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Xtreme Air Purge Spray & Pour Gun
Service Manual
Ref. # 202745
Revision 1.6
April 17, 2023
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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Table of Contents
Related Manuals for PMC Xtreme 202745
Summary of Contents for PMC Xtreme 202745
- Page 1 Xtreme Air Purge Spray & Pour Gun Service Manual Ref. # 202745 Revision 1.6 April 17, 2023 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 2: Table Of Contents
Xtreme TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS ........................i WARRANTY ............................1 SAFETY AND HANDLING ........................3 CHARACTERISTICS .......................... 5 TECHNICAL SPECIFICATIONS ......................5 GENERAL DESCRIPTION ........................6 INSTALLATION AND START UP ....................... 7 EXPANSION PLUG OPERATION ....................8 SHUTDOWN PROCEDURES ...................... -
Page 3: Table Of Contents
Xtreme TABLE OF CONTENTS 202756: SPOOL VALVE REBUILD KIT ..................37 202888: O-RING KIT, XTREME ..................... 38 202888: O-RING KIT, XTREME ..................... 38 203370|203371: GUN BLOCK KIT ....................39 202546: SIDE SEAL KIT, ENGR RESIN ..................40 203386: FULL GUN REBUILD KIT, XTREME ................41 SCREEN SCREW SCREEN SIZE OPTIONS ................ -
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;...
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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.
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Page 8: Characteristics
Xtreme CHARACTERISTICS CHARACTERISTICS TECHNICAL SPECIFICATIONS Maximum Working Pressure: _______________________________ 3,500 psi (245 Bar) Air Pressure: _________________________________________________ 90-125 psi (6.2-8.6 Bar) Maximum Output (1:1 ratio): ____________________________________ 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): _____________________________ 2.2 lbs (1.1 kg) Weight (Including Coupling Block): _________________________________ 2.9 lbs (1.4 kg) -
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 1.6: April 17, 2023... -
Page 10: Installation And Start Up
Xtreme INSTALLATION AND START UP INSTALLATION AND START UP CAUTION! When working with the Xtreme 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 hoses. 2. -
Page 11: Expansion Plug Operation
Xtreme INSTALLATION AND START UP EXPANSION PLUG OPERATION 1. Use a 3/16” Allen Key (P/N 202768 in Tool Kit) to tighten the screw in the Expansion Plug Assembly in the bottom of the XTREME handle. 2. The serrated nut will compress the rubber segment within the handle and keep the Expansion Plug Assembly securely fastened. -
Page 12: 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 13: Maintenance
Xtreme MAINTENANCE MAINTENANCE To obtain maximum performance from your Xtreme Gun, it is necessary to periodically perform certain maintenance operations. WARNING! Before proceeding with any maintenance work on the Xtreme Gun, trigger the gun to remove internal material pressure, ensure the Manual Valves are CLOSED, ensure the Lock LOCKED position,... - Page 14 Xtreme MAINTENANCE 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.
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Page 15: Gun Block And Mixing Chamber Removal
Xtreme MAINTENANCE 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. - Page 16 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.
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Page 17: Screen Screw And Component Maintenance
Xtreme MAINTENANCE 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. -
Page 18: 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 19 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.
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Page 20: 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 21: Triggered Off
Xtreme MAINTENANCE TRIGGERED OFF 1. Compressed dry air enters through the rear of the Gun Handle. 2. The air is directed through the spool valve and into the Rear of the Piston in the Air Cylinder, moving the Piston (and Mixing Chamber) forward to the CLOSED position. 3. -
Page 22: Triggered On
Xtreme MAINTENANCE TRIGGERED ON 1. Compressed dry air is directed through the spool valve and into the front, filling the cavity and pushing the Piston and Chamber backwards. 2. The orifices in the Chamber are now aligned with the Side Seals and exposed to high pressure chemical. -
Page 23: Troubleshooting Guide
Xtreme TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE SOLUTION Insufficient air pressure (minimum 90 psi, 6.2 bar) Ensure 90 psi (6.2 Bar) PCT not flush with Gun Block when Gun Failed Spool Valve Replace, see page 16 is triggered Air passages plugged Clean, See page 19 Lock is in “Locked”... -
Page 24: 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 1.6: April 17, 2023... - Page 25 Xtreme PARTS IDENTIFICATION FINAL GUN ASSEMBLY ITEM PART NUMBER DESCRIPTION 200513 O-RING, VITON, 9.25X1.78mm 200673 TRIGGER, AP-3 201108 SCREW,HEX CAP,10-32 CUSTOM 201109 HHCS, #10-24 X 1.750, ZP STL 201110 SHOULDER BOLT,1/8D,1/8L,SS 201562 BUSHING, AIR CYLINDER 202409 SCREEN SCREW ASSY, A, AP-2/3 202410 SCREEN SCREW ASSY, R, AP-2/3 202568...
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Page 26: 202409|202410: Screen Screw Assembly
Xtreme PARTS IDENTIFICATION 202409|202410: SCREEN SCREW ASSEMBLY GU-819-A GU-819-R 202409: SCREEN SCREW ASSEMBLY, A 202410: SCREEN SCREW ASSEMBLY, R ITEM PART NUMBER DESCRIPTION 202454 SIDE SEAL, .125, ENGR RESIN GU-818-40 FILTER SCREEN; 40 MESH GU-818-60 FILTER SCREEN; 60 MESH GU-818-80* FILTER SCREEN;... -
Page 27: 203337: Check Valve Assembly, Gun Block
Xtreme PARTS IDENTIFICATION 203337: CHECK VALVE ASSEMBLY, GUN BLOCK Use snap ring pliers (203374) included in tool kit for maintenance of Check Valve assemblies 203337: CV ASSY, GUN BLOCK, XTREME ITEM PART NUMBER DESCRIPTION 203292 CHECK VALVE SEAT, XTREME 203293 O-RING, -011, AFLAS 203294 O-RING, -012, AFLAS... -
Page 28: 203350: Piston Assembly
Xtreme PARTS IDENTIFICATION 203350: PISTON ASSEMBLY 203350: PISTON ASSEMBLY, XTREME ITEM PART NUMBER DESCRIPTION 203346 PISTON, SHAFT, XTREME 203347 PISTON, DISK, XTREME 203348 HHCS, FLG, #10-32 x 0.625", GRD 5 ZP 203349 WASHER, LOCK, #10, ZP 202745 REV 1.6: April 17, 2023... -
Page 29: 203369: Expansion Plug Assembly
Xtreme PARTS IDENTIFICATION 203369: EXPANSION PLUG ASSEMBLY 203369: EXPANSION PLUG ASSEMBLY ITEM PART NUMBER DESCRIPTION 203362 PLUG, BASE, XTREME 203363 MTG TAB, STRAP, XTREME 203364 WASHER, FLAT, OS, 1/4, ZP 203365 RUBBER, .250 ID x .750 OD, RED 203366 NUT, SERR FLG, 1/4-20, STL 203380 SHCS, 1/4-20 x 2.000, 18-8 SS 203381... -
Page 30: Gu-020: Manual Valve Assembly
Xtreme PARTS IDENTIFICATION GU-020: MANUAL VALVE ASSEMBLY *See page XX for Manual Valve Software Kit Note: Orientation of the Back-Up Ring is critical. The concave side must be aligned with the O-Ring as shown above when it is installed. GU-020: MANUAL VALVE ASSEMBLY ITEM PART NUMBER DESCRIPTION... -
Page 31: Gu-04001: Coupling Block Assembly
Xtreme PARTS IDENTIFICATION GU-04001: COUPLING BLOCK ASSEMBLY STANDARD ORIENTATION OPTIONAL ORIENTATION GU-04001: COUPLING BLOCK ASSEMBLY ITEM PART NUMBER DESCRIPTION GU-020 MANUAL VALVE ASSY GU-04001-01 BODY, COUPLING BLOCK RA-00005A 1/8 NPT x #5 JIC SWIVEL RA-00006A 1/8 NPT X #6 JIC SWIVEL TN-04192 PIPE PLUG, 1/8 NPT, STL TN-04193... -
Page 32: Gu-844: End Cap Assembly
Xtreme PARTS IDENTIFICATION GU-844: END CAP ASSEMBLY END CAP ASSEMBLY (GU-844) ITEM 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 1.6: April 17, 2023... -
Page 33: Rebuild Kits & Spare Parts
Xtreme REBUILD KITS & SPARE PARTS REBUILD KITS & SPARE PARTS CHAMBER KITS DESCRIPTION KIT NUMBER PART NUMBER FOR USE WITH ILLUSTRATION (INCH) 200476 #63 DRILL (.0370) MIXING NOZZLE MIXING GU-814-DP-000 GU-03031 #70 DRILL (.0280) CHAMBER PORT RM-814-DP-000 CHAMBER #000 DIAMOND PLATED 1.25mm DRILL 200477... -
Page 34: Pct Kits
Xtreme REBUILD KITS & SPARE PARTS CHAMBER KITS (CONTINUED) DESCRIPTION KIT NUMBER PART NUMBER FOR USE WITH ILLUSTRATION (INCH) GU-03028 #44 DRILL (.0860) MIXING NOZZLE MIXING GU-814-DP-03 GU-03035 #54 DRILL (.055) CHAMBER PORT RM-814-DP-03 CHAMBER #03 DIAMOND PLATED 2.4mm DRILL 200481 MIXING NOZZLE (.0945) - Page 35 Xtreme REBUILD KITS & SPARE PARTS PCT KITS (CONTINUED) PART KIT NUMBER DESCRIPTION FOR USE WITH ILLUSTRATION NUMBER #65 DRILL PCT PURGE GU-03027 PORT (.0350) PCT PURGE 1.35mm DRILL 200478 AND NOZZLE (.0531) PORT GU-815-00X O-RING, AFLAS, OR-00042A -016 PATTERN CONTROL RM-815-00X TIP 00.X PCT PURGE...
- Page 36 Xtreme REBUILD KITS & SPARE PARTS PCT KITS (CONTINUED) PART KIT NUMBER DESCRIPTION FOR USE WITH ILLUSTRATION NUMBER PCT PURGE GU-03027 #65 DRILL (.0350) PORT PCT PURGE GU-03035 #54 DRILL (.055) PORT PCT NOZZLE 200480 2mm DRILL (.0787) GU-815-02X PORT O-RING, AFLAS, OR-00042A -016...
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Page 37: Diamond Plated Chamber & Pct Kits
Xtreme REBUILD KITS & SPARE PARTS DIAMOND PLATED CHAMBER & PCT KITS KIT NUMBER PART NUMBER DESCRIPTION GU-814-DP-000 CHAMBER 000 W/ DRILLS KT-814-DP-000 GU-815-000 PCT 000 RND W/ DRILLS OR-00042A O-RING, AFLAS, -016 GU-814-DP-00 CHAMBER 00 W/ DRILLS KT-814-DP-00 GU-815-00 PCT 00 RND W/ DRILLS OR-00042A O-RING, AFLAS, -016... - Page 38 Xtreme REBUILD KITS & SPARE PARTS DRILL BIT KITS KIT PART NUMBER PART DESCRIPTION NUMBER 200476 DRILL 0.94mm (.0370”) DRILL 1.25mm (.0492”) 200477 DRILL 1.35mm (.0531”) 200478 DRILL 2.00mm (.0787”) 200480 DRILL 2.40mm (.0945”) 200481 DRILL 2.90mm (.1142”) 201093 DRILL 2.87mm (.1130”) 201120 DRILL 1.04mm (.0410”) GU-03021...
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Page 39: 202744: Air Cylinder Rebuild Kit
Xtreme REBUILD KITS & SPARE PARTS 202744: AIR CYLINDER REBUILD KIT 202744: AIR CYLINDER REBUILD KIT ITEM PART NUMBER DESCRIPTION 201562 AIR CYLINDER BUSHING 202705 SEAT, CHECK VALVE 202714 BALL, CHECK VALVE 202775 SPRING, CHECK VALVE 203373 O-RING, -018, AFLAS OR-00026A O-RING, VITON, -129 OR-00042A... -
Page 40: 202756: Spool Valve Rebuild Kit
Xtreme REBUILD KITS & SPARE PARTS 202756: SPOOL VALVE REBUILD KIT 202756: SPOOL VALVE REBUILD KIT ITEM PART NUMBER DESCRIPTION 200513 O-RING, VITON, 9.25mm X 1.78mm 202568 SPOOL VALVE LINER, XTREME GU-824 SPOOL VALVE SPRING, XTREME OR-00002A O-RING, AFLAS, -008 OR-804 O-RING, BUNA, 2mm X 4mm 202745... -
Page 41: 202888: O-Ring Kit, Xtreme
Xtreme REBUILD KITS & SPARE PARTS 202888: O-RING KIT, XTREME 202888: O-RING KIT, XTREME ITEM PART NUMBER DESCRIPTION 200513 O-RING, VITON, 9.25mm X 1.78mm 203293 O-RING, -011, AFLAS 203294 O-RING, -012, AFLAS 203373 O-RING, -018, AFLAS OR-00002A O-RING, VITON, -008 OR-00026A O-RING, VITON, -129 OR-00042A... -
Page 42: 203370|203371: Gun Block Kit
Xtreme REBUILD KITS & SPARE PARTS 203370|203371: GUN BLOCK KIT 203370: KIT, GUN BLOCK, CV, ALUMINUM 203371: KIT, GUN BLOCK, CV, STEEL ITEM PART NUMBER DESCRIPTION 201108 SCREW, HEX CAP, 10-32 CUSTOM 202409 SCREEN SCREW ASSY, A, AP-2/3 202410 SCREEN SCREW ASSY, R, AP-2/3 203290 GUN BLOCK, CV, XTREME, AL 203291... -
Page 43: 202546: Side Seal Kit, Engr Resin
Xtreme REBUILD KITS & SPARE PARTS 202546: SIDE SEAL KIT, ENGR RESIN ITEM PART NUMBER DESCRIPTION 202454 SIDE SEAL, .125, RESIN OR-00043B O-RING, AFLAS, -010, 80D 203384: SCREEN SCREW REBUILD KIT ITEM PART NUMBER DESCRIPTION 202454 SIDE SEAL, .125, ENGR RESIN GU-818-80 FILTER SCREEN;... -
Page 44: 203386: Full Gun Rebuild Kit, Xtreme
Xtreme REBUILD KITS & SPARE PARTS 203386: FULL GUN REBUILD KIT, XTREME ITEM PART NUMBER DESCRIPTION 201562 BUSHING, AIR CYLINDER, AP-3 202568 SPOOL VALVE LINER, XTREME 202705 SEAT, CHECK VALVE, XTREME 202714 BALL, 7/32” STEEL 202775 SPRING, CHECK VALVE, XTREME 202888 O-RING KIT, XTREME 203367... -
Page 45: 1/4" Unheated Stainless Steel Hose Assembly
Xtreme REBUILD KITS & SPARE PARTS 1/4” UNHEATED STAINLESS STEEL HOSE ASSEMBLY PART NUMBER DESCRIPTION MA-41 HOSE PACKAGE KIT, UNHEATED MA-41A REPLACEMENT HOSE, “A” SIDE MA-41R REPLACEMENT HOSE, “R” SIDE RECOMMENDED SPARE PARTS PART NUMBER DESCRIPTION PAGE 202546 SIDE SEAL KIT, ENGR RESIN 202744 AIR CYLINDER REBUILD KIT 202888... -
Page 46: Flush Tanks
Xtreme REBUILD KITS & SPARE PARTS FLUSH TANKS Optional 2.5 Gallon Flush Tank (200426, 200427) and 1QT Mini Flush Tank (200216, 200217) shown. 2.5 Gallon Flush Tank 1 QT Mini Flush Tank FLUSH TANKS 2.5 Gallon Flush Tank 1 QT Mini Flush Tank 200426 –... -
Page 47: Flat Tip Adapter Kits
Xtreme FLAT TIP ADAPTER KITS FLAT TIP ADAPTER KITS FLAT TIP ADAPTER KIT (201152) 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... -
Page 48: Flat Tip Retainer Assembly
Xtreme FLAT TIP ADAPTER KITS FLAT TIP RETAINER ASSEMBLY (GU-815-52) 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, AFLAS, -016 *Tips are not included with the Xtreme guns and will need to be purchased separately. -
Page 49: Reference Guide
Xtreme REFERENCE GUIDE REFERENCE GUIDE XTREME GUN MODELS PART CHAMBER GUN BLOCK DESCRIPTION NUMBER SIZE SIZE MATERIAL 202717 XTREME W/00 CHAMBER/FLAT PCT VARIES ALUMINUM 202718 XTREME W/00 CHAMBER/PCT PKG ALUMINUM 202719 XTREME W/00 CHAMBER/PCT PKG, STEEL STEEL 202720 XTREME W/000 CHAMBER/PCT PKG ALUMINUM 202721 XTREME W/00X CHAMBER/PCT PKG, STEEL... -
Page 50: O-Ring Size Guide
Xtreme REFERENCE GUIDE O-RING SIZE GUIDE *O-Rings 200513 and 203294 are the same size but different materials 202745 REV 1.6: April 17, 2023... -
Page 51: List Of Tools
Xtreme REFERENCE GUIDE LIST OF TOOLS LIST OF TOOLS ITEM PART NUMBER DESCRIPTION 200581 3/32" ALLEN WRENCH 200585 QUICK CONNECT, FEMALE 200609 5/64" ALLEN WRENCH 202340 QD, PLUG,1/4 IND X 1/4 FNPT, STL 202767 MINI BALL VALVE 202768 3/16” ALLEN WRENCH 203374 TOOL, SNAP RING PLIERS, .038"... -
Page 52: Grease Gun (Tl-00002) Assembly
Xtreme REFERENCE GUIDE GREASE GUN (TL-00002) ASSEMBLY Screw the rod (2c) into the top of the grease gun (2a) so that the final assembly represents the assembled grease gun (page 8). Unscrew the top of the grease gun (2a) from the bottom of the grease gun (2b). -
Page 53: 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 PMC Air Purge Competitive Air Purge Chamber Number Orifice Size Chamber Number Orifice Size 0.0280 000 (AR2020) 0.0200 0.0350...