Herkules G100 User Manual
INSTRUCTIONS
Part# 1002423-06
1/21/2008
This manual contains important information concerning the
installation and operation of the gun washers listed above.
Read manual thoroughly and keep for future reference
Herkules Equipment Corporation 2760 Ridgeway Court Walled Lake, MI 48390-1662 USA
248-960-7100 800-444-4351 Fax 248 960-7109
Patents USA 7070167 4793369, 4960142, 5174317, 5193561, 5485860 Canada 1299468 & Patents Pending
website: www.herkules.us Made in the USA e-mail: info@herkules.us
Page 1 of 19
Table of Contents
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
Warning Symbol Caution Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Serial Number
Model Number
Purchase Date
Distributor
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
PATENT NUMBERS
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
Page 2 of 19
WARNING
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.
Page 3 of 19
WARNING
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.
•
correct the problem.
• Drain the cleaning solution into a proper storage container when gun washer(s) is not in use.
If there is any static sparking while using the equipment, stop operation immediately. Identify and
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.
Page 4 of 19
Assembly
Stand and tub connections
STEP 1
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.
Note: The frame should be positioned so that the
leg of the angle iron is above the top of the legs.
(see fig.1).
STEP 2
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 1/2 hex bolts, (2) #10 flat washers, (2) 1/4"
lock washers and (2) 1/4" acorn nuts per leg (see fig.1).
STEP 3
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).
1/4" Lock washer
1/4" Acorn nut
Hex bolt
1/4-20 x 1/2
Flat washer #10
Filter/Regulator Leg
Hex bolt
1/4-20 x 1
1/4" Flat Washer
1/4" Acorn nut
1/4" Lock Washer
Fluid hose connections
STEP 4
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.
STEP 5
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).
STEP 6
Attach the other end of the 23" hose to the lower (IN)
90° barb on the pump (see fig.2)
STEP 7
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)
Timer Leg
fig.1
Flare connector
Drain hose assembly
Plug
1/4" Hex nut
16" Black Hose
23" Black HoseMuffler
STEP 8
Attach the white plastic muffler to the exhaust
port of the pump (see fig.2).
Page 5 of 19
Siphon Filter
fig.2
Air hose connections
STEP 9
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.
STEP 10
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).
STEP 11
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).
Assembly
Limit
valve
Black air
hose
Clear air
hose
Blue air
hose
Limit
valve
fig.3
Lid assembly and attachment
STEP 12
Attach the handle to the front 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).
STEP 13
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).
STEP 14
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).
STEP 15
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.
STEP 12
Ground
terminal
Nut
Washer
Ground
terminal
STEP 15
STEP 14
STEP 13
fig.4
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.
fig.5
Page 6 of 19
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