Dux Automatic User manual

Product
Manual
DUX Automatic
P.O. Box 1314 Seahurst WA 98062 | Phone [phone] | Fax [phone] | www.DuxTechnologiesInc.com

AUTOMATIC
Page 1
The DUX Automatic
INSPIRED BY FORMULATHREE RACE CAR
ENGINES.
After more than 5 years of research and
development, DUX has reinvented the spray gun
from the inside out. By incorporating our
patented airflow technology, originally used in
Formula Three race car engines, we’ve
developed the most innovative breakthrough in
spray gun technology in nearly 80 years.
For the first time, finishers can spray nearly any
type of fluid, onto nearly any surface with a
single gun – while reducing coatings waste and
improving finish quality.
TECHNOLOGY THAT’S EASY TO USE AND
EASY ON US.
The DUX Automatic spray gun uses a patented
technology to reduce overspray and booth “fog”.
Less paint in the air means more paint on the
target and a corresponding decrease in booth
filter replacement and hazardous waste disposal
fees, potentially cutting the operating cost of a
paint line by 50%. Since the DUX Automatic
achieves atomization with a lower volume of air,
you may also see a reduction in compressor
energy consumption.
For customer service call 888.389.2732
Patent Information
The design and technology forming the basis of
this product is the confidential information of DUX
Technologies Inc.,aWashington corporation.
The relevant US Patent Numbers are: US
6,793,157;US 6,425,533, and U.S. 7,004,404.
DUX Technologies Inc. may have additional
patents, patent applications, trademarks,
copyrights, or other intellectual property rights
covering subject matter in this document.
Except as expressly provided in any written
license agreement from DUX Technologies
Inc., this document does not grant you any
license to or rights in any such patents,
trademarks, copyrights, or other
intellectual property.
© 2006 DUX Technologies Inc. All
rights
reserved.
DUX, DUX Technologies, DUX Automatic
are either registered trademarks or
trademarks of DUX AREA Inc. in the
United States and/or other countries.
Part No. 510003
Printed in the United States of America

AUTOMATIC
For customer service call 888.389.2732Page 2
Table of Contents
Warnings....................................................................................................Page 3
Safety Information ....................................................................................Page 3
Installation.................................................................................................Page 4
Mounting........................................................................................Page 4
Fittings ...........................................................................................Page 4
Setup.............................................................................................. Page 4
Connections...................................................................................Page 4
Operation...................................................................................................Page 5
Fluid Control Knob.........................................................................Page 5
Fan Control Adjustment.................................................................Page 5
Automatic..................................................................................Page 5
Manual...................................................................…………….Page 5
Operating the Spray Gun...............................................................Page 5
Troubleshooting .......................................................................................Page 6
Maintenance .............................................................................................Page 7
Lubrication ....................................................................................Page 7
Fluid Needle Removal ...................................................................Page 7
Fluid Tip Removal..........................................................................Page 8
Fluid Packing Adjustment.............................................................. Page 8
Fluid Packing Replacement...........................................................Page 9
Removal . ................................................................................. Page 10
Replacement ............................................................................ Page 11
Cleaning ..................................................................................................... Page 12
Flushing................................................................................................. Page 12
General Cleaning .......................................................................... Page 12
Exploded View .......................................................................................... Page 13
Replacement Parts List............................................................................. Page 13
Technical Data/ Specifications................................................................. Page 14
Notes Section............................................................................................. Page 15
Warranty .................................................................................................... Page 16

AUTOMATIC
Page 3
Automatic Safety Information
•Use the equipment only for its intended purpose
•Do not point spray gun at any part of body
•Do not place hand or fingers over spray tip
•Inspect for physical damage or loose fittings before use
•Shut off all air sources and remove coating supply to spray gun before servicing
•Use fluids and solvents that are compatible with equipment wetted parts
•Check equipment often
•Do not alter or modify equipment
•Do not use with improperly operating equipment
•Always refer to the owner’s manual for proper operating instructions
•Comply with all applicable safety regulations
•Read all instruction manuals, tags, and labels before operating the equipment
•Always read the MSDS supplied by the material manufacturer
•Do not exceed 75 psi for air and fluid; 50 psi for triggering air
WARNING
Coatings and solvents may be extremely flammable or combustible. Always use the equipment
in a properly ventilated area. Smoking must never be permitted in the spraying area. Make sure
that all ignition sources are well out of range and always keep fire extinguishing equipment in
the spraying area.
Some solvents may cause eye injury during operation and/or while cleaning the equipment.
Always wear eye protection when working with the equipment.
Always read the MSDS supplied by the material manufacturer.
Some coatings and solvents may be harmful if there is contact with the skin or if inhaled.
Always make sure to read the MSDS supplied by the material manufacturer. Always use the
equipment in a properly ventilated area. If there is a chance of inhalation or contact with skin,
use protective gear such as a respirator and/or proper clothing as suggested by the MSDS.
!
•Clean equipment after each use
•Lubricate spray gun before each use and/or after every cleaning
•Do not submerge spray gun in solvent
•Ensure proper handling of the gun at all times - damage due to dropping or
mishandling of the spray gun is not covered by warranty
•Ensure air and fluid hoses are properly connected
•Do not apply air or fluid pressures above the maximum published inlet pressures
•Problems resulting from any of the above-mentioned situations will jeopardize warranty
Required Maintenance
For customer service call 888.389.2732

AUTOMATIC
Page 4
Quick Reference Guide
Installation
Mounting
When using the supplied mounting bolt, install the
spray gun onto a mounting rod 1/2” and tighten
using the hex screw. The mounting bolt can be
attached to either side of the spray gun by simply
unscrewing the bolt and reversing position.
Fittings
The DUX Automatic spray gun uses push-lock
style fittings as standard equipment. To attach the
hoses, insert one end of the hose into the fitting
until it’s locked it into place. To release the lock,
push the plastic locking ring toward the fitting
while removing the hose (See Figure 2).
Setup
Prior to setting up air and fluid hose(s) please
note:
•All hoses must be cut clean and straight
without deformity for proper fit.
•Use an air filter to ensure a clean, dry
air supply.
•Triggering air, atomizing air and fan
control air (when applicable) must be
supplied and regulated separately.
•The fluid hose must have a regulator,
shut-off valve, and a filter prior to use.
Connections
Attach the triggering air, atomizing air, and fluid
hoses to the corresponding connections on the
spray gun. When applicable also attach the fan
control air.
Fluid Control Knob
Air Cap
Mounting bolt
Triggering Air
Fluid Tip
Fan Control
(Automatic model shown)*
Fluid Connection
Atomizing Air
Trigger Housing
NOTE: When using fittings other than the
supplied push-lock style fittings, installation may
differ.
!
Figure 2
Figure 1 *See figure 4 on
page 5 for manual
fan control
For customer service call 888.389.2732

AUTOMATIC
For customer service call 888 DUX AREA (888 389 2732) Page 5
Fluid Control Knob
The fluid control knob is located at the rear of the
spray gun (See Figure 3). To increase the fluid
flow, turn the fluid control knob
counter-clockwise. Conversely, turn the fluid
control knob clockwise to reduce the fluid flow.
Once the desired settings have been achieved,
turn the fluid control locking ring clockwise to
lock the fluid control knob into place (See Figure
3).
Fan Control Adjustment
The fan control adjustment is located on the side
of the spray gun near the air cap. This
adjustment controls the amount of air delivered
to the horns of the air cap for spray pattern
shaping (See Figure 4).
The DUX Automatic spray gun features two
methods of fan control adjustment:
Automatic Fan Adjustment: Spray guns configured
for automatic fan adjustment have an additional
push-lock fitting for fan control. Air is externally
supplied to the air horns of the air cap to control the
size and shape of the spray pattern. The more air
pressure applied, the larger the fan pattern. When
the optimal results are achieved, record the input
pressure settings for simple future setups.
Manual Fan Adjustment: Spray guns configured for
manual fan adjustment have a fan control valve
with a locking ring (See Figure 4). Pattern shaping
air is obtained from the main air chamber of the
spray gun. With the fan control valve in the fully
closed position (i.e. no threads showing), a
minimum spray pattern size is achieved. Pattern
size increases as the adjustment knob is rotated
counter-clockwise, allowing more air to be directed
to the air horns. When the optimal results are
achieved, turn the locking ring clockwise to lock
valve in place.
Operating the Automatic Spray Gun
1. Turn on the regulated triggering air at a
minimum of 35 psi input pressure.
2. Turn on the regulated fluid line.
3. Trigger spray gun and observe fluid flow.
4. Turn the fluid control knob counter-clockwise
until desired flow rate is achieved.
5. Turn on the regulated atomizing air at the
source of supply.
6. Adjust the atomizing air pressure until
desired fluid atomization is achieved.
7. Adjust fluid flow as necessary to achieve
desired results.
Operation Guide
NOTE: If the fluid control knob stops offering
resistance, maximum needle travel has been
reached. If the flow rate is insufficient, increase
the fluid tip and needle size.
Fluid Control
Knob Locking Ring
Figure 3
!
NOTE: Applying excessive air to the air cap will
result in a split pattern.
!
Locking Ring
Figure 4
Manual Fan Control

AUTOMATIC
Page 6
Troubleshooting
Problem Cause Solution
Coating leakage
out of tip of spray gun Needle packing is too tight
1. Remove triggering assembly
2. Insert screwdriver into rear of spray gun
3. Turn fluid seal nut counter-clockwise 1/4 turn (refer
to page 9 for packing adjustment)
4. Lubricate needle and reinstall
Coating leakage out of rear of
spray gun or drain hole Needle packing is too loose
1. Remove triggering assembly
2. Insert screwdriver into rear of spray gun
3. Turn fluid seal nut clockwise 1/4 turn (refer to page
9 for packing adjustment)
4. Lubricate needle and reinstall
Spray gun does not trigger 1. Insufficient triggering air
2. Piston binding
1. Increase triggering air pressure
Note: Do not exceed 50 psi
2. Remove triggering assembly. Remove trigger piston
and lubricate o-ring. Reinstall
Split pattern 1. Air pressure too high
2. Fluid flow too low
1. Reduce atomizing air pressure
2. Turn fluid control knob counter-clockwise
Note: if fluid flow is still insufficient after adjusting,
replace fluid tip with next largest size
Heavy right or
left side pattern Dirty or damaged air
cap/holes
Clean air cap
Note: Do not use metal tools to clean air cap
Note: If problem persists after cleaning, replace air cap
“Orange peel” or
Heavy pattern
1. Air pressure is too low
2. Spray gun is too close to
working
surface
3. Fluid flow is too high
1. Increase atomizing air pressure
2. Ensure proper distance from surface
is achieved, normally 6-10” from surface
3. Adjust fluid control knob clockwise to
decrease fluid flow
Heavy top or bottom
pattern 1. Air cap dirty or damaged
2. Fluid tip dirty or damaged
1. Clean air cap
Note: Do not use metal tools to clean air cap
2. Clean fluid tip
Note: If problem persists after cleaning replace
air cap or fluid tip
Will not spray
1. Insufficient air pressure
2. Insufficient fluid flow
3. Fluid too heavy for current
setup
1. Check atomizing air and triggering air pressures
and increase if necessary
2. Adjust fluid control knob counter-clockwise to
increase fluid flow
3. Thin coating and/or change fluid tip to next largest
size
Spray gun
sputtering
1. Damaged fluid tip
2. Loose fluid tip
3. Dried material in fluid tip/
needle
4. Fluid source empty/low
5. Needle packing too loose
1. Remove and inspect for damage
2. Ensure fluid tip is tight
3. Flush with solvent
4. Check coating and refill if necessary
5. See solution: (coating leakage out of rear of gun)
Spray pattern starved or dry
1. Air pressure too high
2. Fluid adjustment too low
3. Spray too far from working
surface
1. Reduce atomizing air pressure
2. Adjust fluid control knob counter-clockwise until
desired results are achieved
3. Ensure proper distance from surface is achieved,
normally 6-10”
For customer service call 888.389.2732

AUTOMATIC
Page 7
Fluid Needle Removal
To replace or change the fluid needle:
1. Ensure both fluid and air are depressurized.
2. Unscrew the fluid control knob by turning
counter-clockwise and completely removing
it, along with the fluid needle, from the
trigger housing.
3. Unscrew the spring cap from the fluid
adjustment knob (See Figure 8).
4. Remove the needle spring.
5. Remove and replace the needle.
6. Lubricate needle as required and reinstall
needle assembly.
Maintenance Guide
The DUX Automatic spray gun is a precision
tool that delivers superior finishing results and
cost savings with each use. Optimal results
require good handling and maintenance
processes.
Daily cleaning, lubrication, and proper
maintenance are required to maintain
the warranty coverage.
Lubrication
To ensure the quality and longevity of the
DUX spray gun, it must be lubricated before
every use and after every cleaning. Follow
the diagram below to ensure proper
lubrication (Use DUX lube—part # 310206).
NOTE: Due to the self-cleaning nature of the
fluid tip and needle combination; it is imperative
that both parts are changed together when
increasing or decreasing the fluid tip size.
!
CAUTION: The needle spring is under
pressure and is retained by this cap. It may
spring free when the cap is removed.
!
Figure 5: Unscrew trigger housing
Figure 6: Lubricate thick part of needle
and needle o-rings
Spring Cap
Figure 8
Figure 7: Lubricate the trigger piston
Lubrication areas
Trigger
Piston O-Ring
For customer service call 888.389.2732

AUTOMATIC
Page 8
Maintenance (continued)
Fluid Tip Removal
To replace or change the fluid tips:
1. Ensure the spray gun is depressurized.
2. Remove the air cap retaining ring and air
cap.
3. Using the DUX 10mm fluid tip driver, remove
the fluid tip and inspect the threads for wear
or contamination.
4. Install a new fluid tip and tighten using the
DUX 10mm fluid tip driver.
5. Replace air cap and air cap retaining ring.
Fluid Packing Adjustment
The fluid packing in all DUX spray guns is set
to a pre-determined specification during
assembly. Therefore, depending on the type of
material being sprayed, it is possible that the
packing will need adjustment upon start-up or
after some amount of spraying.
Fluid leakage at the front of the spray gun is
an indication that the fluid needle is not
seating properly in the fluid tip. This may be
caused by dried material in the tip, or if the
fluid packing is too tight. If the packing is set
too tightly for a particular material, the needle
will not to fully seat in the fluid tip and will
require adjustment.
The DUX Automatic features a leak indicator
in the form of a pin hole located above the
mounting bolt (See Figure 9). Fluid leakage at
this pin hole indicates that the fluid packing is
too loose and will need tightening.
NOTE: Due to the self-cleaning nature of the
fluid tip and needle combination; it is impera-
tive that both parts are changed together when
increasing or decreasing the fluid tip size.
!
IMPORTANT: Do not over-tighten. Use a
maximum of 18 INCH pounds of torque or a
half turn past hand tight. The precision
machining of the DUX Automatic makes the
use of a gasket unnecessary.
IMPORTANT: To maintain the precise fit and
seal between the fluid tip and the stainless
steel fluid barrel, paint must not be allowed to
dry on the threads. The threads of both the
fluid barrel and tip must be thoroughly cleaned
after each use.
!
IMPORTANT: Some coating leakage out of
the fluid tip may indicate an adjustment of the
packing is needed. This is not an indication of
the spray gun failing.
Always ensure the spray gun is depressurized
before making adjustments.
!
Pin hole
Figure 9
For customer service call 888.389.2732

AUTOMATIC
Maintenance (continued)
To adjust the packing:
1. Ensure the spray gun is depressurized.
2. Unscrew the trigger housing from the main
body by turning counter-clockwise and
completely removing it, along with the fluid
needle and trigger piston (See Figure 10).
3. Insert a thin, flat-blade screwdriver into the
rear of the main spray gun body (See Figure
11) and turn the fluid seal nut 1/4 turn
clockwise to tighten or counter-clockwise to
loosen (SeeFigure 12 & 13).
4. Reinstall the trigger housing with the fluid
needle and trigger piston onto the spray
gun body.
5. Pressurize the spray gun and test.
6. Repeat if necessary.
Figure 10
Figure 11
Figure 13
Fluid Seal Nut.
Turn counter-
clockwise to
loosen
Figure 12
Fluid Seal Nut.
Turn clockwise
to tighten
CAUTION: The needle spring is under
pressure and is retained by this cap. It may
spring free when the cap is removed.
!
Page 9
For customer service call 888.389.2732