Graco Therm-O-Flow C03509 Operation manual

310530
Rev. F
First choice when
quality counts.t
Model C03509
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)
243276 TOF Plus Pump Module (all voltages)
241987 Pump Module, 480 VAC
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 243276, Therm-O-Flow Plus Pump Module,
200 liter (55 gal.) (all voltages) 21. . . . . . . . . . . . . . .
Model C03509, Therm-O-Flow Pump Module,
20 liter (5 gal.) 480/575 VAC 23. . . . . . . . . . . . . . . .
Model C03512, Therm-O-Flow Pump Module,
20 liter (5 gal.) 240 VAC 24. . . . . . . . . . . . . . . . . . . .
Parts 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 241987, Thermo–O–Flow Pump Module,
200 liter (55 gal.) 480 VAC 25. . . . . . . . . . . . . . . . . .
Model 243451, Displacement Pump 26. . . . . . . . . .
Model 243276, Therm-O-Flow Plus Pump Module,
200 liter (55 gal.) (all voltages) 28. . . . . . . . . . . . . . .
Model C03509, Therm-O-Flow Pump Module,
20 liter (5 gal.) 480/575 VAC 30. . . . . . . . . . . . . . . .
Model C03512, Therm-O-Flow Pump Module,
20 liter (5 gal.) 240 VAC 30. . . . . . . . . . . . . . . . . . . .
Model C03510, Pump Air Motor Mounting Kit 32. .
Technical Data 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Publications 33. . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 34. . . . . . . . . . . . . . . . . . . . . . . . .

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 33.
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 on pages 21–24.
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. 14 (480/575 VAC) or Fig. 15
(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. 14 and 15.
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.14 (480/575 VAC) or Fig. 15
(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.14 and 15 (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.

11310530
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
Dare instructed to relieve the pressure
Dstop spraying/dispensing
Dcheck or service any of the system equipment
Dinstall or clean the spray tip/nozzle
Use this procedure whenever you shut off the dispens-
er/sprayer and before checking or adjusting any part of
the system, to reduce the risk of serious injury.
1. Lock the gun/valve trigger safety.
2. Shut off the main air supply to the pump.
3. Close all air bleed valves.
4. Unlock the gun/valve trigger safety.
5. Hold a metal part of the gun/valve firmly to the side
of a grounded metal drum or pail, and trigger the
gun/valve to relieve pressure.
6. Lock the gun/valve trigger safety.
7. Have a container ready to catch the drainage, then
open the drain valve or pump bleed valve.
8. Leave the drain valve open until you are ready to
spray/dispense again.
If you suspect that the spray tip/nozzle or hose is
completely 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
to relieve pressure gradually, then loosen completely.
Now clear the tip/nozzle or hose.
9. To relieve pressure in the ram, see Ram Pressure
Relief Procedure in the supply unit’s documenta-
tion.
Emergency Stop
See instructions in either supply unit or system docu-
mentation for more information.
1. On supply unit’s electrical control panel:
a. Turn CONTROL ON switch to OFF.
b. Turn OFF main electrical disconnect.
2. Stop pump by closing Bleed-type Master Air Valve
closest to motor’s air inlet.
Daily Maintenance Procedures
WARNING
Use fluids and solvents that are chemically compat-
ible with the equipment wetted parts. See the
Technical Data sections of all the equipment
manuals. Always read the material manufacturer’s
literature before using fluid or solvent in this pump.
1. Clean out material build-up in wet-cup to extend
life of pump packing and displacement rod.
2. Ensure packing nut/wet-cup is tightened to correct
torque setting, 203 –237 N.m (150 –175 ft-lb).
Do not overtighten packing nut.
3. Before starting pump, fill wet-cup 1/3 full with
Graco Throat Seal Liquid or compatible solvent.
NOTE: Adding Graco Throat Seal Liquid or other
compatible solvents to wet-cup will help lubricate
the seal and prevent material leakage.
For additional maintenance procedures, see the Op-
eration/Maintenance section of 308570.

12 310530
Operation
Flushing Safety
WARNING
Use fluids and solvents that are chemically compat-
ible with the equipment wetted parts. See the
Technical Data sections of all the equipment
manuals. Always read the material manufacturer’s
literature before using fluid or solvent in this pump.
Before flushing:
1. Ensure entire system and flushing drums or pails
are properly grounded. See system manual or
supply unit manual for more information.
WARNING
To reduce the risk of serious injury, whenever you
are instructed to relieve pressure always follow the
Pressure Relief Procedure on page 11.
2. Perform the Pressure Relief Procedure on
page 11.
PRESSURIZED FLUID HAZARD
Always use the lowest possible fluid
pressure, and maintain firm metal-to-
metal contact between the gun/valve
and the drum or pail during flushing to reduce the
risk of fluid injection injury, static sparking and
splashing.
WARNING
3. Remove spray tip/nozzle from spray gun/dispens-
ing valve.

13310530
Troubleshooting
For additional trouble-shooting information about the pump, see the pump’s documentation.
Problem Cause(s) Solution(s)
Rapid down stroke or up stroke Material not heated to proper
pumping temperature
Check and adjust temperature set point.
Air is trapped in pump Bleed air from the pump using this pro-
cedure:
1. Place a waste container under the
pump bleed port.
2. Turn on air to the pump
3. Allow material to flow from the bleed
port until it is air-free.
4. Shut off air to the pump and close
the bleed port.
5. Turn air on to the pump and set the
pump air regulator for normal opera-
tion.
Downstroke: Lower check in
pump is worn
Upstroke: Upper check in pump is
worn
Rebuild and replace pump, as neces-
sary.
Material leaks around pump outlet Outlet fitting is loose Tighten outlet fitting.
Material leaks around bleed port Bleed port fitting is loose Tighten bleed port fitting.
Pump won’t move up or down Problem with air motor See Air Motor Troubleshooting chart in
supply unit or system documentation.
Foreign object lodged in pump Remove object and rebuild pump
assembly. See 308570 for pump
rebuild instructions.
WARNING
To reduce the risk of serious injury
whenever you are instructed to relieve
pressure, always follow the Pressure
Relief Procedure on page 11.
Before attempting to dislodge a foreign
object:
1. Relieve system pressure.
2. Remove the pump from the air
motor.
Pump fails to prime properly Pump needs to be primed See Use of the Bleeder Valve in
308570.
Wet-cup leaks Throat seal is worn Replace throat seal. See Servicing the
Throat Packings in 308570

14 310530
Service
This section contains the procedures for:
Dservicing a pump module from a 200 liter (55 gal-
lon) supply unit
Dservicing a pump module from a 20 liter (5 gallon)
supply unit
Dreplacing the sensor and heater bands in the pump-
module
For information about servicing the pump unit itself,
see 308570.
Servicing Pump Module from 200 liter (55
gallon) Supply Unit
This section describes how to:
Dremove a pump module from a supply unit (200
liter/55 gal. or 20 liter/5 gal.)
Dseparate the pump module from the air motor
(including disassembling the pump module)
Dreplace a pump module in a supply unit (200 liter/
55 gal. or 20 liter/5 gal.)
Removing Pump Module from 200 Liter (55 gallon)
Supply Unit
To remove the pump assembly from the ram, follow
this procedure:
1. Remove the material drum from the supply unit:
WARNING
The material and equipment will be
hot! To reduce risk of injury, wear eye
protection, gloves and protective clothing
when installing, operating, or servicing
this dispensing system.
a. Raise the ram out of the drum using the ram
hand valve. At the same time, carefully equal-
ize the pressure in the drum by cycling the
follower blow-off valve open and closed.
b. With the follower completely out of the drum,
remove the drum.
c. Being careful not to damage the follower
wipers, wipe any material build-up from the
follower plate and wipers.
d. Move the ram hand valve to the OFF position.
2. Make sure the ram hand valve is in the OFF
position.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 11.
3. Relieve the supply unit pressure.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve ram pressure, always
follow the Ram Pressure Relief Procedure in the
supply unit or system documentation.
4. Relieve the ram air pressure.
5. Turn the system CONTROL ON switch (located on
the supply unit’s electrical control panel) to OFF.
WARNING
ELECTROCUTION HAZARD
To reduce risk of injury or damage to
equipment, make sure the main discon-
nect is OFF before continuing with this
procedure.
6. Turn OFF the main electrical disconnect.
7. Turn off the electrical power to the supply unit.
Follow all applicable safety procedures and lockout
rules.
8. Bleed off pressure in the system and excess
material by opening the dispense gun and catching
the material in a waste container.
9. Disconnect all material hoses.

Fig. 7
5
4
6
3
15310530
Service
Removing the Pump Module from 200 Liter
(55 gallon) Supply Unit (continued)
10. RTV sealant on the pump shrouds (1) may make it
difficult to remove individual shroud pieces. Using
a knife or razor, scrape the sealant off of the
seams of the shrouds.
Fig. 6
2
1
11. Fig. 6 and Fig.14 for 480/575 VAC, Fig. 15 for
240 VAC. Disconnect the junction box from the
pump module by:
a. Removing the cover of the junction box (2).
b. Disconnecting the sensor wire and heater
wires that come from the pump.
c. Removing the wires from the junction box.
d. Disconnecting the pump’s back shroud and
moving it backwards out of the way.
12. Fig. 7. Loosen the pump mounting screws (5) and
then remove the pump mounting plates (4).
13. Secure the air motor to the ram tie bar (3).
14. Leaving the air motor attached to the tie bar, sepa-
rate the pump module (6) from the air motor. Go
to the Separating the 200 Liter (55 Gallon)
Pump Module from the Air Motor section.

16 310530
Service
Fig. 8
10
20
30
40
1
2
50
70
60
80
90
100
Separating the 200 Liter (55 Gallon) Pump Module
from the Air Motor
Fig. 8. To separate the pump from the air motor:
1. Remove the remaining sheet-metal shrouds from
the pump.
2. Remove the coupling nut (40), which attaches the
pump to the air motor. Be careful not to lose the
collar couplings (30).
3. Remove the nuts (10) from the stand-off rods (20).
You can now separate the pump from the air
motor.
4. Access the bare pump by:
a. Unscrewing the bolts that hold the front shroud
in place, then removing the front shroud.
b. Removing the pump’s insulation.
c. Disconnecting the electrical wires from the
heater band.
d. Unscrewing the screws that hold the heater
bands in place.
e. Removing the heater bands from the pump.
f. Removing the clamp that holds the sensor on
the pump.
g. Removing the sensor.
Replacing the Pump Module in the 200 Liter
(55 Gallon) Supply Unit
1. Put the pump module back together.
2. Replace the pump module into the follower.
3. Re-install pump module into supply unit by follow-
ing procedure for Installing a 200 Liter (55 Gal-
lon) Pump Module.
4. Reverse procedure for Removing the Pump
Module from a 200 liter (55 gallon) Supply Unit
to re-install pump. Be sure to re-apply RTV seal-
ant to seams of shrouds before replacing them on
pump.

17310530
Service
Servicing Pump Module from 20 Liter
(5 gallon) Supply Unit
This section describes how to:
Dremove a pump module from a 20 liter (5 gallon)
supply unit
Dseparate the pump module from the air motor
(including disassembling the pump module)
Dreplace a pump module in a 20 liter (5 gallon)
supply unit
Removing Pump Module from 20 liter (5 gallon)
Supply Unit
To remove the pump assembly from the ram, follow
this procedure:
1. Remove the material pail from the supply unit:
WARNING
The material and equipment will be
hot! To reduce risk of injury, wear eye
protection, gloves and protective clothing
when installing, operating, or servicing
this dispensing system.
a. Raise the ram out of the pail using the ram
hand valve. At the same time, carefully equal-
ize the pressure in the pail by cycling the
follower blow-off valve open and closed.
b. With the follower completely out of the pail,
remove the pail.
c. Being careful not to damage the follower wiper,
wipe any material build-up from the follower
plate and wiper.
d. Move the ram hand valve to the OFF position.
2. Make sure the ram hand valve is in the OFF
position.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 11.
3. Relieve the supply unit pressure.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve ram pressure, always
follow the Ram Pressure Relief Procedure in the
supply unit or system documentation.
4. Relieve the ram air pressure.
5. Turn the system CONTROL ON switch (located on
the supply unit’s electrical control panel) to OFF.
WARNING
ELECTROCUTION HAZARD
To reduce risk of injury or damage to
equipment, make sure the main discon-
nect is OFF before continuing with this
procedure.
6. Turn OFF the main electrical disconnect.
7. Turn off the electrical power to the supply unit.
Follow all applicable safety procedures and lockout
rules.
8. Bleed off pressure in the system and excess
material by opening the dispense gun and catching
the material in a waste container.
9. Disconnect all material hoses.

18 310530
Service
Removing Pump Module from 20 Liter (5 gallon)
Supply Unit (continued)
10. Fig. 9. RTV sealant on the pump shrouds may
make it difficult to remove individual shroud
pieces (8) and (A). Using a knife or razor, scrape
the sealant off of the seams of the shrouds.
11. Fig. 9, Fig. 14 (480/575 VAC) and Fig.15
(240 VAC). Disconnect the junction box from the
pump module and ) by:
a. Removing the cover of the junction box (9).
b. Disconnecting the heater wires and sensor
wires that come from the pump.
c. Removing the wires from the junction box.
d. Disconnecting the pump’s back shroud (A) and
moving it backwards out of the way.
Fig. 9
7
8
9
A
12. Remove the follower from the pump by:
a. Removing the sensor from the follower plate.
b. Removing the air line from the blow-off valve.
c. Removing the bolts from the follower adapter.
d. Sliding off the follower.
13. Separate the pump from the air motor. Go to the
next section, Separating the 20 Liter (5 Gallon)
Pump Module from the Air Motor.

19310530
Service
Fig. 10
10
20
30
40
1
2
50
70
60
80
90
100
Separating the 20 Liter (5 Gallon) Pump Module
from the Air Motor
Fig. 10. To separate the pump from the air motor:
1. Remove the remaining sheet-metal shrouds from
the pump.
2. Remove the coupling nut (40), which attaches the
pump to the air motor. Be careful not to lose the
collar couplings (30).
3. Remove the nuts (10) from the stand-off rods (20).
You can now separate the pump from the air
motor.
4. Access the bare pump by:
a. Unscrewing the bolts that hold the front shroud
in place, then removing the front shroud.
b. Removing the pump’s insulation.
c. Disconnecting the electrical wires from the
heater bands.
d. Unscrewing the screws that hold the heater
bands in place.
e. Removing the heater bands from the pump.
f. Removing the clamp that holds the sensor on
the pump.
g. Removing the sensor.
5. Remove the pump and service it as needed. See
308570 for more information about the pump.
Replacing the Pump Module in the 20 Liter
(5 Gallon) Supply Unit
1. Put the pump module back together.
2. Replace the pump module into the follower.
3. Re-install the pump module into the supply unit by
following the procedure for Installing a 20 Liter
(5 Gallon) Pump Module.
4. Reverse the procedure for Removing the Pump
Module from a 20 liter (5 gallon) Supply Unit, to
reinstall the pump. Be sure to re-apply RTV seal-
ant to the seams of the shrouds before replacing
them on the pump.

20 310530
Service
Replacing Heater Bands and Sensors in
Pump-Module
Module heaters and sensor can be serviced without
removing pump module from supply unit. Remove
front shrouds and pump insulation. When finished
servicing pump module, rewrap pump in new insulation
and re-attach shrouds.
Fig. 11
G
H
IJ
Removing/Replacing Heater Band
1. Unscrew screws that hold front shroud in place,
then remove front shroud.
2. Remove pump’s insulation.
3. Disconnect electrical wires from heater band.
4. Unscrew screw that holds heater band in place.
5. Remove heater band from pump.
6. Fig. 11. Install new heater band in same location
as old heater band:
a. Locate heater terminals (G) so they line up
with back of pump (J).
b. Tighten heater band.
7. Re-connect heater wires and re-attach ceramic
caps that insulate terminal.
NOTE: On TOF Plus machines (all machines
manufactured after June 2000), the heaters are not
identical. The upper heater is 1000 watts and the lower
heater is 500 watts. These heaters also have 3 wiring
lugs, instead of two. Always replace the heaters with
identical units.
Removing/Replacing Sensor
1. Unscrew screws that hold front shroud in place,
then remove front shroud.
2. Remove pump’s insulation.
3. If sensor wire is connected to junction box, discon-
nect it now.
4. Loosen clamp holding sensor on pump.
5. Remove sensor.
6. Fig. 11. Replace sensor (H) in clamp:
a. Coat sensor and mounting surface of sensor
block with non-silicone heat sink compound.
b. Place sensor approximately 30°counter clock-
wise from pump outlet (I).
c. Tighten clamp.
7. Re-connect sensor wire to junction box.
Inspection/Maintenance Frequency
The pump packings do not require any other service or
maintenance, except as described in the Daily Mainte-
nance Procedures. See 308570 for inspection fre-
quency of the pump.
Throat Packings
The pump throat packings are available as a preas-
sembled, prelubricated kit. For series B pumps, order
Part No. 241782. For series A pumps order Part No.
237905. Refer to manual 308570 for replacement
instructions.