HERKULES G205 User manual

Part# 1002531-06
4/29/2020
Made in USA
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
OWNERS MANUAL
Toll Free: 800-444-4351
Phone: [phone]
Fax:
248 960-7109
Website: www.herkules.us
E-mail:
[email protected]
Herkules Equipment Corporation
2760 Ridgeway Court
Walled Lake, MI 48390-1662 USA
Page 1 of 21

Warranty ……………………………………………………………………………………………………………….................... 3
Model Information ……………………………………………………………………………………………………………. 4
Warnings ……………………………………………………………………………………………………………………… 5 - 6
Installation Instructions ……………………………………………………………………………………………………….. 7
Operation ……………………………………………………………………………………………………………………. 8 - 9
Preventive Maintenance ………………………………………………………………………………………………………. 10
Troubleshooting ……………………………………………………………………………………………………………… 11
Drawings with Part Lists …………………………………………………………………………………………………… 12 - 20
G205 Schematic ………………………………………………………………………………………………………................... 21
Herkules Equipment Corporation
A U.S.-based manufacturer, Herkules Equipment Corporation offers a diverse line of products that support multiple
industries by improving efficiency, productivity, ergonomics, comfort, and safety in the work environment. The
company consists of the three product lines: Herkules, Enkon and BossLifts.
Since 1985, Herkules has designed, engineered and manufactured quality products at our Walled Lake,
Michigan facility. Our company supports our products after delivery, with U.S. based customer service, and
replacement parts, enabling our customers to proceed with confidence.
To learn more about Herkules, visit http://herkules.us. Contact us at [email protected] with any
questions or concerns.
Thank you for purchasing a Herkules product!
Table of Contents
Page 2 of 21

Warranty
At Herkules we take great pride in the construction of our American-made products, and we stand behind their reliability.
Our limited liability warranty coverage for Paint Gun Washers warranties the unit for a period of 12 months. Washer pumps
have a separate warranty; the Herkules 338 pump is protected for a period of 2 years from the date of purchase. All other
pumps, including rinse pumps, are warrantied for 12 months.
This warranty does not apply to equipment damaged from accident, abuse, overload, misuse, negligence, improper
installation, abrasive or corrosive materials, or shipping damage.
In the event of product failure, the defective item must be returned, freight prepaid, to the Herkules manufacturing plant for
repair or replacement. If repairs are required, Herkules will not be liable for these repairs to take place in the field regardless
of the application. Proof of purchase and date of purchase must be confirmed. An RGA* (Returned Goods Authorization) and
written approval from Herkules must be obtained before any goods can be shipped to Herkules. We reserve the right to
Determine whether failure is due to defective material, normal wear, and / or other causes.
There are no warranties which extend beyond the description on the face hereof. Herkules
disclaims any warranty of merchantability or fitness for a particular purpose in connection with
the Buyer's purchase of any Product under this agreement. Damages are limited to the sales
price of the Herkules system. The terms and conditions herein represent the entire agreement
between Herkules and the Buyer. Any prior / future representations do not apply.
*To obtain a RGA, contact Herkules at 1-800-444-4351 and have the item model, serial numbers, and invoice number if applicable.
Upon receipt of your equipment, please write your purchase information below. Please retain this manual for your records.
Serial Number Model Number
Purchase Date Distributor (if applicable)
IMPORTANT NOTICE: if you have a problem with your Herkules product,
DO NOT RETURN TO PLACE OF PURCHASE
Contact Herkules: by phone [phone]; by email, [e-mail]; or on the web at herkules.us/contact-us.
Page 3 of 21

Model Information
NOTE: Dimensions listed are overall measurements.
Dimensions in. (mm)
A B C D
Two gun, two cup paint gun washer equipped with
46 20.625 24.5 21.25
a solvent transfer system
(1168) (524) (622) (540)
Warning Symbol
Caution Symbol
Model
Description
Weight
(kg.)
G205
68
(31)
A
B
C
D
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.
Page 4 of 21

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 regulations.
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 5 of 21

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.
•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 solvent 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 6 of 21

Installing the Gun Washer
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. 1].
2) Connect air line with at least 75 psi to the coupler.
Filter/regulator is preset. Do not adjust.
Grounding the lid
Verify the ground wire is attached to lid rivet and the
other end is attached to the tub [see fig. 2].
Installation
Ground wire
fig. 2
Air supply
port
fig. 1
Page 7 of 21

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. 4]. For questions or
2) Connect the solvent fill hose to the clean solvent container. adapter kits contact your paint gun washer distributor.
3) Position both valves on the side panel to fill. Turn the timer Siphon Feed Guns
to the on position. Pump five gallons (18.9 liters) of high Place the gun siphon tube on the short stem support.
quality solvent into the tub. This requires approx. 1-1/2 timer
cycles. Gravity Feed Guns (HVLP)
Place long stem support over one of the short stem
Preparing the Equipment to be washed supports. Place paint inlet of gun on long stem support.
Place the air cap assembly over the air inlet of the gun to
1) Remove paint cup or paint line and the air line from the keep solvent out.
paint gun. Pressure Feed Guns
2) Drain excess paint from cup and gun. Place long stem support over one of the shorter stem
supports. Place paint inlet of gun on long stem support.
3) Remove all gauges and regulators. Pots and Cups
4) Lock the gun trigger in the open position by placing the Place pots and/or cups on divider platform over front
trigger lock around the gun handle and trigger [see fig. 4]. spray nozzles.
CAUTION
All pressure gauges must be removed before placing the
equipment in the gun washer to avoid damaging the
gauges.
Connect to upper
pump fitting
Connect to upper tub
bulkhead
Connect to lower tub
bulkhead
Solvent fill hose
Connect to recycler
outlet (or new solvent
container)
Solvent drain hose
Connect to recycler
inlet (or old solvent
container)
fig. 3
Connect to lower
pump fitting
Page 8 of 21

Operation
Operating the Gun Washer 7) Remove the equipment from the gun washer and wipe
off any remaining solvent.
1) Make sure all wire trigger locks and other accessories
are inside the gun washer tub. Draining the Gun Washer
2) If washing only one set of equipment, place empty cans over 1) Place a 5-gallon bucket underneath the gun washer
the unused nozzles and/or stem supports to prevent
solvent spray from hitting the underside of the gun washer lid. 2) Place the filtered intake hose into the bucket.
3) Close the gun washer lid. 3) Open the ball valve located on the bottom of the tank
and drain the used solvent into the bucket.
4) Position both valves on the side panel to clean.
4) Connect the solvent drain hose to the used solvent
5) Turn the timer knob clockwise 90 degrees to start the gun container.
washer. The gun washer will run for 90 seconds. Turning
the timer knob less than 90 degrees will reduce the timing Note: If using a solvent recycling system, insert the
cycle. Paint equipment will clean in 60 to 90 seconds. solvent drain hose into the recycler's used solvent
container.
6) If the lid is opened prior to the end of the timing cycle, the
safety air cutoff switch will stop the gun washer. The Position both valves on the side panel to drain. Turn the
gun washer will start again when the lid is closed if time timer to the on position.
remains on the timer.
Note: Open the lid slowly to minimize solvent vapor escape.
Trigger Lock
Long Stem Support
Short Stem Support
Gravity Feed
Siphon Feed Gun
Paint Cup
Pressure Feed Gun
Air Cap Assembly
fig. 4
Page 9 of 21

Preventive Maintenance
To keep your machine working efficiently, please follow these directions.
1) ALWAYS 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 solvent flows. Add cleaning solution
to 1” above intake filter.
3) Replace Filter/Regulator yearly. (#11345)
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 solvent
cleaning solution.
Do not change the setting of the filter/regulator. This could
damage the filter/regulator or pump
CAUTION
Filter /
Regulator
(#11345)
fig.5
Page 10 of 21

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 solvent in the gun washer.
The solvent 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 Solution
Problem
Page 11 of 21

G205 Parts Layout
1
2
3
4
6
7
10
14
15
16
18
20
22
12
6
11
13
8
9
23
21
30
5
17
19
Page 12 of 21

Part # Description
112490 Manifold Assembly 1 EA.
225D Divider - Stainless 1 EA.
31001706 Front Decal 1 EA.
41000651 Flammable Caution Sticker 1 EA.
513844 Stand Assembly 1 EA.
61002644 Bulkhead 1-14 UNS x 1/2 NPT - Brass 2 EA.
785B Washer 1-1/2 x 1 - Nylon 1 EA.
862 Adaptor 1/2 NPT x 3/8 NPT Brass 1 EA.
96 Ball Valve 1 EA.
10 12209
Fluid Transfer Panel Assembly
1EA.
11 M5 Tube 5/32 Plastic - Blue 30 IN.
12 M5-BLACK Tube 5/32 Plastic - Black 9 IN.
13 M5-NEUTRAL Tube 5/32 Plastic - Neutral 13 IN.
14 1007865 Pump Mounting Bracket 1 EA.
15 11962 Pump Assembly 1 EA.
16 13242 Tub 1 EA.
17 19196 Lid Assembly 1 EA.
18 1001708 Lid Sticker 1 EA.
19 12491 Filter for Pump Inlet 1 EA.
20 57 Hose Barb 3/8 x 1/4 NPT Brass 1 EA.
21 77 Connector 3/8 T x 1/4 NPT Z 1 EA.
22 1002643 Bulkhead 3/4 NPT x 1/4 NPT - Brass 1 EA.
23 77A Fitting 1/2 T x 3/8 NPT - Zinc 1 EA.
G205 Parts Layout
Quantity
Note: For parts shown but not identified
refer to assembly layouts on pages 16-22.
Page 13 of 21

Part # Description Quantity
1002-161 Washer Flat #10 USS - Zinc 8 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.
719196 Lid Assembly 1 EA.
811957 Actuator Bracket Notched 1 EA.
912321 Lid Stop 1 EA.
10 005-131 Screw 10-24 x 1/2 - Stainless 2 EA.
11 005-137 Nylock Nut 10-24 2 EA.
Note: Parts are shown for reference purposes only
and are not necessarily part of a Herkules assembly.
G205 Lid Layout
6
10
1
5
9
2
3
8
11
7
4
Page 14 of 21

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
2EA.
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.
G205 Manifold Layout
Quantity
12
4
13
1
14
11
3
10
8
6
9
15
5
7
2
12
Page 15 of 21

G205 Pump and Legs Layout
10
11
15
23
14
1
16
15
17
21
20
10
9
11
13
2
12
4
18
3
19
22
5
6
7
8
24
Page 16 of 21

Part # Description
167
Adaptor 1/4 NPT - Brass
1EA.
211962 Pump Assembly 1 EA.
31001441 Muffler 1 EA
413844 Stand Assembly 2 EA.
583
Bolt Hex Full 1/4-20 x 1 GD5 Z
2EA.
6001-705 Washer Flat 1/4 USS 2 EA
785 Washer Lock 1/4 Z 2 EA.
884 Nut Hex 1/4-20 Z 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 85I Washer Flat 1/2 USS Z 2 EA.
15 M1C Limit Valve - Gold 2 EA.
16 1007592 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 11345 Filter / Regulator 1 EA.
23 24E Washer Lock Int Tooth #10 Z 1 EA.
Note: Parts are shown for reference purposes only
and are not necessarily part of a Herkules assembly.
G205 Pump and Legs Layout
Quantity
Page 17 of 21

G205 Panel Layout
15
9
16
24
23
17
10
20
11
21
27
26
3
25
1
19
7
22
12
18
5
13
8
14
13
6
2
4
Page 18 of 21

Part # Description
1C26 Valve 4-Way 1/4 NPT Brass 2 EA.
2C12BX Tee 1/4 NPT Brass 1 EA.
366B Reducer 1/2 NPT x 1/4 NPT Brass 2 EA.
4100-084 Hose 3/8 ID Blue 3.63 IN.
5100-084 Hose 3/8 ID Blue 5.63 IN.
6100-084 Hose 3/8 ID Blue 9 IN.
7100-084 Hose 3/8 ID Blue 29 IN.
8100-084 Hose 3/8 ID Blue 96 IN.
9100-084 Hose 3/8 ID Blue 96 IN.
10 100-084 Hose 3/8 ID Blue 12 IN.
11 100-083 Hose 1/2 ID Blue 18 IN.
12 100-083 Hose 1/2 ID Blue 18 IN.
13 002-131 Elbow 1/4 NPT Brass 2 EA.
14 1002467 Hose Barb 1/2 X 1/4 NPT Brass 2 EA
15 1002466 Panel 1 EA
16 1000981 Hose Barb 3/8 NPT x # 6 Flare 1 EA.
17 1000967
Hose Barb 90 Deg 3/8 X 1/4 NPT Brass
6EA.
18 1000869 Hose Barb 1/2 NPT x # 8 Flare 1 EA.
19 1000841 Hose Barb 90 Deg 3/8 x # 6 Flare 1 EA.
20 1000840 Hose Barb 90 Deg 1/2 x # 8 Flare 1 EA.
21 1000767 Bolt BHSC 1/4-20 X 3/4 Black 4 EA.
22 11243 Filter Assembly 1 EA
23 85 Washer Lock 1/4 Zinc 4 EA.
24 84 Nut Hex 1/4 Zinc 4 EA.
25 57 Hose Barb 3/8 X 1/4 NPT Brass 5 EA
26 6 Ball Valve 1/2 NPT Brass 2 EA
27 001-600A S-Hook 1 EA
Note: Parts are shown for reference purposes only
and are not necessarily part of a Herkules assembly.
G205 Panel Layout
Quantity
Page 19 of 21

Part # Description Quantity
1001-702 Bolt Hex 1/4-20 x 1/2 - Zinc 2 EA.
2001-705 Washer Flat 1/4 USS - Zinc 2 EA.
3008-244 Acorn Nut 1/4-20 - Nickel 2 EA.
483 Bolt Hex 1/4-20 x 1 - Zinc 2 EA.
584 Nut Hex 1/4-20 - Zinc 2 EA.
685 Washer Lock 1/4 - Zinc 4 EA.
G205 Hardware Layout
4
2
1
3
6
5
Page 20 of 21