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Part# GW/R-T-OM
1/12/04 TN
Models:
GW/R-T GW/R-2-T GW/R-3-T
INSTRUCTIONS
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 4793369, 4960142, 5174317, 5193561, 5485860 Canada 1299468 Made in the USA
Page 1 of 19
Table of Contents
……………………………………………………………………………………………………………….. 5
Warnings
…………………………………………………………………………………………………………………. 3-4
Model Information (List of models with descriptions and data)
……………………………………………… 5
Installation
Operation
………………………………………………………………………………………………………………… 6-8
Preventive Maintenance
……………………………………………………………………………………………… 8
Troubleshooting
…………………………………………………………………………………………………………. 9
Notes
…………………………………………………………………………………………………………………….. 10-11
Timed Diaphragm Pump Assembly Instructions
Timed Diaphragm Pump Assembly Drawings
………………………………………………………………. 12
Drawings with part lists:
GW/R-T
………………………………………………………………………………………………………
GW/R-2-T
……………………………………………………………………………………………………
GW/R-3-T
……………………………………………………………………………………………………
14-15
16-17
18-19
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.
Serial Number
Model Number
Purchase Date
Distributor
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.
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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 manufactures 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.
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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.
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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 gun washer area.
Electrically disconnect all 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 manufactures 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.
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Know the specific hazards of the fluid you are using. Read the fluid manufactures 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
Model Information
B
C
A
01981000(100)
D
NOTE:
Dimensions listed are overall measurements.
Model Description
GW/R-T Two gun, two cup paint gun washer/recycler equipped with diaphragm pump, filter-regulator and timer.
GW/R-2-T GW/R-T for use with water based cleaning solutions or standard lacquer thinner solvents.
GW/R-3-T GW/R-T adapted for pressure feed systems, paint hoses, and cans up to 5 gallons.
Model shown: GW/R-T
Weight
(kg.)
74
(33.6)
74
(33.6)
75
(34)
A
41.625
(1057)
41.625
(1057)
41.625
(1057)
Dimensions in. (mm)
B C
20.5
(521)
20.5
(521)
20.5
(521)
24.375
(619)
24.375
(619)
24.375
(619)
D
30.75
(781)
30.75
(781)
30.75
(781)
Installation
Installing the Gun Washer
1 Connect diaphragm pump housing to Gun
Washer. (See page 12)
2 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 open port of the filter/regulator located at the back of the pump housing.
2 Connect air line with 90-120 psi to the coupler.
Filter/regulator is preset. Do not adjust.
Page 5 of 19
Operation
Placing Equipment in the Gun Washer Filling the Gun Washer with Fluid
1 Close ball valve located on the bottom of the tank.
2 Pour five gallons (18.9 liters) of high quality slow evaporating solvent into the tank. DuPont 3661S or equivalent is recommended.
Preparing the Equipment to be washed
To clean guns not mentioned here, use the long or short stem supports as needed (see Fig. 2). For questions or adapter kits contact your paint gun washer distributor.
Siphon Feed Guns
Place the gun siphon tube on the short stem support.
1 Remove paint cup or paint line and the air line from the paint gun.
2 Drain excess paint from cup and gun.
3 Remove all gauges and regulators.
4 Lock the gun trigger in the open position by placing the trigger lock around the gun handle and trigger
(see Fig. 2).
CAUTION
All pressure gauges must be removed before placing the equipment in the gun washer to avoid damaging the gauges.
Gravity Feed Guns
Place long stem support over one of the short stem supports. Place paint inlet of gun on long stem support.
*For Gravity Feed, High Volume Low Pressure Guns an
adapter kit (part number 23K) is available for best
cleaning.
Pressure Feed Guns
Place long stem support over one of the shorter stem supports. Place paint inlet of gun on long stem support.
Pots and Cups
Place pots and/or cups on divider platform over front spray nozzles.
Trigger Lock
Figure 2
Paint Cup
Long Stem Support
Short Stem Support
Siphon Feed Gun
01001245(206)
HVLP Gun Adapter
(Sold Separately)
Page 6 of 19
Operation
Additional Washing Features of Model
GW/R-3-T
Internal Washing of Paint Lines
Remove the brass plugs from the bottom of the 3-way valve and the internal wash bulkhead (see Fig. 3 & 4). Install a female fluid quick coupler with 1/4 in. npt male threads
(suitable for lacquer thinner) into the bottom of the 3-way valve. Install a female fluid quick coupler with 3/8 in. npt male threads (suitable for lacquer thinner) into the internal wash bulkhead. Connect the paint line to the couplers.
Face the pointer of the 3-way valve down and operate the gun washer.
Internal wash bulkhead
Socket plug
#61A
3-way valve pointer
Hex plug
Figure 4
01981002(105)
Washing Five Gallon Cans
Insert the spray nozzle assembly, hanging on the back of the manifold, into the Q.D. coupler in the center of the manifold (See figure 5). Place five gallon can over spray nozzle.
Operate gun washer.
Figure 3
01981004(104)
Spray nozzle assembly
Internal Washing of Paint Lines with Guns Attached
Remove the brass hex plug from the bottom of the 3-way valve.
Install a female fluid quick coupler with 1/4 in. npt male threads (suitable for lacquer thinner). Connect paint line with gun attached, to the coupler. Face the pointer of the
3-way valve down and operate the gun washer. To “bleed” the paint (into a container) hold the trigger of the gun open until clean thinner begins to flow.
Washing Pressure Pot and Lid
Insert the spray nozzle assembly, hanging on the back of the manifold, into the Q.D. coupler in the center of the manifold
(See figure 6). Place pot over spray nozzle. Place pickup tube of lid over one of the short stem supports (remove gauges).
Operate gun washer.
Page 7 of 19
Figure 5
Q.D. Coupler
01981002(98)
Operation
Operating the Gun Washer
1 Make sure all wire trigger locks and other accessories are inside the gun washer tank.
2 If washing only one set of equipment, place empty cans over the unused nozzles and/or stem supports to prevent solvent spray from hitting the underside of the gun washer lid.
3 Close the gun washer lid.
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.
5 If the lid is opened prior to the end of the timing cycle, the safety air cutoff switch will stop the gun washer. The gun washer will start again when the lid is closed if time remains on the timer.
Note: Open the lid slowly to minimize solvent vapor escape.
6 Remove the equipment from the gun washer and wipe off any remaining solvent. The gun hanger on the front of the stand can be used to dry the guns.
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 solvent flows. Add solvent to 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 solvent completely when objects being cleaned become tacky to the touch.
5 Clean inside of tub and intake filter before filling with solvent.
Filter/Regulator
#T17M
CAUTION
Do not change the setting of the filter/regulator.This could damage the filter/regulator or pump
Filter
#1001382
Filter Bowl
Page 8 of 19
Problem
Gun washer will not turn on.
Gun washer turns on but pumps slowly or not at all.
Gun washer will not shut off
Troubleshooting
1
2
3
4
5
Possible Solution
Make sure the air line is properly connected with 90-120 psi.
Make sure lid is fully closed. Make sure the limit valve (#M1C) on the valve bracket (#M1SA) is closed in the downward position.
Check all air connections to ensure that there are no leaks.
Make sure timer cam is engaging the limit valve (#M1C) on the pump housing assembly.
Make sure timer is on and functioning correctly.
5
6
3
4
1
2
7
Make sure intake filter (#70) is not clogged (Clean or replace).
Make sure the air line is properly connected with 90-120 psi.
Check all air connections to ensure that there are no leaks.
Drain filter/regulator of water. See number 3 of PREVENTIVE
MAINTENANCE.
Make sure there is 5 gallons of clean solvent in the gun washer.
The solvent should be an inch above the intake filter (#70).
Make sure lid is fully closed. Make sure the limit valve (#M1C) on the valve bracket (M1SA) is closed in the downward position.
Make sure manifold nozzles and stem supports are not clogged.
1
2
Make sure timer cam (#M230-001A) is moving. If its not, slightly loosen the nuts holding the limit valve (#M1C) on the top panel of the pump housing assembly. Reposition valve and tighten nuts.
Make sure limit valve (#M1C) located on the lid valve bracket assembly or the pump housing is not stuck in closed position.
Page 9 of 19
Notes
Page 10 of 19
Notes
Page 11 of 19
Diaphragm pump housing assembly instructions
1 Place the two nylon spacers over the housing bolts and insert into the gun washer frame holes. Place flat washer, then lock washer, then nut onto the 1” bolt and finger tighten.
Note: The timer knob is at the front of the housing and the air tubing lines are at the rear.
2 Connect the two metal solvent tubes between the
pump and the tub.
Note: Some adjustment of the pump fittings may be
necessary.
a. Connect the 3/8” diameter tube between the
“Material Outlet” of the pump and the top outlet of the tub. Finger tighten.
b. Connect the 1/2” diameter tube between the
“Material Inlet” of the pump and the lower outlet of the tub. Some alignment may be necessary for proper fitting of all four flare connections. Finger tighten.
c. When the housing and the solvent tubes are aligned, tighten the four flare nuts.
Note: When tightening the 1/2” solvent tube, use a 13/16” open end wrench to hold the flare fitting in the pump while tightening the 7/8” flare nut on the solvent tube. This will prevent pump damage when tightening.
3 Tighten the diaphragm pump housing to the
upper stand.
4 Connect air tubing between pump housing and lid valve bracket.
a. Connect the blue plastic air tubing running from the air cut off switch on the pump housing to the in port of the air cut off switch on the lid valve bracket. See drawings pages 12-13. The hose must bottom out in the switch. Pull firmly to test for tight connection.
b. Connect the black plastic air tubing running from the pump housing to the out port of the air cut off switch on the lid valve bracket. See drawings pages 12-13. Again the hose must bottom out in the switch. Pull firmly to test for tight connection
Air cut off switch
IN PORT
OUT PORT
Lid Valve Bracket Assembly
#M1SA
Page 12 of 19
01981000(13)
Diaphragm Pump Kit
#338DT
Black Air Tubing connect to lid air cut off switch out port
Diaphragm Pump Kit
#10305
Black Air Tubing connect to lid air cut off switch out port
Blue Air Tubing connect to lid air cut off switch in port
3/8” Material Outlet Tube connect to upper outlet of tub
1/2” Material Inlet Tube connect to lower outlet of tub
Blue Air Tubing connect to lid air cut off switch in port
3/8” Material Outlet Tube connect to upper outlet of tub
Page 13 of 19
1/2” Material Inlet Tube connect to lower outlet of tub
Divider
#25D
Tank
#1-BLUE
Upper stand
#93BA
Gun hanger
#10045
Intake filter
#70
Lower stand
#93DA
Bulkhead
#41
Ball valve
#6
Parts layout for GW/R-T
Page 14 of 19
01981001(75)
Lid assembly
#002-096SA
Lid valve bracket
#M1SA
Manifold tube
#64A
Bulkhead
#43
Outlet tube
#338-006
Bulkhead
#42
Inlet tube
#314-003
Manifold Assembly
#55A
Note:
Parts called out are not necessarily contained in the assemblies. All parts are not necessarily shown or called out.
Nozzle
#54P1
Manifold block
#002-137
Manifold bolt
#002-136
Pump/Timer Assembly
# 338DT
Timer knob
#M230-002
Hose barb
#T24
Nylon spacer
#M230-005
Limit valve
#M1C
Reducer
#005-134
Timer cam
#M230-003
Stem support
#53A
01960510(254)
Flare fitting
#77
Regulator nut
#1000215
Upper panel
#11212
Filter/Regulator
#T17M
Nylon spacer
#M230-004
Timer
#M230-001A
Diaphragm pump 3/8”
#338
Note:
The following tubing is not shown.
5/32” plastic tubingPart# M5
Flare fitting
#77A
Flare fitting
#005-105
01981003(200)
Page 15 of 19
Tube fitting
#T25
Lower panel
#11211
Parts layout for GW/R-2-T
Divider
#25D
Tank
#1-BLUE
Upper stand
#93BA
Gun hanger
#10045
Intake filter
#70
Lower stand
#93DA
Bulkhead
#41
Ball valve
#6
Page 16 of 19
01981001(75)
Lid assembly
#002-096SA
Lid valve bracket
#M1SA
Manifold tube
#64A
Bulkhead
#43
Outlet tube
#338-006
Bulkhead
#42
Inlet tube
#314-003
Manifold Assembly
#55A2
Note:
Parts called out are not necessarily contained in the assemblies. All parts are not necessarily shown or called out.
Nozzle
#54P1
Manifold block
#002-137
Manifold bolt
#002-136S
Pump/Timer Assembly
# 338DT
Timer knob
#M230-002
Hose barb
#T24
Nylon spacer
#M230-005
Limit valve
#M1C
Reducer
#005-134
Timer cam
#M230-003
Stem support
#53A
01960510(254)
Flare fitting
#1000134
Regulator nut
#1000215
Upper panel
#11212
Filter/Regulator
#T17M
Nylon spacer
#M230-004
Timer
#M230-001A
Diaphragm pump 3/8”
#338
Note:
The following tubing is not shown.
5/32” plastic tubingPart# M5
01981003(200)
Page 17 of 19
Tube fitting
#T25
Flare fitting
#77A
Flare fitting
#005-105
Lower panel
#11211
Tank
#1-BLUE
Bulkhead
#1000135
Plug
#61A
Divider
#25D
Upper stand
#93BA
Gun hanger
#10045
Intake filter
#70
Lower stand
#93DA
Bulkhead
#41
Ball valve
#6
Parts layout for GW/R-3-T
Lid assembly
#002-096SA
Lid valve bracket
#M1SA
Manifold tube
#64A
Elbow
#005-105
Bulkhead
#11A
Flexible tube
#1000523
Bulkhead
#42
Inlet tube
#314-003
01981002(157)
Page 18 of 19
Manifold Assembly
#10170
Note:
Parts called out are not necessarily contained in the assemblies. All parts are not necessarily shown or called out.
Adaptor
#1001107
Nozzle
#54P1
Manifold block
#002-137D
Hex plug
#59
Stem support
#53A
Manifold bolt
#002-136
Pump/Timer Assembly
# 10305
Limit valve
#M1C
Timer knob
#M230-002
Elbow
#005-105
Nylon spacer
#M230-005
Timer cam
#M230-003
Nylon spacer
#M230-004
Timer
#M230-001A
Diaphragm pump 3/8”
#338
Note:
The following tubing is not shown.
5/32” plastic tubingPart# M5
Reducer
#005-134
Flare fitting
#77
01960414(254)
Regulator nut
#1000215
Upper panel
#11212
Filter/Regulator
#T17M
01981003(202)
Page 19 of 19
Tube fitting
#T25
Flare fitting
#77A
Hose barb
#T24
3 way valve
#C26
Lower panel
#11211
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