Air Purge Spray & Pour Gun AP-2 - Polyurethane Machinery Corp
Contents
1. TN 04193 TN 04197 GU 04001 COUPLING BLOCK ASSEMBLY RA 00006A 1 8 NPT X 46 JIC SWIVEL COUPLING BLOCK MOUNTING SCREW COUPLING BLOCK TN 04197 STABILIZER MOUNTING SCREW AP 2 Service Manual AIR MANIFOLD ASSEMBLY GU 843 GU 843 AIR MANIFOLD ASSEMBLY 2 a esm SPOLVAVE s a SPOOLVAVESPRNG 6 1 eus HOSADAPTER 8 7 O RINGMOJZVITON 34 AP 2 Service Manual END CAP ASSEMBLY GU 844 GU 844 END CAP ASSEMBLY 35 p AP 2 Service Manual AIR CYLINDER ASSEMBLY GU 801A GU 801A AIR CYLINDER ASSEMBLY 4 2 GU837 RETAINERRINGSPUTSET 6 1 susz EN GU 829 A P CHECK VALVE 36 AP 2 Service Manual COMPLETE AIR CYLINDER ASSEMBLY GU 845 GU 845 COMPLETE AIR CYLINDER ASSEMBLY 4 1 oR 000438 ORNGROSDARAS 37 AP 2 Service Manual AIR PURGE SPRAY AND POUR GUN GU 850 3 0 6 Ox 0 XX 2E d 38 WT AP 2 Service Manual GU 850 AIR PURGE SPRAY AND POUR GUN a pi sees P2 i ems E 7 5111 courue i isons ever swept i Lu i sse _ e 14 42. Clean see page 22 Steady air leakage Air Cylinder 1a O rings damaged Replace see page 20 from Handle Trigger Valve O rings damaged 8e Replace see page 18 24 p AP 2 Service Manual REFERENCE GUIDE AP 2 CHAMBER KITS 814 KIT PART DESCRIPTION NUMBER NUMBER INCH ILLUSTRATION GU 814 000 70 DRILL MIXING CHAMBER p 0280 RM 814 000 RM 814 000 000 CHAMBER 000 CHAMBERS000 7 GU 814 00 69 DRILL MIXING CHAMBER s EMEN 0292 MAJ 814 00 814 00 CHAMBER 400 00 GU 814 01 reko MIXING CHAMBER 814 01 814 01 01 ET T CHAMBER 401 GU 814 01X SEHE MIXING CHAMBER 0430 RM 814 01X 814 RM 814 01X 01X GU 03024 RM 814 02 RM 814 02 02 451 DLL 0676 kok Fr Mm E DRILL MIXING CHAMBER 0465 EN E TM CHAMBER 02 448 DRILL GU 03051 0760 MIXING NOZZEL GU 814 02X EX ms pa m a RM 814 02X 814 02X MEN E CHAMBER 02X GU 03028 MIXING NOZZEL GU 814 03 i m MIXING CHAMBER E GU 03035 RM 814 03 RM 814 03 03 ET TN CHAMBER 03 GU 03029 RM 814 04 43 DRILL 0890 MIXING NOZZEL DRILL MIXING CHAMBER 0700 04 25 PM POLYMAC USA AP 2 Service Manual 2 PCT KITS GU 815 FOR USE WITH ILL
3. i p AP 2 Service Manual 2 PCT KITS 0 815 CONTINUED GU 03035 454 DRILL 055 PCT PURGE PORT SS O RING 016 o Guosss 1 965 0RILL 0950 PCTPURGEPORT MUN GU 03029 43 DRILL 0935 iut n PATTERN KI CHAMBER PCT KIT 814 21 2 Service Manual AIR MANIFOLD TRIGGER REBUILD KIT KT 826 AIR CYLINDER REBUILD KIT KT 801 GU 830 AIR CYLINDER BUSHING AP 2 O RING KIT KT 827 PMC RECOMMENDED O RING GREASE PART NUMBER DESCRIPTION GP LUBEGREASE LUBRIPLATE GREASE TL 04003 GREASE TUBE FOR USE W GREASE GUN 28 2 Service Manual amp SCREEN SCREW ASSEMBLY KITS KT 819 RECOMMENDED SPARE PARTS PART NUMBER QTY KT 814 000 KT 814 00 KT 814 01 KT 814 01X KT 814 02 KT 814 02X KT 814 03 KT 814 04 KT 826 KT 801 GU 817 90 GU 818 40 GU 818 60 GU 818 80 GU 04007 OR 00043B OR 801A SP 04005 GU 020 KT 850 OR 00042A GU 829 TN 831 TL 04003 OR 800 KT 827 DESCRIPTION CHAMBER 000 W DRILLS CHAMBER 00 W DRILLS CHAMBER 01 W DRILLS CHAMBER 01X W DRILLS CHAMBER 02 W DRILLS CHAMBER 02X W DRILLS CHAMBER 08 W DRILLS CHAMBER 04 W DRILLS AIR MANIFOLD REBUILD KIT AIR CYLINDER REBUILD KIT SIDE SEAL FILTER SCREEN 40 MESH FILTER SCREEN 60 MESH FILTER SCREEN 80 MESH STANDARD SCREEN SCREW O RING 010 80D AFLAS O RING 013 80D AFLAS SPRING SIDE SEAL
4. Pg 40 Hemove and discard O Rings 7e amp 86e Replace the O rings 7e amp Pg 18 and Spring be Pg 18 supplied in KT 826 Pg 27 Extra PMC grease will facilitate reassembly 18 p AP 2 Service Manual NOTE When replacing O rings replace ALL O rings included in KT 826 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 opool Valve to facilitate reassembly 11 Reattach the Trigger and Air Manifold assembly in reverse order 19 AP 2 Service Manual AIR CYLINDER MAINTENANCE 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 Disconnect air supply to gun Set the Gun Lock 1c to the LOCKED position Loosen the Screen Screws 20 using 72 wrench Disconnect Coupling Block 5 from Gun Block 2 using the Nut Driver provided TL 04001 Pg 40 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 pr ce N 20 AP 2 Service Manual 9 Using the Wrench TL 09 Pg 40 provided remove the En
5. 108 VITON O RING as a mono e me a men exiis 7 e a sse SEIXShEGS SHOUUOERSON _ 20 1 08804 O RING 2MMX4MM BUNA Lm a cua an Lm 3 X CHECK VALVE BALL 1 2 3 5 7 10 11 12 13 14 15 16 17 18 20 21 22 23 24 39 p AP 2 Service Manual SCREEN SCREW ASSEMBLY 7 7 22 Y O 24 5 Po SCREEN SCREW COMPONENTS 23 1 Gu oaoo7 SCREEN SCREWSEAL _ 1i 601840 FILTER SCREEN 40 MESH 1 Guste FLTERSCREENGOMESH ejeje 1 6031840 FILTER SCREEN 80 MESH STANDARD 25 1 0881 ORNGIOISSDARAS 36 1 0800 MOIBBACKUPRING 27 1 OROUM3A O RING 010 0D AFLAS 38 1 sp 04005 SPRINGSDESEAL 1 suso Included in KT 819 R and KT 819 A Pg 29 40 1 QTY AP 2 Service Manual LIST OF TOOLS PART NUMBER GU 04019 TL 00002 GU 04021 GU 04022 TL 04003 TL 09 TL 04001 GP 00101 TL 10 4 AP 2 Service Manual APPENDIX GREASE GUN ASSEMBLY 1 Screw the rod 2 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
6. and or Coupling Block 2 Trigger Gun over Waste Container to release internal material pressure SHUT OFF AIR SUPPLY TO GUN Set the Gun Lock 1c Pg 9 to the LOCKED position Use wrench to remove the Screen Screw 20 To clean or replace the Screen 22 remove O Ring 23 and Back Up Ring 24 the Side Seal 27 and Spring 26 from the Screen Screw Inspect the components and O rings Clean or replace as required Inspect for damage and apply PMC lubrication to the O rings and threads and reassemble in reverse order The Gun is now for service NOTE When replacing O rings replace ALL O rings included in the appropriate Kit 17 AP 2 Service Manual AIR MANIFOLD MAINTENANCE 1 p 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 Set the Gun Lock 1c Pg 9 to the LOCKED position Disconnect the air supply from the Gun Use a suitable size wrench and remove the air fitting from the rear of the manifold Remove the trigger from the assembly to access the front of the air manifold Use supplied wrench TL 09 Pg 40 and remove the spool valve retainer 66 Remove the Spring 5e Spool Valve Liner Spool Valve and Liner Bushing 26 using the tool provided TL 10
7. 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 AP 2 Service Manual EA IB E LITI M 2 Q LEA E KN H PA ibd 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 While the trigger is pulled the purge air is shutoff during spraying and the PCT will be retracted to the point of being flush with the front surface of the Gun Block 25 AP 2 Service Manual TROUBLE SHOOTING GUIDE PROBLEM POSSIBLE CAUSE SOLUTION PCT not flush with Insufficient Gun air pressure minimum 90 psi 6 2 Ensure 90 psi 6 2 Bar of Bar air pressure at Gun Gun Block when Gun HH M Trigger Valve requires service Rebuild see page 18 99 Air Passages plugged Clean See page 18 Lock is in Locked position Unlock gun Air supply is not on Turn on air sup
8. 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 42 AP 2 Service Manual MIXING CHAMBER FLOW RATE 1000 PSI 69 Bar 2000 PSI 138 Bar GU81400 4 2 6 3 GU 814 01 9 4 316 7 W 3081403 18 8 32 14 Flow rates will vary depending on viscosity hose length and machine efficiency CHAMBER ORIFICE COMPARISON CHART PMC AIR PURGE CHAMBER NUMBER ORIFICE SIZE 000 AR2020 00200 0 0280 0 0292 0 0410 01 02 AR4242 0 0520 02 0 0465 03 AR6060 0 0600 0 0595 04 AR7070 0 0700 04 0 0700 43 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 8347 Screen Screw have the improved screen screws 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 usi
9. place 8 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 Connect air supply to the Gun 90 to 125 psi 6 2 to 8 6 Bar 7 Setthe Gun Lock 1c to the OPEN position 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 To avoid connection errors the Coupling Connections of the 5 A and Polyol hoses are also different sizes which makes it difficult to swap connections 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 AP 2 Service Manual 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 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 Bloc
10. 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 Service Center go to the company website www polymac usa com or directly contact Polyurethane Machinery Company p 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 li
11. 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 gt SAFETY AND HANDLING AP 2 Service Manual This chapter contains important information on the safety handling and use of your AP 2 series Gun HEAD THIS MANUAL BEFORE OPERATING THIS EQUIPMENT FAILUHE TO FULLY HEAD AND UNDERSTAND THIS MANUAL MIGHT RESULT IN DAMAGE OR LOSS TO PERSONNEL EQUIPMENT OR PROPERTY 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 2 Gun or how to avoid a situation that could cause injuries NOTE 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
12. MANUAL VALVE ASSEMBLY CHECK VALVE ASSEMBLY 016 O RING A P CHECK VALVE 4 40 X SHCS GREASE TUBE 013 BACK UP RING AP 2 O RING KIT OC CI O1 iN gt PART NUMBER QTY KT814 000 1 KT81400 1 1 1 KT81402 1 KT81402x KT81403 1 KT81404 1 1 1 6081740 2 6088640 4 6081860 4 4 6004007 2 OR 00043B 8 8 SP 04005 2 Guo20 Kreso 2 ORO042A 2 1 2 0406 8 827_ 1 RA TN Co 29 WT AP 2 Service Manual SCREEN SIZES OPTIONAL PARTS GU 815 52 2 PCT FLAT TIP GASKET OR 00042A 4 016 O RING GU 817 90D SIDE SEAL DELRIN DENOTES PARTS IN THE GU 815 52 NOTE SPRAY NOT INCLUDED WITH PART NUMBER GU 815 52 CHECK VALVE ASSEMBLY KT 850 PART NUMBER DESCRIPTION CHECK VALVE SEAT CHECK VALVE BALL 30 AP 2 Service Manual 1 4 UNHEATED STAINLESS STEEL HOSE ASSY Optional MA 41 Kit shown on AP 2 Gun Flush Tank TL 12 3l gt PARTS IDENTIFICATION AP 2 Service Manual MANUAL VALVE ASSEMBLY GU 020 GU 020 MANUAL VALVE ASSEMBLY 4 1 ORO16 007 Backup Ring Red 32 AP 2 Service Manual COUPLING BLOCK ASSEMBLY GU 04001 OPTIONAL ORIENTATION
13. POLYURETHANE MACHINERY CORPORATION POLYMAC USA P Air Purge Spray amp 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 PATENT PENDING Polyurethane Machinery Corp REVISION 3 0 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 almed 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 ERE 4 SAFETY AND 6 IMPORTANT SAFETY INFORMATION 7 CHARACTERISTICS 8 TECHNICAL SPECIFICATIONS 8 GENERAL DESCRIPTION 9 INSTALLATION AND START UP tette 10 SHUTDOWN PROCEDURES ttt ttt ttt ttt 12 LOSS OF AIR PRESSURE EMERGENCY SHUT OFF ttt 13 MAINTENANCE 14 GUN BLOCK AND MIXING CHAMBER ee 14 SCREEN SCREW AND COMPONENT MAINTENANCE ee 16 AIR MANIFOLD MAINTENANCE 18 AIR CYLINDER MAINTENANCE 20 GUN OPERATION 22 TRO
14. 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 accessories that are used in the operation of the Product are not covered by this Warranty ouch 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 e Normal wear and tear e Improper or unauthorized installation repair alteration adjustment or modification of the Product e Use of heating devices pumping equipment dispensers or other parts or accessories with the Product that have not been approved or manufactured by PMC e Failure to follow the operating instructions and recommendations provided by PMC may cause loss or damage to personnel equipment or work area e Fire flood acts of God or other contingencies beyond the control of 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 OTHERWISE AND THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FI
15. TNESS FOR A PARTICULAR PURPOSE AND ALL OTHER WARRANTIES ARE HEREBY DISCLAIMED TO THE FULLEST EXTENT PERMITTED BY LAW SHALL NOT BE RESPONSIBLE WHETHER BASED IN CONTRACT TORT INCLUDING WITHOUT LIMITATION NEGLIGENCE WARRANTY OR ANY OTHER LEGAL 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 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 basis 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
16. UBLE SHOOTING GUIDE ttt ttt ttt 24 AP 2 CHAMBER KITS GU 814 25 2 PCT KITS GU 815 Jtt ttt 26 CHAMBER PCT KIT KT 814 27 AIR MANIFOLD TRIGGER REBUILD KIT KT 826 28 AIR CYLINDER REBUILD KIT 8 1 28 2 O RING KIT 827 4 0440100 ttt ttt 28 PMC RECOMMENDED O RING GREASE 28 amp SCREEN SCREW ASSEMBLY KITS KT 819 _ 29 RECOMMENDED SPARE PARTS 29 SCREEN SIZES aeon 30 OPTIONAL PARTS ttt ttt ttt ttt ttt ttt 30 CHECK VALVE ASSEMBLY 850 iakin iin in innn 30 593977000 32 gt AP 2 Service Manual MANUAL VALVE ASSEMBLY GU 020 32 COUPLING BLOCK ASSEMBLY 04001 ttt 33 AIR MANIFOLD ASSEMBLY GU 843 34 END CAP ASSEMBLY 35 AIR CYLINDER ASSEMBLY GU 8014 36 COMPLETE AIR CYLINDER ASSEMBLY GU 845 e 37 AIR PURGE SPRAY AND POUR GUN 850 38 SCREEN SCREW ASSEMBLY 40 LIST OF TOOLS ttt ttt ttt ttt ttt ttes 41 APPENDIX QNM 42 GREASE ASSEMBLY 42 MIXING CHAMBER FLOW 43 CHAMBER ORIFICE COMPARISON CHART ettet 43 TECHNICAL SERVICE BULLETIN ttt 44 MANUAL SAAKI 49 gt WARRANTY Polyurethane Machinery Corporation hereina
17. USTRATION X KIT NUMBER PART NUMBER GU 03033 GU 03035 GU 03032 QTY DESCRIPTION 65 DRILL 0350 4 54 DRILL 055 I GU 815 000 PCT FLAT TIP O RING 016 PATTERN CONTROL TIP 000 Ji OR 00042A 0 GU 03033 GU 03035 GU 03023 GU 815 00 OR 00042A 1 PCT FLAT TIP O RING 016 PATTERN 2 CONTROL 00 a 1 54 DRILL 055 PCT FLAT O RING 016 PATTERN CONTROL TIP 01 465 DRILL 0350 454 DRILL 055 RM 815 00 GU 03033 GU 03035 DS D SS Ik GU 815 01 on 00042A RM 815 01 PCT PURGE PORT PCT PURGE PORT PCT NOZZEL PORT GU 03033 GU 03035 Ta Ta GU 03051 1 4 52 DRILL 0635 PCT FLAT TIP O RING 016 PATTERN CONTROL TIP 01X 465 DRILL 0350 PCT PURGE PORT 454 DRILL 055 PCT PURGE PORT 1 51 DRILL 0676 PCT NOZZEL PORT PCT FLAT TIP O RING 016 PATTERN CONTROL TIP 02 65 DRILL 0350 PCT PURGE PORT 54 DRILL 055 PCT PURGE PORT PCT NOZZEL PORT GU 815 01X OR 00042A RM 815 01X ar gt GU 03033 GU 03035 GU 03024 i GU 815 02 OR 00042A RM 815 02 SA GU 03033 GU 03035 GU 03051 1 446 DRILL 0810 PCT FLAT TIP O RING 016 PATTERN CONTROL TIP 02X GU 815 02X OR 00042A ON RM 815 02X
18. d Cap 2a Pg 20 10 Push on the exposed Piston 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 NOTE When replacing O rings replace ALL O 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 Use wooden or plastic tools or a brass brush for cleaning Do not use metal or abrasive tools that can scratch the contact surfaces 21 Compressed Shop Air 90 120 PSI 6 2 8 3 Bar AP 2 Service Manual N TI Lim 4 Ei TESA MOAN al N pag Zum 1 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 oide 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
19. ded line of instructions to Loss of Air Pressure Emergency Shut off changed OR 00043A to OR 00043B removed air 26 Aug 14 JB safety valve closed in Trouble Shooting Guide corrected Screen Screw Assembly View Added new mixing chambers and PCT tips Updated all tables Page 26 Changed quantity of Part Number GU 03035 in Kit Number GU 815 01 from 2 to 1 Page 33 Added Part Numbers TN 04193 and TN 04197 to Coupling Block Assembly GU 04001 Vadams Page 38 39 Removed Part Numbers TN 04193 and TN 04197 from Top Level Assembly GU 850 49
20. e 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 6 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 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 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 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 fo
21. e recommended Flush Tank 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 A small amount of PMC grease applied to the Mixing Chamber 6 Pg 14 and Side Seals 27 Pg 16 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 15 p AP 2 Service Manual SCREEN SCREW AND COMPONENT MAINTENANCE 22 23 26 SCREEN SCREW COMPONENTS DESCRIPTION 2 A SCREEN SCREW 1 SCREEN SCREW SCREEN SCREW SEAL FILTER SCREEN 40 MESH SEE PAGE 30 1 FILTER SCREEN 60 MESH SEE PAGE 30 FILTER SCREEN 80 MESH SEE PAGE 30 STANDARD O RING 4013 80D AFLAS 013 BACK UP RING 24 CAUTION To avoid possible contamination by the residual chemical inside the Gun do not interchange the Isocyanate A parts with the Polyol parts A side is identified with an on the Screen ocrew 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 gt AP 2 Service Manual CAUTION Excessive force opening or closing Manual Valves may result in damage to the Manual Valves
22. fter 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 AP 2 Service Manual 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
23. k 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 The injection of grease supplied with the Gun at the end of the day will 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 12 AP 2 Service Manual 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 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 1c A 13 AP 2 Service Manual MAINTENANCE To obtain maximum performance from
24. mited 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 AP 2 Service Manual CHARACTERISTICS e Internal mixing from high pressure impingement Automatic cleaning with air pressure No solven
25. ng 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 Original Style Improved Style 44 p AP 2 Service Manual TECHNICAL SERVICE BULLETIN August 16 2013 REF AP 2 STABILIZER 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 15 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 1s quite easy and only requires two Allen wrenches 5 16 spin tite and PMC grease Installation Instructions 1 If th
26. ply Material doesnot Valve 3d CLOSED OPEN see page 10 49 spray when Gun is m F Mixing Chamber 6 Inlet Orifices plugged Clean see page 14 oide Seal 27 Orifices plugged Clean see page 16 Check Valve 4 plugged Replace see page 37 Trigger Valve requires service Rebuild see page 18 Insufficient Gun air pressure minimum 90 psi 6 2 Ensure 90 psi 6 2 Bar of Bar air pressure lowl Piston Assembly requires service Rebuild see page 20 Air Passages plugged Clean see page 22 Mixing Chamber Inspect Side Seals 27 moves slowly then Reacted material around Side Seals 27 Mixing Chamber 6 for reacted materials clean normal speed see pages 14 16 Adjust see Proportioner Incorrect chemical temperature Operating Manual Pattern deformation Mixing Chamber Nozzle dirty Inspect and clean PCT dirty Inspect and clean Mixing Chamber 6 Inlet Orifices plugged Material spray cipe 27 PLIES pressure imbalance Material temperatures not as recommended by Adjust see Proportioner Q Material mistfrom Side Seal 27 damaged Mixing Chamber 3 or PCT 4 Side Seal Screen Screw O rings Pg 16 damaged Replace see page 16 Mixing Chamber Material temperatures and or spray pressures not as Adjust see Proportioner E rspr eso 7 recommended by material supplier Operating Manual Nika ormana Plugged air passages in PCT 7 and Gun Block 1
27. r 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 SECTION A A SCALE 5 1 GU 852 GU 853 HKT 850 Check Valve Assembly Includes the Following Components GU 851 Check Valve Seat AP 2 GU 852 Check Valve Spring AP 2 GU 853 Check Valve Ball AP 2 46 AP 2 Service Manual Technical Service Bulletin August 22 2014 AP 2 New Fluid Check Valve Assembly KT 850 LLA AIIBIB Old Style Check Valve GU 820 47 p AP 2 Service Manual AP 2 STABILIZER KIT KT 828 KT 828 AP 2 STABILIZER KIT PARTS LIST 2 4 QUADORNG 4 1 suse O 6 a suss ORG s a O Not included in kit KT 828 48 p AP 2 Service Manual MANUAL REVISIONS Revision Date Changes Approved P1 Changed Address to Komo Dr Added Rev Control Number Updated entire manual to reflect current AP 2 Gun as of Apr 14 1 0 30APR2014 Added Appendix Technical Service Bulletins aparas Added Revision Sheet Revised warranty revised Safety and Handling bold print ad
28. ts required e Exterior lubrication of the Mix Chamber Weight 2 235 105 1 012 kg w o coupling block 2 302 Ibs 1 317kg with coupling block 6 58 in 167 mm 7 23 in 184 mm 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 Ib min 20 L min Minimum Output 1 1 ratio 3 3 Ib min 1 55 L min Opening Force 110 psi Bar 200 Ib 91 kg Closing Force 110 psi 8 Bar 200 Ib 91 gt 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 16 1b AP 2 Service Manual _ 2b AP 2 GENERAL DESCRIPTION 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 aS Install Coupling Block GU 04001 to the hose 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 set the Gun Lock 1c to the LOCKED position Ensure Check Valve Assemblies 4 Pg 9 are in
29. your AP 2 Gun it is necessary to periodically perform certain maintenance operations WARNING Before proceeding with any maintenance work on the AP 2 Gun SHUT OFF DISCONNECT the air supply ensure the Gun Lock is in the LOCKED position and the Manual Valves are CLOSED Trigger the Gun to remove internal material pressure It is recommended to remove the Gun from the Coupling Block GUN BLOCK AND MIXING CHAMBER REMOVAL 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 AP 2 Service Manual 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 12 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 9 Flush Gun Block 2 Pg 14 to remove any residue Us
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