Harbor Freight Tools 91009 User Manual

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20 OZ. AIR GRAVITY SPRAY GUN

Model 91009

ASSEMBLY and OPERATING

INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at http://www.harborfreight.com

Copyright © 2003 by Harbor Freight Tools® . All rights reserved. No portion of this
manual or any artwork contained herein may be reproduced in any shape or form
without the express written consent of Harbor Freight Tools.

For technical questions and replacement parts, please call 1-800-444-3353

Specifications

Operating and Maximum PSI 40 PSI/ 50 PSI Max.
Average Air Consumption 5 CFM
Paint Capacity 20 oz.
Air Inlet 1/4” - 18 NPS
Nozzle Size 0.055”
Weight 1.5 Lbs. (when empty)

Save This Manual

You will need the manual for the safety warnings and precautions,
assembly instructions, operating and maintenance procedures, parts list and
diagram. Keep your invoice with this manual. Write the invoice number on the
inside of the front cover . K eep the manual and inv oice in a safe and dry place for
future reference.

Safety Warnings and Precautions

WARNING: When using tool, basic safety precautions should always be followed to
reduce the risk of personal injury and damage to equipment.

Read all instructions before using this tool!

1. Keep work area clean. Cluttered areas invite injuries.

2. Observe work area conditions. Do not use machines or power tools in damp or wet
locations. Don’t expose to rain. Keep work area well lit. Do not use air tools in the
presence of flammable gases or liquids.

3. Keep children away. Children must never be allowed in the work area. Do not let
them handle machines, tools, extension cords, or air hoses.

4. Store idle equipment. When not in use, tools must be stored in a dry location to
inhibit rust. Always lock up tools and keep out of reach of children.

5. Use the right tool for the job. Do not attempt to force a small tool or attachment to
do the work of a larger industrial tool. There are certain applications for which this
tool was designed. It will do the job better and more safely at the rate for which it was
intended. Do not modify this tool and do not use this tool for a purpose for which it
was not intended.

6. Dress properly. Do not wear loose clothing or jewelry as they can be caught in
moving parts. Protective, electrically non-conductive clothes and non-skid footwear
are recommended when working. Wear restrictive hair covering to contain long hair.

7. Use eye and ear protection. Always wear ANSI approved impact safety goggles.
Wear an ANSI approved dust mask or respirator when working around chemical
dusts, paints and mists. Wear appropriate ear protection.

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8. Do not overreach. Keep proper footing and balance at all times. Do not reach over or
across running machines or air hoses.

9. Maintain tools with care. Keep tools clean for better and safer performance. Follow
instructions for lubricating and changing accessories. Inspect tool cords and air hoses
periodically and, if damaged, have them repaired by an authorized technician. The
handles must be kept clean, dry, and free from oil and grease at all times.

10. Disconnect air supply. Disconnect air hose when not in use, when changing
accessories, and during maintenance.

11. Remove adjusting wrenches. Check that adjusting wrenches are removed from the
tool before attaching to the air source.

12. Avoid unintentional starting. Be sure the trigger is in the Off position when not in
use and before attaching to the air source. Do not carry any tool with your finger on
the trigger, whether it is attached to the air compressor or not.

13. Stay alert. Watch what you are doing, use common sense. Do not operate any tool
when you are tired.

14. Check for damaged parts. Before using any tool, any part that appears damaged
should be carefully checked to determine that it will operate properly and perform its
intended function. Check for alignment and binding of moving parts; any broken parts
or mounting fixtures; and any other condition that may affect proper operation. Any
part that is damaged should be proper ly repaired or replaced by a qualified
technician. Do not use the tool if any trigger does not operate properly.

15. Guard against electric shock. Prevent body contact with grounded surfaces such as
pipes, radiators, ranges, and refrigerator enclosures.

16. Replacement parts and accessories. When servicing, use only identical
replacement parts. Use of any other parts will void the warranty. Only use accessories
intended for use with this tool. Approved accessories are available from Harbor
Freight Tools.

17. Do not operate tool if under the influence of alcohol or drugs. Read warning
labels if taking prescription medicine to determine if your judgement or reflexes are
impaired while taking drugs. If there is any doubt, do not operate the tool.

18. Use proper size and type extension cord. If an extension cord is required, it must
be of the proper size and type to supply the correct current to the compressor without
heating up. Otherwise, the extension cord could melt and catch fire, or cause
electrical damage to the compressor. Check your compressor’s manual for the
appropriate size cord.

19. Maintenance. For your safety, maintenance should be performed regularly by a
qualified technician.

20. Compressed air only. Never use combustible gas as a power source.

21. Do not spray near open flames, pilot lights, stoves, heaters, or any other heat
source. Most solvents and coatings are highly flammable, particularly when sprayed.

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22. Clean Sprayer with care. Use non-flammable solvents.

23. Do not smoke while spraying. Most solvents and coatings are highly flammable,
particularly when sprayed.

24. Read all of the information concerning coating products and cleaning solvents.
Chlorinated solvents (e.g. 1-1-1 Trichlorethylene and Methylene Chloride, also known
as methyl chloride) can chemically react with aluminum and may explode. Many paint
sprayers contain aluminum. If you have any doubt about potential chemical reactions,
contact the solvent or coating manufacturer.

25. Materials used when painting or cleaning may be harmful or fatal if inhaled or
swallowed. Only use in an area with adequate ventilation. Use a respirator or mask
when painting or using cleaning solvents.

26. Never release the sprayer lid while the cup is pressurized.

27. Never point a spray gun at a person or animal. Always properly mask all objects
that are not to be painted.

Note: P erf ormance of the compressor (if powered by line voltage) may v ary depending

on variations in local line voltage. Extension cord usage may also affect tool perfor­mance.

Warning: The warnings, cautions, and instructions discussed in this instruction manual
cannot cover all possible conditions and situations that may occur. It must be under­stood by the operator that common sense and caution are factors which cannot be
built into this product, but must be supplied by the operator.

WARNING: The brass components of this product contain lead, a chemical
known to the State of California to cause birth defects (or other reproductive
harm). (California Health & Safety code 25249.5, et seq.)

Unpacking

When unpacking, check to make sure the par ts listed on page 8 are included. If any
parts are missing or broken, please call Harbor Freight Tools at the number on the cover of
this manual as soon as possible.

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Operation

1/4” NPS

Sprayer

For best service you should incorporate a regulator and inline filter, as
shown in the diagram above. Hoses, couplers, regulators, and filters are all
available at Harbor Freight Tools.

1 . You will need to prepare a 1/4” air connector (sold separately) to connect to the air inlet

on the Spray Gun. First, wrap the 1/4” air connector (not included) with pipe thread
seal tape before threading it into the Air Inlet (32). Connect the 3/8” ID Air Source Hose
to the Spray Gun.

2. Set the air pressure on your compressor to 40 PSI. Do not exceed the maximum air
pressure of 50 PSI.

3. Check the air connection for leaks and then disconnect the tool from the air source.

Vent (30)

Lid (29)

Cup (28)

Air Nozzle (1)

Trigger (37)

Fluid Control Knob (12)

Spray Regulator Knob (20)

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Air Adjusting Valve (31)

Air Inlet (32)

Page 5

Operation (continued)

Filling the Cup (28)

Warning! The Spray Gun must be disconnected from the air source when filling or refilling

material.

1 . Attach the Cup (28) to the Spray Gun. Make sure to include the Filter (27) in between

the Cup (28) and Gun Body (8) during assembly.

2. Remove the Lid (29) off the top of the Cup (28) of the Spray Gun.

3 . Fill the Cup (28) with the appropriate material and replace the Lid (29) on the top of the

Cup (28). Make sure the Lid (29) is securely tightened. Make sure the Vent (30) is
closed.

Note: Before spra ying, mask all objects you do not want spra yed and la y cloths (not included)

on the floors.

Operation

Note: W e recommend you pr actice on scrap material to adjust and get familiar with the Gun.

1. Connect the air source hose to the Air Inlet (32). Turn on your air compressor to the
recommended air pressure of 40 PSI. Do not exceed the 50 PSI maximum.

2. Pull the Trigger (36) slowly and move the Spray Gun in parallel strokes to the object
being painted. Keep the distance from the object being painted at 4” to 12”. This may
slightly differ depending on the flow adjustment and the material being sprayed.

3 . Release the Trigger (36) after each forward movement; pull the T rigger (36) again on the

return movement.

4. When using a vertical pattern, move the Spray Gun in a horizontal motion; with a
horizontal pattern move the Spray Gun in a v ertical motion. A round pattern requires a
greater distance from the object being painted.

5. When finished, release the Tr igger (36) and disconnect from the air source. The Cup
(28) and Spray Gun may still hold air pressure, fire the Spray Gun toward scrap material
until all of the pressure is expended. Bef ore removing the Lid (29), open the V ent (30).

Spray Gun Adjustments (Refer to page 5 and the Assembly Dra wing on page 9)
Note: We recommend you practice on scrap material to learn the fine tune adjustments.

1 . To change the spray pattern, turn the Spray Regulating Knob (20) and/or adjust the Air

Nozzle (1).

2. To regulate the amount of material entering the Spray Gun, adjust the Fluid Control
Knob (12).

3. To fine tune the air flow, adjust the Air Adjusting Valve (31).

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Troubleshooting

Note: Have any of the following internal repairs completed by an authorized service technician.

Trouble

Gun leaks from fluid tip

Spray pattern
sickle shaped

Spray pattern
oval shaped

Spray pattern flutters

Material bubbles or boils
in the paint cup

Cause

Foreign substance between the fluid tip
and needle preventing a good seal

Air circuit clogged

Dirt on fluid pin tip or air outlet

Not enough material in the cup,
fluid nozzle not tight, needle sealing
damaged, nozzle set dirty or damaged

Too much air flowing through the paint
channel to the cup, loose paint nozzle,
loose air nozzle, clogged filter, defective
gasket, or damaged nozzle insert

Repair

Clean fluid needle in thinner
or replace nozzle set

Soak in thinner and clean the
nozzle set and internal needle

T urn the air nozzle 180°, clean
fluid tip pin and air circuit

Refill material, tighten parts,
clean or replace parts

Clean, tighten, or replace
parts

Note: T o clean, change, or replace the Fluid Nozzle

FIGURE 2

(2), use the Wrench (35) FIGURE 2, to the
right.

Maintenance

Disconnect from the air source.
1 . Remov e the Lid (29).

2. Pour residual paint into the paint container and seal it.

3 . Pour non-flammable paint thinner into the Cup (28).

If water based paint was used, you can use water.

4. Secure the Lid (29) to the Cup (28) and shake the liquid in the cup.

5. Connect to the air source and turn on the air compressor.

6. Spray the liquid onto a piece of scrap material until the spray material is free of paint.

7. Repeat if necessary.

8. Remove the entire Cup (28) by un-threading it. Check the Filter (27) in the Gun Body
(8). If it is not clean, use the Brush (33) to clean it. Replace the Filter (27) and thread on
the Cup (28). See FIGURE 3 on page 8.

9. Use the Brush (33) to clean the recessed, hard to reach areas of the Gun.

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Parts List

Part No. Description Part No. Description

1 Air Nozzle 20 Spray Regulator Knob
2 Fluid Nozzle 21 Screw
3 Air Ring 22 Trigger Bolt
4 Piston Pad 23 Locking Plate
5 Compression Ring 24 Bolt
6 Needle Seal Spring 25 Bolt
7 Air Piston Seal 26 Paint Connector
8 Gun Body 27 Filter
9 Paint Needle 28 Cup
10 Paint Piston Spring 29 Lid
11 Nut 30 Vent
12 Fluid Control Knob 31 Air Adjust. Valve Assy.
13 Air Piston Box 32 Air Inlet
14 Air Piston Packing 33 Brush
1 5 Air Piston 34 Hex Adapter
16 Piston Ring 35 Wrench
1 7 Air Piston 3 6 Trigger
1 8 Air Piston Spring
19 Spray Regulator Screw

FIGURE 3

Cup (28)

Filter (27)

Gun Body (8)

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUF ACTURER AND/OR DISTRIBUT OR HAS PRO VIDED THE PARTS DIAGRAM IN THIS
MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBU­TOR MAKES ANY REPRESENTA TION OR W ARRANTY OF ANY KIND TO THE BUYER THA T HE
OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS
QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER
AND/OR DISTRIBUTOR EXPRESSLY ST A TES THA T ALL REPAIRS AND P ARTS REPLA CEMENTS
SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NO T BY THE
BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER
REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PA RTS THERET O , OR ARISING
OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.

NOTE: Some parts are listed and shown for illustration purposes only and are not available
individually as replacement parts.

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Assembly Drawing

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90 Day Warranty

Harbor Freight Tools Co. makes every effort to assure that its products meet high quality
and durability standards, and warrants to the original purchaser that this product is free from
defects in materials and workmanship for the period of 90 days from the date of purchase. This
warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or
accidents, repairs or alterations outside our facilities, criminal activity, improper installation,
normal wear and tear, or to lack of maintenance. We shall in no event be liable for death,
injuries to persons or property, or for incidental, contingent, special or consequential damages
arising from the use of our product. Some states do not allow the exclusion or limitation of
incidental or consequential damages, so the above limitation of exclusion may not apply to
you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

To take advantage of this warranty, the product or part must be returned to us with
transportation charges prepaid. Proof of purchase date and an explanation of the complaint

must accompany the merchandise. If our inspection veries the defect, we will either repair or

replace the product at our election or we may elect to refund the purchase price if we cannot
readily and quickly provide you with a replacement. We will return repaired products at our
expense, but if we determine there is no defect, or that the defect resulted from causes not
within the scope of our warranty, then you must bear the cost of returning the product.

This warranty gives you specic legal rights and you may also have other rights which vary

from state to state.

3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • [phone]

Page 20 For technical questions, please call 1-800-444-3353. SKU 67450