Practical Guide
WIWA HERKULES HX in Continuous Use: Selecting Hydraulic Airless & Starting Safely
The WIWA HERKULES HX is a hydraulic material pump for large surfaces, high-build applications, and high-viscosity/abrasive media – and a strong option when no compressed air supply is available. In this guide, you will get a practical overview (models, fields of application), guide values for the start, and a professional workflow – with direct product CTAs.
WIWA HERKULES HX (example illustration)
KPI 1
Up to 60% Energy Savings*
Hydraulic drive can be significantly more efficient than compressed air, depending on the setup.
KPI 2
Low Pulsation
For reproducible coating patterns – especially practical for high-build & corrosion protection.
KPI 3
No Icing via Compressed Air
Hydraulic operation avoids typical icing issues found in air motors.
Product Overview: Models, Performance Data, Typical Uses
The HERKULES HX series covers various flow rates and pressure ratios. Below you will find the most important key data per model (derived from brochures/product data; units as specified).
| Model | Flow Rate per Double Stroke | Pressure Ratio | Max. Spray Pressure | Max. Oil Pressure | Typical Selection Logic |
|---|---|---|---|---|---|
| 28003 | 153 cm³ (≈5.17 fl oz) | 3:1 | 450 bar | 150 bar | When high material pressure is important, but a moderate flow rate is sufficient. |
| 34002 | 189 cm³ (≈6.39 fl oz) | 2.4:1 | 360 bar | 150 bar | All-round sweet spot for many corrosion protection and high-build jobs. |
| 35003 | 275 cm³ (≈9.3 fl oz) | 3.4:1 | 450 bar | 133 bar | When you need both a high flow rate and high pressure simultaneously. |
| 48002 | 360 cm³ (≈12.17 fl oz) | 2.6:1 | 390 bar | 150 bar | For large surfaces & high flow rates while maintaining high material pressure. |
| 60001 | 550 cm³ (≈18.6 fl oz) | 1.7:1 | 255 bar | 150 bar | Maximum flow rate – ideal when volume is more important than maximum pressure. |
Note: The series is intended for, among other things, large-surface/high-build work as well as high-viscosity/abrasive materials (e.g., glass flake, cold bitumen, 2K/tar epoxy, zinc primer). Values are technical maximums; see starting settings below for guide values.
Fields of Application & Material Checklist (Brief & Practical)
- Large-surface and high-build coatings
- Shipbuilding/Offshore, steel and hall construction
- Corrosion protection, industrial coatings, fire protection
- Paint circulation systems/paint lines (also as a feed pump for systems/extraction points)
- High-viscosity and/or abrasive materials
- Glass flake, insulating and high-build material
- Antifouling, cold bitumen
- Low-solvent/solvent-free paints, 2K/tar epoxy, micaceous iron oxide, zinc primer
Practical Tip (Yellow Box):
If you are processing high-viscosity or fiber/particle-filled materials, plan for accessories such as material flow heaters or agitators/inlet hoppers from the start.
This stabilizes the viscosity and reduces startup problems (suction issues, uneven spray patterns, unnecessarily high pressure requirements).
Accessories & Equipment Logic (What Really Helps)
A range of accessories is available for HERKULES pumps – including material flow heaters, pneumatic agitators, and inlet containers (depending on the variant/setup). For return-flow setups, a suitable circulation adapter is required.
| Accessory Component | When Is It Useful? | Practical Benefit |
|---|---|---|
| Material Flow Heater | Cold, viscous, high-build, glass flake/bitumen | More constant viscosity, fewer pressure peaks, more stable spray pattern |
| Agitator / Inlet | Sedimenting or sensitive media | Uniform material quality, less filter/nozzle stress |
| Return / Circulation (with Adapter) | When material needs to be conditioned within the system | Getting material "into shape", stabilizing temperature/viscosity |
Select the Right 34002 Configuration Now (Red CTAs)
Model 34002 is frequently ordered – depending on the workplace/logistics as a wall mount, cart, or pallet jack variant.
Recommended Basic Settings (as Guide Values)
The brochure mainly specifies maximum values. For a safe start, conservative guide values are recommended, which you can fine-tune depending on the material and nozzle:
| Parameter | Start Guide Value | Why? |
|---|---|---|
| Hydraulic Oil Pressure | approx. 30–50% of the permissible maximum value (model-dependent; see table for maximums) | Reduces risk of pressure peaks, facilitates venting/suction |
| Material Pressure | as low as possible, as high as necessary (start low first, then increase step by step) | Protects filters/hoses and prevents overspray/material mist |
| Material Conditioning | heat/agitate viscous media early on (if permissible) | Lower viscosity = lower pressure requirement = calmer spray pattern |
Important Note: These are starting guide values, not fixed requirements. Limits (maximum pressures/ratios) can be found in the technical data for each model.
Pro Workflow (5–7 Steps)
- Check Material: Data sheet/pot life (for 2K), filter/filler content, temperature, viscosity.
- Select Setup: 34002 as wall mount/cart/pallet jack to suit the workplace – keep hose routing short & kink-free.
- Decide on Accessories: For "viscous & thick" materials, plan for heater/agitator/inlet early; return flow only with a suitable adapter.
- Connect Hydraulics Properly: First check for leaks, then ramp up slowly (guide value range), allow pressure to stabilize.
- Vent & Prime: Allow material to flow evenly until no more air comes out; monitor filters.
- Adjust Spray Pattern: Start with low material pressure, then increase step by step until the spray pattern "opens" cleanly.
- Document: Record final guide values (oil pressure/material pressure, material temp., setup) as a standard for the next job.
Troubleshooting: 4 Typical Problems + Actions
1) Uneven Spray Pattern / Pulsation
- Condition material (agitate/heat, if permissible) and optimize pressure step by step.
- Check filter/suction line (contamination, bottlenecks, kinks).
2) Pump Primes Poorly / Cavitates
- Reduce suction height, improve inlet (e.g., inlet hopper), and check material temperature.
- Vent the system; check the suction line for leaks.
3) Pressure Rises Sharply / Clog in the System
- Immediately reduce/relieve pressure, then check filter element/hose/nozzle for clogging.
- Check material for lumps/sediment; consider agitating/filtering/material change.
4) Too Much Overspray / Rough Finish
- Reduce material pressure and optimize spray distance/movement.
- Stabilize material viscosity/temperature; use conditioning accessories if necessary.
Maintenance (5 Points, Practice-Oriented)
- Regularly Check Filters: Contamination reduces flow and causes pressure peaks.
- Check Hoses/Fittings: Look for abrasions, kinks, leaks – especially at high pressures.
- Suction Side Tightness: Small leaks cause air intake and unstable pumping.
- Flush Cleanly After Job End: Use suitable agents for the material (and manufacturer approvals) – so that nothing "sets".
- Document Settings: Repeatability saves time and material – especially for series jobs.
FAQ (Practice-Relevant)
Which HERKULES HX is most commonly suitable for corrosion protection?
The 34002 is often a good all-rounder. If you need more volume: 48002/60001. If maximum pressure is the focus: 28003/35003 – always select according to your material and application requirements.
Can I integrate the HX into existing hydraulic systems?
Yes, that is exactly what the series is designed for – integration into existing hydraulic systems is explicitly described (check details for each setup).
Which materials are "typical" for the HX?
High-viscosity/abrasive media such as glass flake, high-build/insulating materials, cold bitumen, antifouling, as well as low-solvent/solvent-free paints and 2K/tar epoxy systems.
Why is low pulsation mentioned as an advantage?
Because the spray pattern becomes more stable and reproducible for critical layer structures (high-build, corrosion protection) – a real quality and time factor in practice.
What starting settings should I use?
Orientation should be based on technical maximums; start conservatively (e.g., 30–50% of the permissible hydraulic maximums as a guide value), then step by step until a clean spray pattern is achieved. Material conditioning significantly reduces pressure requirements.
Conclusion
The WIWA HERKULES HX is a robust hydraulic alternative for high-performance airless coatings – especially for large surfaces, high-build, and high-viscosity/abrasive materials. If you select the model and accessories (heater/agitator/inlet) carefully according to material & logistics and start with conservative guide values, you will quickly achieve a stable setup – and reduce downtime in continuous use.
*Energy saving is to be understood as a manufacturer's "up to" statement; actual values are system-dependent.
