Graco Therm-O-Flow C03508 Parts list manual

310530
Rev. E
First choice when
quality counts.t
Model C03508
INSTRUCTIONS–PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
CARBON STEEL
200 LITER (55 GALLON) AND 20 LITER (5 GALLON)
Therm-O-FlowPump Modules
(Heated Check-Mate800)
with heaters, insulation, and shrouds
398 bar (5850 psi) Maximum Fluid Working Pressure
200 Liter (55 Gallon)
C03508 Pump Module, 480/575 VAC
C03511 Pump Module, 240 VAC
243276 TOF Plus Pump Module (all voltages)
20 Liter (5 Gallon)
C03509 Pump Module, 480/575 VAC
C03512 Pump Module, 240 VAC
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1996, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Parts

2 310530
Air Motor Selection Chart
Use Connection Kit, C03510, to connect the air motor to the Heated Checkmate Pump.
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Air Motor
ÁÁÁÁ
ÁÁÁÁ
Ratio
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
Part Number
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
Manual
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
King
ÁÁÁÁ
ÁÁÁÁ
65:1
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
207647
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
306968
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Quiet King
ÁÁÁÁ
ÁÁÁÁ
65:1
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
220106
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
307741
ÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁ
Bulldog
ÁÁÁÁ
Á
ÁÁ
Á
ÁÁÁÁ
31:1
ÁÁÁÁÁÁ
Á
ÁÁÁÁ
Á
ÁÁÁÁÁÁ
208356
ÁÁÁÁÁÁ
Á
ÁÁÁÁ
Á
ÁÁÁÁÁÁ
307049
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Quiet Bulldog
ÁÁÁÁ
ÁÁÁÁ
31:1
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
215255
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
307304
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Senator
ÁÁÁÁ
ÁÁÁÁ
19:1
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
217540
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
307592
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Quiet Senator
ÁÁÁÁ
ÁÁÁÁ
19:1
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
220571
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
307592
Table Of Contents
Air Motor Selection Chart 2. . . . . . . . . . . . . . . . . . . . . . . .
Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing 200 Liter (55 Gallon) Pump Module 7. . .
Installing 20 Liter (5 Gallon) Pump Module 9. . . . .
Grounding 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulating Additional Components 10. . . . . . . . . . . .
Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 11. . . . . . . . . . . . . . . . . .
Emergency Stop 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Daily Maintenance Procedures 11. . . . . . . . . . . . . .
Troubleshooting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing Pump Module from
200 liter (55 gallon) Supply Unit 14. . . . . . . . . . . . . .
Servicing Pump Module from
20 liter (5 gallon) Supply Unit 17. . . . . . . . . . . . . . . .
Replacing Heater Bands and Sensors
in Pump-Module 19. . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection/Maintenance Frequency 19. . . . . . . . . . .
Throat Packings 20. . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model C03508, Therm-O-Flow Pump Module,
200 liter (55 gal.) 480/575 VAC 21. . . . . . . . . . . . . .
Model C03511, Therm-O-Flow Pump Module,
200 liter (55 gal.) 240 VAC 22. . . . . . . . . . . . . . . . . .
Model 243276, Therm-O-Flow Plus Pump Module,
200 liter (55 gal.) (all voltages) 23. . . . . . . . . . . . . . .
Model C03509, Therm-O-Flow Pump Module,
20 liter (5 gal.) 480/575 VAC 25. . . . . . . . . . . . . . . .
Model C03512, Therm-O-Flow Pump Module,
20 liter (5 gal.) 240 VAC 26. . . . . . . . . . . . . . . . . . . .
Parts 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model C03508, Therm-O-Flow Pump Module,
200 liter (55 gal.) 480/575 VAC 28. . . . . . . . . . . . . .
Model C03511, Therm-O-Flow Pump Module,
200 liter (55 gal.) 240 VAC 28. . . . . . . . . . . . . . . . . .
Model 243276, Therm-O-Flow Plus Pump Module,
200 liter (55 gal.) (all voltages) 30. . . . . . . . . . . . . . .
Model C03509, Therm-O-Flow Pump Module,
20 liter (5 gal.) 480/575 VAC 32. . . . . . . . . . . . . . . .
Model C03512, Therm-O-Flow Pump Module,
20 liter (5 gal.) 240 VAC 32. . . . . . . . . . . . . . . . . . . .
Model C03510, Pump Air Motor Mounting Kit 34. .
Technical Data 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Publications 35. . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 36. . . . . . . . . . . . . . . . . . . . . . . . .

3310530
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the corresponding
instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
corresponding instructions.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and
result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, warnings, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck the equipment daily. Repair or replace worn or damaged parts immediately.
DNever exceed the recommended working pressure or the maximum air inlet pressure stated on
your pump or in the Technical Data on page 35.
DBe sure that all spray/dispensing equipment and accessories are rated to withstand the maxi-
mum working pressure of the pump. Do not exceed the maximum working pressure of any
component or accessory used in the system.
DUse fluids and solvents that are chemically compatible with the equipment wetted parts. See
the Technical Data sections of all the equipment manuals. Always read the material manufac-
turer’s literature before using fluid or solvent in this pump.
DAlways wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid
and solvent manufacturers.
DWear hearing protection when operating this equipment.
DComply with all applicable local, state and national fire, electrical and other safety regulations.
HOT SURFACE AND FLUID HAZARD
Heated fluid can cause severe burns and can cause equipment surfaces to become very hot.
DWear protective gloves and clothing when operating this equipment in a heated system.
DDo not touch the metal heat sink when the surface is hot.
DAllow the equipment to cool thoroughly before servicing.

4 310530
WARNING
INJECTION HAZARD
Spray from the spray gun, hose leaks, or ruptured components can inject fluid into your body and
cause extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on
the skin can also cause serious injury.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate
medical attention.
DDo not point the gun/valve at anyone or at any part of the body.
DDo not put your hand or fingers over the spray tip/nozzle.
DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.
DAlways have the trigger guard on the gun when dispensing.
DCheck the
g
un diffuser operation weekl
y
. Refer to the
g
un manual.
DCheck
the
gun
diffuser
o eration
weekly
.
Refer
to
the
gun
manual
.
DBe sure the gun/valve trigger safety operates before dispensing.
DLock the gun/valve trigger safety when you stop dispensing.
DFollow the Pressure Relief Procedure on page 11 if the nozzle clogs, and before cleaning,
checking or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immedi-
ately. Do not repair high pressure couplings; you must replace the entire hose.
FIRE, EXPLOSION AND ELECTRIC SHOCK HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition
and result in fire, explosion, or electrostatic shock and other serious injury.
DGround the equipment, the object being dispensed, and all other electrically conductive objects
in the dispense area. Proper grounding dissipates static electricity generated in the equipment.
See Grounding on page 10.
DDo not use this equipment with flammable liquids.
DKeep the dispense area free of debris, including solvent, rags, and gasoline.
DIf there is any static sparking while using the equipment, stop dispensing immediately. Identi-
fy and correct the problem.
DMake sure all electrical work is performed by a qualified electrician only.
DMake sure all electrical equipment is installed and operated in compliance with applicable
codes.
DMake sure power is disconnected when servicing and repairing equipment.
DHave any checks, installation, or service to electrical equipment performed by a qualified electri-
cian only.

5310530
WARNING
MOVING PARTS HAZARD
Moving parts, such as the pump inlet can pinch fingers.
DKeep clear of all moving parts when starting or operating the equipment.
DDo not operate the equipment with the guard removed.
DKeep hands and fingers away from the priming piston during operation and whenever the pump
is charged with air.
DKeep clear of the follower plate, pump fluid inlet, and lip of the fluid container when raising or
lowering the ram.
DBefore checking or servicing the ram or pump, follow the Pressure Relief Procedure on
page 11.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, inhaled, or swallowed.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all
local, state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
DAvoid exposure to heated material fumes.
DProvide adequate ventilation.

6 310530
Introduction
The Therm-O-Flow Pump Module consists of a spe-
cially designed Check-Mate 800 Displacement Pump
for heated applications, combined with a sensor,
junction box, band heaters, insulation, and shrouds.
The pump module is the lower pump assembly in
either a 200 liter (55 gal.) or 20 liter (5 gal.) supply unit.
You install it between the bottom of the air motor and
the top of the follower.
This manual describes installing, operating and servic-
ing the pump module. For information about the pump
itself, see 308570.
Fig. 1

7310530
Installation
Installing 200 Liter (55 Gallon) Pump
Module
Before you begin this procedure, make sure:
Dyou have your system documentation and copies of
the following manuals:
D310523 (200 l/55 gal.) ram
D310527 (200 l/55 gal.) TOF supply unit or
309085 (200 l/55 gal.) TOF Plus supply unit
D308570 (servicing the pump)
Deither the air motor is secured in the ram (if you
used the procedure in 310527), or you have 2
people to hold the pump assembly
To connect the pump module to the air motor, follow
this procedure:
1. Make sure coupling nut (40) and coupling
collars (30) are in place on displacement rod.
The collar couplings should be placed in coupling
nut so large flanges point upwards.
2. Attach pump module to air motor. Orient pump’s
fluid outlet (60) to motor’s air inlet (70).
3. Remove or loosen back shroud. This gives you
access to back stand-off rod (90).
NOTE: RTV sealant on the pump shroud may
make it difficult to remove individual shroud pieces.
Use a knife or razor to scrape the sealant off of the
seams of the shrouds.
4. Screw nuts (10) onto 3 stand-off rods (20 and 90),
and torque to 81 –89 N.m (60 –66 ft-lb).
5. Screw coupling nut (40) onto motor shaft loosely.
Hold motor shaft flats with wrench to keep it from
turning. Use adjustable torque wrench to tighten
coupling nut. Torque to 196 –210 N.m (145 –
155 ft-lb).
6. Check torque setting on packing nut/wet-cup (50).
Ensure it is 203 –237 N.m (150 –175 ft-lb).
Fig. 2
10
20
30
40
1
2
Notes
Torque to 81 –89 N.m (60 –66 ft-lb)
Torque to 196 –210 N.m (145 –155 ft-lb)
1
2
50
70
60
80
90
100
7. Attach follower to pump:
a. Push pump inlet (80) into follower until pump
bottoms out.
b. Attach air line to blow-off valve.
c. Attach and secure coupling nuts to follower
conduits and to sensor conduit.
d. Connect follower-plate wires to junction box.
See wiring diagrams in Figs. 12 and 13.
e. Insert follower-plate sensor into follower plate.

8 310530
Installation
Installing 200 Liter (55 Gallon) Pump
Module (continued)
8. When re-installing pump module, wire pump to
junction box (100). If pump module is already
wired to junction box, go to step 9.
a. Open cover of junction box.
b. Connect pump’s heater wires and sensor wire
to correct terminals in junction box. See wiring
diagrams in Fig. 12 (480/575 VAC) or Fig. 13
(240 VAC).
9. Fig. 3. Make remaining connections to and from
junction box. See wiring diagrams in 310527 for
additional wiring information.
Fig. 3
to Main Prox. Switch
(optional)Panel
to Follower
for external
Follower
2nd Sensor
(optional)
Follower
Sensor
to
wiring (optional)
Follower
10. Close pump’s back shroud.
11. Apply RTV sealant to all of shroud’s seams.
12. Connect all fluid hoses.
13. Fill wet-cup/packing nut (50) 1/3 full of Graco
Throat Seal Liquid, or compatible solvent/lubricant.
NOTE: The pump is tested with a lightweight oil. The
oil is left in the pump to protect pump parts from corro-
sion. If the material you are pumping is not compatible
with the oil, flush the pump with an correct solvent
before using the pump. Consult your material supplier
for solvent recommendations.
14. Load material into supply unit using procedure in
either supply unit manual or system documenta-
tion.

9310530
Installation
Installing 20 Liter (5 Gallon) Pump Module
Before starting procedure, make sure:
Dsystem documentation and copies of the following
manuals are available:
D310525 (20 l/5 gal.) ram
D310528 (20 l/5 gal.) supply unit
D308570 (servicing pump)
Dair motor is secured in the ram (if procedure in
310528 was used), or 2 people are available to hold
pump assembly
Connect pump module to air motor as follows:
1. Make sure coupling nut (40) and coupling collars
(30) are in place on displacement rod.
Collar couplings should be placed in coupling nut
so large flanges point upwards.
2. Attach pump module to air motor. Orient pump’s
fluid outlet (60) to motor’s air inlet (70).
3. Remove or loosen back shroud. This gives access
to back stand-off rod (90).
NOTE: RTV sealant on the pump shroud may
make it difficult to remove individual shroud pieces.
Use a knife or razor to scrape the sealant off of the
seams of the shrouds.
4. Screw nuts (10) onto 3 stand-off rods (20 and 90),
and torque to 81 –89 N.m (60 –66 ft-lb).
5. Screw coupling nut (40) onto motor shaft loosely.
Hold motor shaft flats with wrench to keep it from
turning. Use adjustable torque wrench to tighten
coupling nut. Torque to 196 –210 N.m (145 –
155 ft-lb).
6. Check torque setting on packing nut/wet-cup (50).
Ensure it is 203 –237 N.m (150 –175 ft-lb).
7. Attach follower to pump:
a. Attach pump inlet (80) to follower plate.
Tighten screws on follower adapter.
b. Attach air line to blow-off valve.
c. Attach and secure coupling nuts to follower
conduit and to sensor conduit.
d. Connect follower-plate wires to junction box.
See wiring diagrams in Figs. 16 and 17.
e. Insert follower-plate sensor into follower plate.
Fig. 4
10
20
30
40
1
2
Notes
Torque to 81 –89 N.m (60 –66 ft-lb)
Torque to 196 –210 N.m (145 –155 ft-lb)
1
2
50
70
60
80
90
100

10 310530
Installation
Installing 20 Liter (5 Gallon) Pump Module
(continued)
8. When re-installing pump module, wire pump to
junction box (100). If pump module is already
wired to junction box, go to step 9.
a. Open cover of junction box.
b. Connect pump’s heater wires and sensor wire
to correct terminals in junction box. See wiring
diagrams in Fig.16 (480/575 VAC) or Fig. 17
(240 VAC).
9. Fig. 5. Make remaining connections to and from
junction box. See wiring diagrams in 310528 for
additional wiring information.
Fig. 5
to Follower
Follower
to Main
Prox. Switch
(optional)
Panel
10. Close pump’s back shroud.
11. Apply RTV sealant to all of shroud’s seams.
12. Connect all fluid hoses.
13. Fill the wet-cup/packing nut (50) 1/3 full of Graco
Throat Seal Liquid, or compatible solvent/lubricant.
NOTE: The pump is tested with a lightweight oil. The
oil is left in the pump to protect pump parts from corro-
sion. If the material you are pumping is not compatible
with the oil, flush the pump with an correct solvent
before using the pump. Consult your material supplier
for solvent recommendations.
14. Load material into supply unit using procedure in
either supply unit manual or system documenta-
tion.
Grounding
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
Before operating the pump, ground the
system as described in the manual for
your supply unit, or in the system docu-
mentation.
Also read and follow the warnings on
page 4.
You must provide an earth ground to the supply unit’s
electrical control box. Make sure the pump assembly
is installed correctly to ensure that the pump is proper-
ly grounded. See the wiring illustrations in Figs.12
and 13 (200 liter/55 gal.), or Figs.16 and 17 (20 liter/5
gal.).
Insulating Additional Components
It is necessary to insulate some heated components
after the equipment installation is complete. If any
components and/or exposed connection joints are to
be insulated, it will be noted in the system layout
and/or the individual component drawing. Insulate the
required components before the components are
heated.