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 DripLessTip Guard and SwitchTip

240 VAC

232914, A

Hi-boy sprayer with hoses, gun, RAC 5 DripLessTip Guard and SwitchTip

232915, B

Lo-boy sprayer with hoses, gun, RAC 5 DripLessTip Guard and SwitchTip

120 VAC

232919, A

Hi-boy sprayer with hoses, gun, RAC 5 DripLessTip 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 DripLessTip 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

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

E F G

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

without removing tip from spray gun

to allow more flexibility when spraying

pump outlet. Works with pressure adjusting knob.

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.

) 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 Nm). 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 (32C) 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

black

yellow

107 108 22a

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.

green

white

black white

green with yellow stripe

116

Fig. 4

232918, 232915, 232919, 232914, 232665

brown

119

yellow

black red

107

108 22a

96 blue

232910 – 232913, 232916, 232917

black red

8385A

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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