3M PG II User manual


Hot Melt Applicator PG II
Owner’s Manual

Hot Melt Applicator PG II
Use only with 3M™ Hot Melt Adhesives

© 3M 2020.2
Contents
General Information .......................................................................3
Important Safety Instructions.......................................................4
Setup and Installation ....................................................................6
Operation......................................................................................... 7
Preventive Maintenance................................................................8
Troubleshooting ............................................................................ 10
Repair Part Kits................................................................. 11
Repair Procedures ........................................................................ 13
General Assembly (Schematic) ...................................................17
Electrical Control/Wiring Arrangement ................................... 18
Flow Control.................................................................................. 19
Accessories................................................................................... 20
3M Repair Service .........................................................................21
Warranty, Limited Remedy, and Disclaimer..............................21
Limitation of Liability.....................................................................21

© 3M 2020. 3
General Information

Hot Melt Applicator PG II
The 3M™ Hot Melt Applicator PG II is designed to be a simple,
reliable tool for dispensing 3M™ Hot Melt Adhesive Sticks. It
is self-contained and hand held, designed for multi-station or
intermittent manual adhesive application.
The 3M Hot Melt Applicator PG II uses electric heat to melt
the adhesive, and air pressure to deliver the adhesive. Adhesive
temperature is automatically maintained by a fixed thermostat on
the heat block. The system is further protected by a thermal cutout
(TCO), which acts as a thermal fuse.
When trigger (1) is pulled, the variable regulator (2) allows air
pressure into rear of the Speedloader stick feed (3). Air pushes the
piston (4), which advances adhesive stick through the applicator.
As adhesive advances, it passes through hard plastic insulating
sleeve (5) which acts as thermal barrier to keep molten adhesive
and heat in forward
portion of the applicator. The rest of the
applicator stays cool.
As adhesive advances into the heat block, it is melted and liquified.
With pressure from the solid adhesive sticks and the piston, the
liquid adhesive is forced out the tip of the applicator through
the nozzle valve (6). When the trigger is released, air pressure is
released from the rear of the loading chamber. Pressure on the
molten adhesive in the front of the applicator is then also relieved.
Spring tension in the nozzle valve retracts the valve, neatly cutting
off the adhesive flow. The trigger of the 3M Hot Melt Applicator
PG II can be feathered. The operator can pull the trigger back part
way for a small amount of adhesive or pull the trigger back all the
way for maximum flow.
The delivery rate of molten adhesive for the 3M Hot Melt
Applicator PG II is seven pounds per hour with a product like
3M™ Hot Melt Adhesive 3738 utilizing the standard tip 9921.
Adhesive flow rates will vary with the different adhesives in the
line and the nozzle tip you choose.
READ INSTRUCTIONS THOROUGHLY BEFORE OPERATING OR PERFORMING ANY
MAINTENANCE ON 3M HOT MELT APPLICATOR PG II.

© 3M 2020.4
Important Safety Instructions
Explanation of Signal Word Consequences
WARNING Indicates a hazardous situation which, if not avoided, could result in serious injury or death.
CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate
injury and/or property damage.
NOTICE Indicates a situation which, if not avoided, could result in property damage.
WARNING
To reduce the risk of electrical shock or injury, observe the
following safety rules:
• This appliance is not intended for use by persons (including
children) with reduced physical, sensory or mental capabilities,
or lack of experience and knowledge, unless they have been
given supervision or instruction concerning use of the appliance
by a person responsible for their safety.
• Children or persons needing supervision should be supervised to
ensure they do not play with the appliance.
•
WARNING: This tool must be placed on its stand when not in use.
• Operate and service the applicator only as described in this manual.
• Connect the applicator only to a properly grounded outlet.
• Do not unplug the applicator by pulling on the cord. Grasp the
plug, not the cord, to unplug.
• Do not handle the plug or applicator with wet hands.
• Do not use the applicator outdoors or on wet surfaces.
• Do not use the applicator if the cord or plug is damaged.
• Do not use the applicator if it is not working properly or has been
damaged, submerged in water or left outdoors.
WARNING
• Use only 3M-authorized replacement parts. Use of other
replacement parts may cause hazardous conditions or damage
the applicator. Repairs should only be performed by a qualified
repair person.
• If the supply cord is damaged, it must be replaced by a qualified
repair person or returned to 3M. Please contact your local 3M sales
representative for assistance.
• DO NOT USE NEAR HIGHLY FLAMMABLE MATERIALS.
• If an extension cord is used, use an extension cord that complies
with local electrical requirements and is properly rated for
your application. Use of an improper extension cord may cause
electrical shock.
• Do not clean or remove the 3M™ Hot Melt Adhesive with solvent.
May cause fire. For additional health and safety information see the
product label and Safety Data Sheet for Hot Melt Adhesive used.
• Do not modify the plug provided with the applicator or use
with an adaptor or ungrounded outlet. Improper grounding
connection of the applicator may cause electric shock. Check
with a qualified electrician or service person to determine
whether the plug is properly grounded. If the plug will not fit the
outlet, have a qualified electrician or service person install the
proper outlet.
SAFETY INSTRUCTIONS FOR ALL ELECTRIC HOT MELT APPLICATORS

© 3M 2020. 5
Important Safety Instructions
CAUTION
• Avoid contact with hot adhesive and applicator tip. May cause
burns. Wear personal protective equipment (PPE) per workplace
and industry standard operating practices and procedures when
using and cleaning or changing tip. KEEP TIP POINTED AWAY
FROM BODY PARTS.
• Do not damage the white sleeve.
• Do not pull adhesive sticks from the rear of the applicator while
in operation. Removing adhesive from the rear may cause molten
adhesive flow out of the rear of the applicator which may cause
burns and damage the applicator.
• Do not force adhesive. Excessive force can damage the
applicator and cause molten adhesive to flow out the rear.
• USE ONLY 3M™ Hot Melt PG II adhesive sticks. OTHER
ADHESIVES MAY CAUSE BACKMELT AND POSSIBLE INJURY.
Use of other adhesives may damage the applicator or result in
hazardous conditions.
NOTICE
• To avoid charring or plugging of the tip, extrude at least one
adhesive stick every three hours that the applicator is turned on.
• Do not overtighten. Overtightening damages threads.
WARNING
• Prior to making any repairs on the applicator, make certain
that the applicator is at room temperature and that both air
and electrical service lines have been disconnected from
their respective sources. Failure to disconnect the electrical
power source could result in electrical shock or damage to the
applicator. Applicator must be completely assembled before
connecting applicator to electrical outlet. Allow applicator to
cool to room temperature before servicing. Failure to do so may
cause burns. Read owner’s manual before servicing.
CAUTION
• Never pull the trigger on the applicator unless there is adhesive
in the loading chamber.
NOTICE
• Do not connect 3M™ Hot Melt Applicator to air supply with air
pressure greater than 80 psi (551 kPa). Damage to the applicator
may result.
CAUTION
• Do not use low-temperature adhesives with high-temperature
applicators.
CAUTION
To reduce the risks associated with hazardous work positions,
which if not avoided, could result in minor or moderate injury:
• Avoid raising the elbow, bending the wrist, reaching, and
bending over when using this device.

© 3M 2020.6
Setup and Installation
1. Connect Air and Electrical Service
Select a workstation where 120 VAC grounded receptacle and
compressed air service are available. Electrical outlet should be
as close to air supply as possible. Filtered air regulated to 80 psi
(551 kPa) maximum is vital to trouble-free operation. Connect
air hose using two 1/2" (13 mm) open-end wrenches. Remove the
steel swivel portion of the connector and insert the steel swivel
into 1/8" female pipe thread air source. Insert and tighten the brass
fitting into the swivel and snug up all fittings.
2. Install Air Filter and Regulator
An air filter and moisture trap must be installed at the applicator
connection point of the air system. Install an air filter WATTS
#602-2S Model M4 (or equivalent) at the air outlet or as
close as possible to it. The hose connection at the end of the
3M Hot Melt Applicator PG II air hose is 1/8" standard male
pipe fitting.
Hot Melt Applicator PG

3. Install Bench Stand
Prior to start up in operation, set the bench stand on work surface
so that tip of gun points away from work area when gun is not
in use. When bench stand is in most desirable position, fasten
permanently using the screws provided. (If portability of the bench
stand is desired, simply attach the stand to a piece of scrap wood
approximately 7" x 16" (17.8 cm x 40.6 cm) using either screws or
by adhering the stand to the wood.)
Remove the 3M™ Hot Melt Applicator PG II from its shipper and inspect for obvious damage.

© 3M 2020. 7
Operation
Warmup
Make certain that the 3M™ Hot Melt Applicator PG II is
fully loaded with adhesive. Set the o/on switch to the
“on” position, switch should light up, and set 3M Hot Melt
Applicator PG II in the bench stand for 15 minutes. During
this warmup period you may note a slight dripping from
the nozzle tip. This dripping is due to expansion of the
adhesive during warmup.
Loading
After warmup, load applicator with the 3M™ Hot Melt Adhesive
you’ll be using on the job. To do this, fully retract the Speedloader
piston by pulling one of the retract knobs located on either side
of the loading chamber. Insert up to three 3M Hot Melt Adhesive
Sticks into the chamber through the rear loading port. The
applicator is now ready for operation.
As adhesive is extruded, the piston will move forward. This will
be visually evident by the forward movement of the retract knobs.
As the piston approaches the front of the chamber, a whistling
sound will be heard. At this point the piston may be retracted
and another adhesive stick will fall into place. Applicator is again
ready for operation. Adhesive may be loaded into the chamber
via the rear port at any time during operation thus saving time and
increasing productivity.
If it is desired to remove adhesive once it is in the loading chamber,
simply roll the applicator to one side and then point up. This will
allow the adhesive to roll up and out of the chamber.
In order to keep the Speedloader stick feed operating at maximum
efficiency, the chamber should be sprayed inside while the piston
is in the full forward position with 3M™ Silicone Lubricant or
equivalent once a week.
CAUTION
Never pull the trigger on the applicator unless there is adhesive
in the loading chamber.
Application
Get a feel for your new 3M Hot Melt Applicator PG II. Start by
applying small amounts of adhesive in puddles on a piece of scrap
or paper. Try feathering the trigger. The 3M Hot Melt Applicator
PG II is unique in this respect. Pull the trigger back slowly and note
a small discharge of adhesive; pull the trigger back more and note
increasing adhesive flow. When the trigger is fully depressed;
you will get maximum flow. If more or less flow is desired, refer to
page 19 of this manual.
NOTICE
Never operate the applicator without a nozzle tip. Doing so
could seriously damage the nozzle valve.
Changing Tips
The 3M Hot Melt Applicator PG II includes two different tips as
standard equipment. Other tips, available from your 3M Hot Melt
Adhesive distributor, are shown on page 19 of this manual.
WARNING
Disconnect air and electrical power before servicing. Wear heat
resistant gloves while working on tips.
Tips can be changed only when the applicator is hot. You will
need a 5/8" (16 mm) and a 1/2" (13 mm) open-end wrench.
Hold the nozzle valve hex firmly with the 5/8" (16 mm) wrench,
while removing the nozzle tip with the 1/2" (13 mm) wrench.
The accessory tip is mounted using the reverse procedure.
Snug the tip lightly.
NOTICE
Overtightening could damage the valve assembly.

© 3M 2020.8
Preventive Maintenance
Before Operation
CAUTION
Always remember the tip and valve are extremely hot.
1. Make sure filtered compressed air is available, regulated to a
maximum of 80 psi (551 kPa) or to a minimum of 50 psi (345 kPa).
DO NOT OPERATE 3M™ HOT MELT APPLICATOR PG II BELOW
40 PSI (275 kPa). If low flow is experienced at 40 psi (275 kPa)
see page 10.
2. Make sure that the 3M Hot Melt Applicator PG II is plugged
into 120 VAC and that the switch is in the “on” position.
Switch should light up.
Hot MeltApplicator PG II

3. Inspect nozzle tip daily. Make sure tip is clean and clear of
foreign matter. Using a coarse cloth, wipe off any accumulated
adhesive or other foreign matter on the tip.
CAUTION
Valve and nozzle tip are extremely hot. Wear heat resistant
gloves when cleaning tip.
4. Be sure there is adhesive in the loading chamber.
5. Under normal conditions, allow at least 15 minutes for the
applicator to warm up.
Hot MeltApplicator PG

6. Under normal operations the in-line air filter should be removed
and cleaned every six months. Simply remove the filter from
the air supply line and blow compressed air through the filter in
reverse of normal air flow to remove particular matter.
7.
Periodically inspect the applicator to ensure that assembly
is proper (i.e. watch for loose screws, worn pins, etc). See
page 10-16 for Troubleshooting and Repair Procedures.
NOTE: Before shutting down the 3M Hot Melt Applicator PG II
put the electrical switch in the “off” position. Continue using
the applicator until approximately one adhesive stick has been
consumed. If 3M Hot Melt Applicator PG II has not been in
use but still on heat prior to shut down WITHOUT EXTRUDING
ADHESIVE, allow at least one hour for heat-up.

© 3M 2020. 9
Preventive Maintenance
During Operation
Hot Melt Applicator P

Always use the bench stand provided when 3M™ Hot Melt
Applicator PG II is not in use. Do not lay the applicator on its side.
This impedes cooling process and may cause plugging problems.
After Operation
Before shutting down the 3M Hot Melt Applicator PG II put the
electrical switch in the “off” position. Continue using the applicator
until approximately one adhesive stick has been discharged. If
3M Hot Melt Applicator PG II has not been in use but still on heat
prior to shut down without extruding adhesive, allow at least one
hour for heat-up.
Hot Melt Applicator PG II

Open adhesive cartridge stick only when necessary. Keep sticks
clean and free from airborne contaminants.
Lubricate inside loading chamber with 3M™ Silicone Lubricant or
equivalent once a week.

© 3M 2020.10
Troubleshooting
Problem Probable Cause
(In order of priority)
Correction
Low or no adhesive flow 1. Hung adhesive stick Turn on the 3M™ Hot Melt Applicator PG II and allow
it to heat for at least 60 minutes. With incoming air at
80 psi (551 kPa) extrude adhesive. If unsuccessful remove
nozzle assembly and extrude one stick of adhesive. Readjust
incoming air to 80 psi (551 kPa).
2. Low air pressure Check to see if there is sufficient air pressure. Test by setting
pressure at 80 psi (551 kPa). Check in-line filter to ensure that
it is not plugged with contaminants. Disconnect in-line filter
from air hose. Using a compressed air line, blow compressed
air through the filter in the reverse flow position. If this does
not increase air flow through the filter, swivel filter should
be replaced.
3. No electricity Check to see that electrical service is live, and that lighted
switch is in “on” position.
4. Dirty nozzle valve assembly Remove nozzle valve and clean. Run one adhesive stick out.
Replace cleaned valve assembly.
5. Regulator malfunction Squeeze trigger and try to pull retract knobs. If they can be
pulled back easily, install new regulator kit.
6. Burned out heater(s) With Volt/Ohm Meter, run electrical continuity check on each
heater (see page 15 for procedure). If open circuit exists, install
new heater kit.
7. Jammed slugs If the piston is retracted before reaching the point where the
whistle is heard, a jam-up of the adhesive may occur. To free
this, simply retract the piston fully and roll the applicator to
one side so that the adhesive in the magazine will free itself.
Now push the knobs forward until the adhesive stick still in the
chamber is contacted by the piston. Roll the applicator back to
its normal operating position and continue extruding adhesive
until the whistle is heard or until the piston has traveled its full
length as indicated by the orange retract knobs.
No heat 1. Blown thermal cutoff Replace with new Thermostat/TCO kit. Refer to page 16,
procedure paragraph I.
Dripping Nozzle 1. Regulator malfunction With finger off of trigger, attempt to retract piston. If piston is
very difficult to pull back, air regulator may not be shutting off
entirely. Replace regulator.
2. Expanded adhesive stick Extrude one adhesive stick.
3. Worn nozzle valve Replace with new nozzle valve assembly. Refer to page 14,
procedure paragraph C.

© 3M 2020. 11
Troubleshooting
Repair Part Kits
For ease and convenience in repair, 3M™ Hot Melt Applicator PG II
repair part kits are available from your authorized 3M Hot Melt
Adhesive distributor. When ordering part kits, provide the name
and number of the repair part kit. If necessary, part kits can also be
ordered direct from the nearest 3M Hot Melt Adhesive distributor
or contact 3M at 1-800-362-3550.
Note: Depending upon the serial number on your 3M Hot Melt
Applicator PG II, different part kits may be needed. Please check
the Serial Number located on the heat block before ordering
part kits.
Kit # Repair Part Kit
# of
Items/
Kit Kit # Repair Part Kit
# of
Items/
Kit Kit # Repair Part Kit
# of
Items/
Kit
9200 Trigger Kit
a. Trigger Pin 1
b. Trigger Assembly 1
9203 Heat Shield Kit
a. Heat Shield 1
9204 Regulator Kit
a. Regulator Assembly 1
9205 Regulator Hose
Sub-Assembly Kit
a. Hose Assembly 1
9207 Power Cord Kit
a. Power Cord Assembly 1
b. Cable Ties 5
9209 Thermostat/TCO Kit
a. Thermal Cutout Assembly 1
b. Machine Screw Large 1
c. Machine Screw Small 2
d. Thermostat Sub-Assembly 1
9214 Low Temperature -350°F
Thermostat/TCO Kit
a. Thermal Cutout Assembly 1
b. Machine Screw Large 1
c. Machine Screw Small 2
d. Low Temperature
Thermostat Sub-Assembly 1
9938 Hanger Kit
a. Hanger 2
9221 Handle Kit
a. Right-Handle Sub-Assembly 1
b. Left-Handle Sub-Assembly 1
c. Machine Screw 4
d. Machine Screw 3
9219 Switch Kit
a. Switch Sub-Assembly 1
9206 Hose Kit, Main
a. Hose Sub-Assembly 1
b. Cable Ties 5
9220 Hose Kit
a. Hose 1
b. Elbow 1
c. Swivel Filter 1
d. Cable Ties 5
9222 Heater Kit
a. 125 W Heater 4
b. Machine Screw 8
c. Cable Tie 1
9223 Valve Kit
a. Nozzle Tip 1
b. Valve Assembly 1
9224 Miscellaneous Parts Kit
a. Heat Shield Screw, Top 1
b. Heat Shield Screw, Side 2
c. Heat Shield Screw 4
d. Shim 2
e. Electrical Connector Screw 9
f. Connector Strip 2
g. Handle Screw 4
h. Regulator Screw 3
i. Ground Wire Screw 2
j. Hinge Pin 3
k. Bail Screw 2
l. Lock Washer for Bail 2
m. Bail 2
9226 Dump Valve
a. Valve 1
9260 Speedloader Hose Assembly
a. Hose Assembly 1
9261 SL Magazine Extension Kit
a. Magazine Extension 1
9987 Speedloader Assembly
a. Speedloader 1
b. Hose 1
c. Pin 1
d. Bail 1

© 3M 2020.12
Troubleshooting
Recommended Part Kits
Your 3M™ Hot Melt Applicator PG II has been engineered for
durability and reliability. However, as with any electrical-mechanical
device, parts will wear with use and require replacement for maximum
performance. We have listed below certain part kits that you may want
to have available in case the immediate need for replacement arises .
All part kits listed are available from your authorized 3M Hot Melt
Adhesive distributor or contact 3M at 1-800-362-3550.
Please note the serial number of your 3M Hot Melt Applicator
PG II before ordering part kits.
Kit
Number Name Stock Number
No. of 3M™ Hot Melt Applicators in Use
2-5 6-10 11-15 16-20
9200 Trigger Kit 62-9200-6921-8 0 0 1 1
9203 Heat Shield Kit 62-9203-6901-4 0 1 1 2
9204 Regulator Kit 62-9204-6922-8 1 1 2 2
9207 Power Cord Kit 62-9207-6947-8 0 0 0 1
9209 Thermostat/TCO Kit 62-9209-6962-3 1 2 2 3
9219 Switch Kit 62-9219-2798-4 0 0 1 1
9220 Hose Kit 62-9220-2797-4 0 0 0 1
9221 Handle Kit 62-9221-2651-1 0 0 0 1
9222 Heater Kit 62-9222-6930-3 0 0 1 1
9223 Valve Kit 62-9223-6930-1 1 2 3 4
9226 Dump Valve Kit 62-9226-6990-8 0 0 1 1
9260 S/L Hose Assembly Kit 62-9260-2945-5 0 0 1 1

© 3M 2020. 13
Repair Procedures
WARNING
Prior to making any repairs on the applicator, make certain
that the applicator is at room temperature and that both air
and electrical service lines have been disconnected from their
respective sources. Failure to disconnect the electrical power
source
could result in electrical shock. Heat shield must be in
place before connecting applicator to electrical outlet.
Procedure Part Kit
A. Handle Kit
B. Regulator Kit
C. Valve Kit
D. Hose Kit
E. Switch Kit
F. Trigger Kit
All of the above part kits repair procedures require “Handle and
Heat Shield Disassembly”.
G. Heat Shield Kit
H. Heater Kit
I. Thermostat/TCO Kit
All of the above part kits repair procedures require “Heat Shield
Disassembly- procedure G”.
Heat Shield Disassembly Instructions
Disconnect electrical and compressed air service.
Remove the heat shield assembly by removing the two Phillips head
screws from either side of the heat shield and the one Phillips head
screw on the heat shield immediately above the loading chamber.
Reassemble, following reverse procedure.
Handle Disassembly Instructions
With the nozzle of the applicator pointing away from you, remove
the seven Phillips head cap screws in the handle. These screws are
located in the left hand side of the handle grip, two in the pistol
grip itself, two just forward of the wire terminal and three to the
rear of the wire terminal. Remove the long screw on the bottom left
of the flange immediately above the three screws located to the
rear of the wire terminal. Without removing the wires from the wire
terminals, lift the handle up and to the front of the applicator. This
operation will allow for subsequent repair steps.
Handle Disassembly Instructions
A. Handle Kit
Disconnect electrical and compressed air service.
To replace applicator handles, first follow “Handle Disassembly
Instructions.” Next, remove the electrical wiring from the terminal
strip on the left handle, replacing them to the same terminals
on the replacement. The right half of the handle is removed by
removing the four Phillips head cap screws. Next remove the
electrical wiring from the terminal strip and reassemble these to
the replacement right half handle. Lift the switch out of its slot in
the handle and replace it in the new handle. Replace the trigger
and trigger pin at this time. Using reverse procedure, reassemble
the right handle half, then the left. Be sure all the electrical wires
are in place and are not being pinched.

© 3M 2020.14
B. Regulator Kit
Disconnect electrical and compressed air service.
First follow “Handle Disassembly Instructions” then remove the
two large Phillips head screws to the rear of the wire terminals
on the right-hand side of the handle. This allows the regulator
assembly to swing free, connected only by the hose going
from the brass rear of the regulator to the loading chamber
assembly, and the main hose assembly. Remove the main hose
by unscrewing the elbow fitting from the regulator. Use a 5/16"
(8 mm) wrench to remove the loading chamber hose from
the regulator. Reassemble with a new regulator using reverse
procedure. Be sure hose fittings are quite snug. Check for air
leaks by activating the regulator. Once this is done, reassemble
the handle and heat shield.
C. Valve Kit
3M™ Hot Melt Applicator PG II must be heated prior to
repairing nozzle valve.
CAUTION
Avoid contact with hot adhesive and applicator tip. May
cause burns. Wear personal protective equipment (PPE) per
workplace and industry standard operating practices and
procedures when using and cleaning or changing tip. KEEP
TIP POINTED AWAY FROM BODY PARTS. Disconnect Air Line
before making repairs.
Nozzle valve assembly consists of the nozzle tip and the nozzle
valve. Remove the old valve assembly using a 5/8" (16 mm) open-
end wrench. Replace with new assembly. Gently snug up the
valve assembly. With a 1/2" (13 mm) wrench, also snug up
the new tip.
Repair Procedures
D. Hose Kit
Disconnect electrical and compressed air service.
Follow “Handle Disassembly Instructions,” page 13. Remove the
main hose by unscrewing the elbow fitting from the air regulator.
Cut the cable ties holding the power cord and hose assembly
together. Remove the hose and reconnect the new hose using
reverse procedure. Add new cable ties to the hose and power cord.
E. Switch Kit
Disconnect electrical and compressed air service.
Follow “Handle Disassembly Instructions,” page 13. Lift the switch
from the slot in the right half of the handle. The power lead can
be unplugged from the power cord receptacle. The other wires
terminating in ring lugs should be removed from their respective
terminals, noting that the black lead is connected to the Thermal
Cut Out Assembly and the white lead to the heaters. Install the
new switch using reverse procedure.
F. Trigger Kit
Disconnect electrical and compressed air service.
Follow “Handle Disassembly Procedures”. Lift the trigger
assembly off the trigger pin and replace. Reassemble following
reverse procedure.

© 3M 2020. 15
Repair Procedures
Heat Shield Disassembly Instructions
G. Heat Shield Kit
Disconnect electrical and compressed air service.
Remove the heat shield assembly by removing the two Phillips
head screws from either side of the heat shield and the one
Phillips head screw on the heat shield immediately above the
loading chamber. Reassemble, following reverse procedure.
H. Heater Kit
Disconnect electrical and compressed air service.
Follow “Heat Shield Disassembly,” per procedure G. All heater
wires must be disconnected from their respective terminal strips.
With a suitable drift punch, drive the old heaters out through the
top of the heat block. All four heaters should be replaced making
sure to reconnect the wires in the proper places. Refer to the
“Wiring Arrangement” and “Electrical Control” diagrams, page 18.
Be sure that heaters are bottomed out in the heat block. They
should not stick out above the block more than 1/4" (7 mm). It may
be necessary to gently tap the heaters into place, but be careful
not to crack the ceramic.
To ensure that heaters remain in place, gather all the wires
together approximately 1/2" (13 mm) below the heat block and
tightly attach the cable tie provided with the kit.
Heater Check-Out
Disconnect electrical and compressed air service.
Use Volt/Ohm Meter to check electrical continuity of each
heater. If continuity exists, heater is okay. First remove heat
shield. Heaters need not be removed from the block. Check in the
following sequence: left front, right front, right rear, left rear. To
start the check, remove only one wire from its connection on the
terminal strip.
Place one probe from the meter on the connector of the
wire that
has been removed, and with the other probe, touch the matching
connector on opposite side of the applicator. If needle on Volt/
Ohm Meter swings, heater is okay.
Reconnect wire that was removed first, and continue sequence.
If one or more heaters are burned out, refer to Repair Procedure,
pages 13-16.

© 3M 2020.16
I. Thermostat/TCO Kit
Disconnect electrical and compressed air service.
Remove the heat shield assembly by removing the two Phillips
head screws from either side of the heat shield and the one
Phillips head screw on the heat shield immediately above the
loading chamber.
The thermostat and TCO are assembled as a unit and are replaced
as such no matter which component has failed.
The Quick-Slide clips should be removed from the thermostat.
Remove the two screws holding the thermostat, and pry the
thermostat from the block. Insert new thermostat. Make sure the
rear rim of the thermostat is slipped into the slot in the heat block
before affixing screws.
The thermal cutout assembly is then removed by disconnecting the
Phillips head screw, holding the thermal cutout to the head block
on the stand off strip. Remove the other end of the thermal cutout
from the terminal strip with a small Phillips screwdriver. Procedure
is reversed to replace the thermal cutout.
Repair Procedures
J. Heat Block Kit
Disconnect electrical and compressed air service.
If the original heat block is broken or needs replacement,
you may use the 3M factory refurbish program. Please
contact your distributor for information on our PG II
equipment refurbish program.

© 3M 2020. 17
General Assembly
A
G
E
A
E
D
F
B
L
K
M
N
O
I
J
J
C
H
A. 9221 Handle Kit
B. 9204 Regulator Kit
C. 9223 Valve Kit
D. 9220 Hose Kit
E. 9207 Power Cord Kit
F. 9219 Switch Kit
G. 9200 Trigger Kit
H. 9203 Heat Shield Kit
I. 9222 Heater Kit
J. 9209 Thermostat/TCO Kit
9214 Low Temperature -350ºF
Thermostat/TCO Kit
K. 9202 Heat Block Kit
L. 9260 Speedloader Hose Assembly
M. 9226 Dump Valve Kit
N. 9987 Speedloader Chamber Assembly
O. 9938 Hanger Kit
Please check serial number located on the heat block before ordering part kits.

© 3M 2020.18
General Assembly
Electrical Control
17
"
Wiring Arrangement

© 3M 2020. 19
Flow control of adhesive with your new 3M™ Hot Melt Applicator
PG II is easy. An operator familiar with the control devices should
be able to adjust the applicator for desired flow. To adjust adhesive
flow, a combination of these control methods can be used.
The four control devices are:
1. Speed of 3M Hot Melt Applicator PG II movement.
2. The trigger.
3. The nozzle tip.
4. Air pressure.
The trigger of the applicator is uniquely designed to allow for
variable control. By pulling the trigger slowly to the rear, you can
observe the start of adhesive flow. As you continue to pull the
trigger rearward, increasing amounts of adhesive are dispensed.
Two nozzle tips were supplied with your 3M Hot Melt Applicator
PG II: a .093" (9921) fluted tip and a .072" (9946) brass extension
tip. The applicator was shipped with the .093" (9921) tip on the
applicator. This tip will provide maximum flow for all 3M™ Hot
Melt Adhesives except 3746 and 3783. The brass extension tip
(9946) will allow for maximum control of all the adhesives and
substantially eliminate initial surge. This is accomplished at a
decrease in flow rate. Speed of movement is the preferred means
to control flow. In the event that this is inappropriate for your
operation, additional accessory tips are available.
NOTE: DO NOT REDUCE AIR PRESSURE BELOW 40 PSI (275 kPa).
If low adhesive flow occurs when operating at reduced air
pressure, return to maximum (80 psi) (551 kPa) and run at least
one stick of adhesive through the applicator and then return to
the lower pressure.
Flow Control
3M Hot Melt
Applicator PG II Tips
Tip No. Description
9913 2 Hole Spreader
9916 3 Hole Spreader
9917 3 Hole 1" Spreader
9921 .093" Fluted
9922 .063" Fluted
9726 “T” Tip P/G II
9940 .125" Fluted Tip
9946 .072" Brass Extension
9727 “L” Tip P/G II
9726 “T” tip for RSC carton closing and other uses.
9727 “L” tip for FOL carton closing and other uses.
9945 heavy-duty bench stand holds 3M Hot Melt Applicator PG II
in proper position when gun is not is use.

© 3M 2020.20
Accessories
Bench Mount for 3M™ Hot Melt Applicator PG II
A special bench mount assembly is available which allows the
3M Hot Melt Applicator PG II to be mounted in a 45° position and
operated with a foot pedal. It is adjustable to allow positioning of
the nozzle tip from a minimum of 9 1/2" (24.1 cm) to a maximum of
15 1/2" (39.4 cm) from the bench top. A nozzle adaptor that directs
adhesive flow straight down is included in addition to the foot
pedal unit.
Speedloader Magazine Feed for 3M Hot Melt
Applicator PG II
The 3M Hot Melt Applicator PG II can be modified into a semi-
automatic loading mode by the addition of the Speedloader
Magazine Feed. By simply pushing a lever to the rear, the magazine
feeds a new stick of adhesive into the melt chamber. Sticks won’t
jam. The magazine holds 12, 3M™ Hot Melt Adhesive sticks,
reduces the need for frequent reloading and helps increase
production. It is ideal for hands-free benchtop applications in
packaging and assembly.
Bench mounted 3M Hot Melt Applicator PG II with
Speedloader Magazine Feed.