PMC AP-3 Service Manual

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

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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

Before installing the AP-3 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-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.

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 ...................................................................................... 11

Screen Screw and Component Maintenance ................................................................ ................. 13

Air Cylinder Maintenance ............................................................................................................... 15

Cartridge Valve Removal ............................................................................................................... 17

GUN OPERATION ............................................................................................................................ 18

Triggered Off ................................................................................................................................. 18

Triggered On ................................................................................................................................. 19

TROUBLE SHOOTING GUIDE ......................................................................................................... 20

REFERENCE GUIDE ........................................................................................................................ 21

Chamber Kits ................................................................ ................................................................. 21

PCT Kits ................................ ................................................................................................ ........ 22

Chamber/PCT Kits ......................................................................................................................... 25

Soft Chamber Kits .......................................................................................................................... 25

Spare Parts Kit AP2 ................................ ................................................................ ....................... 26

AP2/3-000 Spare Parts Kit (200445) .............................................................................................. 26

AP2/3-00 Spare Parts Kit (200446) ................................................................................................ 27

AP2/3-00X Spare Parts Kit (200447) ............................................................................................. 27

AP2/3-01 Spare Parts Kit (200448) ................................................................................................ 28

AP2/3-01X Spare Parts Kit (200449) ............................................................................................. 28

AP2/3-02 Spare Parts Kit (200450) ................................................................................................ 29

AP2/3-02X Spare Parts Kit (200451) ............................................................................................. 29

AP2/3-03 Spare Parts Kit (200452) ................................................................................................ 30

AP2/3-04 Spare Parts Kit (200453) ................................................................................................ 30

AP2/3-05 Spare Parts Kit (201173) ................................................................................................ 31

AP2/3-05 Package Drill Bits (201174) ............................................................................................ 31

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 ................................ ................................................................ .................. 34

1/4” Unheated Stainless Steel Hose Assy. ..................................................................................... 34

Flush Tanks ................................................................................................................................... 35

PARTS IDENTIFICATION ................................................................................................................. 36

Manual Valve Assembly ................................................................................................................. 36

Coupling Block Assembly .............................................................................................................. 37

Gun Assembly ............................................................................................................................... 38

Gun Block Assembly ...................................................................................................................... 40

Screen Screw Assembly ................................................................................................................ 41

List of Tools ................................................................................................................................... 42

APPENDIX ........................................................................................................................................ 43

Grease Gun Assembly ................................................................................................................... 43

Mixing Chamber Flow Rates ................................................................................................ .......... 44

Chamber/Orifice Comparison Chart ............................................................................................... 44

WARRANTY

Polyurethane Machinery Corporation (hereinafter “PMC”) provides this

LIMITED

WARRANTY

(hereinafter “Warranty”) to the original purchaser (hereinafter “Customer”) 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:

The original invoice must be kept as proof of the date of first sale and the 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.

Product Maintenance:

It is the Customer’s responsibility to maintain the Product properly. See your maintenance schedule and owner’s manual for details. The Warranty does not cover an improperly maintained Product.

Non-PMC Components and Accessories:

Non-PMC manufactured components and 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:

The Warranty does not cover any Product that PMC determines 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.

•

Fire, flood, “acts of God,” or other contingencies beyond the control of PMC.

WARRANTY

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

terms of this Warranty shall have no effect. It is expressly understood that Customer’s

acceptance of

this Warranty, by performance or otherwise, is upon and subject 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.

SAFETY AND HANDLING

This chapter contains important information on the safety, handling and use of your AP-3 Gun.

WARNING!

Presents information to alert of a situation that might cause serious injuries if the instructions are not followed.

CAUTION! Presents information that indicates how to avoid damage

to the AP-3 Gun or how to avoid a situation that could cause injuries.

NOTE! Is relevant information of a procedure being carried out.

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-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.

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 or go to the company website (www.polymacusa.com).

The AP-3 Gun has been designed and built for the application of polyurea chemical systems, polyurethane foam chemical systems and some two-component epoxy systems.

SAFETY AND HANDLING

WARNING! The design and configuration of the AP-3 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-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. 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.

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.

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.

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)

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.

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.

2. Ensure the Manual Valves 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 to the LOCKED position.

4. Ensure Check Valve Assemblies are properly installed in the Gun Block.

5. Connect the Coupling Block to the Gun Block using the Nut Driver provided (Pg. 42). Tighten Coupling Block until there is a hand tight seal.

6. Connect the air supply with 90 to 125 psi (6.2 to 8.6 bar) to the gun.

NOTE!

The material delivery hoses are color coded Red and Blue. The Red corresponds to the Isocyanate (A) and the Blue to the Polyol (R). To avoid connection errors, the (A) and (R) hoses have connections with different sizes to avoid incorrect connections. [

Set the Gun Lock to the OPEN position.]

7. Pull the Trigger several times to check for correct movement of the Mixing Chamber and PCT.

8. Ensure the Proportioner and supply system are in the ready position and the material pressures and temperatures are set as recommended by the chemical supplier (see Machine Service Manual).

9. OPEN each Manual Valve by turning three (3) full turns counter clockwise.

10. Perform a test spray.

SHUTDOWN PROCEDURES

CLOSE the Manual Valves 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 (Pg. 42), lubricate the Mixing Chamber through the Grease Fitting until a

fine mist of grease is sprayed from the gun (Pg. 43 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! The injection of grease supplied with the

Gun at the end of the day will minimize maintenance time and can 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. PMC Grease is recommended. Use of incorrect grease will cause blockage in the mixing chamber.

3. Disconnect the air supply.

LOSS OF AIR PRESSURE/EMERGENCY SHUT-OFF

1. SHUT OFF air supply to gun.

2. Using the palm of your hand, push in on the Gun Lock and rotate clockwise to set it to the LOCKED position.

3. CLOSE each Manual Valve.

CAUTION!

Excessive force closing or opening Manual Valves may result in damage to the Manual Valves and/or Coupling Block. Emergency shut off if trigger sticks – disconnect air line.

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 Gun Lock is in the LOCKED position, and SHUT OFF/DISCONNECT the air supply. It is recommended to remove the Gun from the Coupling Block.

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.

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.

MAINTENANCE

Gun Block and Mixing Chamber Removal

1. CLOSE the Manual Valves by turning them to the full clockwise position.

CAUTION!

Excessive force opening or closing Manual Valves may result in damage to the Manual Valves and/or Coupling Block.

2. Point the gun over a waste container and pull the Trigger to relieve pressure.

3. Using the Nut Driver provided (Pg. 42), remove the Coupling Block from the Gun Block.

4. Flush the Gun Block to remove any residue. Use the recommended Flush Tank (Pg. 35)

5. Shut off air to the gun.

MAINTENANCE

6. .Using the Wrench provided (Pg. 42) or a ½” wrench, loosen or remove both Screen Screws to facilitate easy removal of the Mixing Chamber, as shown below.

7. Loosen the PCT, but do not remove.

8. Using the Nut Driver (Pg. 42) provided, remove the gun block screws mounting screws. (see page 6, item O)

9. Disconnect the Gun Block from the Cylinder.

10. Remove the Mixing Chamber and PCT from the Gun Block.

11. Clean or replace the Mixing Chamber as required.

12. When reassembling in reverse order, it is recommended to screw the PCT onto the Mixing 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. Do not use metal or abrasive tools that can scratch or damage the contact surfaces.

+ 32 hidden pages

PMC AP-3 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual