Hitachi 309067 General Repair Information, Pressure Relief Procedure, Electric Shock Hazard

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General Repair Information

CAUTION

To reduce risk of pressure control malfunction:

DUse needle nose pliers to disconnect a wire. Never pull on wire, pull on connector.

DMate wire connectors properly. Center flat blade of insulated male connector in female connector.

DRoute wires carefully to avoid interference with other connections of pressure control. Do not pinch wires between cover and control box.

Tool List

Phillips screwdriver

1/4 in. hex key wrench

Small flat blade

3/16 in. hex key wrench

screwdriver

5/8 in. socket wrench

Needle nose pliers

3/8 in. open end wrench

Plastic mallet or 20 oz

1/2 in. open end wrench

(max) hammer

3/4 in. open end wrench

12 in. adjustable wrench

7/8 in. open end wrench

Adjustable, open-end

High quality motor oil

wrench

Torque wrench

Bearing grease

1.Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair proce- dures. These parts are not normally provided with replacement assemblies.

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 injec- tion, splashing fluid, or moving parts, follow Pres- sure Relief Procedure whenever you:

Dare instructed to relieve pressure,

Dstop spraying,

Dcheck or service any system equipment,

Dor 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

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Contents 309067 ULTRAr MAXAirless Paint Sprayer 232665, 232918, 232916, 232919 Component Function and IdentificationExplosion Hazard Pressure Relief ProcedureGeneral Repair Information Electric Shock HazardGrounding TroubleshootingElectrical Intermediate Problem Solving Intermediate Problem Solving Move sprayer to shaded, cooler area if 232910 232913, 232916 SetupMotor Test Armature Short Circuit TestTest brushes Motor Brushes232912 232913 232915 232917 Displacement PumpRepairing pump Removing pump SeeMotor LED Sprayer Operation Indicates What to do Blinks Motor control board diagnosticsPressure Control Repair Motor control board removal232916, 232917 Power CordOn/Off Switch Pressure Adjusting PotentiometerDrive Housing, Connecting Rod, Crankshaft Removal InstallationPressure Transducer Pressure Transducer Seal9666A Replacement Drain ValveRepair Technical Data DimensionsAccessories Complete Sprayer Parts 232915, B 232917, B232914, 232915, 232918, 232919 YExtra Warning Labels available free 232914, a 232916, a 232918, a 232919, a 101 232665, a 218359 232914 232918, a 232916, a 232919, a 232914, A, 232665, aModel 232912 and 232913, Series B Includes 55 51H 235014 ASSEMBLY, drain valve240519 CONNECTING, rod assy 243189 KIT, pump, displacementModel 232910 and 232911, Series a 239979 CRANKSHAFT, U-695236352 POTENTIOMETER, pressure adj Toll Free Graco Standard WarrantyAdditional Warranty Coverage Phone Number