Cornwell Tools PSG-1000 User manual

PSG-1000 1 Rev. 07/24/07
Operating Instructions • Warning Information • Parts Breakdown
PSG-1000
Gravity Feed HVLP
Spray Gun with
Regulator and
Metal Cup

PSG-1000 2 Rev. 07/24/07
WARNING - FOLLOW THESE RULES FOR SAFE OPERATION!
• During cleaning and flushing, solvents
can be forcefully expelled from fluid
and air passages. Some solvents can
cause eye injury.
• Be sure all others in the area are
wearing impact-resistant eye and face protection.
• Even small projectiles can injure eyes and
cause blindness.
• Air under pressure can cause severe injury. Always
shut off air supply, drain hose of air pressure and
disconnect tool from air supply when not in use,
before changing accessories or when making repairs.
Never direct air at yourself or anyone
else. Whipping hoses can cause serious
injury. Always check for damaged or loose
hoses and fittings. Never use quick change
couplings at tool. They add weight and
could fail due to vibration. Instead, add a
hose whip and connect coupling between air supply,
and hose whip, or between hose whip and leader
hose. Do not exceed maximum air pressure of 43
PSI.
• Always use tool a safe distance from other people in
work area.
• Maintain tools with care. Keep tools clean and oiled
for best and safest performance. Follow instructions
for lubricating and changing accessories. Wiping or
cleaning rags and other flammable waste materials
must be placed in a tightly closed metal container
and disposed of later in the proper fashion.
• Do not wear loose or ill-fitting clothing, remove
watches and rings.
• Don’t over reach. Keep proper footing
and balance at all times. Slipping,
Tripping and Falling can be a major
cause of serious injury or death. Be
aware of excess hose left on the
walking or work surface.
• Don’t force tool. It will do the job better and safer at
the rate for which it was designed.
• Don’t abuse hoses or connectors. Never carry tool by
the hose or yank it to disconnect from power supply.
Keep hoses from heat, oil and sharp edges. Check
hoses for weak or worn condition before each use,
making certain that all connections are
secure.
• High sound levels can cause permanent
hearing loss. Protect yourself from
noise. Noise levels vary with work
surface. Wear ear protectors.
• When possible, secure work with clamps or vise so
both hands are free to operate tool.
• Repetitive work motions, awkward positions and
exposure to vibration can be harmful to hands
and arms.
• Avoid inhaling dust or handling debris from work
processes which can be harmful to your health.
• Operators and maintenance personnel must be
physically able to handle the bulk, weight and power
of this tool.
• This tool is not intended for using in explosive
atmospheres and is not insulated for contact with
electric power sources.
• Solvent and coatings can be highly
flammable or combustible especially
when sprayed. Adequate exhaust must
be provided to keep air free of
accumulations of flammable vapors.
• Smoking must never be allowed in the spray area.
• Fire extinguishing equipment must be present in
the spray area.
• Never spray near sources of ignition such as pilot
lights, welders, etc.
• Halogenated hydrocarbon solvents — for example;
methylene chloride, are not chemically compatible
with the aluminum that might be used in many
system components. The chemical reaction caused by
these solvents reacting with aluminum can become
violent and lead to an equipment explosion. Guns
with stainless steel fluid passages may be used with
these solvents. However, aluminum is widely used in
other spray application equipment - such as material
pumps, cups and regulators, valves, etc. Check all
other equipment items before use and make sure
they can also be used safely with these solvents. Read
the label or data sheet for the material you intend to
spray. If in doubt as to whether or not a coating or
cleaning material is compatible, contact your
material supplier.
• Sprayed materials may be harmful if inhaled, or
if there is contact with the skin. Adequate
exhaust must be provided to keep the air
free of accumulations of toxic materials.
Use a mask or respirator whenever there is
a chance of inhaling sprayed
materials. The mask must be compatible with the
material being sprayed and its concentration.

PSG-1000 3 Rev. 07/24/07
This spray gun is rugged in construction, and is built to yield exceptional value. The life of this product and the efficiency
of its operation depend upon a knowledge of its construction, use and maintenance.
INSTALLATION
Never mount oil and water extractor on or near the air compressor.
During compression, air temperature is greatly increased. As the air cools down to room temperature, moisture
condenses in the air line, on its way to the spray gun. Therefore, always mount the oil and water extractor at a point in
the air supply system where the compressed air temperature is lowest.
Drain air lines properly.
Pitch all air lines back towards the compressor so that condensed moisture will flow back into the air receiver where
it can be drained off. Each low point in an air line acts as a water trap. Such points should be fitted with an easily
accessible drain. See diagram above.
Drain
AIR SUPPLY
Length of Pipe (ft.)
Air Flow
CFM 50 100 150 200
10
20
30
40
50
70
1/2"
3/4"
3/4"
1"
1"
1"
3/4"
3/4"
3/4"
1"
1"
1"
3/4"
1"
1"
1"
1-1/4"
3/4"
3/4"
1"
1"
1"
1-1/4"
Oil & Water
Extractor
Drain
Oil and Water Extractor should be at least 25 ft. from the compressor, farther if possible.
25 Feet or
More
Install drain at
each low point
Compressor Unit
Pitch pipe back toward air receiver
GRAVITY FEED CUP HOOKUP
Air pressure for atomization is regulated at extractor.
Amount of fluid is adjusted by fluid control screw on
gun, viscosity of paint, and air pressure.
Air Inlet
Oil and Water
Extractor
Fluid
Control
Screw
Gravity
Feed
Cup
Atomization
Pressure Gauge

PSG-1000 4 Rev. 07/24/07
In normal use, the nozzle wings are horizontal as shown
here. This provides a vertical fan-shaped pattern which
gives maximum, even, material coverage as the
gun is moved back and forth parallel
to the surface being finished.
®
®
®
FOR BEST PERFORMANCE, PLEASE BE SURE TO DO
THE FOLLOWING BEFORE USING THIS TOOL
• Tighten the gun to the cup securely with the nut and fitting supplied.
• Be sure to have the proper air pressure at the gun to operate. Proper air pressure for this tool should be
35 PSI for lacquer and 43 PSI for enamel.
• Adjust fluid control screw and spray width adjustment screw to your desired pattern before using
on production.
• Clean all parts after use.
SPRAYING
ADJUSTMENTS
Spray pattern may be infinitely
adjusted from round to flat.
Set atomization pressure at no more than 43 PSI. For
optimum performance, some materials may spray better
at PSI ratings below 43. If unsure, always test at PSI
ratings before using on final production. Try spray. If it is
too fine, decrease the air pressure or open fluid control
screw. If the spray is too thick, close the fluid control
screw. Regulate the pattern width and repeat adjust-
ment of spray as needed.
HVLP SPRAY GUN
The model you have purchased is a
professional high volume, low pressure,
spray gun. It is designed to spray very
efficiently with virtually no overspray.
To accomplish this, the inlet pressure
regulation is critical. Please be sure to
read pressure requirements carefully.
Spray width adjustment screw
Turn right for round, left for fan.
Fluid control screw. Turn
right to decrease flow, left
to increase.

PSG-1000 5 Rev. 07/24/07
AIR NOZZLE, FLUID NOZZLE,
AIR VALVE ASSEMBLY
1. All nozzles and needles are made to exact standards.
They should be handled carefully.
2. To clean nozzles, immerse them in solvent until any
dried material is dissolved, then blow them clean.
3. Do not use metal or sharp instrument to probe any of
the holes in the nozzles.
4. Air flow should occur before fluid-flow when the gun
is triggered. It may be necessary to adjust the fluid
control screw to make sure air flows before fluid.
5. Do not alter the gun in any way.
GRAVITY FEED
Turn off air supply. Remove cover of cup. Empty the cup
of material. Clean the cup and cover. Add some cleaning
solvent to cup. Replace cup cover. Turn on air supply and
spray with proper cleaning solvent. Repeat with clean
solvent if necessary. Remove solvent, disconnect gun,
remove cup cover and clean. Wipe gun and cup with rag
dampened with solvent.
CAUTION…
Do not remove brass baffle attached to front of body
of gun (see page 7, Parts Diagram). Special technical
training and tools are required. Only authorized service
centers should remove this part.
To avoid cross-threading, all spray gun parts should be
screwed in hand tight initially. If the parts can not easily
be turned by hand , be sure you have the correct parts,
unscrew, realign, and try again. NEVER use excessive
force in matching parts.
Hold the gun from 6 to 12 inches away from the surface
depending on material and atomizing pressure. For a
uniform finish, lap each stroke over the preceding stroke,
making sure the spray is smooth and wet.
Using the lowest possible atomizing air pressure will
reduce overspray and provide maximum efficiency.
Proper handling of the gun is essential for obtaining a
good finish. The gun should be held at a right angle to
the surface being covered, and moved parallel with it. For
precise control of the gun and material, the trigger should
be released before the end of the stroke.
Light Coat Heavy Coat
Start
stroke
Pull
trigger
Release
trigger
End of
Stroke
WRONGRIGHT
Even and wet coat
6 to 12 inches
SPRAY GUN
1. Submerge the front end of the gun in solvent just until
the fluid connection is covered.
2. Paint that has built up on the gun should be removed
using a bristle brush and solvent.
3. Never submerge all of the spray gun in solvent
because:
• This will dissolve the lubricant in the leather
packings and on wear surfaces, causing them to dry
out and resulting in difficult operation and
faster wear.
• Air passages in the gun will become clogged with
dirty solvent.
4. Using a rag moistened with solvent, wipe down the
outside of the gun.
5. Oil gun daily. Use a drop of lightweight machine
oil on:
A. fluid needle packing
B. air valve packing
C. trigger pivot point
See Fig. 1 for Location of
Above Points.
6. Caution: Do not use lubricants
which contain silicone. Silicone
may cause defects in the
finish application.
CLEANING & MAINTENANCE
OPERATION
Fig. 1
A
B
C

PSG-1000 6 Rev. 07/24/07
TROUBLESHOOTING
One side of nozzle wing
is clogged.
PROBLEMSPRAY PATTERN/
CONDITION
A.) Loose air nozzle.
B.) Material around outside of
air nozzle has dried.
A.) Atomization air pressure is set
too high.
B.) Trying to spray a thin material
in too wide a pattern.
Spitting
SOLUTION
A.) Reduce air pressure.
B.) Increase material control by turning fluid
control screw to left, while reducing spray
width by turning spray width adjustment
screw to right.
Soak nozzle in solvent to loosen clog, then blow
air through until clean. To clean orifices use a
broom straw or toothpick. Never try and detach
dried material with sharp tool.
A.) Tighten air nozzle.
B.) Take off air nozzle and wipe off fluid tip,
using rag moistened with thinner.
A.) Back up knurled nut, put a few drops of
machine oil on packing, re-tighten nut.
B.) Take off fluid nozzle, clean rear of nozzle and
seat in gun body. Replace nozzle and bring in
tight to body.
C.) Tighten or change out swivel nut.
A.) Packing around needle valve
is dried out.
B. Fluid nozzle loosely installed,
or dirt between nozzle
and body.
C.) Loose or defective swivel nut
on siphon cup.
Fluid leakage from
packing nut.
A.) Packing nut loose.
B.) Packing worn or dry.
A.) Tighten, but not so tight as to grip needle.
B.) Replace packing or lubricate.
Dripping from fluid tip.
A.) Dry packing.
B.) Sluggish needle.
C.) Tight packing nut.
D.) Worn fluid nozzle or needle.
A.) Lubricate.
B.) Lubricate.
C.) Adjust.
D.) For pressure feed, replace with new fluid nozzle
and needle.
Thin, sandy coarse finish.
Thick, dimpled finish
resembling orange peel.
A.) Gun held too far from surface.
B.) Atomization pressure set
too high.
Gun held too close to surface.
A.) Move gun closer to surface.
B.) Adjust atomization pressure.
Move gun further from surface.
Will not spray.
A.) No air pressure at gun.
B.) Fluid pressure too low with
internal mix cap and
pressure tank.
C.) Fluid control screw not
open enough.
D.) Fluid too heavy for
suction feed.
A.) Check air supply and air lines.
B.) Increase fluid pressure at tank.
C.) Open fluid control screw.
D.) Thin material or change to pressure feed.
Unable to get round spray. Fan adjustment screw not
seating properly. Clean or replace.
Improper spray pattern. A.) Gun improperly adjusted.
B.) Dirty air cap.
C.) Fluid tip obstructed.
D.) Sluggish needle.
A.) Readjust gun. Follow instructions carefully.
B.) Clean air cap.
C.) Clean.
D.) Lubricate.

PSG-1000 7 Rev. 07/24/07
PARTS BREAKDOWN - PSG-1000
NOTE: Brass Baffle has left handed threads.
RS9003PKG
(10 Pack)
RS1732
RS1731
RS1730A
RS9601-1.3
RS1724A
RS1722
RS1725A
RS9604 -1.3
RS1713
RS1705
RS1706
RSR1707
RS1708
RS1709
RS1710
RS9616-1.3
RS9626
RS1733
RS1715
RS1720
RS1714
RS1711
PSG-RS1729AL-1
(5 Pack)
RS9617
RS9618 RS9619
*
PSG-RG
Optional Nozzle Kits Available:
PSG-1000-1.3 (#9002-1.3) - 1.3mm
PSG-1000-1.4 (#9002-1.4) - 1.4mm
PSG-1000-1.7 (#9002-1.7) - 1.7mm
PSG-1000-2.0 (#9002-2.0) - 2.0mm
Nozzle Kits consist of:
1 Air Cap
1 Fluid Needle
1 Fluid Nozzle
1785RK Includes all parts as
asterisked on parts diagram
RS9612N-0
PSG-1000CCGFC
* *
* * * *
*
*
*
*
*
*
*

PSG-1000 8 Rev. 07/24/07
ITEM NO. DESCRIPTION
RS1785RK Repair Kit*
RS1705 Packing Screw
RS1706 Teflon Seal
RS1707 Washer
RS1708 Spring
RS1709 Brass Baffle (Left-Hand Thread)
RS1710 Gasket
RS1711 Connector
RS1713 Air Valve Assembly
RS1714 Fan Adjustment
RS1715 Control Knob
RS1720 Screw
RS1722 Trigger
RS1724A Screw & Nut
RS1725A Pin & Clip
RS1730A Spanner
RS1731 Socket Spanner
RS1732 Brush
RS1733 Air Adjusting Valve Assembly
RS9003PKG Material Filter (10 Pack)
RS9601-1.3 Air Nozzle 1.3MM
RS9604-1.3 Fluid Nozzle 1.3MM
RS9616-1.3 Paint Needle 1.3MM
RS9617 Spring
RS9618 Lock for Fluid Control Knob
RS9619 Fluid Control Knob
RS9626 Air Connection
9RS612N-0 Hanger
PSG-1000CCGFC Replacement Aluminum Cup and Lid
PSG-RG Dial Regulator
PSG-RS1729AL-1 Gasket for Aluminum Lid (5 pack)
*Includes all parts as asterisked on parts diagram.
PARTS LIST - PSG-1000
WARRANTY
Cornwellwarrantsitsairtoolsforaperiodof1yeartothe
consumer. We will repair any air tool covered under this
warranty which proves to be defective in material or
workmanship during the warranty period. In order to
have your tool repaired, return the tool to any Cornwell
Authorized Warranty Center, freight prepaid. Please
include a copy of your proof of purchase and a brief
description of the problem. The tool will be inspected
and if any part or parts are found to be defective in
material or workmanship, they will be repaired free of
charge and the repaired tool will be returned to you
freight prepaid.
This warranty gives you specific rights. You may also
have other rights which vary from state to state.
TheforegoingobligationisCornwell’ssoleliabilityunder
this or any implied warranty and under no
circumstances shall Cornwell be liable for any
incidental or consequential damages.
Note: Some states do not allow the exclusion or
limitation of incidental or consequential damages so
the above limitation or exclusion may not apply to
you.