PMC AP-2 Service Manual
PATENT PENDING
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
REVISION 2.0
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
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. All of the information is aimed at
improving user safety and avoiding possible breakdowns from the incorrect
use of the AP-2 Gun.
AP-2 Service Manual
Table of Contents
WARRANTY ............................................................................................................................................. 4
SAFETY AND HANDLING ...................................................................................................................... 6
IMPORTANT SAFETY INFORMATION ........................................................................................... 7
CHARACTERISTICS ................................................................................................................................ 8
TECHNICAL SPECIFICATIONS ............................................................................................................. 8
GENERAL DESCRIPTION ....................................................................................................................... 9
INSTALLATION AND START UP ........................................................................................................ 10
SHUTDOWN PROCEDURES ................................................................................................................. 12
LOSS OF AIR PRESSURE/EMERGENCY SHUT-OFF ........................................................................ 13
MAINTENANCE ..................................................................................................................................... 14
GUN BLOCK AND MIXING CHAMBER REMOVAL
SCREEN SCREW AND COMPONENT MAINTENANCE ........................................................... 16
AIR MANIFOLD MAINTENANCE .................................................................................................... 18
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) ........................................................................................ 28
AP-2 O-RING KIT (KT-827) .............................................................................................................. 28
PMC RECOMMENDED O-RING GREASE ................................................................................... 28
A & R SCREEN SCREW ASSEMBLY KITS (KT-819-_) ............................................................. 29
................................................................ 14
RECOMMENDED SPARE PARTS ................................................................................................. 29
SCREEN SIZES ................................................................................................................................. 30
OPTIONAL PARTS ............................................................................................................................ 30
CHECK VALVE ASSEMBLY (KT-850) ........................................................................................... 30
2
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) ........................................................................ 38
SCREEN SCREW ASSEMBLY ....................................................................................................... 40
LIST OF TOOLS ................................................................................................................................. 41
APPENDIX ............................................................................................................................................... 42
GREASE GUN ASSEMBLY ............................................................................................................. 42
MIXING CHAMBER FLOW RATE* ................................................................................................. 43
AP-2 Service Manual
CHAMBER/ORIFICE COMPARISON CHART .............................................................................. 43
TECHNICAL SERVICE BULLETIN ................................................................................................. 44
MANUAL REVISIONS ........................................................................................................................... 49
3
AP-2 Service Manual
WARRANTY
Polyurethane Machinery Corporation (hereinafter “PMC”) provides this
WARRANTY
covering this equipment and the original PMC manufactured accessories delivered with the
equipment (hereinafter “Product”) against defects in material or workmanship of the Product
(hereinafter “Defect” or “Defective”) for a period of one (1) year from the date of first
purchase as shown on the original PMC invoice (hereinafter “Warranty Period”).
If during the Warranty Period under normal use, the Product is suspected by Customer to
be 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 the following:
Original Invoice:
Product serial number. The Warranty does not cover any Product if the Original Invoice
appears to have been modified or altered, or when the serial number on the Product
appears to have been altered or defaced.
LIMITED
(hereinafter “Warranty”) to the original purchaser (hereinafter “Customer”)
The original invoice must be kept as proof of the date of first sale and the
Product Maintenance:
your maintenance schedule and owner’s manual for details. The Warranty does not cover an
improperly maintained Product.
Non-PMC Components and Accessories:
accessories that are used in the operation of the Product are not covered by this Warranty.
Such components and accessories shall be subject to the warranty offered to the
Customer, if any, by the original manufacturer of such component or accessory.
Other Warranty Exclusions:
has been damaged or fails to operate properly due to misuse, negligence, abuse,
carelessness, neglect, or accident. By way of example only, this includes:
Normal wear and tear.
Improper or unauthorized installation, repair, alteration, adjustment or modification of
the Product.
Use of heating devices, pumping equipment, dispensers, or other parts or accessories
with the Product that have not been approved or manufactured by PMC.
Failure to follow the operating instructions and recommendations provided by
PMC may cause loss or damage to personnel, equipment, or work area.
It is the Customer’s responsibility to maintain the Product properly. See
Non-PMC manufactured components and
The Warranty does not cover any Product that PMC determines
Fire, flood, “acts of God,” or other contingencies beyond the control of PMC.
4
AP-2 Service Manual
WARRANTY (cont’d)
THE WARRANTY DESCRIBED HEREIN IS THE EXCLUSIVE REMEDY FOR THE
CUSTOMER AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED,
STATUTORY OR OTHERWISE, AND THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ALL
OTHER WARRANTIES ARE HEREBY DISCLAIMED. TO THE FULLEST EXTENT
PERMITTED BY LAW, PMC SHALL NOT BE RESPONSIBLE, WHETHER BASED IN
CONTRACT, TORT (INCLUDING, WITHOUT LIMITATION, NEGLIGENCE), WARRANTY
OR ANY OTHER LEGAL OR EQUITABLE GROUNDS, FOR ANY CONSEQUENTIAL,
INDIRECT, INCIDENTAL, LOST PROFITS, SPECIAL, PUNITIVE OR EXEMPLARY
DAMAGES, WHETHER TO PERSON OR PROPERTY, ARISING FROM OR
RELATING TO THE PRODUCT, EVEN IF PMC HAS BEEN ADVISED OF THE
POSSIBILITY OF SUCH LOSSES OR DAMAGES.
Non-Warranty Service by PMC: If PMC determines that the suspected Defect of the Product is
not covered by this Warranty, disposition of the Product will be made pursuant to the terms
and conditions
of PMC’s written estimate on a time and materials bas
is.
Continuing Warranty for Products Repaired or Replaced under Warranty: Following the
repair or replacement of a Product covered by this Warranty, such Product will continue to be
subject to the original Warranty for the remainder of original Warranty Period or for three (3)
months from the repair or replacement date, whichever is longer.
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; nor does PMC encourage
the infringement of same.
Exclusive Warranty: This writing is the final, complete, and exclusive expression of the
Warranty covering the Product. Any statements made by PMC, its employees or agents that
differ from the
Customer’s acceptance of
solely to the terms and conditions hereof, and any additional or different terms and conditions
proposed or expressed by Customer or anyone, whether in writing or otherwise, are null and
void unless specifically agreed to in writing by an Officer of PMC.
terms of this Warranty shall have no effect. It is expressly understood that
this Warranty, by performance or otherwise, is upon and subject
5
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.
AP-2 Service Manual
SAFETY AND HANDLING
This chapter contains important information on the safety, handling and use of your AP-2 series
Gun.
WARNING!
serious injuries if the instructions are not followed.
CAUTION!
AP-2 Gun or how to avoid a situation that could cause injuries.
NOTE:
Careful study of this Manual will enable the operator to know the characteristics of the Gun
and the operating procedures. 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.
Keep this Service Manual for future reference to useful information. If you lose this Manual,
ask for a new copy from your PMC Service Center, go to the company website
(www.polymac-usa.com), or directly contact Polyurethane Machinery Company.
Is relevant information of a procedure being carried out.
Presents information to alert of a situation that might cause
Presents information that indicates how to avoid damage to the
6
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.
Use suitable protection when operating, maintaining or being present in the
area where the equipment is functioning. This includes, but is not limited to,
the use of protective goggles, gloves, shoes and safety clothing and
breathing equipment.
The equipment includes components that reach high temperatures and
can cause burns. Hot parts of the equipment must not be handled or
touched until they have cooled completely.
AP-2 Service Manual
IMPORTANT SAFETY INFORMATION
The AP-2 Gun has been designed and built for the application of polyurea chemical systems,
polyurethane foam chemical systems and some two-component epoxy systems.
WARNING! The design and configuration of the AP-2 Gun does not allow its
use in potentially explosive atmospheres or exceeding the pressure and
temperature limits described in the 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. Use breathing equipment when working with the
Gun in enclosed spaces or in areas with insufficient ventilation. The introduction and follow-up
of safety measures must not be limited to those described in this Manual. Before beginning to
work with the Gun, a comprehensive analysis must be made of the risks derived from the
products to be dispensed, the type of application and the working environment.
The equipment sprays high pressure fluids that can lead to fluid being
injected under the skin or eyes. Severe injury could be incurred. Proper
personal protective equipment should be used in conjunction with
training and situational awareness of all personnel on the job
7
.
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)
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)
Closing Force @ 110 psi (8 Bar): __________________________________________ 200 lb (91 kg)
8
AP-2 GENERAL DESCRIPTION
ITEM
QTY
PART NUMBER
DESCRIPTION
1b 1 GU-801
Air Cylinder
1c 1 GU-804
Gun Lock and End Cap
2 1 GU-816
Gun Block
2b 1 GU-837
Grease Fitting
3 1 GU-802
Piston
3d 2 GU-020
Manual Valves
4
2
GU-851
Check Valve Seat
2
GU-852
Check Valve Spring
2
GU-853
¼” Check Valve Ball
5 1 GU-04001
Coupling Block Assembly
6b 1 GU-812
Lock Collar
9 1 GU-827-1
Gun Handle
10 1 GU-828
Trigger
12 1 GU-843
Air Manifold
13 1 GU-842
Head Latch
20
1
GU-819-A
“A” Screen Screw
1
GU-819-R
“R” Screen Screw
1
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.
9
NOTE:
The material delivery hoses
are color coded Red and Blue,
allowing the user to recognize them.
The Red corresponds to the
Isocyanate (A) and the Blue to the
Polyol (R). To avoid connection
errors, the Coupling Connections of
the Isocyanate (A) and Polyol (R)
hoses are also different sizes, which
makes it difficult to swap
connections.
AP-2 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.
2. Ensure the Coupling Block Manual Valves (3d) are CLOSED
by turning them to the full clockwise position.
CAUTION! Excessive force closing or opening the
Manual Valves may result in damage to the Manual
Valves and/or Coupling Block.
3. Set the Gun Lock (1c) to the LOCKED position.
4. Ensure Check Valve Assemblies (4, Pg. 9) are in place.
5. Connect the Coupling Block (5) to the Gun Block (2) using the
nut driver provided (TL-04001, Pg. 40). Tighten Coupling Block
until there is a hand tight seal.
6. Connect air supply to the Gun (90 to 125 psi, 6.2 to 8.6 Bar).
7. Set the Gun Lock (1c) to the OPEN position.
8. Pull the Trigger (10) several times to check for correct movement of the Mixing
Chamber (6, Pg. 14) and PCT (pattern control tip) (7).
10
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).
10. OPEN each Manual Valve (3d, Pg. 10) by turning three full turns counter clockwise.
11. Perform a test spray.
AP-2 Service Manual
11
AP-2 Service Manual
SHUTDOWN PROCEDURES
1.
CLOSE the Manual Valves (3d) by turning them to the full clockwise position.
CAUTION! Excessive force closing or opening Manual Valves may result
in damage to the Manual Valves and/or Coupling Block.
2. Using the supplied Grease Gun (2, TL-00002, Pg. 40), lubricate the Mixing Chamber
through the Grease Fitting (2b) until a fine mist of grease is sprayed from the gun (see
page 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.
3. Disconnect the air supply.
NOTE:
minimize maintenance time and eliminate the need to remove the Mixing
Chamber each day to clean it. Use of grease with high moisture content will
not achieve the desired results.
The injection of grease supplied with the Gun at the end of the day will
12
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.
3. CLOSE each Manual Valve (3d).
CAUTION! Excessive force closing or opening Manual Valves may result in
damage to the Manual Valves and/or Coupling Block. Emergency shut off if
AP-2 Service Manual
trigger sticks – disconnect air line.
13
MAINTENANCE
To obtain maximum performance from your AP-2 Gun, it is necessary to periodically perform
certain maintenance operations
AP-2 Service Manual
WARNING! Before proceeding with any maintenance work on the AP-2 Gun,
OFF/DISCONNECT
position and the Manual Valves are
material pressure. It is recommended to remove the Gun from the Coupling
Block.
GUN BLOCK AND MIXING CHAMBER REMOVAL
the air supply, ensure the Gun Lock is in the
CLOSED
. Trigger the Gun to remove internal
LOCKED
SHUT
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.
14
2. Trigger Gun over Waste Container to release internal material pressure.
3. Using the wrench provided (TL-09, Pg. 40) or
a standard 5/8” wrench, remove the Pattern
Control Tip (7, Pg. 14) from the mixing
chamber.
4. Using a ½” wrench, loosen or remove both
Screen Screws (20, Pg. 14) to facilitate easy
removal of the mixing chamber.
5. Using the nut driver provided (TL-04001, Pg.
14), remove the Coupling Block (5, Pg. 14)
from the Gun Block (2, Pg. 14).
6. Disengage the Head Latch (13, Pg. 14) from
the Gun Block (5, Pg. 14).
7. Loosen the Locking Collar (6b) from the Gun Block (2, Pg.
14) and remove the Gun Block (2, Pg. 14) from the Air
Cylinder (1b, Pg. 14).
8. Remove the Chamber from the Piston Rod (3a, Pg. 14).
AP-2 Service Manual
9. Flush Gun Block (2, Pg. 14) to remove any residue.
Use recommended Flush Tank (TL-12, Pg. 31).
10. Clean or replace the Mixing Chamber (6, Pg. 14) as
required.
11. Reassemble the Mixing Chamber (6, Pg. 14) in reverse
order.
NOTE!
Mixing Chamber (6, Pg. 14) and Side Seals (27, Pg.
16) upon assembly is recommended.
CAUTION!
brush for cleaning. Do not use metal or abrasive
tools that can scratch or damage the contact
surfaces.
A small amount of PMC grease applied to the
Use wooden or plastic tools or a brass
15
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