Graco Foam-Cat Foam Gun Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1982, Graco Inc. is registered to I.S. EN ISO 9001
Foam-CatrFoam Gun
1500 psi (10.5 MPa, 105 bar) Maximum Working Pressure
Model 217373, Series E
Order a needle/nozzle kit separately. See page 5.
U.S. Patent No. 4,427,153
U.K. Patent No. 0,116,613
Patented Bréveté 1986 Canada
Other Foreign Patents Pending.
307546T
Read warnings and instructions.
See page 2 for Table of Contents.

2 307546
Table of Contents
Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Nozzle Performance Chart 5. . . . . . . . . . . . . . . . .
Pour Nozzle Performance Chart 5. . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional O-rings 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing a Needle/Nozzle Kit on a New Gun 8. . . . .
Connecting Hoses 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 11. . . . . . . . . . . . . . . . . . . .
Adjusting Cleanoff Air 12. . . . . . . . . . . . . . . . . . . . . . . .
Spray Pattern Adjustment 13. . . . . . . . . . . . . . . . . . . . . .
Effects of Fluid Temperature and Pressure 13. . . . . .
Observing the Effects of Varying Fluid Temperature
and Pressure 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About Surface Texture 13. . . . . . . . . . . . . . . . . . . . . . .
About Poured Foam Texture 13. . . . . . . . . . . . . . . . . .
Surface Texture Descriptions 14. . . . . . . . . . . . . . . . . . . .
Replacing the Needle/Nozzle Assembly 15. . . . . . . . . .
Cleaning the Nozzle 17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Foam Spraying Nozzles 17. . . . . . . . . . . . . . . . . . . . . .
Foam Pouring Nozzles 17. . . . . . . . . . . . . . . . . . . . . . .
Maintenance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keeping the Gun Clean While Spraying 18. . . . . . . .
Fluid Buildup on Nozzle 18. . . . . . . . . . . . . . . . . . . . . .
Fluid Buildup on Needle 18. . . . . . . . . . . . . . . . . . . . . .
Cleaning the Fluid Manifold 18. . . . . . . . . . . . . . . . . . .
Shutdown 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Needle Valves 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Valve 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Valve 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nozzle Kit Summary 29. . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 30. . . . . . . . . . . . . . . . . . . . . .
Graco Information 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

307546 3
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
DGround the equipment and the object. See Grounding on page 7.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvent or the fluid being
dispensed.
DExtinguish all the open flames or pilot lights in the dispense area.
DKeep the dispense area free of debris, including solvent, rags, and gasoline.
DDo not turn on or off any light switch in the dispense area while operating or if fumes are present.
DDo not smoke in the dispense area.
DDo not operate a gasoline engine in the dispense area.
DIf there is any static sparking while using the equipment, stop dispensing immediately. Identify
and correct the problem.
INJECTION HAZARD
Spray from the 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 medi-
cal attention.
DDo not point the gun at anyone or at any part of the body.
DDo not put hand or fingers over the gun nozzle.
DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.
DBe sure the gun trigger safety operates before dispensing.
DLock the gun trigger safety when you stop dispensing.
DIf the nozzle clogs, stop dispensing, lock the gun trigger safety, and follow the instructions of page
17 to clean the nozzle.
DKeep the tip of the nozzle and the nozzle head free of foam buildup. Foam buildup on the nozzle
can cause foam shots to be misdirected and splash foam in the eyes or on the skin.
DFollow the Pressure Relief Procedure on page 11 whenever you: are instructed to relieve pres-
sure; stop dispensing; clean, check, or service the equipment; and install or clean the nozzle.
DTighten all the fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.

4 307546
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result
in a serious injury.
DThis equipment is for professional use only.
DRead all the instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
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.
DDo not exceed the maximum working pressure of the lowest rated system component. See the
front cover or the Technical Data for the maximum working pressure of your gun model.
DRoute the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces.
DDo not use the hoses to pull the equipment.
DUse only Graco approved hoses. Do not remove hose spring guards, which help protect the hose
from rupture caused by kinks or bends near the couplings.
DUse fluids or solvents that are compatible with the equipment wetted parts. See the Technical
Data section of all the equipment manuals. Read the fluid and solvent manufacturer’s warnings.
DComply with all applicable local, state and national fire, electrical and other safety regulations.
PLURAL COMPONENT MATERIAL HAZARD
Before using this equipment, read the material manufacturer’s warnings and determine all facts relat-
ing to the materials used, including any of the potential hazards relating to toxic fumes, fires, explo-
sions, reactions times, and exposure of humans to the individual components or their resultant mix-
tures.
DWear appropriate protective clothing, gloves, eyewear, face mask, and respirator.
DKnow the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
DGraco does not manufacture or supply any of the reactive chemical components that may be used
in this equipment and is not responsible for their effects. Graco assumes no responsibility for loss,
damage, expense or claims for personal injury or property damage, direct or consequential, arising
from the use of such chemical components.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state, and national guidelines.
HOT MATERIAL HAZARD
Heated foam can cause severe burns and can cause equipment surfaces to become very hot. To
avoid a burn or injury from the foam adhering to the skin:
DWear protective gloves and clothing when operating the equipment in a heated system.
DDo not come in contact with the dispensed material until it has cooled and cured.
DAllow the equipment to cool thoroughly before servicing.
DIf you are burned, get emergency medical care at once. Do not pull the foam from your skin.

307546 5
Spray Nozzle
Performance Chart
DELIVERY
Nozzle Kit
No.
Needle
Diameter
In. (mm)
1Outlet
Pressure
psi (bar)
2Flow Rate
lb/min
(kg/min)
3Pattern
Diameter
in. (mm)
217420 0.125
(3.18) 1200 (83) 950 (66)
750 (53)
52 (23.4)
45 (20.3)
37 (16.7)
20 (508)
217421 0.114
(2.90) 1200 (83) 950 (66)
750 (53)
41 (18.4)
35 (15.8)
29 (13.1)
18 (457)
217423 0.089
(2.26) 1000 (70) 750 (53) 19 (8.6) 15 (6.6) 17 (432)
217424 0.073
(1.85) 1000 (70) 750 (53) 10.5 (4.7) 8.5 (3.8) 12 (305)
217425 0.083
(2.11) 1000 (70) 750 (53) 15 (6.8) 12 (5.4) 16 (406)
217426 0.102
(2.59) 1200 (83) 950 (66)
750 (53)
29 (13.1)
25 (11.3)
21.5 (9.7)
17 (432)
217428 0.060
(1.52) 1200 (83) 950 (66)
750 (53)
8 (3.6)
6 (2.7)
4 (1.8)
9 (228)
Pour Nozzle
Performance Chart
DELIVERY
Nozzle Kit No.
Needle
Diameter
In. (mm)
1Outlet
Pressure
psi (bar)
2Flow Rate
lb/min
(kg/min)
217427
220616 0.187 (4.75) 0.073 (1.85) 700 (48) 700 (48) 16–20 (7–9) 6–8 (2.7–3.6)
NOTES:
1Select a nozzle that will not exceed the maximum
recommended flow rate of your foam spray system as
the desired working pressure. Too high a flow rate may
exceed the performance capabilities of the foam
heater and other sprayer components, causing poor
foam development and equipment problems.
2Flow rate test conditions:
D2.7 lb (1.22 Kg) foam
DISO viscosity of 200 cps (200 mPa.s) at 77_F
(25_C)
DRES viscosity of 650 cps (650 mPa.s) at 68_F
(20_C)
Dheater and hose temperature of 85–95_F
(29–35_C) for Pour Nozzle Kits 217427 and 220616
Dheater and hose temperature of 115_F (43_C) for
all Spray Nozzle Kits
DPump outlet pressure as indicated in chart
3At the recommended spraying distance:
D18–24 in. (457–610 mm) for Pour Nozzle Kits
217427 and 220616
D30 in. (762 mm) for all Spray Nozzle Kits

6 307546
Installation
The Graco Foam-CatrGun has been designed and
manufactured to withstand rugged use. However, the
interior surfaces and cavities of the gun, and the
needle and nozzle, do require care during installation,
maintenance and service to avoid nicks and scratches.
The following tools are supplied with the gun:
D3/16 in. hex, T–handle hex key wrench (48)
D3/32 in. hex, T–handle hex key wrench (47)
D7/16 in. x 1/2 in. open end wrench (53)
DPin vise (51) for cleaning pin supplied with Needle/
Nozzle Kits
DNut driver (50)
D1/4 in. open end wrench (52)
In addition, you will need to purchase an air valve hook
(O) to service the air valve, a pressing tool (P) to
service the piston (see Accessories, page 28), and a
small adjustable wrench (A). See Fig. 1.
You will also need a solvent flushing system to clean
the gun. See page 28 to order an accessory solvent
flush kit.
Fig. 1
48 50
47
52
53
50
O
A
51

307546 7
Installation
Safety
For your safety, read all of the warnings and instruc-
tions in this manual, all system component manuals,
and the chemical manufacturer’s literature before
installing or operating the equipment. The warnings,
cautions and instructions are designed to help all
operators use this equipment with safety and confi-
dence.
This gun has a trigger safety latch. To engage the
trigger safety latch (ON SAFE) and make the trigger
inoperative, pul out on the trigger safety latch (B) and
turn it so it is perpendicular to the gun body. To disen-
gage the trigger safety latch (OFF SAFE) turn it so it is
parallel to the gun body. See Fig. 2.
WARNING
To reduce the risk of serious bodily injury from
injection of high pressure fluid, always engage the
trigger safety latch (ON SAFE) whenever you stop
spraying and close the needle valves (C) complete-
ly with the nut driver (50).
Grounding
When used with Graco Heated Hose, this gun is
grounded through hose connections. For other types of
hoses, be sure the hose you use is static grounded, or
attach a grounding wire between a metal part of the
gun and a true earth ground.
Optional O-rings
This gun is supplied with flourocarbon o-rings (44)
installed in the gun check valves, for use with methy-
lene chloride solvent. A set of silicone o-rings (60) is
also included (not installed) for use with DMF (Dime-
thyl Formamide) and Cellosolversolvents. Fig. 2
C
Trigger Safety (B
)
shown in ON
SAFE position
Trigger Safety (B)
shown in OFF
SAFE position

8 307546
Installation
Installing a Needle/Nozzle Kit on a New Gun
The needle/nozzle kit includes the parts shown in Fig.
3, except the pin vise (51) which holds the cleaning pin
(H), and the nozzle retainer (23).
Fig. 3
23
51
H
KEY
23 Nozzle Retainer
51 Pin vise
D Needle
E Nozzle
F Packing
G Packing Nut
D
G
F
E
To install the nozzle kit:
1. Use the 3/16 in. wrench (48) to remove the caps-
crew (7) from the fluid manifold (26) and to remove
the two capscrews (7) from the nozzle housing (2).
See Fig. 4.
2. Trigger the gun, then pull the housing straight off
the gun body (1).
3. Use the 1/2 in. end of the wrench (53) to remove
the nozzle retainer (23) from the back of the
housing (2). Refer to Fig. 5.
4. Insert the nozzle (E), tapered end first, into the
back of the housing. See Fig. 5.
5. Slide the packing nut (G), nozzle retainer (23), and
packing (F) onto the needle (D). Screw the packing
nut (G) into the nozzle retainer (23) until the top
threads of the packing nut is flush with the back of
the retainer. See Fig. 6.
6. Slide the needle assembly through the nozzle and
into the nozzle housing. Refer to Fig. 6.
CAUTION
Do not overtighten the nozzle retainer. This can
compact the nozzle and damage it or cause it to seat
improperly, resulting in spray pattern distortion.
Fig. 4
48 26 721
7
KEY
1 Gun body
2 Nozzle housing
7 Capscrew
26 Manifold
48 Wrench
Fig. 5
2
23
E
DF
G
53
KEY
2 Nozzle housing
23 Nozzle retainer
53 Wrench
D Needle
E Nozzle
F Packing
G Packing nut
Fig. 6
E23
G
F
Top thread of packing nut
(G) must be flush with
back of retainer (23)
KEY
23 Nozzle retainer
E Nozzle
F Packing
G Packing nut

307546 9
Installation
7. Adjust the needle so it protrudes 1–3/4 in. (44 mm)
from the rear of the housing. See Fig. 7.
Fig. 7
8. Screw the nozzle retainer (23) snugly into the back
of the housing. Tighten using the open end wrench
(53). Torque to 25–35 in-lb (2.8–3.9 NSm).
9. Guide the needle of the nozzle assembly into the
front opening (J) of the gun body (1). The piston
(20) rod has a socket in the side of it which must
face down. Tilt the nozzle assembly up and swing
the ball of the needle (D) into the piston rod
socket. See Fig. 8.
Fig. 8
JD
120
KEY
1 Gun body
20 Piston
D Needle
J Front opening
10. Push the nozzle assembly further into the front
opening (J) until the back of the assembly meets
the gun body. Refer to Fig. 8.
11. Use the 3/16 in. wrench (48) to install the two
capscrews (7) firmly into the nozzle housing.
Torque to 40 in-lb (4.5 NSm). Refer to Fig. 9.
WARNING
To reduce the risk of serious bodily injury from fluid
injection, be sure the trigger safety latch (B) is
engaged (ON SAFE) before proceeding. Refer to
Fig. 2 on page 7.
12. Screw on the air cap (24). Connect an air line (K)
to the inlet bushing (9) of the gun. See Fig. 9.
Fig. 9
743
24
7
25
32
9
K
KEY
7 Capscrew
9 Bushing
24 Air cap
25 Manifold
32 Plug
40 O-ring
K Air line

10 307546
Installation
13. Use the 7/16 in. end of wrench (53) to adjust the
packing nut (G) until it is just snug. Don’t over-
tighten it. See Fig. 10.
14. Install the plastic shield (43) around the exposed
part of the needle assembly to keep foam over
spray from collecting on the needle. See Fig. 10.
15. Connect the fluid manifold (25) to the gun using
the 3/16 in. wrench (48) to tighten the capscrew
(7) firmly. Torque to 40 in-lb (4.5 NSm). See Fig.
10.
Fig. 10
24
G
53
KEY
24 Air cap
53 Wrench
G Packing nut
Connecting Hoses
CAUTION
The Graco heated hoses and the fluid manifold (25)
inlets are labeled ISO and RES. Be very careful to
make only ISO to ISO and RES to RES connections.
Crossing fluid can damage the hoses and gun. Refer
to hose manual 307544.
1. The fluid hoses can be connected straight down
from the manifold or straight back from it as shown
in Fig. 10. Plug the manifold inlets that will not be
used with steel plugs (32).
2. Connect the fluid hoses to the manifold inlets. Be
sure the air hose (K) is connected to the gun. See
Fig. 10.

307546 11
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or dispensing accidentally. Fluid
under high pressure can be injected through the
skin and cause a serious injury. To reduce the risk
of an injury from injection, splashing fluid, or mov-
ing parts, follow the Pressure Relief Procedure
whenever you:
Dare instructed to relieve the pressure,
Dstop dispensing,
Dcheck or service any of the system equipment,
Dinstall or clean the nozzle.
1. Engage the spray gun trigger latch.
2. Shut off the air to the feed pumps.
3. Turn off the electric motor switch in a hydraulic
system.
4. Turn off the air to the proportioning system in an
air-powered system.
5. Close the gun manifold needle valves.
6. Disengage the trigger safety latch, trigger the gun
to relieve pressure, and engage the trigger safety
latch again.
7. Open both fluid filter drain valves, having a con-
tainer ready to catch the draining fluid.
8. If you are working on any part of the heater, shut
off the main electrical power to the heater.

12 307546
Operation
1. Adjust cleanoff air as instructed in the next
column. Be sure the needle valves (C) are closed.
See Fig. 11.
2. Adjust the fluid temperature. Most foam fluids
are designed for spraying at 100_to 140_F (38_to
60_C). Adjust the heater and hose controls to the
chemical manufacturer’s recommended tempera-
ture. If no temperature is specified, start at 115_F
(43_C).
Refer to manual 307543 for specific instructions on
adjusting and operating the Foam-Cat Heater and
Heated Hose Controls.
3. Adjust the pump outlet pressure to 1000 psi (70
bar). This is adequate for most spray applications.
If more fluid flow is needed at that pressure, try
using a larger fluid nozzle. Refer to the Nozzle
Performance Chart on page 5. Increasing the
fluid pressure could distort the spray pattern.
4. Allow the fluid to heat thoroughly. The Graco
Heater and Heated Hose requires 15 minutes
warm up time.
5. Spray for several seconds in cold weather to
bring thoroughly warmed fluid to the gun. Release
the gun trigger safety latch, open the needle
valves (C), and aim the gun at a large piece of
cardboard when testing spraying.
CAUTION
Open the RES side first to help prevent nozzle
damage.
6. Test for proper foam texture. Trigger the gun in
one second intervals to test the spray pattern. A
good spray pattern should be round and well
atomized and it should harden with a fairly smooth
surface. Refer to the chart on page 4 for the
proper size of pattern and spraying distance for the
nozzle being used.
7. Release the gun trigger at least once a minute
while spraying if you use a no–release triggering
method. This actuates the mechanical purger and
avoids fluid buildup on the nozzle tip and air cap.
CAUTION
Do not nick or scratch the nozzle tip as this could
distort the spray pattern.
Adjusting Cleanoff Air
Each time the gun’s trigger is released, the needle
purges the nozzle and the cleanoff air blows the
purged foam off the tip of the nozzle. Be sure the
cleanoff air is properly adjusting to avoid a build up of
foam on the nozzle or under the air cap.
WARNING
To reduce the risk of an injection injury, follow this
procedure before adjusting the cleanoff air:
Engage the trigger safety (40), close the needle
valves (64), disengage the trigger safety, and
trigger the gun to relieve the fluid pressure. Engage
the trigger safety again.
1. Screw in the air adjusting setscrew (19) using the
3/32 in. wrench (47), until no air or almost no air is
escaping. See Fig. 11.
2. Regulate the air to the gun to 100 psi (0.7 MPa, 7
bar).
3. Back off the setscrew two turns as a test setting.
4. If the air appears to affect the spray pattern, screw
in the setscrew another turn. If build up behind the
air cap occurs, back off the setscrew about 1/2
turn at a time.
NOTE: Use the minimum amount of air needed to
clean the nozzle. Too much air could affect the spray
pattern.
Fig. 11
47
19
RES
C
KEY
19 Setscrew
47 Wrench
C Needlevalves

307546 13
Spray Pattern Adjustment
Effects of Fluid Temperature and Pressure
This section will help you determine how fluid temper-
ature and pressure affect the spray pattern, and what
adjustment can be made to correct a poor spray
pattern. Since fluid temperature and pressure, and the
nozzle, all affect the spray pattern, experimenting will
help you learn how to control these variables.
Changing the fluid temperature affects viscosity and
reaction time of the fluid. Raising the temperature
reduces the viscosity and produces a wider spray
pattern with finer atomization; it has much the same
effect as raising the fluid pressure.
As the fluid temperature gets too high, the pattern
becomes square with less foam in the center. Too high
a temperature can also cause the chemical reaction to
occur before the foam hits the spraying surface, which
causes an undesirable rough surface.
Observing the Effects of Varying Fluid
Temperature and Pressure
It is helpful to observe the effects of varying the fluid
pressure and temperature. Raising the fluid tempera-
ture has about the same affect as raising the fluid
pressure.
1. With fluid temperature set at 115_F (43_C), test
the spray pattern at 300 psi (2.1 MPa, 21 bar).
Increase the pressure in 100 psi (0.7 MPa, 7 bar)
increments up to 1000 psi (7 MPa, 70 bar). In the
lower pressure range, the pattern will be narrow
and coarse. As the pressure is raised, the pattern
becomes wider and finer. When the pressure
becomes too high, the pattern becomes square
and light in the middle.
2. Now, lower the fluid pressure and raise the fluid
temperature in 5_increments up to 135_. Notice
that the spray pattern is affected much the same
by fluid temperature as it is by fluid pressure.
3. To minimize over spray and fogging, always use
the lowest fluid pressure possible to get the
desired spray pattern.
4. The output pressure of both displacement pumps
should be within 150 psi (1.1 MPa, 10.5 bar) of
each other to keep the viscosity of the ISO and
RES similar. To change the pressure in only one
displacement pump, adjust the temperature.
To raise the fluid pressure, decrease the fluid
temperature.
To lower the fluid pressure, increase the fluid
temperature.
About Surface Texture
The quality of foam developed is reflected in its
surface texture. There are several causes of poor
surface texture, including improper equipment adjust-
ments. Descriptions of surface textures and recom-
mendations on how to adjust the equipment to improve
the texture are on the following pages.
About Poured Foam texture
Poured foam should have no dark or soft spots. The
surface should be relatively smooth with only small
ripples. There should be no blow holes larger than 1/4
in. (6 mm) diameter.

14 307546
Surface Texture Descriptions
Smooth Surface Texture
Description
Wavy texture.
Equipment Adjustments
None; has good surface texture.
Orange Peel Texture
Description
Fine texture; like the skin of an orange.
Equipment Adjustments
None; has good surface texture.
Coarse Orange Peel Texture
Description
Surface texture has nodules and valleys of similar size
and shape.
Equipment Adjustments
More flow-out time needed before the rise and cream
time.
Atomized material too coarse. Increase fluid pressure.
If condition persists, increase fluid temperature.
Try holding the gun further away from the spray sur-
face.
Popcorn Surface Texture
Description
Linear surface pattern; forms sharp valleys and over-
hangs.
Equipment Adjustments
More flow-out time needed before the rise and cream
time.
Slow the foam reaction time by lowering fluid tempera-
ture; since this increases the viscosity of the chemi-
cals, the fluid pressure must be raised to maintain
good atomization.
This type of surface pattern can also be caused by
spraying a second lift of foam on top of the first lift
while it is still creaming and rising.
Isocyanate-Rich Surface Texture
Description
Foam is dark in color; does not become tack-free in
the time specified by the chemical manufacturer.
Caused by lack of resin in the foam.
Equipment Adjustments
1. Refill or replace the resin supply.
2. Clean or replace the resin feed pump.
3. Clean the intake filter of the resin proportioning
pump.
4. Clean or repair the resin proportioning pump.
Resin-Rich Surface Texture
Description
Foam has appearance of white shaving cream; does
not become tack-free in the time specified by the
chemical manufacturer. Caused by lack of isocyanate
in the foam.
Equipment Adjustments
1. Refill or replace the isocyanate supply.
2. Clean or replace the isocyanate feed pump.
3. Clean the intake filter of the isocyanate proportion-
ing pump.
4. Resin temperature is too high. Resin is frothing in
the nozzle. Reduce resin temperature.

307546 15
Replacing the Needle/Nozzle Assembly
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of serious bodily injury including
fluid injection, splashing in the eyes or on the skin,
follow the Pressure Relief Procedure whenever
you:
Dare instructed to relieve the pressure,
Dstop spraying,
Dcheck or service any of the system equipment,
Dor install or clean the spray nozzle.
1. Have a solvent pail ready to clean the old parts.
2. Solvent flush the gun as instructed in Flushing
steps 1–9 on page 19.
3. Disconnect the solvent manifold.
4. Remove the two capscrews (7) using the 3/16 in.
wrench (48). See Fig. 12. With the air connected
to the gun, hold the gun with the nozzle housing
straight down and briefly trigger the gun to push
the nozzle housing away from the gun body.
Disconnect the air line.
5. Tilt the nozzle housing up and disengage the
needle ball from the piston (20) rod. Remove the
housing from the gun. See Fig. 13.
6. Pull the needle out from the rear of the nozzle
assembly. Use the 1/2 in. end of the wrench (53)
to unscrew and remove the nozzle retainer (23).
Remove the air cap (24). Place all parts in the
solvent. Refer to Fig. 5 on page 8.
7. Use your fingers or a soft tool such as pencil
eraser to push on the front of the nozzle (E) and
pop it out the rear of the housing. Place the nozzle
in solvent, being careful to keep it separated from
the other parts to avoid damage. See Fig. 14.
NOTE: If the nozzle impingers holes are blocked, refer
to the section, Cleaning the Nozzle on page 17.
CAUTION
Do not use a sharp tool to remove the nozzle.
Scratches on the edge of the nozzle may distort the
spray pattern. Scratches or nicks on the raised
surfaces prevent the nozzle from sealing properly in
the nozzle housing. An improper seal can result in
fluid crossover which clogs the gun passages.
Fig. 12
B
7
50
C
25
7
KEY
7 Capscrew
25 Manifold
50 Nut driver
B Safety latch
C Needle valves
Fig. 13
KEY
20 Piston
20
Fig. 14
KEY
E Nozzle E

16 307546
Replacing the Needle/Nozzle Assembly
8. Check the interior surfaces of the nozzle housing
(2). The tapered “steps”inside the nozzle housing
must be free of fluid buildup. Soak the housing in
solvent to soften the foam, then use a soft bristled
brush to gently clean the interior surfaces.
9. Remove the check valve housings (45, 46) and
strainers (34) from the nozzle housing and clean in
solvent. Then reinstall the parts. See page 15.
10. Install the needle/nozzle assembly as instructed in
steps 4–15 on pages 8–10.
11. Reconnect the foam manifold. Fig. 15
46
2
34
45
KEY
2 Nozzle housing
34 Strainer element
45 ISO check valve housing
46 RES check valve housing

307546 17
Cleaning the Nozzle
Foam Spraying Nozzles
Nozzle
Bore Dia.
in. (mm)
Cleaning
Pin Dia.
in. (mm)
Cleaning Pin
Part No.
0.125 (3.18)
0.114 (2.90) 0.033 (0.84) 0.029 (0.75) 106542 106543
0.102 (2.54)
0.089 (2.26) 0.026 (0.66) 0.024 (0.61) 106548 106545
0.073 (1.85)
0.083 (2.11
0.060 (1.52)
0.018 (0.46)
0.020 (0.51)
0.018 (0.46)
106546
106547
106546
Foam Pouring Nozzles
0.187 (4.75)
0.073 (1.85) 0.029 (0.75) 0.020 (0.51) 106543 106547
1. Solvent flush the gun as instructed in Flushing,
steps 1–9 on page 19. Disconnect the solvent
manifold.
2. Remove the nozzle from the nozzle housing as
instructed on page 15.
3. Insert the correct impinger cleaning pin (H) in the
pin vise (51) so that it protrudes about 1/2 in. (13
mm). Tighten the vise jaws.
CAUTION
Each needle/nozzle kit has a specially-sized impinger
cleaning pin (H). Be sure to use the correct pin to
avoid damaging the nozzle. Refer to the tables
above.
4. Clean the rear impinger holes (M) of the nozzle
(E) first. From the tip end of the nozzle, look
through the nozzle while inserting the cleaning pin
(H) into the rear impinger holes. See Fig. 16.
The rear impinger holes are directly on the centerline
of the nozzle. Push the pin through the impinger hole
and into the middle of the nozzle. Don’t push the pin all
the way through or scratch the interior of the nozzle.
Clean each of the rear holes.
5. Insert the needle (D) through the large end of the
nozzle and push out any debris.
6. Repeat Steps 4 and 5 to be sure the rear impinger
holes are clean.
Fig. 16
KEY
51 Pin vise
D Needle
E Nozzle
H Cleaning pin
M Rear impinger holes
N Front impinger holes
D
E
M
N
51H
7. Now clean the front impinger holes (N). On the
spray nozzles these impinger holes are not on the
centerline of the nozzle, but are just off center. On
pour nozzles these holes are on the centerline. It is
important that the pin be inserted at the same
angle that the impinger hole is bored in order to
clean it properly.
Look through the nozzle from the tip end. Insert the pin
(H), pushing it through the impinger hole and into the
center of the nozzle. But do not push the pin all the
way through which will scratch the interior of the
nozzle. See Fig. 16.
8. Insert the needle (D) through the large end of the
nozzle and push out any debris.
9. Repeat Steps 7 and 8 to be sure the impinger
holes are clean.

18 307546
Maintenance
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of serious bodily injury including
fluid injection, splashing in the eyes or on the skin,
follow the Pressure Relief Procedure whenever
you:
Dare instructed to relieve the pressure,
Dstop spraying,
Dcheck or service any of the system equipment,
Dor install or clean the spray nozzle.
KEY
43 Needleshield
50 Nut driver
B Safety latch
C Needle valves
Fig. 17
B
50
C
43
Keeping the Gun Clean While Spraying
Coat it with grease or cover it with a plastic bag. Be
sure the plastic shield (43) is in place around the
exposed area of the needle. See Fig. 17.
Fluid Buildup on Nozzle
A build up of fluid on the nozzle and under the air cap
can cause an irregular spray pattern. If that happens,
follow the Pressure Relief Procedure on page 11.
Then thoroughly clean the air cap and nozzle. Be sure
that the cleanoff air is properly adjusted, also.
Fluid Buildup on Needle
If build up of fluid causes the needle (D) to stick, use
the 1/4 in. open end wrench (52) on the hex of the
needle and rotate to free it.
A dirty needle can be cleaned by buffing it lightly with
bronze wool or very fine steel wool.
Cleaning the Fluid Manifold
Clean the manifold with solvent and a brush whenever
it is removed from the gun to keep fluid from hardening
on it.
Shutdown
WARNING
To reduce the risk of serious bodily injury from fluid
injection or splashing fluid in the eyes or on the
skin, engage the trigger safety latch (B) and close
the needle valves (C) whenever you stop spraying.
See Fig. 2, page 7.
For overnight shutdown:
1. Follow the Pressure Relief Procedure on page
11, and Flushing, steps 1–9 on page 19.
2. Disconnect the solvent manifold and store the gun.

307546 19
Flushing
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of serious bodily injury including
fluid injection, splashing in the eyes or on the skin,
follow the Pressure Relief Procedure whenever
you:
Dare instructed to relieve the pressure,
Dstop spraying,
Dcheck or service any of the system equipment,
Dor install or clean the spray nozzle.
CAUTION
Thorough flushing of the nozzle and nozzle housing
is essential each day to reduce fluid buildup which
will quickly ruin the nozzle.
Graco recommends using a power flushing method,
such as the Solvent Power Flush Kit, Part No.
218669. If you use this kit, refer to instruction manual
307692 for specific flushing procedure.
Use this flushing procedure when a Graco Solvent
Flush Kit is not available.
1. Remove the foam manifold capscrew (7) using the
3/16 in. wrench (68), then disconnect the manifold.
See Fig. 4, page 8.
2. Connect a solvent manifold to the gun; tighten the
capscrew.
3. Open the needle valves (C).
WARNING
To reduce the risk of static sparking which could
result in fire or explosion and serious bodily injury
and property damage:
DBe sure all equipment used in the flushing
operation is properly grounded.
DNever flush gun while standing on or near a
surface where foam has been applied.
KEY
C Needlevalves
R Ground wire and clamp
Fig. 18
C
R
4. Use the lowest possible pressure and hold the gun
firmly to a grounded metal pail when flushing. See
Fig. 18.
5. Flush the gun for 10 seconds.
6. Engage the trigger safety latch.
7. Turn off the solvent system.
8. Follow the Pressure Relief Procedure on page
11.
Fig. 19
46 34
45
KEY
34 Strainerelement
45 ISO check valve housing
46 RES check valve housing
9. Remove and clean the check valve housings (45
and 46) and strainers (34) in solvent. See Fig. 19.
10. Remove the solvent manifold and reconnect the
foam manifold.
NOTE: Whenever the foam manifold is removed, clean
it with solvent and a brush.
CAUTION
Use a solvent which is compatible with the check
valve o-rings. See page 7.
Never immerse the entire gun in solvent.
These steps help prevent damage to the gun o-rings
and seals.

20 307546
Troubleshooting
WARNING
To reduce the risk of serious injury, whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 11.
DRelieve the pressure before checking or servicing
the equipment.
DCheck all possible problems and causes before
disassembling the pump.
Problem Cause Solution
Coarse atomization Fluid temperature too low. Increase temperature.
Fingering in spray pattern Fluid temperature too low. Increase temperature; use smaller
nozzle.
Square spray pattern with hollow
center Fluid temperature too high or fluid pressure too high. Decrease temperature and/or reduce fluid pressure.
Triangular spray pattern with hol-
low center Fluid temperature too high and a nozzle impinger hole blocked. Decrease temperature; clean nozzle. See page 17.
Round spray pattern with hollow
center Too much fluid flow. Reduce fluid pressure or tempera-
ture.
Fluid buildup on walls of impinger
holes. Clean nozzle. See page 17.
Middle of spray pattern dense Too little fluid flow. Increase fluid flow and/or tempera-
ture.
ISO check valve screen blocked. Remove check valve and clean
strainer. See step 9, page 16.
Air valve leaks O-rings exposed to solvent. Replace o-rings. See page 24. Do not
immerse gun in solvent.
Split spray pattern Nozzle impinger hole blocked. Clean nozzle. See page 17.
Distorted, irregular spray pattern Too much cleanoff air. Reduce air. See page 12.
Light-colored foam Too little ISO. Check and clean check valve strain-
ers. See step 9, page 16.
Check and clean proportioning pump
filter screens.
Check and refill ISO fluid supply.
Check proportioning pump ratios.
Dark-colored foam Too little RES. Check and clean check valve strain-
ers. See step 9, page 16.
Check and clean proportioning pump
filter screens.
Check and refill ISO fluid supply.
Check proportioning pump ratios.