932 Figure 32 Replace Power Supply 1 Perform Shutdown page 49 2 Disconnect power sup...

Page 78: ... 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 g...

Page 79: ...1 Drain the proportioner coolant loop See Drain Coolant page 50 2 Loosen hose clamp 37 and pull coolant hose 112 off of elbow ﬁtting 248 Figure 35 3 Remove elbow ﬁtting 248 4 Pull out ﬁlter 247 Inspect washers 246 and ﬁlter Brush out ﬁlter and sight glass 245 Replace if necessary 5 Insert washer 246 and ﬁlter 247 in elbow ﬁtting 248 Connect elbow ﬁtting 248 and sight glass 245 Note To prevent an a...

Page 80: ...ear the coolant loop ﬁll bottle 1 Drain the proportioner coolant loop See Drain Coolant page 50 2 Remove cap C and ﬁlter 643 from ﬁlter housing 630 3 Pull out ﬁlter 643 Brush out ﬁlter and replace if necessary 4 Insert ﬁlter 643 into cap C and tighten cap into ﬁlter housing 630 80 3A1706K All manuals and user guides at all guides com ...

Page 81: ...nel away from batteries See Technical Speciﬁcations page 154 for battery requirements and recommended battery size 1 Remove plastic caps PC from battery terminals and disconnect battery cables from battery 2 Disconnect strap and remove battery 3 Place new battery on bracket and secure with strap 4 Reconnect battery cables and cover battery terminals with plastic caps PC Ensure red cable is connect...

Page 82: ... in that path is blown and needs to be replaced 4 Remove fusible link harness 90 from engine 5 Carefully cut open heat shrink encasing the fuse holder along lines shown 6 Pull away heat shrink Squeeze the fuse holder cover and disconnect from base latches If latches break off replace entire fuse holder with fuse holder 118 shipped loose with the system 7 Remove two M5 nuts from fuse holder base 8 ...

Page 83: ...r 111 over the red battery cable 47 Position the red cap insulator so that the stud is not exposed 13 Insert cable tie 81 through cap insulator 111 and tighten to the red battery cable 47 Ensure that the stud is not exposed 14 Reconnect black battery cable to the negative battery terminal and the red battery cable to the positive battery terminal NOTICE Always connect the red battery cable to batt...

Page 84: ...8 Figure 39 4 Remove eight screws 605 top bracket 604 and bottom bracket 606 5 Loosen hose clamps 622 and coolant hose from radiator 603 inlet and outlet 6 Carefully swing the bottom of the radiator 603 away from the engine and lift out of cover 601 Figure 40 7 Inspect radiator for any obstructions Replace or have serviced if necessary 8 Install new radiator assembly in reverse order 9 Follow Reﬁl...

Page 85: ...to lower the back panel 28 3 Disconnect harness M and harness F connectors from the back of the engine control module 428 See Engine Control Module Wiring Diagram page 145 4 Loosen engine control module mounting screws and remove the engine control module 428 5 Install new engine control module 428 in air control panel Secure clips in place and tighten mounting screws 6 Connect all wire harnesses ...

Page 86: ...e HPTCM See Fig 45 page 86 1 Perform Shutdown page 49 2 Remove hole plug screw 551 and washer 554 from the back side of the electrical enclosure 3 Open electrical enclosure door 502 4 Disconnect all connectors from the HPTCM 542 inside and outside the power distribution box 5 Remove screw 551 and washer 554 from mounting bracket 536 6 Install new HPTCM module 542 Reassemble parts in reverse order ...

Page 87: ...Repair MCM Repair Figure 43 LPTCM Repair Figure 44 HPTCM Repair Figure 45 3A1706K 87 All manuals and user guides at all guides com ...

Page 88: ... 37 and disconnect the proportioner coolant outlet and inlet coolant lines 112 113 Figure 47 5 Cut the cable tie T that secures the wire harnesses behind the A side of the proportioner 23 to the pallet 1 6 Disconnect engine wire harness E connectors 49 from J1 and J2 from the load center 242 See Load Center Wiring Diagram page 143 Cut engine harness cable ties inside the proportioner cabinet and p...

Page 89: ...efully tip the proportioner forward and the other person center the four supports under both sides of the proportioner frame 12 Have one person hold the proportioner in place and the other remove the two front mounting screws 24 NOTICE Do not strain wire harness between proportioner and electrical enclosure to prevent damage to connectors 13 Carefully slide the proportioner 23 off the pallet suppo...

Page 90: ... all harnesses to pallet and inside cabinet with cable ties Repair Engine Contact your nearest Perkins distributor for repair and maintenance Replace Engine RTD 1 Perform Shutdown page 49 2 Drain the engine coolant loop See Drain Coolant page 50 3 Disconnect RTD cable 632 from extension cable 59 4 Remove compression ﬁtting 619 and RTD 632 from the ﬁtting The RTD probe 632 cannot be removed from th...

Page 91: ...Notes Notes 3A1706K 91 All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 92: ...Systems 259079 E 30i 259080 E 30i with Booster Heat 259081 E XP2i with Booster Heat For systems with an air compressor see 259089 259090 and 259091 page 100 92 3A1706K All manuals and user guides at all guides com ...

Page 93: ...Parts 3A1706K 93 All manuals and user guides at all guides com ...

Page 94: ...Parts 94 3A1706K All manuals and user guides at all guides com ...

Page 95: ...o 25 ft lbs 33 8 N m 5 Torque to 40 ft lbs 54 N m 6 Torque to 15 20 in lbs 1 7 2 N m 7 Torque to 25 in lbs 2 8 N m 9 Safety and warning labels are from label sheet 55 10 Bundle fuel lines above engine inside ﬂexible plastic split conduit with cable ties 81 to avoid direct contact 3A1706K 95 All manuals and user guides at all guides com ...

Page 96: ... 4 20 36 36 36 21 125625 TIE cable ﬁr tree 5 5 5 PROPORTIONER E 30i 230v 1ph see Proportioners page 104 1 PROPORTIONER E 30i 4 0kw 230v 1ph see Proportioners page 104 1 23 PROPORTIONER E xp2i 4 0kw 230v 1ph see Proportioners page 104 1 24 125626 SCREW hex hd ﬂanged 3 in 76 mm 3 8 16 6 6 6 25 16H456 BRACKET mounting 1 1 1 ENCLOSURE electrical heat see Electrical Enclosure page 121 1 1 26 ENCLOSURE ...

Page 97: ... 1 48 CABLE battery 30 in 762 mm black 1 1 1 49 16K301 HARNESS E DC diesel engine 1 1 1 50 125751 CABLE grounding braided engine 1 1 1 51 125752 HARNESS M AC sense genset control 1 1 1 52 125753 CABLE AC power 240v alternator 1 1 1 53 16K299 HARNESS H DC disconnect check 1 1 1 54 125756 HARNESS N AC power reactor cart 1 1 1 55 16K939 LABEL identiﬁcation 1 1 1 56 16K398 SHIELD motor E 30i 1 1 1 57 ...

Page 98: ... mm 8 32 8 8 8 79 16M207 COVER electrical side panel 1 1 1 81 125871 TIE cable 7 50 in 33 33 33 83 16M317 GUARD engine top 1 1 1 84 16M319 GUARD alternator mount 1 1 1 85 16M321 GUARD alternator plate 1 1 1 87 16K761 INSTRUCTIONS startup not shown 1 1 1 88 16K913 INSTRUCTIONS shutdown not shown 1 1 1 89 15G280 LABEL warning 1 1 1 90 24L964 HARNESS DC link fusible 1 1 1 91 125754 CABLE AC alternato...

Page 99: ...CREW 1 2 in 12 mm M8 x 1 25 1 1 1 110 110911 NUT hex M5 x 0 8 1 1 1 111 126054 INSULATOR cap 1 1 1 112 16T798 HOSE coolant 1 in ID 2 66 ft 0 81 m 1 1 1 113 16T799 HOSE coolant 1 in ID 2 92 ft 0 89 m 1 1 1 114 24N281 COVER MCM 1 1 1 115 169970 FITTING airline 1 4 18 NPT m 3 3 3 116 15V837 SENSOR RTD 18 in 457 mm 1 1 1 117 16P405 FUSE bolt down 60A 1 1 1 118 16P406 HOLDER fuse bolt down 1 1 1 123 15...

Page 100: ...ir Compressor 259090 E 30i with Booster Heat and Air Compressor 259091 E XP2i with Booster Heat and Air Compressor Apply anaerobic sealant to all non swivel pipe threads 100 3A1706K All manuals and user guides at all guides com ...

Page 101: ...e threads 2 For additional automatic water drain capability order Hankinson automatic electric timed drain part no 531 02 175 1 Install between tee ﬁtting and lower ball valve 3A1706K 101 All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 102: ...Parts 102 3A1706K All manuals and user guides at all guides com ...

Page 103: ...ORTIONER see table for part number 1015 125428 CONNECTOR male 1 4 NPT f 3 1016 125991 VALVE drain automatic 1 1017 15B565 VALVE ball 2 1023 214656 HOSE coupled 61209 10 ft 3 m 1 Ref Part Description Qty 1024 218093 HOSE coupled 1 2 14 NPT 2 1026 297436 STRAIGHT nipple hex 3 8 1 1028 105324 SCREW cap hex hd 1 18 in 30 mm M12 x 1 75 4 1029 109570 WASHER plain 4 1030 16N177 BULKHEAD brass 3 8 1 1031 ...

Page 104: ...Parts Proportioners E 30i E 30i with Booster Heat E XP2i with Booster Heat 104 3A1706K All manuals and user guides at all guides com ...

Page 105: ...Parts 3A1706K 105 All manuals and user guides at all guides com ...

Page 106: ...Parts 106 3A1706K All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 107: ...Parts 3A1706K 107 All manuals and user guides at all guides com ...

Page 108: ...crylate pipe sealant to all non swiveling pipe threads 2 Apply grease to tube ﬁtting threads Torque to 43 ft lbs 58 N m 3 Safety and warning labels are from label sheet 279 108 3A1706K All manuals and user guides at all guides com ...

Page 109: ...P motor 2 2 2 217 112125 PLUG tube 2 2 2 218 116746 FITTING barbed plated 1 4 hose ID 1 8 27 NPT 2 2 2 219 191892 FITTING elbow street 90 1 8 NPT 2 2 2 220 117502 FITTING reducer 5 JIC x 8 JIC 1 1 1 221 117677 FITTING reducer 6 JIC x 10 JIC 1 1 1 222 297216 BRACKET reservoir lube 1 1 1 223 258707 RESERVOIR bottle assembly 1 1 1 224 205447 COUPLING hose 2 2 2 225 TUBE PTFE 6 6 6 226 15K742 TRANSFOR...

Page 110: ...ASHER plain 2 2 2 247 STRAINER 1 1 1 248 125477 FITTING 1 in beaded barb x 3 4 14 NPT m 1 1 1 249 112958 NUT hex ﬂanged 3 8 16 16 16 16 250 113505 NUT keps hex hd 14 14 14 251 125858 SCREW serrated ﬂange 2 in 51 mm 6 32 8 8 8 253 111800 SCREW cap hex hd 0 625 in 16 mm 5 16 18 4 4 4 254 125943 NUT serrated ﬂange hex hd 7 16 14 8 8 8 255 125944 SCREW serrated ﬂanged hex hd 2 25 in 57 mm 7 16 14 4 4 ...

Page 111: ... headless 2 2 2 271 16K361 COVER horizontal heater 1 1 121311 FITTING connector 3 8 18 NPT x 8 JIC 2 272 125643 FITTING elbow 3 8 NPT x 8 JIC 2 2 273 113796 SCREW ﬂanged hex hd 0 75 in 19 mm 1 4 20 22 24 24 274 24J721 MODULE fan transformer breaker 1 1 1 275 157785 FITTING swivel 3 4 14 NPS x 3 4 14 NPT 1 1 1 277 125806 CABLE splitter M8 4 pin ffm 1 5m 1 1 1 278 123656 CABLE 5 pin male female 1 1 ...

Page 112: ...TING 12 JIC swivel x 3 4 NPT m 2 2 2 299 125856 SCREW 8 32 serrated ﬂange 11 11 11 300 125857 SCREW 10 24 serrated ﬂange 2 2 2 Replacement Warning labels signs tags and cards are available at no cost Includes four 30 Amp 12 vdc relays Purchase Relay Repair Kit 24L958 Includes two fuses Purchase Fuse Repair Kit 24L959 Order 125774 Valve Repair Kit to replace all internal valve parts Order 125787 Co...

Page 113: ...44 HOSE rubber 5 16 in 1 ft 0 3 m 1 298 HOSE coolant 1 in ID 0 33 ft 0 1 m 1 22 kW Diesel Generator page 124 562 CLAMP hose dia 3 4 1 3 4 in 1 Radiator page 126 620 HOSE formed 1 1 4 upper radiator 1 621 HOSE coolant 1 in ID 6 in 152 4 mm 1 622 CLAMP hose dia 3 4 1 3 4 in 4 623 CLAMP hose dia 11 16 1 1 2 in 2 627 HOSE formed 1 1 4 lower radiator 1 628 HOSE 1 in ID 0 271 ft 0 08 m 1 629 HOSE 5 16 i...

Page 114: ...oil or grease Assemble pump cylinders ﬂush to one full thread under ﬂush of housing surface 3 Torque to 115 135 in lbs 13 15 N m 4 Torque to 20 30 ft lbs 27 40 6 N m 5 Crankshaft must be in line with crankshaft at other end of motor 6 Torque to 70 80 ft lbs 95 108 N m 114 3A1706K All manuals and user guides at all guides com ...

Page 115: ...ket hd 3 8 16 x 2 1 4 in 57 mm 8 8 314 104008 WASHER lock spring 12 12 315 106115 WASHER lock hi collar 8 8 193031 NUT retaining 2 316 193394 NUT retaining 2 318 116192 WASHER thrust 2 2 319 101864 SCREW cap socket hd 5 16 18 x 1 in 25 mm 4 4 320 116618 MAGNET 1 1 321 125757 SWITCH reed M8 4pin cable 1 1 322 116838 PIN spring 2 2 326 102962 SCREW cap socket hd 5 16 18 x 1 1 4 in 31 mm 4 4 327 1047...

Page 116: ...on swiveling threads and threads without o rings 5 Apply lithium grease lubricant to o rings before assembling in block 1 6 Remove tape from probe tip and Orientate sensor as shown Insert probe until it bottoms on heating element Tighten ferrule on sensor probe 1 4 turn past ﬁnger tight 116 3A1706K All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 117: ...SS M8 x thermal switch 3 PIN 1 359 15B135 MIXER immersion heater 2 360 SENSOR RTD 1 kohm 90 4 pin tip 2 361 124131 SCREW machined pan hd 0 375 in 9 5 mm 6 32 2 362 15M177 INSULATOR foam heater horizontal 1 366 158683 ELBOW 90 1 2 14 NPT x 1 2 14 NPT 2 368 124132 O RING ﬂuoroelastomer 4 369 15H305 PLUG hollow hex 1 3 16 SAE 2 370 COMPRESSION 1 8 NPT SST 2 371 125644 BRANCH TEE 1 2 NPT 2 372 248187 ...

Page 118: ...Parts Air Control Panel 118 3A1706K All manuals and user guides at all guides com ...

Page 119: ...vel 5 32 OD x 1 8 NPT f 3 Ref Part Description Qty 415 116257 GAUGE pressure 0 160 psi 0 1 MPa 0 11 bar 3 416 116513 REGULATOR air 3 417 116514 NUT regulator plastic 3 418 104641 BULKHEAD 1 in 25 4 mm 3 4 20 x 1 4 18 NPT 4 419 156971 NIPPLE short 1 4 18 NPT 4 420 125539 UNION Y 3 8 OD tubing 1 421 114558 COUPLER line air 1 4 18 NPT 4 422 16H531 FITTING ﬂow control 1 4 18 NPT 1 423 TUBE nylon round...

Page 120: ... pressure ﬂuid outlet 2 456 15J915 HANDLE red 1 457 15J916 HANDLE blue 1 458 112309 NUT hex jam 2 462 117556 NIPPLE 8 JIC x 1 2 NPT 1 463 117557 NIPPLE 10 JIC x 1 2 NPT 1 Ref Part Description Qty 464 121309 ADAPTER 8 SAE x 8 JIC 2 465 100840 ELBOW street 1 4 18 NPT 2 466 111457 O RING PTFE 2 467 189285 LABEL caution 1 468 150829 SPRING compression 2 Replacement Warning labels signs tags and cards ...

Page 121: ...Parts Electrical Enclosure Electrical Enclosure with Heat Electrical Enclosure without Heat 3A1706K 121 All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 122: ...und kit 1 1 515 123374 POWER SUPPLY 24 VDC 2 5 A 60 W 1 1 516 16M049 PANEL side 1 1 517 24L947 MODULE disconnect breaker 1 1 519 121612 CONNECTOR thru M12 m x f 1 1 522 120859 NUT strain relief M40 thread 1 1 523 125789 CABLE can female female 0 5m 2 1 525 24J728 MODULE din rail assy 1 1 526 100023 WASHER ﬂat 4 4 527 100133 WASHER lock 3 8 4 4 528 100307 NUT hex 3 8 16 4 4 529 157021 WASHER lock i...

Page 123: ...15322 WASHER lock external 4mm 10 10 557 277674 ENCLOSURE cube door 2 558 111280 NUT locking 4 4 559 121597 CABLE can 90 female 90 female 1 560 120094 SCREW pan hd phillips zinc 2 in 51 mm 8 32 4 4 561 125784 FAN 3x3 230 V 1 1 562 114417 SCREW self tap pan hd 8 32 x 0 625 in 16 mm 8 563 16K800 HARNESS AC fan cooling box 1 1 564 121070 SCREW machine 8 x1 375 2 565 125677 ROD connecting on off 1 1 5...

Page 124: ... to 100 ft lbs 135 6 N m 4 Torque to 40 ft lbs 54 N m 6 Apply sealant red to threads 7 Apply sealant blue to threads 8 Torque to 15 ft lbs 20 N m 9 Torque to 15 20 in lbs 1 7 2 N m 10 Apply lubrication to engine end of hose prior to assembly 124 3A1706K All manuals and user guides at all guides com ...

Page 125: ...4 20 4 572 24L965 CIRCUIT breaker 90A 1 Ref Part Description Qty 572 a SCREW 2 572 b WASHER 2 572 c NUT 2 575 125631 BUSHING cable lay in strain relief 1 576 120858 BUSHING strain relief M40 thread 1 577 125625 TIE cable ﬁr tree 4 579 120859 NUT strain relief M40 thread 1 580 See Radiator page 126 1 581 120736 SCREW hex ﬂange hd M6 x 1 2 582 115942 NUT hex ﬂange head 2 583 MUFFLER 2 in 50 8 mm exh...

Page 126: ...Parts Radiator See assembly notes on next page 126 3A1706K All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 127: ... 355 6 mm 2 in dia 1 602c GASKET radiator isolation 3 in 76 2 mm 2 in dia 1 603 RADIATOR 1 604 16H868 BRACKET top 1 605 113161 SCREW ﬂanged hex hd 1 4 20 x 1 2 in 13 mm 20 606 16H870 BRACKET bottom 1 607 16H717 FAN 16 in 12V 1 608 16K156 BRACKET plate 1 609 125579 ISOLATOR mount radiator top 1 610 16H876 BRACKET support 1 611 111803 SCREW cap hex hd 3 8 16 x 2 in 50 8 mm 1 612 112958 NUT hex ﬂange...

Page 128: ...ttom 1 638 16M141 BRACKET overﬂow bottle 1 640 125361 HOSE formed 1 1 4 upper engine 1 641 125163 CLAMP hose 7 32 in 5 8in 4 642 125382 HOSE formed 1 1 4 lower engine 1 643 STRAINER 40 mesh not shown 1 included in Heat Exchanger Kit 24L946 Included in Radiator Repair Kit 24L937 Included in Coolant Bottle Repair Kit 24L942 Included in Radiator Isolator Kit 24L945 Included in Filter Housing Kit 24T0...

Page 129: ...ker 2P 10A UL489 1 658 126127 CIRCUIT breaker 2P 15A UL489 2 659 125668 BAR 18 pos power buss 1 660 125669 BAR bus connector 2 661 125670 TERMINAL block end cover 1 Ref Part Description Qty 662 125671 TERMINAL block three wire 4 663 125672 TERMINAL block bridge jumper 2 671 125767 TERMINAL block three wire ground 2 673 WIRE black 10 AWG UL 1015 14 in 355 6 mm K130 2 674 WIRE red 10 AWG UL 1015 14 ...

Page 130: ... TERMINAL stop end 2 903 125816 TERMINAL block 2 level 4 conduct 2 904 125814 TERMINAL block end cap 1 905 125815 TERMINAL block feed thru 2 906 24L960 KIT circuit breaker 50 amp 2 pole 1 907 125767 CIRCUIT block three wire ground 1 908 WIRE cu electrical 8 AWG black 2 909 FERRULE wire 8 AWG 4 130 3A1706K All manuals and user guides at all guides com ...

Page 131: ... 125645 GROMMET tank 2 753 125646 GROMMET tank 1 754 125647 FITTING suction assy 1 Ref Part Description Qty 755 125648 FITTING 3 16 barbed 1 756 125649 VALVE drain 1 758 24L955 CAP fuel 1 3A1706K 131 All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 132: ...4L918 EXCHANGER heat side B 1 804 24L916 VALVE solenoid 3 4 NPT 12 VDC 2 805 160327 UNION ADAPTER 90 2 806 24J702 KIT FITTING outlet heat exchanger 1 Ref Part Description Qty 807 24J703 KIT ﬁtting inlet heat exchanger 1 808 C20487 NIPPLE hex 2 810 112958 NUT hex ﬂanged 8 811 16J741 WASHER nylon 30 glass 3 4 OD 8 Order 125774 Valve Repair Kit to replace all internal valve parts Order 125787 Coil Re...

Page 133: ... O RING ﬂuoroelastomer y strainer inlet series B 2 Ref Part Description Qty 15H199 PLUG y strainer inlet series A 2 858 16V879 CAP ﬁlter series B 2 104813 PLUG pipe series A 2 859 555808 PLUG pipe series B 2 860 15D757 HOUSING thermometer VISCON HP 2 863 109077 VALVE BALL 3 4 NPT 2 864 160032 NIPPLE 1 1 4 in x 2 in 3 4 NPT 2 865 157785 FITTING swivel 4 Optional 80 mesh ﬁlter 255082 2 pack Series A...

Page 134: ...ntrol Module page 145 H 53 16K299 Load Center Electrical Enclosure Load Center page 143 Electrical Enclosure page 136 K 52 125753 Alternator Enclosure Electrical Enclosure Alternator Enclosure page 147 Electrical Enclosure page 136 M 51 125752 Alternator Enclosure Engine Control Module Alternator Enclosure page 147 Engine Control Module page 145 N 54 125756 Reactor Electrical Enclosure MCM Reactor...

Page 135: ...ule Zone B This code is used throughout the wiring schematics on the following pages Circuit Breaker Identiﬁcation Ref Size Component CB01 30 A High Power Temperature Control Module HPTCM CB02 20 A Motor Control Module MCM CB03 5 A Two Motor Fans Cabinet Fan Power Supply and Coolant Circulation Pump CB04 30 A Auxiliary Power Air Compressor CB05 10 A Auxiliary Power CB06 20 A Auxiliary Power Ref Si...

Page 136: ...Ground Bar 122313 TCM H 6 PSU TCM H 6 CAN 1 CAN 1 TCM H TCM H 4 CONTACT CAN 1 MCM TCM H 2 RTD HOSE 16K800 125684 N030 BLK N020 BLK BRN BLU 15W902 BLK BLK FERRITE BEAD 125839 HOSE RTD EXT 122837 1 N010 GRN YEL N040 GRN YEL 15Y824 GRN YEL N060 BLK N080 BLK N030 BLK N020 BLK K070 WHT K050 RED K030 BLK K010 GRN H100 ORG H110 ORG N010 GRN YEL N040 GRN YEL CT02 CB01 CB0 2 C B03 C B04 C B05 C B06 CB0 7 C...

Page 137: ... Enclosure With Optional Heater Wiring Diagram 16A111 BOOSTER HEATER 24L936 BLACK BLACK Electrical Enclosure BLACK BLACK BLAC K WHITE 124262 124262 125760 123408 J23 OVERTEMP SW J23 TCM A B TCM B 1 J23 TCM A 1 J23 TCM A 3 HTR A TCM B 3 HTR B TCM A 2 J24 TCM B 2 HT RTD B TCM A 24L951 TCM B 24L951 J24 TCM A J24 HT RTD A 125762 125762 255716 2x 255716 255716 16A111 HEATER A HEATER B RTD A RTD B OT SW...

Page 138: ...A TCM A CAN TCM B TCM A CAN TCM H TCM A 5 PWR TCM B 5 PWR CAN 1 MCM BLK GRN To MCM 1 2 4 4 5 3 CT02 CB01 CB0 2 C B03 C B04 C B05 C B06 CB0 7 CB08 T B12 TB11 TB18 TB17 TB16 TB15 TB14 TB13 GND L2 L1 WHT GRN 1 Rotary switch set to 0 2 Rotary switch set to A 3 Rotary switch set to B 4 Torque terminal blocks to 5 7 in lbs 0 5 0 8 N m 5 Torque circuit breaker connections to 23 25 in lbs 2 5 2 8 N m See ...

Page 139: ...Diagram CAN 121 CAN 1 POWER SUPPLY 123374 WHT BLK 16K799 HPTCM 24L950 LPTCM 24L951 TCM H 6 TCM A TCM B CAN PSU TCM B CAN TCM A TCM B 5 PWR 1 4 5 3 GRN 4 New power supply connection in port 6 5 Unterminated 3A1706K 139 All manuals and user guides at all guides com ...

Page 140: ...ing Diagram SPLITTER 124654 BULKHEAD 121612 BULKHEAD 121612 CAN 121000 CAN 123652 C AN 125789 HPTCM 24L950 CAN 123652 CAN 1 TCM H TCM H 6 CAN 1 ENCLOSURE BOUNDARY To MCM To Remote Display CAN 2 CAN 1 140 3A1706K All manuals and user guides at all guides com ...

Page 141: ...t Breaker Conﬁguration Options in the Reactor Operation Manual 240 VAC AUXILIARY LOAD L1 L2 120 VAC AUXILIARY LOAD L1 L2 N EU T RA L 120 VAC LINE NEUTRAL 120VAC AUXILIARY LOAD 120VAC AUXILIARY LOAD 120 VAC LINE NEUTRAL 240VAC AUXILIARY LOAD L1 L2 240 VAC LINE LINE 120 VAC NEUTRALS NE UT R AL CT02 CB01 CB0 2 C B03 C B04 C B05 C B06 CB0 7 CB08 T B12 TB11 TB18 TB17 TB16 TB15 TB14 TB13 MAIN POWER SWIT...

Page 142: ...N050 GRN YEL CB20 TB23 TB25 TB24 TB21 TB22 TRANSFORMER 247812 DETAIL A DETAIL A CIRCUIT BREAKER AND TERMINAL BLOCK DESIGNATION PRIMARY 3 4 1 2 3 4 N120 BLK N040 GRN YEL N130 BLK N060 BLK N080 BLK N050 GRN YEL N070 BLK N090 BLK N060 BLK SECONDARY 2 1 1 Torque thin terminal block connections to 5 7 in lbs 0 5 0 8 N m 2 Torque large terminal block connections to 13 15 in lbs 1 4 1 7 N m 142 3A1706K A...

Page 143: ...F0 70 F0 40 F0 30 F0 10 E02 0 E220 E010 1 E620 BRN E611 BLK E150 WHT E100 ORG E630 BLU E200 GRY E190 TAN E020 RED E220 PUR E010 BLK WHT 5 D140 GRY D130 BLK WHT D120 BLU D150 BLK WHT D100 RED D11 T 0 BLK WH H100 ORG H110 ORG F020 RED F0 20 1 Manual Valve Switch o OFF Automatic Operation 1 ON Manual Operation Coolant Valve 12 VDC Wiring Diagram Load Center Harness D 16K646 Connection Description Pin...

Page 144: ...CM 8 PRESSURE B MCM 5 J22 TO ELECTRICAL ENCLOSURE HARNESS N 125756 GRN YEL J21 1 HX RTD A J21 2 HX RTD B RTD 24L972 122837 J22 ENGINE RTD J22 MC M 15V837 FERRITE BEAD 120448 A B HEAT EXCHANGERS RTD ENGINE COOLANT TEMPERATURE 1 2 N020 BLK N030 BLK BLK RED MCM 24L949 1 N010 GRN YEL RTD 24L972 1 Rotary switch setting E 30i 0 E XP2i 1 See Cable Routing Table on next page 144 3A1706K All manuals and us...

Page 145: ... PRES SURE B MCM 8 B PRES SURE 15M669 MCM 9 PRES SURE A MCM 9 A PRES SURE 15M669 HARNESS N MCM 12 ELECT ENCL 125756 TO MOTOR MCM 13 MOTOR 24K393 Engine Control Module Wiring Diagram TO LOAD CENTER HARNESS F 16K297 TO 120 240VAC ALTERNATOR HARNESS M 125752 M06 0 WH T M040 RED M020 BLK 24M665 ENGINE CONTROL MODULE F010 F020 F030 F0 40 F070 F080 F100 F110 F120 M020 M040 M060 FERRITE BEAD 125835 F020 ...

Page 146: ... RED C030 RED E020 RED E020 RED FUSIBLE LINK HARNESS C 24L964 FUSE 16P405 FUSE HOLDER 16P406 E033 BLK WHT E035 BLK WHT E614 BLK YEL RADIATOR FAN OIL PRESSURE SWITCH WATER TEMPERATURE SWITCH J7 J8 J10 J11 GLOW PLUGS FD 2 3 1 1 E150 WHT E200 GRY E220 PUR E010 BLK WHT E100 ORG D B 1 Splice located inside the 3 4 in loom above the starter 2 Splice located inside the 3 4 in loom above the panel holding...

Page 147: ...TRICAL ENCLOSURE K010 GRN K070 WHT K030 BLK K050 R M040 RED M060 WHT M020 BLK 1 F6 and F7 Fuse replacement kit 24M723 contains two fuses 2 CB10 circuit breaker replacement kit 24L965 3 Two ferrite beads 125835 not shown are located on two bundles of wires from the alternator to the circuit board These are installed to eliminate electrical interferences and are needed to ensure proper operations 4 ...

Page 148: ...ENCLOSURE BLK WHT GRN CORD GRIP 16M826 TO AIR COMPRESSOR 1 L1 3 L2 5 L3 2 T1 4 T2 6 T3 GRN BLK BLK BLK BLK CT02 CB01 CB0 2 C B03 C B04 C B05 C B06 CB0 7 CB08 T B12 TB11 TB18 TB17 TB16 TB15 TB14 TB13 GND L2 L1 2 1 1 Tighten all power cable connections to 23 25 in lbs 2 6 2 8 N m 2 Torque all air compressor wire connections to 30 32 in lbs 3 4 3 6 N m 148 3A1706K All manuals and user guides at all g...

Page 149: ...Proportioner Module 306 15C851 E XP2i Pump Repair Kit Proportioner Module 306 246963 E XP2i Wet Cup Repair Kit Proportioner Module 306 246964 E 30i Wet Cup Repair Kit Proportioner Module 360 370 24L973 RTD Repair Kit Engine Heat Exchanger Heater 452 247824 Drain Valve Cartridge Fluid Manifold 453 102814 Air Pressure Gauge Fluid Manifold 455 15M669 Pressure Sensor Fluid Manifold 569 24L963 Engine S...

Page 150: ...ng Repair Kit includes full length of air control tubing Air Control Panel 542 24L950 High Power Temperature Control Module HPTCM for hose heat Electrical Enclosure 543 24L951 Low Power Temperature Control Module LPTCM for booster heaters Electrical Enclosure 561 125784 Cooling Fan Electrical Enclosure 654 126130 30A Circuit Breaker Electrical Enclosure 655 126128 20A Circuit Breaker Electrical En...

Page 151: ...Dimensions Dimensions Top View Figure 52 Side View Figure 53 3A1706K 151 All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 152: ...op View System with Compressor and Hose Rack Accessories Figure 54 Front View Figure 55 Side View System with Compressor and Hose Rack Accessories Figure 56 152 3A1706K All manuals and user guides at all guides com ...

Page 153: ...Dimensions Pallet Mounting Dimensions Figure 57 3A1706K 153 All manuals and user guides at all guides com ...

Page 154: ...ating Ambient Temperature Range Temperature 20 to 120 F 7 to 49 C Auxiliary Power Available Voltage 120 Vac or 240 Vac 60 Hz Engine Model Perkins 404 22G 2 2 L 29 HP Alternator Model Mecc Alte 22 kW 240 V 1 PH 60 Hz pancake style Battery Requirements Voltage 12 Vdc Minimum Cold Cranking Amps 800 CCA Connection Type Post Style Recommended Battery Size BC Group Number 34 Length 10 25 in 260 mm Width...

Page 155: ...2 gpm 7 6 lpm 91 0 dBA Fluid Inlets Component A ISO and Component B RES 3 4 NPT f with 3 4 NPSM f union Fluid Outlets Component A ISO 8 1 2 in JIC with 5 5 16 in JIC adapter Component B RES 10 5 8 in JIC with 6 3 8 in JIC adapter Fluid Circulation Ports Size 1 4 NPSM m with plastic tubing Maximum Pressure 250 psi 1 75 MPa 17 5 bar Weight E 30i 1750 lb 794 kg E 30i with booster heat 1800 lb 816 kg ...

Page 156: ... Temperature 20 to 120 F 7 to 49 C Auxiliary Power Available Voltage 120 Vac or 240 Vac 60 Hz Engine Model Perkins 404 22G 2 2 L 29 HP Alternator Model Mecc Alte 22 kW 240 V 1 PH 60 Hz pancake style Battery Requirements Voltage 12 Vdc Minimum Cold Cranking Amps 800 CCA Connection Type Post Style Recommended Battery Size BC Group Number 34 Length 10 25 in 260 mm Width 6 81 in 173 mm Height 7 88 in ...

Page 157: ...d from 3 1 ft 1 m at 2000 psi 14 MPa 138 bar 1 0 gpm 3 8 lpm 91 0 dBA Fluid Inlets Component A ISO and Component B RES 3 4 NPT f with 3 4 NPSM f union Fluid Outlets Component A ISO 8 1 2 in JIC with 5 5 16 in JIC adapter Component B RES 10 5 8 in JIC with 6 3 8 in JIC adapter Fluid Circulation Ports Size 1 4 NPSM m with plastic tubing Maximum Pressure 250 psi 1 75 MPa 17 5 bar Weight E XP2i 1800 l...

Page 158: ... sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY...

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