PMC AP-2 User manual

Air Purge
Spray & Pour Gun
AP-2
PATENT PENDING
For use with non-flammable Foam and
Polyurea
For professional use only
Not for use in explosive atmospheres
Service Manual
Ref. # MN-04006
Revision4.7
June 23, 2017
Subscribe to our channel,
Polyurethane Machinery
Corporation PMC, for
video instructions.
Polyurethane Machinery Corp.
Corporate: 1 Komo Drive, Lakewood, NJ 08701
Manufacturing: 2 Komo Drive, Lakewood, NJ 08701
Phone: [phone]
Fax: [phone]
URL: http://www.polymacusa.com
Before installing the AP-2 Gun and start-up, carefully read all the
technical and safety documentation included in this manual. Pay
special attention to the information in order to know and understand
the operation and the conditions of use of the AP-2 Gun. All of the
information is aimed at improving user safety and avoiding possible
breakdowns from the incorrect use of the AP-2 Gun.

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.......................................................................9
MAINTENANCE ................................................................................................................................10
Gun Block and Mixing Chamber Removal......................................................................................11
Screen Screw and Component Maintenance.................................................................................13
Air Manifold Maintenance ..............................................................................................................15
Air Cylinder Maintenance...............................................................................................................17
GUN OPERATION ............................................................................................................................19
Triggered Off .................................................................................................................................19
Triggered On .................................................................................................................................20
TROUBLE SHOOTING GUIDE .........................................................................................................21
REFERENCE GUIDE........................................................................................................................22
Chamber Kits.................................................................................................................................22
PCT Kits........................................................................................................................................23
Chamber/PCT Kits.........................................................................................................................25
Soft Chamber Kits..........................................................................................................................26
Air Manifold Trigger Rebuild Kit .....................................................................................................26
Air Cylinder Rebuild Kit..................................................................................................................27
AP-2 O-Ring Kit.............................................................................................................................27
PMC Recommended O-Ring Grease.............................................................................................27
Screen Sizes .................................................................................................................................27
A & R Screen Screw Assembly Kits...............................................................................................28
Recommended Spare Parts...........................................................................................................28
Optional Parts................................................................................................................................29
Check Valve Assembly..................................................................................................................29
1/4” Unheated Stainless Steel Hose Assy......................................................................................29
PARTS IDENTIFICATION .................................................................................................................31
Manual Valve Assembly.................................................................................................................31

TABLE OF CONTENTS
Coupling Block Assembly ..............................................................................................................32
Air Manifold Assembly ...................................................................................................................33
End Cap Assembly........................................................................................................................34
Air Cylinder Assembly....................................................................................................................35
Complete Air Cylinder Assembly....................................................................................................36
Air Purge Spray and Pour Gun ......................................................................................................37
Screen Screw Assembly................................................................................................................39
List of Tools...................................................................................................................................40
APPENDIX........................................................................................................................................41
Grease Gun Assembly...................................................................................................................41
Mixing Chamber Flow Rates*.........................................................................................................42
Chamber/Orifice Comparison Chart...............................................................................................42
TECHNICAL SERVICE BULLETINS .................................................................................................43
April 24, 2013 ................................................................................................................................43
August 16, 2013.............................................................................................................................43
August 16, 2013.............................................................................................................................44
AP-2 Stabilizer Kit..........................................................................................................................45
August 26, 2014.............................................................................................................................46
June 13, 2017................................................................................................................................48

1
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 maintainedProduct.
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 ofsuch 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 havenot been approved ormanufacturedby PMC.
• Failure to follow the operating instructions and recommendations provided by PMC may
causelossordamagetopersonnel,equipment,orworkarea.
• Fire, flood, “acts of God,” or other contingencies beyond the control of PMC.

WARRANTY
2
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.

3
SAFETY AND HANDLING
This chapter contains important information on the safety, handling and use of your AP-2 Gun.
Before installing the AP-2 Gun and start-up, carefully read all
the technical and safety documentation included in this
manual. Pay special attention to the information in order to
know and understand the operation and the conditions of use
of the AP-2 Gun. All of the information is aimed at improving
user safety and avoiding possible breakdowns from the
incorrect use of the AP-2 Gun.
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-EX 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-2
Gun; you will provide a better opportunity for incident-free operation for a longer time,
greater productivity and the possibility of detecting and resolving problems fast and simply.
Keep this Service Manual for future reference to useful information. If you lose this Manual, ask
for a new copy from your PMC Service Center or go to the company website (www.polymac-
usa.com).
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.

SAFETY AND HANDLING
4
WARNING! The design and configuration of the AP-2 Gun
does not allow its use in potentially explosive atmospheres
or exceeding the pressure and temperature limits described
in the Technical Specifications of this Manual to be
exceeded.
Always use liquids and solvents that are compatible with the AP-2 Gun. If in doubt, consult PMC
Technical Service.
When working with the AP-2 Gun, it is recommended that the operator wear suitable clothing
and elements of personal protection, including, without limitation, gloves, protective goggles,
safety footwear and face masks. Use breathing equipment when working with the Gun in
enclosed spaces or in areas with insufficient ventilation. The introduction and follow-up of safety
measures must not be limited to those described in this Manual. Before beginning to work with
the Gun, a comprehensive analysis must be made of the risks derived from the products to be
dispensed, the type of application and the working environment.
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.

5
CHARACTERISTICS
•Internal mixing from high pressure impingement
•Automatic cleaning with air pressure
•No solvents required
•Exterior lubrication of the Mix Chamber
TECHNICAL SPECIFICATIONS
Maximum Working Pressure: _______________________________ 3,500 psi (245 Bar)
Air Pressure:_________________________________________________90-125 psi (6.2-8.6 Bar)
MaximumOutput(1:1ratio): _____________________________________ 40 lb/min (20 L/min)
Minimum Output (1:1 ratio): ____________________________________ 3.3 lb/min (1.55 L/min)
Opening Force @ 110 psi (8 Bar): ____________________________________ 200 lb (91 kg)
Closing Force @ 110 psi (8 Bar): ________________________________________ 200 lb (91 kg)
Weight (Not including Coupling Block): _________________________ 2.235 lbs (1.014 kg)
Weight (Including Coupling Block):_____________________________ 2.902 lbs (1.316 kg)

6
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.
A. Air Cylinder
B. Gun Lock and End Cap
C. Gun Block
D. Grease Fitting
E. Piston
F. Manual Valves
G. Check Valves
H. Coupling Block Assembly
I. Lock Collar
J. Gun Handle
K. Trigger
L. Air Manifold Assembly
M. Head Latch
N. Screen Screws

7
INSTALLATION AND START UP
CAUTION! When working with the AP-2 Gun or
performing maintenance work, wear suitable
safety protection in accordance with the
recommendations and specifications provided
by the product suppliers.
1. Install Coupling Block 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 (G, Pg. 6) are in place.
5. Connect the Coupling Block to the Gun Block using the
Nut Driver provided (Pg. 40). 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! Thematerialdelivery hoses are color coded Red andBlue. The Red correspondsto
the Isocyanate (A) and the Blue to the Polyol (R). To avoid connection errors, the (A) and (B)
hoseshaveconnectionswithdifferentsizes to avoidincorrect connections.
7. Set the Gun Lock to the OPEN position.
8. Pull the Trigger several times to check for correct
movement of the Mixing Chamber and PCT.
9. 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).
10. OPEN each Manual Valve by turning three (3)
full turns counter clockwise.
11. Perform a test spray.

8
SHUTDOWN PROCEDURES
1. 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. 40), lubricate the Mixing Chamber through the
Grease Fitting until a fine mist of grease is sprayed from the gun (Pg. 41 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.

9
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. 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.

10
MAINTENANCE
To obtain maximum performance from 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, 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.
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.

MAINTENANCE
11
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 Wrench provided (Pg. 40), or a standard 5/8” wrench, remove the PCT from
the mixing chamber, as shown below.
4. Using the Wrench provided (Pg. 40) or a ½” wrench, loosen or remove both Screen
Screws to facilitate easy removal of the Mixing Chamber, as shown below.

MAINTENANCE
12
5. Using the Nut Driver provided (Pg. 40), remove the
Coupling Block from the Gun Block.
6. Disengage the Head Latch from the Gun Block.
7. Loosen the Locking Collar from the Gun Block
and remove the Gun Block from the Air Cylinder.
8. Remove the Mixing Chamber from the Piston
Rod.
9. Flush the Gun Block to remove any residue. Use
the recommended Flush Tank (Pg. 30).
10. Clean or replace the Mixing Chamber as required.
11. 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.

MAINTENANCE
13
Screen Screw and Component Maintenance
CAUTION! To avoid possible contamination by the residual chemical
inside the Gun do not interchange the Isocyanate (A) parts with the
Polyol (R) parts. The Isocyanate (A) side is identified with an (A) on
the Screen Screw Head and the Polyol (R) side is marked with an (R)
on the Screen Screw Head. The Gun Block is also marked with (A) and
(R) designation.
1. CLOSE the Manual Valves 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. SHUT OFF air supply to the gun.
4. Set the Gun Lock to the LOCKED position.
5. Use the Wrench provided (Pg. 40) or a ½” wrench to remove the Screen Screw.

MAINTENANCE
14
6. To clean or replace the Screens, remove the larger O-Ring and Back Up Ring.
7. Remove the Side Seal and Spring from the Screen Screw. Inspect all components
and O-rings. Clean or replace as required.
8. Inspect for damage and apply PMC lubrication to all O-rings and threads and
reassemble in reverse order .
9. The gun is now ready for service .
NOTE! When replacing O-rings, replace ALL O-rings included in the
appropriate Kit.

MAINTENANCE
15
Air Manifold Maintenance
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. Set the Gun Lock to the LOCKED position.
3. Disconnect the air supply from the gun.
4. Use a suitable size wrench and remove the air fitting from the rear of the Air Manifold.
5. Remove the Trigger from the assembly to access the front of the Air Manifold.
6. Use the Tool provided (Pg. 40) and remove the Spool Valve Retainer.
7. Remove the Spring, Spool Valve Liner, Spool Valve, and Liner Bushing using the
tool provided (Pg. 40), as shown below.
8. Remove and discard all O-Rings.

MAINTENANCE
16
9. Replace the O-rings and Spring supplied in KT-826 (Pg. 26). Extra PMC grease will
facilitate reassembly.
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 Spool
Valve to facilitate reassembly.
11. Reattach the Trigger and Air Manifold assembly in reverse order.

MAINTENANCE
17
Air Cylinder Maintenance
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. DISCONNECT air supply to gun.
4. Set the Gun Lock to the LOCKED position.
5. Loosen the Screen Screws using the Wrench provided
(Pg. 40) a ½” wrench.
6. Disconnect Coupling Block from Gun Block using the
Nut Driver provided (Pg. 40).