MAX I-MISER PBC7600-GTO Spray Gun Instruction Manual

MAX I-MISER PBC7600-GTO Spray Gun Instruction Manual

This manual contains important warnings and instructions.
Please read these instructions carefully and keep for your reference.

Safety

Read all instructions and safety precautions before operating the unit

DANGER
Indicates a hazardous situation, which, if not avoided, will result in death or serious injury.

WARNING
Indicates a hazardous situation, which, if not avoided, could result in death or serious injury.

CAUTION
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.

WARNING
Risk of fire or explosion! Solvent and paint fumes can explode or ignite, causing severe injury and property damage.

Paints and solvents containing HYDROGENATED HYDROCARBONS can react explosively with aluminium. 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 Hindi-Hold™ Docking Station on the turbine to avoid tipping.

PBC7600-GTO HVLP Spray Guns

CONGRATULATIONS!! You have just purchased the PBC7600-GTO Spray gun, the finest spray gun available to spray cars, boats and airplanes. When combined with one of our turbo finishing systems you find that you will enjoy the great benefits of the TrueHVLP. 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 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 gun.

Check the contents of your box. The following are included:

• 1. PBC7600-GTO Spray gun
• (1) Air Feed Connector
• (1) Instruction Manual
• (1) Cleaning Brush
• (1) Wrench
• (1) Spray Gun Lube
• (1) Non-return valve
• (1) Cup Top Gasket
• (1) Air Valve Bushing Tool (A7562)

How Your PBC7600-GTO Spray Gun Works

Your PBC7600-GTO Spray gun operates similar to a typical compressed air spray gun with some minor differences. The cup on your PBC7600-GTO spray gun is pressurised 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 PBC7600-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.

The PBC7600-GTO & Turbine Systems

The PBC7600 is a standard turbine spray gun – non-bleed type. When the turbine is turned on, NO air will flow through the spray gun. When the trigger is partially pulled, air will flow through the air cap. When the trigger is fully pulled, paint will flow through the nozzle (tip) to meet the air flow, atomize, and project to your work surface. It is most important that your turbine system be equipped with a proper internal air relief valve to handle the back pressure when the trigger is released, and the turbine is running

If you are using the Apollo PBC7600 spray gun with a turbine system other than one manufactured by APOLLO, it is advised to inquire with the turbine manufacturer to determine if your unit is configured to accept a non-bleed spray gun. If you are not sure, or if you cannot get accurate information, it is strongly advised that you install Apollo part number A7538A prior to using the PBC7600 spray gun.

Setup

Installing Air Relief Mechanism (Turbine Systems Only)
As previously noted, Apollo Models 725, 825, 835, 835VR, 1025, 1035, 1040VR,1050, 1050VR, Falcon Series, Power Series and Precision Series have an air relief mechanism internally installed and DO NOT require an external air relief mechanism. All other Apollo Models require the installation of Apollo Part # A7538A to the turbine air outlet prior to operating the 7600 spray gun The air relief mechanism Part #A7538A must also be installed on ANY MAKE turbine system that does not have an air relief mechanism installed. If using with a system other than Apollo, please check with the manufacturer to determine if a non-bleed spray gun can be safely operated on your system. If not, install Part #A7538A before operating the 7600 spray gun.

Mounting Your PBC7600-GTO Spray Gun Cup

Good quality results with your spray finishing equipment are a combination of careful preparation of your surface, a proper spraying environment and a basic knowledge of the coatings you will be using and how these coatings work with your finishing equipment.

Your PBC7600-GTO spray gun comes with one of 4 sizes gravity feed cup assemblies, 90cc, 250cc, 600cc or 1000cc. Some minor assembly is required:

1. Screw the cup to the material connector on the top of the spray gun body
   

2. Remove the screw in the side of the spray gun body using the wrench (spanner) provided
   

3. Screw the air feed connector 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 twist the two halves of the air relief valve and pull them apart. You will hear the air escape from the cup. Reattach before spraying again. Do not mix the air relief valve with solvent as it is not made for direct contact with solvent.

Operating your PBC7600-GTO Spray Gun

The PBC7600-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)

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
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 colour-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

B-HS
1.0MM (.039)| Base Coat, single stage, Metallics, Primers| 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

7600 Nozzles and Needle Identification
When pairing the 7600 needles and nozzles together it is important to look at the markings on both the needle and the nozzle. The nozzle has the actual size laser marked onto the side of the nozzle itself. The needle has a stock number laser marked onto the shaft. The first 3 numbers of the stock number do not mean anything. The last 3-4 numbers are the size of the needle.

Below, we have put together a chart showing what the various nozzle sizes we offer for the 7600 series spray gun and the corresponding needle identification numbers which they are paired with. If you have any questions, please give customer service a call at 1-888-900-4857.

Please note: The 1.3mm and 1.5mm nozzles use the same size needle. The 1.8mm and 2.0mm nozzles use the same size needle also. All other size nozzles are paired with only one needle size.

NOTE: Every time you change nozzle sizes you will need to reseat the air distributor gasket, item #5. To do so, pull
it out of the front of the air distributor and reinstall it so that it is flush with the front of the air distributor.

Viscosity Chart Guideline

Coating| Thin/Reduce| Viscosity in Seconds
Lacquers| 25% – 50%| 15-22 seconds
Sanding Sealer| 20% – 30%| 15-22 seconds
Enamels| 20% – 40%| 16-22 seconds
Stains| use from can| 15 seconds
Acrylic Enamel| 50% – 60%| 15-17 seconds
Catalyzed Polyurethane| 10% – 30%| 15-18 seconds
Varnishes| 20% – 30%| 16-22 seconds
Water based Coatings| 00% – 10%| 24-34 seconds

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.

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| | | 5| 0.1| 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| 1| 100| 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/counterclockwise. 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 over spray. 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.

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.
4. At the end of a “pass” always release the trigger. To continue, spray in the opposite direction and overlap your previous coat by 1/3 to 1/2.
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 slowly.
6. When spraying an entire car, start at the top and work down.
7. Try to spray the hard to reach and underneath surfaces first.

Common sense and some forethought will prevent errors. Remember, that a light wet film will generally produce better results than a heavy wet coat. When spraying a vertical surface, it is advisable to apply a thin/light “tack” coat first, followed by a normal light wet coat. This technique will help prevent “runs” and “sags”.

Chart C

Spray Gun Technique

When using your Spray Gun you control five variables:

1. Fluid flow.
2. Distance of the spray gun from your work. 4”-8” (10-20cm) is ideal. Closer if necessary.
3. Pattern direction (vertical fan, horizontal fan and round).
4. Speed of application.
5. Fan pattern width.

NOTE: Items 1, 2, and 4 directly relate to each other

Cleaning Your PBC7600-GTO Spray Gun
After you have finished spraying, follow these simple steps to clean your PBC7600-GTO spray gun:

Partial Cleaning

Cleaning your PBC7600-GTO spray gun does not have to be a difficult task. Often, when spraying a variety of clear coatings, a thorough rinsing and wiping of basic parts is all that may be necessary. The basic steps below are for simple and easy cleaning of your PBC7600-GTO spray gun.

1. Empty any unused material (paint) from the cup and wash out any residue with an appropriate cleaner compatible with the coating, or water if using water-based material. Partially fill the cup with cleaner and spray through the gun to flush out the material passages.
2. Remove the Air Cap (#2) and clean. Ensure that all the air holes in the air cap are clean.
3. Using a brush and solvent, remove any paint deposits on the outer surface of the tip/nozzle (#3). (Apollo FS1900 cleaning brush kit recommended).
4. Unscrew and remove the Material Adjustment Screw (#19).
5. Remove the needle spring (#20).
6. Pull the trigger and then pull the needle (#21) out through the back of the spray gun.
7. Remove the fluid nozzle (#3) with the wrench (spanner) provided.
8. Clean both fluid nozzle and needle assembly using cleaner or water and a brush.
9. Reassemble following the instructions in the next section for thorough cleaning. Make sure to oil the  needle spring (#20),the Air Valve Stem (#14) and the Gland Seal (#24) to prevent the needle from sticking.
10. To adjust the Gland nut (#23) tighten until the needle sticks, then back off the nut about 1/8 turn. Do not  over tighten the gland nut or the needle will stick. Do not under tighten or the Gland Seal will leak.
11. Check the Cup Top Gasket and replace if damaged. Always seat the cup top gasket flat in the cup groove. Failure to do this will allow the cup to drip and impair the spray pattern due to loss of cup pressure.

Thorough Cleaning

Follow steps above for partial cleaning.
To further disassemble the spray gun now that you have already removed the air cap ring (#1), air cap (#2), fluid nozzle (#3) and needle (#21), locate the air cap seal (#4). To remove the air cap seal, lay the spray gun on its side.

1. Locate the small groove on the air cap seal. You can rotate the groove to a comfortable position for removal. (3 o’clock or 9 o’clock)
   

2. Place the flat tip of the wrench (spanner) in the air cap seal groove. Push in and pry up until the air cap seal pops out. (Clean if necessary).
   

3. Remove the air distributor (#6) and clean if necessary.

4. Remove the fan adjustment ring (#8) and air distributor plate (#7). The air distributor plate is attached to the ring. These two pieces separate. Clean them both if necessary.
   
   Note: Make sure you reassemble the two pieces correctly or you will only get a round fan pattern.

5. Remove the fan adjustment seal (#9). Clean if necessary.
   

Re-Assemble the Spray Gun

1. Insert the fan adjustment seal (#9).
2. Insert the fan adjustment ring and air distributor plate. (#7 and #8). If you have separated these two pieces it is critical that the white air distributor plate is correctly re-inserted into the fan adjustment ring. Note that the open slots on the air distributor plate must be visible through the holes of the fan adjustment ring at the 12 o’clock and 6 o’clock positions.
   

Using the back end of the needle, move the distributor plate so that the round screw hole is at the 5 o’clock position. DO NOT put the distributor plate and fan adjustment ring together as show in the picture marked “incorrect”. You will only be able to achieve a round spray pattern.

1. Place the Air Distributor (#6) on top of the paired fan adjustment ring and Air Distributor plate.
   

2. Align the screw hole in the Air Distributor with the holes in the fan adjustment ring and air distributor plate.
   

3. Place the Air Distributor onto the body of the spray gun aligning the pin with the hole in the spray gun body at the 5 o’clock position.

4. Screw the fluid nozzle (#3) back onto the spray gun, finger tight. Rotate the fan adjustment ring to be sure it rotates freely and easily. Tighten the nozzle slightly more with the wrench (spanner). Rotate fan adjustment ring again. Do not over tighten the fluid nozzle as it will stop the fan adjustment ring from rotating. If too tight, back off slightly. Be sure that the fluid nozzle is not too loose or leaking will occur.

5. Insert the air cap seal (#4). To insert, observe both sides of the seal. One side should have three small circles. This side goes toward the spray gun. Snap the air cap seal onto the air distributor (#6)

6. Push the needle (#21) back into the spray gun.
   

7. Insert the Needle spring into the Material Adjustment Screw (#19).
   

8. Install the Material Adjustment Screw with Needle Spring (#20).
   

9. Install air cap and air cap ring. Spray gun is now re-assembled and ready to use.
   
   Periodically, use Apollo lubricant to lubricate the air valve bushing as shown.

CAUTION
Pressure will remain in the spray cup when unit is off. If you pull the trigger back, a stream of fluid will flow. To prevent accidents, turn material flow screw clockwise until it is completely closed. The trigger is now locked in the closed position.

To relief the cup pressure prior to opening the cup use the twist connector located between the check valve and the cup lid. Undo the connector and the air pressure will exhaust through the tube. If you don’t relieve the air pressure prior to opening the lid on the cup, paint can fly out and down the side of the cup

Reseating Air Valve Bushing

1. Remove A7514 bushing from the spray gun (#14)
   

2. Place A7514 bushing (#14) onto the end of the A7562 bushing insert tool
   

3. Insert A7514 (#14) use bushing insert tool A7562 to carefully press the bushing into the back of the spray gin. Rotate to ensure bushing is secure.
   

4. Reassemble the rest of the spray gun and test for air leaks.

Air Pressure and Viscosity

When using your ™ spray system it is important to understand the nature of the coating you are spraying and the viscosity.
Fairly thin materials like Base coats can generally be sprayed with approximately 2-4 PSI. Medium bodied materials such as sealers will require a little more air pressure, approximately 4-6 PSI. High Solids and heavy viscosity materials are going to require 6 PSI or more to atomise them nicely. Always use the minimal amount of air pressure possible to achieve the best results.

Chart D

Turbine Performance

Record of Spray Gun Use

Record Of Spray Gun Use

Model| Serial #| Date Purchased
| |
Date| Hours Of Use| Total Hours
| |
| |
| |
| |
| |
| |

Turbine Recommended Maintenance: Clean and/or change pre-filters and/or cartridge filters every 50 hours or when necessary. See Accessories Page for appropriate filter replacement for your model.

Record of Spray Gun Maintenance

Troubleshooting

1. Your paint cup is full of material, the HVLP air is supplied to the spray gun, trigger is pulled and no paint comes out Reason: Cup not pressurising.
   A. Check Non-return valve installed correctly. (Black side towards cup)
   B. Check Non-return valve. Clean or replace as necessary.
   C. Check Air feed connector has a blockage. Check/clean as necessary
   D. Check to make sure the cup is clamped tight.
   E. Check the cup top gasket to make sure that the gasket is not damaged or worn and that the cup is sealing correctly on it. Replace if necessary.
   F. Gravity cup: check air pressure feed line is properly connected and not crimped.
   G. Gravity cup: check the cup top gasket to make sure that the gasket is not damaged or worn and that the cup is sealing correctly on it. Replace if necessary.

2. If you think that you are getting too much “over spray” Try:
   A. Moving the spray gun closer to the work (Turbine or compressor).
   B. Reduce the fluid flow
   C. Considering using a smaller nozzle and needle assembly (Turbine or compressor
   D. Reduce air pressure (Compressor or Precision series turbines)

3. If the sprayed surface is not flat and level after drying (orange peel effect) Try:
   A. Increasing air pressure (Compressor or Turbine Models 835VR, 1050VR, 1100 & 1200, POWER-5, PRECISION-5, PRECISION-6)
   B. Thin the coating more. (Turbine or compressor)

4. If the finish looks like “dry mist” or if you think the speed of the application is too slow. Try:
   A. Increasing the fluid flow
   B. Moving the spray gun slower
   C. Moving the spray gun closer to the work piece
   D. Thin the coating more.

5. Fan Pattern Control Ring is hard to rotate or will not turn. Try:
   A. Loosening the fluid nozzle slightly. (Caution – Do not loosen to much or leakage will occur)

6. When rotating Fan Pattern Control Ring you only get a round spray pattern.
   Try: Locate part (#8) Air Distributor Plate which is attached to part (#7) Air Distributor. The position of the air distributor plate is critical to the operation of the Fan Pattern Control Ring. (See page 29 for correct and incorrect position). Adjust if necessary.

If you have any additional questions, please refer to our website located at www.hvlp.com or call our technical service line at 888-900-4857.

Genuine Apollo Accessories

Using genuine Apollo accessories is important to the longevity, ergonomics and portability of your equipment. Other brands of accessories are not designed specifically with your Apollo brand equipment in mind and could cause abnormal functionality. For a complete list of Genuine Apollo parts please visit our website at www.hvlp.com or call a sales associate at 888-900-HVLP (4857).

FS1680 – Pack of 5, Air Feed Tube’s with  Non-return Valves and Air Relief Valves-12”

FS1900 – Deluxe Cleaning Kit, Life Time Warranty

A5033A, A5034A & A7536A – Gravity Feed Cup  Assemblies 250cc, 600cc 1000cc

Rebuilt Kits

Nozzle, Needle and Air Cap Sets

Viscosity Cup

Diagram & Parts List

Warranty

Two Year Warranty
The machine and Equipment are WARRANTED by APOLLO SPRAYERS INTERNATIONAL, INC. for a total period of TWO YEARS from the ORIGINAL date of purchase by the ORIGINAL PURCHASER. Proof of purchase to be included and all SHIPPING CHARGES to be pre-paid.

APOLLO SPRAYERS INTERNATIONAL INC., upon examination of the machine/equipment will replace or repair at their discretion any defects in material or workmanship.

This WARRANTY does NOT include misuse, damage, neglect, alterations, disassembled equipment or modifications, lack of maintenance, cleaning, water damage to electrical parts, INCORRECT VOLTAGE CONNECTION.

This Warranty is in lieu of all other express warranties, any WARRANTY implied by law, including but not limited to, implied Warranties of merchantability or fitness, is excluded to the maximum extent permitted by law and, if not excludable, is limited to the duration of the express Warranty.

No representative or person is authorized to extend this Warranty or to create for APOLLO SPRAYERS INTERNATIONAL, INC. any other liability in connection with the sale of any APOLLO SPRAYERS product. APOLLO SPRAYERS INTERNATIONAL, INC. shall not be liable for any consequential, incidental or special damages of any kind directly or indirectly resulting from breach of any express or implied warranty.

Some states do allow the exclusion or limitation of incidental or consequential damages or limitations on the length of any Warranty so that the above limitations and exclusions may not apply to you: however, to the maximum extent permitted under applicable law, the only rights and remedies shall be to obtain a replacement for any defective product.

This Warranty gives you specific legal rights and you may also have other rights which vary from State to State.

Apollo Sprayers International, Inc. 1030 Joshua Way, Vista, CA 92081
Customer Service: 760-727-6226
Fax: 760-727-9325
Toll Free Sales & Service: (888) 900-HVLP (4857)
www.hvlp.com

WARNING: This product can expose you to chemicals including Chromium, which is known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.

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