HERKULES G200 User manual

Part# 1002655-02
4/6/2007
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 18

Warnings ……………………………………………………………………………………………………………………… 3-4
Assembly Instructions ……………………………………………………………………………………………………….. 5-6
Model Information ……………………………………………………………………………………………………………. 7
Installation ………………………………………………………………………………………………………………….. 7
Operation ……………………………………………………………………………………………………………………. 8-9
Preventive Maintenance ………………………………………………………………………………………………………. 9
Troubleshooting ……………………………………………………………………………………………………………… 10
Drawings with Part Lists …………………………………………………………………………………………………… 11-17
Notes ………………………………………………………………………………………………………………………….. 18
Serial Number
Model Number
Purchase Date
Distributor
Table of Contents
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 18

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
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 18

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 cleaning solution.
•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 cleaning solutions, 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
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 18

Stand and tub connections
Attach the four legs to the frame using (4) 1/4-20 x 1/2"
hex bolts, (4) #10 flat washers, (4) 1/4" lock washers
and (4) 1/4" acorn nuts per leg (see fig.1).
Note: The leg assembly containing the timer and the
leg assembly containing the filter/regulator must be
positioned as shown in fig.1.
Position the pump mount bracket between the timer
leg assembly and the filter/regulator leg assembly.
Attach the pump mount bracket to the stand using (2)
1/4-20 x 3/4" 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.2).
Attach the ball valve to the reducing nipple on the
bottom of the tub (see fig.3).
Attach the white plastic muffler to the exhaust
port of the pump (see fig.3).
Slide (1) #10 flat washer then (1) 1/8" nylon spacer
then the timer knob over the shaft protruding from
the timer leg assembly (see fig.3)
STEP 5
STEP 6
STEP 1
STEP 2
STEP 3
STEP 4
Assembly
fig.1
Hex bolt
1/4-20 x 1/2"
Flat washer #10 1/4" Acorn nut
1/4" Lock
washer
Hex bolt
1/4-20 x 1"
1/4" Hex nut
1/4" Lock washer
Flat washer 1/4"
fig.2
Hex bolt
1/4-20 x 1/2" Flat washer #10
1/4" Acorn nut
1/4" Lock washer
Timer leg
assembly
Filter/Regulator
le
g
assembl
y
fig.3
Ball valve
Muffler
Flat washer #10
Nylon Spacer
Timer knob
Page 5 of 18

Connecting fluid and air hoses
Connect the 14" long fluid outlet tube between the fluid
outlet port of the pump and the upper bulkhead on the tub.
DO NOT HEAT HOSE (see fig.4).
Connect the 16" long fluid inlet tube between the fluid
inlet port of the pump and the lower bulkhead on the tub.
DO NOT HEAT HOSE (see fig.4).
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.4).
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.4).
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.4).
Connecting lid rod and actuator linkage
Slide the actuator over the lid rod opposite the drilled end
and hand tighten approx. 4" from the end of the rod. Insert
the actuator into the large slot in the right rear leg (see fig 6).
Attach the lid rod to the lid bracket using the 1/4" clevis pin
and circular cotter pin supplied (see fig. 5).
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. 6).
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. 5).
STEP 14
STEP 15
STEP 10
STEP 11
STEP 12
STEP 13
STEP 7
STEP 8
STEP 9
Assembly
fig.5
Lid screw
Ground wire
Lid rod
Cotter pin
Lid bracket
Clevis pin
Limit valve
Limit
valve
Clear air
hose
14" Fluid
outlet tube
16" Fluid
inlet tube fig.4
Black air
hose
Blue air
hose
fig.6
Lid rod
Actuator
Set screw
Page 6 of 18

Model Information
Parts bag contents
001-702 Hex bolt 1/4-20 x 1/2 18 ea.
002-161 Flat washer #10 19 ea.
008-244 Acorn nut 1/4-20 18 ea.
001-705 Flat washer 1/4 2 ea.
6 Ball valve 1 ea.
83 Hex bolt 1/4-20 x 1 2 ea.
84 Hex nut 1/4-20 2 ea.
85 Lock Washer 1/4 20 ea.
1000652 Clevis pin 1/4 dia. 1 ea.
1000252 Cotter pin 1 ea.
11957 Actuator 1 ea.
C9A Nipple 1/8 NPT X 4-1/2 2 ea.
53B Stem support female 2 ea.
M230-002 Timer Knob 1 ea.
M230-005 Spacer 1/8" Nylon 1 ea.
M5 Tube 5/32 blue plastic 30 in.
M5-BLACK Tube 5/32 black plastic 9 in.
M5-NEUTRAL Tube 5/32 clear plastic 13 in.
NOTE: Dimensions listed are overall measurements.
Dimensions in./(mm)
A
BCD
Two gun, two cup paint gun washer equipped with 46 20.625 24.5 21.25
diaphragm pump, filter-regulator and timer. (1168) (524) (622) (540)
Cleans both solvent and water based paints.
Installing the Gun Washer
1) Place gun washer on a level surface in a properly
ventilated paint mixing room or paint booth.
Grounding the Gun Washer
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
supply port of the filter/regulator located on the right rear
leg (see fig. 7).
2) Connect air line with at least 75 psi to the coupler.
Filter/regulator is preset. Do not adjust.
(31)G200
Model Weight
lbs/(kg)
Description
68
Installation
A
BC
D
Air supply
port
fig.7
Page 7 of 18

Operation
Filling the Gun Washer with Fluid Placing Equipment in the Gun Washer
1) Close ball valve located on the bottom of the tank. To clean guns not mentioned here, use the long or short
stem supports as needed (see Fig. 8). For questions or
2) Pour five gallons (18.9 liters) of high quality adapter kits contact your paint gun washer distributor.
cleaning solution into the tub. Unit is capable
of cleaning both solvent and water based paints. Siphon Feed Guns
Place the gun siphon tube on the short stem support.
Preparing the Equipment to be washed Gravity Feed Guns (HVLP)
1) Remove paint cup or paint line and the air line from the Place long stem support over one of the short stem
paint gun. supports. 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. keep cleaning solution out.
3) Remove all gauges and regulators. Pressure Feed Guns
Place long stem support over one of the shorter stem
4) Lock the gun trigger in the open position by placing the supports. Place paint inlet of gun on long stem support.
trigger lock around the gun handle and trigger (see fig. 8).
CAUTION Pots and Cups
All pressure gauges must be removed before placing the Place pots and/or cups on divider platform over front
equipment in the gun washer to avoid damaging the spray nozzles.
gauges.
fig. 8 Trigger Lock
Long Stem Support
Short Stem Support
Gravity Feed
Gun (HVLP)
Siphon Feed Gun
Paint Cup
Pressure Feed Gun
A
ir Cap
A
ssembly
Page 8 of 18

Operation
Operating the Gun Washer
1) Make sure all 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 tub. safety air cutoff switch will stop the gun washer. The
gun washer will start again when the lid is closed if time
2) If washing only one set of equipment, place empty cans over remains on the timer.
the unused nozzles and/or stem supports to prevent
spray from hitting the underside of the gun washer lid. 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
any remaining cleaning solution.
4) Turn the timer knob clockwise 90 degrees to start the gun
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.
Preventive Maintenance
1) Drain excess paint from cup or pot before placing in gun
washer.
2) Drain paint sludge from gun washer tank weekly. Do this
after a weekend so that it has settled. Open ball valve
and drain until clear solution flows. Add cleaning solution
to fill 1" above intake filter.
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 intake filter before filling with
cleaning solution.
Do not change the setting of the filter/regulator.This could
damage the filter/regulator or pump
CAUTION
Filter/Regulato
r
#T17M
Filte
r
#1001382
Filter Bowl
Page 9 of 18

Troubleshooting
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 5 gallons of clean solution in the gun washer.
The cleaning solution should be an inch above the intake filter.
5Make sure lid is fully closed. Make sure the lid rod actuator is making
full contact with the limit valve on the right rear leg.
6 Make sure manifold nozzles and stem supports are not clogged.
Gun washer will not shut off 1 Make sure timer cam is moving. If its 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.
Possible SolutionProblem
Page 10 of 18

G200 Parts Layout
6
19
9
8
12
14
23
20
1
11
4
3
2
7
18
5
10
17
14
16
22
15
24
21
13
25
26
Page 11 of 18

Part # Description
16 Ball Valve 1 EA.
211958 Pump Mounting Bracket 1 EA.
311959 Filter Leg Assy 1 EA. See pg. 15
411960 Timer Leg Assembly 1 EA. See pg. 15
512025 Lid Assembly 1 EA. See pg. 13
612490 Manifold Assembly 1 EA. See pg. 14
712517 Pump Assembly 1 EA. See pg. 15
81000651 Flammable Caution Sticker 1 EA.
91001706 Front Decal 1 EA.
10 1001708 Lid Sticker 1 EA.
11 1002378 Leg 2 EA.
12 1002428 Stand Frame 1 EA.
13 002-120A-72 Ground Wire 2 EA.
14 1002644 Bulkhead with Nut - Brass 3 EA.
15 1002650 Hose Barb 3/8 x 3/8 NPT 90° - Brass 2 EA.
16 1002654 Hose Barb 3/8 x 3/8 NPT - Brass 1 EA.
17 12491 Filter for Pump Inlet 1 EA.
18 1-BLUE Tub 1 EA.
19 25D Divider 1 EA.
20 62 Reducing Nipple - Brass 1 EA.
21 64PE Hose Inlet 16 IN.
22 64PE Hose Outlet 14 IN.
23 85B Washer 1-1/2 x 1 - Nylon 1 EA.
24 M5 Tube 5/32 Plastic - Blue 30 IN.
25 M5-BLACK Tube 5/32 Plastic - Black 9 IN.
26 M5-NEUTRAL Tube 5/32 Plastic - Neutral 13 IN.
Note: For parts shown but not identified
refer to assembly layouts on pages 13-17
Quantity
G200 Parts Layout
Page 12 of 18

Part # Description
1002-161 Washer Flat #10 USS - Zinc 4 EA.
21000252 Actuator Clip Ring 1 EA.
31000652 Actuator Pin 1 EA.
41001708 Lid Sticker 1 EA.
51002546 Screw 10-24 x 1/2 4 EA.
61002572 Actuator Rod 1 EA.
710A Handle 1 EA.
811219 Lid 1 EA.
911957 Actuator Bracket Notched 1 EA.
10 12024 Actuator Lid Bracket 1 EA.
11 12321 Lid Stop 1 EA.
12 14C Rivet 3/16 x 1/2 - Aluminum 4 EA.
13 17 Rivet 3/16 x 1/4 - Stainless 2 EA.
14 39C Hinge 2 EA.
Note: Parts are shown for reference purposes only
and are not necessarily part of a Herkules assembly.
Quantity
G200 Lid Layout
32115
7
9
6
12 14 13
10
84
1
Page 13 of 18

Part # Description
157 Hose Barb 3/8 x 1/4 NPT - Brass 1 EA.
259 Hex Plug 1/8 NPT - Brass 2 EA.
312509 Air Cap Assembly - Brass and Stainless 2 EA.
41002321 Manifold Half - Stainless 2 EA.
51002651 E-ring - Stainless 2 EA.
6002-121A-6 Manifold Ground Wire 1 EA.
7002-136S Manifold Bolt - Stainless 2 EA.
8002-137 Manifold Block 1 EA.
9002-192 Ground Wire Rivet 2 EA.
10 22BA Trigger Lock Assembly 2 EA.
11 53A Stem Support Male 2 EA.
12 53B Stem Support Female 2 EA.
13 54P1 Full jet Nozzle - White 12 EA.
14 64PE Manifold Hose 7 IN.
15 C9A Nipple 4-1/2" - Brass 2 EA.
Note: Parts are shown for reference purposes only
and are not necessarily part of a Herkules assembly.
G200 Manifold Layout
Quantity
12
4
13 1 14
11
3 10
8
6
9
15 5
7
2
Page 14 of 18

G200 Pump and Legs Layout
10
14
4
22
23
11 15
4 19 1618
20
1
21
10
5
15
11
17
13
2
8
23
6
3
12
7
9
Page 15 of 18

Part # Description
167 Adaptor 1/4 NPT - Brass 1 EA.
2338 Pump 1 EA.
31000204 Plastic Muffler 1 EA
41002378 Leg 2 EA.
51002414 ON/OFF Sticker 1 EA.
61002650 Hose Barb 3/8 x 3/8 NPT 90° - Brass 2 EA
7002-106 Wire Terminal 3 EA.
8002-120A-72 Ground Wire 2 EA.
9002-161 Washer Flat #10 USS - Zinc 1 EA.
10 002-171 Screw 8-32 x 1 - Black 4 EA.
11 002-172 Nut Nylock 8-32 - Zinc 4 EA.
12 005-131 Screw 10-24 x 1/2 - Stainless 1 EA.
13 005-132 Nut Hex 10-24 - Stainless 1 EA.
14 85D Washer Flat 1/2 - Zinc 2 EA.
15 M1C Limit Valve - Gold 2 EA.
16 M230-001A Timer 1 EA.
17 M230-002 Knob for Timer 1 EA.
18 M230-003 Cam For Timer 1 EA.
19 M230-004 Spacer 1/4" Thick - Nylon 2 EA.
20 M230-005 Spacer 1/8" Thick - Nylon 2 EA.
21 M230-006 Timer Screw #4 x 5/8 2 EA.
22 T17M Filter / Regulator 1 EA.
23 T25 5/32 Hose fitting 90° Swivel 2 EA.
Note: Parts are shown for reference purposes only
and are not necessarily part of a Herkules assembly.
G200 Pump and Legs Layout
Quantity
Page 16 of 18

Part # Description
1001-702 Bolt Hex 1/4-20 x 1/2 - Zinc 18 EA.
2001-705 Washer Flat 1/4 USS - Zinc 2 EA.
3002-161 Washer Flat #10 USS - Zinc 19 EA.
4008-244 Acorn Nut 1/4-20 - Nickel 18 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 20 EA.
Quantity
G200 Hardware Layout
5
2
4
3
4
7
6
7
4
31
Page 17 of 18

Notes
Page 18 of 18