Apollo Sprayers MAXI-MISER 2000 User manual

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Instruction Manual 
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This manual contains important warnings and instructions.
Please read these instructions carefully and keep for your reference.
©2014 Apollo Sprayers International, Inc.

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TableofContents
1Safety.............................................................................................................................................3
2Maxi-Miser™ Spray Finishing Systems..........................................................................................5
3 How Your Maxi-Miser™ Turbo System Works................................................................................5
4How Your PBC-GTO™ Spray Gun Works......................................................................................6
5Preparing To Use Your Maxi-Miser™ Turbo System......................................................................6
6Setting up Your PBC-GTO™ Spray Gun.........................................................................................7
6.1Operating your PBC-GTO Spray Gun......................................................................................8
6.2 Spray Gun Technique............................................................................................................10
6.3 Cleaning Your PBC-GTO Spray Gun ....................................................................................11
6.3.1 Partial Cleaning................................................................................................................11
6.3.2 Thorough Cleaning ..........................................................................................................12
6.3.3 Re-Assemble The Spray Gun..........................................................................................13
7Get To Know Your Maxi-Miser™ Turbo System...........................................................................18
8 Maxi-Miser™ 2000 Operation......................................................................................................18
9 Turbo Air Pressure and Viscosity ................................................................................................19
10 Using Pressure Pots with Turbo Systems....................................................................................20
10.1 Testing Air Pressure in a Pressure Pot...................................................................................21
10.1.1 Cleaning Your Pressure Pot ...........................................................................................21
11 Record of Turbo Use....................................................................................................................22
12Record of Turbo Maintenance......................................................................................................22
13 Turbo Maintenance and Cleaning................................................................................................23
13.1 Pre-Filter Maintenance ..........................................................................................................27
13.2 Filter Maintenance.................................................................................................................24
14 Model 4500 Diagram ...................................................................................................................25
15 Model 4500 Parts List..................................................................................................................26
16 Model 4550 Diagram ...................................................................................................................27
17 Model 4550 Parts List..................................................................................................................28
18 Geniune Apollo Accessories........................................................................................................29
19 Warranty......................................................................................................................................31
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1. Safety
Read all instructions and safety precautions before operating the unit.
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Indicates a hazardous situation, which, if not avoided, will result in death or serious injury.
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Indicates a hazardous situation, which, if not avoided, could result in death or serious injury.
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Indicates a hazardous situation, which, if not avoided, could result in minor or moderate injury. 
NOTICE 
Indicates a situation that could result in damage to the equipment or other property. 
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Risk of fire or explosion! Solvent and paint fumes can explode or ignite, causing
severe injury and property damage. 
Paints and solvents containing HALOGENATED HYDROCARBONS can react
explosively with aluminum. Always check the product’s label before using these
materials in the unit. 
Hazardous vapors: Paint, solvents, insecticides and other materials may be harmful
if inhaled, causing severe nausea, fainting or poisoning. 
Make sure the room is well ventilated. Avoid all ignition sources, such as static electricity,
sparks, open flames, hot objects, sparks from connecting and disconnecting power
cords, and working light switches. 
Follow the material and solvent manufacturers’ safety precautions and warnings. Do
not use liquids with flash points less than 100° F (38° C). 
Static electricity can be produced by HVLP spraying. Make sure any electrically
conductive object being sprayed is grounded to prevent static sparking. The sprayer
is grounded to prevent static sparking. The sprayer is grounded through the
electrical cord. 
Use a respirator or mask whenever there is a chance that vapors may be inhaled.
Read all instructions with the mask to ensure that the mask will provide the
necessary protection against the inhalation of harmful vapors. 
Do not carry the turbo while spraying. 
Keep the turbo at the maximum distance from the spraying area. 
NOTICE
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Tipping the spray gun causes the spray gun to clog. Dried spray material also clogs the pressure
delivery tube and fittings. The spray gun does not function when clogging occurs. 
NOTICE
When not in use, be sure to disconnect the hose and place the spray gun into the Handi-Hold™ Docking
Station on the turbo to avoid tipping.
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Improper installation of the ground plug can result in the risk of electrical shock.
If repair or replacement of the plug or cord is necessary, do not connect the
ground wire to either flat blade terminal. The wire with green insulation (with or
without a yellow stripe) is the grounding wire. 
1. For any question regarding proper installation of the ground plug, consult a qualified (licensed or
certified) electrician.
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2. Do not modify the plug provided. If the plug does not fit the outlet, have the proper outlet installed
by a qualified electrician.
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3. This product is for use on a normal 110-volt circuit and has a grounding plug that looks like the plug in Figure 2. Make sure
that the product is connected to an outlet having the same configuration as the plug. Do not use
adapters with this product.
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4. If an extension cord is required, use only a three wire extension cord that has the same
configuration as the unit cord, including the (round) ground terminal. Make sure that the extension
cord is plugged into a properly grounded receptacle.
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5. When using an extension cord, be sure it is in good condition and heavy enough to meet the
specifications in the chart below. If an extension cord is needed the following wire sizes must be
used.
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25’ cord (7.62m)…………………………............................ 10, 12, or 14 Gauge 
50’ cord (15.24m)………………………………................... 10 or 12 Gauge 
100’ cord (30.48m)…………..……………………………...... 10 Gauge 
Figure 2 
Grounding instructions for all countries using a 2 pronged plug configuration. 
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This product must be properly grounded. In the event of an electrical short circuit, grounding reduces
the risk of electrical shock by providing an alternate path for the electrical current. 
This product is equipped with a cord that has a ground wire and an appropriate ground plug. Plug the unit into an outlet that
is properly installed and grounded in accordance with local codes and ordinances.
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Safety Note: Users in countries in continental Europe and Australia and anywhere that offers a two pronged plug must be
aware that this configuration does not provide grounding.

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2. Maxi-Miser™ Spray Finishing Systems
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CONGRATULATIONS!! You have just purchased the Maxi-Miser 2000 HVLP turbo
system, the finest spray system available to spray cars, boats and airplanes. You are
about to enjoy the great benefits of the Maxi-Miser™ system. Our designs are the result
of over 40 years of experience in manufacturing HVLP turbo spray systems and spray
guns. We have painstakingly worked and consulted with professional spray finishers in
your industry to bring you this versatile, well engineered tool. 
Whether you are new to spray finishing, you have spray finished before, or are just new
to Maxi-Miser spraying; there are some basic spray finishing guidelines that will help
you to achieve the best results and optimum success from your new equipment.
Reading this information carefully and following these simple steps will ensure that you
get the best performance and results from your new TrueHVLP™ spray system. 
Check the contents of your box. The following are included: 
(1) Maxi-Miser™ 2000 Turbo Unit (1) Spray Gun Lube
(1) PBC-GTO™ Clear Coat Spray Gun (1) Blow-off Tool
(1) PBC-GTO™ Base Coat Spray Gun (1) Cleaning Brush 
(1) 37’ Flex-Air Hose (1) Electric Cord 
(1) Instruction Manual (1) Wrench
(3) Quick Couplers (2x Handi-Hold™) (1x Hose Coupler) 
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3. How Your Maxi-Miser™ Turbo System Works
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Your Maxi-Miser™ system has three components: the turbo unit (1), spray gun (2) and air hose (3). The turbo unit,
when connected to the correct electrical power supply and with the on/off switch in the “on” position, provides a
continuous source of clean, warm, dry, High Volume Low Pressure (HVLP) air. The air hose connects the turbo unit to the
spray gun. Air flows through the hose to the nozzle of the specially designed TrueHVLP™ spray gun. Atomization of the
coating is achieved when the air mixes with the stream of fluid passing through the tip/nozzle. This low pressure
atomization principle achieves minimum misting (overspray) to the spray environment and maximum savings in paint.
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4. How Your PBC-GTO Spray Gun Works
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Your Apollo Maxi-Miser™ PBC-GTO™ Spray gun operates similar to a typical compressed air spray gun with some minor
differences. The cup on your PBC-GTO™ spray gun is pressurized through the air feed tube. This will help deliver fluid
to the tip/nozzle and produce a larger fan pattern. It is possible to use the PBC-GTO™ spray gun without the air feed
tube connected, but only with certain types of paints and using larger needle and nozzle sizes. You will notice a much
smaller fan pattern when using the spray guns without the air feed tube connected.
When the material adjustment screw is opened and the trigger pulled back, fluid flows through the tip/nozzle mixing with
the air flow delivered from the air cap and projects a fine atomized mist to your work piece. You can adjust the fluid flow
by opening or closing the material adjustment screw to your liking. The fan adjustment ring is located in the front of the
spray gun. Locate the adjustment marks on the side of the spray gun body. Turn the fan control ring up to achieve a
smaller fan or down to achieve a larger fan.
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5. Preparing To Use Your Maxi-Miser™ Turbo System
Connect the male end of the air hose to the turbo system. Pull back the spring
loaded quick disconnect coupler and insert the male connector on the air hose into
the turbo connector. Release the ring. Your air hose will be locked into place. To
release the air hose, pull back on the spring loaded quick coupler ring with your
fingers and pull.
Connect female end of air hose to your spray gun using this same procedure.
Plug the power cord into an outlet that is properly installed and grounded in accordance with local codes and ordinances
and the proper voltage. Your Maxi-Miser™ system is rated for either 120 volts or 240 volts. Please check the Serial
number plate located underneath of the system to check which voltage your system is designed for. The Turbo system
does not work on dual voltage. Plugging the turbo system into the wrong voltage will damage the motor and void your
warranty.
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NOTICE 
Do not cover or enclose the turbo. It is important to draw cool/ambient air through the unit for
optimum performance. Avoid placing the turbo in a warm environment or in direct sunlight.

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6. Setting up Your PBC-GTO Spray Gun
Good quality results with your TrueHVLP™ spray finishing equipment are a combination
of careful preparation of your project, a proper spraying environment, a basic knowledge
of the coatings you will be using and how these coatings work with your Maxi-Miser™
finishing equipment.
Your PBC-GTO spray gun comes with a 600cc Gravity Feed cup assembly. Some minor
assembly is required:
1. Screw the cup to the material connector on the
top of the spray gun body. Tighten with
(spanner) wrench only as shown in the “correct”
picture.
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DO NOT tighten by holding the cup in the “incorrect” picture.
NOTE: Failure to tighten correctly can result in damaging the seal at the base of the
cup.
2. Remove the screw in the side of the spray gun body using the
wrench (spanner) provided.
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3. Screw the air feed connector onto the side of the spray gun body.
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4.Pushtheairfeedtubeontotheairfeedconnector.
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5.Pushtheotherendoftheairfeedtubeontothe
cuplidconnector.
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NOTE:
Make sure you attach the air feed tube so that the black end of the air valve is pointing
towards the cup lid as shown in the illustration.
NOTE:
Above the non-return valve you will see an air relief valve. The purpose of this valve it to
release pressure from the cup prior to opening the cup lid to prevent paint splatter. To release
the pressure all you need to do is turn the air relief valve.
6.1 Operating your PBC-GTO Spray Gun
The PBC-GTO spray gun has a unique and simple fan pattern control. Locate
the Fan Adjustment Ring in the front of the spray gun. Turn the spray gun on its
side and notice the fan size indicator stamped into the spray head casting, just to
the right of the fan adjustment ring. You will notice that there is a “-” sign at the
top and a “+” sign at the bottom with two arrows indicating the direction of
rotation. Rotating the ring UPWARD will begin to reduce the size of the fan
pattern until the pattern is round. Rotating the ring DOWNWARD will provide a
full, open, wide pattern. (Relative to the distance the spray gun is held from the
work surface).

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To adjust the direction of the fan pattern, loosen the air cap ring, (Fig. 1) rotate the air cap ears (Fig. 2) to either a vertical
or horizontal position as noted in the diagram. This will provide your vertical or horizontal fan pattern.
Spray Patterns
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Fig. 1 Use this position when spraying across from side to side.
Fig. 2 Use this position when spraying from top to bottom.
Fig. 3 Use this position for spotting small objects, corners and sharp angles and touch up.
Install the appropriate fluid nozzle, needle assembly and color coded air cap (A, B, C or D) for the viscosity of the fluid
being sprayed. See Chart B for recommendations. Prepare your coating as you would normally, (Thinning if necessary).
Filter and pour into spray gun cup. 
Chart A Nozzle, Needle and Air Caps for PBC-GTO™ Spray Guns
Tip/Needle Size Application Air Cap 
0.5MM (.019) Clear Coats CC
0.8MM (.031) Base Coats and Metallics B-HS
1.0MM (.039) Base Coat, single stage, Metallics B-HS
1.3MM (.051) Single Stage, Primers B-HS 
1.5MM (.059) Single Stage, Primers C-HS
1.8MM (.070) Primers C-HS
2.0MM (.079) Primers C-HS
2.5MM (.098) Gelcoat or under sealant D

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Chart B Viscosity Cup Comparison
Viscosity chart should be used as a guide to thinning various coatings. Follow reduction guidelines provided by
paint manufacturer. Using a slow solvent or hot temperature solvent will enhance results with turbo spray
technology and is strongly recommended.
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Zahn Cup
sec (#2)Zahn Cup sec (#4)Ford cup sec (#3)Ford cup sec (#4)Poise P Centi-poise cPKrebs 
KUSaybolt
SSU
1650.1 10 60
17815 80
181210 0.2 20 100
191512 25 130
201915 0.3 30 150
222517 0.4 40 210
242919 0.5 50 30250
273321 0.6 60 33320
303623 0.7 70 35370
344126 0.8 80 37430
374529 0.9 90 38480
41105031 1100 40530
49115836 1.2 120 43580
53136641 1.4 140 46690
56146745 1.6 160 48790
741651 1.8 180 50900
Connect the appropriate air hose to the spray gun. Begin turning the material adjustment screw (#19) anti or counter
clockwise 1 – 2 full turns. Look at the size of the fluid pattern and flow volume. Adjust before applying material to your
substrate. If you have too much fluid flow, turn the material adjustment screw clockwise. If you do not have enough fluid
flow, adjust the material adjustment screw anti/counter clockwise. Hold spray gun 4” – 8” (10cm-20cm) from your work
surface depending on the size of your substrate. Closer is generally preferred for highest efficiency and the least amount
of overspray. Follow the proper spray technique as outlined in the spray technique diagram. You can increase or decrease
the fluid flow as desired as well as the distance from your work surface as necessary. Adjust the Fan Adjustment Ring as
desired.
6.2 Spray Gun Technique
Like any skill, practice makes perfect. Never try to rush the spray finishing process. Learn the characteristics of the coating
you will be spraying. Build up layers of material. Sand between coats and allow proper drying time between applications. 
Here are some general guidelines for effective spray finishing: 
1. Remember to always keep the distance between the spray gun and the surface the same when moving across your
work, (or up and down) called a “pass”. Do not rotate or turn your wrist from side to side. See Chart C below. 
2. Move the spray gun across your work from end to end. 
3. Be sure to maintain the same speed of movement. This ensures an even application of coating. 