Apollo Sprayers Maxi-Miser 3000 PRO User manual

Instruction Manual
This manual contains important warnings and instructions. Please read
these instructions carefully and keep for your reference.
©2023 Apollo Sprayers International, Inc.

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Table of Contents
1 Safety ............................................................................................................................................. 1
2 Maxi-Miser™ Spray Finishing Systems............................................................................................3
3 How Your Maxi-Miser™ Turbo System Works ................................................................................3
4 How Your PBC-GTO™ Spray Gun Works ..................................................................................... 4
5 Preparing to Use Your Maxi-Miser™ Turbo System .......................................................................5
6 Setting up Your PBC-GTO™ Spray Gun ....................................................................................... 5
6.1 Operating your PBC-GTO Spray Gun .............................................................................................6
6.2 Spray Gun Technique......................................................................................................................8
6.3 Cleaning Your PBC-GTO Spray Gun ..............................................................................................9
6.3.1 Partial Cleaning................................................................................................................................9
6.3.2 Thorough Cleaning .........................................................................................................................10
6.3.3 Re-Assemble the Spray Gun ..........................................................................................................11
7 Get to Know Your Maxi-Miser™ Turbo System...............................................................................16
8 Maxi-Miser™ 3000 Operation .........................................................................................................16
9 Turbo Air Pressure and Viscosity ....................................................................................................17
10 Turbine Maintenance and Cleaning ................................................................................................17
10.1 Pre-Filter Maintenance ....................................................................................................................18
10.2 Filter Maintenance ...........................................................................................................................18
10.3 Fan Filter Maintenance ...………………………………………………………………………………….19
11 Record of Turbine Use .................................................................................................................…21
12 Record of Turbine Maintenance ......................................................................................................21
13 Genuine Apollo Accessories.............................................................................................................22
14 Warranty ..........................................................................................................................................23

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1. Safety
Read all instructionsand safetyprecautions before operatingthe unit.
Indicates a hazardous situation, which, if not avoided, will result in death or serious injury. Indicates a
hazardous situation, which, if not avoided, could result in death or serious injury.
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.
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 turbine while spraying.
Keep the turbine at the maximum distance from the spraying area.
NOTICE
•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.
•When not in use, be sure to disconnect the hose and place the spray gun into the Handi-Hold™ Docking
Station on the turbine 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.
2. Do not modify the plug provided. If the plug does not fit the outlet, have the proper
outlet installed by a qualifiedelectrician.
3. This product is for use on a nominal 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 configurationas the plug. Do not use adapters with this product.
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 extensioncord is plugged into a properlygrounded receptacle.
5.
W hen 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.
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
Groundinginstructionsfor all countries using a 2-prongedplug configuration.
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 properlyinstalled and groundedin accordancewith local codes and ordinances.
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
CONGRATULATIONS!! You have just purchased the Maxi-Miser 3000 PRO HVLP
turbo spray 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 50 years of experience in manufacturing HVLP turbo
spray systems and spray guns. We have progressively 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 spray systems; 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® 3000 Turbo Unit (1) Wrench
(1) PBC-GTO™ Clearcoat Spray Gun (1) Spray Gun Lube
(1) PBC-GTO™ Basecoat Spray Gun (1) Blow-off Tool
(1) PBC-GTO™ Primer Spray Gun (1) Cleaning Brush
(1) 37’ Flex-Air Hose (1) Electric Cord
(1) Instruction Manual (1) Booth Installation Kit
3. How Your Maxi-Miser™ Turbo Spray System Works
We have designed 3 PBC-GTO spray guns for spraying various automotive finishes. Each of the spray guns are
designated with a different colored handle to help you keep track of which gun is for what material.
The PBC-GTO spray guns with the GREEN handle are for spraying Base coats. Most
basecoats spray very nicely with the 0.8mm needle and nozzle set up along with the B-HS
air cap. This is the standard size for the basecoat spray gun.
The PBC-GTO spray guns with the GREY handle are for spraying Primers. Most primers
spray nicely using a 1.0mm needle and nozzle set up along with the B-HS air cap. This is
the standard size in the primer spray gun.

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The PBC-GTO spray guns with the matte brown spray head and the BLACK handle are
for spraying clear coats. Depending on if you are spraying spot repairs or larger areas
you could have one of two different size needles, nozzles or air caps. For spot repairs
we recommend the 0.5mm with our “CC” air cap. For spraying 2 or more panels or large
areas we recommend the 0.8mm needle and nozzle with the B-HS air cap.
Your Maxi-Miser® system has three components: the turbo unit (your air supply) (1), spray gun (2) and air hose (3).
The turbo unit, when connected to single phase 240 volt 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
turbine 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.
4. How Your PBC-GTO Spray Gun Works
Your Apollo Maxi-Miser® PBC-GTO™ spray gun operates like 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 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. It is always recommended to use
the spray gun with the air hose attached.
When the material adjustment screw is opened and the trigger pulled back, fluid flows through the 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 at 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 turbine 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 a single phase 240 volt outlet that is properly installed and grounded in accordance with local
codes and ordinances. Your Maxi-Miser® system is rated for 240 volts. Plugging the turbo system into the wrong
voltage will damage the motor and void your warranty.
NOTICE!
Do not cover or enclose the turbine. It is important to draw cool/ambient air through the unit for optimum
performance. Avoid placing the turbine in a warm environment or in direct sunlight. Do not spray in ambient
temperatures above 90 degrees. If you want to be able to spray in hotter temperatures, we recommend placing
a fan in front of your turbine to help it pull in cool air or place it in an air conditioned environment.
6. Setting up Your PBC-GTO Spray Guns
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 guns come with a 600cc gravity feed cup assembly standard. 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.
3. Screw the air feed connector (A5211N) onto the side of the spray gun body.
4. Push the air feed tube onto the air feed connector
5. Push the other end of the air feed tube onto the cup lid connector.
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

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full, open, wide pattern. (Relative to the distance the spray gun is held from the
work surface).
To adjust the direction of the fan pattern, rotate the air cap ears (Fig. 2) clockwise to either a vertical or horizontal
position as noted in the diagram. This will provide your vertical or horizontal fan pattern.
Spray Patterns
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 PBC7600-GTO™ Spray Guns
Tip/Needle Size Application Air Cap
0.5MM (.019) Clearcoats CC
0.8MM (.031) Clearcoats and Basecoats B-HS
1.0MM (.039) Basecoat, single stage B-HS
1.3MM (.051) Single Stage, Primers B-HS
1.5MM (.059) Single Stage, Primers C-HS
1.8MM (.070) Primers, Truck Bed Liner C-HS
2.0MM (.079) Primers, Truck Bed Liner C-HS
2.5MM (.098)
Gelcoat or under sealant
D
Viscosity chart should be used as a guide to thinning various coatings. Follow reduction guidelines provided by paint
manufacturer. Using a slow reducer or hot temperature reducer will enhance results with turbo spray technology and is
strongly recommended.

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Chart B:
Viscosity Cup Comparison
Zahn Cup
sec (#2) Zahn Cup sec (#4) Ford cup sec (#3) Ford cup sec (#4) Poise P Centi-poise cP Krebs KU Say bolt 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
6.2 Spray Gun Technique
Connect the appropriate air hose to the spray gun. Begin turning the material adjustment screw (#19) anti or
counterclockwise 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/counterclockwise. Hold spray gun 4” – 6” (10cm-15cm) 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.
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.
4. At the end of a “pass” always release the trigger. To continue, spray in the opposite direction and overlap your
previous coat by 50-75%
5. When finished you should have an even wet coat on your work. If you have dry spots, you have overlapped too wide.
If you have heavy or wet spots, you have overlapped too much or moved the spray gun too slow.