Herkules G200 User Manual
INSTRUCTIONS
Part# 1002655-04
3/19/2009
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 18
Table of Contents
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
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 num ber s :
7070167, 5485860, 5193561, 5174317
4960142, 4793369, 1299468
and Patents Pending
website: www. h erk u les . us
1002742
Page 2 of 18
Page 2 of 18
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 18
Page 3 of 18
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 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.
•
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 18
Page 4 of 18
Assembly
Stand and tub connections
STEP 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).
STEP 2
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).
STEP 3
Hand tighten ball valve to the reducing nipple on the
bottom of the tub (see fig.3).
Ensure bulkhead DOES NOT TURN when tightening.
1/4-20 x 1/2"
Hex bolt
STEP 4
Attach the white plastic muffler to the exhaust
port of the pump (see fig.3).
Flat washer 1/4"
Hex bolt
1/4-20 x 1"
Flat washer #10
1/4" Acorn nut
1/4" Lock
washer
fig.1
1/4" Lock washer
1/4" Hex nut
fig.2
Page 5 of 18
Ball valve
Muffler
fig.3
Assembly
Connecting fluid and air hoses
STEP 7
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).
STEP 8
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).
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.4).
Limit
valve
14" Fluid
outlet tube
Black air
hose
Limit valve
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.4).
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.4).
Connecting lid rod and actuator linkage
STEP 12
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).
STEP 13
Attach the lid rod to the lid bracket using the 1/4" clevis pin
and circular cotter pin supplied (see fig. 5).
Clear air
hose
Lid bracket
Cotter pin
Ground wire
Lid rod
16" Fluid
inlet tube
Blue air
hose
fig.4
Clevis pin
Lid screw
fig.5
STEP 14
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
STEP 15
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).
Page 6 of 18
Lid rod
Actuator
Set screw
fig.6
Loading...