Cornwell Tools PSG-1200 User manual

PSG-1200 1 Rev. 07/24/07
PSG-1200
Touch-Up
Gravity Feed
Spray Gun
and Cup
Operating Instructions • Warning Information • Parts Breakdown

PSG-1200 2 Rev. 07/24/07
• 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 aluminu can
become violent and lead to an equipment explosion. Guns with
stainless steel fluid passage 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 the can also be used safely with these solvents. Read
the label or data sheet for the material you inten 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.
WARNING - FOLLOW THESE RULES FOR SAFE OPERATION!

PSG-1200 3 Rev. 07/24/07
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
Air Hose
Oil and Water
Extractor
This spray gun is rugged in construction, and is built to yield exceptional value. The life of this product and the efficiency of its opera-
tion 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
Fluid Control
Screw
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"
Gravity
Feed
Cup
Atomization
Pressure Gauge
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

PSG-1200 4 Rev. 07/24/07
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
In normal use, the nozzle wings are hor-
izontal 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.
Spray pattern may be
infinitely adjusted from round to flat.
Set atomization pressure at no more than 43 PSI. For opti-
mum 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. Regu-
late the pattern width and repeat adjustment of spray as
needed.
®
®
®
Fluid control screw
Turn right to decrease flow, left to increase.
Spray width adjustment screw
Turn right for round, left for fan.

PSG-1200 5 Rev. 07/24/07
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.
Hold the gun from 6 to 12 inches away from the surface
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.
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 sol-
vent if necessary. Remove solvent, disconnect gun,
remove cup cover and clean. Wipe gun and cup with rag
dampened with solvent.
CAUTION…
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.
CLEANING & MAINTENANCE
OPERATION
Fig. 1
A
B
C

PSG-1200 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-1200 7 Rev. 07/24/07
PARTS BREAKDOWN - PSG-1200
Optional Nozzle Kits Available:
PSG-1200-0.5 (#9001-0.5) - .5mm
PSG-1200-0.8 (#9001-0.8) - .8mm
PSG-1200-1.0 (#9001-1.0) - 1.0mm
Nozzle Kits consist of:
1 Air Cap
1 Fluid Needle
1 Fluid Nozzle
RS2001 RS2006 RS2007
RS2008
RS2009-1
RS9003PKG
RS2012AL-1
PSG-150CC
RS2021
RS2022
RS2041
RS2030
RS2029
RS2016A
RS2013
RS2015A
RS2027
RS2028
RS2035
RS2019
RS2018RS2020
RS2009
RS2005
RS2010
RS1732
RS1730A
RS2000RK Includes all parts as
asterisked on parts diagram

PSG-1200 8 Rev. 07/24/07
PARTS LIST - PSG-1200
ITEM NO. DESCRIPTION
RS1730A Spanner
RS1732 Brush
RS2000RK* Repair Kit
RS2001 Air Nozzle 0.8MM (Standard)
RS2005 O-Ring
RS2006 Fluid Nozzle 0.8MM (Standard)
RS2007 Gasket
RS2008 Packing Screw
RS2009 Teflon Seal
RS2009-1 Spring
RS2010 Connector
RS2013 Trigger
RS2015A Screw with E-Ring
RS2016A Trigger Pin with E-Ring
RS2018 Fluid Control Knob
RS2019 Lock Nut
RS2020 Spring
RS2021 Paint Needle 0.8MM (Standard)
RS2022 Washer
RS2027 Air Valve Assembly
RS2028 Screw
RS2029 Control Knob
RS2030 Fan Adjustment
RS2035 Air Connection
RS2041 Air Valve Assembly
RS2012AL-1 Gasket for Cup
RS9003PKG Material Filter (10 Pack)
PSG-150CC 150CC Aluminum Cup & Lid
*Includes all parts as asterisked on parts
diagram.
WARRANTY
Cornwell warrants its air tools for a period of 1 year to the
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.
The foregoing obligation is Cornwell’s sole liability
under this or any implied warranty and under no
circumstances shall Cornwell be liable for any incidental or con-
sequential damages.
Note: Some states do not allow theexclusion or
limitation of incidental or consequential damages so the above
limitation or exclusion may not apply to you.