PMC AP-2 Service Manual
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PMC AP-2 Service Manual

Air purge spray & pour gun
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PATENT PENDING
REVISION 2.0
Before installing the AP-2 Gun and start-up, carefully read all the technical
and safety documentation included in this manual. Pay special attention to
the information in order to know and understand the operation and the
conditions of use of the AP-2 Gun.
improving user safety and avoiding possible breakdowns from the incorrect
use of the AP-2 Gun.
Air Purge
Spray & Pour Gun
AP-2
For use with non-flammable Foam and
Polyurea
For professional use only
Not for use in explosive atmospheres
Manual
Ref. # MN-04006
Polyurethane Machinery Corp.
Corporate: 1 Komo Drive, Lakewood, NJ 08701
Manufacturing: 2 Komo Drive, Lakewood, NJ 08701
Phone: 732-415-4400
http://www.polymac-usa.com
All of the information is aimed at
Fax: 732-364-4025

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  • Page 1 Phone: 732-415-4400 Fax: 732-364-4025 http://www.polymac-usa.com Before installing the AP-2 Gun and start-up, carefully read all the technical and safety documentation included in this manual. Pay special attention to the information in order to know and understand the operation and the conditions of use of the AP-2 Gun.

  • Page 2: Table Of Contents

    AIR CYLINDER MAINTENANCE ....................20 GUN OPERATION ..........................22 TROUBLE SHOOTING GUIDE ......................24 AP-2 CHAMBER KITS (GU-814-_ _ _)................... 25 AP-2 PCT KITS (GU-815-_ _ _)....................... 26 CHAMBER/PCT KIT (KT-814-_ _ _) ....................27 AIR MANIFOLD TRIGGER REBUILD KIT (KT-826) ..............28 AIR CYLINDER REBUILD KIT (KT-801) ..................
  • Page 3 AP-2 Service Manual PARTS IDENTIFICATION ........................32 MANUAL VALVE ASSEMBLY (GU-020) ..................32 COUPLING BLOCK ASSEMBLY (GU-04001) ................33 AIR MANIFOLD ASSEMBLY (GU-843) ..................34 END CAP ASSEMBLY (GU-844) ....................35 AIR CYLINDER ASSEMBLY (GU-801A) ..................36 COMPLETE AIR CYLINDER ASSEMBLY (GU-845) ..............37 AIR PURGE SPRAY AND POUR GUN (GU-850) ................

  • Page 4: Warranty

    Defective in material or workmanship, it is Customer’s responsibility to contact PMC and return the Product to PMC as directed by PMC, freight prepaid. If PMC determines that the Product is Defective and that such Defect is covered by this Warranty, PMC will credit Customer for the reasonable freight charges incurred by Customer in returning the Defective Product to PMC, and PMC (or its authorized agent) will, at PMC’s option, repair or...
  • Page 5 No Rights Implied: Nothing in the sale, lease or rental of any Product by PMC shall be construed to grant any right, interest or license in or under any patent, trademark, copyright, trade secret or other proprietary right or material owned by anyone;...

  • Page 6: Safety And Handling

    AP-2 Service Manual SAFETY AND HANDLING This chapter contains important information on the safety, handling and use of your AP-2 series Gun. READ THIS MANUAL BEFORE OPERATING THIS EQUIPMENT. FAILURE TO FULLY READ AND UNDERSTAND THIS MANUAL MIGHT RESULT IN DAMAGE OR LOSS TO PERSONNEL, EQUIPMENT, OR PROPERTY.

  • Page 7: Important Safety Information

    Technical Specifications of this Manual to be exceeded. Always use liquids and solvents that are compatible with the AP-2 Gun. If in doubt, consult PMC Technical Service. When working with the AP-2 Gun, it is recommended that the operator wear suitable clothing and elements of personal protection, including, without limitation, gloves, protective goggles, safety footwear and face masks.

  • Page 8: Characteristics

    AP-2 Service Manual CHARACTERISTICS  Internal mixing from high pressure impingement  Automatic cleaning with air pressure  No solvents required  Exterior lubrication of the Mix Chamber Weight: 2.235 lbs (1.012 kg) (w/o coupling block) 2.302 lbs (1.317kg) (with coupling block)

  • Page 9: General Description

    AP-2 Service Manual GENERAL DESCRIPTION For better knowledge of the AP-2 Gun, the main components and their description are shown. For a more precise identification, see the Parts Identification section. AP-2 GENERAL DESCRIPTION ITEM PART NUMBER DESCRIPTION GU-801 Air Cylinder...

  • Page 10: Installation And Start Up

    Service Manual INSTALLATION AND START UP CAUTION! When working with the AP-2 Gun or performing maintenance work, wear suitable safety protection in accordance with the recommendations and specifications provided by the product suppliers. 1. Install Coupling Block (GU-04001) to the hose.
  • Page 11 AP-2 Service Manual 9. Ensure that the Proportioner and the supply system is in the ready position and the material pressures at the Proportioner and the material temperatures in the Material Heaters and Heated Hoses are set as recommended by the chemical supplier (see Machine Service Manual).

  • Page 12: Shutdown Procedures

    42 for Grease Gun Assembly Instructions). This action will help prevent ISOCYANATE from crystallizing on the mixing chamber which may cause damage to the internal parts. Note: PMC Grease is recommended. Use of incorrect grease will cause blockage in the mixing chamber.

  • Page 13: Loss Of Air Pressure/Emergency Shut-Off

    AP-2 Service Manual LOSS OF AIR PRESSURE/EMERGENCY SHUT-OFF 1. Shut off air supply to gun. 2. Using the palm of your hand, push in on the Gun Lock (1c) and rotate clockwise to set it to the LOCKED position. In the locked position the Gun Lock will restrict the movement of the air piston (center line) from moving to the rear to an open position, thus rendering the gun inoperable.

  • Page 14: Maintenance

    AP-2 Service Manual MAINTENANCE To obtain maximum performance from your AP-2 Gun, it is necessary to periodically perform certain maintenance operations WARNING! Before proceeding with any maintenance work on the AP-2 Gun, SHUT OFF/DISCONNECT the air supply, ensure the Gun Lock is in the LOCKED position and the Manual Valves are CLOSED.
  • Page 15 11. Reassemble the Mixing Chamber (6, Pg. 14) in reverse order. NOTE! A small amount of PMC grease applied to the Mixing Chamber (6, Pg. 14) and Side Seals (27, Pg. 16) upon assembly is recommended. CAUTION! Use wooden or plastic tools or a brass brush for cleaning.

  • Page 16: Screen Screw And Component Maintenance

    AP-2 Service Manual SCREEN SCREW AND COMPONENT MAINTENANCE SCREEN SCREW COMPONENTS ITEM QTY PART NUMBER DESCRIPTION GU-819-A “A” SCREEN SCREW GU-819-R “R” SCREEN SCREW GU-04007 SCREEN SCREW SEAL GU-818-40 FILTER SCREEN; 40 MESH. SEE PAGE 30 GU-818-60 FILTER SCREEN; 60 MESH. SEE PAGE 30 GU-818-80 FILTER SCREEN;...
  • Page 17 7. Remove the Side Seal (27) and Spring (26) from the Screen Screw. Inspect the components and O-rings. Clean or replace as required. 8. Inspect for damage and apply PMC lubrication to the O-rings and threads and reassemble in reverse order.

  • Page 18: Air Manifold Maintenance

    Spool Valve (3e), and Liner Bushing (2e) using the tool provided (TL-10, Pg. 40). 8. Remove and discard O-Rings (7e & 8e) 9. Replace the O-rings (7e & 8e, Pg. 18) and Spring (5e, Pg. 18) supplied in KT-826 (Pg. 27). Extra PMC grease will facilitate reassembly.
  • Page 19 Rebuild Kit. 10. Inspect, clean and/or replace all remaining assembly components. Apply a small amount of PMC grease to the inside of the manifold cavity and to the O-rings on the Spool Valve to facilitate reassembly. 11. Reattach the Trigger and Air Manifold assembly in reverse order.

  • Page 20: Air Cylinder Maintenance

    AP-2 Service Manual AIR CYLINDER MAINTENANCE 1. CLOSE the Manual Valves (3d) by turning them to the full clockwise position. CAUTION! Excessive force opening or closing Manual Valves may result in damage to the Manual Valves and/or Coupling Block. 2. Trigger Gun over Waste Container to release internal material pressure.
  • Page 21 When replacing O-rings, replace ALL O- rings included in the KT-801 Rebuild Kit. 13. Coat the inside of the Cylinder and all O-rings with PMC grease to facilitate reassembly. 14. Reassemble the Air Cylinder in reverse order. CAUTION! Use wooden or plastic tools or a brass brush for cleaning.

  • Page 22: Gun Operation

    AP-2 Service Manual GUN OPERATION Compressed Shop Air 90 – 120 PSI (6.2 – 8.3 Bar) TRIGGERED OFF Compressed shop air:  Enters through the rear of the Air Manifold.  Passes around the Spool Valve to the back of the Piston moving the Piston and Chamber forward to the CLOSED position and maintaining it closed.
  • Page 23 AP-2 Service Manual GUN OPERATION Compressed Shop Air 90 – 120 PSI (6.2 – 8.3 Bar) TRIGGERED ON  Compressed shop air passes through the open Spool Valve, filling the cavity and pushing the Piston and Chamber rearward.  The orifices in the Chamber are now captured within the Side seal and exposed to high pressure chemical.

  • Page 24: Trouble Shooting Guide

    AP-2 Service Manual TROUBLE SHOOTING GUIDE PROBLEM POSSIBLE CAUSE SOLUTION Insufficient Gun air pressure (minimum 90 psi, 6.2 Ensure 90 psi (6.2 Bar) of PCT not flush with Bar) air pressure at Gun Gun Block when Gun Trigger Valve requires service...

  • Page 25: Chamber Kits (Gu-814

    AP-2 Service Manual REFERENCE GUIDE AP-2 CHAMBER KITS (GU-814-_ _ _) PART DESCRIPTION FOR USE WITH ILLUSTRATION NUMBER NUMBER (INCH) #61 DRILL GU-03032 MIXING NOZZEL (.0390) #70 DRILL MIXING CHAMBER GU-814-000 GU-03031 (.0280) PORT RM-814-000 CHAMBER #000 #56 DRILL GU-03023 MIXING NOZZEL (.0465)

  • Page 26: Pct Kits (Gu-815

    AP-2 Service Manual AP-2 PCT KITS (GU-815-_ _ _) PART DESCRIPTION FOR USE WITH ILLUSTRATION NUMBER NUMBER GU-03033 #65 DRILL (.0350) PCT PURGE PORT GU-03035 #54 DRILL (.055) PCT PURGE PORT PCT NOZZEL GU-03032 #61 DRILL (.0390) PORT GU-815-000 PCT FLAT TIP OR-00042A O-RING .016...

  • Page 27: Chamber/Pct Kit (Kt-814

    AP-2 Service Manual AP-2 PCT KITS (GU-815-_ _ _) CONTINUED GU-03033 #65 DRILL (.0350) PCT PURGE PORT GU-03035 #54 DRILL (.055) PCT PURGE PORT PCT NOZZEL GU-030-28 #44 DRILL (.0860) PORT GU-815-03 PCT FLAT TIP OR-00042A O-RING .016 PATTERN RM-815-03...

  • Page 28: Air Manifold Trigger Rebuild Kit (Kt-826)

    O-RING #008 VITON OR-00037B QUAD RING #011 VITON OR-00042A #016 O-RING GU-829 A/P CHECK VALVE GU-830 AIR CYLINDER BUSHING AP-2 O-RING KIT (KT-827) PART NUMBER DESCRIPTION OR-800 #013 BACK UP RING OR-801A O-RING #013 80D AFLAS OR-803 O-RING #012 VITON...

  • Page 29: A & R Screen Screw Assembly Kits (Kt-819-_)

    O-RING #013 80D AFLAS SP-04005 SPRING; SIDE SEAL GU-020 MANUAL VALVE ASSEMBLY CHECK VALVE ASSEMBLY KT-850 OR-00042A #016 O-RING GU-829 A/P CHECK VALVE TN-831 4-40 X ½ SHCS TL-04003 GREASE TUBE OR-800 #013 BACK UP RING KT-827 AP-2 O-RING KIT...

  • Page 30: Screen Sizes

    AP-2 Service Manual SCREEN SIZES PART NUMBER DESCRIPTION FILTER SCREEN, 80 MESH (STANDARD) GU-818-80 GU-818-60 FILTER SCREEN, 60 MESH GU-818-40 FILTER SCREEN, 40 MESH OPTIONAL PARTS PART NUMBER DESCRIPTION GU-815-50-509 BLASTER TIP .059 GU-815-51 POUR TIP GU-815-52 PCT FLAT TIP RETAINER ASSEMBLY...

  • Page 31: Service Manual

    AP-2 Service Manual 1/4” UNHEATED STAINLESS STEEL HOSE ASSY. PART NUMBER DESCRIPTION MA-41 HOSE PACKAGE KIT, UNHEATED MA-41A REPLACEMENT HOSE, “A” SIDE MA-41R REPLACEMENT HOSE, “R” SIDE Optional MA-41 Kit shown on AP-2 Gun Flush Tank (TL-12)

  • Page 32: Parts Identification

    AP-2 Service Manual PARTS IDENTIFICATION MANUAL VALVE ASSEMBLY (GU-020) GU-020 MANUAL VALVE ASSEMBLY ITEM PART NUMBER DESCRIPTION GU-022 Manual Valve Housing GU-021 Manual Valve Stem GU-023 Manual Valve Seat OR-016 007 PTFE Backup Ring OR-015 #007 Aflas O-Ring...

  • Page 33: Coupling Block Assembly (Gu-04001)

    AP-2 Service Manual COUPLING BLOCK ASSEMBLY (GU-04001) GU-04001 COUPLING BLOCK ASSEMBLY ITEM PART NUMBER DESCRIPTION GU-04001-01 COUPLING BLOCK BODY TN-04192 1/8 NPT PIPE PLUG GU-020 MANUAL VALVE ASSY RA-00005A 1/8 NPT X #5 JIC SWIVEL RA-00006A 1/8 NPT X #6 JIC SWIVEL...

  • Page 34: Air Manifold Assembly (Gu-843)

    AP-2 Service Manual AIR MANIFOLD ASSEMBLY (GU-843) GU-843 AIR MANIFOLD ASSEMBLY ITEM PART NUMBER DESCRIPTION GU-826 AIR MANIFOLD GU-825-2 LINER BUSHING GU-823 SPOOL VALVE GU-825-1 SPOOL VALVE LINER GU-824 SPOOL VALVE SPRING GU-833 HOSE ADAPTER OR-00002A O-RING #008 VITON OR-803...

  • Page 35: End Cap Assembly (Gu-844)

    AP-2 Service Manual END CAP ASSEMBLY (GU-844) GU-844 END CAP ASSEMBLY ITEM PART NUMBER DESCRIPTION GU-804 LOCK KNOB GU-806 SPRING GU-803 CYLINDER END CAP GU-807 TWO POSITION STOP GU-831 RETAINING SCREW OR-00043B O-RING #010 80D AFLAS OR-00026A O-RING #129 VITON...

  • Page 36: Air Cylinder Assembly (Gu-801A)

    AP-2 Service Manual AIR CYLINDER ASSEMBLY (GU-801A) GU-801A AIR CYLINDER ASSEMBLY ITEM QTY PART NUMBER DESCRIPTION GU-801 AIR CYLINDER TN-04186 GREASE FITTING GU-836 SIDE MOUNT EXT RETAINING RING GU-837 RETAINER RING SPLIT-SET GU-830 AIR CYLINDER BUSHING GU-812 LOCK COLLAR OR-00042A...

  • Page 37: Complete Air Cylinder Assembly (Gu-845)

    AP-2 Service Manual COMPLETE AIR CYLINDER ASSEMBLY (GU-845) GU-845 COMPLETE AIR CYLINDER ASSEMBLY ITEM PART NUMBER DESCRIPTION GU-801A AP-2 AIR CYLINDER ASSEMBLY GU-844 AP-2 END CAP ASSEMBLY GU-802 PISTON OR-00043B O-RING #10 80D AFLAS OR-00026A O-RING #129 VITON...

  • Page 38: Air Purge Spray And Pour Gun (Gu-850)

    AP-2 Service Manual AIR PURGE SPRAY AND POUR GUN (GU-850)
  • Page 39 AP-2 Service Manual GU-850 AIR PURGE SPRAY AND POUR GUN ITEM PART NUMBER DESCRIPTION GU-845 COMPLETE AIR CYLINDER ASSEMBLY GU-816 GUN BLOCK ASSEMBLY A/R SCREEN SCREW ASSEMBLY GU-04001 COUPLING BLOCK ASSEMBLY GU-814-000 CHAMBER 000 W/ DRILLS GU-814-00 CHAMBER 00 W/ DRILLS...

  • Page 40: Screen Screw Assembly

    AP-2 Service Manual SCREEN SCREW ASSEMBLY SCREEN SCREW COMPONENTS ITEM QTY PART NUMBER DESCRIPTION GU-819-R * “R” SCREEN SCREW GU-819-A * “A” SCREEN SCREW GU-04007 * SCREEN SCREW SEAL GU-818-40 FILTER SCREEN; 40 MESH GU-818-60 FILTER SCREEN; 60 MESH GU-818-80...

  • Page 41: List Of Tools

    AP-2 Service Manual LIST OF TOOLS LIST OF TOOLS ITEM PART NUMBER DESCRIPTION GU-04019 AIR HOSE TL-00002 GREASE GUN GU-04021 QUICK DISCONNECT; FEMALE GU-04022 QUICK DISCONNECT; MALE TL-04003 GREASE TUBE TL-09 OPEN END WRENCH TL-04001 5/16 SPINTITE; NUT DRIVER GP-00101...

  • Page 42: Appendix

    AP-2 Service Manual APPENDIX GREASE GUN ASSEMBLY 1. Screw the rod (2c) into the top of the grease gun (2a) so that the final assembly represents the assembled grease gun (2, Pg. 40). 2. Unscrew the top of the grease gun (2a) from the bottom of the grease gun (2b).

  • Page 43: Mixing Chamber Flow Rate

    10.5 GU-814-02 GU-814-02X GU-814-03 GU-814-04 *Flow rates will vary depending on viscosity, hose length and machine efficiency. CHAMBER/ORIFICE COMPARISON CHART COMPETITIVE AIR PURGE PMC AIR PURGE CHAMBER NUMBER ORIFICE SIZE CHAMBER NUMBER ORIFICE SIZE 000 (AR2020) 0.0200 0.0280 00 (AR2929) 0.0290...

  • Page 44: Technical Service Bulletin

    REF: AP-2 SCREEN SCREW IMPROVEMENT PART NUMBER GU-819-A and GU-819-R All AP-2 spray guns starting with serial #347 Screen Screw have the improved screen screws. The screen screws have been improved to extend the service life of the Screen Screw O-Ring when operating at high pressure.
  • Page 45 The #KT-828 Stabilizer Bar Kit can be field retrofit onto any AP-2 gun manufactured prior to this date. The installation is quite easy and only requires two Allen wrenches, 5/16” spin-tite and PMC grease.
  • Page 46 AP-2 New Fluid Check Valve Assembly # KT-850 PMC has recently introduced a more robust, less expensive fluid check valve for the AP-2 air purge gun. Part number KT-850 Check Valve Assembly Set now replaces the former GU-820 check valve. All PMC AP-2 guns manufactured after August 15, 2014 have been fitted with the new check valves.
  • Page 47 AP-2 Service Manual Technical Service Bulletin August 22, 2014 AP-2 New Fluid Check Valve Assembly # KT-850 Old Style Check Valve # GU-820...
  • Page 48 AP-2 Service Manual AP-2 STABILIZER KIT # KT-828 KT-828 AP-2 STABILIZER KIT PARTS LIST ITEM QTY PART NUMBER DESCRIPTION OR-804 O-RING OR-00037B QUAD O-RING GU-841 RISER BLOCK GU-842 STABILIZER GU-808 SHOULDER BOLT GU-805 O-RING TN-04197 COUPLING BLOCK SCREW (BLACK) TN-830...

  • Page 49: Manual Revisions

    AP-2 Service Manual MANUAL REVISIONS Revision Date Changes Approved P1 Changed Address to Komo Dr, Added Rev Control Number; Updated entire manual to reflect current AP- 30-Apr-14 Vadams 2 Gun as of 30APR2014; Added Appendix - Technical Service Bulletins; Added Revision Sheet...

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