PMC 202745 User manual

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

Xtreme
TABLE OF CONTENTS
202745
REV 1.6 April 17, 2023
i
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 .............................................................................................................9
LOSS OF AIR PRESSURE/EMERGENCY SHUT-OFF.......................................................................9
MAINTENANCE................................................................................................................................10
GUN BLOCK AND MIXING CHAMBER REMOVAL.......................................................................12
SCREEN SCREW AND COMPONENT MAINTENANCE ..............................................................14
AIR CYLINDER MAINTENANCE...................................................................................................15
SPOOL VALVE MAINTENANCE...................................................................................................17
TRIGGERED OFF.........................................................................................................................18
TRIGGERED ON...........................................................................................................................19
TROUBLESHOOTING GUIDE..........................................................................................................20
PARTS IDENTIFICATION.................................................................................................................21
FINAL GUN ASSEMBLY ...............................................................................................................21
202409|202410: SCREEN SCREW ASSEMBLY...........................................................................23
203337: CHECK VALVE ASSEMBLY, GUN BLOCK.....................................................................24
203350: PISTON ASSEMBLY .......................................................................................................25
203369: EXPANSION PLUG ASSEMBLY .....................................................................................26
GU-020: MANUAL VALVE ASSEMBLY.........................................................................................27
GU-04001: COUPLING BLOCK ASSEMBLY.................................................................................28
GU-844: END CAP ASSEMBLY....................................................................................................29
REBUILD KITS & SPARE PARTS....................................................................................................30
CHAMBER KITS............................................................................................................................30
PCT KITS ......................................................................................................................................31
DIAMOND PLATED CHAMBER & PCT KITS................................................................................34
202744: AIR CYLINDER REBUILD KIT.........................................................................................36
202744: AIR CYLINDER REBUILD KIT.........................................................................................36
202756: SPOOL VALVE REBUILD KIT .........................................................................................37

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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................................................................................41
1/4” UNHEATED STAINLESS STEEL HOSE ASSEMBLY ............................................................42
RECOMMENDED SPARE PARTS................................................................................................42
OPTIONAL PARTS........................................................................................................................42
FLUSH TANKS..............................................................................................................................43
FLAT TIP ADAPTER KITS................................................................................................................44
FLAT TIP ADAPTER KIT...............................................................................................................44
FLAT TIP RETAINER ASSEMBLY ................................................................................................45
REFERENCE GUIDE........................................................................................................................46
XTREME GUN MODELS...............................................................................................................46
O-RING SIZE GUIDE.....................................................................................................................47
LIST OF TOOLS............................................................................................................................48
GREASE GUN (TL-00002) ASSEMBLY........................................................................................49
MIXING CHAMBER FLOW RATES...............................................................................................50
CHAMBER/ORIFICE COMPARISON CHART...............................................................................50
Before installing the Xtreme 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 Xtreme Gun. All of the
information is aimed at improving user safety and avoiding possible
breakdowns from the incorrect use of the Xtreme Gun.

Xtreme
WARRANTY
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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
reasonablefreight charges incurred by Customer inreturning 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 onthe 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 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 of suchcomponent 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,orworkarea.
• Fire, flood, “acts of God,” or other contingencies beyond the control of PMC.

Xtreme
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 PARTICULARPURPOSEANDALL 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 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.

Xtreme
SAFETY AND HANDLING
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SAFETY AND HANDLING
This chapter contains important information on the safety, handling and use of your Xtreme Gun.
Before installing the Xtreme 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
Xtreme Gun. All of the information is aimed at improving user
safety and avoiding possible breakdowns from the incorrect use
of the Xtreme 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 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 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 Xtreme 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 Xtreme Gun has been designed and built for the application of polyurea chemical systems,
polyurethane foam chemical systems and some two-component epoxy systems.

Xtreme
SAFETY AND HANDLING
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WARNING! The design and configuration of the Xtreme 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 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. 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.

Xtreme
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): _____________________________ 2.2 lbs (1.1 kg)
Weight (Including Coupling Block):_________________________________ 2.9 lbs (1.4 kg)

Xtreme
GENERAL DESCRIPTION
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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.

Xtreme
INSTALLATION AND START UP
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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. 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. 39). 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.

Xtreme
INSTALLATION AND START UP
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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.

Xtreme
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. With the purge air on, use the supplied Grease
Gun (Pg. 39) to lubricate the Mixing Chamber
through the Grease Fitting until a fine mist of
grease is sprayedfrom the gun (Pg. 49 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.

Xtreme
MAINTENANCE
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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
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.

Xtreme
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.

Xtreme
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. 39), remove the
Mounting Screw and disconnect the gun from the
Coupling Block.
4. Pump grease through the Gun Block to remove any
residue using the grease gun supplied (Pg. 43).
5. Shut off air to the gun.
6. Using the Wrench provided (Pg. 39) or a ½” wrench,
loosen or remove both Screen Screws to facilitate
easy removal of the Mixing Chamber, as shown
below.

Xtreme
MAINTENANCE
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7. Loosen the PCT, but do not remove.
8. Using the Nut Driver (Pg. 39) provided, remove the gun block mounting screws (Pg 6).
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.

Xtreme
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. 39), remove the Coupling Block from the Gun Block.
4. Flush the gun block to remove any residue. Use the recommended Flush Tank (Pg. 43)
5. SHUT OFF air supply to the gun.
6. Set the Gun Lock to the LOCKED position.

Xtreme
MAINTENANCE
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7. Use the Wrench provided (Pg. 39) 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. 43)
6. Loosen the Screen Screws using the Wrench
provided (Pg. 39) or a ½” wrench.
7. Disconnect Coupling Block from Gun Block using
the Nut Driver provided (Pg. 39).

Xtreme
MAINTENANCE
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8. Using the Nut Driver provided, remove the gun block mounting screws and disconnect the
Gun Block.
9. Using the Wrench provided (Pg. 39) or 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.

Xtreme
MAINTENANCE
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SPOOL VALVE 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 Handle.
5. Remove the Trigger from the assembly to access the front of the Handle.
6. Use the Tool provided (Pg. 39) and remove the Spool Valve Retainer.
7. Remove the Spring, Spool Valve Liner, and Spool Valve using the tool provided (Pg.
39), as shown below.
8. Remove and discard all O-Rings.
9. Replace the O-rings and Spring supplied in the Spool Valve Rebuild Kit - 202756 (page
30).
NOTE! 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.