Graco RTX 900 Operating instructions

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2006, Graco Inc. is registered to I.S. EN ISO 9001
For Water-Based Materials Only
Models: 254974 and 254975
70 psi (0.49 MPa, 4.9 bar)
Maximum Fluid Working Pressure
Related Manuals
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
311777
311768
Model 254975 Shown
ti8867a
311772G
Repair
Interior Texture Sprayers
RTX 900 & RTX 1250
U
S
C
Conforms to ANSI/UL
standard 1450

Warnings
2311772G
Warnings
The following are general warnings related to the setup, use, grounding, maintenance and repair of this equipment.
Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols
appearing in the body of the manual refer to these general warnings. When these symbols appear through the
manual, refer back to these pages for a description of the specific hazard.
Warnings
Fire and Explosion Hazard
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result
in fire or explosion and serious injury.
• The system is for use with water-based materials only. Only use fluids compatible with the
equipment. Refer to Technical Data of all equipment manuals. Read fluid and solvent manufacturers
warnings.
• Ground all equipment in the work area. See Grounding and Electrical Requirements, page 6.
• If there is any static sparking or you feel an electric shock while using this equipment, stop spraying
immediately. Do not use the equipment until you identify and correct the problem.
• Keep work area free of debris, including solvent, rags and gasoline.
• Comply with all applicable state and national fire, electrical and safety regulations.
• Keep a fire extinguisher in the work area.
Equipment Misuse Hazard
Equipment misuse can cause equipment to rupture, malfunction, or start unexpectedly and cause serious
injury.
• Before operating this equipment, read all manuals, tags, and labels, including material labels and
instructions.
• Do not expose system to rain. Always store system indoors.
• Do not alter or modify equipment.
• Do not spray cementitious materials.
• Do not exceed maximum working pressure of lowest rated component in your system.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• To reduce risk of serious injury, including electric shock and splashing fluid in eyes, follow Pressure
Relief Procedure on page 6 before servicing the unit.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Route hoses away from traffic areas, sharp edges, moving parts and hot surfaces. Do not expose
Graco hoses to temperatures above 130° F (55° C) or below -35° F (-37° C).
• Air hoses at the compressor end, can get very hot! Allow sprayer to cool down 15 minutes before
removing air hose.
• Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
• Never directly inhale compressed air. Compressed air may contain toxic vapors.

Warnings
311772G 3
Electric Shock Hazard
To reduce the risk of electric shock:
• Be sure sprayer is adequately grounded through electrical outlet, page 6.
• Use only 3-wire, extension cords.
• Make sure ground prongs are intact on sprayer and extension cords.
• Do not operate with cover removed.
• Turn off sprayer. Follow Pressure Relief Procedure, page 6, and unplug unit, before removing any
parts.
Pressurized Equipment Hazard
Fluid from gun, leaks or ruptured components can splash in the eyes or on skin and cause serious injury.
• Follow Pressure Relief Procedure, page 6 when you stop spraying and before cleaning, checking
or servicing.
• Do not point spray gun at anyone; put hand, fingers or rag over nozzle, or stop or deflect leaks with
your hand, body, glove, or rag.
• Wear protective clothing, gloves, and eyewear.
Cleaning Solvent Hazard with Plastic Parts
Use only compatible water-based solvents to clean plastic structural or pressure-containing parts. Many
solvents can degrade plastic parts to the point where they could fail. Such failure could cause serious
injury or property damage. See Technical Data on page 33 of this instruction manual and in all other
equipment manuals. Read fluid and solvent manufacturer’s warnings.
Burn Hazard
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns,
do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
Personal Protective Equipment
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
• Gloves
• Hearing Protection
Warnings

Warnings
4311772G
CAUTION
Water or material remaining in unit when temperatures are below freezing can damage
motor and/or delay pump startup.
To insure water and material are completely drained out of unit:
1. Remove material line from sprayer.
2. Tip sprayer up as shown.
Before adding material or starting unit in cold weather, run warm water through pump.
Before adding material to hopper, install burp guard. When only a small amount of material
remains in the hopper, the burp guard prevents material from shooting out when the unit is
turned off. This material could splash in the operator’s eyes or on skin, or into the air.
ti9016a
ti9010a

Component Identification
311772G 5
Component Identification
Item Component Item Component
A Handle N Burp Guard
B Toolbox P Material/Air Hose
C Power Cord (120V, 25 ft) Q Accessories Bag
D Side Pump Access Panel (RTX 1250 Only) R Material Thickness Gauge
ERotoFlex™II Pump (inside) SNozzle(4Total)
F Pump Hose Outlet T Hose Plug
G Air Hose Outlet U Touch-Up Hopper (3/4 gallon)
H Material Flow Gauge V Gun Plug
J Material Flow Control W Air Control
K ON/OFF Switch bb Hopper Clamp
L Selector Switch (Hopper Gun/Sprayer) cc Gun Plug Clip
M Material Hopper - 10 gallon, RTX 900
Material Hopper - 12 gallon, RTX 1250
dd Hopper Gun
M
D
F
A
G
C
L
Model 254975 Shown
E
K
U
T
V
B
S
W
R
P
bb
N
H
J
ti8939a
cc
dd

Component Identification
6311772G
Pressure Relief Procedure
To reduce risk of injury, follow this procedure
whenever you see this symbol throughout this
manual, Also, perform this procedure whenever
you:
• Stop spraying
• Check or repair any part of this system
• Install or clean spray nozzle
1. Turn Power Switch OFF.
2. Trigger gun into material hopper.
3. Open gun air valve.
Grounding and Electrical
Requirements
This sprayer must be grounded. Grounding reduces the
risk of electrical shock by providing an escape wire for
the electrical current. The sprayer cord includes a
grounding wire with an appropriate grounding plug. The
plug must be plugged into an outlet that is properly
installed and grounded in accordance with all local
codes and ordinances.
Check with a qualified electrician or if grounding
instructions are not completely understood, or if in doubt
as to whether the product is properly grounded. Do not
modify plug provided; if it will not fit the outlet, have
proper outlet installed by a qualified electrician.
120V AC Systems
• This equipment requires a 120V AC, 60 Hz, 15A
circuit with a grounding receptacle. Do not use an
adapter with this product.
Extension Cords
• Use only an extension cord with an undamaged,
3-prong plug.
• For 25 to 50 ft (7.6 to 15.2 m) cords, use 3-wire, 14
AWG (1.5 mm2) minimum.
• For up to 100 ft. (30.48 m) cord, use 3-wire, 12 AWG
(2.5 mm2) minimum.
Auxiliary Air Compressor
Do not use an auxiliary air compressor with this spray
system.
Generator Requirements
3500 W (3.5 KW) minimum.
Hose Size and Length
The system comes with a hose set consisting of a 3/4 in.
ID x 25 ft (25 mm x 7.6 m) material hose and a 3/8 in-ID
air hose.
ti9221a
ti9084a
ti8528a

Shroud Removal
311772G 7
Shroud Removal
Disassembly
1. Relieve Pressure, page 6.
2. Unplug sprayer from outlet.
3. Loosen bottom hopper fitting by hand and pull
hopper up and off from handle.
4. Loosen and remove 2 knobs (14) on sprayer handle
(12).
5. Spread handle bars apart and pull up to remove
from sprayer.
6. Loosen screws (30) and screw (31) from toolbox
and remove toolbox (2) from sprayer.
7. Loosen screws (31) on shroud.
8. Loosen and remove screw (70) from lower right cor-
ner of side access panel (RTX1250) only.
9. Loosen knob (42) on side access panel and swing
open door.
10. Use screwdriver to remove second screw (30).
11. Remove two shroud halves (5 and 7) from sprayer.
ti2810b
ti8871a
ti8875a
14
12
ti8884a
31
2
30
ti8882a
31
70
ti8874a
ti8872a
42
ti9283a
30
ti8883a
57

Shroud Removal
8311772G
Reassembly
1. Angle left shroud half (5) into base and push down
into place. Then replace right shroud half (7).
2. Replace and tighten second screw (30).
3. Swing access door down (RTX 1250) and tighten
knob (42).
4. Tighten screw (70) into lower right corner of side
access plate.
5. Replace toolbox (2) and tighten screws (30) and
screw (31).
6. Tighten screws (31) on shroud.
7. Spread handle bars apart and slide handle down
into place.
8. Tighten 2 knobs (14) on sprayer handle (12).
9. Replace hopper and tighten hopper fitting by hand
until snug.
ti9015a
5
ti9283a
30
42
ti8938a
ti8874a
70
ti8884a
31
2
30
ti8882a
31
ti8875a
14
12

RotoFlex™ II Pump (RTX 900)
311772G 9
RotoFlex™ II Pump (RTX 900)
Disassemble
1. Relieve Pressure, page 6.
2. Unplug sprayer from outlet.
3. Remove Shroud, page 7.
4. Loosen and remove screw (28) on hose bracket.
5. Remove hose bracket (25).
6. Slide pump fittings over and push through keyhole
slots.
7. Grab pump hose (16) from side of unit and remove
pump hose by hand.
Reassemble
1. Bend hose (16) so colored dots on hose fittings face
each other.
2. Slide new pump hose (16) over rollers. Move pump
rollers by hand until or flip power switch to rotate
rollers until they are positioned correctly with pump
hose.
3. Feed pump fittings through front access panel
keyhole slots and slide into place.
4. Replace hose bracket (25) to lock pump hose fit-
tings into place.
5. Replace hose bracket (25) and tighten screw (28).
6. Replace Shroud, page 7.
7. Break in new pump by adding 1 cup of water to
pump and running dry for 3 minutes.
ti2810b
28
ti9009a
ti8881a
25
ti8869a
16
ti8949a
ti9331a
ti8868a

RotoFlex™ II Pump (RTX 1250)
10 311772G
RotoFlex™ II Pump (RTX 1250)
Disassemble
1. Relieve Pressure, page 6.
2. Unplug sprayer from outlet.
3. Loosen knob (42) on side access panel.
4. Remove screw (70) from side access panel.
5. Pull access panel (13) out to release 3 fastening
tabs and flip up to expose side access to pump.
6. Loosen and remove knob (42) on hose bracket (25).
7. Remove hose bracket (25).
8. Slide pump fittings over and through keyhole slots.
9. Grab pump hose (16) from side access panel and
remove pump hose from unit.
ti2810b
ti8870a
42
70
ti8874a
ti8872a
13
42
ti8945a
25
ti9288a
25
ti8869a
16
ti9333a

RotoFlex™ II Pump (RTX 1250)
311772G 11
Reassemble
1. Bend hose (16) so colored dots on hose fittings face
each other.
2. Slide new pump hose (16) in from side access
panel. Move pump rollers by hand until or flip power
switch to rotate rollers until they are positioned cor-
rectly with pump hose.
3. Replace hose bracket (25) to lock pump hose into
place.
4. Tighten hose bracket knob (42).
5. Flip side access panel (13) down and tighten knob
(42).
6. Replace and tighten screw (70) from side access
panel.
7. Break in new pump by adding 1 cup of water to
pump and running dry for 3 minutes.
ti9331a
ti8868a
ti9288a
25
42
ti8945a
42
ti8938a
70
ti8874a

Compressor
12 311772G
Compressor
Use Compressor Repair Kit, 288612.
Disassembly
1. Relieve Pressure, page 6.
2. Unplug sprayer from outlet.
3. Remove Shroud, page 7.
4. Remove RotoFlex™II Pump hose; page 9 or 10.
5. Unscrew and remove grounding screw (49) from
compressor.
6. Use 9/16 in. socket and wrench to remove pivot bolt
(26) and nut (27).
7. Unscrew and remove second 1/2 in. grounding
screw (49) from bracket (21).
8. Remove 4 screws (29) and lift bracket (21) off of
compressor.
9. Remove shoulder bolt (49) holding pump roller in
place.
10. Use a wrench to push down on push-to-connect
fittings and pull out all nylon hoses.
11. Disconnect all electrical wire connectors, see
Wiring Diagram, page 27.
12. Thoroughly clean inside housing, removing dust and
debris.
To service the compressor, remove it from the sprayer
body and place it a vice. Tighten the vice onto the main
pulley to hold the compressor in place while servicing.
ti2810b
49
ti8941a
ti8878a
26
27
49
ti9013a
ti8877a
29
21
ti8879a
49
ti8952a
ti8951a

Compressor
311772G 13
Reassembly
1. Carefully position compressor back into sprayer
body. Make sure piston head facing front of sprayer.
2. Replace and tighten grounding screw (49).
3. Reattach air lines to compressor.
4. Reattach 2 wires to compressor see Wiring
Diagram, page 27.
5. Replace air cylinder and tighten shoulder bolt (49) to
lock into place.
6. Replace bracket (21) and tighten 4 screws (29).
7. Replace grounding screw (49) and tighten onto
bracket (21).
8. Replace pivot bolt (26) and nut. Use 9/16 in. socket
and wrench to tighten into place. Tighten screw until
spring washers are flattened.
9. Replace and tighten second grounding screw (49) to
bracket (21).
10. Replace RotoFlex™II Pump hose; page 9 or 10.
11. Replace Shroud, page 7.
ti8940a
ti8950a
49
ti8941a
ti8873a
ti8879a
49
ti8877a
29
21
ti8878a
26
49
ti9013a
21

Piston/Cylinder
14 311772G
Piston/Cylinder
Use Piston/Cylinder Repair Kit 288609.
Disassembly
1. Relieve Pressure, page 6.
2. Unplug sprayer from outlet.
3. Remove Shroud, page 7.
4. Remove RotoFlex™II Pump hose; page 9 or 10.
5. Remove Compressor, page 12.
6. Remove muffler (110) from head (74) by pulling
straight out by hand.
7. Use 1/2 in. socket to remove three bolts (100) from
head (74).
8. Use flat-blade screwdriver to pry head (74) from top
of valve plate (75) and cylinder (76) from bottom of
valve plate (75).
9. Use 7/32 in. allen wrench to remove hex screw (87)
from piston rod (77).
ti2810b
100
74
75
76
110
ti8887a
ti8893a
87
77

Piston/Cylinder
311772G 15
Reassembly
1. Replace piston (77) and cylinder (76) and use 7/32
in. allen wrench to tighten hex screw (87) into piston
rod.
2. Replace valve plate (75) with ribs facing up toward
head.
3. Replace three bolts (100) and use 1/2 in. socket to
tighten into head (74). Torque all three bolts to 75
in-lb, then torque all bolts again to 210 in-lb.
4. Position muffler (110) as seen below and press onto
head (74) until it snaps into place.
5. Replace Compressor, page 12.
6. Replace RotoFlex™II Pump hose; page 9 or 10.
7. Replace Shroud, page 7.
CAUTION
Piston and cylinder come packaged
together. Do NOT let piston and cylinder
come apart. If they do, make sure you
drop the piston down through the top of
the cylinder and tilt the piston as you
pull it through the cylinder. Do NOT
push the piston up from the bottom. You
could easily damage the piston gasket. ti8943a
ti8893a
87
77
100
74
75
76
110
ti8887a

Valve Plate
16 311772G
Valve Plate
Use Valve Plate Repair Kit 288610.
Disassembly
1. Relieve Pressure, page 6.
2. Unplug sprayer from outlet.
3. Remove Shroud, page 7.
4. Remove RotoFlex™II Pump hose; page 9 or 10.
5. Remove Compressor, page 12.
6. Remove muffler (110) from head (74) by pulling
straight out by hand.
7. Use 1/2 in. socket to loosen and remove three bolts
(100) from head (74).
8. Use flat-blade screwdriver to pry head (74) from top
of valve plate (75) and cylinder (76) from bottom of
valve plate (75).
Reassembly
1. Replace valve plate (75) with ribs facing up toward
ribs on head (74).
2. Replace three bolts (100) and use 1/2 in. socket to
tighten into head (74). Torque all three bolts to 75
in-lb, then torque all bolts again to 210 in-lb.
3. Replace Compressor, page 12.
4. Replace RotoFlex™II Pump hose; page 9 or 10.
5. Replace Shroud, page 7.
ti2810b
100
74
75
76
110
ti8887a

Motor
311772G 17
Motor
Use Motor Repair Kit 288613.
Disassembly
1. Relieve Pressure, page 6.
2. Unplug sprayer from outlet.
3. Remove Shroud, page 7.
4. Remove RotoFlex™II Pump hose; page 9 or 10.
5. Remove Compressor, page 12.
6. Remove compressor from sprayer body and place it
in a vice. Tighten the vice onto the main pulley to
hold the compressor in place while servicing motor.
7. Loosen set screw and remove fan (72).
8. Use a box end wrench to loosen and remove two
mounting bolts (105) on motor (71).
9. Angle motor (71) and slide motor pulley through
compressor belt to remove motor from compressor.
10. Use 7/32 in. allen wrench to remove hex screw (87)
from piston rod (77).
11. Remove compressor belt (84).
ti2810b
ti8951a
ti8892a
72
CAUTION
Be careful not to bend or damage the cooling tube
when removing it from the motor.
Compressor belt (84) should be replaced every
time motor is replaced.
ti8891a
105
71
ti9012a
71
ti8893a
87
77
84
ti8894a

Motor
18 311772G
Reassembly
1. Angle motor pulley through compressor belt (84)
and pull motor (71) into position.
2. Tighten two mounting bolts (105) on motor (71) until
snug, then back 1/8 of a turn.
3. Insert torque wrench into square hole (SQ) on motor
and tighten bolts to 130-150 in-lb (this may require
two people; one to torque while the other tightens
mounting bolts). Tighten motor bolts (105).
4. Take compressor out of vice and rotate pump pulley
(104) one full revolution to seat the belt properly.
5. Place compressor back into vice and torque bolts as
described in steps 2 and 3.
6. Replace fan (72) and tighten set screw.
7. Replace Compressor; page 12.
8. Replace RotoFlex™II Pump hose; page 9 or 10.
9. Replace Shroud, page 7.
When replacing motor (71), make sure the
square-shaped hole (SQ) is facing toward the out-
side of the compressor. This hole will be used to
torque the mounting bolts.
SQ
ti8890a
71
84
ti8891a
105 71
ti8896a
104
ti8892a
72

Cooling Tube
311772G 19
Cooling Tube
Use Cooler Repair Kit 288614.
Disassembly
1. Relieve Pressure, page 6.
2. Unplug sprayer from outlet.
3. Remove Shroud, page 7.
4. Remove RotoFlex™II Pump hose; page 9 or 10.
5. Remove Compressor, page 12.
6. Use 3/8 in. socket to remove screw (101) and
washer (102) under cooling tube (79).
7. Use wrench to push against fitting (86) and carefully
pull cooling tube (79) out.
8. Use 5/8 in. wrench to unscrew cooling tube fitting.
The cooling tube is extremely hot and can cause
serious burns. Allow unit to completely cool before
servicing the cooling tube.
ti2810b
ti8886a
101
102
79
ti8952a
ti8944a

Cooling Tube
20 311772G
Reassembly
1. Insert new cooling tube fitting and use 5/8 in.
wrench to tighten.
2. Insert cooling tube (79) and push into new fitting
(86). Make sure tube is fully seated.
3. Rotate cooling tube around and insert free end into
push-to-connect fitting. Make sure tube is fully
inserted.
4. Replace screw (101) and washer (102) under cool-
ing tube (79) and use 3/8 in. socket to tighten.
5. Replace Compressor; page 12.
6. Replace RotoFlex™II Pump hose; page 9 or 10.
7. Replace Shroud, page 7.
CAUTION
When replacing cooling tube, make sure coil is facing
up when you push the tubing into the fitting. If you
push from any other angle you could bend or damage
the tube.
ti8942a
ti8895a
79
86
ti9014a
ti8886a
101
102
79