PMC AP-3 User manual

AP-3 Air Purge Spray & Pour Gun
Service Manual
Ref. # MN-04030
Revision 1.5
April 20, 2020
For use with non-flammable Foam and Polyurea
For professional use only
Not for use in explosive atmospheres
Polyurethane Machinery Corp.
1 Komo Drive, Lakewood, NJ 08701
732-415-4400
URL: http://www.polymacusa.com

AP-3
TABLE OF CONTENTS
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TABLE OF CONTENTS
WARRANTY .......................................................................................................................................1
SAFETY AND HANDLING..................................................................................................................3
CHARACTERISTICS ..........................................................................................................................5
TECHNICAL SPECIFICATIONS.........................................................................................................5
GENERAL DESCRIPTION..................................................................................................................6
INSTALLATION AND START UP.......................................................................................................7
SHUTDOWN PROCEDURES .............................................................................................................8
LOSS OF AIR PRESSURE/EMERGENCY SHUT-OFF.......................................................................8
MAINTENANCE..................................................................................................................................9
GUN BLOCK AND MIXING CHAMBER REMOVAL.......................................................................11
SCREEN SCREW AND COMPONENT MAINTENANCE ..............................................................13
AIR CYLINDER MAINTENANCE...................................................................................................14
CARTRIDGE VALVE REMOVAL...................................................................................................16
GUN OPERATION ............................................................................................................................17
TRIGGERED OFF.........................................................................................................................17
TRIGGERED ON...........................................................................................................................18
TROUBLESHOOTING GUIDE..........................................................................................................19
REFERENCE GUIDE........................................................................................................................20
CHAMBER KITS............................................................................................................................20
PCT KITS ......................................................................................................................................22
CHAMBER/PCT KITS....................................................................................................................25
SOFT CHAMBER KITS .................................................................................................................25
DIAMOND PLATED CHAMBER/PCT KITS ...................................................................................26
AP-2/AP-3 SPARE PARTS KITS DESC ........................................................................................27
AP-2/AP-3 SPARE PARTS KITS...................................................................................................28
AP-2/AP-3 SPARE PARTS KITS (DIAMOND PLATED) ................................................................29
PMC RECOMMENDED O-RING GREASE....................................................................................30
MISCELLANEOUS PARTS/KITS......................................................................................................31
SIDE SEAL KIT, RESIN................................................................................................................31
SCREEN SIZES ............................................................................................................................31
A & R SCREEN SCREW ASSEMBLY KITS ..................................................................................31
AP-3 O-RING KIT..........................................................................................................................32
AIR CYLINDER REBUILD KIT.......................................................................................................32
1/4” UNHEATED STAINLESS STEEL HOSE ASSEMBLY ............................................................32

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RECOMMENDED SPARE PARTS................................................................................................33
OPTIONAL PARTS.......................................................................................................................33
FLUSH TANKS..............................................................................................................................34
PARTS IDENTIFICATION.................................................................................................................35
FINAL GUN ASSEMBLY ...............................................................................................................35
MANUAL VALVE ASSEMBLY.......................................................................................................37
CHECK VALVE ASSEMBLY..........................................................................................................38
COUPLING BLOCK ASSEMBLY...................................................................................................39
SCREEN SCREW ASSEMBLY .....................................................................................................40
END CAP ASSEMBLY...................................................................................................................41
LIST OF TOOLS............................................................................................................................42
APPENDIX........................................................................................................................................43
GREASE GUN ASSEMBLY...........................................................................................................43
MIXING CHAMBER FLOW RATES...............................................................................................44
CHAMBER/ORIFICE COMPARISON CHART...............................................................................44
Before installing the AP-3 Gun and start-up, carefully read all the
technical and safety documentation included in this manual. Pay
special attention to the information in order to know and understand
the operation and the conditions of use of the AP-3 Gun. All of the
information is aimed at improving user safety and avoiding possible
breakdowns from the incorrect use of the AP-3 Gun.

AP-3
WARRANTY
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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
reasonablefreight charges incurred by Customer in returning the Defective ProducttoPMC, 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
havebeenmodified or altered, or when theserialnumber on the Product appearsto havebeen
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 ComponentsandAccessories: Non-PMC manufactured components and accessories
thatareusedintheoperationoftheProductarenotcoveredbythisWarranty.Suchcomponentsand
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 PMCdetermines has
been damaged or fails to operate properly due to misuse, negligence, abuse, carelessness,
neglect, or accident. By way of example only, this includes:
• Normal wear and tear.
• Improper or unauthorized installation, repair, alteration, adjustment or modification of
the Product.
• Use of heating devices, pumping equipment, dispensers, or other parts or accessories with
the Product that have not been approved or manufactured by PMC.
• FailuretofollowtheoperatinginstructionsandrecommendationsprovidedbyPMCmaycause
lossor damagetopersonnel, equipment,or workarea.
• Fire, flood, “acts of God,” or other contingencies beyond the control of PMC.

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WARRANTY
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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 ANDFITNESSFORA PARTICULARPURPOSEANDALLOTHER
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 ORDAMAGES.
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.

AP-3
SAFETY AND HANDLING
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SAFETY AND HANDLING
This chapter contains important information on the safety, handling and use of your AP-3 Gun.
Before installing the AP-3 Gun and start-up, carefully read all the
technical and safety documentation included in this manual. Pay
special attention to the information in order to know and
understand the operation and the conditions of use of the AP-3
Gun. All of the information is aimed at improving user safety and
avoiding possible breakdowns from the incorrect use of the AP-
3 Gun.
WARNING! Presents information to alert of a situation that
might cause serious injuries if the instructions are not
followed.
CAUTION! Presents information that indicates how to avoid damage
to the AP-3 Gun or how to avoid a situation that could cause injuries.
NOTE! Is relevant information of a procedure being carried out.
Careful study of this Manual will enable the operator to know the characteristics of the Gun and
the operating procedures. By following the instructions and recommendations contained, you will
reduce the potential risk of accidents in the installation, use or maintenance of the AP-3 Gun;
you will provide a better opportunity for incident-free operation for a longer time, greater
productivity and the possibility of detecting and resolving problems fast and simply.
Keep this Service Manual for future reference to useful information. If you lose this Manual, ask
for a new copy from your PMC Service Center or go to the company website
(www.polymacusa.com).
The AP-3 Gun has been designed and built for the application of polyurea chemical systems,
polyurethane foam chemical systems and some two-component epoxy systems.

AP-3
SAFETY AND HANDLING
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WARNING! The design and configuration of the AP-3 Gun
does not allow its use in potentially explosive atmospheres
or exceeding the pressure and temperature limits described
in the Technical Specifications of this Manual to be
exceeded.
Always use liquids and solvents that are compatible with the AP-3 Gun. If in doubt, consult PMC
Technical Service.
When working with the AP-3 Gun, it is recommended that the operator wear suitable clothing and
elements of personal protection, including, without limitation, gloves, protective goggles,
safety footwear and face masks. Use breathing equipment when working with the Gun in
enclosed spaces or in areas with insufficient ventilation. The introduction and follow-up of safety
measures must not be limited to those described in this Manual. Before beginning to work with
the Gun, a comprehensive analysis must be made of the risks derived from the products to be
dispensed, the type of application and the working environment.
To prevent possible injury caused by incorrect handling of the
materials and solvents used in the process, carefully read the
Safety Data Sheet (SDS) 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-3
CHARACTERISTICS
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CHARACTERISTICS
TECHNICAL SPECIFICATIONS
Maximum Working Pressure: _______________________________ 3,500 psi (245 Bar)
Air Pressure:_________________________________________________90-125 psi (6.2-8.6 Bar)
MaximumOutput(1:1ratio): ____________________________________50 lb/min (22.7 L/min)
Minimum Output (1:1 ratio): ____________________________________ 3.3 lb/min (1.55 L/min)
Opening Force @ 110 psi (8 Bar): ____________________________________ 200 lb (91 kg)
Closing Force @ 110 psi (8 Bar): ________________________________________ 200 lb (91 kg)
Weight (Not including Coupling Block): _____________________________ 2.4 lbs (1.1 kg)
Weight (Including Coupling Block):_________________________________ 3.1 lbs (1.4 kg)

AP-3
GENERAL DESCRIPTION
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GENERAL DESCRIPTION
For better knowledge of the AP-3 Gun, the main components and their description are shown.
For a more precise identification, see the Parts Identification section.

AP-3
INSTALLATION AND START UP
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INSTALLATION AND START UP
CAUTION! When working with the AP-3 Gun or
performing maintenance work, wear suitable
safety protection in accordance with the
recommendations and specifications provided
by the product suppliers.
1. Install Coupling Block to the hose.
2. Ensure the Manual Valves are CLOSED by turning them to the
full clockwise position.
CAUTION! Excessive force closing or opening
the Manual Valves may result in damage to the
Manual Valves and/or Coupling Block.
3. Set the Gun Lock to the LOCKED position.
4. Ensure Check Valve Assemblies are properly installed in the
Gun Block.
5. Connect the Coupling Block to the Gun Block using the Nut
Driver provided (Pg. 42). Tighten Coupling Block until there
is a hand tight seal.
6. Connect the air supply with 90 to 125 psi (6.2 to 8.6 bar) to the gun.
NOTE! The material delivery hoses are color coded Red and Blue. The Red corresponds to
the Isocyanate (A) and the Blue to the Polyol(R). To avoid connection errors, the (A) and (R)
hoseshaveconnectionswithdifferentsizestoavoidincorrectconnections.[ Set the Gun Lock
to the OPEN position.]
7. Pull the Trigger several times to check for correct
movement of the Mixing Chamber and PCT.
8. Ensure the Proportioner and supply system are in
the ready position and the material pressures and
temperatures are set as recommended by the
chemical supplier (see Machine Service Manual).
9. OPEN each Manual Valve by turning three (3) full
turns counter clockwise.
10. Perform a test spray.

AP-3
SHUTDOWN PROCEDURES
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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. 42), lubricate the
Mixing Chamber through the Grease Fitting until a fine
mist of grease is sprayed from the gun (Pg. 43 for Grease
Gun Assembly Instructions). This action will help prevent
Isocyanate from crystallizing on the mixing chamber
which may cause damage to the internal parts.
NOTE! The injection of grease supplied with the
Gun at the end of the day will minimize
maintenance time and can eliminate the need to
remove the Mixing Chamber each day to clean it.
Use of grease with high moisture content will
not achieve the desired results. PMC Grease is
recommended. Use of incorrect grease will
cause blockage in the mixing chamber.
3. Disconnect the air supply.
LOSS OF AIR PRESSURE/EMERGENCY SHUT-OFF
1. SHUT OFF air supply to gun.
2. Using the palm of your hand, push in on the Gun Lock and rotate clockwise to set it to
the LOCKED position.
3. CLOSE each Manual Valve.
CAUTION! Excessive force closing or opening Manual Valves may
result in damage to the Manual Valves and/or Coupling Block.

AP-3
MAINTENANCE
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MAINTENANCE
To obtain maximum performance from your AP-3 Gun, it is necessary to periodically perform
certain maintenance operations.
WARNING! Before proceeding with any maintenance work on
the AP-3 Gun, trigger the gun to remove internal material
pressure, ensure the Manual Valves are CLOSED, ensure the
Gun Lock is in the LOCKED position, and SHUT
OFF/DISCONNECT the air supply. It is recommended to
remove the Gun from the Coupling Block.

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MAINTENANCE
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To prevent possible injury caused by incorrect handling of the
materials and solvents used in the process, carefully read the
Safety Data Sheet (SDS) 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-3
MAINTENANCE
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GUN BLOCK AND MIXING CHAMBER REMOVAL
1. CLOSE the Manual Valves by turning them to the full clockwise position.
CAUTION! Excessive force opening or closing
Manual Valves may result in damage to the
Manual Valves and/or Coupling Block.
2. Point the gun over a waste container and pull the Trigger
to relieve pressure.
3. Using the Nut Driver provided (Pg. 42), remove the
Coupling Block from the Gun Block.
4. Flush the Gun Block to remove any residue. Use the
recommended Flush Tank (Pg. 34)
5. Shut off air to the gun.
6. .Using the Wrench provided (Pg. 42) or a ½”
wrench, loosen or remove both Screen Screws to
facilitate easy removal of the Mixing Chamber, as
shown below.

AP-3
MAINTENANCE
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7. Loosen the PCT, but do not remove.
8. Using the Nut Driver (Pg. 42) provided, remove the
gun block screws mounting screws. (see page 6,
item O)
9. Disconnect the Gun Block from the Cylinder.
10. Remove the Mixing Chamber and PCT from the Gun
Block.
11. Clean or replace the Mixing Chamber as required.
12. When reassembling in reverse order, it is
recommended to screw the PCT onto the Mixing
Chamber first, then insert the Mixing Chamber
into the front of the Gun Block. This helps to
reduce wear on the PCT O-ring.
NOTE! A small amount of PMC grease applied
to the Mixing Chamber and Side Seals upon
assembly is recommended.
CAUTION! Use wooden or plastic tools or a brass brush for cleaning.
Do not use metal or abrasive tools that can scratch or damage the
contact surfaces.

AP-3
MAINTENANCE
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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. Using the Nut Driver provided (Pg. 35), remove the Coupling Block from the Gun Block.
4. Flush the gun block to remove any residue. Use the recommended Flush Tank (Pg. 34)
5. SHUT OFF air supply to the gun.
6. Set the Gun Lock to the LOCKED position.

AP-3
MAINTENANCE
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7. Use the Wrench provided (Pg. 42) or a ½” wrench to remove the Screen Screw.
8. To clean or replace the Screens, remove the larger O-Ring and Back Up Ring.
9. Remove the Side Seal and Spring from the Screen Screw. Inspect all components and O-
rings. Clean or replace as required.
10. Inspect for damage and apply PMC lubrication to all O-rings and threads and reassemble in
reverse order .
11. The gun is now ready for service .
NOTE! When replacing O-rings, replace ALL O-rings included in the
appropriate Kit.
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. Flush the gun block to remove any residue. Use the
recommended Flush Tank (Pg. 34)
6. Loosen the Screen Screws using the Wrench provided
(Pg. 42) a ½” wrench.
7. Disconnect Coupling Block from Gun Block using the
Nut Driver provided (Pg. 42).

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MAINTENANCE
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8. Using the Nut Driver provided, remove the gun block mounting screws and disconnect the
Gun Block.
9. Using an 11/16” Wrench, remove the End Cap.
10. Push on the front of the Piston to remove the Piston from the rear of the Air Cylinder.
11. Inspect the O-rings on the Piston and Shaft and replace as required.
12. Inspect the O-ring on the End Cap and replace as required.
NOTE! When replacing O-rings, replace ALL O-rings included in the 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.

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MAINTENANCE
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CARTRIDGE VALVE REMOVAL
1. Remove the trigger from the handle.
2. Remove the Snap Ring from in front of the Cartridge Valve.
3. Eject the Cartridge Valve by pushing it out through the hole indicated by the arrow above
WARNING! It is very important to remove the cartridge valve before
cleaning the gun with any type of solvent. If the cartridge valve is
soaked in solvent its internal O-Rings could be damaged and it will no
longer function properly. If the cartridge valve is compromised the
trigger will not respond correctly which could lead to severe gun
malfunction. If you are experiencing inconsistent trigger behavior,
consider replacing the cartridge valve.
.

AP-3
GUN OPERATION
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GUN OPERATION
TRIGGERED OFF
1. Compressed dry air enters through the rear or bottom of the Gun Handle.
2. The air is directed through the cartridge valve and into the Rear of the Piston in the Air
Cylinder, moving the Piston (and Mixing Chamber) forward to the CLOSED position.
3. In the CLOSED position, the orifices in the Mixing Chamber are NOT aligned with the Side
Seal ports. The orifices in the Mixing Chamber are exposed to the air/grease chamber in the
Gun Block.
4. Purge air passes through the Spool Valve and the Check Valve, and into the Air Cylinder and
Gun Block.
5. Purge air and residual grease enter the Mixing Chamber and pass through the Mixing
Chamber and PCT, expelling mixed material out of the chamber area in the process.
6. Purge air is also expelled from the PCT in a circular trajectory to keep the tip clean.
Compressed
Shop Air
90 –120 PSI
(6.2 –8.3 Bar)