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PMC AP-3 Service Manual

Air purge spray & pour gun
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AP-3 Air Purge Spray & Pour Gun
Service Manual
Ref. # MN-04030
Revision 1.5
April 20, 2020
For use with non-flammable Foam and Polyurea
For professional use only
Not for use in explosive atmospheres
Polyurethane Machinery Corp.
1 Komo Drive, Lakewood, NJ 08701
732-415-4400
URL:
http://www.polymacusa.com

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  • Page 1 AP-3 Air Purge Spray & Pour Gun Service Manual Ref. # MN-04030 Revision 1.5 April 20, 2020 For use with non-flammable Foam and Polyurea For professional use only Not for use in explosive atmospheres Polyurethane Machinery Corp. 1 Komo Drive, Lakewood, NJ 08701...

  • Page 2: Table Of Contents

    DIAMOND PLATED CHAMBER/PCT KITS ................... 26 AP-2/AP-3 SPARE PARTS KITS DESC ..................27 AP-2/AP-3 SPARE PARTS KITS ....................28 AP-2/AP-3 SPARE PARTS KITS (DIAMOND PLATED) ..............29 PMC RECOMMENDED O-RING GREASE ..................30 MISCELLANEOUS PARTS/KITS ...................... 31 SIDE SEAL KIT, RESIN ........................ 31 SCREEN SIZES ..........................
  • Page 3 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.

  • 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

    AP-3 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)

  • Page 9: General Description

    AP-3 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. MN-04030 REV 1.5: April 20, 2020...

  • Page 10: Installation And Start Up

    AP-3 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 and 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

    AP-3 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 AP-3 MAINTENANCE To prevent possible injury caused by incorrect handling of the materials and solvents used in the process, carefully read the Safety Data Sheet (SDS) provided by your supplier. To avoid damage caused by the impact of pressurized fluids,...

  • Page 14: Gun Block And Mixing Chamber Removal

    AP-3 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.
  • 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

    AP-3 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: Air Cylinder Maintenance

    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 NOTE! 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 19: Cartridge Valve Removal

    AP-3 MAINTENANCE CARTRIDGE VALVE REMOVAL 1. Remove the trigger from the handle. 2. Remove the Snap Ring from in front of the Cartridge Valve. 3. Eject the Cartridge Valve by pushing it out through the hole indicated by the arrow above...

  • Page 20: Gun Operation

    AP-3 GUN OPERATION GUN OPERATION TRIGGERED OFF 1. Compressed dry air enters through the rear or bottom of the Gun Handle. Compressed Shop Air 90 – 120 PSI (6.2 – 8.3 Bar) 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 21: Triggered On

    AP-3 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.

  • Page 22: Troubleshooting Guide

    AP-3 TROUBLESHOOTING GUIDE TROUBLESHOOTING 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 page16 is triggered Air Passages plugged Clean, See page 17-18 Lock is in “Locked”...

  • Page 23: Reference Guide

    AP-3 REFERENCE GUIDE REFERENCE GUIDE CHAMBER KITS DESCRIPTION PART NUMBER FOR USE WITH ILLUSTRATION NUMBER (INCH) 200476 #63 DRILL (.0370) MIXING NOZZLE MIXING GU-03031 #70 DRILL (.0280) CHAMBER GU-814-000 PORT RM-814-000 CHAMBER #000 200476 #63 DRILL (.0370) MIXING NOZZLE MIXING...
  • Page 24 AP-3 REFERENCE GUIDE CHAMBER KITS (CONTINUED) 1.45mm DRILL 200479 MIXING NOZZLE (.0571) MIXING GU-814-DP- GU-03021 #59 DRILL (.0410) CHAMBER PORT RM-814-DP-01 CHAMBER #01 DIAMOND PLATED GU-03053 #52 DRILL (.0635) MIXING NOZZLE MIXING GU-814-01X GU-03052 #57 DRILL (.0430) CHAMBER PORT RM-814-01X...

  • Page 25: Pct Kits

    AP-3 REFERENCE GUIDE CHAMBER KITS (CONTINUED) 2.4mm DRILL 200481 MIXING NOZZLE (.0945) MIXING GU-814-04 GU-03054 #50 DRILL (.0700) CHAMBER PORT RM-814-04 CHAMBER #04 2.4mm DRILL 200481 MIXING NOZZLE (.0945) MIXING GU-814-DP- GU-03054 #50 DRILL (.0700) CHAMBER PORT RM-814-DP-04 CHAMBER #04...
  • Page 26 AP-3 REFERENCE GUIDE PCT KITS (CONTINUED) #65 DRILL PCT PURGE GU-03033 PORT (.0350) PCT PURGE 1.35mm DRILL 200478 AND NOZZLE (.0531) PORT GU-815-00X O-RING, VITON, - OR-00042A RM-815- PATTERN CONTROL TIP 00.X PCT PURGE GU-03033 #65 DRILL (.0350) PORT PCT PURGE &...
  • Page 27 AP-3 REFERENCE GUIDE PCT KITS (CONTINUED) #65 DRILL PCT PURGE GU-03033 (.0350) PORT PCT PURGE GU-03035 #54 DRILL (.055) PORT 2mm DRILL PCT NOZZLE 200480 GU-815-02X (.0787) PORT O-RING, VITON, OR-00042A -016 PATTERN RM-815- CONTROL TIP #65 DRILL PCT PURGE GU-03033 (.0350)

  • Page 28: Chamber/Pct Kits

    AP-3 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 O-RING, VITON, -016 GU-814-00 CHAMBER 00 W/ DRILLS KT-814-00 GU-815-00 PCT 00 RND W/ DRILLS OR-00042A O-RING, VITON, -016...

  • Page 29: Diamond Plated Chamber/Pct Kits

    AP-3 REFERENCE GUIDE DIAMOND PLATED CHAMBER/PCT KITS KIT NUMBER PART NUMBER DESCRIPTION GU-814-DP-000 CHAMBER 000 W/ DRILLS KT-814-DP-000 GU-815-000 PCT 000 RND W/ DRILLS OR-00042A O-RING, VITON, -016 GU-814-DP-00 CHAMBER 00 W/ DRILLS KT-814-DP-00 GU-815-00 PCT 00 RND W/ DRILLS...

  • Page 30: Ap-2/Ap-3 Spare Parts Kits Desc

    AP-3 REFERENCE GUIDE AP-2/AP-3 SPARE PARTS KITS DESC PART NUMBER DESCRIPTION REFERENCE PAGE 200445 AP-2/AP-3-000 SPARE PARTS KIT 200446 AP-2/AP-3-00 SPARE PARTS KIT 200447 AP-2/AP-3-00X SPARE PARTS KIT 200448 AP-2/AP-3-01 SPARE PARTS KIT 200449 AP-2/AP-3-01X SPARE PARTS KIT 200450 AP-2/AP-3-02 SPARE PARTS KIT...

  • Page 31: Ap-2/Ap-3 Spare Parts Kits

    AP-3 REFERENCE GUIDE AP-2/AP-3 SPARE PARTS KITS KIT PART NUMBER PART NUMBER DESCRIPTION 200459 O-RING, VITON, -018 200592 000 PKG DRILL BITS 200593 00 PKG DRILL BITS 200598 00X PKG DRILL BITS KT-830 01 PKG DRILL BITS 200596 01X PKG DRILL BITS...

  • Page 32: Ap-2/Ap-3 Spare Parts Kits (Diamond Plated)

    AP-3 REFERENCE GUIDE AP-2/AP-3 SPARE PARTS KITS (DIAMOND PLATED) KIT PART NUMBER PART NUMBER DESCRIPTION 200459 O-RING, VITON, -018 200592 000 PKG DRILL BITS 200593 00 PKG DRILL BITS 200598 00X PKG DRILL BITS KT-830 01 PKG DRILL BITS 200596...

  • Page 33: Pmc Recommended O-Ring Grease

    AP-3 REFERENCE GUIDE AP-2/AP-3 PACKAGE DRILL BITS KIT PART NUMBER PART DESCRIPTION NUMBER 200476 DRILL 0.94mm (.0370”) DRILL 1.25mm (.0492”) 200477 DRILL 1.35mm (.0531”) 200478 DRILL 2.00mm (.0787”) 200480 DRILL 2.40mm (.0945”) 200481 DRILL 2.90mm (.1142”) 201093 DRILL 2.87mm (.1130”) 201120 DRILL 1.04mm (.0410”)

  • Page 34: Miscellaneous Parts/Kits

    AP-3 MISCELLANEOUS PARTS/KITS MISCELLANEOUS PARTS/KITS SIDE SEAL KIT, RESIN (202546) PART NUMBER DESCRIPTION 202454 SIDE SEAL, .125, RESIN OR-00043B O-RING, AFLAS 80D, -010 SCREEN SIZES PART NUMBER DESCRIPTION GU-818-40 FILTER SCREEN, 40 MESH GU-818-60 FILTER SCREEN, 60 MESH GU-818-80 FILTER SCREEN, 80 MESH (STANDARD)

  • Page 35: O-Ring Kit

    AP-3 MISCELLANEOUS PARTS/KITS AP-3 O-RING KIT (201118) PART NUMBER DESCRIPTION 200459 O-RING, VITON, -018 O-RING, VITON, -129 OR-00026A O-RING, VITON, -016 OR-00042A OR-00043B O-RING, AFLAS, -010 OR-800 #013 BACK UP RING OR-801A O-RING, AFLAS, -013 OR-804 O-RING, BUNA, 2mm X 4mm...

  • Page 36: Recommended Spare Parts

    AP-3 MISCELLANEOUS PARTS/KITS RECOMMENDED SPARE PARTS PART NUMBER DESCRIPTION PAGE 201118 AP-3 O-RING KIT 202244 AIR CYLINDER REBUILD KIT 202546 SIDE SEAL KIT, RESIN GU-020 MANUAL VALVE ASSEMBLY GU-04007 SCREEN SCREW SEAL GU-818-40 FILTER SCREEN 40 MESH GU-818-60 FILTER SCREEN 60 MESH...

  • Page 37: Flush Tanks

    AP-3 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 38: Parts Identification

    AP-3 PARTS IDENTIFICATION PARTS IDENTIFICATION FINAL GUN ASSEMBLY NOTE: WHEN ASSEMBLING BE SURE TO APPLY GREASE TO ALL O-RINGS. THIS ENSURES GOOD PERFORMANCE AND REDUCES RISK OF GUN MALFUNCTION. MN-04030 REV 1.5: April 20, 2020...
  • Page 39 MIXING CHAMBER 201108 SCREW, HEX CAP, 10-32 CUSTOM 202410 SCREEN SCREW ASSEMBLY, R-SIDE 202409 SCREEN SCREW ASSEMBLY, A-SIDE 200635 ALUMINIUM GUN BLOCK, AP-3 200636 STEEL GUN BLOCK, AP-3 KT-850 CHECK VALVE ASSEMBLY GU-04001 GUN BLOCK ASSEMBLY 200459 O-RING, VITON, -018...

  • Page 40: Manual Valve Assembly

    AP-3 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 ITEM QTY PART NUMBER DESCRIPTION GU-022 MANUAL VALVE HOUSING GU-021 MANUAL VALVE STEM...

  • Page 41: Check Valve Assembly

    AP-3 PARTS IDENTIFICATION CHECK VALVE ASSEMBLY (KT-850) CHECK VALVE ASSEMBLY ITEM QTY PART NUMBER DESCRIPTION GU-851 CHECK VALVE SEAT GU-852 CHECK VALVE SPRING 1/4” CHECK VALVE BALL GU-853 MN-04030 REV 1.5: April 20, 2020...

  • Page 42: Coupling Block Assembly

    AP-3 PARTS IDENTIFICATION COUPLING BLOCK ASSEMBLY (GU-04001) COUPLING BLOCK ASSEMBLY 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...

  • Page 43: Screen Screw Assembly

    AP-3 PARTS IDENTIFICATION SCREEN SCREW ASSEMBLY (A-SIDE: 202409 / R-SIDE: 202410) NOTE: WHEN ASSEMBLING BE SURE TO APPLY GREASE TO ALL O-RINGS. THIS ENSURES GOOD PERFORMANCE AND REDUCES RISK OF GUN MALFUNCTION. SCREEN SCREW ASSEMBLY ITEM QTY PART NUMBER DESCRIPTION 202454 SIDE SEAL, .125, RESIN...

  • Page 44: End Cap Assembly

    AP-3 PARTS IDENTIFICATION END CAP ASSEMBLY (GU-844) NOTE: WHEN ASSEMBLING BE SURE TO APPLY GREASE TO ALL O-RINGS. THIS ENSURES GOOD PERFORMANCE AND REDUCES RISK OF GUN MALFUNCTION. SCREEN SCREW COMPONENTS ITEM QTY PART NUMBER DESCRIPTION GU-803 CYLINDER END CAP...

  • Page 45: List Of Tools

    AP-3 PARTS IDENTIFICATION LIST OF TOOLS LIST OF TOOLS ITEM PART NUMBER DESCRIPTION 200581 3/32" ALLEN WRENCH 200585 QUICK CONNECT, FEMALE 200609 5/64" ALLEN WRENCH 202340 QD,PLUG,1/4 IND X 1/4 FNPT,STL GP-00101 DOUBLE ENDED PIN VISE GU-04019 AIR HOSE TL-00002...

  • Page 46: Appendix

    AP-3 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 (page 8). 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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