Repair. Graco 3A8476A, SST Switch3D Gun
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Repair
Repair
To help prevent serious injury from pressurized fluid, relieve pressure before cleaning, checking or servicing the equipment
Removal of SST Switch 3D Gun
From Robot for Repair
NOTE: Clean the SST Switch 3D Gun, robot and all parts surrounding it before removing the SST Switch 3D
Gun.
1. Make sure air and material pressures are relieved. a. Follow the
Flush the SST Switch 3D Gun page
b. Follow the Pressure Relief Procedure
page
2. Disconnect the material inlet hose. Always use two wrenches when loosening the high pressure hose connection.
3. Disconnect the 8mm air hose.
F IG . 11
7. The SST Switch 3D Gun can be now be removed from the robot.
4. Unplug the cable connectors by unscrewing the fitting on the 5 pin cable connector (1001) and 8 pin cable connector (1003) if fitted. See F IG . 10.
1001 and
1003 if equipped with sensors
Customer supplied 8mm air hose.
Customer supplied material hoses
F IG . 10
5. Remove the screws that attach the swivel housing
(511) to the anti-rotation bracket.
6. Unscrew the three screws that mount the SST
Switch 3D Gun to the robot mounting flange. See
16 3A8476A
SST Switch 3D Gun
Disassembly
The SST Switch 3D Gun can be disassembled after
being removed from the robot. See Removal of SST
Switch 3D Gun From Robot for Repair .
NOTICE
Materials dispensed by the SST Switch 3D Gun are extremely abrasive, harden quickly and the parts must be thoroughly cleaned before or during any disassembly and repair or damage can occur to components.
Repair
Washer seals should be replaced with new ones
before reassembly. See F IG . 13.
614
615
607
616
609
Remove Cover Plates
1. To access SST Switch 3D gun internal parts, remove side covers (605), top cover (606) and outer cover (520), by removing screws (519) with a hex
605
606
605
617
610
518
F IG . 13
Remove the Material Inlet Block
1. Remove customer supplied inlet fitting and 1/2 in.
BSPP washer seal (603).
2. Take off the SST single inlet adapter (602) by removing the four M5 SHCS screws (601) with a hex key wrench.
3. Discard packing Viton O-ring (613) and replace with
a new one when reassembling. See F IG . 14.
519
520
F IG . 12
Remove Electrical Components
1. Disconnect solenoid valve cable connections (617) from solenoid valves (518).
2. Solenoid valves (518) can be removed from the air valve manifold (516) by the screws attached to the solenoid valves.
3. Remove the dual connector bracket (616) with the dual cable connector (614) attached by removing the two screws (615)with a hex key wrench.
4. Remove the RTD sensor (609), pressure transducer
(610) and 10mm washer seals (607) if equipped.
Customer supplied inlet fitting
F IG . 14
603
601
602
613
3A8476A 17
Repair
Remove the Pneumatic Section
1. Air cylinder assembly (401-417) and needle ball shut off valves (418) are removed together by removing the three M5 SHCS screws (408).
NOTE: Be careful to not damage or bend the needle ball shut off valves (418) when extracting from housing.
Various seals and gaskets that are discarded in the following procedures need to be replaced by new before reassembly.
2. Air gaskets (410) should be discarded.
3. Remove air manifold (516) by removing M3 SHCS screw fasteners (517) with a hex key wrench. Air gasket (514) should be discarded.
4. Remove inner cover (513) by removing M3 flathead screws (515)with a hex key wrench.
5. Remove the 1/8 in. BSPP swivel elbow fitting (512)
with a hex key wrench. See F IG . 15.
410
408
401-417
514
516
517
515
513
409
404
403
418
401
407
405
406
402
F IG . 16
4. Remove short and long seal bearing guides (413 and 414) with a 10mm wrench.
5. Using a knife edge tool or screwdriver, carefully pry the lower bearings (417) out of the seal bearing guides (413-414). Discard lower bearings.
6. Using a hook tool extract the needle packing (411) seals from the seal bearing guide side and discard.
7. Remove the two needle packing (411) seals and upper bearings (412) from the seal bearing guides and discard the needle packing and upper bearings.
8. Remove the O-rings (415 and 416) and discard.
512
F IG . 15
Remove Pneumatic Section
1. Detach cylinder cover (402) by removing three M4
SHCS screws (401) with hex key wrench. Loosen screws evenly because the cover is under spring
(403) tension and could bind when removed.
2. Loosen M3 set screws (405) three turns each and pull ball shut off needles (418) out of the assembly.
3. Extract pistons (404) from air cylinder housing (409)
Discard guide rings (406) and O-rings (407).
411
F IG . 17
411
414
409
412
413
415
417
416
411
18 3A8476A
Repair
Nozzle Adapter Removal
1. Loosen the turnbuckle locking nut (101) by turning it counter clockwise as seen facing the main body of the SST Switch 3D Gun. The nut rotation will separate the 3 head adapter assembly (105) away from the 3D long tube assembly (103).
2. Discard adapter gasket (102) and valve shut off
102
103
101
105
104
F IG . 18
Central Body Removal
1. Loosen the turnbuckle locking nut (101) by turning it counter clockwise as seen facing the main body of the SST Switch 3D Gun. The nut rotation will separate the 3D long tube assembly (103) away from the 3D center body (301). Discard adapter gasket (102).
2. Loosen the two M5 SHCS screws (203) with a hex key wrench and remove the lock ring assembly
(201) along with the washer (202).
3. To release the pressure on the internal seals and ease disassembly, align access holes on the 3D center body (301) with the four M6 screws (503) and loosen the screws.
4. Tap the 3D center body (301) out of the swivel housing assembly (511) using a soft face mallet.
301
101
201
101
103
203
503
102
301
F IG . 19
Swivel Housing Disassembly
1. Dust seal ring (501) can be removed from the air distribution ring bearing (504)
2. Remove flange bearings (502) and discard.
3. Remove M6 flathead screws (503) with a hex key wrench and remove the air distribution ring bearing
(504).
4. Remove the four O-rings (505) and four air seals
(506) from the air distribution ring bearing (504) and discard.
5. Tap the internal components (507-510) out of the swivel housing assembly (511). It is recommended to use seal installation /removal tool 17V972 and a soft face mallet to tap the internal components from the swivel housing.
6. Discard the rotary seals (508). See F IG . 20 on page
3A8476A 19
Repair
501
507
502
503
504
509
510
511
508 502
506
505
F IG . 20
SST Switch 3D Gun Assembly
NOTE : Before assembly, It is recommended to have
Yearly Service Kit, 25U328 on page No. 38. Make sure
parts are thoroughly cleaned. Refer to the fastener torque settings in the
on
page No. 50. Suitable lubricant and thread locking
compound should also be available.
Swivel Housing Assembly
NOTE: For general sequence of swivel housing
NOTE: Medium strength thread locker used for this assembly is Loctite equivalent.
® 242 or equivalent. Anti seize lubricant used for this assembly is Loctite ® 77164 or
1. Insert support ring (510) into the larger bore end of the swivel housing assembly (511) until the support ring is square against the internal shoulder.
2. Apply a thin coat of lithium grease onto the outside of the O-ring on the rotary seal (508). To prevent damage to the Rotary seal O-ring insert into the bore of the swivel housing (511) at an angle. Make sure that the O-ring does not tear against the inlet opening and push the rotary seal against the
support ring (510). See side view F IG . 25.
511
508
510
F IG . 21
3. Insert material distributor ring (509) into the bore of the swivel housing (511). It is recommended to use
the Material Seal Insertion/Removal Tool,
17V972 on page No. 39 and a soft faced mallet.
Push the material distribution ring (509) and rotary seal (508) fully to the bottom of the bore.
20 3A8476A
Repair
4. Apply a thin coat of lithium grease onto the outside of the next O-ring on the rotary seal (508). To prevent damage to the Rotary seal O-ring insert into the bore of the swivel housing (511) at an angle.
Make sure that the O-ring does not tear against the weepage port and push the rotary seal against the
material support ring (509). See top view F IG . 25.
508 509
504
505
506
505
506
511
F IG . 22
5. Insert weepage distributor ring (507) into the bore of the swivel housing (511). It is recommended to use the
Material Seal Insertion/Removal Tool,
17V972 on page No. 39 and a soft faced
mallet.Push the weepage distributor ring and rotary seal (508) fully against the material support ring
507 508
F IG . 24
7. Apply a thin coat of lithium grease to the O-rings
(505) and insert into the bore of the swivel housing
(511). Apply anti seize to M6 flathead socket screws
(503) and thread in finger tight. See F IG . 25.
8. Push one flange bearing (502) into the swivel housing (511), and one flange bearing (502) into the
air distribution ring bearing (504). See F IG . 25.
9. Install dust seal ring (501) around the outside surface of the air distribution ring bearing (504). See
502
504
501 619
502
511
511
F IG . 23
6. Install the O-rings (505) and air seals (506) onto the
air distribution ring bearing (504). See F IG . 24.
503
F IG . 25
Center Body Assembly
1. Apply a thin coat of lithium grease to the sealing diameters of the center 3D body (301) and insert into the swivel housing assembly (511).
3A8476A 21
Repair
2. Align the four access holes in the center 3D body
(301) with the M6 flathead socket screws (503) in the swivel housing assembly (511). Torque fasteners to 80 in-lb (9.0 N•m).
503
511
501
301
619
503
Material Tube Assembly
1. Install adapter gasket (102) into the end of the center body (301).
2. Apply anti seize to lubricant to threads of center body (301) and long 3D tube assembly (503).
3. Rest the turnbuckle locking nut (101) on the threaded end of the center body (301) but do not thread on.
4. Align and insert the pins on the end of the 3D long tube assembly (103) into the central body (301).
Turn the turnbuckle nut clockwise as seen facing the swivel housing so that the threads of the long 3D tube assembly (103) and center body engage simultaneously. Torque the nut to 75 ft-lb (101.69
F IG . 26
3. With a soft face mallet, gently tap the center 3D body (301) into the swivel housing assembly (511) to ensure the center 3D body is positioned against the flange bearing (502).
4. Slide the lock ring assembly (201) onto the shank of the center 3D body (301) and into place against the flange bearing (502). Ensure that the pin in the one half of the lock ring (201) is engaged in the hole of the washer (202).
5. Apply medium strength threadlocker to the two M5
SHCS screws (203) and torque to 57.5 in-lb (6.5
F IG . 28
102
101
201
203
301
103
202
511
F IG . 27
22
301
3A8476A
Air Cylinder Section Assembly
1. Install O-rings (415) then (416) onto the short bearing seal guide (413) and the long bearing seal guide (414).
2. Install one needle packing (411) seal into the short and long bearing seal guides (413 and 414) O-ring end. Open spring side of needle packing seals need to face outwards.
3. Press the lower bearing (417) into the O- ring end of the short and long bearing seal guides (413 and
414).
4. Insert two needle packing (411) seals into each upper bearing (412).Open spring side of needle packing seals need to face outwards on either side of the upper bearing. Insert this assembly into the threaded end of the bearing seal guides (413 and
NOTE:
F IG . 29 shows a short seal bearing guide (413)
however both long and short guides are assembled the same.
411
409
413
414
F IG . 30
6. Apply a thin coat of lithium grease to the ball shut off needles (418) and insert through the short and long bearing seal guides (413 and 414).
7. Install O-rings (407) and guide rings (406) onto pistons (404).
8. Place pistons (404) onto ball shut off needles (418) until the needle bottoms out in the piston. Torque
M3 set screws (405) to 8 in-lb (0.9 N•m).
9. Apply a thin coat of lithium grease to the O-rings
(407) and guide rings (406) and insert pistons into the bores of the air cylinder housing (409) until the pistons bottom out in the bores of the air piston
412
415
416
417
409 413
414
413
404
418
411
F IG . 29
5. Apply medium strength thread locker to the threads of the short and long bearing seal guides (413 and
414) and screw into the air cylinder housing (409).
Torque to 15 ft-lb (20.34 N•m) See F IG . 30.
405
405
404
418
406
407
F IG . 31
10. Install springs (403) and cylinder cover (402). Install
M4 SHCS screws (401) through cylinder cover into air cylinder housing (409). Tighten down M4 SHCS screws (401) evenly to compress springs without binding assembly. Torque M4 screws to 29.2 in-lb
Repair
3A8476A 23
Repair
401
402
403
409
601
602
613
511
F IG . 32
11. Apply a thin coat of lithium grease to the air gaskets
(410) and insert into the 3D center body (301).
12. Insert the air cylinder assembly into the center body
(301). apply medium strength threadlocker onto the
M5 screws (408) and torque to 57.5 in-lb (6.5 N•m).
NOTE : The dimple (A) in the face of the 3D center body
(301) lines up with the long bearing seal guide (414).
408
402
410
A
512
F IG . 34
3. Attach inner cover (513) to the swivel housing assembly (511) with two M3 flathead screws (515) and torque to 8 in-lb (0.9 N•m).
4. Apply a thin coat of lithium grease to air gasket
(514). Locate air valve manifold (516) dowel pins onto the swivel housing assembly (511). Insert two
M3 SHCS fastener screws (517) and torque to 8 in-lb (0.9 N•m).
5. Attach air valves (518) with their included captured screws onto the air valve manifold (516). Install solenoid valve cable connections (617) to air valves.
F IG . 33
Connection Housing Assembly
1. Apply a thin coat of lithium grease to O-ring (613) and locate it on the swivel housing (511). Locate the
SST single inlet adapter (602) on the dowel pins and place onto the swivel housing (511). Apply thread locker to the four M5 SHCS screws (601) and torque to 57.5 in-lb (6.5 N•m).
2. Apply a thin coat of lithium grease to the seal on the
1/8 in. BSPP elbow fitting (512). See F IG . 34.
24 3A8476A
Repair
610
609
607
602
514
516
513
611
517
515
612
608
617
518
F IG . 35
6. Apply a thin coat of lithium grease to the threads of the M10 hex head cap screw (608) and 10MM seal washer (607). Apply a thin coat of lithium grease to the threads of the SST M10 plug (612) and copper washer (611) and install into the and install into the
SST single inlet adapter (602). Torque to 15 ft-lb
(20.34 N•m). If sensors are an option, apply a thin coat of lithium grease to the threads of the RTD sensor (609) and pressure transducer (610) if used and their 10MM seal washers (607). Install the sensors and torque to 15 ft-lb (20.34 N•m).
F IG . 36
7. Connect solenoid valve cable connections (617) and if equipped, sensor wires from the RTD sensor
(609) and /or pressure transducer (610) to the dual
cable connector (614). See 5 Pin - No Sensor for
25T991 and 25T994 on page 48 and
Pin Connections for Temperature and Pressure
Sensors. Model No. 25T992, 25T993, 25T995 and
8. Install dual cable connector (614) into dual connector bracket (616) and tighten nuts. Attach connector bracket to the swivel housing assy (511) with two M5 SHCS screws (615) and torque to 57.5
in-lb (6.5 N•m). See F IG . 37.
3A8476A 25
Repair
615
616 614
519
605
603
606
602
Customer supplied inlet fitting
F IG . 37
9. Install cover plates including the outer blue cover
(520), two side blue covers (605) and top blue cover
(606) with twelve M3 BHCS screws (514) torqued to
12 in-lb (1.35 N•m).
10. Apply a thin coat of lithium grease to the 1/2 in.
BSPP washer seal (603) and threads of the customer supplied inlet fitting. Thread into the SST single inlet adapter (602) and torque to Torque to 15 ft-lb (20.34 N•m).
520
605
F IG . 38
Nozzle Group Assembly
1. Install adapter gasket (102) into the end of the 3D long tube assembly (103). Install valve shut off bearing (104) onto the ball shut off needles (418).
NOTE: The open end of the valve shut off bearing (104) must towards the dispensing nozzles.
2. Apply anti seize lubricant to the threads of the 3D long tube assembly (103) and the 3 head adapter assembly (105).
3. Rest the turnbuckle locking nut (101) on the threaded end of the long 3D tube assembly (503) but do not thread on.
NOTE: Refer to
Assembly on page 29 to determine which 3 head
adapter assembly goes with which model number.
4. Insert the dowel pins of the 3 head adapter assembly (105) into the long 3D tube assembly
(103). Turn the turnbuckle nut clockwise as seen facing the swivel housing so that the threads of the long 3D tube assembly (103) and the 3 head adapter assembly (105) Torque the nut to 75 ft-lb
26 3A8476A
F IG . 39
102
103
104
101
105
Testing Before Installation
If the SST Switch 3D Gun has been assembled after a major repair or maintenance operation, it is recommended to perform a function test before the SST
Switch 3D Gun is returned to production.
A minimum level of function test is to connect the compressed air supply and check for air leakage by opening each of the solenoid valves (613) manually.
The cable connections can be checked using an
Ohm-meter to test the connections from the plug to the terminals and to make sure that there are no short-circuits.
Repair
If the SST Switch 3D Gun is tested offline with material pressure applied, to avoid skin injection always keep clear of the nozzles when test spraying.
Make a last check on all assembly screws and then follow the
Installation instructions on page 8 to mount
the SST Switch 3D Gun on the robot.
3A8476A 27

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