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PMC 202745 Service Manual

Xtreme air purge spray & pour gun
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Xtreme Air Purge Spray & Pour Gun
Service Manual
Ref. # 202745
Revision 1.0
January 4, 2021
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

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  • Page 1 Xtreme Air Purge Spray & Pour Gun Service Manual Ref. # 202745 Revision 1.0 January 4, 2021 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...

  • Page 2: Table Of Contents

    DIAMOND PLATED CHAMBER/PCT KITS .................. 24 AP-2/AP-3 SPARE PARTS KITS DESC ..................25 AP-2/AP-3 SPARE PARTS KITS (DIAMOND PLATED) ..............26 PMC RECOMMENDED O-RING GREASE ..................27 MISCELLANEOUS PARTS/KITS ...................... 28 SIDE SEAL KIT, RESIN ........................ 28 SCREEN SIZES ..........................28 A &...
  • Page 3 Xtreme Gun. All of the information is aimed at improving user safety and avoiding possible breakdowns from the incorrect use of the Xtreme Gun. 202745 REV 1.0: January 4, 2021...

  • Page 4: Warranty

    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...
  • Page 5 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;...

  • Page 6: Safety And Handling

    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).
  • Page 7 Technical Specifications of this Manual to be exceeded. Always use liquids and solvents that are compatible with the Xtreme Gun. If in doubt, consult PMC Technical Service. When working with the Xtreme 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.

  • Page 8: Characteristics

    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) 202745 REV 1.0: January 4, 2021...

  • Page 9: General Description

    Xtreme GENERAL DESCRIPTION GENERAL DESCRIPTION For better knowledge of the Xtreme Gun, the main components and their description are shown. For a more precise identification, see the Parts Identification section. 202745 REV 1.0: January 4, 2021...

  • Page 10: Installation And Start Up

    (see Machine Service Manual). 9. OPEN each Manual Valve by turning three (3) full turns counter clockwise. 10. Perform a test spray. 202745 REV 1.0: January 4, 2021...

  • Page 11: Shutdown Procedures

    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.

  • Page 12: Maintenance

    Xtreme Gun, trigger the gun to remove internal material pressure, ensure the Manual Valves are CLOSED, ensure the Lock LOCKED position, SHUT OFF/DISCONNECT the air supply. It is recommended to remove the Gun from the Coupling Block. 202745 REV 1.0: January 4, 2021...
  • Page 13 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. 202745 REV 1.0: January 4, 2021...

  • Page 14: Gun Block And Mixing Chamber Removal

    6. 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. 7. Loosen the PCT, but do not remove. 202745 REV 1.0: January 4, 2021...
  • Page 15 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.

  • Page 16: Screen Screw And Component Maintenance

    3. Using the Nut Driver provided (Pg. 40), remove the Coupling Block from the Gun Block. 4. Flush the gun block to remove any residue. Use the recommended Flush Tank (Pg. 32) 5. SHUT OFF air supply to the gun. 6. Set the Gun Lock to the LOCKED position. 202745 REV 1.0: January 4, 2021...

  • Page 17: Air Cylinder Maintenance

    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.
  • Page 18 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.

  • Page 19: Spool Valve Maintenance

    When replacing O-rings, replace ALL O-rings included in 202756 Rebuild Kit. 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. 202745...

  • Page 20: Triggered Off

    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. 202745 REV 1.0: January 4, 2021...

  • Page 21: Triggered On

    PCT. 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. 202745 REV 1.0: January 4, 2021...

  • Page 22: Troubleshooting Guide

    Buildup of material Plugged air passages in PCT and Gun Block Clean, see page 11 on PCT Air Cylinder O-rings damaged Replace, see page 38 Air leakage from Handle Spool Valve Damaged Replace, see page 16 202745 REV 1.0: January 4, 2021...

  • Page 23: Reference Guide

    MIXING NOZZLE MIXING GU-814-DP- GU-03023 #56 DRILL (.0465) CHAMBER PORT RM-814-DP-02 CHAMBER #02 DIAMOND PLATED 200480 2mm DRILL (.0787) MIXING NOZZLE MIXING GU-814-DP- GU-03050 #55 DRILL (.0520) CHAMBER PORT RM-814-DP-02X CHAMBER #02X DIAMOND PLATED 202745 REV 1.0: January 4, 2021...

  • Page 24: Pct Kits

    CONTROL TIP 000 PCT PURGE GU-03033 #65 DRILL (.0350) PORT PCT PURGE GU-03035 #54 DRILL (.055) PORT 1.25mm DRILL PCT NOZZLE 200477 GU-815-00 (.0492) PORT O-RING, VITON, - OR-00042A PATTERN RM-815-00 CONTROL TIP 00 202745 REV 1.0: January 4, 2021...
  • Page 25 CONTROL TIP 01X PCT PURGE GU-03033 #65 DRILL (.0350) PORT PCT PURGE GU-03035 #54 DRILL (.055) PORT PCT NOZZLE GU-03024 #51 DRILL (.0676) GU-815-02 PORT O-RING, VITON, - OR-00042A PATTERN RM-815-02 CONTROL TIP 02 202745 REV 1.0: January 4, 2021...
  • Page 26 PATTERN RM-815-04 CONTROL TIP #65 DRILL PCT PURGE GU-03033 (.0350) PORT PCT PURGE GU-03035 #54 DRILL (.055) PORT 2.9mm DRILL PCT NOZZLE 201093 200919 (.114) PORT O-RING, VITON, OR-00042A -016 PATTERN 200918 CONTROL TIP 202745 REV 1.0: January 4, 2021...

  • Page 27: Diamond Plated Chamber/Pct Kits

    O-RING, VITON, -016 GU-814-DP-04 CHAMBER 04 W/ DRILLS KT-814-DP-04 GU-815-04 PCT 04 RND W/ DRILLS OR-00042A O-RING, VITON, -016 200920 CHAMBER 05 W/ DRILLS KT-814-DP-05 200918 PCT 05 RND W/ DRILLS OR-00042A O-RING, VITON, -016 202745 REV 1.0: January 4, 2021...

  • Page 28: Ap-2/Ap-3 Spare Parts Kits Desc

    AP-2/AP-3-01X SPARE PARTS KIT, DP 202541 AP-2/AP-3-02 SPARE PARTS KIT, DP 202542 AP-2/AP-3-02X SPARE PARTS KIT, DP 202543 AP-2/AP-3-03 SPARE PARTS KIT, DP 202544 AP-2/AP-3-04 SPARE PARTS KIT, DP 202545 AP-2/AP-3-05 SPARE PARTS KIT, DP 202745 REV 1.0: January 4, 2021...

  • Page 29: Ap-2/Ap-3 Spare Parts Kits (Diamond Plated)

    CHECK VALVE KIT OR-00026A O-RING, VITON, -129 OR-00042A O-RING, VITON, -016 OR-00043B O-RING, AFLAS, -010 OR-800 #013 BACK UP RING OR-801A O-RING, AFLAS, -013 O-RING, BUNA, OR-804 2MMX4MM OR-805 O-RING, VITON, -108 SP-04005 SPRING; SIDE SEAL 202745 REV 1.0: January 4, 2021...

  • Page 30: Pmc Recommended O-Ring Grease

    DRILL 1.32mm (.0520”) GU-03050 DRILL 1.09mm (.0430”) GU-03052 DRILL 1.61mm (.0635”) GU-03053 DRILL 1.78mm (.0700”) GU-03054 PMC RECOMMENDED O-RING GREASE PART NUMBER DESCRIPTION GP-LUBEGREASE LUBRIPLATE GREASE TL-04003 GREASE TUBE FOR USE W/ GREASE GUN 202745 REV 1.0: January 4, 2021...

  • Page 31: Miscellaneous Parts/Kits

    SCREEN SCREW SEAL GU-819-A A SCREEN SCREW KT-819-A OR-800 #013 BACK UP RING OR-801A O-RING, AFLAS, -013 GU-04007 SCREEN SCREW SEAL GU-819-R R SCREEN SCREW KT-819-R OR-800 #013 BACK UP RING OR-801A O-RING, AFLAS, -013 202745 REV 1.0: January 4, 2021...

  • Page 32: O-Ring Kit

    O-RING, BUNA, 2mm X 4mm 202715 WASHER, FLAT, NO 3, SS 1/4” UNHEATED STAINLESS STEEL HOSE ASSEMBLY PART NUMBER DESCRIPTION MA-41 HOSE PACKAGE KIT, UNHEATED REPLACEMENT HOSE, “A” SIDE MA-41A REPLACEMENT HOSE, “R” SIDE MA-41R 202745 REV 1.0: January 4, 2021...

  • Page 33: Spool Valve Rebuild Kit

    O-RING, VITON, -129 OR-00042A O-RING, AFLAS, -016, BLK OR-00043B O-RING, AFLAS, -010, 80D OR-800 BACKUP RING, -013 OR-801A O-RING, AFLAS, -013, 80D OR-804 O-RING, BUNA, 2mm X 4mm SP-04005 SPRING, SIDE SEAL TL-04003 GREASE TUBE 202745 REV 1.0: January 4, 2021...

  • Page 34: Recommended Spare Parts

    POUR TIP GU-815-53 POUR NOZZLE GU-815-52 PCT FLAT TIP RETAINER ASSEMBLY GU-815-52-1 PCT FLAT TIP BODY GU-815-52-2 PCT FLAT TIP GASKET GU-815-52-3 PCT FLAT TIP RETAINER OR-00042A O-RING, VITON, -016 202454 SIDE SEAL, .125, RESIN 202745 REV 1.0: January 4, 2021...

  • Page 35: Flush Tanks

    1 QT Mini Flush Tank 200426 – Solvent Flush Kit, 2.5 Gal, AP 200216 – Solvent Flush Kit, Quart, AP 200427 – Solvent Flush Kit, 2.5 Gal, F-AP 200217 – Solvent Flush Kit, Quart, F-AP 202745 REV 1.0: January 4, 2021...

  • Page 36: Parts Identification

    Xtreme PARTS IDENTIFICATION PARTS IDENTIFICATION FINAL GUN ASSEMBLY NOTE: WHEN ASSEMBLING BE SURE TO APPLY GREASE TO ALL O-RINGS. THIS ENSURES GOOD PERFORMANCE AND REDUCES RISK OF GUN MALFUNCTION. 202745 REV 1.0: January 4, 2021...
  • Page 37 O-RING, AFLAS, -010 OR-00026A O-RING, VITON, -129 GU-844 END CAP ASSEMBLY, AP-2/3 200513 O-RING, VITON, 9.25mm X 1.78mm OR-00002A O-RING, VITON, -008 OR-804 O-RING, BUNA, 2mm X 4mm 202715 WASHER, FLAT, NO 3, SS 202745 REV 1.0: January 4, 2021...

  • Page 38: Manual Valve Assembly

    MANUAL VALVE SEAT OR-016 007 VITON CURVED BACKUP RING OR-015 #007 AFLAS O-RING MANUAL VALVE SOFTWARE KIT (KT-020) PART NUMBER DESCRIPTION GU-LOCTITE LOCTITE #242 OR-015 O-RING, AFLAS, -007 OR-016 #007 VITON CURVED BACKUP RING 202745 REV 1.0: January 4, 2021...

  • Page 39: Check Valve Assembly

    Xtreme PARTS IDENTIFICATION CHECK VALVE ASSEMBLY (KT-850) CHECK VALVE ASSEMBLY ITEM QTY PART NUMBER DESCRIPTION GU-851 CHECK VALVE SEAT GU-852 CHECK VALVE SPRING 1/4” CHECK VALVE BALL GU-853 202745 REV 1.0: January 4, 2021...

  • Page 40: Coupling Block Assembly

    ITEM QTY PART NUMBER DESCRIPTION GU-04001-01 COUPLING BLOCK BODY TN-04192 1/8 NPT PIPE PLUG GU-020 MANUAL VALVE ASSY RA-00005A 1/8 NPT X #5 JIC SWIVEL RA-00006A 1/8 NPT X #6 JIC SWIVEL TN-04193 COUPLING BLOCK MOUNTING SCREW 202745 REV 1.0: January 4, 2021...

  • Page 41: Screen Screw Assembly

    “R” SCREEN SCREW GU-819-R “A” SCREEN SCREW GU-819-A GU-04007 SCREEN SCREW SEAL OR-00043B O-RING, AFLAS, -010 OR-800 #013 BACK UP RING OR-801A O-RING, AFLAS, -013 SP-04005 SPRING; SIDE SEAL *Included in KT-819-R and KT-819-A (Pg. 28) 202745 REV 1.0: January 4, 2021...

  • Page 42: End Cap Assembly

    ENSURES GOOD PERFORMANCE AND REDUCES RISK OF GUN MALFUNCTION. SCREEN SCREW COMPONENTS ITEM QTY PART NUMBER DESCRIPTION GU-803 CYLINDER END CAP GU-804 LOCK KNOB GU-806 SPRING GU-807 TWO POSITION STOP GU-831 RETAINING SCREW OR-00026A O-RING, VITON, -129 OR-00043B O-RING, AFLAS, -010 202745 REV 1.0: January 4, 2021...

  • Page 43: List Of Tools

    202340 QD,PLUG,1/4 IND X 1/4 FNPT,STL GP-00101 DOUBLE ENDED PIN VISE GU-04019 AIR HOSE TL-00002 GREASE GUN TL-04001 5/16 SPINTITE, NUT DRIVER TL-04003 GREASE TUBE TL-09 OPEN END WRENCH TL-10 CHECK VALVE REMOVAL TOOL 202745 REV 1.0: January 4, 2021...

  • Page 44: Flat Tip Adapter Kits

    NOTE: This kit is intended for use with 201099 (PCD, TP-100, PX-7) for foam applications. PCT FLAT TIP RETAINER ASSEMBLY (201152) ITEM PART NUMBER DESCRIPTION 201150 FLAT TIP ADAPTER GASKET 201151 FLAT TIP RETAINER GU-815-52-1 FLAT TIP ADAPTER BODY 202745 REV 1.0: January 4, 2021...

  • Page 45: Flat Tip Retainer Assembly

    PCT FLAT TIP RETAINER ASSEMBLY (GU-815-52) ITEM PART NUMBER DESCRIPTION 200712 DRILL, 3.10mm, (.1220"/3.10mm) GU-03054 DRILL, #50, (.0700"/1.78mm) GU-815-52-1 FLAT TIP ADAPTER BODY GU-815-52-2 PCT FLAT TIP GASKET GU-815-52-3 PCT FLAT TIP RETAINER OR-00042A O-RING, VITON, -016 202745 REV 1.0: January 4, 2021...

  • Page 46: Appendix

    Screw the top of the grease gun (2a) back on to the bottom of the grease gun (2b). Push down on the latch (2d) to release the plunger and push plunger completely back in. 202745 REV 1.0: January 4, 2021...

  • Page 47: Mixing Chamber Flow Rates

    GU-814-01X 10.5 GU-814-02 GU-814-02X GU-814-03 GU-814-04 200920 *Flow rates will vary depending on viscosity, hose length and machine efficiency. CHAMBER/ORIFICE COMPARISON CHART Competitive Air Purge PMC Air Purge Chamber Chamber Orifice Size Orifice Size Number Number 000 (AR2020) 0.0200 0.0280 00 (AR2929) 0.0290...
  • Page 48 Xtreme APPENDIX 202745 REV 1.0: January 4, 2021...

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