Graco 25D117 Instruction Manual

3A5354B
EN
Operation
Warm Melt Supply
System
For use with heated bulk supply of medium to high viscosity sealant and adhesive
materials. Intended for indoor use only. For professional use only.
Not for use in hazardous locations or explosive atmospheres.
25D117
26C258
D20 3 inch dual post
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure for
Air cylinder.
60 psi (0.4 MPa, 4 bar) Maximum Air Inlet Pressure for
Air motor.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
The Graco Control Architecture Electric Components
are listed in Intertek’s Directory of Listed Products.

23A5354B
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
System Description . . . . . . . . . . . . . . . . . . . . . . . 5
Power Requirements . . . . . . . . . . . . . . . . . . . . . 5
Heat Control Zone Selection . . . . . . . . . . . . . . . . 5
Component Identification . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Location Requirements . . . . . . . . . . . . . . . . . . . . 9
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connect Power Source . . . . . . . . . . . . . . . . . . . 10
Connect Electrical Cord . . . . . . . . . . . . . . . . . . 11
Install/Adjust Drum Low Level Switch . . . . . . . . 12
Light Tower Accessory . . . . . . . . . . . . . . . . . . . 12
Check Resistance . . . . . . . . . . . . . . . . . . . . . . . 13
Hose Installation and Care . . . . . . . . . . . . . . . . 15
Overview of Temperature Control Settings . . . . 15
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Low Level Adjustment . . . . . . . . . . . . . . . . . . . . 16
Load Material . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System Heat Up . . . . . . . . . . . . . . . . . . . . . . . . 18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pressure Relief Procedure . . . . . . . . . . . . . . . . 20
Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Start and Adjust Ram . . . . . . . . . . . . . . . . . . . . 20
Start and Adjust Pump . . . . . . . . . . . . . . . . . . . 21
Change Drums . . . . . . . . . . . . . . . . . . . . . . . . . 21
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Replace Throat Seals . . . . . . . . . . . . . . . . . . . . 23
Platen Maintenance . . . . . . . . . . . . . . . . . . . . . 24
Pump Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . 26
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Displacement Lower . . . . . . . . . . . . . . . . . . . . . 31
Disconnect Platen from Pump . . . . . . . . . . . . . 32
Connect Platen to Pump . . . . . . . . . . . . . . . . . . 32
Replace Platen Heaters and Sensor O/T Device 33
Replace Pump Heaters and Sensor O/T Device 34
Replace Ram Piston Rod Seals . . . . . . . . . . . . 35
Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . 36
Display/User Interface . . . . . . . . . . . . . . . . . . . . 38
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 40
Electrical Enclosure Schematic . . . . . . . . . . . . . 40
Ram A Schematic . . . . . . . . . . . . . . . . . . . . . . . 40
Typical Hose/Applicator Wiring . . . . . . . . . . . . . 41
Ram A Schematic . . . . . . . . . . . . . . . . . . . . . . . 41
Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . 41
Ram A Schematic . . . . . . . . . . . . . . . . . . . . . . . 41
Pump and Platen Schematic . . . . . . . . . . . . . . . 42
Ram A Schematic . . . . . . . . . . . . . . . . . . . . . . . 42
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
System and Supply Unit 25D117 and 26C258 . 43
Ram A Schematic . . . . . . . . . . . . . . . . . . . . . . . 43
Ram Kit 25D092 . . . . . . . . . . . . . . . . . . . . . . . . 44
Ram A Schematic . . . . . . . . . . . . . . . . . . . . . . . 44
Heated Platen 25D085 . . . . . . . . . . . . . . . . . . . 45
Ram A Schematic . . . . . . . . . . . . . . . . . . . . . . . 45
Electrical Enclosure 25D113 and 26C257 . . . . . 46
Ram A Schematic . . . . . . . . . . . . . . . . . . . . . . . 46
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Technical Specifications . . . . . . . . . . . . . . . . . . . . 48
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 50
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 50
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Warnings
3A5354B 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion 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.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause elec-
tric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and regu-
lations.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent
flowing through the equipment can cause static sparking. 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 sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• 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.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are
anti-static or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until
you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, 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 dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.

Warnings
43A5354B
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 power sources.
SPLATTER HAZARD
Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin. During blow off of platen,
splatter may occur.
• Use minimum air pressure when removing platen from drum.
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 Safety Data Sheets (SDSs) 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.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
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 com-
ponent. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifica-
tions in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete infor-
mation about your material, request Safety Data Sheets (SDSs) from distributor or retailer.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• 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. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call you 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.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not
limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
WARNING

Overview
3A5354B 5
Overview
System Description
Warm melt supply systems are used for melting and
pumping warm melt adhesives and high viscosity seal-
ants.
The system consists of an air-powered ram that drives a
Check-Mate pump and a heated platen into a drum of
material. The heated platen heats the material and the
pump removes it from the drum. The material is then
pushed through a supply hose to the applicator.
All features of the warm melt supply system are con-
trolled by Graco Control Architecture components: Tem-
perature Control Modules (TCM) and the display
module. The TCMs control the heaters, and the display
module provides the user interface for the entire warm
melt supply system.
Power Requirements
A 30A (minimum) - 40A (maximum) circuit breaker (not
provided) must be installed on the incoming power sup-
ply. See TABLE 1 and Technical Specifications, page
48, for more information regarding electrical require-
ments.
Heat Control Zone Selection
Warm melt supply systems have six heat zones (see
FIG. 1).
• Zones 1 and 2 are always used for the heated
platen and the heated pump respectively.
• Zones 3, 4, 5, and 6 are used for the heated hose
and gun, or a heated regulator. Zones 3 and 4 are
integrated into one receptacle, and zones 5 and 6
are integrated into another. These zones are rated
for 2000 watts at 220 volts.
There are four receptacles with a 12-pin connector on
the control board inside. Heated hoses also have a
12-pin connector on the inlet end cable, and an 8-pin
connector on the outlet end cable. All heated valves,
manifolds and heaters are equipped with a 12-pin con-
nector.
Table 1: Electrical Requirements
AC Panel
Voltage HZ Phase
Full Load
Amps
220~240 50/60 1 44
220~240 50/60 3 18
FIG. 1: Heat Control Zone Selection
Receptacle 1
ZONE 1
Receptacle 3
ZONE 3 & ZONE 4
Receptacle 2
ZONE 2
Receptacle 4
ZONE 5 & ZONE 6
Platen Pump
Hose Hose
Gun Gun
(or heated valve,
manifold, heater, etc.)
(or heated valve,
manifold, heater, etc.)

Component Identification
63A5354B
Component Identification
Key:
ARamAssembly
B Air Motor
C Heated Displacement Lower
D Heated Platen
E Air Controls (See FIG. 3)
F Air Motor Lift Ring
G Platen Bleed Port
H Blow off Air Supply Line
J Air Motor Bracket
K Pump Bleed Valve
LWetCup
M System Air Inlet
N Material Outlet
P Electrical Enclosure
Q ADM Display Module
R Electrical Enclosure Bracket
S Low Level Switch
T Low Level Switch Bar
U Power Cable
FIG. 2: System Components
Q
R
L
N
C
U
D
G
A
K
M
H
E
J
B
F
S
T
P
(Note: Do not use the motor
lift ring to lift the entire system.)

Component Identification
3A5354B 7
Air Controls
•Main air ball valve (BA): turns air on and off to the
system. When closed, the valve relieves pressure
downstream.
•Ram air regulator (BB): controls ram up and down
pressure and blow off pressure.
•Ram director valve (BC): controls ram direction.
•Air motor regulator (BE): controls air pressure to
the motor.
•Air motor ball valve (BF): turns air on and off to
the air motor. When closed, the valve relieves air
trapped between it and the air motor.
•Blow off button (BG): turns air on and off to push
the platen out of an empty drum.
•Safety Valve (BH): relieves air pressure if the air
motor pressure exceeds 60 psi (0.4 MPa, 4 bar).
•Safety Valve (BJ): relieves air pressure if the inlet
air pressure exceeds 100 psi (0.7 MPa, 7 bar).
FIG. 3. Integrated Air Controls
BB
BC
BA
BE
BG
BF
BH
BJ

Component Identification
83A5354B
User Interface User Interface Display
Display Screen Components
FIG. 4 calls out the components shown on each display
screen, including navigation (1), status (2), and general
informational (3).
Key Function
CA Controller enable/disable
CC Stop all system processes
CD Defined by icon next to soft key
CE Abort current operation
CF Accept change, acknowledge error,
select item, toggle selected item
CG Toggle between run and setup screens
CH Navigate within a screen or to a new
screen
NOTICE
To prevent damage to soft key buttons, do not press
the buttons with sharp objects such as pens, plastic
cards, or fingernails.
CG
CA CC
CD
CE
CF
CH
FIG. 4: Display Screen Components
12
3

Installation
3A5354B 9
Installation
Location Requirements
• Refer to Dimensions on page 47 for ram mounting
and clearance dimensions.
• Install indoors only, and do not install near water or
any other liquid that is sprayed.
Location
The system should be lifted by the holes located on the
air motor bracket (J). Perform the following steps to lift
the supply system:
1. Remove the low level switch bar (T) from the left lift
hole on the air motor bracket (J)
2. Attach a lifting sling at the proper lift locations. Lift
off the pallet using a crane or a forklift.
3. Remove the lifting sling and replace the low level
switch bar (T) after the system has been lowered
into the desired location.
There are two options for the location of the supply sys-
tem:
Option #1:
Using the holes in the ram base as a guide, drill holes
for 5/16 in. (8 mm) anchors. Ensure that the ram base is
level in all directions. If necessary, level the base using
metal shims. Secure the base to the floor using 5/16 in.
(8 mm) anchors that are long enough to prevent the ram
from tipping.
Option #2:
Use M10x1.5 hex screws (not supplied) in each corner
of the base plate to act as jack bolts to level the machine
frame.
All electrical wiring must be done by a qualified elec-
trician and comply with all local codes and regula-
tions.
The lifting tool can pinch or amputate fingers. When
raising and lowering the system, keep fingers and
hands away from the lifting location.
NOTICE
Always lift the supply system at the proper lift loca-
tions shown in FIG. 5. Do not lift in any other way.
Lifting the system at any other location could result
in damage to the air motor.
FIG. 5: Lift Locations
Lift Locations
JJ
FIG. 6: Remove Low Level Switch Bar
T
J

Installation
10 3A5354B
Grounding
Ground the supply system as instructed here and in the
individual component manuals.
Pump: use a ground wire and clamp. Loosen the
grounding lug locknut and washer. Insert one end of the
supplied ground wire into the slot in the lug and tighten
the locknut securely. Connect the other end of the wire
to a true earth ground. See FIG. 7.
Air and fluid hoses: use only electrically conductive
hoses.
Air compressor: follow the manufacturer’s recommen-
dations.
Dispense valve: ground through the connection to a
properly grounded fluid hose and pump.
Fluid supply container: follow the local code.
Solvent pails used when flushing: follow the local
code. Use only conductive metal pails, placed on a
grounded surface. Do not place the pail on a non-con-
ductive surface, such as paper or cardboard, which
interrupts grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: hold the metal part of the dispense
valve firmly to the side of a grounded metal pail, then
trigger the valve.
Connect Power Source
The electrical enclosure comes already attached and
wired to the ram; however, before the supply system
becomes functional you must connect the electrical
enclosure to a power source.
NOTE: Required voltage and amperage is noted on the
electrical enclosure label. Also see Table 1. Before run-
ning power to the unit, make sure the plant electrical
service meets the supply system’s electrical require-
ments.
NOTE: See Power Requirements, page 5, for circuit
protection requirements.
1. Open the electrical enclosure door (ED).
2. Have a qualified electrician perform the following
steps:
a. Connect your plant power to the electrical
enclosure power line filter according to local
codes. A 1-3/8 in. (35 mm) diameter opening is
provided on the side of the enclosure adjacent
to the label. This opening is suitable for a 1 in.
npt conduit or strain relief fitting (supplied).
b. Connect a power protective ground (DB) to the
center post on the line end of the power line fil-
ter.
The power source conduit is not an adequate ground
for the system. The unit must be bonded to either the
building ground or a true earth ground. To reduce the
risk of static sparking and electric shock, ground the
pump, the object being dispensed to, and all other
dispensing equipment used or located in the dispens-
ing area. All electrical wiring must be done by a quali-
fied electrician and comply with local codes and
regulations.
FIG. 7: Ground
ti8250a
Have a qualified electrician connect power according
to national, state, and local safety and fire codes. Fail-
ure to do so may result in static spark or electric
shock.

Installation
3A5354B 11
Connect Electrical Cord
NOTE: The installed strain relief bushing (SR) fits a
0.71-0.98 in. (18-25 mm) OD electrical cord.
1. Turn the main power switch (MP) OFF.
2. Open the electrical enclosure door (ED).
3. Insert the electrical cord through the electrical
enclosure strain relief bushing (SR).
4. Attach insulated ferrules to the end of each wire.
5. Connect the ground wire (DA) to the chassis ground
(DB).
6. Connect power wires to the main power switch (MP)
as shown below.
NOTE: Use a flat-head or Pozidriv screwdriver to tighten
the terminals to 7-10 in-lb (0.8-1.1 N•m).
7. Tighten the strain relief bushing (SR) around the
electrical cord.
8. Close the electrical enclosure door (ED).
FIG. 8
SR
ED
I ON
O OFF
MP
DB
DA
ti31214a

Installation
12 3A5354B
Install/Adjust Drum Low Level
Switch
1. Verify the power is off.
2. Install the low level switch (S) onto the air motor
bracket (J) with two M5 washers and screws (MS).
3. Install the position bar (T) onto the air motor bracket
with two M20 nuts (M20).
4. Use a cable (CBL) to connect the low level switch
onto the control board (J4 connector).
5. Turn the main power switch (MP) to the ON position,
then press the power button to turn on the ADM.
6. Adjust the position bar height by threading at the
desired level (low or empty).
7. Check the low level switch function by lowering the
ram and letting the position bar hit the switch. Check
to make sure the light tower signal is red for the low
level alarm.
Light Tower Accessory
If the light tower kit (25C662) flashes red, there is a low
level alarm.
FIG. 9
M20
CBL MS S
J
T
FIG. 10: J4 Connector
J4 Connector

Installation
3A5354B 13
Check Resistance
Check the Resistance Between the Supply
System and the True Earth Ground
Have a qualified electrician check the resistance
between each supply system component and the true
earth ground. The resistance must be less than 0.3
ohms. If the resistance is greater than 0.3 ohms, a dif-
ferent ground site may be required.
NOTE: Use a meter that is capable of measuring resis-
tance at this level.
Sensor Resistance Checks
NOTE: For dispense valve and hose sensor resistance
checks, refer to your dispense valve manual or hose
manual.
The supply system includes a heat sensor and controller
for each of the six heated zones. To check the sensor
resistance:
1. Make sure the power is off and the main power
switch (MP) is in the OFF position.
2. Make electrical resistance checks for the compo-
nents.
3. Replace any parts that have resistance readings
that do not comply with the ranges listed in Table 2.
NOTE: Check the resistance at ambient room tempera-
ture (63°– 77°F [17°– 25°C]).
To reduce the risk of electric shock, the resistance
between the supply system components and true
earth ground must be less than 0.3 ohms. If the resis-
tance exceeds 0.3 ohms, perform the following steps:
• Verify the grounding stud is correctly in place in the
electrical enclosure (see FIG. 11).
• Check the supply system resistance between
each supply system component and the grounding
stud.
• If the resistance exceeds 0.3 ohms after following
the previous steps, contact Graco technical sup-
port. Do not operate the system until the problem
is corrected.
FIG. 11: Grounding Stud
DB
To reduce the risk of electric shock, conduct electrical
checks with the main power switch (MP) OFF.
Table 2: RTD Sensor Resistance
Zone Component Connector Pin Range (ohms)
1 Platen Pin K and M 1050-1100
2 Fluid Pump Pin K and M 1050-1100
FIG. 12: RTD Connector Pins


A
B
C
D
E
F
G
H
J
K
L
M
Pin K
Pin M

Installation
14 3A5354B
Heater Resistance Checks
NOTE: For dispense valve and hose sensor resistance
checks, refer to your dispense valve manual or hose
manual.
To check the heater resistance:
1. Make sure the power is off and the main power
switch (MP) is in the OFF position.
2. Make electrical resistance checks for the compo-
nents. Refer to TABLE 3.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in TABLE 3.
NOTE: Check the resistance at ambient room tempera-
ture (63°– 77°F [17°– 25°C]).
To reduce the risk of electric shock, conduct electrical
checks with the main power switch (MP) OFF.
Table 3: Resistance Chart of All Heaters
Zone Component
Between
Terminals
Unit
Voltage
Range
(ohms)
2 Platen C and D 220 80 +10/-10
3 Pump C and D 220 37 +5/-5
FIG. 13: Heater Terminal Pins
A
B
C
D
E
F
G
H
J
K
L
M
Pin C
Pin D

Installation
3A5354B 15
Hose Installation and Care
NOTE: The warm melt supply system requires Graco
single-circuit material hoses rated at a maximum of
2000 Watts.
Hose Installation
1. Connect the heated hose to the pump outlet. Con-
nect with an adapter if the pump outlet and hose
end have different thread sizes.
2. Use two wrenches to tighten. Torque to 470-550
in-lbs (53.1-62.1 N•m).
3. Wrap the exposed fittings on the pump outlet with
heat-resistant insulation, and secure the insulation
using fiberglass tape.
4. Connect the hose electric connector onto the recep-
tacle of the control board. See FIG. 14.
5. Securely tighten the 12-pin electrical connectors on
the long heated hose leads into the 12-socket
receptacles on the end of the hose adapter.
6. Securely tighten the 8-socket electrical connectors
on the short heated hose leads into the 8-pin recep-
tacle located on the dispense valves or heat gun.
Hose Care Guidelines
Refer to your Hot Melt/Warm Melt Heated Hose Instruc-
tions manual for details regarding hose care guidelines.
Mechanical Setup
1. Fill displacement lower wet cup 2/3 full with Graco
Throat Seal Liquid (TSL).
2. Turn all air regulators to their full counterclockwise
position.
3. Connect a 3/4 in. (19 mm) air line from an air source
to the system air inlet. Refer to the pump perfor-
mance curves in the Check-Mate Pump Packages
Instruction-Parts manual to determine your air sup-
ply flow requirements.
NOTE: Quick disconnects restrict the flow for large air
motors.
Overview of Temperature
Control Settings
Temperature controls are set in Setup mode.
Press the left horizontal arrow to go into the Diag-
nostic screen. Information on temperatures for each
zone can be seen here.
FIG. 14
Control Board
Receptacle

Setup
16 3A5354B
Setup
The pump was tested with lightweight oil, which is left in
the fluid passages to protect parts. To avoid contaminat-
ing the fluid with oil, flush the pump with a compatible
solvent before use. See Purge System, step 2.
Purge System
Purging the system before initial use can prevent mate-
rial contamination, which may cause the material to fail
or perform poorly.
Perform the following procedure to purge the system:
1. Select the material for the initial material load.
2. Verify whether the factory-test oil and the initial
material load are compatible:
a. If the two substances are compatible, omit the
remaining steps in this procedure and refer to
the operation instructions.
b. If the two substances are incompatible, perform
the remaining steps in this procedure to flush
the system at ambient temperature.
3. Select a container of solvent that can eliminate the
factory-test oil from the system. If necessary, check
with Graco or the material supplier for a recom-
mended solvent.
4. Before purging, ensure the entire system and waste
container are properly grounded.
NOTE: Remove any dispense valve orifices before
purging. Reinstall after purging has been completed.
5. Purge the material through the system for approxi-
mately 1 to 2 minutes. See the Pump Fluid Purge Kit
Instructions manual for further instructions.
6. Remove the container if purge solvent was used.
Low Level Adjustment
Adjust the nut position along the low level switch bar (T)
as shown in FIG. 15.
NOTICE
Purge the system before performing the initial mate-
rial loading procedure. The system was fac-
tory-tested using a light soluble oil, a soybean oil, or
some other oil as tagged. Flush the system to avoid
contaminating the material that has been designated
for initial material loading.
To avoid fire and explosion, always use fluids that are
chemically compatible with the equipment wetted
parts. See the Technical Data sections in the equip-
ment manuals.
NOTICE
This equipment should not be used with more than
one type of fluid due to potential compatibility issues
that could result in an unpredictable reaction. To pre-
vent equipment corrosion, Graco recommends using
new hoses when chemicals are changed, or care
must be taken to assure that all traces of one chemi-
cal are removed before introducing a second chemi-
cal.
FIG. 15: Low Level Machinery
S
Nuts
T

Setup
3A5354B 17
Load Material
NOTE: Before loading material, ensure that there is a
minimum overhead clearance of 20 in. (51 cm) and all
air regulators are backed off to their full counterclock-
wise position.
1. Close all air regulators and air valves. See FIG. 3 on
page 7.
2. Open the main air ball valve (BA) and set the ram
air regulator (BB) to 40 psi (0.28 MPa, 2.8 bar). Set
the director valve handle (BC) to the UP position
and let the ram rise to its full height.
3. Lubricate the platen seals with grease or other lubri-
cant compatible with the fluid you will pump.
4. Remove the drum cover and smooth the surface of
the fluid with a straightedge.
5. Put a full drum of fluid on the ram base, slide it back
against the drum stops, and center it under the
platen.
6. Remove the bleed stick (DE) from the platen bleed
port. See FIG. 16.
7. If the drum has a plastic liner, pull it over the edge of
the drum. Secure the liner with tape wrapped
around the circumference of the drum.
8. Set the director valve (BC) to the DOWN position
and lower the ram until fluid appears at the top of
the platen bleed port. Adjust the ram air regulator
(BB) as needed. Set the director valve (BC) to neu-
tral and close the platen bleed port (G).
NOTICE
Do not use a drum of material that has been dented or
otherwise damaged; damage to the platen wiper can
result.
Moving parts can pinch or amputate fingers. When
the pump is operating and when raising or lowering
the ram, keep fingers and hands away from the pump
intake, platen, and lip of the drum.
FIG. 16: Heated Platen
G
D
DE

Setup
18 3A5354B
System Heat Up
NOTE: Operate at the lowest temperature and pressure
necessary for your application.
1. Turn the main power switch (MP) on the electrical
control panel door to the ON position. See FIG. 17.
2. Press the On/Off key while in the Heat Run
screen to turn the heaters on for the enabled heat
zones.
3. Press on the ADM to set up the warm melt
zones. Press to set up the Zone type. Select
Zone Type and set the temperature. Press to
complete the setup.
4. Press or to activate the zone for warm
melt running. The light will change from yellow to
green. The alarm light will also be lit as the zone is
heating.
5. Press the left horizontal arrow to go into the
Diagnostic screen. Information on the system heat-
ing can be seen here.
To prevent skin injection and splashing fluid from a
burst hose, never pressurize the system while using
warm melt materials before turning on heat.
Many warm melt materials tend to expand when
heating and may cause a heated hose to burst.
Avoid the potential of bursting a hose by opening
the dispense valve during system heat up and lock-
ing the dispense valve trigger open every time you
shut the system down.
FIG. 17: Power Switch ON
I ON
O OFF
MP

Setup
3A5354B 19
NOTE: Users can set up the language, temperature unit
and weight unit, etc. before testing.

Operation
20 3A5354B
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
This procedure describes how to relieve pressure for the
supply system. Use this procedure whenever you shut
off the system and before checking or adjusting any part
of the system.
1. Lock the gun/dispense valve trigger.
2. Turn the ADM off by pressing the On/Off key .
3. Close the air motor ball valve (BF) and the main air
ball valve (BA) on the ram(s).
4. Set the ram director valve (BC) to the DOWN posi-
tion. The ram will slowly drop.
5. After the ram reaches the bottom, jog the director
valve (BC) up and down to bleed air from the ram
cylinders.
6. Unlock the gun/dispense valve trigger.
7. Hold a metal part of the dispense valve firmly to the
side of a grounded metal pail, and trigger the
gun/dispense valve to relieve pressure.
8. Lock the gun/dispense valve trigger.
9. Open the bleed valve (K). Have a container ready to
catch the drainage. Leave the bleed valve open until
ready to dispense again.
If you suspect the dispense tip/nozzle or hose is com-
pletely clogged, or that pressure has not been fully
relieved after following the steps above, very slowly
loosen the tip guard retaining nut or hose end coupling
and relieve pressure gradually, then loosen completely.
Then clear the tip/nozzle or hose.
Trigger Lock
Always engage the trigger lock when you stop dispens-
ing to prevent the gun from being triggered accidentally
by hand or if dropped or bumped.
Start and Adjust Ram
To start and adjust the ram(s), follow the Load Material
procedure on page 17.
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 Pro-
cedure when you stop spraying and before cleaning,
checking, or servicing the equipment.
FIG. 18: Advanced Display Module
Moving parts can pinch or amputate fingers. When
the pump is operating and when raising or lowering
the ram, keep fingers and hands away from the pump
intake, platen, and lip of the drum.