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Summary of Contents for wiwa HERKULES HX
- Page 1 Operation Manual HERKULES HX Type: 28003XL 34002XL 35003XXL 48002XXL 60001XXL Serial No.: 1alhh_BA_en_B0550088 ✓(2023/07/19)
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Page 2: Ec Declaration Of Conformity
EC declaration of conformity in accordance with Annex II, No. 1 A of Machine Directive 2006 / 42 / EC, as amended by 2009 / 127 / EC The company WIWA Wilhelm Wagner GmbH & Co. KG 35633 Lahnau Gewerbestraße 1–3 Germany... -
Page 3: Eu Declaration Of Conformity
EU declaration of conformity in accordance with ATEX Directives The company WIWA Wilhelm Wagner GmbH & Co. KG 35633 Lahnau Gewerbestraße 1–3 Germany hereby declares that the machine HERKULES HX type with serial no. conforms with the provisions of Directive 2014 / 34 / EU. -
Page 5: Table Of Contents
Contents Contents 1 Foreword 2 Safety 2.1 Explanation of symbols ......2.2 Safety notes ....... 2.2.1 Working pressure . - Page 6 Contents 5.4 Pressure relief ......32 5.5 Work interruption ......33 5.6 Decommissioning .
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Page 7: Foreword
If questions should arise, we would be happy to assist you. We wish you excellent working results with your machine WIWA Wilhelm Wagner GmbH & Co. KG Copyright © 2025 WIWA The copyright to this operation manual belongs to WIWA Wilhelm Wagner GmbH &... -
Page 8: Safety
We recommend that the machine owner have this confirmed in writing. 2.1 Explanation of symbols Safety notes warn of potential accident risks and describe the measures required for accident prevention. In the WIWA operation manuals, safety notes are high- lighted and labeled as follows: DANGER... - Page 9 Safety General risk of accident Risk of explosion due to explosive atmosphere Risk of explosion due to explosive substances Risk of accident due to electricity or electrostatic charge Warning of crushing Warning of corrosive substances Risk of injuries due to rotating machine parts Risk of burning due to hot surfaces Risk of freezing due to cold surfaces The first line of the safety instructions indicates the personal protective equipment...
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Page 10: Safety Notes
Safety Wear protective gloves Signals an instruction to wear protective gloves in order to prevent injuries due to aggressive chemicals, burns when processing heated materials, or freezing due to contact with very cold surfaces. Wear safety shoes Signals an instruction to wear safety shoes, in order to prevent foot injuries due to falling, toppling or rolling objects, as well as slipping on slippery floors. -
Page 11: Working Pressure
Safety 2.2.1 Working pressure WARNING Parts that are not designed for the maximum permissible working pressure may rupture and cause serious injuries. It is essential to observe the prescribed maximum working pressures for all parts. With varying working pressures, the lowest value always applies as the maximum working pressure for the complete machine. -
Page 12: Risks Due To Electrostatic Charge
Never spray solvents or materials containing solvents into narrow-mouthed cans or drums with a bung opening! Only use electrically conductive material hoses. All original material hoses from WIWA are conductive and designed for our devices. Only use electrically conductive accessories/accessory parts. WARNING Dirty machines can become electrostatically charged. -
Page 13: Risks Due To Hot Surfaces
Safety WARNING During the stroke movement of the lift, moving parts may cause crushing and impact injuries. The lift may always only be operated by one person. No persons may remain inside the stroke area of the lift during stroke move- ment. -
Page 14: Explosion Protection
Safety 2.2.6 Explosion protection The following short designations are used in the instructions of WIWA: Ex protection: Explosion protection Ex area: potentially explosive or non-explosion protected area Non-Ex area: non-explosive or explosion protected area Ex zone: Explosion protection zone according to ATEX Directive... -
Page 15: Information Signs On The Machine
For your safety • Pour votre sécurité The information signs attached to the ma- Por razones de seguridad • Для вашей безопасности Güvenliğiniz için • Dla Twojego bezpieczeństwa www.wiwa.de För din säkerhet • Para a sua segurança chine, such as for example the safety card www.wiwa.com Spritzpistole nicht auf Personen oder Tiere richten (Fig. -
Page 16: Safety Features
Safety 2.4 Safety features WARNING If one of the safety features is missing or is not fully functional, the operating safety of the machine is not guaranteed! Put the machine out of operation immediately if you detect safety feature defects or any other faults on the machine. Only put the machine back into operation once the faults have been fully rectified. -
Page 17: Operating And Maintenance Personnel
Safety 2.5 Operating and maintenance personnel 2.5.1 Obligations of the owner The owner: is responsible for training the operating and maintenance personnel, must instruct the operating and maintenance personnel on correct handling of the machine, and on wearing the correct work clothing and protective equip- ment, must make work aids, such as e. -
Page 18: Personal Protective Equipment
When repairing and maintaining the machine, original spare parts from WIWA must be used. If spare parts are used that have not been produced or supplied by WIWA, the warranty is void and all liability shall be excluded. Original Operation Manual ✓(2023/07/19), Status: 2023/10/12... -
Page 19: Accessories
Safety 2.6.2 Accessories If you use original WIWA accessories, their suitability for use in our machines is guaranteed. If you use third-party accessories, these must be suitable for the machine – in particular with respect to the working pressure, the current connection data, the connection variables, and use in Ex-zones, if applicable. -
Page 20: Leakage
Safety 2.7.2 Leakage WARNING In case of leakage, material may escape under very high pressure and cause serious physical injuries and property damage. Stop the machine immediately and relieve the pressure. Tighten threaded connections and replace defective parts (must be performed by trained personnel). -
Page 21: Description
Description 3 Description The HERKULES HX is a hydraulically powered airless spray device, which is suitable for large-area and thick-film coatings. Airless indicates a spray process in which the processing material is applied to the surface under high pressure without an additional air supply. The atomization of the processing material is achieved solely through the material pressure and the nozzle incorporated in the spray gun. -
Page 22: Erroneous Use
WIWA (see section 2.6.1 on page 12), accessories are used that are not suitable for the machine (see section 2.6.2... -
Page 23: Construction
Description 3.3 Construction The different sizes and design variations are presented below as an example. Fig. 4: Airless Herkules HX on cart with suction hose Designation For details, see Cart Hose holder Hydraulic motor Airless device type plate section 8.2 on page 44 including QR code and section 8.4 on page 45... -
Page 24: Optional Expansions And Accessories
The detailed accessory catalog can be found at www.wiwa.de. For further infor- mation and order numbers, you can also contact an approved WIWA dealer or WIWA customer service. Original Operation Manual ✓(2023/07/19), Status: 2023/10/12... -
Page 25: Spraying Accessory Kits
Description Observe and follow the separate operation manuals for all accessories used. 3.4.1 Spraying accessory kits The spraying accessory is not part of the scope of delivery by default, since the materials used and the application areas are too diverse. In the spraying accessory kits, you will compile the best suited spraying accessories for your specific application. - Page 26 Description Observe and adhere to the separate operation manual for the material fluid heater. Original Operation Manual ✓(2023/07/19), Status: 2023/10/12 1alhh_BA_en_B0550088...
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Page 27: Transport, Installation, And Assembly
Transport, installation, and assembly 4 Transport, installation, and assembly The machine left the factory in faultless condition, packaged correctly for transport. Check the machine at the time of receipt for any transport damage and for com- pleteness. 4.1 Transport When transporting the machine, observe the following information: With cart: Tilt the machine backwards by the handle and move it on the attached transport rollers. -
Page 28: Installation Site
Transport, installation, and assembly 4.2 Installation site The machine is intended for installation outside of Ex-zones by default. Installation inside of Ex-zones is only possible with the explosion-protected version of the machine. The machine can be installed inside or outside spray booths. However, in order to avoid contamination, an external installation is preferable. -
Page 29: Assembly
Transport, installation, and assembly 4.3 Assembly WARNING If untrained personnel carry out assembly work, they endanger themselves and others, and risk the operational safety of the machine. Electrical and electronic parts may only be installed by specialist personnel with electrical training; all other parts, e. g. the spraying hose and spray gun, may only be installed by personnel trained for this. -
Page 30: Connecting The Compressed Air Supply To The Lift Truck
It must be greater than or equal to the maximum working pressure stated on the type plate. Only use conductive material hoses. All original material hoses from WIWA are conductive and designed for our machines. 1. Connect the spraying hose to the material outlet on the high pressure filter (Fig. -
Page 31: Grounding The Machine
The grounding point for the machine is located on the high pressure filter. 4.3.5 Connecting the hydraulic supply The HERKULES HX is connected to a hydraulic unit provided by the owner. Observe the connections for the hydraulic oil input and output. - Page 32 Transport, installation, and assembly The requirements for the hydraulic unit must correspond to the technical data of the HERKULES HX to be used, see section 8.1 on page 44 The following is also required to operate the machine: a hydraulic valve to regulate the oil pressure with pressure limiter,...
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Page 33: Operation
Operation 5 Operation Only put the machine into operation if you are equipped with the prescribed personal protective equipment. Details on this can be found in section 2.5.4 on page 12. The machine must be correctly installed and fully assembled. The processing material must be available in sufficient quantity. -
Page 34: Spraying
Operation 5.2 Spraying Before spraying, the work steps for commissioning must have been performed (see section 5.1 on page 27). 1. Establish the material supply. For the type with suction tube: Put the suction into the processing material. For the type with lift truck: Set the rotary knob of the lift truck to the upward movement until there is enough clearance for a material drum. - Page 35 Operation Only operate the machine with as much pres- sure as required, in order to attain good atom- ization at the recommended spray distance of approx. 30 –40 cm (12”-16”). An overly high spraying pressure increases material consumption and paint mist. If the spraying pressure is too low, this leads to streaking and varying coating thickness.
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Page 36: Tips For Good Coatings
Operation 5.2.2 Tips for good coatings Hold the spray gun at a right angle (90°) to the surface to be coated. As soon as you hold the spray gun at a different angle, the coating will become uneven and patchy (see Fig. -
Page 37: Flushing
Operation 5.3 Flushing Flushing the machine is necessary during initial commissioning so that the processing material is not influenced by the test substance with which the machine was tested for fault-free functioning in the factory. when material is changed. when work is interrupted and when decommissioning in order to flush process- ing material out of the machine during an interruption to the spray operation before it hardens. -
Page 38: Pressure Relief
Operation Set the rotary knob of the lift truck to “Stop”. Place the container with the cleaning agent under the suction of the high pressure pump. Set the rotary knob of the lift truck to the downward movement until the suction tube is completely in the container. -
Page 39: Work Interruption
The machine has been specially configured for your application case. It is necessary to check compatibility of the materials used with other materials in each individual case. WIWA is happy to help determine the suitability of your machine for another material. -
Page 40: Storage
Operation 3. Completely reduce the air inlet pressure (0 bar). 4. Close and lock the spray gun. 5. Relieve the pressure in the device (see section 5.4 on page 32). 6. After completing the work, spraying may begin with a new material (see sec- tion 5.2 on page 28). -
Page 41: Maintenance
Maintenance and repair work on electrical parts may only be performed by specialist personnel with electrical qualifications — all other maintenance and repair work may only be done by WIWA customer service or specially trained personnel. WARNING During maintenance work, ignition sources may arise (e. -
Page 42: Regular Testing
The test certificate or a copy of this must be available at the machine’s place of use. Have repair work carried out exclusively by WIWA Service or trained specialist personnel (in/from authorized workshops if necessary). When using the machine in Ex zones, the specialist personnel must have knowl- edge of ATEX. -
Page 43: High Pressure Pump
6.3.2 Filling the release agent and checking the fill level Prior to every commissioning, check the release agent level if possible. Top off the release agent if necessary. We recommend using the release agent from WIWA (order no. 0163333). Original Operation Manual ✓(2023/07/19), Status: 2023/10/12... -
Page 44: High Pressure Filter
Maintenance Description To fill the release agent, slide the cover for the filler opening to the side and press the release agent in by means of the dosing bottle. The release agent should be at the center of the inspection glass for optimal filling. Fig. -
Page 45: Filter Elements For The High Pressure Filter
Insert a filter element in the high pressure filter that is appropriate for the processing material and fits the spray nozzle. The mesh size should always be somewhat finer than the hole in the nozzle used. Filter element Nozzle size WIWA order number M 200 (white) up to 0.23 mm/.009” 0659107-200 M 150 (red) >... -
Page 46: Checking The Compressed Air, Hydraulic And Material Hoses
The duration of use of a hose line, including any possible storage duration, should not exceed 6 years. The manufacturing date of a hose line (month/year) is stamped on the ferrule. 6.6 Recommended operating fluids Only use original operating fluids from WIWA: Operating fluid WIWA order number Release agent, yellow, standard (0.5 l)¹... -
Page 47: Special Tool
Maintenance 6.7 Special tool For the assembly and disassembly of the fluid pump and high pressure filter, the HERKULES HX is equipped with the following special tool: Hook wrench WIWA order no. 80/90 0660287 110/115 0660288 Fig. 17: Hook wrench Original Operation Manual ✓(2023/07/19), Status: 2023/10/12... -
Page 48: Eliminating Operational Faults
Remove hardened material with a solvent if possible, soak parts in solvent if neces- sary, otherwise mechanically remove and replace. Contact WIWA service if necessary. Pump does not start up despite No oil pressure. Increase oil pressure. operation of the spray gun and... - Page 49 Eliminating operational faults fault possible cause remedy Pump is conveying material, but Packing or bottom valve and/or Replace parts. does not stop when the spray piston valve worn. gun is closed. Pump running smoothly, but the Oil pressure is too low. Increase oil pressure at the hy- required spraying pressure is not draulic valve and check that the...
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Page 50: Technical Information
Technical Information 8 Technical Information 8.1 Technical data Type 28003 34002 35003 48002 6001 Hydraulic motor 70/120 70/120 100/120 100/120 100/120 Fluid pump 153/120 189/120 275/120 360/120 550/120 Pressure ratio 2.4:1 3.4:1 2.6:1 1.7:1 Max. oil pressure (bar/psi) 150/2175.6 150/2175.6 133/1929 150/2175.6 150/2175.6 Max. -
Page 51: Packings
The QR code is located on the cart and on the back of this operation manual and contains a link which will direct you to machine support for your device type on the WIWA website. You can find further information for your device there, such as e.g. spare parts lists, repair instructions, etc. - Page 52 Headquarter and production WIWA Wilhelm Wagner GmbH & Co. KG Gewerbestraße 1–3 35633 Lahnau Germany Phone: +49 (0)6441 609-0 Fax: +49 (0)6441 609-2450 Email: info@wiwa.de Website: www.wiwa.de WIWA subsidiary USA WIWA LLC – USA, Kanada, Lateinamerika 107 N. Main St.
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