HERKULES G100 User manual

Part# 1002423-07
1/18/2010
This manual contains important information concerning the
installation and operation of the gun washers listed above.
Read manual thoroughly and keep for future reference
INSTRUCTIONS
This manual contains important information concerning the
installation and operation of the gun washers listed above.
Read manual thoroughly and keep for future reference
INSTRUCTIONS
Herkules Equipment Corporation 2760 Ridgeway Court Walled Lake, MI 48390-1662 USA
248-960-7100 800-444-4351 Fax [phone]
Patents USA 7070167 4793369, 4960142, 5174317, 5193561, 5485860 Canada 1299468 & Patents Pending
website: www.herkules.us Made in the USA e-mail: [e-mail]
Page 1 of 19

Warnings ……………………………………………………………………………………………………………………… 3-4
Assembly Instructions ……………………………………………………………………………………………………….. 5-7
Model Information ……………………………………………………………………………………………………………. 8
Installation ………………………………………………………………………………………………………………….. 8
Operation ……………………………………………………………………………………………………………………. 9-10
Preventive Maintenance ………………………………………………………………………………………………………. 10
Troubleshooting ……………………………………………………………………………………………………………… 11
Drawings with part lists: …………………………………………………………………………………………………… 12-18
Notes ………………………………………………………………………………………………………………………….. 19
Table of Contents
Warnin
g
S
y
mbol Caution S
y
mbol
Page 2 of 19
Serial Number
Model Number
Purchase Date
Distributor
Warning
Symbol
Caution
Symbol
CAUTION
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions. This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
This product has patent protection under
one or more of the following patent numbers:
7070167, 5485860, 5193561, 5174317
4960142, 4793369, 1299468
and Patents Pending
website: www.herkules.us 1002742
PATENT NUMBERS
Page 2 of 19

EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly
and result in serious injury.
•This equipment is for professional use only.
•Read all instruction manuals, tags, and labels before operating the equipment.
•Use the equipment only for its intended use.
•Do not alter or modify this equipment.
•Do not exceed the maximum working pressure of the lowest rated system component.
•Do not operate the gun washer at a pressure above the maximum working pressure rating of the
gun(s) being cleaned.
•Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces.
•Do not use the hoses to pull the equipment.
•Do not move pressurized equipment.
•Use fluids or solvents that are compatible with the equipment wetted parts. Read the fluid and
solvent manufacturer's warnings
•Comply with all applicable local, state and national fire, electrical and other safety regulation.
PRESSURIZED EQUIPMENT HAZARD
WARNING
Page 3 of 19
Spray from hose leaks, ruptured components, or from operating the gun washer with an open lid
can splash fluid in the eyes or on the skin and cause serious injury.
•A safety device has been installed to shut off the pump when the gun washer lid is opened.
Do not tamper with or alter this device.
•Open the gun washer lid slowly.
•Do not prop the gun washer lid open with an object or by any other means.
•Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
•Tighten all fluid connections before operating the equipment.
•Replace worn, damaged, or loose parts immediately.
WARNING
Page 3 of 19

FIRE AND EXPLOSION HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition
and result in fire or explosion and serious injury.
•Ground the equipment. See Installation for grounding procedure.
•Provide fresh air ventilation to avoid the build up of flammable fumes from the solvent.
•Extinguish all open flames or pilot lights in the gun washer area.
•Disconnect all electrical equipment in the gun washer area.
•Keep the gun washer area free of debris, including solvent, rags, and gasoline.
•Do not turn on any light switch in the gun washer area while operating or if fumes are present.
•Do not smoke in the gun washer area.
•Do not operate a gasoline engine in the gun washer area.
•Follow the gun manufacturer's solvent and other cleaning recommendations.
•Use solvent with the highest possible flash point.
•If there is any static sparking while using the equipment, stop operation immediately. Identify and
correct the problem.
•Drain the cleaning solution into a proper storage container when gun washer(s) is not in use.
TOXIC FLUID HAZARD
WARNING
Page 4 of 19
TOXIC
FLUID
HAZARD
Hazardous fluids or toxic fumes can cause serious injury or death if splashed in eyes or on the
skin, swallowed, or inhaled.
•Know the specific hazards of the fluid you are using. Read the fluid manufacturer's warnings.
•Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state
and national guidelines.
•Wear the appropriate protective clothing, gloves, eyewear and respirator.
•Pipe and dispose of the exhaust air safely. If diaphragm fails, the fluid may be exhausted along with
the air.
WARNING
Page 4 of 19

Stand and tub connections
Position the pump mount bracket between the timer
leg and the filter/regulator leg of the stand assembly.
Attach the pump mount bracket to the stand using (2)
1/4-20 x 1/2 hex bolts, (2) #10 flat washers, (2) 1/4"
lock washers and (2) 1/4" acorn nuts per leg (see fig.1).
Attach the pump to the stand using the (2) 1/4-20 x 1
hex bolts, (2) 1/4" flat washers, (2) 1/4" lock washers
and (2) 1/4" hex nuts per leg (see fig.1).
STEP 1
Assembly
STEP 2
Hex bolt
1/4-20 x 1
1/4" Flat Washer
Hex bolt
1/4-20 x 1/2
Flat washer #10 1/4" Acorn nut
1/4" Lock Washer
Fluid hose connections
Connect the drain hose assembly to the flare connector
on the bottom of the tub and tighten. This can easily be
disconnected when inserting into a 5-gallon can.
(see fig.2).
Ensure bulkhead DOES NOT TURN when tightening.
Attach the siphon filter to the 23" length of black hose by
inserting the barb into the end of the hose. Slide the
white plastic plug over the opposite end of the hose
so that the threads are in the direction of the filter
(see fig.2).
Attach the other end of the 23" hose to the lower (IN)
90° barb on the pump (see fig.2)
Run the 16" black hose from the upper (OUT) 90° barb
on the pump to the 90° barb at the rear-left corner
on the underside of the tub (see fig.2)
Attach the white plastic muffler to the exhaust
port of the pump (see fig.2).
STEP 3
STEP 4
STEP 6
STEP 7
STEP 5
16" Black Hose
23" Black HoseMuffler
Plug
Siphon Filter
Drain hose assembly
Flare connector
fig.2
Hex bolt
1/4-20 x 1
1/4" Flat Washer
fig.1
Hex bolt
1/4-20 x 1/2
Flat washer #10 1/4" Acorn nut
1/4" Hex nut
1/4" Lock Washer
Page 5 of 19

Air hose connections
Connect the black 5/32" air hose between the regulator
and the air in port of the limit valve located on the rear leg
of the gun washer. Press tubing in through the collar until
seated. Pull firmly on hose to test for a tight connection.
(see fig.3).
Note: Air-in port of limit valve is the port opposite the roller.
Connect the blue 5/32" air hose between the air in port of
limit valve located on the front leg and the air out port of the
limit valve located on the rear leg of the gun washer.
Press tubing in through the collar until seated. Pull firmly on
hose to test for a tight connection (see fig.3).
Connect the clear 5/32" air hose between the pump and
the air out port of the limit valve located on the front leg
of the gun washer. Press tubing in through the collar until
seated. Pull firmly on hose to test for a tight connection.
(see fig.3).
Lid assembly and attachment
Attach the handle to the front of the lid using (2) 10-24 x 1/2
STEP 10
Assembly
STEP 8
STEP 9
STEP 11
fig.3
Limit
valve
Limit
valve
Black air
hose
Blue air
hose
Clear air
hose
STEP
14
STEP 15
ttac t e a d e to t e o t o t e d us g ( ) 0 /
stainless screws, (2) #10 nylon washers, and (2) 10-24
stainless nuts (see fig.4).
Attach the actuator bracket to the right side of the lid using
(2) 10-24 x 1/2 stainless screws, (2) #10 nylon washers,
and (2) 10-24 stainless nuts (see fig.4).
Attach the (2) hinges to the rear of the lid using
(1) 10-24 x 1/2 stainless screw, (1) #10 nylon washer
and (1) 10-24 stainless nut for each hinge (see fig.4).
Note: Install the internal ground wire while attaching the
hinge on the actuator side of the lid (see fig.5).
Place the lid on the tub and align the holes in the hinges
with the inserts in the lip of the tub. Use (2) 10-32 x 3/8
black screws and (2) #10 flat washers to secure the
hinges to the tub. Finger tighten screw closest to the
actuator bracket.
Note: If the lid does not sit flat, extra washers should be
added beneath the hinges at either side to ensure the lid
sits flat on the tub.
Refer to the parts call-out for the lid assembly on pg.14
for descriptions and placements of parts.
STEP 13
STEP 12
STEP 14
fig.3
Limit
valve
Limit
valve
Black air
hose
Blue air
hose
Clear air
hose
fig.4
STEP 12
STEP 14
STEP 13
STEP 15
fig.5
Ground
terminal
Ground
terminal
Washer
Nut
Page 6 of 19

Grounding the lid
Using an 1/8" allen wrench, remove the back right lid screw.
Connect the ground wire (with the aluminum terminal
attached) from the pump to the lid screw and reconnect it
to the tub (see fig.6).
Connecting lid rod and actuator linkage
Slide the actuator over the lid rod and hand tighten approx.
2" from the end of the rod. Insert the actuator into the large
slot in the right rear leg (see fig.7).
Attach the lid rod to the lid bracket using the 1/4" clevis pin
and circular cotter pin supplied (see fig.6).
To adjust the actuator, close the lid and loosen the set
screw on the actuator. Slide the actuator down until it
completely closes the limit valve and retighten the set
screw (see fig.7).
Note: It is necessary for the roller switch to be completely
engaged for the pump to operate properly. Be sure that
the actuator is absolutely secure and at the lowest possible
point.
Assembly
STEP 17
STEP 18
STEP 15
STEP 16
Lid screw
Ground wire
Lid rod
Cotter pin
Lid bracket
Clevis pin
fig.6
Lid rod Actuator
Set screw
po t
If the pump is operating slowly, check the actuator first.
Final Assembly
Using a 3/8" hex socket with either a ratchet or power drill,
drive the (2) #14 screws through the two holes in the
frame and into the underside of the tub's lip(see fig.8).
Note: Be sure to provide pressure down from the top of
the tub while driving the screws. Do NOT over-tighten.
Install the timer knob on the protruding shaft on the
front right leg by first using (1) #10 flat washer,
followed by (1) 1/2" OD nylon spacer, then slide the
knob over the shaft (see fig.8).
STEP 20
STEP 19
Lid screw
Ground wire
Lid rod
Cotter pin
Lid bracket
Clevis pin
fig.6
fig.7
Lid rod Actuator
Set screw
fig.8
Knob
Spacer
Washer
Screw #14 x 3/4
Page 7 of 19

001-702 Bolt Hex 1/4-20 x 1/2 Z 2 ea.
001-705 Flat washer 1/4" 2 ea.
002-158 Screw #14 x 3/4 - zinc 2 ea.
002-160 Nut Hex 10-32 Z 2 ea.
002-161 Flat washer #10 5 ea.
005-131 Screw 10-24 x 1/2 - stainless 6 ea.
005-132 Nut hex 10-24 - stainless 6 ea.
005-155 Screw 10-32 x 3/8 - black 2 ea.
008-244 Acorn nut 1/4-20 - nickle 2 ea.
10A Handle 1 ea.
1000132 Hinge 2 ea.
1000252 Cotter pin 1 ea.
1000652 Clevis pin 1/4 dia. 1 ea.
1002423 Owner's Manual 1 ea.
1002656 Flat washer #10 - nylon 6 ea.
11130 Slotted plug - nylon 1 ea.
11957 Actuator 1 ea.
12131 Actuator bracket 1 ea.
53B Stem support female 1 ea.
83 Hex bolt 1/4-20 x 1 - zinc 2 ea.
84 Hex nut 1/4-20 - zinc 2 ea.
85 Lock washer 1/4" 4 ea.
C9A Nipple 1/8 NPT x 4-1/2 1 ea.
NOTE: Dimensions listed are overall measurements.
M5
Tube 5/32 blue plastic 27 in.
M5-BLACK Tube 5/32 black plastic 9in.
M5-NEUTRAL Tube 5/32 clear plastic 11 in.
M230-002 Knob for timer 1 ea.
M230-005 S
p
acer 1/8" thick - n
y
lon 1 ea.
Model Information
A
BC
D
Parts bag contents
30 005
Space /8 t c yo
ea
A
BCD
One gun, one cup paint gun washer equipped
35.625 16.75 22.5 20.375
with diaphragm pump, filter-regulator and timer. (905) (425.5) (571.5) (517.5)
Capable of cleaning solvent and water base paints.
Installing the Gun Washe
r
1) Place gun washer on a level surface in a properly
ventilated paint mixing room or paint booth.
Grounding the Gun Washe
r
1) Connect the ground wire on the gun washer’s pump to a
true earth ground.
2) Ground all equipment used or located in the gun washer
area.
Connecting the Air Line
1) Install a 1/4 in. npt male coupler, that is compatible with
the quick disconnect of your air supply line, into the air-in
port of the filter/regulator located on the right rear leg
(see fig.9).
2) Connect air line with at least 75 psi to the coupler.
Filter/regulator is preset. Do not adjust.
DescriptionModel
Installation
20.2
Dimensions (in/mm)
44.5
Weight
(lbs/kg)
G100
A
BC
D
Air in port
fig.9
Ground
Parts bag contents
Page 8 of 19

Connecting the Cleaning Solution to the Washer Placing Equipment in the Gun Washer
1) Disconnect the drain hose from the flare connector on the To clean guns not mentioned here, use the long or short
bottom of the tank. stem supports as needed (see pg.15). For questions or
2) Insert the drain hose and siphon tube into a fresh 5 gallon adapter kits contact your paint gun washer distributor.
cleaning solution can and secure the plug in the opening.
3) Reconnect the drain hose and tighten. Siphon Feed Guns
4) The can must contain at least 4 gallons of solution to pump Place the gun siphon tube on the short stem support.
properly. Use a high quality cleaning solution.
Preparing the Equipment to be washed Gravity Feed Guns (HVLP)
1) Remove paint cup or paint line and the air line from the Place the long stem support over the short stem
paint gun. support. Place paint inlet of gun on long stem support.
Place the air cap assembly over the air inlet of the gun to
2) Drain excess paint from cup and gun. prevent solution from entering the passage.
3) Remove all gauges and regulators. Pressure Feed Guns
Place long stem support over the short stem support.
4) Lock the gun trigger in the open position by placing the Place paint inlet of gun on long stem support.
trigger lock around the gun handle and trigger (see fig.10). Pots and Cups
CAUTION Place a pot or a cup on the 4-armed platform.
All pressure gauges must be removed before placing the
equipment in the gun washer to avoid damaging the
gauges.
Operation
Page 9 of 19
Gravity Feed
Gun (HVLP)
Air Cap
Assembly
Paint Cup
Long Stem Support
Paint Cup
Siphon Feed Gun
Short Stem Support
Trigger Lock
Pressure Feed Gun
Paint Cup
fig.10
Page 9 of 19

Operating the Gun Washer
1) Make sure wire trigger locks and other accessories 5) If the lid is opened prior to the end of the timing cycle, the
are inside the gun washer tank. safety air cutoff switch will stop the gun washer. The
gun washer will start again when the lid is closed if time
2) Place equipment in the tank according to the diagrams remains on the timer.
shown in fig.10. Note: Open the lid slowly to minimize vapor escape.
3) Close the gun washer lid. 6) Remove the equipment from the gun washer and wipe off
4) Turn the timer knob clockwise 90 degrees to start the gun any remaining cleaning solution.
washer. The gun washer will run for 90 seconds. Turning
the timer knob less than 90 degrees will reduce the timing
cycle. Paint equipment will clean in 60 to 90 seconds.
1) Drain excess paint from cup or pot before placing in gun
washer.
2) Drain paint sludge from 5 gallon can weekly.
Do this after a weekend so the sludge has settled.
Access the 5 gallon can by removing the black hose from
the nylon plug and remove the plug from the can
Preventive Maintenance
Operation
Filter/Regulator
#T17M
Page 10 of 19
the
nylon
plug
and
remove
the
plug
from
the
can
.
Pour the solution into a second container and drain the
sludge into a disposal container. Refill can from the
second container and add solution to reach the
4 gallon minimum, or 3" from the top of can.
Clean siphon tube with cloth and brush to remove residue.
3) Remove the filter bowl and check the filter inside the
regulator for excess buildup approx. every 6 months.
4) Change cleaning solution completely when objects being
cleaned become tacky to the touch.
5) Clean inside of tub and internal manifold.
Do not change the setting of the filter/regulator.This could
damage the filter/regulator or pump
CAUTION
Filter/Regulator
#T17M
Filter
#1001382
Filter Bowl
Page 10 of 19

Gun washer will not turn on. 1Make sure the air line is properly connected with at least 75 psi.
Air pressure is regulated at 75 psi.
2Make sure lid is fully closed. Make sure the lid rod actuator is making
full contact with the limit valve on the right rear leg.
3 Check all air connections to ensure that there are no leaks.
4 Make sure timer cam is engaging the limit valve on the right front leg.
5 Make sure timer is on and functioning correctly.
Gun washer turns on but 1 Make sure intake filter is not clogged (Clean or replace).
pumps slowly or not at all. 2 Make sure the air line is properly connected with at least 75 psi.
Air pressure is regulated at 75 psi.
3 Check all air connections to ensure that there are no leaks.
4 Make sure there is at least 4 gallons of cleaning solution in the can.
5 Make sure the siphon hose is far enough into the can to draw cleaning solution.
Possible SolutionProblem
Troubleshooting
Page 11 of 19
6Make sure lid is fully closed. Make sure the lid rod actuator is making
full contact with the limit valve on the right rear leg.
7 Make sure manifold nozzles and stem supports are not clogged.
Gun washer will not shut off 1 Make sure timer cam is moving. If it's not, slightly loosen the nuts
holding the limit valve on the right front leg of the stand. Reposition
valve and tighten nuts.
2Make sure limit valves located on the right front leg or right rear leg
of the stand are not stuck in closed position.
Page 11 of 19

G100 Parts Layout
21
20
2
34
5
6
10
9
19
1
16
21
20
15
2
34
5
6
8
11
12
13
10
7
18
17
9
14
19
1
Page 12 of 19

Part # Description
11-MINI-BLUE Tub 1 ea.
21001706 Front Decal 1 ea.
31002650 Hose Barb 90° - Brass 2 ea.
464PE Hose 1/2 OD x .062 Black PE 5.75 in.
512129 Manifold Assembly 1 ea. See pg.15
613981 Stand Assembly for G100 1 ea.
71002644 Bulkhead with Nut - Brass 2 ea.
864PE Hose 1/2 OD x .062 Black PE 16 in.
964PE Siphon Hose 1/2 OD x .062 Black PE 23 in.
10 11243 Filter Assembly 1 ea.
11 1002791 Connector Flare - Brass 1 ea.
12 12865 Drain Hose Assembly 1 ea.
13 11130 Plug Slotted - Nylon 1 ea.
14 M5-NEUTRAL Tube 5/32 Plastic - Neutral 11 in.
15 M5 Tube 5/32 Plastic - Blue 27 in.
16 11958 Pump Mounting Bracket 1 ea.
17 12018 Pump Assembly 1 ea. See pg.16-17
18 002-120A-72 Ground Wire 2 ea.
19 M5-BLACK Tube 5/32 Plastic - Black 9 in.
20 12132 Lid (Parts Breakdown) 1 ea. See pg.14
21 1001708 Lid Sticker 1 ea.
G100 Parts Layout
Quantity
Note: For parts shown but not identified refer
to assembly layouts on pages 14-18.
Page 13 of 19
Note: For parts shown but not identified refer
to assembly layouts on pages 14-18.
Page 13 of 19

G100 Lid Layout
2
46 1
89
5
3
13
12
10
Part # Description
1002-161 Washer Flat #10 USS - Zinc 2 ea.
2005-131 Screw 10-24 x 1/2 - Stainless 6 ea.
3005-132 Hex Nut 10-24 - Stainless 6 ea.
4005-155 Screw 10-32 x 3/8 - Black 2 ea.
510A Handle 1 ea.
61000132 Hinge 2 ea.
71000252 Cotter Pin 1 ea.
81000652 Clevis Pin 1/4 dia. 1 ea.
91002571 Actuator Rod 1 ea.
10 1002656 Washer Flat #10 - Nylon 6 ea.
11 11957 Actuator 1 ea.
12 12131 Lid Bracket 1 ea.
13 12132 Lid 1 ea.
Note: Parts are shown for reference purposes only
and are not necessarily part of a Herkules assembly.
Quantity
2
46 1
89
11
53
13
12
7
10
Page 14 of 19

G100 Manifold Layout
12
13
5
1
11
8
9
10
6
2
3
4
7
14
Part # Description
1002-121A-6 Manifold Ground Wire 1 ea.
2002-192 Ground Wire Rivet 1 ea.
3005-107A Elbow 45° 1/8 NPT - Brass 2 ea.
41002422 Cup Holder 1 ea.
51002529 Manifold - Stainless 1 ea.
61002651 E-ring - Stainless 1 ea.
712509 Air Cap Assembly w/ SS Clip 1 ea.
822BA Trigger Lock Assembly 1 ea.
953A Stem Support Male 1 ea.
10 53B Stem Support Female 1 ea.
11 54P1 Full jet Nozzle - White 5 ea.
12 54 Full jet Nozzle - Brass 1 ea.
13 C9A Nipple 4-1/2" - Brass 2 ea.
14 M27 Hose Barb - Brass 1 ea.
Note: Parts are shown for reference purposes only
and are not necessarily part of a Herkules assembly.
Quantity
12
13
5
1
11
8
9
10
6
2
3
4
7
14
Page 15 of 19

G100 Pump and Legs Layout
19
18
20
3
2
6
21
11
1
12
10 79
3
2
615
19
5
18
20
3
2
6
21
11
1
12
4
10 79
3
8
2
6
17
16
18
15
14
13
Page 16 of 19

Part # Description
1002-161 Washer Flat #10 USS - Zinc 1 ea.
2002-171 Screw 8-32 x 1 - Black 4 ea.
3002-172 Nut Nylock 8-32 - Zinc 4 ea.
41002414 ON/OFF Sticker 1 ea.
513844 Stand Assembly 1 ea.
6M1C Limit Valve - Gold 2 ea.
7M230-001A Timer 1 ea.
8M230-002 Knob for Timer 1 ea.
9M230-003 Cam For Timer 1 ea.
10 M230-004 Spacer 1/4" Thick - Nylon 2 ea.
11 M230-005 Spacer 1/8" Thick - Nylon 1 ea.
12 M230-006 Timer Screw #4 x 5/8 2 ea.
13 002-120A-72 Ground Wire 2 ea.
14 1002650 Hose Barb 90° 3/8 NPT - Brass 2 ea.
15 005-131 Screw 10-24 x 1/2 - Stainless 1 ea.
16 005-132 Nut Hex 10-24 - Stainless 1 ea.
17 338 Pump 1 ea.
18 T25 5/32 Hose fitting 90° Swivel 2 ea.
19 T17M Filter / Regulator 1 ea.
20 85D Washer Flat 1/2 - Zinc 1 ea.
21 67 Adaptor 1/4 NPT - Brass 1 ea.
Note: Parts are shown for reference purposes only
and are not necessaril
y
p
art of a Herkules assembl
y
.
Quantity
G100 Pump and Legs Layout
Page 17 of 19
and
are
not
necessarily
part
of
a
Herkules
assembly.
Page 17 of 19

G100 Hardware Layout
1
5
8
Part # Description
1001-705 Washer Flat 1/4 USS - Zinc 2 ea.
2002-161 Washer Flat #10 USS - Zinc 2 ea.
3008-244 Acorn Nut 1/4-20 - Nickel 2 ea.
4001-702 Bolt Hex 1/4-20 x 1/2 - Zinc 2 ea.
583 Bolt Hex 1/4-20 x 1 - Zinc 2 ea.
684 Nut Hex 1/4-20 - Zinc 2 ea.
785 Washer Lock 1/4 - Zinc 4 ea.
8002-158 Screw #14 x 3/4 - Zinc 2 ea.
Quantity
1
2
3
4
5
6
7
8
Page 18 of 19

Notes
Page 19 of 19Page 19 of 19