Hitachi 695 309067 User Manual
INSTRUCTIONS-PARTS LIST
309067
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
ULTRA MAX 695
EUROPRO 650
Airless Paint Sprayer
3000 psi (210 bar, 21 MPa) Maximum Working Pressure
230 VAC
232918, A; 232665, A (EUROPRO)
Hi-boy sprayer with hoses, gun,
RAC 5 DripLessTip Guard and SwitchTip
240 VAC
232914, A
Hi-boy sprayer with hoses, gun,
RAC 5 DripLessTip Guard and SwitchTip
232915, B
Lo-boy sprayer with hoses, gun,
RAC 5 DripLessTip Guard and SwitchTip
120 VAC
232919, A
Hi-boy sprayer with hoses, gun,
RAC 5 DripLessTip Guard and SwitchTip
120 VAC
232910, A; 232911, A; 232912, B; 232913, B
232911 Hi–boy & 232913 Lo–boy sprayers with hoses, gun,
RAC 5 DripLessTip Guard and SwitchTip
232910 Hi–boy & 232912 Lo–boy sprayers
100 VAC
232916, A; 232917, B
Basic Hi-boy sprayer; Basic Lo-boy sprayer
232915
232917
Rev. D
First choice when
quality counts.
9659A
9660A
232918
232916
232919
232914
232665
Related Manuals
Operation 309066. . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 308815. . . . . . . . . . . . . . . . .
Fluid Filter 308249. . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Gun 309091. . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip 309055. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents
Component Function and Identification 2. . . . . . . . . . . . . . . . .
General Repair Information 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Test 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Brushes 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Control Board 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Cord 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On/Off Switch 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Adjusting Potentiometer 14. . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Drive Housing, Connecting Rod, Crankshaft 15. . . . . .
Pressure Transducer 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Transducer Seal 16. . . . . . . . . . . . . . . . . . . . . .
Drain Valve 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete Sprayer Parts 20. . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Phone Number 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Function and Identification
B
S
D
R
E
F
G
M
K
J
Fig. 1
A Motor (Under shield shown) DC motor, permanent magnet, totally enclosed, fan cooled
B Pressure Adjusting Knob Controls fluid outlet pressure
C ON/OFF Switch Power switch that controls VAC main power to sprayer
D Drive Assembly Transfers power from DC motor to the displacement pump
E Fluid Filter Filter of fluid between source and spray gun
F Fluid Outlet Main hose to spray gun is connected here
G Pail Hanger Container for fluid to be sprayed may be hung here
H Displacement Pump Transfers fluid to be sprayed from source through spray gun
J 50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends
K RAC 5 Tip Guard Reverse-A-Clean (RAC) tip guard reduces the risk of fluid injection injury
L Contractor Gun High pressure spray gun with gun safety latch
M RAC 5 Switch Tip RAC switch tip uses high pressure fluid to remove clogs from spray tip
N 3 ft (0.9 m) Hose 3/16 in. ID, grounded, nylon hose used between 50 ft hose and spray gun
P Pressure Drain Valve Relieves fluid outlet pressure when open; diverts fluid to drain line
R Pressure Control Controls motor speed to maintain fluid outlet pressure at displacement
S Spray Gun Safety Latch Inhibits accidental triggering of spray gun
232665, 232918, 232916, 232919 and 232914
L
without removing tip from spray gun
to allow more flexibility when spraying
pump outlet. Works with pressure adjusting knob.
H
N
A
C
R
P
9661A
2 309067
General Repair Information
CAUTION
To reduce risk of pressure control malfunction:
Use needle nose pliers to disconnect a wire. Never
pull on wire, pull on connector.
Mate wire connectors properly. Center flat blade of
insulated male connector in female connector.
Route wires carefully to avoid interference with
other connections of pressure control. Do not pinch
wires between cover and control box.
Tool List
Phillips screwdriver
Small flat blade
screwdriver
Needle nose pliers
Plastic mallet or 20 oz
(max) hammer
12 in. adjustable wrench
Adjustable, open-end
wrench
Torque wrench
1. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair procedures. These parts are not normally provided with
replacement assemblies.
1/4 in. hex key wrench
3/16 in. hex key wrench
5/8 in. socket wrench
3/8 in. open end wrench
1/2 in. open end wrench
3/4 in. open end wrench
7/8 in. open end wrench
High quality motor oil
Bearing grease
WARNING
ELECTRIC SHOCK HAZARD
To reduce risk of serious injury, including
electric shock, do not touch moving or
electrical parts with fingers or tools while
testing repair. Shut off and unplug sprayer when
inspection is complete. Install all covers, gaskets,
screws and washers before operating sprayer.
2. Test repair after problem is corrected.
3. If sprayer does not operate properly, review
repair procedure to verify procedure was done
correctly. If necessary, see Troubleshooting,
page 4, for other possible solutions.
WARNING
EXPLOSION HAZARD
Motor and drive housing are very hot
during operation and could burn skin if
touched. Flammable materials spilled on
hot, bare motor could cause fire or explosion. Have
motor shield in place during operation to reduce
risk of burns, fire or explosion.
CAUTION
Do not run sprayer dry for more than 30 seconds to
avoid damaging pump packings.
4. Install motor shield before operation of sprayer
and replace if damaged. Motor shield directs
cooling air around motor to prevent overheating. It
can also reduce risk of burns, fire or explosion; see
preceding WARNING.
Pressure Relief Procedure
WARNING
INJECTION HAZARD
System pressure must be manually
relieved to prevent system from starting
or spraying accidentally. Fluid under high
pressure can be injected through skin and cause
serious injury. To reduce risk of injury from injection, splashing fluid, or moving parts, follow Pres-
sure Relief Procedure whenever you:
are instructed to relieve pressure,
stop spraying,
check or service any system equipment,
or install or clean spray tip.
1. Lock gun safety latch.
2. Turn ON/OFF switch to OFF.
3. Unplug power cord.
4. Unlock gun safety latch. Hold metal part of gun
firmly to grounded metal pail. Trigger gun to relieve
pressure.
5. Lock gun safety latch.
6. Open pressure drain valve. Leave pressure drain
valve open until ready to spray again.
If suspected that spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following steps above, VERY SLOWLY loosen tip
guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Now clear
tip or hose obstruction.
309067 3
Grounding
WARNING
Improper installation or alteration of grounding plug
results in risk of electric shock, fire or explosion
that could cause serious injury or death.
1. The 232918, 232665, 232915, 232914 require a
230 VAC, 50 Hz, 10A circuit with a grounding
receptacle. The 232919 requires a 120 VAC, 50/60
Hz, 15A circuit with a grounding receptacle. The
232916, 232917 require a 100 VAC, 50 Hz, 15A
circuit with a grounding receptacle. The 232910 –
232913 require 120 VAC, 60 HZ, 15A with a
grounding receptacle. See Fig. 2.
2. Do not alter ground prong or use adapter.
Troubleshooting
Relieve pressure; page 3.
Basic Problem Solving
Grounding Plug
230 VAC plug and outlet
Grounded
Outlets
Fig. 2
3. A 12 AWG, 3 wires with grounding prong, 300 ft
(90 m) extension cord may be used. Long lengths
reduce sprayer performance.
9248A
TYPE OF
PROBLEM
Fluid Pressure 1. Pressure control knob setting. Motor will not run if at mini-
Mechanical 1. Frozen or hardened paint in pump (18). Use a screwdriver
Electrical 1. Electrical supply with volt meter.
WHAT TO CHECK
If check is OK, go to next check
mum setting (fully counterclockwise).
2. Clogged spray tip or fluid filter, if used. Refer to separate
gun, tip or fluid filter instruction manual.
and carefully rotate fan at back of motor. See page 12.
2. Pump connecting rod pin (14). Pin must be completely
pushed into connecting rod (12), and retaining spring (15)
must be firmly in connecting rod groove. See Fig. 9, page
11.
3. For motor damage. Remove drive housing assembly (2).
See page 15. Try to rotate motor
fan by hand.
Meter must read 90–110 VAC for 232916, 232917.
Meter must read 105–125 VAC for 232910 – 232913,
232919.
Meter must read 210–250 VAC for 232918, 232915,
232914, 232665.
2. Extension cord for damage. Check extension cord continuity with volt meter.
WHAT TO DO
When check is not OK, refer to this column
1. Slowly increase pressure setting to see if
motor starts.
2. If tip is still clogged, relieve pressure;
refer to separate gun or tip instruction
manual for tip cleaning. Clean or replace
filter element. See manual 308249.
1. Thaw sprayer if water or water-based
paint has frozen in sprayer. Place sprayer in warm area to thaw. Do not start
sprayer until completely thawed. If paint
hardened (dried) in sprayer the pump
packings and/or pressure transducer
must be replaced. See page 11 (pump)
or 16 (pressure transducer).
2. Push pin into place and secure with
spring retainer.
3. Replace motor (85) if fan won’t turn. See
page 12.
1. Reset building circuit breaker; replace
building fuse. Try another outlet.
2. Replace extension cord.
4 309067
3. Sprayer power cord (30) for damage such as broken insulation or wires.
3. Replace power cord. See page 14.
Basic Problem Solving
TYPE OF
PROBLEM
Electrical
(continued)
WHAT TO CHECK
If check is OK, go to next check
4. Motor brushes for the following:
a. Loose terminal screws.
b. Broken or misaligned brush springs.
c. Brushes binding in holders.
d. Broken leads.
e. Worn brushes.
f. Brush leads snagged on spring clip.
NOTE: Brushes do not wear at same rate on both
sides of motor. Check both brushes.
5. Motor armature commutator for burn spots, gouges and
extreme roughness. Remove motor cover and brush inspection plates to check. See page 10.
6. Motor armature for shorts using armature tester (growler)
or perform motor test. See page 9.
7. That leads from pressure transducer and motor to motor
control board (22a) are securely fastened and properly
mated.
WHAT TO DO
When check is not OK, refer to this column
4. Refer to page 10.
a. Tighten.
b. Replace broken spring and/or align
spring with brush
c. Clean brush holders. Remove carbon
with small cleaning brush. Align brush
leads with slot in brush holder to as-
sure free vertical brush movement.
d. Replace brushes
e. Replace brushes if less than 0.5 in.
(12.5 mm) long.
f. Correctly route wires. See page 10.
5. Remove motor and have motor shop
resurface commutator if possible.
See page 12.
6. Replace motor. See page 12.
7. Replace loose terminals; crimp to leads.
Be sure male terminal blades are straight
and firmly connected to mating part.
8. Motor control board (22a) by performing motor control
board diagnostics on page 13. If diagnostics indicate, substitute with a good board.
CAUTION: Do not perform this check until motor armature
is determined to be good. A bad motor armature can burn
out a good board.
9. Power cord (30).
232918, 232915, 232914, 232665. Disconnect brown and
blue power cord terminals; connect volt meter to these
leads.
Plug in sprayer. Meter must read 210–250 VAC.
232910 – 232913, 232919. Disconnect brown and blue
power cord terminals; connect volt meter to these leads.
Plug in sprayer. Meter must read 105–125 VAC.
232916, 232917.Disconnect black and white power cord
terminals; connect volt meter to these leads.
Plug in sprayer. Meter must read 90–110 VAC.
Unplug sprayer.
10. ON/OFF switch (80).
232918, 232915, 232914, 232665. Disconnect brown wire
(96) between motor control board (22a) and switch and
connect volt meter between exposed terminal switch and
power cord blue wire (94). Plug in sprayer and turn ON.
Meter must read 210–250 VAC.
232910 – 232913, 232919. Disconnect brown wire (96)
between motor control board (22a) and switch and connect volt meter between exposed terminal switch and
power cord blue wire (94). Plug in sprayer and turn ON.
Meter must read 105–125 VAC.
232916, 232917.Disconnect black wire (96) between
motor control board (22a) and switch and connect volt
meter between exposed terminal of (96) and power cord
white wire. Plug in sprayer and turn ON.
Meter must read 90–110 VAC.
Turn OFF and unplug sprayer.
8. Replace board. See page 13.
9. Replace power cord.
See page 14.
10. Replace ON/OFF switch. See page 14.
309067 5
Basic Problem Solving
TYPE OF
PROBLEM
WHAT TO CHECK
If check is OK, go to next check
11. Motor thermal cutout switch. Connect ohmmeter between
motor yellow leads. Meter must read 1 ohm maximum.
12. Pressure transducer (67) by replacing it with a new one. 12.Replace pressure transducer.
13. Pressure adjustment potentiometer (77) by replacing it
with a new one.
WHAT TO DO
When check is not OK, refer to this column
11. Allow motor to cool. Correct cause of
overheating. If switch remains open after
motor cools, replace motor.
See page 16.
13.Replace potentiometer. See page 14.
Intermediate Problem Solving
TYPE OF
PROBLEM
Low output 1. For worn spray tip. 1. Follow Pressure Relief Procedure
WHAT TO CHECK
If check is OK, go to next check
2. Verify pump does not continue to stroke when gun trigger
is released. Plug in and turn on sprayer. Prime with paint.
Trigger gun momentarily, then release and engage safety
latch. Relieve pressure, turn off and unplug sprayer.
3. Release gun trigger. Observe resting position of pump rod
(222).
WHAT TO DO
When check is not OK refer to this column
Warning on page 3, then replace tip.
See your separate gun or tip manual.
2. Service pump. See page 11.
3. If pump consistently comes to rest
with rod (222) fully extended, the piston
packings and/or piston valve may be
worn. Service pump. See page 11.
Low output
(continued)
4. Electrical supply with volt meter.
Meter must read 90–110 VAC for 232916, 232917.
Meter must read 105–125 VAC for 232910 – 232913,
232919
Meter must read 210–250 VAC for 232918, 232915,
232914, 232665.
5. Extension cord size and length; must be at least 12 AWG
(1.5 mm
6. Motor brushes. See Electrical – What To Check, item 4, on
page 5.
7. Motor control board (22a) by substituting with a good
board.
CAUTION: Do not perform this check until motor armature
is determined to be good. A bad motor armature can burn
out a good board.
8. Motor armature for shorts by using an armature tester
(growler) or perform motor test. See page 9.
2
) and no longer than 300 ft (90 m).
4. Reset building circuit breaker; replace
building fuse. Repair electrical outlet or
try another outlet.
5. Replace with a correct, grounded extension cord.
6. See page 10.
7. Replace board. See page 13.
8. Replace motor. See page 12
.
6 309067
Intermediate Problem Solving
TYPE OF
PROBLEM
Drain valve
leaks
No output:
motor runs
and pump
strokes
WHAT TO CHECK
If check is OK, go to next check
1. Drain valve for correct torque and/or worn parts. Check for
debris trapped on seat.
1. Paint supply. 1. Refill and reprime pump.
2. For clogged intake strainer. 2. Remove and clean, then reinstall.
3. For loose suction tube or fittings. 3. Tighten; use thread sealant on
4. To see if intake valve ball and piston ball are seating
properly. See page 11.
5. For leaking around throat packing nut which may indicate
worn or damaged packings. See page 11.
6. Release gun trigger. Observe resting position of pump rod
(222).
WHAT TO DO
When check is not OK, refer to this column
1. Tighten to 185 in-lb (21 Nm). Clean
valve and replace with new gasket (55)
and sealant 110–110. See page 18.
npt threads of adapter fitting (43).
4. Remove intake valve and clean. Check
ball and seat for nicks; replace as needed. See page 11. Strain paint before using to remove particles that could clog
pump.
5. Replace packings. See page 11. Also
check piston valve seat for hardened
paint or nicks and replace if necessary.
Tighten packing nut.
6. If pump consistently comes to rest
with rod (222) fully extended, piston
packings and/or piston valve may be
worn. Service pump. See page 11.
No output:
motor runs but
pump does not
stroke
Spray pattern
variations
1. Displacement pump connecting rod pin (14).
See Fig. 9, page 11.
2. Connecting rod assembly (12) for damage. See page 15. 2. Replace connecting rod assembly. See
3. Be sure crank in drive housing rotates; plug in sprayer and
turn on briefly to check. Turn off and unplug sprayer.
See page 15.
1. Spray tip worn beyond sprayer pressure capability. 1. Replace spray tip.
2. Motor control board (22a) by performing motor control
board diagnostics on page 13. If diagnostics indicate, substitute with a good board.
CAUTION: Do not perform this check until motor armature
is determined to be good. A bad motor armature can burn
out a good board.
1. Replace pin if missing. Be sure retainer
spring (15) is fully in groove all around
connecting rod.
page 15.
3. Check drive housing assembly for damage and replace if necessary. See
page 15.
NOTE: Smaller size tip provides
longer life.
2. Replace board. See page 13.
309067 7
Intermediate Problem Solving
TYPE OF
PROBLEM
Spray pattern
variations
(continued)
Motor is hot and
runs intermittently
Building circuit
breaker opens
as soon as
sprayer switch is
turned on.
WHAT TO CHECK
If check is OK, go to next check
3. Pressure adjustment potentiometer (77) by replacing
with a new one.
4. Low Output section, page 6.
1. Determine if sprayer was operated at high pressure with
small tips, which causes excessive heat build up.
2. Be sure ambient temperature where sprayer is located is
no more than 90
direct sun.
3. Motor. 3. Replace motor. See page 12.
1. All electrical wiring for damaged insulation,
and all terminals for loose fit or damage.
Also check wires between pressure transducer
and motor. See page 12.
2. For missing motor brush inspection plate gasket (see
page 10), bent terminal forks or other metal to metal
contact points which could cause a short.
3. Motor armature for shorts. Use an
armature tester (growler) or perform motor test.
See page 9. Inspect windings for burns.
4. Motor control board (22a) by performing motor control
board diagnostics on page 13. If diagnostics indicate,
substitute with a good board.
F (32C) and sprayer is not located in
WHAT TO DO
When check is not OK, refer to this column
3. Replace potentiometer. See page 14..
1. Decrease pressure setting or increase tip
size.
2. Move sprayer to shaded, cooler area if
possible.
1. Repair or replace any damaged wiring or
terminals. Securely reconnect all wires.
2. Correct faulty conditions.
3. Replace motor. See page 12.
4. Replace board. See page 13.
Circuit breaker
opens after
sprayer operates for 5 to 10
minutes.
Building circuit
breaker opens
as soon as
sprayer is
plugged into
outlet and
sprayer is not
turned on.
Unit will not run
on generator but
does run on AC
power
CAUTION: Do not perform this check until motor armature is determined to be good. A bad motor armature
can burn out a good board
1. Basic Problems – Electrical’ on page 4.
1. ON/OFF switch (80). Be sure sprayer is unplugged!
Disconnect wires from switch. Check switch with
ohmmeter. The reading should be infinity with ON/OFF
switch OFF, and zero with switch ON.
CAUTION: A short in motor circuit can damage switch
and or motor control board (22a).
2. For damaged or pinched wires in junction box (20). 2. Replace damaged parts.
1. Generator “peak” voltage.
Sprayer will not run if peak voltage is above 165 or below 75 VAC for 232916, 232917; above 190V or below
100V for 232910 – 232913, 232919 or above 260V or
below 180V for 232918, 232915, 232914, 232665.
1. Replace ON/OFF switch. See page 14.
1. Use AC power or a different generator.
8 309067
Motor Test
Relieve pressure; page 3.
For checking armature, motor winding and brush
electrical continuity.
Setup
1. Unplug sprayer.
2. Remove drive housing. See page 15. This ensures
that any resistance noticed in armature test is due
to motor and not to worn gears in drive housing.
Armature Short Circuit Test
1. Remove fan cover (B). See Fig.3.
2. Spin motor fan by hand. If there are no shorts,
motor coasts two or three revolutions before
coming to complete stop. If motor does not spin
freely, armature is shorted and motor must be
replaced. See page 12.
Armature, Brushes, and Motor Wiring
Open Circuit Test (Continuity)
1. Fig. 4 Connect red and black motor leads (C)
together with a test lead. Turn motor fan by hand
at about two revolutions per second.
brown
80
black
D
yellow
96
107
108
22a
67
3. Fig. 3. Remove brush inspection covers (A).
4. Fig.4. Remove screws (25, 26). Lower control
board (22a). Disconnect two leads (C) from motor
to board.
B
A
green
30
white
80
black
white
green
with yellow
stripe
116
Fig. 4
232918, 232915, 232919, 232914, 232665
78
brown
119
yellow
C
black red
C
107
E
108
22a
96
blue
E
232910 – 232913, 232916, 232917
D
78
black red
77
8385A
67
77
8386A
Fig. 3
02991
2. If uneven or no resistance, check for: broken brush
springs, brush leads, motor leads; loose brush
terminal screws or motor lead terminals; worn
brushes. See page 10.
3. If still uneven or no resistance, replace motor;
page 12.
309067 9
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