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PMC AP-2 Service Manual

Air purge spray & pour gun
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Before installing the AP-2 Gun and start-up, carefully read all the
technical and safety documentation included in this manual.
special attention to the information in order to know and understand
the operation and the conditions of use of the AP-2 Gun. All of the
information is aimed at improving user safety and avoiding possible
breakdowns from the incorrect use of the AP-2 Gun.
Air Purge
Spray & Pour Gun
AP-2
PATENT PENDING
For use with non-flammable Foam and
Polyurea
For professional use only
Not for use in explosive atmospheres
Service Manual
Ref. # MN-04006
Revision 4.7
June 23, 2017
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Polyurethane Machinery
Corporation
video instructions.
Polyurethane Machinery Corp.
Corporate: 1 Komo Drive, Lakewood, NJ 08701
Manufacturing: 2 Komo Drive, Lakewood, NJ 08701
Phone: 732-415-4400
Fax: 732-364-4025
URL:
http://www.polymacusa.com
PMC,
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Summary of Contents for PMC AP-2

  • Page 1 AP-2 Gun. All of the information is aimed at improving user safety and avoiding possible...

  • Page 2: Table Of Contents

    Soft Chamber Kits .......................... 26 Air Manifold Trigger Rebuild Kit ..................... 26 Air Cylinder Rebuild Kit ........................27 AP-2 O-Ring Kit ..........................27 PMC Recommended O-Ring Grease ..................... 27 Screen Sizes ..........................27 A & R Screen Screw Assembly Kits ....................28 Recommended Spare Parts ......................
  • Page 3 Mixing Chamber Flow Rates* ......................42 Chamber/Orifice Comparison Chart ....................42 TECHNICAL SERVICE BULLETINS ....................43 April 24, 2013 ..........................43 August 16, 2013..........................43 August 16, 2013..........................44 AP-2 Stabilizer Kit .......................... 45 August 26, 2014..........................46 June 13, 2017 ..........................48...

  • 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 replace...
  • 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

    By following the instructions and recommendations contained, you will reduce the potential risk of accidents in the installation, use or maintenance of the AP-2 Gun; you will provide a better opportunity for incident-free operation for a longer time, greater productivity and the possibility of detecting and resolving problems fast and simply.
  • Page 7 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

    CHARACTERISTICS • Internal mixing from high pressure impingement • Automatic cleaning with air pressure • No solvents required • Exterior lubrication of the Mix Chamber TECHNICAL SPECIFICATIONS Maximum Working Pressure: _______________________________ 3,500 psi (245 Bar) Air Pressure: _________________________________________________ 90-125 psi (6.2-8.6 Bar) Maximum Output (1:1 ratio): _____________________________________ 40 lb/min (20 L/min) Minimum Output (1:1 ratio): ____________________________________ 3.3 lb/min (1.55 L/min) Opening Force @ 110 psi (8 Bar): ____________________________________ 200 lb (91 kg)

  • Page 9: General Description

    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. Air Cylinder Coupling Block Assembly Gun Lock and End Cap Lock Collar Gun Block...

  • Page 10: Installation And Start Up

    INSTALLATION AND START UP CAUTION! When working with the AP-2 Gun or performing maintenance work, wear suitable safety protection accordance with recommendations and specifications provided by the product suppliers. 1. Install Coupling Block to the hose. 2. Ensure the Manual Valves are CLOSED by turning them to the full clockwise position.

  • Page 11: Shutdown Procedures

    Mixing Chamber each day to clean it. Use of grease with high moisture content will not achieve the desired results. PMC Grease is recommended. Use of incorrect grease will cause blockage in the mixing chamber.

  • Page 12: Loss Of Air Pressure/Emergency Shut-Off

    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 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 13: Maintenance

    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, trigger the gun to remove internal material pressure, ensure the Manual Valves are CLOSED, ensure the...

  • Page 14: Gun Block And Mixing Chamber Removal

    MAINTENANCE Gun Block and Mixing Chamber Removal 1. CLOSE the Manual Valves 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. Point the gun over a waste container and pull the Trigger to relieve pressure. 3.
  • Page 15 Chamber first, then insert the Mixing Chamber into the front of the Gun Block. This helps to reduce wear on the PCT O-ring. NOTE! A small amount of PMC grease applied to the Mixing Chamber and Side Seals upon assembly is recommended. CAUTION! Use wooden or plastic tools or a brass brush for cleaning.

  • Page 16: Screen Screw And Component Maintenance

    MAINTENANCE Screen Screw and Component Maintenance CAUTION! To avoid possible contamination by the residual chemical inside the Gun do not interchange the Isocyanate (A) parts with the Polyol (R) parts. The Isocyanate (A) side is identified with an (A) on the Screen Screw Head and the Polyol (R) side is marked with an (R) on the Screen Screw Head.
  • Page 17 7. Remove the Side Seal and Spring from the Screen Screw. Inspect all components and O-rings. Clean or replace as required. 8. Inspect for damage and apply PMC lubrication to all O-rings and threads and reassemble in reverse order. 9. The gun is now ready for service.

  • Page 18: Air Manifold Maintenance

    MAINTENANCE Air Manifold Maintenance 1. CLOSE the Manual Valves 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. Set the Gun Lock to the LOCKED position. 3.
  • 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

    MAINTENANCE Air Cylinder Maintenance 1. CLOSE the Manual Valves 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. Point the gun over a waste container and pull the Trigger to relieve pressure.
  • Page 21 NOTE! 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

    GUN OPERATION Triggered Off Compressed Shop Air 90 – 120 PSI (6.2 – 8.3 Bar) • Compressed shop air enters through the rear of the Air Manifold. • The air passes around the Spool Valve to the Rear of the Piston in the Air Cylinder, moving the Piston (and Mixing Chamber) forward to the CLOSED position.

  • Page 23: Triggered On

    GUN OPERATION Triggered On Compressed Shop Air 90 – 120 PSI (6.2 – 8.3 Bar) • Compressed shop air passes through the open Spool Valve, filling the cavity and pushing the Piston and Chamber backwards. • The orifices in the Chamber are now captured within the Side Seals and exposed to high pressure chemical.

  • Page 24: Trouble Shooting Guide

    TROUBLE SHOOTING GUIDE PROBLEM POSSIBLE CAUSE SOLUTION Insufficient air pressure (minimum 90 psi, 6.2 bar) Ensure 90 psi (6.2 Bar) PCT not flush with Gun Block when Trigger Valve requires service Rebuild, see page 14 Gun is triggered Air Passages plugged Clean, See page 14 Lock is in “Locked”...

  • Page 25: Reference Guide

    REFERENCE GUIDE Chamber Kits DESCRIPTION PART FOR USE WITH ILLUSTRATION NUMBER NUMBER (INCH) #63 DRILL MIXING 200476 (.0370) NOZZLE MIXING GU-814- #70 DRILL GU-03031 CHAMBER (.0280) PORT RM-814-000 CHAMBER #000 1.25mm DRILL MIXING 200477 (.0492) NOZZLE MIXING GU-814- #69 DRILL GU-03027 CHAMBER (.0292)

  • Page 26: Pct Kits

    REFERENCE GUIDE Chamber Kits (Continued) DESCRIPTION PART FOR USE WITH ILLUSTRATION NUMBER NUMBER (INCH) 2mm DRILL MIXING 200480 (.0787) NOZZLE MIXING GU-814- #55 DRILL GU-03050 CHAMBER (.0520) PORT CHAMBER RM-814-02X #02X #44 DRILL MIXING GU-03028 (.0860) NOZZLE MIXING GU-814- #54 DRILL GU-03035 CHAMBER (.055)
  • Page 27 REFERENCE GUIDE PCT Kits (Continued) PART FOR USE DESCRIPTION ILLUSTRATION NUMBER NUMBER WITH #65 DRILL PCT PURGE GU-03033 PORT (.0350) PCT PURGE 1.35mm DRILL 200478 AND NOZZLE (.0531) PORT GU-815- PCT FLAT TIP OR-00042A O-RING .016 PATTERN RM-815-00X CONTROL TIP 00.X #65 DRILL PCT PURGE...

  • Page 28: Chamber/Pct Kits

    REFERENCE GUIDE PCT Kits (Continued) PART FOR USE DESCRIPTION ILLUSTRATION NUMBER NUMBER WITH #65 DRILL PCT PURGE GU-03033 (.0350) PORT #54 DRILL PCT PURGE GU-03035 (.055) PORT 2mm DRILL PCT NOZZLE 200480 GU-815- (.0787) PORT PCT FLAT TIP OR-00042A O-RING .016 PATTERN RM-815-02X CONTROL TIP...

  • Page 29: Soft Chamber Kits

    REFERENCE GUIDE Chamber/PCT Kits (Continued) KIT NUMBER PART NUMBER DESCRIPTION GU-814-01X CHAMBER 01X W/ DRILLS KT-814-01X GU-815-01X PCT 01X RND W/ DRILLS GU-814-02 CHAMBER 02 W/ DRILLS KT-814-02 GU-815-02 PCT 02 RND W/ DRILLS GU-814-02X CHAMBER 02X W/ DRILLS KT-814-02X GU-815-02X PCT 02X RND W/ DRILLS GU-814-03...

  • Page 30: Air Cylinder Rebuild Kit

    O-RING 2mmx4mm BUNA 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 31: A & R Screen Screw Assembly Kits

    O-RING #013 80D AFLAS SP-04005 SPRING; SIDE SEAL GU-020 MANUAL VALVE ASSEMBLY KT-850 CHECK VALVE ASSEMBLY 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 32: Optional Parts

    REFERENCE GUIDE Optional Parts PART NUMBER DESCRIPTION GU-815-50-509 BLASTER TIP .059 GU-815-50 BLASTER TIP 3.5 GU-815-51 POUR TIP GU-815-52 PCT FLAT TIP RETAINER ASSEMBLY GU-815-53 POUR NOZZLE * GU-815-52-1 PCT FLAT TIP BODY * GU-815-52-2 PCT FLAT TIP GASKET * GU-815-52-3 PCT FLAT TIP RETAINER * OR-00042A #016 O-RING...
  • Page 33 PARTS IDENTIFICATION Optional MA-41 Kit shown on AP-2 Gun Flush Tanks Optional 2.5 Gallon Flush Tank (200426, 200427) and 1QT Mini Flush Tank (200216, 200217) shown.

  • Page 34: Parts Identification

    PARTS IDENTIFICATION PARTS IDENTIFICATION Manual Valve Assembly (GU-020) NOTE: The orientation of the back-up ring is important. The concave face must point towards the O-Ring. MANUAL VALVE ASSEMBLY (GU-020) ITEM PART NUMBER DESCRIPTION MANUAL VALVE GU-022 HOUSING GU-021 MANUAL VALVE STEM GU-023 MANUAL VALVE SEAT 007 VITON CURVED...

  • Page 35: Coupling Block Assembly

    PARTS IDENTIFICATION Coupling Block Assembly (GU-04001) COUPLING BLOCK ASSEMBLY (GU-04001) 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 TN-04193 COUPLING BLOCK MOUNTING SCREW TN-04197...

  • Page 36: Air Manifold Assembly

    PARTS IDENTIFICATION Air Manifold Assembly (GU-843) AIR MANIFOLD ASSEMBLY (GU-843) 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 O-RING #012 VITON...

  • Page 37: End Cap Assembly

    PARTS IDENTIFICATION End Cap Assembly (GU-844) END CAP ASSEMBLY (GU-844) 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 38: Air Cylinder Assembly

    PARTS IDENTIFICATION Air Cylinder Assembly (GU-801A) AIR CYLINDER ASSEMBLY (GU-801A) 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 #016 O-RING GU-829 A/P CHECK VALVE...

  • Page 39: Complete Air Cylinder Assembly

    PARTS IDENTIFICATION Complete Air Cylinder Assembly (GU-845) COMPLETE AIR CYLINDER ASSEMBLY (GU-845) ITEM QTY 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 40: Air Purge Spray And Pour Gun

    PARTS IDENTIFICATION Air Purge Spray and Pour Gun (GU-850) AIR PURGE SPRAY AND POUR GUN (GU-850) 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 41 PARTS IDENTIFICATION AIR PURGE SPRAY AND POUR GUN (GU-850) ITEM PART NUMBER DESCRIPTION GU-814-00X CHAMBER 00X W/ DRILLS GU-814-01 CHAMBER 01 W/ DRILLS GU-814-01X CHAMBER 01X W/ DRILLS GU-814-02 CHAMBER 02 W/ DRILLS GU-814-02X CHAMBER 02X W/ DRILLS GU-814-03 CHAMBER 03 W/ DRILLS GU-814-04 CHAMBER 04 W/ DRILLS GU-815-000...

  • Page 42: Screen Screw Assembly

    PARTS IDENTIFICATION 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 FILTER SCREEN 80 MESH (STANDARD) OR-801 * O-RING #013 80D AFLAS OR-800 *...

  • Page 43: List Of Tools

    PARTS IDENTIFICATION 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 DOUBLE ENDED PIN VISE TL-10 CHECK VALVE REMOVAL TOOL...

  • Page 44: Appendix

    APPENDIX Grease Gun Assembly Screw the rod (2c) into the top of the grease gun (2a) so that the final assembly represents assembled grease gun (2, Pg. 39). Unscrew the top of the grease gun (2a) from the bottom of the grease gun (2b).

  • Page 45: Mixing Chamber Flow Rates

    GU-814-01 GU-814-01X 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 Chamber Orifice Size Orifice Size Number Number 000 (AR2020) 0.0200 0.0280 00 (AR2929) 0.0290...

  • Page 46: Technical Service Bulletins

    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 47: August 16, 2013

    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 48: Ap-2 Stabilizer Kit

    TECHNICAL SERVICE BULLETINS AP-2 Stabilizer Kit (KT-828) AP-2 STABILIZER KIT (KT-828) 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 OR-805 O-RING TN-04197 COUPLING BLOCK SCREW (BLACK) TN-830 SHCS BOLT *Not included in kit KT-828...

  • Page 49: August 26, 2014

    Ref: 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 50 TECHNICAL SERVICE BULLETINS Old Style Check Valve # GU-820...

  • Page 51: June 13, 2017

    ASSEMBLY: 1. Use Part # GP-Lube-Grease (REF Table: PMC Recommended O-Ring Grease) to grease the groove of the Manual Valve Steam (GU-021). 2. Check the Red Back-up ring (OR-016) for any imperfections before using.

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