HERKULES G511 User manual

Part# 1004543-03
8/19/2020
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
OWNERS MANUAL
Toll Free: 800-444-4351
Phone: [phone]
Fax: [phone]
Website: www.herkules.us
E-mail: [e-mail] Herkules Equipment Corporation 2760 Ridgeway Court
Walled Lake, MI 48390-1662 USA
Page 1 of 16

Warranty ……………………………………………………………………………………………………………….................... 3
Model Information ……………………………………………………………………………………………………………. 4
Warnings ……………………………………………………………………………………………………………………… 5 - 6
Installation ………………………………………………………………………………………………………………….. 7
Operation ……………………………………………………………………………………………………………………. 7 - 9
Preventive Maintenance ………………………………………………………………………………………………………. 10
Troubleshooting ……………………………………………………………………………………………………………… 11
Drawings with Part Lists …………………………………………………………………………………………………… 12-15
G511 Schematic ………………………………………………………………………………………………………................... 16
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 [e-mail] with any
questions or concerns.
Thank you for purchasing a Herkules product!
Table of Contents
Page 2 of 16

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 16

Model Information
Dimensions in./(mm)
A
B
C
D
Manual cleaning waterborne Gun Washer includes 42.25 15.5 20.5 20
pressure cleaning gun, blow-off gun, flow thru brush and (1073) (394) (521) (508)
coagulation accelerator.
Weight
lbs/(kg)
55.5
Warning Symbol Caution Symbol
NOTE: Dimensions listed are overall measurements.
Model
G511 (25)
Description
A
BC
D
CAUTIONWARNING
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 16

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.
• Comply with all applicable local, state and national fire, electrical and other safety regulation.
PRESSURIZED EQUIPMENT HAZARD
Spray from hose leaks or ruptured components can splash fluid in the eyes or on the skin and cause
serious injury.
• 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 16

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 fumes.
• 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.
•
If there is any static sparking while using the equipment, stop operation immediately. Identify and
correct the problem.
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 16

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 back right
leg).
2) Connect air line with at least 75 psi to the coupler.
Filter/regulator is preset. Do not adjust.
Adding Water to the Gun Washer
1) Insert the filter mount frame into the bucket.
2) Fill the bucket with water until the water level reaches
the bottom of the filter support cross arms.
3) Connect the large filter bag to the filter mount frame so
that the bottom of the filter is resting on the filter
support.
4) Insert the small filter bag into the large bag and
connect to the filter mount frame.
5) Place the bucket under the Gun Washer and insert the
pick up tube between the bucket wall and the filter.
6) Close ball valve.
Preparing the equipment to be washed
1) Remove paint cup or paint line and the air line from the
paint gun.
2) Drain excess paint from cup and gun into a separate container.
3) Remove all gauges and regulators from painting equipment.
Installation
Operation
Air supply
port
Filter mount
frame
Ball valve
Pick up tube
Fig. 2
fig. 1
Page 7 of 16

4) Remove the air cap/fluid tip from the paint gun.
5) Connect the air channel line to the spray gun using the supplied
quick disconnects or replace the supplied quick disconnects
with ones compatible with the shop's equipment. See Fig. 2
CAUTION
All pressure gauges must be removed before cleaning the
equipment in the gun washer to avoid damaging the
gauges.
Cleaning equipment
1) Set the toggle switch on the right side of the unit to Clean.
This will activate the pump and supply water pressure to both
the manual cleaning brush and the pressure clean gun. Both 4) To activate the manual cleaning brush, turn the lever of
are located inside the tub area. the mini ball valve to send water through the brush.
2) Place the nozzle of the cleaning gun into the paint channel Note: Position the spray gun so that the flow of water
of the spray gun. exiting the paint gun is contained within the
Gun Washer tub.
3) Squeeze the trigger of the paint gun while squeezing the
trigger of the cleaning gun to send a pressurized flow of
water through the paint channel.
Filtering Dirty Solution/Paint Mixture (optional)
1) Remove the cleaning platform from inside of the tank.
2) Pour the dirty paint mixture to be recycled into the tank.
Do not exceed the 5 gallon capacity of the tank.
2) Add flocculant / coagulant to the dirty paint mixture. (Herkules
CoAgent P/N CA01 recommended.)
Note: Contact local distributor to purchase flocculant/coagulant.
Amount of flocculant/coagulant required will vary depending on
the brand of flocculant being used.
3) If using Herkules CoAgent P/N CA01, add 1 tablespoon
per 5 gallons of dirty paint mixture.
4) Set the switch on the side of the Gunwasher to Agitator.
Stir mixture for 30 seconds during agitation. Allow
the dirty paint mixture / flocculant mix to agitate
for 30 to 120 seconds (dependent upon quality of
flocculant). Let the mixture sit for 30 seconds.
Return the toggle switch to the center (Off) position.
Operation
Paint channel
Cleaning gun
Air
channel
line
Fig. 2
fig. 3
Page 8 of 16

Note: Repeat process if adequate separation does not
occur (dependent upon quality of flocculant).
5) Open the ball valve to allow the mixture to drain
through the filter bags. The filter bags capture the
paint debris, and the bucket captures the filtered cleaning
solution / water mixture that can be reused for cleaning.
Note: Reuse the cleaning solution / water mixture until it
becomes tacky to the touch. Dispose of all waste materials
according to local, state, and federal regulations.
6) Empty the paint waste out of the inner filter. Place inner
filter back on the filter holder for up to 10 uses.
Note: place solid waste onto a piece of cardboard to finish
drying. This will speed the process as the cardboard will
absorb the moisture from the paint debris.
7) Close the ball valve. Replace filter bags (P/N 1003348
& P/N 1003351) as needed.
8) Dispose of all waste materials according to all local, state,
and federal regulations.
9) Wipe inner tank after each use.
Filter Inner
P/N 1003348
Filter Outer
P/N 1003351
fig. 4
Page 9 of 16

To keep your machine working efficiently and effectively, please follow these directions.
1) Always drain excess paint from cup or pot before placing in gun
washer.
2) Replace Filter/Regulator yearly. (#11345)
3) Change water completely when objects being cleaned
become tacky to the touch.
4) Clean inside of tub and intake filter before filling with
cleaning solution.
Clean siphon tube with cloth and brush to remove residue.
Do not change the setting of the filter/regulator. This
could damage the filter/regulator or pump.
Preventative Maintenance
CAUTION
Filter / Regulator
(#11345)
fig.5
Page 10 of 16

Troubleshooting
Pump turns on but wash water 1Make sure wash bucket is not empty.
does not flow. 2Make sure the filter at the end of the pick up tube is completely submerged
in water.
3 Check all fluid connections to ensure that there are no leaks.
4 Make sure the indicator on the side is set to Clean.
Pump does not turn on. 1 Make sure intake filter is not clogged (Clean or replace).
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.
No flow through the manual brush. 1 Make sure wash bucket is not empty.
2Make sure the filter at the end of the pick up tube is completely submerged
in water.
3 Check all fluid connections to ensure that there are no leaks.
4 Make sure the indicator on the side is set to Clean.
5 Make sure ball valve is open.
Possible SolutionProblem
Page 11 of 16

G511 Parts Layout
25
2
15
31
4
23
36
35
10
22
14
13
1
38
19
30
5
7
20
3
8
21
24
18
9
33
32
27
26
29
28
34 39
40
43
45
46
37
17
11
41
42
44
16
12
13
36
14
38
14
6
Page 12 of 16

Part #
Description
1
6 Ball Valve 1 EA
2
13053 Filter Assembly 1 EA
3
62 Reducer 1/2 NPT X 3/8 NPT 1 EA
4
85 Lock Washer 1/4 2 EA
5
13123 Pump Assembly 1 EA
6
13800 Air Gun Assembly 1 EA
7
13901 Cleaning Platform 1 EA
8
19676 Lid Assembly 1 EA
9
1000563 Brush 1 EA
10
1006461
Hose Barb 90
°
3/8 x 1/4 NPT
1 EA
11
T12 Nipple Close 1/4 NPT Brass 2 EA
12
14805 Fluid Gun Assembly 1 EA
13
1002546 Screw BHSC 10-24 x 1/2 4 EA
14
1002643 Bulkhead 3/4 - Brass 3 EA
15
1002644 Bulkhead 1 - Brass 1 EA
16
C16 Coupler 1/8 NPT Brass 1 EA
17
M6 Elbow Street 1/8 NPT Brass 1 EA
18
14648 Stand Assembly 1 EA
19
1002912 Toggle valve 1 EA
20
1002914 Bucket 1 EA
21
1002953 Clip Spring 2 EA
22
1002967 Filter mount frame 1 EA
23
1002968 Tube Coiled 5/32 2 EA
24
1003048 Front Decal 1 EA
25
1004587 Side Toggle Sticker 1 EA
26
1003055 Lid Sticker 1 EA
27
1003348 Filter inner 1 EA
28
1003351 Filter outer 1 EA
29
14141 Whip Line 1/2 x 36 1 EA
30
1003597 Rivet 1/4 x 1/2 Aluminum 16 EA
31
1004559 Ball Valve Mini 1/4 NPT x 1/4 NPT 1 EA
32
001-702 Bolt Hex 1/4-20 X 1/2 Zinc 2 EA
33
002-118 Hose Fitting 90° 1/4 NPT x 1/4 NPT 1 EA
34
002-129 Hose Fitting 90° 5/32 x 1/8 NPT 2 EA
35
002-134 Nozzle 1/4 NPT Brass 1 EA
36
002-161 Flat Washer #10 6 EA
37
C8 Coupler QD 210 w/ O-Ring 1/4 NPT 1 EA
38
005-134 Reducer Bushing 1/4 NPT x 1/8 NPT Brass 2 EA
39
005-137 Nut Nylock 10-24 Zinc 2 EA
40
008-244 Acorn Nut 1/4-20 2 EA
41
T25
Fitting PTC 90
°
Swivel 5/32 x 1/4 NPT
1 EA
42
T4 Fitting PTC 5/32 x 1/8 NPT 3 EA
43
19678 Kit Tub Replacement G511 1 EA
44
1000524 Check Valve 1 EA
45
85B Washer 1-1/2 x 1 Nylon 2 EA
46
C12BX Tee 1/4 NPT Brass 1 EA
Note:
For parts shown but not identified
refer to assembly layouts on pages 12
G511 Parts Layout
Quantity
Page 13 of 16

G511 Pump and Legs Layout
9
12
17
13
11
18
14
2
5
6
3
4
1
16
19
10
8
7
20
15
Page 14 of 16

Part #
Description
1
67 Adapter 1/4 NPT Brass 1 EA
2
83 Bolt Hex 1/4-20 x 1 - Zinc 2 EA
3
84 Hex Nut 1/4-20 Zinc 2 EA
4
85 Lock Washer 1/4 Zinc 2 EA
5
13123 Pump Assembly 1 EA
6
1007865 Pump Mounting Bracket 1 EA
7
1001441 Muffler 3/8 NPT Zinc 1 EA
8
1006470 Hose Barb 90° 3/8 X 3/8 NPT Brass 2 EA
9
001-705 Washer Flat 1/4 USS - Zinc 2 EA
10
002-118 Hose Fitting 90° 1/4 x 1/4 NPT 1 EA
11
002-120A-72 Ground Wire 1 EA
12
005-131 Screw 10-24 x 1/2 - Stainless 1 EA
13
005-132 Nut Hex 10-24 - Stainless 1 EA
14
005-134 Reducer 1/4 NPTx1/8 NPT Brass 2 EA
15
24E Toothed Lock Washer #10 1 EA
16
85I Washer Flat 1/2 USS Z 2 EA
17
C12CX Tee Street 1/4 NPT Brass 2 EA
18
11345 Filter / Regulator 1 EA
19
T25 Hose Fitting 90° 5/32 x 1/4 NPT 1 EA
20
T4 Hose Fitting 5/32 x 1/8 NPT 2 EA
Note:
Parts are shown for reference purposes only
and are not necessarily part of a Herkules assembly.
G511 Pump and Legs Layout
Quantity
Page 15 of 16

Page 16 of 16