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
SCREEN SCREW COMPONENTS
ITEM
QTY
PART NUMBER
DESCRIPTION
22
1
GU-819-A
“A” SCREEN SCREW
1
GU-819-R
“R” SCREEN SCREW
23 1 GU-04007
SCREEN SCREW SEAL
24
1
GU-818-40
FILTER SCREEN; 40 MESH. SEE PAGE 30
1
GU-818-60
FILTER SCREEN; 60 MESH. SEE PAGE 30
1
GU-818-80
FILTER SCREEN; 80 MESH. SEE PAGE 30 (STANDARD)
25 1 OR-801
O-RING #013 80D AFLAS
26 1 OR-800
#013 BACK UP RING
27 1 OR-00043B
O-RING #010 80D AFLAS
28 1 SP-04005
SPRING; SIDE SEAL
29 1 GU-817-90
SIDE SEAL
AP-2 Service Manual
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. The Gun Block is also marked with (A) and (R) designation.
1. CLOSE the Manual Valves (3d, Pg. 9) by turning them to the full clockwise position.
16
CAUTION! Excessive force opening or closing Manual Valves may result in
AP-2 Service Manual
damage to the Manual Valves and/or Coupling Block.
2.
Trigger Gun over Waste Container to release internal material pressure
3.
SHUT OFF AIR SUPPLY TO GUN.
4.
Set the Gun Lock (1c, Pg. 9) to the LOCKED position.
5.
Use a ½” wrench to remove the Screen Screw (20).
6.
To clean or replace the Screen (22), remove O-Ring (23) and Back Up Ring (24).
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
9.
The Gun is now ready for service
NOTE:
appropriate Kit.
When replacing O-rings, replace ALL O-rings included in the
.
.
.
17
AP-2 Service Manual
AIR MANIFOLD MAINTENANCE
1. CLOSE the Manual Valves (3d, Pg. 9) 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 (1c, Pg. 9) to the LOCKED position.
3. Disconnect the air supply from the Gun.
4. Use a suitable size wrench and remove the air
fitting from the rear of the manifold.
5. Remove the trigger from the assembly to access
the front of the air manifold.
6. Use supplied wrench (TL-09, Pg. 40) and remove
the spool valve retainer (6e).
7. Remove the Spring (5e), Spool Valve Liner (4e),
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.
18
AP-2 Service Manual
NOTE! When replacing O-rings, replace
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.
ALL
O-rings included in KT-826
19
AIR CYLINDER MAINTENANCE
AP-2 Service Manual
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.
3. Disconnect air supply to gun.
4. Set the Gun Lock (1c) to the LOCKED position.
5. Loosen the Screen Screws (20) using a ½” wrench.
6. Disconnect Coupling Block (5) from Gun Block (2) using
the Nut Driver provided (TL-04001, Pg. 40).
7. Disengage the Head Latch (13) from the Gun Block (2).
8. Loosen the Locking Collar (6b) from the Gun Block (2) and
remove the complete Gun Block assembly from the Air
Cylinder (1a).
20
9. Using the Wrench (TL-09, Pg. 40) provided, remove the
End Cap (2a, Pg. 20).
10. Push on the exposed Piston (3a, Pg. 20) by the
Locking Collar (6b, Pg. 20) to remove the Piston (3a,
Pg. 20) from the rear of the Air Cylinder (1a, Pg. 20).
11. Inspect the O-rings (4a, 5a, Pg. 20) on the Piston and
shaft and replace as required.
12. Inspect the O-ring on the End Cap (2a. Pg. 20) and
replace as required.
AP-2 Service Manual
NOTE!
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!
brush for cleaning.
Do not use metal or abrasive tools that can
scratch the contact surfaces.
When replacing O-rings, replace ALL O-
Use wooden or plastic tools or a brass
21
Compressed
Shop Air
90 – 120 PSI
(6.2 – 8.3 Bar)
GUN OPERATION
AP-2 Service Manual
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.
In the closed position, the orifices in the Chamber are not concealed within the
Side Seal ports and are opened to the air/grease chamber in the Gun Block.
Purge air passes through the spool valve and past a check valve and into the air
cylinder and gun block.
Purge air and residual grease enter the mixing chamber and pass through the
chamber and PCT expelling mixed material out of the chamber area.
Purge air is also expelled from the PCT in a circular trajectory to keep the tip clean.
22
Compressed
Shop Air
90 – 120 PSI
(6.2 – 8.3 Bar)
GUN OPERATION
AP-2 Service Manual
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.
High pressure chemical enters the chamber from the opposing orifices. The high
pressure chemicals mix by impingement, and the mixture then travels down the
chamber and out the PTC.
NOTE!
PCT will be retracted to the point of being flush with the front surface of the Gun
Block.
While the trigger is pulled, the purge air is shutoff during spraying and the
23
PROBLEM
POSSIBLE CAUSE
SOLUTION
PCT not flush with
Gun Block when Gun
is triggered
Insufficient Gun air pressure (minimum 90 psi, 6.2
Bar)
Ensure 90 psi (6.2 Bar) of
air pressure at Gun
Trigger Valve requires service
Rebuild, see page 18
Air Passages plugged
Clean, See page 18
Material does not
spray when Gun is
triggered
Lock is in “Locked” position
Unlock gun
Air supply is not on
Turn on air supply
Manual Valve (3d) CLOSED
OPEN, see page 10, #9
Mixing Chamber (6) Inlet Orifices plugged
Clean, see page 14
Side Seal (27) Orifices plugged
Clean, see page 16
Check Valve (4) plugged
Replace, see page 37
Mixing Chamber
moves slowly
Trigger Valve requires service
Rebuild, see page 18
Insufficient Gun air pressure (minimum 90 psi, 6.2
Bar)
Ensure 90 psi (6.2 Bar) of
air pressure
Piston Assembly requires service
Rebuild, see page 20
Air Passages plugged
Clean, see page 22
Mixing Chamber
moves slowly, then
normal speed
Reacted material around Side Seals (27)
Inspect Side Seals (27),
Mixing Chamber (6) for
reacted materials, clean,
see pages 14,16
Pattern deformation
Incorrect chemical temperature
Adjust, see Proportioner
Operating Manual
Mixing Chamber Nozzle dirty
Inspect and clean
PCT dirty
Inspect and clean
Material spray
pressure imbalance
Mixing Chamber (6) Inlet Orifices plugged
Clean
Side Seal (27) Orifices plugged
Clean, see page 16
Dirty screens
Replace
Material temperatures not as recommended by
material supplier
Adjust, see Proportioner
Operating Manual
Iso and/or Resin in
Gun Air Passages
Side Seal (27) damaged
Replace, see page 16
Mixing Chamber (6) damaged
Replace, see page 14
Side Seal/ Screen Screw O-rings (Pg 16) damaged
Replace, see page 16
Material mist from
Mixing Chamber (3)
or PCT (4)
Side Seal (27) damaged
Replace, see page 16
Mixing Chamber (6) damaged
Replace, see page 14
Side Seal/Screen Screw O-rings (Pg 16) damaged
Replace, see page 16
Excessive overspray
Material temperatures and/or spray pressures not as
recommended by material supplier
Adjust, see Proportioner
Operating Manual
Buildup of material
on PCT
Plugged air passages in PCT (7) and Gun Block (1)
Clean, see page 22
Steady air leakage
from Handle
Air Cylinder (1a) O-rings damaged
Replace, see page 20
Trigger Valve O-rings damaged (8e)
Replace, see page 18
TROUBLE SHOOTING GUIDE
AP-2 Service Manual
24
AP-2 CHAMBER KITS (GU-814-_ _ _)
KIT
NUMBER
PART
NUMBER
QTY
DESCRIPTION
(INCH)
FOR USE WITH
ILLUSTRATION
GU-814-000
GU-03032
1
#61 DRILL
(.0390)
MIXING NOZZEL
GU-03031
1
#70 DRILL
(.0280)
MIXING CHAMBER
PORT
RM-814-000
1
CHAMBER #000 - -
GU-814-00
GU-03023
1
#56 DRILL
(.0465)
MIXING NOZZEL
GU-03027
1
#69 DRILL
(.0292)
MIXING CHAMBER
PORT
RM-814-00
1
CHAMBER #00 - -
GU-814-01
GU-03035
1
#54 DRILL
(.055)
MIXING NOZZEL
GU-03021
1
#59 DRILL
(.0410)
MIXING CHAMBER
PORT
RM-814-01
1
CHAMBER #01 - -
GU-814-01X
GU-03053
1
#52 DRILL
(.0635)
MIXING NOZZEL
GU-03052
1
#57 DRILL
(.0430)
MIXING CHAMBER
PORT
RM-814-01X
1
CHAMBER #01X
-
-
GU-814-02
GU-03024
1
#51 DRILL
(.0676)
MIXING NOZZEL
GU-03023
1
#56 DRILL
(.0465)
MIXING CHAMBER
PORT
RM-814-02
1
CHAMBER #02 - -
GU-814-02X
GU-03051
1
#48 DRILL
(.0760)
MIXING NOZZEL
GU-03050
1
#55 DRILL
(.0520)
MIXING CHAMBER
PORT
RM-814-02X
1
CHAMBER #02X
-
-
GU-814-03
GU-03028
1
#44 DRILL
(.0860)
MIXING NOZZEL
GU-03035
1
#54 DRILL
(.055)
MIXING CHAMBER
PORT
RM-814-03
1
CHAMBER #03 - -
GU-814-04
GU-03029
1
#43 DRILL
(.0890)
MIXING NOZZEL
GU-03054
1
#50 DRILL
(.0700)
MIXING CHAMBER
PORT
RM-814-04
1
CHAMBER #04 - -
REFERENCE GUIDE
AP-2 Service Manual
25
AP-2 PCT KITS (GU-815-_ _ _)
KIT
NUMBER
PART
NUMBER
QTY
DESCRIPTION
FOR USE WITH
ILLUSTRATION
GU-815-000
GU-03033
1
#65 DRILL (.0350)
PCT PURGE PORT
GU-03035
1
#54 DRILL (.055)
PCT PURGE PORT
GU-03032
1
#61 DRILL (.0390)
PCT NOZZEL
PORT
OR-00042A
1
PCT FLAT TIP
O-RING .016
-
RM-815-000
1
PATTERN
CONTROL TIP 000
-
GU-815-00
GU-03033
1
#65 DRILL (.0350)
PCT PURGE PORT
GU-03035
1
#54 DRILL (.055)
PCT PURGE PORT
GU-03023
1
#56 DRILL (.0465)
PCT NOZZEL
PORT
OR-00042A
1
PCT FLAT TIP
O-RING .016
-
RM-815-00
1
PATTERN
CONTROL TIP 00
-
GU-815-01
GU-03033
1
#65 DRILL (.0350)
PCT PURGE PORT
GU-03035
2
#54 DRILL (.055)
PCT PURGE &
NOZZEL PORT
OR-00042A
1
PCT FLAT TIP
O-RING .016
-
RM-815-01
1
PATTERN
CONTROL TIP 01
-
GU-815-01X
GU-03033
1
#65 DRILL (.0350)
PCT PURGE PORT
GU-03035
1
#54 DRILL (.055)
PCT PURGE PORT
GU-03051
#52 DRILL (.0635)
PCT NOZZEL
PORT
OR-00042A
1
PCT FLAT TIP
O-RING .016
-
RM-815-01X
1
PATTERN
CONTROL TIP 01X
-
GU-815-02
GU-03033
1
#65 DRILL (.0350)
PCT PURGE PORT
GU-03035
1
#54 DRILL (.055)
PCT PURGE PORT
GU-03024
1
#51 DRILL (.0676)
PCT NOZZEL
PORT
OR-00042A
1
PCT FLAT TIP
O-RING .016
-
RM-815-02
1
PATTERN
CONTROL TIP 02
-
GU-815-02X
GU-03033
1
#65 DRILL (.0350)
PCT PURGE PORT
GU-03035
1
#54 DRILL (.055)
PCT PURGE PORT
GU-03051
1
#46 DRILL (.0810)
PCT NOZZEL
PORT
OR-00042A
1
PCT FLAT TIP
O-RING .016
-
RM-815-02X
1
PATTERN
CONTROL TIP 02X
-
AP-2 Service Manual
26
CHAMBER/PCT KIT (KT-814-_ _ _)
KIT NUMBER
PART NUMBER
QTY
DESCRIPTION
KT-814-000
GU-814-000
1
CHAMBER 000 W/ DRILLS
GU-815-000
1
PCT 000 RND W/ DRILLS
KT-814-00
GU-814-00
1
CHAMBER 00 W/ DRILLS
GU-815-00
1
PCT 00 RND W/ DRILLS
KT-814-01
GU-814-01
1
CHAMBER 01 W/ DRILLS
GU-815-01
1
PCT 01 RND W/ DRILLS
KT-814-01X
GU-814-01X
1
CHAMBER 01X W/ DRILLS
GU-815-01X
1
PCT 01X RND W/ DRILLS
KT-814-02
GU-814-02
1
CHAMBER 02 W/ DRILLS
GU-815-02
1
PCT 02 RND W/ DRILLS
KT-814-02X
GU-814-02X
1
CHAMBER 02X W/ DRILLS
GU-815-02X
1
PCT 02X RND W/ DRILLS
KT-814-03
GU-814-03
1
CHAMBER 03 W/ DRILLS
GU-815-03
1
PCT 03 RND W/ DRILLS
KT-814-04
GU-814-04
1
CHAMBER 04 W/ DRILLS
GU-815-04
1
PCT 04 RND W/ DRILLS
AP-2 PCT KITS (GU-815-_ _ _) CONTINUED
GU-815-03
GU-03033
1
#65 DRILL (.0350)
PCT PURGE PORT
GU-03035
1
#54 DRILL (.055)
PCT PURGE PORT
GU-030-28
1
#44 DRILL (.0860)
PCT NOZZEL
PORT
OR-00042A
1
PCT FLAT TIP
O-RING .016
-
RM-815-03
1
PATTERN
CONTROL TIP 03
-
GU-815-04
GU-03033
1
#65 DRILL (.0350)
PCT PURGE PORT
GU-03035
1
#54 DRILL (.055)
PCT PURGE PORT
GU-03029
1
#43 DRILL (.0935)
PCT NOZZEL
PORT
OR-00042A
1
PCT FLAT TIP
O-RING .016
-
RM-815-04
1
PATTERN
CONTROL TIP 04
-
AP-2 Service Manual
27
AIR CYLINDER REBUILD KIT (KT-801)
PART NUMBER
QTY
DESCRIPTION
OR-00026A
2
O-RING #129 VITON
OR-00043A
3
O-RING #010 80D AFLAS
OR-00002A
1
O-RING #008 VITON
OR-00037B
2
QUAD RING #011 VITON
OR-00042A
1
#016 O-RING
GU-829
1
A/P CHECK VALVE
GU-830
1
AIR CYLINDER BUSHING
AP-2 O-RING KIT (KT-827)
PART NUMBER
QTY
DESCRIPTION
OR-800
2
#013 BACK UP RING
OR-801A
2
O-RING #013 80D AFLAS
OR-803
7
O-RING #012 VITON
OR-804
1
O-RING 2MMX4MM BUNA
OR-805
4
#108 VITON O-RING
OR-00002A
3
O-RING #008 VITON
OR-00026A
2
O-RING #129 VITON
OR-00037B
2
QUAD RING #011 VITON
OR-00042A
1
#016 O-RING
OR-00043B
4
O-RING #010 80D AFLAS
PMC RECOMMENDED O-RING GREASE
PART NUMBER
QTY
DESCRIPTION
GP-LUBEGREASE
1
LURIPLATE GREASE
TL-04003
1
GREASE TUBE FOR USE W/ GREASE GUN
AIR MANIFOLD TRIGGER REBUILD KIT (KT-826)
PART NUMBER
QTY
DESCRIPTION
GU-825-1
1
SPOOL VALVE LINER
GU-825-2
1
LINER BUSHING
GU-824
1
SPOOL VALVE SPRING
OR-803
7
O-RING #012 VITON
OR-00002A
3
O-RING #008 VITON
OR-804
1
O-RING 2MMX4MM BUNA
OR-00037B
2
QUAD RING #011 VITON
AP-2 Service Manual
28
A & R SCREEN SCREW ASSEMBLY KITS (KT-819-_)
KIT NUMBER
PART NUMBER
QTY
DESCRIPTION
KT-819-R
GU-819-R
1
R SCREEN SCREW
GU-04007
1
SCREEN SCREW SEAL
OR-800
1
#013 BACK UP RING
OR-801
1
O-RING #013 80D AFLAS
KT-819-A
GU-819-A
1
A SCREEN SCREW
GU-04008
1
SCREEN SCREW SEAL
OR-800
1
#013 BACK UP RING
OR-801
1
O-RING #013 80D AFLAS
RECOMMENDED SPARE PARTS
PART NUMBER
QTY
DESCRIPTION
PAGE
KT-814-000
1
CHAMBER 000 W/ DRILLS
25
KT-814-00
1
CHAMBER 00 W/ DRILLS
25
KT-814-01
1
CHAMBER 01 W/ DRILLS
25
KT-814-01X
1
CHAMBER 01X W/ DRILLS
25
KT-814-02
1
CHAMBER 02 W/ DRILLS
25
KT-814-02X
1
CHAMBER 02X W/ DRILLS
25
KT-814-03
1
CHAMBER 03 W/ DRILLS
25
KT-814-04
1
CHAMBER 04 W/ DRILLS
25
KT-826
1
AIR MANIFOLD REBUILD KIT
28
KT-801
1
AIR CYLINDER REBUILD KIT
28
GU-817-90
2
SIDE SEAL
40
GU-818-40
4
FILTER SCREEN 40 MESH
40
GU-818-60
4
FILTER SCREEN 60 MESH
40
GU-818-80
4
FILTER SCREEN 80 MESH (STANDARD)
40
GU-04007
2
SCREEN SCREW SEAL
40
OR-00043B
8
O-RING #010 80D AFLAS
40
OR-801A
8
O-RING #013 80D AFLAS
40
SP-04005
2
SPRING; SIDE SEAL
40
GU-020
1
MANUAL VALVE ASSEMBLY
32
KT-850
2
CHECK VALVE ASSEMBLY
30
OR-00042A
2
#016 O-RING
38
GU-829
1
A/P CHECK VALVE
36
TN-831
2
4-40 X ½ SHCS
38
TL-04003
1
GREASE TUBE
41
OR-800
8
#013 BACK UP RING
40
KT-827
1
AP-2 O-RING KIT
28
AP-2 Service Manual
29
SCREEN SIZES
PART NUMBER
QTY
DESCRIPTION
GU-818-80
1
FILTER SCREEN, 80 MESH (STANDARD)
GU-818-60
1
FILTER SCREEN, 60 MESH
GU-818-40
1
FILTER SCREEN, 40 MESH
OPTIONAL PARTS
PART NUMBER
QTY
DESCRIPTION
GU-815-50-509
1
BLASTER TIP .059
GU-815-51
1
POUR TIP
GU-815-52
1
PCT FLAT TIP RETAINER ASSEMBLY
* GU-815-52-1
1
PCT FLAT TIP BODY
* GU-815-52-2
1
PCT FLAT TIP GASKET
* GU-815-52-3
1
PCT FLAT TIP RETAINER
* OR-00042A
1
#016 O-RING
GU-817-90D
1
SIDE SEAL; DELRIN
CHECK VALVE ASSEMBLY (KT-850)
PART NUMBER
QTY
DESCRIPTION
GU-851
4
CHECK VALVE SEAT
GU-852
2
CHECK VALVE SPRING
GU-853
2
¼” CHECK VALVE BALL
AP-2 Service Manual
NOTE: SPRAY TIP NOT INCLUDED WITH PART NUMBER GU-815-52
*DENOTES PARTS IN THE GU-815-52
30
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
AP-2 Service Manual
Optional MA-41 Kit shown on AP-2 Gun
Flush Tank
(TL-12)
31
GU-020 MANUAL VALVE ASSEMBLY
ITEM
QTY
PART NUMBER
DESCRIPTION
1 1 GU-022
Manual Valve Housing
2 1 GU-021
Manual Valve Stem
3 1 GU-023
Manual Valve Seat
4 1 OR-016
007 PTFE Backup Ring
5 1 OR-015
#007 Aflas O-Ring
AP-2 Service Manual
PARTS IDENTIFICATION
MANUAL VALVE ASSEMBLY (GU-020)
32
GU-04001 COUPLING BLOCK ASSEMBLY
ITEM
QTY
PART NUMBER
DESCRIPTION
1 1 GU-04001-01
COUPLING BLOCK BODY
2 2 TN-04192
1/8 NPT PIPE PLUG
3 2 GU-020
MANUAL VALVE ASSY
4 1 RA-00005A
1/8 NPT X #5 JIC SWIVEL
5 1 RA-00006A
1/8 NPT X #6 JIC SWIVEL
AP-2 Service Manual
COUPLING BLOCK ASSEMBLY (GU-04001)
33
GU-843 AIR MANIFOLD ASSEMBLY
ITEM
QTY
PART NUMBER
DESCRIPTION
1 1 GU-826
AIR MANIFOLD
2 1 GU-825-2
LINER BUSHING
3 1 GU-823
SPOOL VALVE
4 1 GU-825-1
SPOOL VALVE LINER
5 1 GU-824
SPOOL VALVE SPRING
6 1 GU-833
HOSE ADAPTER
7 3 OR-00002A
O-RING #008 VITON
8 7 OR-803
O-RING #012 VITON
AP-2 Service Manual
AIR MANIFOLD ASSEMBLY (GU-843)
34
GU-844 END CAP ASSEMBLY
ITEM
QTY
PART NUMBER
DESCRIPTION
1 1 GU-804
LOCK KNOB
2 1 GU-806
SPRING
3 1 GU-803
CYLINDER END CAP
4 1 GU-807
TWO POSITION STOP
5 1 GU-831
RETAINING SCREW
6 1 OR-00043B
O-RING #010 80D AFLAS
7 1 OR-00026A
O-RING #129 VITON
END CAP ASSEMBLY (GU-844)
AP-2 Service Manual
35
GU-801A AIR CYLINDER ASSEMBLY
ITEM
QTY
PART NUMBER
DESCRIPTION
1 1 GU-801
AIR CYLINDER
2 1 TN-04186
GREASE FITTING
3 1 GU-836
SIDE MOUNT EXT RETAINING RING
4 2 GU-837
RETAINER RING SPLIT-SET
5 1 GU-830
AIR CYLINDER BUSHING
6 1 GU-812
LOCK COLLAR
7 1 OR-00042A
#016 O-RING
8 1 GU-829
A/P CHECK VALVE
AP-2 Service Manual
AIR CYLINDER ASSEMBLY (GU-801A)
36
GU-845 COMPLETE AIR CYLINDER ASSEMBLY
ITEM
QTY
PART NUMBER
DESCRIPTION
1 1 GU-801A
AP-2 AIR CYLINDER ASSEMBLY
2 1 GU-844
AP-2 END CAP ASSEMBLY
3 1 GU-802
PISTON
4 1 OR-00043B
O-RING #10 80D AFLAS
5 1 OR-00026A
O-RING #129 VITON
AP-2 Service Manual
COMPLETE AIR CYLINDER ASSEMBLY (GU-845)
37
AIR PURGE SPRAY AND POUR GUN (GU-850)
AP-2 Service Manual
38
GU-850 AIR PURGE SPRAY AND POUR GUN
ITEM
QTY
PART NUMBER
DESCRIPTION
1 1 GU-845
COMPLETE AIR CYLINDER ASSEMBLY
2 1 GU-816
GUN BLOCK
3 2 ASSEMBLY
A/R SCREEN SCREW ASSEMBLY
5 1 GU-04001
COUPLING BLOCK ASSEMBLY
6
1
GU-814-000
CHAMBER 000 W/ DRILLS
1
GU-814-00
CHAMBER 00 W/ DRILLS
1
GU-814-01
CHAMBER 01 W/ DRILLS
1
GU-814-01X
CHAMBER 01X W/ DRILLS
1
GU-814-02
CHAMBER 02 W/ DRILLS
1
GU-814-02X
CHAMBER 02X W/ DRILLS
1
GU-814-03
CHAMBER 03 W/ DRILLS
1
GU-814-04
CHAMBER 04 W/ DRILLS
7
1
GU-815-000
PCT 000 RND W/ DRILLS
1
GU-815-00
PCT 00 RND W/ DRILLS
1
GU-815-01
PCT 01 RND W/ DRILLS
1
GU-815-01X
PCT 01X RND W/ DRILLS
1
GU-815-02
PCT 02 RND W/ DRILLS
1
GU-815-02X
PCT 02X RND W/ DRILLS
1
GU-815-03
PCT 03 RND W/ DRILLS
1
GU-815-04
PCT 04 RND W/ DRILLS
8 1 OR-00042A
#016 O-RING
9 1 GU-827-1
GUN HANDLE #1
10 1 GU-828
TRIGGER
11 1 TN-04190
SHOULDER SCREW
12 1 GU-843
AIR MANIFOLD ASSEMBLY
13 1 GU-842
HEAD LATCH
14 4 OR-805
#108 VITON O-RING
15 1 TN-04191
4-40 ELASTIC STOP NUT
16 2 TN-830
4-40 X 5/16 SHCP
17 1 TN-831
4-40 X 1/2 SHCP
18 2 GU-808
5/32 X 5/16 6-32 SHOULDER BOLT
19 1 TN-04197
COUPLING BLOCK MOUNTING SCREW
20 1 OR-804
O-RING 2MMX4MM BUNA
21 2 OR-00037B
QUAD RING #011 VITON
22 2 GU-852
CHECK VALVE SPRING
23 2 GU-853
¼” CHECK VALVE BALL
24 2 GU-851
CHECK VALVE SEAT
AP-2 Service Manual
39
SCREEN SCREW COMPONENTS
ITEM
QTY
PART NUMBER
DESCRIPTION
22
1
GU-819-R *
“R” SCREEN SCREW
1
GU-819-A *
“A” SCREEN SCREW
23 1 GU-04007 *
SCREEN SCREW SEAL
24
1
GU-818-40
FILTER SCREEN; 40 MESH
1
GU-818-60
FILTER SCREEN; 60 MESH
1
GU-818-80
FILTER SCREEN 80 MESH (STANDARD)
25 1 OR-801 *
O-RING #013 80D AFLAS
26 1 OR-800 *
#013 BACK UP RING
27 1 OR-00043A
O-RING #010 80D AFLAS
28 1 SP-04005
SPRING; SIDE SEAL
29
1
GU-817-90
SIDE SEAL
1
GU-817-180
SIDE SEAL (FOR CHAMBERS 03 & 04)
SCREEN SCREW ASSEMBLY
AP-2 Service Manual
*Included in KT-819-R and KT-819-A (Pg. 29)
40
LIST OF TOOLS
ITEM
QTY
PART NUMBER
DESCRIPTION
1 1 GU-04019
AIR HOSE
2 1 TL-00002
GREASE GUN
3 1 GU-04021
QUICK DISCONNECT; FEMALE
4 1 GU-04022
QUICK DISCONNECT; MALE
5 1 TL-04003
GREASE TUBE
6 1 TL-09
OPEN END WRENCH
7 1 TL-04001
5/16 SPINTITE; NUT DRIVER
8 1 GP-00101
DOUBLE ENDED PIN VISE
9 1 TL-10
CHECK VALVE REMOVAL TOOL
LIST OF TOOLS
AP-2 Service Manual
41
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).
3. Pull the handle (2e) on the
bottom of the grease gun (2b) so
that it resembles the picture.
4. Remove the tape and cap from
the grease tube (5) and insert
the uncapped end of the grease
tube (5) into the bottom of the
grease gun (2b).
5. Remove the foil from the grease
tube (5).
6. Screw the top of the grease gun
(2a) back on to the bottom of the
grease gun (2b).
7. Push down on the latch (2d) to
release the plunger and push
plunger completely back in.
AP-2 Service Manual
42
MIXING CHAMBER FLOW RATE*
CHAMBER
Lbs/Per/Min @
1000 PSI
KG/Per/Min
@ 69 Bar
Lbs/Per/Min @
2000 PSI
KG/Per/Min
@ 138 Bar
GU-814-000
4 2 6
3
GU-814-00
7 3 11
5
GU-814-01
9 4 16
7
GU-814-01X
10.5
4.5
19
8.5
GU-814-02
12 5 22
10
GU-814-02X
15
7.5
27
12
GU-814-03
18 8 32
14
GU-814-04
25
11
47
21
CHAMBER/ORIFICE COMPARISON CHART
COMPETITIVE AIR PURGE
PMC AIR PURGE
CHAMBER NUMBER
ORIFICE SIZE
CHAMBER NUMBER
ORIFICE SIZE
000 (AR2020)
0.0200
000
0.0280
00 (AR2929)
0.0290
00
0.0292
01 (AR3737)
0.0420
01
0.0410
02 (AR4242)
0.0520
02
0.0465
03 (AR6060)
0.0600
03
0.0595
04 (AR7070)
0.0700
04
0.0700
*Flow rates will vary depending on viscosity, hose length and machine efficiency.
AP-2 Service Manual
43
Improved Style
Original Style
AP-2 Service Manual
TECHNICAL SERVICE BULLETIN
April 24, 2013
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. The improvement entails a back up ring (OR-800) in addition to the O-Ring
(OR-801). See Details below.
The original screen screw Will Not accept the backup ring and o-ring. The customers using the original
Screen Screw can continue to use this design. Any new Screen Screws sold will be the new style and
will be ordered under Part Numbers KT-819-A (A side) and KT-819-R (Resin Side).
These part numbers will include the following, Screen Screw (GU-819-A or GU-819-R, O-Ring (OR-801),
backup ring (OR-800), Screen Screw Gasket (GU-04007).
NOTE: The new style Screen Screw also has a larger hex on the end for easy removal from the gun
block.
______________________________________________
Backup Ring (PN# OR-800) must be installed as shown on the detail below.
Backup Ring PN# (OR-800) O-Ring PN# (OR-801A)
44
AP-2 Service Manual
TECHNICAL SERVICE BULLETIN
August 16, 2013
REF: AP-2 STABILIZER BAR KIT # KT-828
See exploded drawing and parts details attached.
PMC has recently added the #KT-828 Stabilizer Bar Kit to all guns produced after this date. The new
Stabilizer Kit will help prevent racking to the gun caused by the chemical hoses dangling during the
spray operation. The addition of the Stabilizer Bar creates a more rigid gun assembly which leads to an
improved alignment between the chamber and the side seals. The result is less wear on the chamber and
side seals and longer parts life.
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.
Installation Instructions
1) If the gun is connected to the coupling block turn off the manual valves and remove the gun from
the coupling block.
2) Remove two TN-830 socket head cap screws from front of existing trigger manifold.
3) Slide off the air cylinder from the trigger manifold.
4) Remove all old O-rings.
5) Clean the parts and apply a small amount of PMC grease into each O-ring location.
6) Install all new supplied O-rings as per the exploded view.
7) Install the Riser Block #GU-841 onto the air cylinder.
8) Install the trigger manifold onto the Riser Block.
9) Secure with 4 supplied screws #TN-830.
10) Install Stabilizer Bar #GU-842 onto Riser Block # GU-841. Secure with two supplied shoulder
bolts #GU-828.
11) Insert 4 O-rings #OR-805 into Stabilizer Bar.
12) Secure Gun to Coupling Block using the supplied Coupling Block Screw # TN-04197.
You are now ready to Spray!
45
Quantity
Part Number
Description
4
GU-851
Check Valve Seat, AP-2
2
GU-852
Check Valve Spring, AP-2
2
GU-853
Check Valve Ball, AP-2
AP-2 Service Manual
Technical Service Bulletin
August 26, 2014
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. In the past
you would be required to order an individual check valve under part number GU-820. The new check
valve assembly set, part number KT-850, actually includes the components for TWO check valves (two
springs, two balls, two check valve seats) plus two extra check valve seats. The spring and the ball can
be cleaned and re-used. The valve seats in cases of a severe cross over may be damaged during
disassembly and thus the reason for the extra seats. The cost of the KT-850 with all the components
included above is less than the cost of one of the previous GU-820 check valves.
New Style Check Valve Assembly # KT-850
GU-852 GU-853
GU-851
#KT-850 Check Valve Assembly Includes the Following Components
46
Technical Service Bulletin
August 22, 2014
AP-2 New Fluid Check Valve Assembly # KT-850
AP-2 Service Manual
Old Style Check Valve # GU-820
47
KT-828 AP-2 STABILIZER KIT PARTS LIST
ITEM
QTY
PART NUMBER
DESCRIPTION
1 2 OR-804
O-RING
2 4 OR-00037B
QUAD O-RING
3 1 GU-841
RISER BLOCK
4 1 GU-842
STABILIZER
5 2 GU-808
SHOULDER BOLT
6 4 GU-805
O-RING
7 1 TN-04197
COUPLING BLOCK SCREW (BLACK)
8 4 TN-830
SHCS BOLT
AP-2 STABILIZER KIT # KT-828
AP-2 Service Manual
*Not included in kit KT-828
48
Revision
Date
Changes
Approved
1.0
30-Apr-14
P1 Changed Address to Komo Dr, Added Rev Control
Number; Updated entire manual to reflect current AP-
2 Gun as of 30APR2014; Added Appendix - Technical
Service Bulletins; Added Revision Sheet
Vadams
2.0
26-Aug-14
Revised warranty, revised Safety and Handling bold
print, added line of instructions to Loss of Air
Pressure/Emergency Shut-off, changed OR-00043A to
OR-00043B, removed “air safety valve closed” in
Trouble Shooting Guide, corrected Screen Screw
Assembly View, Added new mixing chambers and PCT
tips, Updated all tables
Vadams
MANUAL REVISIONS
AP-2 Service Manual
49
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