Page 1 Repair-Parts ® Reactor 2 Elite Integrated 332637M 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.
Page 2 Replace Pressure Transducers ... . . 79 ® Graco Extended Warranty for Integrated Reactor Components ......187...
Page 3 Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
Page 4 Warnings WARNING SKIN INJECTION HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. • Do not spray without tip guard and trigger guard installed.
Page 5 Warnings WARNING THERMAL EXPANSION HAZARD Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to the thermal expansion. Over-pressurized can result in equipment rupture and serious injury. • Open a valve to relieve the fluid expansion during heating. •...
Page 6 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.
Page 7 Warnings WARNING ENTAGLEMENT HAZARD Rotating parts can cause serious injury. • Keep clear of moving parts. • Do not operate equipment with protective guards or covers removed. • Do not wear loose clothing, jewelry or long hair while operating equipment. •...
Page 8 Important Isocyanate Information Important Isocyanate Information Isocyanate (ISO) are catalysts used in two component materials. Isocyanate Conditions Spraying or dispensing fluids that contain isocyanate creates potentially harmful mists, vapors, and atomized particulates. • Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards and precautions related to isocyanates.
Page 9 Important Isocyanate Information Material Self-Ignition Moisture Sensitivity of Isocyanates Exposure to moisture (such as humidity) will cause ISO to partially cure, forming small, hard, abrasive crystals that become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, Some materials may become self-igniting if applied increasing in viscosity.
Page 10 Models Models Reactor 2 E-30i Elite All base systems include fluid inlet pressure and temperature sensors and Graco Insite™. For part numbers, see Parts, page 112. No Air Compressor/Dryer ▲ With Air Compressor/Dryer Model E-30i E-30i with heat E-30i E-30i with heat...
Page 11 Models Reactor 2 E-XP2i Elite All base systems include fluid inlet pressure and temperature senors and Graco InSite™. For part numbers, see Parts, page 112. No Air Compressor/Dryer ▲ With Air Compressor/ Dryer Model E-XP2i with heat E-XP2i with heat Base Machine★...
Page 12 Approvals Approvals Accessories Kit Number Description Intertek approvals apply to proportioning systems without hoses. Remote Display Module Protective 15M483 Covers (10 pack) Model Proportioning System Approvals: 15V551 ADM Protective Covers (10 pack) 272079 Fluid Temperature Sensor (FTS) with 272080 24K207 272081 272089 24K333...
Page 13 The following manuals are for accessories used with The following manuals are shipped with the Reactor. the Reactor. Refer to these manuals for detailed equipment information. Component Manuals in English: Manuals are also available at www.graco.com. Manuals are available at ww.graco.com. Manuals Description System Manuals 332636...
Page 14 There are three types of errors that can occur. Errors Otherwise, manually navigate to help.graco.com are indicated on the display as well as by the light tower and search for the active error.
Page 15 NOTE: When an error occurs, be sure to determine the code before resetting it. If you forget which error code occurred, see the Errors screen to view the last 200 errors with date, time and description. See help.graco.com for more detail on troubleshooting error code.
Page 16 Troubleshooting Error Type Description Cause Solution A4DH High Current Hose Supply voltage and/or Measure voltage and frequency at system frequency fluctuation disconnect switch and confirm that they are may be affecting hose stable. current control. Generator may be Use continuous-run compressor with overloaded.
Page 17 Update software in all modules by following the procedure in your system’s manual. Make certain to wait until the upload is complete before removing the token. For more information on loading software, also refer to the module programming manual by searching for “3A1244” at www.graco.com 332637M...
Page 18 For more information on loading software, refer to the module programming manual by searching for “3A1244” at www.graco.com. Loose or broken CAN Check the CAN cables running between cable. GCA modules. Check for cross threading and tighten if needed.
Page 19 Troubleshooting Error Type Description Cause Solution DADX Pump Runway Flow rate is too large. Mix chamber too large for system selected. Use mix chamber rated for system. Ensure the system has chemical and the feed pumps are operating correctly. No material in pumps. Verify pumps are supplying chemical.
Page 20 Troubleshooting Error Type Description Cause Solution • Mix chamber is too large for set F9DX High Pressure/Flow Machine is operating pressure. Cutback above pressure/flow rating. • Set pressure is too high for given mix chamber. See operation manual for Performance Charts.
Page 21 Troubleshooting Error Type Description Cause Solution H4MA High Frequency A Line frequency is Check frequency. If out of tolerance, see above 65 Hz. supplied 120/240 V alternator manual for repair instructions. H4MB High Frequency B Line frequency is Check frequency. If out of tolerance, see above 65 Hz.
Page 22 Troubleshooting Error Type Description Cause Solution P0AX Pressure Imbalance A Pressure difference Ensure material flow is equally restricted on High between A and B both material lines. material is greater than the defined value. Pressure imbalance is Ensure that the pressure imbalance value, defined too low.
Page 23 Troubleshooting Error Type Description Cause Solution P2FA Low Inlet Pressure A Inlet pressure lower Ensure that inlet pressure to the pump is than defined value. sufficient. Value defined too high. Ensure that the low pressure alarm level defined on the System Setup screen is acceptable.
Page 24 Troubleshooting Error Type Description Cause Solution P6BX Pressure Sensor Error Loose/bad connection. Check to ensure the pressure transducer is properly installed and all wires are properly connected. Bad sensor. Check if the error follows the transducer. Disconnect transducer cables from the MCM (connectors 6 and 7).
Page 25 Troubleshooting Error Type Description Cause Solution P7AX Pressure Imbalance A Pressure difference Ensure material flow is equally restricted on High between A and B both material lines. material is greater than the defined value. Pressure imbalance is Ensure that the pressure imbalance value, defined too low.
Page 26 Troubleshooting Error Type Description Cause Solution T2AE Low Temperature Heat Coolant circulation Check for 240 VAC on pump. If there is the Exchanger A pump not working. correct voltage, replace circulation pump. Air lock in pump Check for coolant flow in sight glass. circulation.
Page 27 Troubleshooting Error Type Description Cause Solution T2DA Low Temperature A Flow is too high at Use a smaller mix chamber that is rated for current setpoint. the unit in use. If recirculating, decrease flow or decrease temperature setpoint. Bad RTD or bad RTD Swap A and B heater output cables and placement against RTD cables and see if issue follows.
Page 28 Troubleshooting Error Type Description Cause Solution T2FB Lower Temperature Inlet fluid temperature Recirculate fluid through heaters until inlet Inlet B is below the defined fluid temperature is above defined error level. level. Increase the low temperature deviation level on the System Setup screen. T3CH Hose Cutback Hose current has been...
Page 29 Troubleshooting Error Type Description Cause Solution T3CM Motor Temperature Motor control Ensure ambient temperature is below Cutback temperature is too 120°F (48°C) before using the system. high. Verify that all fans are working. T4AE High Temperature Manual valve switch Open cabinet cover and turn switch to the Heat Exchanger A (MV) on load center is OFF position.
Page 30 Troubleshooting Error Type Description Cause Solution T4DA High Temperature A Bad RTD or bad RTD Swap A and B heater output cables and placement against RTD cables and see if issue follows. If so, heater. replace RTD. Flow too high for Use a smaller mix chamber that is rated for temperature setpoint, the unit in use.
Page 31 • Replacement insulation is available from Graco or a hardware store. Setting the A and B Increase hose setpoint so it is closer to A setpoint much higher and B setpoints.
Page 32 Troubleshooting Error Type Description Cause Solution T4EA High Temperature Overtemperature Heater was delivered too much power, Switch A switch sensed a fluid causing the overtemperature switch to temperature above open. RTD is not reading properly. After the 230°F (110°C). heater cools down, replace RTD. Switch closes and the error can be cleared when the heater temperature falls below 190°F (87°C).
Page 33 Troubleshooting Error Type Description Cause Solution T4NM High Temperature High ambient Ensure ambient temperature is below Motor temperature. 120°F (48°C) before using system. • Check to see that the motor fan is Cooling fan is not moving. Measure voltage to fan. There operating properly.
Page 34 Troubleshooting Error Type Description Cause Solution T6DA Sensor Error A Disconnect or loose Check all wiring and connection to RTD. RTD cable or connection. Bad RTD. Switch the RTD with another and see if the error message follows the RTD. Replace RTD if the error follows the RTD.
Page 35 Troubleshooting Error Type Description Cause Solution T6NM Sensor Error Motor Disconnect or loose Verify wiring between the motor motor temperature temperature sensor and the module. cable Failed motor Measure resistance between pins 1 and 3 temperature sensor. on motor temperature cable connector. Readings vary depending on temperature, but at room temperature (72°F/22°C), the resistance should be approximately 1500 to...
Page 36 Troubleshooting Error Type Description Cause Solution T8BE No Temperature Rise No coolant flow. Check coolant level. Check for coolant flow Heat Exchanger B in sight glass. Ensure that circulation pump has 240 VAC. If not, replace the circulation pump. Low chemical supply Chemical below 32°F (0°C) at startup.
Page 37 Troubleshooting Error Type Description Cause Solution T8DB No Temperature Rise Bad RTD or bad RTD Swap A and B heater output cables and placement against RTD cables and see if issue follows. If so, heater. replace RTD. Loose heater wires or Check for loose heater element wires or connectors.
Page 38 Troubleshooting Error Type Description Cause Solution V1MB Low Voltage B Loose connection or Check wiring for loose connection or tripped circuit breaker. tripped circuit breaker. Low generator line Measure voltage across main power switch voltage. (CT01). Voltage should measure between 195 and 264 VAC.
Page 39 Troubleshooting Error Type Description Cause Solution V4MA High Voltage A Incoming line voltage is Measure voltage across main power switch too high. (CT01). Voltage should measure between 195 and 264 VAC. If voltage is too high, see supplied alternators manual for generator specifics and repair.
Page 40 Troubleshooting System See Supplied Manuals, page 13, for air compressor service or warranty contact information. Before performing any troubleshooting procedures: 1. Relieve Pressure. See Pressure Relief Procedure, page 59. 2. Turn main power switch OFF. 3. Allow equipment to cool. Problem Cause Solution...
Page 41 Troubleshooting Problem Cause Solution Electric motor cooling fan not Tripped circuit breaker (CB03). Reset circuit breaker (CB03). Check working. 240 VAC at output of breaker. Loose wire. Check the fan. See Electrical Schematics, page 159. Fan blade obstructed. Remove obstruction. Defective fan.
Page 42 Troubleshooting Problem Cause Solution Air compressor shuts down during Compressor oil over temperature Check continuity of overtemperature operation. switch triggering shutdown. switch and cabling. Switch is normally closed. Oil temperature range during normal operations is 170°-190°F (77°-88°C). Compressor oil over temperature switch opens at oil temperature of approximately 230°F (110°C).
Page 43 Troubleshooting Coolant System Problem Cause Solution Proportioner Coolant Loop Air bubbles in sight glass. Air trapped in heat exchanger See Refill Proportioner Coolant coolant. Loop, page 66. Coolant hoses between the Ensure coolant hoses have a proportioner coolant loop and engine constant rise in elevation.
Page 44 Troubleshooting Problem Cause Solution Engine Coolant Loop Engine coolant does not reach full Radiator fan does not shut off. Check fan relay. Check fan wiring. temperature. Radiator core becoming plugged. Replace radiator. See Radiator, page 143. Engine thermostat not opening. Replace engine thermostat.
Page 45 Troubleshooting Hose Heat System Before performing any troubleshooting procedures: 1. Relieve Pressure. See Pressure Relief Procedure, page 59. 2. Turn main power switch OFF. 3. Allow equipment to cool. Problem Cause Solution Hose heats but heats slower than Ambient temperature is too cold. Use auxiliary hose heat system.
Page 46 Troubleshooting Problem Cause Solution Erratic hose temperature. 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.
Page 47 Troubleshooting Problem Cause Solution Hoses near Reactor are warm, but Shorted connection or failed hose With power off, check the hose hoses downstream are cold. heating element. resistance with and without the whip hose attached. With the whip hose attached, the reading should be less than 3 ohms.
Page 48 Troubleshooting Booster Heater Before performing any troubleshooting procedures: 1. Relieve Pressure. See Pressure Relief Procedure, page 59. 2. Turn main power switch OFF. 3. Allow equipment to cool. Problems Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and controls are properly set and wiring is correct before assuming there is a problem.
Page 49 Troubleshooting Load Center Diagnostics Reference Replace Load Center Relays and Fuses, page 77, and Electrical Schematics, page 159. The LEDs on the load center board are helpful diagnostic tools when troubleshooting problems with the engine. Before referencing the Engine, complete the following steps: 1.
Page 50 Troubleshooting 2. Determine if the LEDs are expected to be in the Table 1 lists a likely order of potential failures in the load state observed. Determine if an unlit LED should be center output-side components. on by referring to the LED Expected Operation table.
Page 51 Troubleshooting 4. Engine just started; glow plugs continue to warm Description engine. Flashing LED Sequence for Engine Startup and Operation 1. After pressing the green start button on Engine Control Module, glow plugs start warning engine. 5. Engine is running; with main power switch off, the radiator fan runs continuously.
Page 52 Troubleshooting Engine Contact Perkins for diesel engine service or warranty. See Supplied Manuals, page 13 Problem Cause Solution Engine Control Module does not Discharged or failed battery. Verify battery voltage is 11- 13 volts power up from sleep mode. Charge or replace battery as required.
Page 53 Troubleshooting Problem Cause Solution Reference Load Center Diagnostics, page 49. Engine does not turn over. Main power switch on electrical Turn switch to OFF position. enclosure is in the ON position. Discharged or failed battery. Verify battery voltage is 11 -13 volts Charge or replace battery as required.
Page 54 Troubleshooting Problem Cause Solution Reference Load Center Diagnostics, page 49. Engine turns over, but does not start. Low fuel level. Refill fuel tank. Lost prime. Ensure fuel tank is at least half full, prime with bulb until fuel is flowing through return line to tank.
Page 55 Troubleshooting Problem Cause Solution Reference Load Center Diagnostics, page 49 Engine shuts down, Engine Control Loose or incorrect wiring Verify wiring connections (including Module shows no errors. connections. grounds) related to engine fuel shutoff solenoid. Check Engine Harness (E), and Engine Control Module Harness (F).
Page 56 Troubleshooting Problem Cause Solution Reference Load Center Diagnostics, page 49. Engine shuts down, Engine Control Low engine coolant level. Inspect coolant system for leaks. Module shows High Coolant Repair as necessary and refill Temperature Shutdown icon. system. Engine water temperature switch Check for shorts to switch wiring.
Page 57 Troubleshooting Problem Cause Solution Engine shuts down. Engine Control Low oil level. Check oil level and refill. Module shows Low Oil Pressure Loose or incorrect wiring Verify wiring connections (including Shutdown Icon. connections. grounds) related to oil pressure switch. Check Engine Harness (E), and Engine Control Module Harness (F).
Page 58 Use extension cable 16X521 and move cellular module to a location with a clear view of the sky. Cannot view data for my unit(s) on Graco InSite unit has not been Activate unit. See Registering and website. activated. Activating the Graco InSite section.
Page 59 Pressure Relief Procedure Pressure Relief Procedure 4. Route fluid to waste containers or supply tanks. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to Follow the Pressure Relief Procedure whenever you see this symbol. PRESSURE RELIEF/CIRCULATION . Ensure gauges drop to 0. This equipment stays pressurized until pressure is manually relieved.
Page 60 Shutdown Shutdown Daily Shutdown NOTICE Proper system setup, startup, and shutdown proce- dures are critical to electrical equipment reliability. The following procedures ensure steady voltage. Failure to follow these procedures will cause voltage fluctuations that can damage electrical equipment and void the warranty. Shutdown system to avoid electric shock.
Page 61 Shutdown 9. Turn main power switch OFF. Allow engine cooling 5. Press to park the Component A Pump. The dwell time prior to shutting down the engine. park operation is complete when green dot goes out. Verify the park operation is complete before moving to next step.
Page 62 Flushing Flushing 11. Close all fluid supply valves. 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.
Page 63 Repair Repair NOTE: Clean the A-side screen only during daily startup. This minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing operations. 1. Close the fluid inlet valve at the pump inlet and shut off the appropriate feed pump.
Page 64 Repair Drain Coolant 4. To drain proportioner coolant loop: a. Remove the proportioner coolant loop fill bottle (HF) cap. 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 b.
Page 65 Repair 5. To drain proportioner coolant loop from filter 6. To drain engine coolant loop: housing. Only available on Series B systems. a. Remove the engine coolant loop (RC) cap. a. Remove the proportioner coolant loop fill bottle cap (HF). b.
Page 66 Repair Refill Proportioner Coolant Loop 3. Replace cap and tighten past the safety latch position. Purge air from proportioner coolant loop when it is filled with new coolant or when air enters the coolant system. 4. Press start button twice on the engine control module.
Page 67 Repair Refill Engine Coolant Loop 5. Turn main power switch on. Refill the engine coolant loop when the coolant is below the cold level line at ambient temperature. To avoid burns, do not perform maintenance on the 6. Inspect coolant loops for leaking fittings or valves. coolant system until the coolant system has reached ambient temperature.
Page 68 Repair Changing Pump Lubricant 6. Manually prime the ISO pump. Plug the small vent hole (H) between the tube grommets while squeezing the bottle to force the lubricant up the Check the condition of the ISO pump lubricant daily. feed tube. Repeat until the fluid level reaches the Change the lubricant if it becomes a gel, its color ISO pump to force the air out.
Page 69 Repair Remove Pump 9. Allow engine dwell time. NOTICE Allow engine dwell time, per manufacturer recom- mendations, prior to shutdown. Dwell time will help engine cool down after running at operating tem- Pump rod and connecting rod move during perature for any period of time operation.
Page 70 Repair 16. Loosen locknut (G) by hitting firmly with a 17. Disconnect fluid inlet (C) and outlet (D). Also non-sparking hammer. Unscrew pump far enough disconnect steel outlet tube from heater inlet. to expose rod retaining pin. Push retaining wire clip 18.
Page 71 Repair Install Pump 7. Start threading pump into bearing housing (M). When pin holes align, insert pin. Pull retaining wire NOTE: Steps 1-5 apply to pump B. To reconnect pump clip down. A, proceed to step 6. 8. Continue threading pump into bearing housing (M) 1.
Page 72 Repair Repair Drive Housing 10. Press on the engine control module. Removal 11. Open air compressor bleed valve to relieve pressure and remove water from tank. 1. Press to stop the pumps. 12. Remove screws (294) and motor shield (293), see .
Page 73 Repair 2. Install one bronze washer (308) in drive housing, then installed 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.
Page 74 Repair Repair Electric Motor Removal NOTICE Be careful not to drop or damage the motor. The motor is heavy and may require two people to lift. 1. Remove drive housing and pump assemblies. See Repair Drive Housing, page 72. 2. Disconnect electric motor (301) power cable from port #15 on the MCM.
Page 75 Repair Repair Circuit Breaker Module 2. Using an ohmmeter, check for continuity across circuit breaker (left to right). If no continuity, trip breaker, reset, and retest. If still no continuity, replace breaker as follows: a. Refer to Electrical Schematics, page 159, and tables on next page.
Page 76 Repair . 16: Circuit Breakers Inside Alternator Assembly . 15: Circuit Breakers Inside Cabinet Ref. Size Component Ref. Size Component CB10 90 A 120/240 V Alternator CB20 50 A Heated Hose 332637M...
Page 77 Repair Replace Load Center Relays and Fuses 1. Disconnect the negative lug from the negative post of the battery. See Replace Battery, page 96. 2. Remove the bad relay or fuse from the load center (242) and install a new relay or fuse. See F .
Page 78 Repair Replace Load Center Replace Engine Solenoid Relays 1. Perform Shutdown, page 60. NOTICE Before handling board, put on a static conductive 2. Disconnect the negative lug from the negative post wrist strap to protect against static discharge which of the battery. See Replace Battery, page 96. can damage board.
Page 79 Repair Replace Fluid Inlet Sensor Replace Pressure Transducers 1. Perform Shutdown, page 60. 1. Perform Shutdown, page 60. 2. Perform Pressure Relief Procedure, page 59. 2. Perform Pressure Relief Procedure, page 59. 3. Disconnect inlet sensor cable from the fluid inlet 3.
Page 80 Repair Replace Fans Replace Proportioner Module Fan 1. Perform Shutdown, page 60. 2. Remove cabinet panel (70). 3. Refer to Electrical Schematics, page 159. Check Shutdown system to avoid electrical shock. To avoid connections of all wires going to terminal block burns, do not perform maintenance on the fan until TB21 and TB22.
Page 81 Repair Replace Radiator Fan Replace Electrical Enclosure Fan 1. Perform Shutdown, page 60. 1. Perform Shutdown, page 60. 2. Remove four screws (605) and disconnect power 2. Open electrical enclosure door (502). Loosen four cable (PC). nuts (558) and remove fan (561). 3.
Page 82 Repair Repair Booster Heater 10. Press on the engine control module. Replace Heater Element 11. Open air compressor bleed valve to relieve pressure and remove water from tank. 12. Perform Pressure Relief Procedure, page 59. 13. Wait for heater to cool. 1.
Page 83 Repair 4. Verify blue wire and brown/black wires from cable 6. If switch fails test, remove screws. Discard failed (54) “HTR-OT” are connected to overtemperature switch. Apply thin layer of thermal compound switch (358). See Electrical Schematics, 110009, install new switch in same location on page 159.
Page 84 Repair 5. A side RTD: 7. Replace RTD (360). a. Follow “HT-RTD-A” RTD cable (360) and open a. Apply PTFE tape and thread sealant to male split loom about 18 in. (457.2 mm) away from pipe threads and tighten RTD housing (H) into the heater attachment.
Page 85 Repair Repair Heated Hose 3. For Series A only: Disconnect hose connector (V) at Reactor. Refer to the heated hose manual 309572 for hose replacement parts. Check Hose Heat Power Connectors 1. Perform Shutdown, page 60. NOTE: Whip hose must be connected. 2.
Page 86 Repair Check RTD Cables and FTS 1. Perform Shutdown, page 60. 2. Disconnect RTD cable (C) at Reactor. 3. Test with an ohmmeter between pins of cable connector C. NOTE: Do not touch outer ring with test probe. Pins Result 3 to 1 See RTD Resistance vs.
Page 87 Repair RTD Resistance vs. Temperature RTD or FTS RTD or FTS Approximate Resistance (Ohms) Temperature °C (°F) -40 (-40) -30 (-22) -20 (-4) -10 (14) 1000 0 (32) 1039 10 (50) 1078 20 (68) 1117 30 (86) 1155 40 (104) 1194 50 (122) 1232...
Page 88 Repair Repair Fluid Temperature Sensor (FTS) Installation The Fluid Temperature Sensor (FTS) is supplied with the system. Install FTS between main hose and whip hose. See Heated Hose manual 309572 for instructions. Transformer Primary Check . 29 1. Perform Shutdown, page 60. Test/Removal 2.
Page 89 Repair 3. Close the circuit breaker CB20 (906). 7. Press to turn on hose heat zone. This equipment is used with heated fluid which can cause equipment surfaces to become very hot. To avoid severe burns: • Do not touch hot fluid or equipment. •...
Page 90 Repair Replace Transformer 9. See the Diagnostic Run Screen on the ADM. The Diagnostic Run Screen displays the incoming (240 1. Perform Shutdown, page 60. VAC) to the TCM “Hose Voltage” and the hose current. The diagnostic screen will show if the 2.
Page 91 Repair Replace Heat Exchanger g. Disconnect two swivel fittings (805) and swivel fittings on heat exchanger outlet (806) from the 1. If a wall is installed between the generator and the heat exchangers (802, 803). proportioner, remove the proportioner from the pallet.
Page 92 Repair Replace Heat Exchanger RTD 4. Remove compression fitting (272) from the back of the heat exchanger with the RTD (273) attached. 1. Perform Shutdown, page 60. The RTD probe cannot be removed from the compression nut. 2. Remove Reactor cabinet cover. NOTICE 3.
Page 93 Repair Replace Power Supply Replace Control Valve Follow these instructions to replace a control valve solenoid coil or remove the component A control valve, component B control valve, or the bypass control valve. 1. Perform Shutdown, page 60. 1. Perform Shutdown, page 60. 2.
Page 94 Repair Replace Circulation Pump 6. Press in tabs to disconnect power wires (W). 7. Remove four outside nuts (254). Hold on to the pump flanges (234) and remove the circulation pump (233). Remove four inside nuts (254) to remove flanges from the pump. To prevent burns, do not perform maintenance on 8.
Page 95 Repair Repair Filter Housing Filter 1. Drain the proportioner coolant loop. See Drain Coolant, page 64. 2. Remove cap (C) and filter (643) from filter housing (630). 3. Pull out filter (643). Brush out filter and replace if necessary. 4. Insert filter (643) into cap (C) and tighten cap into filter housing (630).
Page 96 Repair Remove Fuel Tank See Technical Specifications, page 183 for battery requirements and recommended battery size. 1. Perform Shutdown, page 60. 1. Remove plastic caps (PC) from battery terminals 2. Disconnect fuel lines (38, 39). Keep elevated or plug and disconnect battery cables from battery. to prevent siphoning.
Page 97 Repair Repair Fusible Link Harness 4. Remove fusible link harness (90) from engine. 5. Carefully cut open heat shrink encasing the fuse Follow this procedure to replace fuses inside the fusible holder along lines shown. link harness (90). See Electrical Schematics, page 159, for fusible link harness connections and wire identification.
Page 98 Repair 9. Replace M5 nuts over fuse and ring terminals. 3. Remove screws (17) and back panel (8). Torque to 44 in-lb (5 N·m). 10. Connect fuse holder cover to fuse holder base. Wrap entire fuse holder and heat shrink 3-4 times with tape (44).
Page 99 Repair 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 damage. Replace if necessary. 4. Update software by inserting an upgrade token into ADM (27) and cycling system power.
Page 100 Repair Software Update Procedure 6. Update software by inserting an upgrade token into ADM and cycling system power. Wait until update is complete before removing the token and NOTICE restarting the system. Repair kit GCA modules are shipped pre-pro- grammed. Upgrade token part number 17E206. If software version upgrade is necessary, follow the procedure in the manual provided.
Page 101 Repair Remove Proportioner 4. Loosen the coolant clamps (37) and disconnect the proportioner coolant outlet and inlet coolant lines (36). Only remove the proportioner from the pallet or repair the heat exchangers or coolant valves between the proportioner and generator. The back of the proportioner could slide off of the pallet and support brackets during removal and installation.
Page 102 Repair 10. Use 6 in. x 6 in. x 11 in. pieces of wood (S1, S2, S3, 14. Secure the proportioner frame to the empty pallet and S4) to support the proportioner during the you positioned on the floor with c-clamps. removal and installation process.
Page 103 Repair Repair Engine Contact your nearest Perkins distributor for repair and maintenance. Replace Engine RTD 1. Perform Shutdown, page 60. 2. Drain the engine coolant loop. See Drain Coolant, page 64. 3. Disconnect RTD cable (632) from extension cable (59). 4.
Page 104 Repair Optional Accessories Installation and Repair Install Air Compressor 6. Install two motor brackets (736) with screws (738) on top of frame (704). for the steps below, see Parts, page 112 to view callouts. 1. Install air compressor frame (704) and air dryer frames (705) on a pallet with screws (723).
Page 105 Repair Connect Cables 3. Connect the compressor over-temperature cable from the motor starter (712) to the compressor over-temperature switch in the enclosure (702d). CABLE 16X011 TO MOTOR STARTER AIR COMPRESSOR OVER TEMPERATURE BOX 1. Turn off the 120/240 VAC alternator circuit breaker CORD GRIP 260067 CB10 (572).
Page 106 Repair 7. Use a screwdriver to punch out two 3/4 in. 14. Turn on the 120/240 VAC alternator circuit breaker knockouts. Install cord grips (702g) at the bottom CB10 (572). hole and (746) in the upper hole. TI23260b ELECTRICAL ENCLOSURE Connect Air Lines 1.
Page 107 Repair Update Compressor Motor Wiring 5. Remove the wire schematic label from the inside of the compressor motor starter box cover. Replace it with the label (16X422) provided in the kit. The following procedure must be carried out by properly trained service personnel. Due to stored energy in the motor capacitors (702m, 702n), this procedure exposes the service personnel to potential shock, arcing, or flying metal debris from arcing.
Page 108 Repair 10. Install the opposite end of updated harness 11. Reinstall the compressor motor junction box cover 24U079 into the motor junction box through the and the compressor motor starter box cover. strain relief. Refer to Compressor Motor Junction 12. Secure the harnesses with provided cable ties. box in Electrical Schematics, page 159 to match Cables should not touch the engine or sharp edges.
Page 109 Repair Replace Compressor Motor Capacitors 5. Wait a minimum of five hours after completing the Shutdown procedure for motor capacitors (702m, 702n) to partially self-discharge. 6. Remove six bolts (MB) that secure the cover on the motor capacitor housing (CH). The following procedure must be carried out by properly trained service personnel.
Page 110 Repair 10. Replace capacitor (702m, 702n): 12. Use six bolts (MB) to secure cover on motor capacitor housing (CH). a. Disconnect wires and remove old capacitors 13. Turn on main circuit breaker CB10 (572) located on (702m, 702n). engine (2). b.
Page 111 Notes Notes 332637M...
Page 112 Parts Parts Systems 272079, E-30i 272080, E-30i with Booster Heat 272081, E-XP2i with Booster Heat For systems with an air compressor, see page 151 (272086, 272090, and 272091). Torque to 40 ft-lb (54 N·m). Torque to 25 in-lb (2.8 N·m). Safety and warning labels are from label sheet (55).
Page 113 Parts Safety and warning labels are from label sheet (55). Included with generator (2). 332637M...
Page 114 Parts Safety and warning labels are from label sheet Torque to 25 ft-lb (33.8 N·m). (55). Torque to 25 in-lb (2.8 N·m). Included with generator (2). 332637M...
Page 115 Parts Apply lubrication to all push-on hoses prior to assembly. Torque to 25 in-lb (2.8 N·m). Safety and warning labels are from label sheet (55). 332637M...
Page 116 Parts Quantity Ref. Part Description 272079 272080 272081 24J658 BASE, pallet - - - GENERATOR, diesel, 22 kW, see 22 kW Diesel Generator 16H732 SUPPORT, generator 24L953 KIT, isolator (4 pack) 111192 SCREW, cap flange hd; 0.875 in. (22 mm), 3/8-16 105324 SCREW, cap, hex hd;...
Page 117 16K299 HARNESS, dc, disconnect check 54 ◆ 24T242 CABLE, over-temp, single reactor 24U109 CABLE, over-temp, switch short 55 ▲ 16K939 LABEL, safety, system, multi 16X154 LABEL, Graco InSite 57 ◆ 121002 CABLE, can, female/female 1.5 m 58 ◆ 125358 CABLE, m8, 4-pin, mf, .5 m, mold 59 ◆...
Page 118 Parts Quantity Ref. Part Description 272079 272080 272081 71 ◆ 125357 CABLE, m8, 4-pin, mf, 1 m, molded 108290 SCREW, mach, binding hd; 1/4 in., #8-32 16W216 LABEL, E-30i, elite 16W217 LABEL, E-XP21, elite 74 ✖ 287292 COVER, drive, plastic 75 ✖...
Page 119 Parts Quantity Ref. Part Description 272079 272080 272081 186494 CLIP, spring 169967 FITTING, line air; 1/4-18 NPT (f) 16P405 FUSE, bolt-down, 60A 16P406 HOLDER, fuse, bolt-down 16W213 LABEL, Reactor 16D576 LABEL, made in USA 113505 NUT, keps, hex hd 16X121 GASKET, door 16X122 GASKET, door 16X123 GASKET, door 16X124 GASKET, door...
Page 120 Parts Proportioners 332637M...
Page 121 Parts Apply grease to tube fitting threads. Torque to 43 ft-lb (58 N·m). 332637M...
Page 122 Parts Safety and warning labels are from label sheet (283). 332637M...
Page 123 Parts Fan air flow towards motor. 332637M...
Page 124 Parts Apply grease to tube fitting threads. Torque to 43 ft-lb (58 N·m). Safety and warning labels are from label sheet (283). 332637M...
Page 125 Parts Fan air flow towards motor. 332637M...
Page 126 Parts Quantity E-30i with E-XP2i with E-30i Booster Booster Ref. Part Description Heat Heat - - - FRAME 16W233 BRACKET, tube guard 24T870 MANIFOLD, fluid 16W235 BRACKET, tube mount 16W608 FITTING, elbow 8 JIC swivel x 8 JICm 24V143 KIT, assembly, pair, inlet 16W611 FITTING, bulk hd 1/2 nptm x 8 JICm 15H189 BOOT, wire feed through 15G816 COVER, plate, wire way...
Page 127 Parts Quantity E-30i with E-XP2i with E-30i Booster Booster Ref. Part Description Heat Heat 24L915 PUMP, centrifugal, circulation 24J699 KIT, fitting, pump 24K286 KIT, fitting, drain 16W191 BRACKET, strainer, left 16W193 BRACKET, strainer, right 125170 HOSE, formed, 1 in. ID, lower 237 ❊...
Page 128 Parts Quantity E-30i with E-XP2i with E-30i Booster Booster Ref. Part Description Heat Heat 16W199 TUBE, A-side, inlet 16W202 TUBE, B-side, inlet 24V145 HEATER, assy, 4.0 kW, hybrid, 2 zone; see Dual Zone 4.0 Kw Fluid Heater 104765 PLUG, pipe, headless 16K361 COVER, horizontal heater 121311 FITTING, connector, 3/8-18 npt x 1/2 JIC...
Page 129 Parts Quantity E-30i with E-XP2i with E-30i Booster Booster Ref. Part Description Heat Heat 118444 SCREW, mach, slot hex wash hd; 1/2 in. x #10-24 194337 WIRE, grounding, door 16X129 SCREW, mach, phillips, tooth washer, 0.375 in. x #8-32 16W201 TUBE, A-side, outlet 16W204 TUBE, A-side, outlet 16W203 TUBE, B-side, outlet 16W205 TUBE, B-side, outlet...
Page 130 Parts Pump Inlet Assembly Kits Description Includes: E-30i A side 24L926 258-1 E-30i B side 24L927 259-3 E-XP2i A side 24L928 258-2 E-XP2i B side 24L929 259-4 Qty: Complete Coolant Hose Kit, 24L939 Ref. Description Qty. System HOSE, coolant, 1 in. ID, 2.66 ft (0.81 m) HOSE, coolant, 1 in.
Page 131 Parts Proportioner Module 24V152, Module for E-30i 24V153, Module for E-XP2i Torque to 190-210 in-lb (21-24 N·m). Lubricate threads with ISO oil or grease. Assemble pump cylinders flush to one full thread under-flush of housing surface. Apply grease to all gear teeth proportionally, motor pinion and drive housing. Torque to 20-30 ft-lb (27-40.6 N·m).
Page 132 Parts Quantity Ref. Part Description 24V152 24V153 24U051 MOTOR, brushless, double ended, 2 hp 302 ✚ 17W869 KIT, repair, drive housing 245927 HOUSING, bearing 257355 HOUSING, bearing 304 ✖ 287290 KIT, repair, gear 305 † 241279 KIT, rod, connecting 306 ◆ 245971 PUMP, displacement, B 245972...
Page 133 Parts Dual Zone 4.0 Kw Fluid Heater 24V145 Torque to 120 ft-lb (163 N·m). Torque to 23 ft-lb (31 N·m). Apply thermal paste. Apply pipe sealant and PTFE tape to all non-swiveling threads and threads without o-rings. Apply lithium grease lubricant to o-rings before assembling in block (1). Remove tape from probe tip and orientate sensor as shown.
Page 134 Parts 24V145 Ref. Part Description Qty. Ref. Part Description Qty. SCREW, machined, pan hd, 351 15M878 BLOCK, horizontal 361 124131 0.375 in. (9.5 mm), #6-32 REDUCER, #14 SAE x 1/2-14 352 15H302 INSULATOR, foam, heater, NPT(f) 362 15M177 horizontal 353 121319 ADAPTER, 1/2-14 NPT x #8 JIC ELBOW, 90°, 1/2-14 NPT x 354 15H304 PLUG, 9/16 SAE...
Page 135 Parts Air Control Panel Apply pipe sealant to all non-swiveling pipe Torque to 10 +/- 2 ft-lb (14 N·m). threads. See parts illustration for air flow direction. Apply anaerobic thread sealant to threads. Torque to 25 +/- 2 ft-lb (34 N·m). 332637M...
Page 136 Parts Ref. Part Description Qty. Ref. Part Description Qty. 401 16H452 BRACKET, air control 116513 REGULATOR, air BRACKET, mounting, booth 116514 NUT, regulator, plastic 402 277853 control BULKHEAD, 1 in. (25.4 mm), 104641 SCREW, SHCS, 0.5 in. (12 3/4-20 x 1/4-18 NPT 403 117026 mm), M5 x 0.8 156971...
Page 137 Parts 424 Identification Table Ref. Length in. (mm) Qty. 424-1 11 (279.4) 424-2 13.5 (342.9) 424-3 16.5 (419.1) 424-4 16 (406.4) 424-5 16.5 (419.1) 424-6 15 (381) 424-7 6.5 (165.1) 424-8 5.5 (139.7) 4 (101.6) Fluid Manifold 24T870 Apply PTFE tape and thread sealant to gauge Torque to 355-395 in-lb (40-44.6 N·m).
Page 138 Parts Ref. Part Description Qty. Ref. Part Description Qty. 255228 MANIFOLD, fluid ELBOW, street, 1/4-18 NPT x 100840 1/4-18 NPT 247824 KIT, valve, cartridge, drain † * ✚ 111457 O-RING, PTFE 452a 158674 O-RING, BUNA-N 465 ▲ 189285 LABEL, hot surface 452b 247779 SEAL, seat, valve 150829...
Page 139 Parts Electrical Enclosure 332637M...
Page 140 Parts Electrical Enclosure Ref. Part Description Qty. Ref. Part Description Qty. BUSHING, strain relief, m50 - - - ENCLOSURE, electrical, power 517 127253 thread MODULE, BREAKER, integr 502 24T061 518 127254 NUT, strain relief, m50 thread reactor 519 24T174 HARNESS, control box 503 24U855 MODULE, TCM CABLE, CAN, power, m12 fem, 504 26D472 MODULE, TCM...
Page 141 Parts 22 kW Diesel Generator Torque to 26 ft-lb (35.25 N·m). Apply sealant (blue) to threads. Torque to 15 ft-lb (20 N·m). Torque to 15-20 in-lb (1.7-2 N·m). Apply lubricant to engine end of hose prior to Torque to 100 ft-lb (135.6 N·m). assembly.
Page 142 Parts 22 kW Diesel Generator Ref. Part Description Qty. Ref. Part Description Qty. 24L965 CIRCUIT, breaker, 90A - - - ENGINE, diesel, Perkins 572a - - - SCREW ALTERNATOR, 22 kW, diesel 24R079 engine 572b - - - WASHER 16J883 BRACKET, engine mount, left 572c - - -...
Page 143 Parts Radiator See assembly notes on next page. 332637M...
Page 144 Parts Secure adhesive side of gasket to parts opposing Apply pipe sealant to all non-swiveling pipe threads. radiator, not radiator. Torque to 25 +/- 2 ft-lb (34 N·m). See parts list for length. Torque to 10 +/- 2 ft-lb (14 N·m). Torque to 25 in-lb (2.8 N·m).
Page 145 Parts Circuit Breaker Modules 24T061, Din Rail Circuit Breaker Assembly See Electrical Schematics, page 159. Torque to 5-8 in-lb (0.6-1 N·m). Torque to 4-5 in-lb (0.5-0.6 N·m). Torque to 23-26 in-lb (2.6-3 N·m). Ref. Part Description Qty. Ref. Part Description Qty.
Page 146 Parts 17H073, Transformer and Fan Circuit Breaker Module 903 904 902 ti27068a Torque to 5-8 in-lb (0.6-1 N·m). Torque to 23-26 in-lb (2.6-3 N·m). See Electrical Schematics, page 159. Ref. Part Description Qty. Ref. Part Description Qty. - - - DIN RAIL 905 125815 TERMINAL, block, feed thru...
Page 147 Parts 24T059, Transformer and Fan Circuit Breaker Module (Series A only) Torque to 5-8 in-lb (0.6-1 N·m). Torque to 23-26 in-lb (2.6-3 N·m). See Electrical Schematics, page 159. Ref. Part Description Qty. Ref. Part Description Qty. - - - DIN RAIL CIRCUIT, breaker, 50 AMP, 2 906 24L960 pole...
Page 148 Parts Fuel Tank 24K390 Ref. Part Description Qty. Ref. Part Description Qty. - - - TANK, fuel 125648 FITTING, 3/16 barbed 752 125645 GROMMET, tank 756 125649 VALVE, drain 753 125646 GROMMET, tank 758 24L955 CAP, fuel 754 125647 FITTING, suction, assy 332637M...
Page 149 Parts Heat Exchanger Assembly Ensure flow direction arrows on solenoids valves (804) are pointing down. Apply anaerobic pipe sealant to all non-swiveling fittings before assembling. Ref. Part Description Qty. Ref. Part Description Qty. 16H759 BRACKET, heat exchanger KIT, FITTING, outlet, heat 24J702 exchanger 24L917...
Page 150 Parts Fluid Inlet Kit 24T871 Apply sealant to all tapered pipe threads. Apply sealant to female threads. Apply to at least the first four threads and approximately 1/4 turn wide. Apply thermal paste to the stem of dial before assembling into housing. Ref.
Page 151 Parts 272089, E-30i with Air Compressor 272090, E-30i with Booster Heat and Air Compressor 272091, E-XP2i with Booster Heat and Air Compressor Apply anaerobic sealant to all non-swiveling pipe threads. Torque to 40 ft-lb (54 N·m). See Motor Starter, page 157 for component parts. 332637M...
Page 152 Parts Apply anaerobic sealant to all non-swiveling pipe threads. Use from safety label (55) or (283). See Switch Box Enclosure, page 156 for component parts. 332637M...
Page 153 Parts Cable Routing - Air Compressor and Air Dryer Do not allow cables from starter box to touch engine. Secure all cables with cable ties (742) to frame approximately where shown every 6-12 in. as needed. Secure with cable ties (742) to pallet tie downs where shown. Coil extra cable and use cable tie (742) to attach to underside of air dryer (703).
Page 154 Parts Discard plug supplied on compressor and install Parts included with compressor (702b). thermal switch (702h). Coupler supplied with compressor (702b) needs Discard lift ring to install flange. to be pressed on to motor (702a) as shown in detail view. Discard steel washer on (702g) before assembly.
Page 155 Parts Air Compressor Parts All air compressor parts are included in the Air Compressor Accessory Kit. See Accessories, page 12. Ref. Part Description Qty. Ref. Part Description Qty. COMPRESSOR, tankless, 5 113505 NUT, keps, hex hd; #10 16Y567 hp; includes 702a-702k 112958 NUT, hex, flanged;...
Page 156 Parts Switch Box Enclosure Assemble switch blocks as shown. Ref. Part Description Qty. Ref. Part Description Qty. 709a 16W575 ENCLOUSRE, front 709f 120495 BLOCK, switch, N.C. SWITCH, start, push button, 709g 260067 FITTING, strain relief, 1/2 npt 709b 121618 green 709h 117625 NUT, locking SWITCH, stop, push button,...
Page 157 Parts Motor Starter Attach ground connector bar aligned vertically to electrical box with screw and washer. Labels from sheet (712s). 332637M...
Page 158 Parts Motor Starter (continued) Diagram depicts wiring configuration for system series “D” and following. See for system series “A” through “C” wiring configuration. Torque to 38-42 in-lb (4.3-4.7 N·m). Torque to 18-22 in-lb (2-2.5 N·m). Torque to 28-32 in-lb (3.1-3.6 N·m). Ref.
Page 159 Electrical Schematics Electrical Schematics Harness Identification All wire harnesses are identified by a letter. The first letter on each wire in a wire harness corresponds with the wire harness. Use the table below to identify the wire harness, system component connections, and wiring diagram page number(s).
Page 160 Electrical Schematics Wire Label Identification Code The plastic wire wrap labels applied to many of the cables in the system use a code that indicates both the near-end and far-end connections made with the labeled wire. The first half of the code describes the module and port that the near-end of the cable connects to.
Page 161 Electrical Schematics Electrical Enclosure Wiring Diagram 127253 126881 DOOR GROUND WIRE 121603 127254 126891 194337 CIRCUIT BREAKER DIN RAIL 24T061 CB01 CB02 CB03 CB04 CB05 CB06 CB07 CB08 P110 '24 VDC' 24T241 K120 WHT K110 RED GRN / YEL K100 BLK 125859 H100 ORG H110 ORG...
Page 162 Electrical Schematics MCM Cable Routing Item End 1 End 2 Part Item End 1 End 2 Part MCM- Temperature and MCM- TCM- MCM-8 MCM Port CAN-1 121000 Pressure Inlet 16W131 CAN-1 CAN-2 INLET-A Sensor A Electrical Temperature and MCM- MCM-9 MCM Port MCM- Enclosure...
Page 163 Electrical Schematics MCM Wiring Diagram 'INLET-A MCM' 'INLET-B MCM' RTD-ENGINE 24T051 'INSITE MCM' 16W131 16W131 127286 PRESSURE-B 'PRESSURE-B MCM' 127286 PRESSURE-A 'PRESSURE-A MCM' 24T878 120858 127253 120859 127254 ELECTRICAL ENCLOSURE K070 WHT 'MCM-12 CYCLE-CNT' 'MCM-6 PRESSURE-A' 'MCM-7 PRESSURE-B' 'MCM-8 INLET-A' 'MCM-9 INLET-B' 'MCM-11 LOAD-CTR' 'MCM-14 INSITE'...
Page 164 Electrical Schematics Booster Heater Wiring Diagram 'HT-RTD-A TCM' 261821 HTR-OT HT-RTD-B 'HT-RTD-B TCM' 24L973 261821 126881 127253 126891 127254 ELECTRICAL ENCLOSURE 24U855 'TCM-B HT-RTD-B' 'TCM-A HT-RTD-A' TCM-OT 332637M...
Page 165 Electrical Schematics Optional Remote Display Module and Feed Pump Kit Wiring Diagram ELECTRICAL ENCLOSURE 'MCM-CAN-2 CAN-1' ti23006a Rotary switch setting: E-30i = 0 E-XP2i = 1 See Cable Routing Table on page 157. 332637M...
Page 166 Electrical Schematics Optional Customer Auxiliary Power Wiring Diagram See Circuit Breaker Identification, page 160, for circuit breaker identification table and other available circuit breakers. Before making any changes to the standard auxiliary circuit breaker configuration, refer to Circuit Breaker Configuration Options in the Reactor Operation Manual. POWER SUPPLY 240 VAC AUXILIARY LOAD...
Page 167 Electrical Schematics Reactor Cabinet Wiring Diagram REACTOR ENCLOSURE PRIMARY SECONDARY ELEC ENCL GND STUD N130 BLK N120 BLK ti27070b Torque thin terminal block connections to 5-7 in-lb (0.5-0.8 N·m). Torque large terminal block connections to 13-15 in-lb (1.4-1.7 N·m). 332637M...
Page 168 Electrical Schematics Load Center Wiring Diagram E630 - BLU TO ENGINE E620 - BRN HARNESS ‘E’ E611 - BLK 16K301 E150 - WHT E100 - ORG E200 - GRY FUSE REPAIR KIT E190 - TAN 24L959 E020 - RED (contains two replacement fuses) E220 - PUR E010 - BLK/WHT RELAY REPAIR KIT...
Page 169 Electrical Schematics Engine Control Module Wiring Diagram For System Series “C” and Following TO 120 / 240 VAC FERRITE ALTERNATOR BEAD HARNESS 'M', 17L263 125835 24A854, ENGINE CONTROL MODULE DSE PIN 20 F010 BLK / YEL F020 RED F030 GRY F040 GRN TO LOAD CENTER F070 WHT...
Page 170 Electrical Schematics For System Series “A” and “B” Only TO 120 / 240 VAC FERRITE ALTERNATOR BEAD HARNESS 'M', 16Y518 125835 24M665, ENGINE CONTROL MODULE DSE PIN 16 F010 BLK / YEL F020 RED F030 GRY TO LOAD CENTER F040 ORG HARNESS 'F', 16K297 F070 WHT F080 PUR...
Page 171 Electrical Schematics Engine Wiring Diagram FOR ALT. W/ 2 PIN CONNECTOR 3 - POST VERSION E190 - TAN E020 - RED CHARGE ALTERNATOR C020 - RED E190 - TAN E190 - TAN FUSIBLE LINK HARNESS ‘C’, 24L964 CHARGE ALTERNATOR C020 - RED C010 - RED FUSE, 16P405, FUSE HOLDER, 16P406 C030 - RED...
Page 172 Electrical Schematics Alternator Enclosure Wiring Diagram ALTERNATOR ENCLOSURE K080-WHT 125822 M070-WHT 125631 TO ENGINE CONTROL SP11 M020-BLK F6, 2 AMP MODULE F7, 2 AMP M040-RED SP12 HARNESS 'M',17L263 K070-WHT K020-BLK TO POWER 125754 K030-BLK DISTRIBUTION BOX K040-RED 90 AMP K050 - RED 125755 CB10 HARNESS 'K',125753...
Page 173 Electrical Schematics Air Compressor Wiring Diagram CB01 CB02 CB03 CB04 CB05 CB06 CB07 CB08 PD-N PD-CB8-4 PD-CB6-4 ti31518a PD-CB6-2 Tighten all power cable connections to 23-25 in-lb (2.6-2.8 N·m). Torque all air compressor wire connections to 30-32 in-lb (3.4-3.6 N·m). 332637M...
Page 174 Electrical Schematics Compressor Motor Junction Box For system series “D” and later. For system series “A” through “C” only. MOTOR JUNCTION BOX MOTOR JUNCTION BOX WIRE NUT WIRE NUT WIRE NUT WIRE NUT AC-W1 AC-W4-W8 AC-W1-W5 AC-W4-W8 AC-GND AC-GND AC-W5 GROUND GROUND STUD...
Page 175 Electrical Schematics Compressor Motor Capacitor Wiring Diagram Start capacitor - smaller diameter. Run capacitor - larger diameter. 332637M...
Page 176 Electrical Schematics Motor Starter - For System Series “D” and Following CORD GRIP 16M826 16X011 MS-QD1 MS-QD1 24U076 MS-A2 16X012 MS-L1 MS-L2 MS-L3 Motor STARTER WITH BOX CABLE 16X011 24U081 TO COMPRESSOR OVER TEMP SENSOR MS-23 CABLE 24U076 TO COMPRESSOR START STOP BOX MS-13 AUXILIARY CONTACTOR...
Page 177 Electrical Schematics Motor Starter - For System Series “A” Through “C” Only CORD GRIP 16M826 16X011 MS-QD1 MS-QD1 24U076 MS-A2 16X012 MS-L1 MS-L2 MS-L3 Motor STARTER WITH BOX CABLE 16X011 24U081 TO COMPRESSOR OVER TEMP SENSOR MS-23 CABLE 24U076 TO COMPRESSOR START STOP BOX MS-13 AUXILIARY CONTACTOR...
Page 178 Repair and Spare Parts Reference Repair and Spare Parts Reference Recommended Common Spare Parts Ref. Part Description Part of Assembly 24K207 Hose FTS (Fluid Temperature Sensor) Systems 16P405 Fusible Link Fuse (Replacement For Fusible Link Harness) Systems 16P406 Fusible Link Fuse Holder (Replacement For Fusible Link Harness) Systems 24L958 Load Center Relay Repair Kit, for load center (4 Relays) Proportioner...
Page 179 Recommended Rebuild Spare Parts Recommended Rebuild Spare Parts Ref. Part Description Part of Assembly 24U854 Advanced Display Module (ADM) System 24U832 Motor Control Module (MCM) Proportioner 24R756 Cooling Fan, Motor and Lower Cabinet Proportioner 24L915 Coolant Circulation Pump Proportioner 24L957 Load Center Repair Kit Proportioner 24L916...
Page 180 Dimensions Dimensions . 45 332637M...
Page 181 Dimensions . 46 332637M...
Page 182 Dimensions . 47: Floor Mount Hole Pattern 332637M...
Page 183 Technical Specifications Technical Specifications Reactor 2 Elite Integrated Proportioning Systems Metric Maximum Fluid Working Pressure E-30i 2000 psi 14 MPa, 140 bar E-XP2i 3500 psi 24.1 MPa, 241 bar Maximum Fluid Temperature E-30i 150°F 65°C E-30i with booster heater 180°F 82°C...
Page 184 Technical Specifications Reactor 2 Elite Integrated Proportioning Systems Metric Recommended Battery Size BC Group Number Length 10.25 in. 260 mm Width 6.81 in. 173 mm Height 7.88 in. 200 mm Booster Heater Power E-30i None E-30i with booster heater 4000 Watts...
Page 185 Technical Specifications Reactor 2 Elite Integrated Proportioning Systems Metric Fluid Circulation Ports Size 1/4 NPSM(m), with sst braided tubing Maximum Pressure 250 psi 1.75 MPa, 17.5 bar Weight E-30i 1750 lb 749 kg E-30i with compressor and dryer 2200 lb...
Page 186 Notes Notes 332637M...
Page 187 With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
Page 188 Original instructions. This manual contains English. MM332637 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com...

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