Graco Reactor A-20 Use and care manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2006, Graco Inc. is registered to I.S. EN ISO 9001
311512A
Repair - Parts
Reactor A-20
For spraying or dispensing 1:1 mix ratio materials, including epoxies, and
polyurethane foam. Not for use in explosive atmospheres.
253831 Air operated, electrically heated, plural component
proportioner.
This model is field-configurable to the following supply voltages:
230 V, 1 Phase
230 V, 3 Phase
380 V, 3 Phase
2,000 psi (14 MPa, 140 bar) Maximum Fluid Working Pressure
120 psi (0.84 MPa, 8.4 bar) Maximum Air Working Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
ti8447a

2311512A
Contents
Supplied Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 6
Keep Components A and B Separate . . . . . . . . . . 6
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 6
Before Beginning Repair . . . . . . . . . . . . . . . . . . . . 7
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 7
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Shroud Removal . . . . . . . . . . . . . . . . . . . . . . . . 12
Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pump Installation . . . . . . . . . . . . . . . . . . . . . . . 14
Recirculation / Over Pressure Relief Block . . . . 15
Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reversing Switch . . . . . . . . . . . . . . . . . . . . . . . 16
Solenoid Valve Replacement . . . . . . . . . . . . . . 16
Air Inlet Filter / Water Separator (Auto Drain) . . 16
Primary Heater . . . . . . . . . . . . . . . . . . . . . . . . . 17
Heating Elements . . . . . . . . . . . . . . . . . . . . . . . 18
Fluid Inlet Filter Screen . . . . . . . . . . . . . . . . . . . 19
Isocyanate Pump Lubricant . . . . . . . . . . . . . . . 19
Fluid Temperature Sensor (FTS) . . . . . . . . . . . . 20
Replacing Control Components . . . . . . . . . . . . . . 22
Hose Power Controller / Circuit Breaker / Relays 22
Air Motor Up / Down / Pressure Regulators /
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Control Panel Wiring . . . . . . . . . . . . . . . . . . . . . 23
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Recommended Spare Parts . . . . . . . . . . . . . . . . . 25
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Reactor A-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Electrical Control Panel . . . . . . . . . . . . . . . . . . . 28
Relief Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
A-20 Air Motor Pump Assembly . . . . . . . . . . . . 32
Primary 6000W Heater . . . . . . . . . . . . . . . . . . . 34
Air Tubing Connections . . . . . . . . . . . . . . . . . . . . . 36
Reactor A-20 Wiring Schematic . . . . . . . . . . . . . . 38
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Heater Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Pump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Hose Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 48
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 48

Supplied Manuals
311512A 3
Supplied Manuals
The following manuals are shipped with the Reactor™
A-20 Proportioner. Refer to these manuals for detailed
equipment information.
Order Part No. 15B535 for a compact disk of Reactor
manuals translated in several languages.
Manuals are also available at www.graco.com.
Related Manuals
The following manuals are for accessories used with the
Reactor™.
Order Part No. 15B535 for a compact disk of Reactor
manuals translated in several languages.
Order Part No. 15B381 for a compact disk of Fusion
manual translated in several languages.
Reactor A-20 Proportioner
Part No. Description
311511 Reactor A-20 Proportioner, Operation Man-
ual (English)
Proportioning Pump
Part No. Description
309577 Proportioning Pump Repair-Parts Manual
(English)
Feed Pump Kit
Part No. Description
309815 Instruction-Parts Manual (English)
Air Supply Kit
Part No. Description
309827 Instruction-Parts Manual (English) for Feed
Pump Air Supply Kit
Circulation and Return Tube Kit
Part No. Description
309852 Instruction-Parts Manual (English)
Heated Hose
Part No. Description
309572 Instruction-Parts Manual (English)
Fusion Air Purge Spray Gun
Part No. Description
309550 Instruction-Parts Manual (English)
Fusion Mechanical Purge Spray Gun
Part No. Description
309856 Instruction-Parts Manual (English)
Circulation Hose Manifold Kit
Part No. Description
309818 Instruction-Parts Manual (English)

Warnings
4311512A
Warnings
The following general warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Addi-
tional, more specific warnings may be found throughout the body of this manual where applicable. Symbols appear-
ing in the body of the manual refer to these general warnings. When these symbols appear throughout the manual,
refer back to these pages for a description of the specific hazard.
WARNING
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on sprayer and extension cords.
• Do not expose to rain. Store indoors.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear impervious gloves when spraying or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
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 point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.

Warnings
311512A 5
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical
reaction and equipment rupture, and result in death, serious injury, and property damage.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
WARNING

Isocyanate Hazard
6311512A
Isocyanate Hazard
Moisture Sensitivity of
Isocyanates
Isocyanates (ISO) are catalysts used in two component
foam and polyurea coatings. ISO will react with moisture
(such as humidity) to form small, hard, abrasive crystals,
which become suspended in the fluid. Eventually a film
will form on the surface and the ISO will begin to gel,
increasing in viscosity. If used, this partially cured ISO
will reduce performance and the life of all wetted parts.
To prevent exposing ISO to moisture:
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
• Keep the felt washers in the pump wet-cups satu-
rated with Graco ISO pump oil, Part No. 217374.
The lubricant creates a barrier between the ISO and
the atmosphere.
• Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system; see
Accessories, page 24.
• Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
• Never use solvent on one side if it has been contam-
inated from the other side.
• Always park pumps when you shutdown.
• Always lubricate threaded parts with Part No.
217374 ISO pump oil or grease when reassembling.
Keep Components A and
B Separate
Changing Materials
• When changing materials, flush the equipment mul-
tiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after flushing;
see Fluid Inlet Filter Screen, page 19.
• Check with your material manufacturer for chemical
compatibility.
• Most materials use ISO on the A side, but some use
ISO on the B side.
• Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.
Read material manufacturer’s warnings and material
MSDS to know the specific hazards of isocyanates.
Use equipment in a well-ventilated area. Wear respi-
rator, gloves, and protective clothing when using iso-
cyanates.
The amount of film formation and rate of crystalli-
zation varies depending on the blend of ISO, the
humidity, and the temperature.
CAUTION
To prevent cross-contamination of the equipment’s
wetted parts, never interchange component A (isocy-
anate) and component B (resin) parts.

Before Beginning Repair
311512A 7
Before Beginning Repair
Pressure Relief
Procedure
1. Turn off feed pumps and agitator if used.
2. Turn PARK/RUN switch to PARK.
3. Trigger gun to relieve pressure.
4. Turn off air inlet valve.
5. Engage gun piston safety lock.
6. Verify gun fluid manifold valves A and B are closed.
7. Close pump inlet supply valves.
Flushing
• Flush with a compatible solvent.
• Use lowest possible pressure when flushing.
• To flush entire system, circulate through gun fluid
manifold (with gun removed from manifold).
• Always leave hydraulic oil or a non-water based,
non-water absorbent fluid in system. Do not use
water.
Repairing this equipment requires access to parts
that may cause electric shock or other serious injury if
work is not performed properly. Electrical trouble-
shooting must be done by a qualified electrician. Be
sure to shut off all power to equipment and lock out
power at the source before repairing.
TI2409a
TI2421a
Flush equipment only in a well-ventilated area. Do not
spray flammable fluids. Do not turn on heaters while
flushing with flammable solvents.
Only use flush solvents that are compatible with Fluo-
roelastomer seals. Non-compatible solvents will dam-
age seals and cause hazardous conditions, such as
high pressure leaks and pressure switch failure.

Troubleshooting
8311512A
Troubleshooting
Power
Pumps and Pressures
PROBLEM CAUSE SOLUTION
Reactor does not operate No power Plug in power cord
Turn Main Disconnect Switch ON
Power cord not connected properly Check connections
No power when disconnect switch is
turned on; using 230V, 1 phase or
230V, 3 phase power
Power terminal jumper still at 380V, 3
phase position, as shipped from fac-
tory
Place jumpers in correct position; see
operation manual 311511 and label
inside front lower cabinet.
External main supply power circuit
breaker trips and Reactor disconnect
switch fails when switch is turned on.
Power terminal jumper was left in
230V, 1 phase position. When using
230V, 3 phase or 380V, 3 phase
power
Place jumpers in correct position; see
manual 311511. Replace main power
disconnect switch; see page 26.
No temperature display lights at star-
tup
No power Plug in power cord
Turn Main Disconnect Switch ON
Control power fuses blown Check and replace fuses on long ter-
minal strip
Reactor stops working; all lights are
off except temperature displays
Red stop switch was pushed Reset all control switches to START
PROBLEM CAUSE SOLUTION
Pump does not run up and down but
green switch light is on
PARK/RUN switch in PARK position Turn PARK/RUN switch to RUN
No air supply Air supply line not connected
Open inlet air ball valve
Air pressure regulators set at 0 psi Turn up air pressure regulators
Pump runs but no fluid pressure Fluid inlet ball valves closed Open fluid ball valves
Fluid pressure low or dropping Air supply pressure low when spray-
ing
Increase inlet air pressure
Increase air compressor size to meet
flow requirements
Remove airline quick disconnects
Use 3/8 in. (0.95 cm) ID or larger air
supply hose
Icing in air motor quick exhausts or
mufflers
Check and repair fan
Check inlet filter water separator; see
page ##. Stop spraying for 5 minutes
while fan melts ice.
Pump output low Obstructed gun impingement ports or
filters
Flush and clean gun; see gun manual
One pressure gauge drops when
pumps are stalled on both the
upstroke and the downstroke
Leaking pump throat Repair pump; see 309577
Leak between pump and gun Check fluid tubes, heater, and hoses
Spray gun is leaking on one side Clean and repair spray gun
One pressure gauge drops when
pumps are stalled on the downstroke,
but not the upstroke
Inlet ball check not sealing Clean or replace; see 309577
Inlet check seat o-ring not sealing Repair pump; see 309577

Troubleshooting
311512A 9
One pressure gauge drops when
pumps are stalled on the upstroke,
but not the downstroke
Piston check ball not sealing Repair pump; see 309577
Piston packing not sealing Repair pump; see 309577
Loose piston stud in pump Repair pump; see 309577
Bad inside sleeve seal Repair o-ring; see 309577
A side rich; lack of B side A side gauge is low B side restriction downstream of
gauge. Check gun check valve
screen, mix module, or mix manifold
restrictor.
B side gauge is low B side material supply problem.
Check B side inlet strainer and pump
intake valve.
B side rich; lack of A side A side gauge is low A side material supply problem.
Check A side inlet strainer and pump
intake valve.
B side gauge is low A side restriction downstream of
gauge. Check gun check valve
screen, mix module, or mix manifold
restrictor.
Fluid pressures not balanced
between A and B side
Fluid viscosities not equal Sometimes normal if pressure offset
is below 200 psi (14 bar)
Preheat material in drums by recircu-
lating; see Operation manual 311511
Inlet Y-strainer screen plugged on low
pressure side
Clean inlet filter screen
Gun port or filter plugged on high
pressure side
Clean or replace; see gun manual
Pump inlet ball not seating or sticking Clean seating; see pump manual
Drum fluid outlet supply hose too
small
Use 3/4 in. (1.9 cm) ID hose with
short length
Low side feed pump not working Turn on or repair feed pump
Pump does not reverse direction Obstruction of air motor or pumps Check and clear obstruction
Reversing switch failed Check and service switch assembly;
see page 16.
Air solenoid valve failed. Check solenoid valve, see page 16.
Unequal fluid pressure between
UP/DOWN stroke
Air regulator pressures not set cor-
rectly. Feed pumps boost pressure on
up stroke.
Adjust UP/DOWN air regulators to
create equal fluid outlet pressures;
see Operation manual 311511.
Pumps stop moving, Pump Mode
Function green knob light off
Over-pressure shutdown from imbal-
anced pressures. Plugging one side
will double the pressure. Starving
one side will double the pressure on
the other side.
Check for gun restriction, see Gun
manual
Air pressure set too high; lower air
pressure
Pump cavitating on low pressure
side; check inlet and clean strainer.
Check feed pump.
Heater plugged on low pressure side;
see Repair, page 18.
PROBLEM CAUSE SOLUTION

Troubleshooting
10 311512A
Hose Heat
Air motor doesn’t move with air pres-
sure applied
Reversing switch failed Inspect and repair parts; see page
32.
Solenoid valve failed Replace valve.
Pump movement speed is erratic Worn air motor seals Replace seals; see page see page
32.
Worn pump seals Replace seals; see Pump manual.
Worn solenoid valve seals Replace solenoid valve; see pages
16 and 32.
PROBLEM CAUSE SOLUTION
PROBLEM CAUSE SOLUTION
Hose temperature controller display
flashing “SbEr” and “H20.0”
FTS not connected. Control does not
see thermocouple.
Check and connect FTS connector at
each joint; see page 20.
Hose temperature controller display
dropping with hose switch green light
on
Hose power-lock connector loose Connect hose power-lock at Reactor
Check and reconnect all connector
points along hose. Use wire tie to
hold together.
Hose heat switch green light goes out Hose over-temperature shutdown Measure hose for proper amperage.
Repair or replace hose power con-
trollers. See page 22. Reset
over-temperature hose control knob
to START.
Set Point 2 (SP2) deviation alarm set
too low. Raise SP2 to 30 °F (17 °C)
default setting.
Hose temperature display overshoots
setpoint and/or green switch light
goes out
Hose coiled up on itself too much,
sends overheated fluid to FTS
Straighten out coiled hose
Insulation peeled off of hose at FTS
sensor inside hose causes the rest of
hose to overheat.
Insulate hose up to FTS. FTS must
represent bulk of heated hose.
Hose heat too low Temperature setpoint too low Check setpoint (SP1); adjust if nec-
essary
Fluid flow too high Use smaller mix chamber. Decrease
pressure.
Hose heat not turned on long
enough. More than 310 ft. connected.
Allow more time for hose heat to heat
up or preheat supply drums
Loose electrical connectors. Green
light on Power Controller is off.
Check power and FTS connections;
see page 20.
Either heat temperature controller
display dark
Controller connector loose Check and reconnect
No lights on hose power controller in
lower cabinet while temperature con-
troller 01 output light is on steady.
Green switch light is on. Not heat in
hose.
No 4.5 to 12 Vdc signal from temper-
ature controller
Make sure 01 light on top tempera-
ture controller is on.
Polarity is reversed on 4.5 to 12 Vdc Reverse blue wires.
No power to hose power controller
terminals 2 and 3; 220-240 Vac
Make sure green light on hose switch
is on. Make sure hose primary circuit
breaker is on.

Troubleshooting
311512A 11
Primary Heater
Hose power controller in lower cabi-
net illuminates green light, but amber
light not on. Temperature controller
01 output light is on steady. No heat
in hose.
Opening in hose circuit Disconnect main hose plug. Check
for only 0.4 - 6 ohm resistance
through hose circuit. Make sure all
hose connections are secure.
Hose secondary circuit breaker open Check hose secondary breaker.
Check for continuity across breaker.
Check current sensor for 18 ohms.
Hose power controller in lower cabi-
net illuminates green light, but amber
light not on. Temperature controller
01 output light is on steady. High heat
in hose.
Current sensor doughnut not con-
nected
Check hose power controller connec-
tions 15 and 16.
Hose cable not running through cur-
rent sensor doughnut
Check hose cable and reroute if
needed. Check sensor for 18 ohms.
Hose power controller is set too high Contact Graco Technical Assistance.
Low heat in hose. Hose power con-
troller in lower cabinet illuminates
green light, but amber light not on.
Temperature controller 01 output light
is on steady. No heat in hose.
More than 210 ft (64 m) of heated
hose used on machine (prevents
hose from reaching 45 amps)
Running at full voltage. Orange light
only comes on when power controller
is at 45 amp current limit.
PROBLEM CAUSE SOLUTION
Primary heat temperature controller
green switch light goes out
Primary heater 230°F (110 °C)
over-temperature switch tripped.
Reset heater switch to START after
cooling.
Solid state relay failed closed. Replace solid state relay 165 SSR.
Primary heat display low; power ON Temperature setpoint too low Check setpoint (SP1) and adjust if
necessary.
Fluid flow too high Use smaller mix chamber; decrease
pressure.
Heating element burned out Check heater element resistance;
see page 17.
Heating element fuse blown Determine high current cause;
replace fuse; see page 17.
Fluid too cold for flow rate Recirculate fluid in supply drum; see
Operation manual 311511.
No Primary heat. Temperature con-
troller output light is on. Green switch
light is on. Solid state relay indicator
light is on.
Contactor relay failed (190 CR) Check for line voltage across contac-
tor. Replace contactor.
Circuit breaker tripped (110 CB) Reset circuit breaker; investigate
cause.
Solid state relay failed (165 SSR) Check for line voltage across relay.
Primary heat temperature controller
displays “SbEr”
Thermocouple connection reversed Correct connections; see electrical
diagram in Heating Elements on
page 18.
Open thermocouple Check thermocouple resistance;
replace.

Repair
12 311512A
Repair
Shroud Removal
Rear Upper Half
1. Remove two screws (A) on sides of shroud.
2. Lift shroud up over three pins holding it in place at
top of Reactor.
3. Lift shroud completely off and remove from Reactor.
Rear Lower Half
1. Remove two screws (B) from lower half of shroud.
2. Pull lower half of shroud up and off to remove from
Reactor.
Lower Front Cover
1. Remove two bolts (C) at bottom of front cover.
2. Pull cover down and out to remove from Reactor.
Air Motor Cover
1. Pull out and remove pin (D) holding two shroud
halves together.
2. Remove two screws (E) on each side of shroud.
3. Remove fan wires if required.
Pump Removal
1. Shut off Primary Heater Switch and Hose Heater
Switch.
2. Perform Pressure Relief Procedure; see page 7.
3. Perform Flushing Procedure; see page 7.
4. Turn Main Disconnect Switch OFF (H) and discon-
nect power supply.
Unless otherwise noted, all repair procedures must be
completed with incoming power switched OFF and
locked out at the source. Any electrical repair or trou-
bleshooting required beyond the scope of this manual
must be performed by a qualified electrician. Shut off
air inlet ball valve and shut off all air supply pressure.
B
A
C
ti8453a Air motor shaft, yoke, pump rod and connecting rod
move during operation. Moving parts can cause seri-
ous injury such as pinching or amputation. Keep hands
and fingers away from connecting rod during operation.
See manual 311391 for pump repair instructions.
D
E
H
KJ
ti8455a

Repair
311512A 13
5. Shut off both feed pumps and close both inlet supply
valves (F).
6. Shut off inlet air ball valve (G).
7. Remove air motor cover on side to be repaired; see
page 12.
8. Disconnect fittings at inlet (Q) and outlet (M). Also
disconnect steel outlet tube (P) from heater inlet.
9. Disconnect tubes (N) from Iso Lube Pump on A side
only.
10. Push retaining wire clip (R) up. Push retaining pin
out.
11. Loosen locknut (S) by hitting firmly with a
non-sparking hammer.
12. Unscrew pump out of pump mounting plate (T).
F
G
ti8448a
PQ
Mti8454a
M
N
ti8481a
S
R
T
ti8456a

Repair
14 311512A
Pump Installation
1. Ensure locknut (431) is screwed on pump with flat
side up. Grease pump mounting threads in plate
(412) with lithium grease. Screw pump into pump
mounting plate (401) until top of pump thread is
above mounting plate 1/2 to 1 1/2 threads above
flush.
2. Align pump rod hole with link hole. Push retaining
pin (436) in. Pull retaining wire down to cover pin
ends.
3. Reconnect fluid inlet (Q) and outlet (M).
4. Tighten locknut (431) by hitting firmly with a
non-sparking hammer.
5. For Iso A pump only: reconnect two tubing lines (N)
from ISO Pump Lube reservoir. Flush and refill res-
ervoir with TSL 206995.
6. Refill Resin B pump wet cup with TSL 206995.
7. Reconnect fan wires if they were disconnected.
8. Reinstall air motor cover and tighten two screws (E).
ti8456a
431
412
452
454,
455
M
Q
ti8487a
N
ti8455a
E

Repair
311512A 15
Recirculation / Over Pressure
Relief Block
Valves can be serviced with the block on the machine
(see page 32 for parts view). For thorough cleaning,
remove the block assembly as follows.
1. Remove both rear shrouds and lower front shroud;
see page 12.
2. Disconnect two fluid tubes connected to back of
recirculation block.
3. Loosen and remove two screws (ST) in back of
recirculation block.
4. See Relief Manifold, page 30. Clean and inspect all
parts for damage. Ensure that the seat (8a) and
gasket (8b) are positioned inside each valve car-
tridge (8).
5. Apply PTFE pipe sealant to all tapered pipe threads
before reassembling.
6. Reassemble in reverse order, following all notes.
Air Motor
See A-20 Air Motor Pump Assembly on page 32.
1. Remove four cover bolts (404) from outside hous-
ings (402). Leave fan connected.
2. Raise retaining spring (444) and knock retaining
pins (436) out of pump rod slots. Leave yoke (415)
and link (414) in place.
3. Press in tube fitting ferrules and pull out tubing to
disconnect air lines.
4. Remove four bolts (408) to remove entire air motor
assembly.
5. Remove lock nut (434) from piston rod (437) and
remove pump yoke (415).
6. Remove four lock nuts (409), washers (407), and
tie-rod bolts (408).
7. Lift top plate (406) and remove from air cylinder
(405).
8. Push piston rod assembly out of the air cylinder and
replace piston o-ring (438) and lubricate.
9. Replace bottom plate bearing (434), u-cup seal
(435), and lubricate. U-cup seal open end faces up.
10. Replace top and bottom o-rings (439) in the plates.
Use lubricant to hold in place.
11. Assemble in reverse order.
12. Torque tie rod bolts in small increments evenly to
17-22 in/lbs (3•4 Nm).
Air Motor Seal Repair Kit 255057 is available to
change all air motor seals.
ST ti8485a
ti8491a
402
ti8457a
408
434
415
406
405
437

Repair
16 311512A
Reversing Switch
1. Remove single screw and remove cover from
reversing switch (410).
2. Inspect parts for damage or wear; replace switch
assembly if necessary.
3. Disconnect wire from terminal block (follow wire
back to where it connects to terminal block and dis-
connect).
4. Remove two screws (404) from mounting bracket.
Solenoid Valve Replacement
See A-20 Air Motor Pump Assembly, page 32.
1. Disconnect all tubing attached to air control solenoid
valve (430). To disconnect, push end sleeve in and
pull tube. Mark each tube according to its corre-
sponding fitting.
2. Loosen self-contained plug retaining screw on each
end and remove electronic plug.
3. Remove three screws (424) on air control solenoid
valve.
4. Replace fittings (425, 426, 428) and muffler (427)
onto new valve.
5. Reattach mounting screws and plug retaining
screws.
6. Reconnect all tubing lines.
Air Inlet Filter / Water Separator
(Auto Drain)
Air Filter Element Removal
See Air Inlet, page 30.
1. Close air inlet valve (302) on filter (301).
2. Hold in metal spring clip and twist black cover coun-
terclockwise to remove.
3. Unscrew clear drain cover by hand.
4. Unscrew black filter element retainer to remove ele-
ment.
5. Inspect filter element. Clean or replace.
Air Filter Element Installation
1. Insert cleaned or replacement filter (114228).
2. Hand-screw filter retainer into place.
3. Hand-screw clear drain cover until tight.
4. Reposition black cover and turn. Make sure it
“snaps” back into place.
ti8487a
410
404
427
ti8456a
302
301

Repair
311512A 17
Primary Heater
1. Turn Main disconnect Switch OFF.
2. Perform Pressure Relief Procedure; see page 7.
3. Wait for heater to cool.
4. Perform Flushing procedure; see page 7.
5. Remove both rear shrouds and lower front shroud;
see page 12.
Removal
1. Disconnect two fluid lines at bottom of heater.
2. Disconnect two upper fluid lines at the connection to
the recirculation manifold. Leave tubing assemblies
connected to heater.
3. Follow brown thermocouple wire up to hose heat
temperature control and disconnect. See Wiring on
page 35.
4. Disconnect over pressure switches.
a. Loosen retaining screw.
b. Unplug connector front and back.
5. Disconnect two main power leads from wire harness
at heater assembly terminal blocks.
6. Disconnect two wires from over temperature switch.
7. Remove back screw holding wiring bracket to heater
shelf. Retain screw.
8. Remove four screws underneath heater. Retain four
thermal barrier spacers for later installation.
9. Pull heater assembly out and remove from unit.
Service
See parts breakdown on page 34 for servicing.
Installation
Reconnect and install in reverse order.
Read Warnings on page 4. Wait for heater to cool be-
fore repairing.
ti8484a

Repair
18 311512A
Heating Elements
The primary heater contains four 1500-watt (30-36
ohms each) heating elements wired in parallel. To check
if the elements are functional, perform the following
steps:
1. Turn OFF and lock out incoming power at source.
2. Allow heater to cool.
3. Remove two rear shrouds; see page 12.
4. Measure the resistance of all four heating elements
wired in parallel together at the heater contactor.
When measured at points T1 on 165 SSR and T3
on 190 CR (see figure below), ohms reading should
be 8.5. If ohm reading is above 10 ohms, see step 5.
5. Check each fuse in fuse holder. Swing open fuse
holder by pulling on tab. Test each fuse for electrical
continuity from end to end. Replace if open resis-
tance is measured. If fuses are good, see step 6.
6. Measure resistance of two heating elements wired
in parallel with fuse holders open.
Resistance between 1A and 2A to be 17 ohms.
Resistance between 1B and 2B to be 17 ohms.
If resistance is higher than 25 ohms, determine
which heating element is failed open. Disconnect
each heating element wire from fuse holder and
measure resistance.
7. Each heating element resistance reading should be
34 ohms.
,
4
&5
ȍ
665
ti8606a
ti8607a

Repair
311512A 19
Fluid Inlet Filter Screen
A Y-line filter screen before each proportioning pump
traps solid matter to ensure proper operation of ball
check valves in pump base. Inspect and clean both
screens. See Reactor A-20 Operation manual (311511).
Remove and clean filter screens as follows:
1. Follow Pressure Relief Procedure on page 7.
2. Place a rag beneath filter base to catch drain-off of
chemical when removing screen plug.
3. Loosen screen plug just enough to allow material to
drain out onto rag.
4. Unthread screen plug and remove it.
5. Pull screen straight out of strainer. Clean or replace.
See Accessories, page 24, for alternate mesh size.
6. Thoroughly clean screen gasket and material inside
strainer.
7. Position screen on shoulder of plug and screw
securely back into strainer.
8. Reconnect transfer pump air supply and open mate-
rial inlet supply valve. Ensure there are no leaks and
wipe equipment clean.
Isocyanate Pump Lubricant
Check pump lubricant daily. Change lubricant before it
becomes a gel or when its color darkens. The time inter-
val between changes due to gel formation will depend
on environmental conditions.
To change lubricant, use the following steps.
1. Lift lubricant reservoir out of bracket and remove
reservoir from cap.
2. Flush reservoir thoroughly and fill 3/4 full with TSL
Throat Seal Lubricant 206995.
3. Thread reservoir back onto cap assembly and
return it to the bracket.
The lubrication system is now ready from operation. No
priming is required.
Regularly clean isocyanate pump screen during
start-up procedure. This minimizes moisture con-
tamination problems by immediately flushing out
any isocyanate residue at start of dispensing oper-
ation.

Repair
20 311512A
Fluid Temperature Sensor (FTS)
Check FTS operation by connecting directly to Reactor.
FTS Cable Test
1. Disconnect FTS cable (SS) at Reactor.
2. Test with ohmmeter between pins of cable
connector.
3. If cable fails test, retest at FTS.
FTS Test
1. Turn Main Disconnect Switch OFF. Disconnect
power supply cord.
2. Relieve pressure; see page 7.
3. Remove tape and protective covering from FTS.
Disconnect hose cable. Test with ohmmeter
between pins of cable connector.
4. If FTS fails test, replace FTS.
An alternating hose controller display of SbEr and
H0.00 indicates a loss of signal from the FTS. Two
conditions must be satisfied for proper FTS
operation:
• The sensor must be functional
• The signal must travel uninterrupted from the
sensor to the control unit
Pins Result
1 to 2 Approximately 35 ohms per 50 ft
(15.2 m) of hose, plus approximately
10 ohms for FTS
1 to 3 Infinity
SS
ti8444a
Pins Result
1 to 2 Approximately 35 ohms per 50 ft
(15.2 m) of hose, plus approximately
10 ohms for FTS
1 to 3 Infinity
3 to FTS ground
screw
0 ohms
1 to FTS com-
ponent A fitting
(ISO)
Infinity