Graco G-3S User manual

3A5591D
EN
Instructions
3D Gun
Swiveling applicator for robotic sealing applications. For professional use only.
Not approved for use in European explosive atmosphere locations.
See page 2 for model information.
Important Safety Instructions
Read all warnings and instructions in this
manual before using this equipment.
Save these instructions.

23A5591D
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Component Identification . . . . . . . . . . . . . . . . . . . . 6
Main Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 6
Central Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Swivel Chamber . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connection Housing . . . . . . . . . . . . . . . . . . . . . . 9
Connection Housing (cont.) . . . . . . . . . . . . . . . 10
Nozzle Head Assembly . . . . . . . . . . . . . . . . . . . 11
Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . 12
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . 13
Mounting Flange . . . . . . . . . . . . . . . . . . . . . . . . 13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Typical Applicator Installation . . . . . . . . . . . . . . 14
Applicator Removal . . . . . . . . . . . . . . . . . . . . . . 16
Disassembly and Reassembly of Applicator . . . 17
Applicator Disassembly . . . . . . . . . . . . . . . . . . . 17
Applicator Assembly . . . . . . . . . . . . . . . . . . . . . 21
Parts and Wire Diagram . . . . . . . . . . . . . . . . . . . . 25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Preventative Maintenance . . . . . . . . . . . . . . . . . 25
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Technical Specifications . . . . . . . . . . . . . . . . . . . . 27
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 28
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 28
Models
Related Manuals
Part No. Model Name Description
Applied Material
Quantity Sensor Types
Wetted Parts
Material
17V558 G-3S Dispenser, 3D 1 N/A Aluminum Alloy
17V559 G-3ST Dispenser, 3D 1 Temperature Aluminum Alloy
17V560 G-3SP Dispenser, 3D 1 Pressure Aluminum Alloy
17V561 G-3STP Dispenser, 3D 1 Temperature
and Pressure
Aluminum Alloy
17V562 G-3D Dispenser, 3D 2 N/A Aluminum Alloy
17V563 G-3DT Dispenser, 3D 2 Dual Tempera-
ture
Aluminum Alloy
17V564 G-3SSS Dispenser, 3D 1 (water based) N/A SST
17V565 G-3SSS Dispenser, 3D 1 (water based) Temperature
and Pressure
SST
Manuals
3A5641 3D Gun, One Material Parts
3A5642
3D Gun, One Material, with Tem-
perature and Pressure Sensors
Parts
3A5643 3D Gun, Two Material Parts
3A6164 3D Gun, Stainless Steel, One
Material Parts

Warnings
3A5591D 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
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.
• Relieve pressure 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.
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 relieve pressure 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.

Warnings
43A5591D
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical
reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or prop-
erty damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or flu-
ids containing such solvents.
• Do not use chlorine bleach.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier
for compatibility.
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.
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
3A5591D 5
Overview
Description
The Graco 3D gun is a lightweight, high-pressure
multi-nozzle applicator designed for robotic applications
with high precision and quality demands. The applicator
is equipped with a swivel for optimum robot flexibility
and has three individually operated nozzles. The swivel
makes it possible for the robot to rotate the nozzle head
independently of the cables and hoses supplying the
applicator.
The nozzle head can be specified for various nozzle
angles and slot directions.
Due to its flexibility, the 3D gun is designed for applica-
tions like: Underbody coating (UBC), Underbody Seal-
ing (UBS), Liquid applied sound deadening (LASD) and
seam sealing.
The Graco 3D gun is designed to handle most types of
single component adhesives and sealants with medium
to high viscosity.
The solenoid valves operating the pistons for the mate-
rial valves are mounted externally for easy mainte-
nance.
Material circulation is provided through the entire length
of the applicator for material thixotropic breakdown and
temperature control.
If required, the following optional features can be added
to the basic configuration of the applicator:
- One PT 100 temperature sensor in the material
inlet, measuring the inlet material temperature.
- The material pressure can be monitored by a
pressure transducer mounted in the material
return channel.
- The central body can be insulated for better
temperature control.

Component Identification
63A5591D
Component Identification
Main Assemblies
Key:
A Central body assembly
B Swivel chamber
C Connection housing
D Nozzle head assembly
E Cylinder assembly
F Material valve needle
G Lock ring
FIG. 1
DE
A
B
C
F
G

Component Identification
3A5591D 7
Central Body
Key:
H Central body (with lance)
J Packing set material inlet
K Packing set material return
LGasket
M Locating pins
N Valve needle guide
O Valve needle packing set
The central body connects material, air and electrical
signals from the solenoid valves. Two parallel channels
supply material up to the nozzle head. A third channel is
provided for the material return flow back to the swivel
housing.
A needle guide (N) is located at the front end of the cen-
tral body (H) to align the needle valves with the valve
seats in the nozzle head. The nozzle head gasket (L)
seals between the material supply and the nozzle head
(D). The two nozzle head locating pins (M) ensure that
the nozzle head is always mounted in the correct posi-
tion. The valve needles packing set (O) seals off the
valve needles from material and air pressure.
Channel arrangements in the central body:
Blue: Product in
Red: Return (if unit is equipped with circulation)
Green: Signals from the solenoid valves
FIG. 2
H
J
J
K
L
M
N
O
FIG. 3: Product Flow
Air Signals
Product In
Return
Product In

Component Identification
83A5591D
Swivel Chamber
Key:
P Retaining ring
Q Lock ring
The swivel chamber supplies the material from the
connection housing to the central body and the cylinder
unit. External solenoid valves supply compressed air to
the cylinder unit.
The material supply includes normally two channels,
one for the material supply, the other for the material
return. The return channel is in the front end of the
swivel housing. The two channels are separated by a
non-sealing distance ring.
When using the applicator for two different materials,
the supply and return channels are sealed off by using a
seal ring between the two channels.
If the applicator is used in an application without mate-
rial circulation, the two material channels are joined to
one, supplying material through all three channels in the
central body.
The compressed air is supplied through the channel at
the rear end of the swivel chamber.
At the front end of the swivel chamber a bearing
ensures that the swivel chamber is always in a centered
position on the central body.
The distance ring in front of the leakage hole is located
between the channels for material and air.
All sealings and distance rings are locked in place by
the retaining ring at the rear end of the swivel chamber.
The lock-ring in front of the swivel chamber keeps the
swivel chamber in position on the central body.
FIG. 4: Swivel Chamber
Swivel for two different materials
Swivel for one material
PQ

Component Identification
3A5591D 9
Connection Housing
Key:
AA Connection piece, upper
AB Screw ISO 4762 M5 x 20
AC Connection piece, lower
AD Left side cover
AE Screw ISO 7046-1 M3 x 6 Z
AF Pressure transducer (with amplifier)
AG O-ring 10 x 2, 2
AH Connection cable, Solenoid valve
AJ Gasket 1/8”
AK PT 100 sensor (high pressure)
AL Right side cover
AM Female connector 18 pin CPL
AN Screw ISO 4762 M5 x 30
AP Gasket
AQ Nipple
AR Connection flange
AS Upper cover
AT Connector T3
AV Material return
AW Material supply
The connection housing is designed as the common
platform for all external connections to the applicator.
The connections for material supply (AW) and return
(AV) are placed in the upper connection piece.
The connections are internal 3/8” BSP. One or two con-
nectors for electrical signals are mounted in the bracket
attached to the base module.
The base module may also include a PT100 tempera-
ture sensor (AK) in the material inlet and a pressure
transducer (AF) in the material return channel. When
spraying there is no return flow, the pressure then in the
return line is equal to the pressure just before the nozzle
head.
These sensors and the solenoid valves are connected
to terminals on the pin connector (AM). Note that differ-
ent pin connectors exist depending on applicator ver-
sions i.e. 5 or 18 pins.
FIG. 5: Connection Housing
AA
AB
AC
AD
AE
AF
AG
AH
AJ AK
AL
AM
AN AP
AQ
AR
AS
AT
AV
AW

Component Identification
10 3A5591D
Connection Housing (cont.)
Mounted on the connection housing is the swivel locking
bracket (two versions available) that locks the connec-
tion housing and the swivel chamber to a fixed point
between axis 5 and 6 on the robot. This design makes
sure that the connections follow the motion of axis 5.
Only the central body follows the motion of axis 6.
NOTE: See your Repair-Parts manual for more informa-
tion on which swivel locking bracket should be used with
your applicator model. Graco provides an ABB robot
arm swivel locking bracket solution. Any other robot arm
requires a swivel locking bracket specific to the robot
model being used.
FIG. 6: Swivel Locker
Swivel Locking Bracket Swivel Locking Bracket with frame

Component Identification
3A5591D 11
Nozzle Head Assembly
Key:
BA Nozzle Cap
BB Nozzle Head
BC Spray nozzle
BD Gasket
BE M6 hex screw
BF M4 screw
The nozzle head assembly includes two main parts:
the nozzle head (BB), and the nozzle cap (BA). The
nozzle head base part includes the valve seats for the
material valve and mounted to the central body with
three M4 screws (BF). The nozzle cap is fixed to the
base part with one center screw.
The nozzle head is designed to accommodate guided
nozzles with standard measurements.
The nozzle heads are designed with various nozzle and
slot angles.
FIG. 7
BB
BA
BB
BC
BE
BD
BF

Component Identification
12 3A5591D
Cylinder Assembly
Key:
CA Packing, cylinder
CB Cylinder housing
CC Screw ISO 7046 M4 x 25
CD Spring
CE Cylinder cover
CF Screw ISO 4762 M4 x 20
CG Needle packing
CH Threaded needle
CJ Piston
CK O-ring
CL Set screw ISO 4029 M4 x 5
CM Guide ring
The cylinder assembly contains the cylinder housing
(CB) and three pneumatically operated pistons (CJ) that
actuate the material valves, three springs (CD) and a
cylinder cover (CE). Th pistons are actuated by external
24 V mono stable 3/2 port solenoid valves.
FIG. 8: Cylinder Assembly
CA
CB
CC
CD
CE
CF
CG
CH
CJ
CK
CL
CM

Component Identification
3A5591D 13
Solenoid Valves
The external solenoid valves controlling the product
valves are easily accessible under the cover.
Mounting Flange
Key:
EA Flange
EB Guide pins, ISO 8734 4x10
EC Guide pin, ISO 8734 6x12
ED M6 screws
EE Extra low head screws
The mounting flange is the interface between the
applicator and the sixth axis of the robot. Consequently,
the design of the mounting flange is robot dependent.
The flange (EA) is fixed to the robot using screws with
an extra low head (EE). The guide pin (EC) locks the
flange in the exact position. With the flange fixed to the
robot, the applicator is mounted on the flange and fixed
in exact position by two guide pins (EB) and three M6
screws (ED).
FIG. 9
FIG. 10
EAEB
EB
EC
ED
EE

Installation
14 3A5591D
Installation
Before starting installation of the Graco 3D gun, refer to
the Description on page 5 and Component Identifica-
tion on page 6, in order to be familiar with the various
parts of the applicator.
To ensure a trouble free operation of the applicator, it is
very important that the unit is properly installed on the
robot. It is also very important that the function of the
applicator is carefully checked before start up.
Graco recommends using the tools supplied in kit
17V859 (sold separately) for convenience and correct
fit.
Typical Applicator Installation
The following parts are normally required:
• 1 pc. Graco 3D gun with nozzle head and nozzle
cap.
• 1 pc. Robot mounting flange.
• 1 pc. Swivel locking bracket.
• 1 pc. Cable with 18-pin connector (other configura-
tions possible).
• 6 pcs. M6x16 mm hex socket head screws with
extra low head.
• 2 pc. Guide pin Ø 6 mm
• 3 pcs. M6x20 mm hex socket head screws.
• 4 pcs. M5x14 hex socket head screws.
Begin the installation by mounting the mounting flange
(see page 13) on the sixth axis of the robot using the six
M6x16 screws with extra low heads. When the flange is
fixed on the robot, the applicator is attached to the
flange with the three M6x20 screws. It is important to
check that the guide pins are inserted in the right posi-
tions.
When the applicator is mounted to the robot, the swivel
locking bracket (two options are available) must be
attached to the connection housing and to the fixation
point on the robot using the two M5X14 hex head
screws.
The swivel locking bracket option used depends on how
the applicator is attached to the robot arm. Use the first
option when routing the cable from the top, and use the
second option when routing the cable from the bottom.
Standard parts fitting the ABB swivel locking bracket are
available, and other non-standard parts can be made
available upon request.
To avoid personal injury, be especially careful when
connecting the high pressure material supply system
and always keep clear of the nozzles when test spray-
ing.
FIG. 11
Swivel Locking Bracket Option 1:
Swivel Locking Bracket Option 2:

Installation
3A5591D 15
Before installing the spray nozzles (BC), it is important
to check that the nozzle gaskets (BD) are in their correct
positions. The nozzles must be inserted in the nozzle
cap (BA), then the nozzle cap with the nozzles must be
firmly fixed to the nozzle head (BB) using the M6 hex
button head screw (BE) in the center of the cap.
When the applicator is fixed in the correct position the
electrical cable can be connected. First connect the
cable to the applicator, then install the cables to the
robot and make the appropriate connections in the con-
trol cabinet.
See the appropriate Repair-Parts manual for your appli-
cator model. See Related Manuals on page 2.
The air supply is connected to the applicator with a 8
mm PU-hose to the push-in coupling on the side of the
swivel housing.
The material supply hose is connected to the connection
point “Inlet”. The material return hose is connected to
the connection point “Return”. If circulation was not
selected, the return connection is plugged. If dual mate-
rials are supplied, both connections are inlets (no return
possible).
After completion of the installation of hoses and cables,
there free movement must be checked by moving the
fifth axis of the robot. The hoses and cables must be
able to move freely without stretching or scratching the
robot arm.
Test for Leaks
With the applicator properly installed on the robot, the
functions of the unit can be tested. First open the air
supply. There must be no sound from leaking air.
Check that the solenoid valves are working properly by
open and closing each valve from the robot pendant and
listen to the sound of the piston in operation.
Apply material supply pressure and check for leakage.
Move the applicator to the purge position and purge all
nozzles one by one until the unit is completely filled up
with material and all entrapped air is removed from the
supply system.
Open the circulation valve and purge the material
through the dump valve until all entrapped air in the
material return is removed.
FIG. 12
FIG. 13
BE
BA
BB
BD
BC
FIG. 14

Installation
16 3A5591D
Applicator Removal
NOTE: Clean the unit and all parts surrounding it before
removing the applicator.
1. Make sure air and material pressures are relieved.
a. Shut of the power to the pump.
b. Turn off the air and fluid supply inlet to the appli-
cator.
c. Open the outlet into a grounded metal waste
container to relieve the fluid pressure.
d. Clear the applicator tip.
2. Disconnect the material inlet hose and the material
return hose. Always use two wrenches when loos-
ening the high pressure hose connection.
3. Disconnect the air hose.
4. Unplug the electrical connectors by pulling the cable
connectors backwards from the cable.
5. Unscrew the three screws that mounts the applica-
tor to the robot mounting flange.
6. Unscrew the two screws that fixes the connection
housing to the swivel lock bracket.
7. Now the main parts of the applicator can be
removed from the robot.
NOTE: Be sure to store all removed parts in a safe loca-
tion.
To help prevent serious injury from pressurized fluid,
relieve pressure before cleaning, checking or servic-
ing the equipment.
FIG. 15
FIG. 16

Disassembly and Reassembly of Applicator
3A5591D 17
Disassembly and Reassembly of Applicator
Applicator Disassembly
NOTE: Ensure a proper work bench with a vice with
“soft jaws” and access to compressed air are available
to facilitate the work.
1. The disassembly starts with removing the nozzle
head (BB). First remove the nozzle cap (BA). To do
this, unscrew the M6 hex button head screw (BE).
Then remove the nozzle cap with nozzles (BC).
Take care not to lose the nozzle gaskets (BD).
2. Unscrew the three hex head screws (Allen screws)
that fixes the nozzle head to the front end of the
central body. If necessary, remove the nozzle head
packing at the front of the central body.
3. With the nozzle head removed from the central
body, loosen the two screws and take away the lock
ring and washer.
4. Slide off the swivel chamber with connection hous-
ing.
FIG. 17
FIG. 18
BE
BA
BB
BD
BC
FIG. 19
FIG. 20

Disassembly and Reassembly of Applicator
18 3A5591D
5. If need be, the swivel chamber and connection
housing can now be separated.
6. All internal parts can now be removed from the
swivel chamber (special tool 17V862 recom-
mended). If need be, also the solenoid valves can
be detached.
7. All internal gaskets and seals should be replaced if
the swivel chamber is dismantled.
FIG. 21
FIG. 22
FIG. 23

Disassembly and Reassembly of Applicator
3A5591D 19
8. The connection housing can also be further disman-
tled if o-rings or sensors (if so equipped) need to be
replaced.
FIG. 24
AA
AB
AC
AD
AE
AF
AG
AH
AJ AK
AL
AM
AN
AP
AQ
AR
AS
AT

Disassembly and Reassembly of Applicator
20 3A5591D
9. To access the material valve needles, remove the
cylinder cover, screws and springs.
10. Remove the piston by loosening the two screws
locking the piston and needle together. Once the
piston is accessible, o-ring and guide ring can be
removed.
11. Remove the three Torx screws holding the cylinder
housing. Lift the housing and remove the cylinder
packing. There are also three needle packing
located in the cylinder housing. The material valve
needles, gasket and guide can now be removed
from the central body.
12. With the needles removed, pull out the needle pack-
ing spacers. Note that there are two sizes. See the
appropriate Parts manual for additional information
and special tools.
13. Pick up the packings and needle guides with the
special tool (17V861).
14. With all parts removed, clean all parts that will be fit-
ted again. Discard parts not needed for reassembly.
NOTE: Refer to spare parts manual for additional infor-
mation and spare parts numbers.
FIG. 25
FIG. 26
FIG. 27
FIG. 28
FIG. 29