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PMC AP-3 Service Manual

Air purge spray & pour gun. for use with non-flammable foam and polyurea for professional use only not for use in explosive atmospheres
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Before installing the AP-3 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-3 Gun. All of the
information is aimed at improving user safety and avoiding possible
breakdowns from the incorrect use of the AP-3 Gun.
Air Purge
Spray & Pour Gun
AP-3
For use with non-flammable Foam and
Polyurea
For professional use only
Not for use in explosive atmospheres
Service Manual
Ref. # MN-04030
Revision 1.4
November 21, 2018
Subscribe to our channel,
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,
for
Pay

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Summary of Contents for PMC AP-3

  • Page 1 AP-3 Gun. All of the information is aimed at improving user safety and avoiding possible...

  • Page 2: Table Of Contents

    Table of Contents WARRANTY ............................1 SAFETY AND HANDLING ........................3 CHARACTERISTICS ........................... 5 TECHNICAL SPECIFICATIONS ......................5 GENERAL DESCRIPTION ........................6 INSTALLATION AND START UP ......................7 SHUTDOWN PROCEDURES ......................8 LOSS OF AIR PRESSURE/EMERGENCY SHUT-OFF ............... 8 MAINTENANCE ..........................9 Gun Block and Mixing Chamber Removal ..................
  • Page 3 TABLE OF CONTENTS Air Cylinder Rebuild Kit ........................32 AP-3 O-Ring Kit ..........................32 PMC Recommended O-Ring Grease ..................... 32 Screen Sizes ..........................32 A & R Screen Screw Assembly Kits ....................33 Recommended Spare Parts ......................33 Optional Parts ..........................34 Check Valve Assembly ........................

  • 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 the Product, subject to...
  • 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-3 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-3 Gun. If in doubt, consult PMC Technical Service. When working with the AP-3 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 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): ____________________________________ 50 lb/min (22.7 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) Closing Force @ 110 psi (8 Bar): ________________________________________ 200 lb (91 kg) Weight (Not including Coupling Block): _____________________________ 2.4 lbs (1.1 kg) Weight (Including Coupling Block): _________________________________ 3.1 lbs (1.4 kg)

  • Page 9: General Description

    GENERAL DESCRIPTION For better knowledge of the AP-3 Gun, the main components and their description are shown. For a more precise identification, see the Parts Identification section.

  • Page 10: Installation And Start Up

    INSTALLATION AND START UP INSTALLATION AND START UP CAUTION! When working with the AP-3 Gun or performing maintenance work, wear suitable safety protection in accordance with the recommendations specifications provided by the product suppliers. 1. Install Coupling Block to the hose.

  • 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: Maintenance

    MAINTENANCE MAINTENANCE To obtain maximum performance from your AP-3 Gun, it is necessary to periodically perform certain maintenance operations. WARNING! Before proceeding with any maintenance work on the AP-3 Gun, trigger the gun to remove internal material pressure, ensure the Manual Valves are CLOSED, ensure the...
  • Page 13 MAINTENANCE To prevent possible injury caused by incorrect handling of the materials and solvents used in the process, carefully read the Material Safety Data Sheet (MSDS) provided by your supplier. To avoid damage caused by the impact of pressurized fluids, do not open any connection or perform maintenance work on components subject to pressure until the pressure has been completely eliminated.

  • 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.
  • 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 9. Remove the Side Seal and Spring from the Screen Screw. Inspect all components and O- rings. Clean or replace as required. 10. Inspect for damage and apply PMC lubrication to all O-rings and threads and reassemble in reverse order.

  • Page 18: 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 19 When replacing O-rings, replace ALL O-rings included in the 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 20: Cartridge Valve Removal

    MAINTENANCE Cartridge Valve Removal 1. Remove the trigger from the handle. 2. Remove Push On Cap. 3. Remove the Split Ring from in front of the Cartridge Valve. Eject the Cartridge Valve by pushing it out through the hole indicated by the arrow above.

  • Page 21: Gun Operation

    GUN OPERATION Triggered Off Compressed Shop Air 90 – 120 PSI (6.2 – 8.3 Bar) 1. Compressed dry air enters through the rear or bottom of the Gun Handle. 2. The air is directed through the cartridge valve and into the Rear of the Piston in the Air Cylinder, moving the Piston (and Mixing Chamber) forward to the CLOSED position.

  • Page 22: Triggered On

    GUN OPERATION Triggered On Compressed Shop Air 90 – 120 PSI (6.2 – 8.3 Bar) 1. Compressed dry air is directed through the cartridge valve and into the front, filling the cavity and pushing the Piston and Chamber backwards. 2. The orifices in the Chamber are now aligned with the Side Seals and exposed to high pressure chemical.

  • Page 23: 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 Gun Failed cartridge valve Replace, see page17 is triggered Air Passages plugged Clean, See page 18-19 Lock is in “Locked”...

  • Page 24: Reference Guide

    REFERENCE GUIDE Chamber Kits DESCRIPTION PART FOR USE WITH ILLUSTRATION NUMBER NUMBER (INCH) #63 DRILL MIXING 200476 (.0370) NOZZLE MIXING #70 DRILL GU-814-000 GU-03031 CHAMBER (.0280) PORT RM-814-000 CHAMBER #000 1.25mm DRILL MIXING 200477 (.0492) NOZZLE MIXING #69 DRILL GU-814-00 GU-03027 CHAMBER (.0292)

  • Page 25: Pct Kits

    REFERENCE GUIDE Chamber Kits (Continued) DESCRIPTION PART FOR USE WITH ILLUSTRATION NUMBER NUMBER (INCH) #44 DRILL MIXING GU-03028 (.0860) NOZZLE MIXING #54 DRILL GU-814-03 GU-03035 CHAMBER (.055) PORT RM-814-03 CHAMBER #03 2.4mm DRILL MIXING 200481 (.0945) NOZZLE MIXING #50 DRILL GU-814-04 GU-03054 CHAMBER...
  • Page 26 REFERENCE GUIDE PCT Kits (Continued) PART FOR USE KIT NUMBER DESCRIPTION ILLUSTRATION NUMBER WITH #65 DRILL PCT PURGE GU-03033 PORT (.0350) PCT PURGE 1.35mm DRILL 200478 AND NOZZLE (.0531) PORT GU-815-00X PCT FLAT TIP OR-00042A O-RING .016 PATTERN RM-815-00X CONTROL TIP 00.X #65 DRILL PCT PURGE...
  • Page 27 REFERENCE GUIDE PCT Kits (Continued) PART DESCRIPTION FOR USE 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 (.0787) PORT GU-815-02X PCT FLAT TIP OR-00042A O-RING .016 PATTERN RM-815- CONTROL TIP...

  • Page 28: Chamber/Pct Kits

    REFERENCE GUIDE Chamber/PCT Kits KIT NUMBER PART NUMBER DESCRIPTION GU-814-000 CHAMBER 000 W/ DRILLS KT-814-000 GU-815-000 PCT 000 RND W/ DRILLS OR-00042A PCT FLAT TIP O-RING .016 GU-814-00 CHAMBER 00 W/ DRILLS KT-814-00 GU-815-00 PCT 00 RND W/ DRILLS OR-00042A PCT FLAT TIP O-RING .016 GU-814-00X CHAMBER 00X W/ DRILLS...

  • Page 29: Spare Parts Kit Ap2

    REFERENCE GUIDE Spare Parts Kits AP2 PART NUMBER DESCRIPTION REFERENCE PAGE 200445 AP2/3-000 SPARE PARTS KIT 200446 AP2/3-00 SPARE PARTS KIT 200447 AP2/3-00X SPARE PARTS KIT 200448 AP2/3-01 SPARE PARTS KIT 200449 AP2/3-01X SPARE PARTS KIT 200450 AP2/3-02 SPARE PARTS KIT 200451 AP2/3-02X SPARE PARTS KIT 200452...

  • Page 30: Ap2/3-00 Spare Parts Kit (200446)

    REFERENCE GUIDE AP2/3-00 Spare Parts Kit (200446) PART NUMBER DESCRIPTION KT-814-00 CHAMBER/PCT ROUND 00 W/DRILLS GU-020 MANUAL VALVE ASSY. GU-04007 SCREEN SCREW SEAL GU-818-80 FILTER SCREEN; 80 MESH OR-801A O-RING #013 80D AFLAS OR-00043B O-RING; #10 AFLAS SP-04005 SPRING; SIDE SEAL GU-817-90 SIDE SEAL OR-00042A...

  • Page 31: Ap2/3-01 Spare Parts Kit (200448)

    REFERENCE GUIDE AP2/3-01 Spare Parts Kit (200448) PART NUMBER DESCRIPTION KT-814-01 CHAMBER/PCT ROUND 01 W/DRILLS GU-020 MANUAL VALVE ASSY. GU-04007 SCREEN SCREW SEAL GU-818-80 FILTER SCREEN; 80 MESH OR-801A BACK UP RING; #013 OR-00043B O-RING; #10 AFLAS SP-04005 SPRING; SIDE SEAL GU-817-90 SIDE SEAL OR-00042A...

  • Page 32: Ap2/3-02 Spare Parts Kit (200450)

    REFERENCE GUIDE AP2/3-02 Spare Parts Kit (200450) PART NUMBER DESCRIPTION KT-814-02 CHAMBER/PCT ROUND 02 W/DRILLS GU-020 MANUAL VALVE ASSY. GU-04007 SCREEN SCREW SEAL GU-818-80 FILTER SCREEN; 80 MESH OR-801A BACK UP RING; #013 OR-00043B O-RING; #10 AFLAS SP-04005 SPRING; SIDE SEAL GU-817-90 SIDE SEAL OR-00042A...

  • Page 33: Ap2/3-03 Spare Parts Kit (200452)

    REFERENCE GUIDE AP2/3-03 Spare Parts Kit (200452) PART NUMBER DESCRIPTION KT-814-03 CHAMBER/PCT ROUND 03 W/DRILLS GU-020 MANUAL VALVE ASSY. GU-04007 SCREEN SCREW SEAL GU-818-80 FILTER SCREEN; 80 MESH OR-801A BACK UP RING; #013 OR-00043B O-RING; #10 AFLAS SP-04005 SPRING; SIDE SEAL GU-817-180 SIDE SEAL OR-00042A...

  • Page 34: Ap2/3-05 Spare Parts Kit (201173)

    REFERENCE GUIDE AP2/3-05 Spare Parts Kit (201173) PART NUMBER DESCRIPTION 201164 CHAMBER/PCT ROUND 05 W/DRILLS GU-020 MANUAL VALVE ASSY. GU-04007 SCREEN SCREW SEAL GU-818-80 FILTER SCREEN; 80 MESH OR-801A BACK UP RING; #013 OR-00043B O-RING; #10 AFLAS SP-04005 SPRING; SIDE SEAL GU-817-180 SIDE SEAL OR-00042A...

  • Page 35: Air Cylinder Rebuild Kit

    OR-00037B QUAD RING #011 VITON OR-00042A #016 O-RING GU-829 A/P CHECK VALVE GU-830 AIR CYLINDER BUSHING 200459 #018 O-RING AP-3 O-Ring Kit (201118) PART NUMBER DESCRIPTION OR-800 #013 BACK UP RING OR-801A O-RING #013 80D AFLAS OR-804 O-RING 2MMX4MM BUNA...

  • Page 36: A & R Screen Screw Assembly Kits

    O-RING #010 80D AFLAS OR-801A 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 TL-04003 GREASE TUBE OR-800 #013 BACK UP RING 201118 AP-3 O-RING KIT...

  • Page 37: 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-815-53 POUR NOZZLE GU-815-52 PCT FLAT TIP RETAINER ASSEMBLY * 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 38: Flush Tanks

    REFERENCE GUIDE Flush Tanks Optional 2.5 Gallon Flush Tank (200426, 200427) and 1QT Mini Flush Tank (200216, 200217) shown. 2.5 Gallon Flush Tank 1 QT Mini Flush Tank FLUSH TANKS 2.5 Gallon Flush Tank 1 QT Mini Flush Tank 200426 – Solvent Flush Kit, 2.5 Gal, AP 200216 –...

  • Page 39: 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 QTY PART NUMBER DESCRIPTION GU-022 MANUAL VALVE HOUSING GU-021 MANUAL VALVE STEM GU-023 MANUAL VALVE SEAT 007 VITON CURVED...

  • Page 40: Coupling Block Assembly

    PARTS IDENTIFICATION Coupling Block Assembly (GU-04001) COUPLING BLOCK ASSEMBLY (GU-04001) ITEM QTY 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...

  • Page 41: Gun Assembly

    PARTS IDENTIFICATION Gun Assembly (200631)
  • Page 42 PIPE PLUG, 1/16, NPT , STEEL 200634 VALVE, CARTRIDGE, 4-WAY 200637 HANDLE, AP-3 200638 PISTON, AP-3 201092 CYLINDER, PINNED, AP-3 201109 10-24 X 1-3/4 HEX MACH SCREW, STEEL, ZINC 201110 STEP AP203 201111 RETAINING RING, INT, 1/2 ID 201124 CAP, PUSH-ON, 7/64 OD, EPDM...

  • Page 43: Gun Block Assembly

    PARTS IDENTIFICATION Gun Block Assembly GUN BLOCK COMPONENTS ITEM QTY PART NUMBER DESCRIPTION 201108 SCREW, HEX CAP, 10-32 CUSTOM 200635 ALUMINUM GUN BLOCK, AP-3 200636 STEEL GUN BLOCK, AP-3 GU-04007 SCREEN SCREW SEAL GU-818-80 FILTER SCREEN, 80 MESH GU-817-90 SIDE SEAL SP-04005 SPRING;...

  • Page 44: Screen Screw Assembly

    PARTS IDENTIFICATION Screen Screw Assembly SCREEN SCREW COMPONENTS ITEM QTY PART NUMBER DESCRIPTION “R” SCREEN SCREW GU-819-R * “A” SCREEN SCREW GU-819-A * 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-801A * O-RING #013 80D AFLAS OR-800 *...

  • Page 45: 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 46: Appendix

    APPENDIX Grease Gun Assembly Screw the rod (2c) into the top of the grease gun (2a) so that the final assembly represents the assembled grease gun (2, Pg. 41). Unscrew the top of the grease gun (2a) from the bottom of the grease gun (2b).

  • Page 47: Mixing Chamber Flow Rates

    GU-814-01X 10.5 GU-814-02 GU-814-02X GU-814-03 GU-814-04 200920 *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...

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