PMC 202745 Service Manual Download

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Xtreme

TROUBLESHOOTING GUIDE

202745

REV 1.0: January 4, 2021

TROUBLESHOOTING GUIDE

PROBLEM

POSSIBLE CAUSE

SOLUTION

PCT not flush with
Gun Block when Gun
is triggered

Insufficient air pressure (minimum 90 psi, 6.2 bar)

Ensure 90 psi (6.2 Bar)

Failed Spool Valve

Replace, see page 16

Air passages plugged

Clean, See page 18

Material does not
spray when Gun is
triggered

Lock is in “Locked” position

Unlock gun

Air supply is not on

Turn on air supply

Manual Valve CLOSED

OPEN, see page 7

Mixing Chamber inlet orifices plugged

Clean, see page 11

Side Seal orifices plugged

Clean, see page 13

Check Valve plugged

Replace

Mixing Chamber
moves slowly

Failed Spool Valve

Replace, see page 17

Insufficient air pressure (minimum 90 psi, 6.2 Bar)

Ensure 90 psi (6.2 Bar) of air
pressure

Piston assembly requires service

Rebuild, see page 14

Air passages plugged

Clean, see page 18

Mixing Chamber
moves slowly, then
normally

Reacted material around Side Seals

Inspect Side Seals, Mixing
Chamber and clean, see
pages 11, 13

Pattern deformation

Incorrect chemical temperature

See Proportioner Manual

Mixing Chamber nozzle and/or PCT dirty

Inspect and clean

Material spray
pressure imbalance

Mixing Chamber inlet orifices plugged

Clean

Side Seal orifices plugged

Clean, see page 13

Dirty screens

Replace

Material temperatures not as recommended by
material supplier

Adjust, see Proportioner
Operating Manual

Iso and/or Resin in
Gun Air Passages

Side Seal damaged

Replace, see page 13

Mixing Chamber damaged

Replace, see page 11

Side Seal/ Screen Screw O-rings damaged

Replace, see page 13

Material mist from
Mixing Chamber or
PCT

Side Seal damaged

Replace, see page 13

Mixing Chamber damaged

Replace, see page 11

Side Seal/Screen Screw O-rings damaged

Replace, see page 13

Excessive
overspray

Material temperatures and/or spray pressures not as
recommended by material supplier

Adjust, see Proportioner
Operating Manual

Buildup of material
on PCT

Plugged air passages in PCT and Gun Block

Clean, see page 11

Air leakage from
Handle

Air Cylinder O-rings damaged

Replace, see page 38

Spool Valve Damaged

Replace, see page 16

Summary of Contents for 202745

Page 1: ...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...

Page 2: ...TENANCE 14 SPOOL VALVE MAINTENANCE 16 TRIGGERED OFF 17 TRIGGERED ON 18 TROUBLESHOOTING GUIDE 19 REFERENCE GUIDE 20 CHAMBER KITS 20 PCT KITS 21 DIAMOND PLATED CHAMBER PCT KITS 24 AP 2 AP 3 SPARE PARTS...

Page 3: ...P RETAINER ASSEMBLY 42 APPENDIX 43 GREASE GUN ASSEMBLY 43 MIXING CHAMBER FLOW RATES 44 CHAMBER ORIFICE COMPARISON CHART 44 Before installing the Xtreme Gun and start up carefully read all the technica...

Page 4: ...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 Maintenanc...

Page 5: ...arranty 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...

Page 6: ...to the Xtreme 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...

Page 7: ...om 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...

Page 8: ...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 ______________________...

Page 9: ...IPTION 202745 REV 1 0 January 4 2021 6 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 Id...

Page 10: ...ect 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 gu...

Page 11: ...g 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...

Page 12: ...y 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...

Page 13: ...perating 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 eq...

Page 14: ...int the gun over a waste container and pull the Trigger to relieve pressure 3 Using the Nut Driver provided Pg 40 remove the Mounting Screw and disconnect the gun from the Coupling Block 4 Pump grease...

Page 15: ...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...

Page 16: ...ead 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 i...

Page 17: ...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...

Page 18: ...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 include...

Page 19: ...5 Remove the Trigger from the assembly to access the front of the Handle 6 Use the Tool provided Pg 40 and remove the Spool Valve Retainer 7 Remove the Spring Spool Valve Liner and Spool Valve using...

Page 20: ...ion 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...

Page 21: ...mber are now aligned with the Side Seals and exposed to high pressure chemical 3 High pressure chemical enters the chamber from the opposing orifices The high pressure chemicals mix by impingement and...

Page 22: ...Side Seals Mixing Chamber and clean see pages 11 13 Pattern deformation Incorrect chemical temperature See Proportioner Manual Mixing Chamber nozzle and or PCT dirty Inspect and clean Material spray p...

Page 23: ...L 0531 MIXING NOZZLE GU 03032 1 61 DRILL 0390 MIXING CHAMBER PORT RM 814 DP 00X 1 CHAMBER 00X DIAMOND PLATED GU 814 DP 01 200479 1 1 45mm DRILL 0571 MIXING NOZZLE GU 03021 1 59 DRILL 0410 MIXING CHAMB...

Page 24: ...44 Drill 0860 MIXING NOZZLE 201120 1 33 DRILL 0 1130 MIXING CHAMBER PORT RM 814 DP 05 1 CHAMBER 05 DIAMOND PLATED PCT KITS KIT NUMBER PART NUMBER QTY DESCRIPTION FOR USE WITH ILLUSTRATION GU 815 000 G...

Page 25: ...79 1 1 45mm DRILL 0571 PCT PURGE NOZZLE PORT OR 00042A 2 O RING VITON 016 RM 815 01 1 PATTERN CONTROL TIP 01 GU 815 01X GU 03033 1 65 DRILL 0350 PCT PURGE PORT GU 03035 1 54 DRILL 055 PCT PURGE PORT G...

Page 26: ...03035 1 54 DRILL 055 PCT PURGE PORT GU 03028 1 44 DRILL 0860 PCT NOZZLE PORT OR 00042A 2 O RING VITON 016 RM 815 03 1 PATTERN CONTROL TIP 03 GU 815 04 GU 03033 1 65 DRILL 0350 PCT PURGE PORT GU 03035...

Page 27: ...15 01 1 PCT 01 RND W DRILLS OR 00042A 1 O RING VITON 016 KT 814 DP 01X GU 814 DP 01X 1 CHAMBER 01X W DRILLS GU 815 01X 1 PCT 01X RND W DRILLS OR 00042A 1 O RING VITON 016 KT 814 DP 02 GU 814 DP 02 1 C...

Page 28: ...P 2 AP 3 02X SPARE PARTS KIT 28 200452 AP 2 AP 3 03 SPARE PARTS KIT 28 200453 AP 2 AP 3 04 SPARE PARTS KIT 28 201173 AP 2 AP 3 05 SPARE PARTS KIT 28 202536 AP 2 AP 3 000 SPARE PARTS KIT DP 29 202537 A...

Page 29: ...2 2 2 2 2 2 2 2 2 GP 00101 PIN VICE 1 1 1 1 1 1 1 1 1 1 GP LUBEGREASE GREASE TUBE 1 1 1 1 1 1 1 1 1 1 GU 020 MANUAL VALVE ASSY 1 1 1 1 1 1 1 1 1 1 GU 04007 SCREEN SCREW SEAL 2 2 2 2 2 2 2 2 2 2 GU 818...

Page 30: ...1142 1 201120 DRILL 2 87mm 1130 1 GU 03021 DRILL 1 04mm 0410 1 GU 03023 DRILL 1 18mm 0465 1 GU 03024 DRILL 1 70mm 0670 1 GU 03027 DRILL 0 74mm 0292 1 GU 03028 DRILL 2 18mm 0860 1 1 GU 03031 DRILL 0 71...

Page 31: ...FILTER SCREEN 60 MESH GU 818 80 1 FILTER SCREEN 80 MESH STANDARD KT 818 40 1 FILTER SCREEN 40 MESH PKG 10 KT 818 60 1 FILTER SCREEN 60 MESH PKG 10 KT 818 80 1 FILTER SCREEN 80 MESH PKG 10 A R SCREEN...

Page 32: ...4mm AIR CYLINDER REBUILD KIT 202744 PART NUMBER QTY DESCRIPTION 200459 1 O RING VITON 018 201562 1 AIR CYLINDER BUSHING 202705 1 SEAT CHECK VALVE 202714 1 BALL CHECK VALVE 202712 1 SPRING CHECK VALVE...

Page 33: ...78mm 201562 1 BUSHING AIR CYLINDER AP 3 202454 2 SIDE SEAL 125 RESIN 202568 1 SPOOL VALVE LINER XTREME 202705 1 SEAT CHECK VALVE XTREME 202712 1 SPRING CHECK VALVE XTREME 202714 1 BALL 7 32 STEEL 2027...

Page 34: ...80 MESH STANDARD 28 KT 850 1 CHECK VALVE ASSEMBLY 36 OR 00042A 2 O RING VITON 016 29 OR 00043B 8 O RING AFLAS 010 29 OR 800 8 013 BACK UP RING 29 OR 801A 8 O RING AFLAS 013 29 SP 04005 2 SPRING SIDE...

Page 35: ...00427 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 Solvent Flush Kit 2 5 Gal AP 200216 Solvent F...

Page 36: ...IDENTIFICATION 202745 REV 1 0 January 4 2021 33 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 GU...

Page 37: ...01562 AIR CYLINDER BUSHING 12 1 202716 CYLINDER PINNED XTREME 13 1 TN 04186 GREASE FITTING 1 4 28 14 2 201109 HHCS 10 24 X 1 750 ZP 15 1 202705 SEAT CHECK VALVE 16 1 202714 BALL CHECK VALVE 17 1 20271...

Page 38: ...R 015 4 O RING AFLAS 007 OR 016 4 007 VITON CURVED BACKUP RING NOTE The orientation of the back up ring is important The concave face must point towards the O Ring MANUAL VALVE ASSEMBLY ITEM QTY PART...

Page 39: ...NTIFICATION 202745 REV 1 0 January 4 2021 36 CHECK VALVE ASSEMBLY KT 850 CHECK VALVE ASSEMBLY ITEM QTY PART NUMBER DESCRIPTION 1 2 GU 851 CHECK VALVE SEAT 2 2 GU 852 CHECK VALVE SPRING 3 2 GU 853 1 4...

Page 40: ...LY GU 04001 COUPLING BLOCK ASSEMBLY ITEM QTY PART NUMBER DESCRIPTION 1 1 GU 04001 01 COUPLING BLOCK BODY 2 2 TN 04192 1 8 NPT PIPE PLUG 3 2 GU 020 MANUAL VALVE ASSY 4 1 RA 00005A 1 8 NPT X 5 JIC SWIVE...

Page 41: ...REEN SCREW ASSEMBLY ITEM QTY PART NUMBER DESCRIPTION 1 1 202454 SIDE SEAL 125 RESIN 2 1 GU 818 40 FILTER SCREEN 40 MESH 1 GU 818 60 FILTER SCREEN 60 MESH 1 GU 818 80 FILTER SCREEN 80 MESH STANDARD 3 1...

Page 42: ...ASE TO ALL O RINGS THIS ENSURES GOOD PERFORMANCE AND REDUCES RISK OF GUN MALFUNCTION SCREEN SCREW COMPONENTS ITEM QTY PART NUMBER DESCRIPTION 1 1 GU 803 CYLINDER END CAP 2 1 GU 804 LOCK KNOB 3 1 GU 80...

Page 43: ...81 3 32 ALLEN WRENCH 2 1 200585 QUICK CONNECT FEMALE 3 1 200609 5 64 ALLEN WRENCH 4 1 202340 QD PLUG 1 4 IND X 1 4 FNPT STL 5 1 GP 00101 DOUBLE ENDED PIN VISE 6 1 GU 04019 AIR HOSE 7 1 TL 00002 GREASE...

Page 44: ...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 QTY 1 201150 FLAT TIP...

Page 45: ...15 52 PCT FLAT TIP RETAINER ASSEMBLY GU 815 52 ITEM PART NUMBER DESCRIPTION QTY 1 200712 DRILL 3 10mm 1220 3 10mm 1 2 GU 03054 DRILL 50 0700 1 78mm 1 3 GU 815 52 1 FLAT TIP ADAPTER BODY 1 4 GU 815 52...

Page 46: ...m of the grease gun 2b 3 Pull the handle 2e on the bottom of the grease gun 2b so that it resembles the picture 4 Remove the tape and cap from the grease tube 5 and insert the uncapped end of the grea...

Page 47: ...2 14 GU 814 04 25 11 47 21 200920 28 20 50 23 Flow rates will vary depending on viscosity hose length and machine efficiency CHAMBER ORIFICE COMPARISON CHART Competitive Air Purge PMC Air Purge Chambe...

Page 48: ...Xtreme APPENDIX 202745 REV 1 0 January 4 2021 45...

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