Graco King 96A388 User manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 2000, Graco Inc. is registered to I.S. EN ISO 9001
WALL MOUNT OR FLOOR STAND, HIGH-FLOr
3:1 and 4:1 Ratio Kingr
Circulation Packages 310562 Rev.B
Read warnings and instructions.
See page 2 for table of contents and list of
models.
TI0826
Model 96A388 Shown
307107 Fluid Regulator
307628 Fluid Ball Valves
307707 Surge Tanks
307741 King Air Motors
308115 Fluid Regulators
308168 High Volume Air Regulators
308201 Runaway Valves
309136 3:1, 4:1 High Flo Plus Pumps
Related Manuals:
Parts

2 310562
Table of Contents
List of Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification 5. . . . . . . . . . . . . . . . . . . . . . . .
Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layouts 29. . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Models
Model Pump Description –Pump Model Ratio
Maximum Fluid
Working Pressure
Maximum Pump
Air Input Pressure
Parts
Page
96A388 King Right Hand Pump Mount
High Flo Plust300
3:1 270 psi
(1.9 MPa, 19 bar)
90 psi
(0.6 MPa, 6.2 bar)
16
96A893 King Right Hand Pump Mount
High Flo Plust300, Low Shear
3:1 270 psi
(1.9 MPa, 19 bar)
90 psi
(0.6 MPa, 6.2 bar)
16
96A784 King Right Hand Pump Mount
High Flo Plust300
4:1 360 psi
(2.5 MPa, 25 bar)
90 psi
(0.6 MPa, 6.2 bar)
16
96A899 King Right Hand Pump Mount
High Flo Plust300, Low Shear
4:1 360 psi
(2.5 MPa, 25 bar)
90 psi
(0.6 MPa, 6.2 bar)
16
96A647 King Left Hand Pump Mount
High Flo Plust300
3:1 270 psi
(1.9 MPa, 19 bar)
90 psi
(0.6 MPa, 6.2 bar)
18
96A894 King Left Hand Pump Mount
High Flo Plust300, Low Shear
3:1 270 psi
(1.9 MPa, 19 bar)
90 psi
(0.6 MPa, 6.2 bar)
18
96A785 King Left Hand Pump Mount
High Flo Plust300
4:1 360 psi
(2.5 MPa, 25 bar)
90 psi
(0.6 MPa, 6.2 bar)
18
96A900 King Left Hand Pump Mount
High Flo Plust300, Low Shear
4:1 360 psi
(2.5 MPa, 25 bar)
90 psi
(0.6 MPa, 6.2 bar)
18
96A907 King Right Hand Pump Mount, Dual Filter
High Flo Plust300
3:1 270 psi
(1.9 MPa, 19 bar)
90 psi
(0.6 MPa, 6.2 bar)
20
96A926 King Right Hand Pump Mount, Dual Filter
High Flo Plust300
4:1 360 psi
(2.5 MPa, 25 bar)
90 psi
(0.6 MPa, 6.2 bar)
20
96A908 King Left Hand Pump Mount, Dual Filter
High Flo Plust300
3:1 270 psi
(1.9 MPa, 19 bar)
90 psi
(0.6 MPa, 6.2 bar)
22
96A927 King Left Hand Pump Mount, Dual Filter
High Flo Plust300
4:1 360 psi
(2.5 MPa, 25 bar)
90 psi
(0.6 MPa, 6.2 bar)
22

310562 3
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure stated on the equipment or in the Technical Data
for your equipment. Do not exceed the maximum working pressure of the lowest rated component
in your system.
DUse fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 180_F (82_C) or below –40_F (–40_C).
DWear hearing protection when operating this equipment.
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
PRESSURIZED EQUIPMENT HAZARD
Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin
and cause serious injury.
DDo not point the gun at anyone or at any part of the body.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DFollow the Pressure Relief Procedure on page 10 whenever you: are instructed to relieve pres-
sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.

4 310562
WARNING
MOVING PARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the pump.
DBefore servicing the equipment, follow the Pressure Relief Procedure on page 10 to prevent the
equipment from starting unexpectedly.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
DGround the equipment and the object being sprayed. Refer to Grounding on page 9.
DIf there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing immediately. Do not use the equipment until you identify and correct the problem.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
DKeep the spray area free of debris, including solvent, rags, and gasoline.
DElectrically disconnect all equipment in the spray area.
DExtinguish all open flames or pilot lights in the spray area.
DDo not smoke in the spray area.
DDo not turn on or off any light switch in the spray area while operating or if fumes are present.
DDo not operate a gasoline engine in the spray area.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

310562 5
Component Identification
Fi
g
. 1
A Ref
Model 96A388 Shown
TI0827
KEY
A Fluid Outlet
B Fluid Gauge and Dampener
C Fluid Gauge Ball Valve
D Fluid Filter
E Filter Ball Valve
F Fluid Drain Valve
G Air Supply Inlet
H Air Filter
TI0828
Side View
J Fluid Surge Tank
K Air Motor Master Air Valve
L Air Regulator and Gauge
M Pump Runaway Control Valve
N Pump
P Ground Wire
R Wall Mount Frame
S Air Line Lubricator
B
B
C
D Ref
A
E
F Ref
G
HJ K
L
M N P
R
S
T
U
V
W
Y
Z
T Fluid Return
U Fluid Return Valve
V Fluid Regulator and Gauge
W Bleed–type Master Air Valve
(not supplied)
Y Air Line Drain Valve
(not supplied)
Z Facility Air Supply
1Ensure that there is 5 ft (1.5 m) overhead clearance
for a wall mounted system and at least 7 ft (2.1 m)
for a floor mounted system.
2Mount the circulation package so the top of the
bracket is 4 to 5 ft (1.2 to 1.5 m) above the floor.
2
1
1
1
D
F

6 310562
Setup
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
Site Preparation
Fig. 1. Relieve system pressure. For installing any
one of the packages listed in this manual, select a site
with at least 5 ft (1.5 m) overhead clearance for the
wall mounted systems and at least 7 ft (2.1 m) for the
floor mounted systems.
Ensure that the wall is strong enough to support the
weight of the circulation package and accessories,
fluid, hoses, and stress caused during pump operation.
Ensure that you have an adequate compressed air
supply.
Bring an air supply line from the facility air supply (Z) to
the circulation package location. Be sure all air lines
are properly sized and pressure-rated for the system.
Use only electrically conductive hoses. The air hose
should have a 3/8 npt(m) thread.
Install a bleed-type shutoff valve (W) in the air line to
isolate the air line components for servicing. Install a
moisture trap and drain valve (Y) to help remove
moisture and contaminants from the compressed air
supply.
Keep the site clear of any obstacles or debris that
could interfere with the operator’s movement.
Have a grounded, metal pail available for use when
flushing the system.
Supplied Components
Refer to Fig. 1.
WARNING
A red-handled bleed-type master air valve (K) and
a fluid drain valve (F) are supplied. These compo-
nents help reduce the risk of serious injury, includ-
ing splashing of fluid in the eyes or on the skin, and
injury from moving parts if you are adjusting or
repairing the pump.
The bleed-type master air valve relieves air trapped
between this valve and the pump after the air is
shut off. Trapped air can cause the pump to cycle
unexpectedly.
The fluid drain valve assists in relieving fluid pres-
sure in the displacement pump, fluid filter, hose,
and gun. Triggering the gun to relieve pressure
may not be sufficient.
DThe red-handled bleed-type master air valve (K)
is required in your system to relieve air trapped
between it and the air motor when the valve is
closed (see the preceding WARNING).
DThe fluid drain valve (F), is mounted on the
bottom of the fluid filter bowl. The fluid drain valve
is required in your system to relieve fluid pressure
in the displacement pump, fluid filter, hose, and
gun. (see the preceding WARNING).
DThe pump air filter (H) includes an air filter with a
40 micron polypropylene element, to remove harm-
ful dirt and moisture from the compressed air
supply.
DThe pump air regulator and gauge (L) controls
pump speed and outlet pressure by adjusting the
air pressure to the pump. The gauge provides a
readout of air pressure to the pump. See manual
308168 for further details.
DThe pump runaway control valve (M) protects
the pump against damage by a runaway air motor.
See manual 308201 for further details.
DThe air line lubricator (S) provides automatic
lubrication of the air motor.
DThe pump (N), run by air motor, circulates fluid
throughout the system. See pump manual 309136
and air motor manual 307741 for further details.
DFluid is supplied to the pump through the fluid
outlet (A). Fluid pressure is monitored by the two
fluid gauges (B).
DThe fluid filter (D) includes a 60 mesh (250 mi-
cron) stainless steel element to filter particles from
the fluid as it leaves the pump.
DThe fluid surge tank (J) protects against surges in
the fluid lines during gun use and system operation.
DThe fluid regulator and gauge (V) controls fluid
outlet pressure. The gauge provides a readout of
fluid pressure at the outlet. See manual 307107 for
further details.
DFluid is returned from the circulation package to the
the system through the fluid return valve (U). See
valve manual 307628 for further details.

310562 7
Setup
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
Wall Mount installation of the Circulation
Package
Fig. 1. The circulation package consists of the pump
mounted on the wall mount frame. Also on the wall
mount frame are air filter, master air valve, air controls,
lubricator, surge tank, fluid filter, and plumbing.
NOTE: Ensure that there is 5 ft (1.5 m) overhead
clearance for a wall mounted system.
NOTE: Refer to Fig. 1, and to the Dimension drawing
on page 28 and the Mounting Hole Layout on page 29.
1. Relieve system pressure prior to installation of
circulation package. Follow Pressure Relief
Procedure on page 10.
2. Ensure that wall is strong enough to support
weight of circulation package, accessories, fluid
plumbing, and stress caused during pump opera-
tion.
3. Using capable hoist, position wall mount frame (R)
so that the top edge is 4 to 5 ft (1.2 to 1.5 m)
above floor. Check that wall mount frame is level.
Mark four holes on wall for each of four wall mount
feet.
4. Drill holes where marked on wall.
WARNING
The wall mount frame (R) must be bolted to the
wall. Do not simply hang the wall mount frame.
Failure to do so may cause circulation package to
fall causing equipment damage or personal injury.
5. Using capable hoist, lift circulation package back
into position. Bolt wall mount frame (R) to wall.
Use 1/2 in. bolts and washers to mount circulation
package to wall. Use bolts that are long enough to
keep wall mount frame from vibrating during
operation.
Single or Dual Floor Mount installation of
the Circulation Package
Fig. 1. The circulation package consists of the pump
mounted on the wall mount frame. Also on the wall
mount frame are air filter, master air valve, air controls,
lubricator, surge tank, fluid filter, and plumbing.
NOTE: Ensure that there is 7 ft (2.1 m) overhead
clearance for a floor mounted system.
NOTE: Refer to Fig. 1, and to the Single Mount Floor
Stand drawing on page 24 or the Dual Mount Floor
Stand drawing on page 25. Also refer to the Mounting
Hole Layouts on page 29.
1. Relieve system pressure prior to installation of
circulation package. Follow Pressure Relief
Procedure on page 10.
2. Anchor either single or dual floor stand to floor
using 1/2 in. bolts.
WARNING
Do not attempt to mount two circulation packages
on a single mount floor stand. Use dual mount
stand for dual or back–to–back installations. Failure
to do so can result in mount failure causing equip-
ment damage or personal injury
3. Using capable hoist, position wall mount frame (R)
so that the top edge is level with the top edge of
the floor stand. For dual, use second hoist and
align with dual floor stand and first circulation
package.
4. Bolt single unit or dual units to floor stand using
3/8 in. hardware.

8 310562
Setup
Connect the Fluid Lines
Fig. 1. Connect system fluid supply line to the circula-
tion package at fluid supply inlet (A). Close filter ball
valves (E) to isolate the circulation package from the
main fluid supply line.
Connect circulation package to the system fluid return
line at fluid return outlet (T). Close fluid return valve (U)
to isolate the circulation package from the main fluid
return line.
Connect the Air Line
Fig. 1. Bring an air supply line from the facility air
supply (Z) to the circulation package location. Be sure
all air lines are properly sized and pressure-rated for
the system. Use only electrically conductive hoses. Air
hose should have a 3/8 npt(m) thread.
Install a bleed-type shutoff valve (W) in the air line to
isolate the air line components for servicing. Install a
moisture trap and drain valve (Y) to help remove
moisture and contaminants from the compressed air
supply.
Using the Quick Connectors
Fig. 2. To open a quick connector (A), loosen the
captive screw (B) and open the connector. Slide the
desired component into or out of the connector, close,
and tighten the screw.
06278
Fig. 2
B
A

310562 9
Setup
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the circulation pack-
age, ground the system as explained
below. Also read the section FIRE AND
EXPLOSION HAZARD on page 4.
1. Pump: use the ground wire and clamp (A, sup-
plied). See Fig. 3. Loosen the grounding lug lock-
nut (W) and washer (X). Insert one end of the
ground wire (A) into the slot in lug (Z) and tighten
the locknut securely. Connect the ground clamp to
a true earth ground.
Fig. 3
W
A
X
Z
0720
2. Air and fluid hoses: use only electrically conductive
hoses.
3. Air compressor: follow manufacturer’s recommen-
dations.
4. Spray gun: ground through connection to a prop-
erly grounded fluid hose and pump.
5. Fluid supply container: follow your local code.
6. Object being sprayed: follow your local code.
7. Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place the
pail on a nonconductive surface, such as paper or
cardboard, which interrupts the grounding continu-
ity.
8. To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the spray
gun firmly to the side of a grounded metal pail,
then trigger the gun.

10 310562
Operation
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The system pressure must be manually relieved to
prevent the system from starting or spraying acci-
dentally. To reduce the risk of an injury from acci-
dental spray from the gun, splashing fluid, or
moving parts, follow the Pressure Relief Proce-
dure whenever you:
Dare instructed to relieve the pressure,
Dstop spraying,
Dcheck or service any of the system equipment,
Dor install or clean the spray nozzle.
1. Fig. 4. Relieve the pressure of the entire system
following applicable system pressure relief proce-
dures. Ensure that system pressure is relieved
before proceeding with step 2.
2. Close the red-handled bleed-type master air valve
(W, required in your system).
3. Trigger the gun at the last gun station to relieve
fluid pressure. Maintain firm metal-to-metal contact
between the gun and a grounded waste pail.
Repeat for all gun stations.
4. Open the fluid drain valve (2) to relieve fluid pres-
sure which may be trapped in the pump, plumbing,
or hose.
If you suspect that pressure is not fully relieved after
following the steps above, wrap a fitting near the pump
outlet with a rag, and slowly and carefully loosen the
fitting to relieve pressure. Be careful to protect your
eyes from splashing.
Packing Nut
Fig. 4. Before starting, fill the packing nut (AA) 1/3 full
with Graco Throat Seal Liquid (TSL) or compatible
solvent.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
The packing nut is torqued at the factory and is ready
for operation. If it becomes loose and there is leaking
from the throat packings, relieve pressure, then torque
the nut to 34–40 NSm (25–30 ft-lb). Do this whenever
necessary. Do not overtighten the packing nut.
Flush the Circulation Package Before First
Use
The circulation package is tested with lightweight oil,
which is left in to protect the circulation package parts.
If the fluid you are using may be contaminated by the
oil, flush it out with a compatible solvent. See Flush-
ing on page 13.

310562 11
Operation
Fi
g
. 4
1Torque packing nut (H) to 34–40 NSm (25–30 ft-lb).
Packing nut is partially hidden.
Model 96A388 Shown
TI0827
TI0828
Side View
8 Ref
4
2 Ref
BB
22
23
36
W
Y
1
8
2
AA

12 310562
Operation
Starting and Adjusting the Pump
1. Fig. 4. Open all fluid shutoff valves (4–two) (36).
2. Open the spray gun at the last gun station and
keep it open while starting the pump.
3. Open the bleed-type master air valves (W, 22).
4. Slowly open air regulator (23) until the pump
starts. The air regulator controls the pump speed
and fluid outlet pressure.
5. Adjust the fluid pressure to the lowest setting
necessary to get the desired results. Higher pres-
sures may not improve the spray pattern and will
cause premature component wear. Use the air
regulator (23) to adjust the pump speed and fluid
pressure until the spray is completely atomized.
6. To adjust the spray pattern, follow the complete
instructions in your gun manual.
7. When you have achieved the desired spray pat-
tern, release the gun trigger. The pump will contin-
ue to cycle as long as air is supplied.
8. One at a time, open any other guns in the system
to purge air from the lines.
NOTE: In a circulating system, the pump will continue
to cycle as long as air is supplied. In a direct supply
system, the pump starts when the gun is opened, and
stops when the gun is closed.
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of overpressurizing
your system, which could cause
component rupture and serious injury,
never exceed the specified maximum air input
pressure to the pump (see Technical Data on
page 26).
CAUTION
Do not allow the pump to run dry. It will quickly
accelerate to a high speed, causing damage. If your
pump is running too fast, stop it immediately and
check the fluid supply. If the container is empty and
air has been pumped into the lines, refill the con-
tainer and prime the pump and the lines, or flush and
leave it filled with a compatible solvent. Eliminate all
air from the fluid system.
Shutdown
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
For overnight shutdown, stop the pump at the bottom
of its stroke to prevent fluid from drying on the ex-
posed displacement rod and damaging the throat
packings. Relieve the pressure.
Always flush the pump before the fluid dries on the
displacement rod. See Flushing on page 13.

310562 13
Maintenance
Preventive Maintenance Schedule
The operating conditions of your particular system
determine how often maintenance is required. Estab-
lish a preventive maintenance schedule by recording
when and what kind of maintenance is needed, and
then determine a regular schedule for checking your
system.
Flushing
WARNING
FIRE AND EXPLOSION HAZARD
Before flushing, read the section FIRE
AND EXPLOSION HAZARD on page
4. Be sure the entire system and flush-
ing pails are properly grounded. Refer to
Grounding on page 9.
Fig. 4. Flush the pump:
DBefore the first use
DWhen changing colors or fluids
DBefore fluid can dry or settle out in a dormant pump
(check the pot life of catalyzed fluids)
DBefore storing the pump.
Flush with a fluid that is compatible with the fluid you
are pumping and with the wetted parts in your system.
Check with your fluid manufacturer or supplier for
recommended flushing fluids and flushing frequency.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
1. Fig. 4. Relieve the pressure.
2. Remove the air cap and spray tip from the gun.
See the gun manual.
3. Fig. 4. Remove the filter element from the fluid
filter (8). Reinstall the filter bowl.
4. Hold a metal part of the gun firmly to the side of a
grounded metal pail.
5. Start the pump. Always use the lowest possible
fluid pressure when flushing.
6. Trigger the gun. Flush the system until clear
solvent flows from the gun.
7. Release the gun trigger and lock the trigger safety.
The pump will continue to cycle as long as air is
supplied.
8. Direct drain hose into a waste container. Continue
flushing until clear fluid comes from the hose.
9. Relieve the pressure.
10. Clean the air cap, spray tip, and fluid filter element
separately, then reinstall them.
Fluid Filter Service
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
1. Fig. 4. Relieve the pressure.
2. Replace the fluid filter as required to maximize
filtering efficiency and to avoid excessive pressure
drop.
3. Close two filter ball valves (4). Open filter drain
valve (2) and partially loosen filter top to allow fluid
in filter to drain into waste container.
4. Install new filter, close filter drain valve (2) and
open filter ball valves (4).

14 310562
Maintenance
Air Filter Service
1. Fig. 4. Every day, drain contaminants from the
bowl before reaching the baffle level by opening
the drain at the bottom of the bowl (BB).
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
2. Clean the air filter regularly to maximize filtering
efficiency and to avoid excessive pressure drop.
Fully relieve pressure to remove the bowl (BB).
3. Clean the filter element and bowl using household
soap and water or denatured alcohol. Use com-
pressed air to blow out the filter body. Blow the
filter element out from the inside.
4. Clean the sight glass thoroughly. Do not leave
solvent residue in the sight glass as it may attack
or weaken the glass. If the sight glass appears
damaged, replace it immediately.

310562 15
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow
the Pressure Relief Procedure (page 10).
For pump service see manual 309136. For air motor service see manual 307741.
Problem Cause(s) Solution(s)
Pump output low on both strokes Restricted air or hydraulic lines Clear any obstructions; be sure all
valves are open; increase pressure.
Empty fluid supply Refill and reprime pump. In an air-pow-
ered system, use pump runaway valve.
Clogged fluid outlet line, valves, etc. Clear.
Worn packings Tighten packing nut; replace all pack-
ings. See 309136.
Pump output low on only one stroke Held open or worn check valve Check and repair. See 309136.
Worn piston packings Replace. See 309136.
No output Improperly installed ball check valves Check and correct. See 309136.
Pump operates erratically Exhausted fluid supply Refill and reprime pump. In an air-pow-
ered system, use pump runaway valve.
Held open or worn check valves Check and repair. See 309136.
Worn piston packings Replace. See 309136.
Pump does not operate Restricted air or hydraulic power sup-
ply lines
Clear any obstructions; be sure all shut-
off valves are open; increase pressure.
Exhausted fluid supply Refill and reprime pump.
Clogged fluid outlet line, valves, etc. Clear.
Damaged air motor See 307741.
Fluid dried on piston rod Disassemble and clean pump. Stop
pump at bottom of stroke. See 309136.

16 310562
Parts
Right Hand Mount Models: 96A388, 96A893, 96A784, 96A899
3:1 and 4:1 Ratio, King Pumps
TI0828
TI0828
TI0828
Model 96A388 Shown
1
2
3
4
5,6
7,17,18
2
4
5,6
8
9
5,6
10
11
12
5,6
13
14
15
16
19 20 21 22 23 24 25 26 27 26,29 28
30 31
32
33,
34,
35
36
37
38,
39
40,
41,
42
414043,44,45

310562 17
Parts
Right Hand Mount Models: 96A388, 96A893, 96A784, 96A899
3:1 and 4:1 Ratio, King Pumps
Ref Part
No. No. Description Qty
Ref Part
No. No. Description Qty
1 515571 GAUGE and DAMPENER, sst 2
2 237528 BALL VALVE, sst, 1/4”npt 2
See 307628 for parts
3 515036 ELBOW, street, 90_, sst, 1/4”npt 1
4 515564 BALL VALVE, sst, 1–1/2”npt 2
5 51A297 CLAMP, sanitary, sst, 1–1/2”8
6 51A306 GASKET, sanitary, Teflon, 1–1/2”8
7 618119 BRACKET, pipe support, 3/4”2
8 916367 FILTER, model 12, sst, 1–1/2”1
9 618096 HEADER, filter discharge, 1–1/2”1
10 618098 HEADER, discharge, 1–1/2 x 1–1/4”1
11 160327 UNION, 90_, swivel, 3/4”1
12 106150 FILTER, air, 3/4”npt 1
13 238985 TANK, surge, 1–1/2”1
See 307707 for parts
14 180783 BRACKET, angle 3
15 51A796 ELBOW, 90_, sst, 1–1/2”1
16 51B381 HOSE, material, 1–1/2 x 4”1
17 100057 SCREW, hex hd, 5/16 x 18–3/4”2
18 100214 WASHER, lock, 5/16”2
19 516830 NIPPLE, pipe, 3/4”npt 2
20 166466 TEE, pipe, 3/4”npt 1
21 C19260 PLUG, pipe, 3/4”npt 1
22 107141 VALVE, ball, air, 3/4”npt 1
23 180187 REGULATOR, air, 3/4”npt 1
See 308168 for parts
24 100960 GAUGE, air, 0–200 psi, 1/4 npt 1
25 214956 HOSE, air, 3/4 x 2”1
26 100627 NIPPLE, pipe, 3/4”npt 2
27 224040 VALVE, runaway, 3/4”npt 1
See 308201 for parts
28 214849 LUBRICATOR, air, 3/4”npt 1
29 C19515 ELBOW, street, 3/4”npt 1
30 618097 HEADER, surge tank discharge,1–1/2”1
31 618094 FRAME, wall mount 1
32 243749 PUMP, 3:1 King, sst 1
(used on 96A388 and 96A893)
See 309136 for parts
243747 PUMP, 4:1 King, sst 1
(used on 96A784 and 96A899)
See 309136 for parts
33 C19126 SCREW, hex hd, 3/8 x 1–3/4”4
34 C19213 WASHER, lock, 3/8”4
35 100307 NUT, hex, 3/8”4
36 515551 VALVE, double union, sst, 1”npt 1
37 516772 NIPPLE, sst, 1”x 4”1
38 208997 REGULATOR, standard, sst 1
(used on 96A388 and 96A784)
See 307107 for parts
224486 REGULATOR, low shear, sst 1
(used on 96A893 and 96A899)
See 307107 for parts
39 515992 BUSHING, reducer, sst, 1–1/4x1”npt 2
(used on 96A388 and 96A784)
516306 BUSHING, reducer, sst, 1–1/2x1”npt 2
(used on 96A893 and 96A899)
40 516037 ELBOW, street, 90_, sst, 1–1/4”npt 2
41 515983 BUSHING, reducer, sst, 2x1–1/4”npt 2
42 518312 ADAPTOR, tube, 1–1/2 x 1”2
43 516582 SCREW, hex hd, 5/8 x 1”3
44 100128 WASHER, lock, 5/8”3
45 100127 NUT, hex, 5/8”3

18 310562
Parts
Left Hand Mount Models: 96A647, 96A894, 96A785, 96A900
3:1 and 4:1 Ratio, King Pumps
Model 96A647 Shown
TI0829
TI0829
TI0829
1
2
3
4
5,6
7,17,18
2
4
5,6
8
9
5,6
10
11
12
5,6
13
14
15
16
19202122232425262726,29
28
30 31
32
33,
34,
35
36
37
38,
39
40,
41,
42
41
40 43,44,45

310562 19
Parts
Left Hand Mount Models: 96A647, 96A894, 96A785, 96A900
3:1 and 4:1 Ratio, King Pumps
Ref Part
No. No. Description Qty
Ref Part
No. No. Description Qty
1 515571 GAUGE and DAMPENER, sst 2
2 237528 BALL VALVE, sst, 1/4”npt 2
See 307628 for parts
3 515036 ELBOW, street, 90_, sst, 1/4”npt 1
4 515564 BALL VALVE, sst, 1–1/2”npt 2
5 51A297 CLAMP, sanitary, sst, 1–1/2”8
6 51A306 GASKET, sanitary, Teflon, 1–1/2”8
7 618119 BRACKET, pipe support, 3/4”2
8 916367 FILTER, model 12, sst, 1–1/2”1
9 618096 HEADER, filter discharge, 1–1/2”1
10 618098 HEADER, discharge, 1–1/2 x 1–1/4”1
11 160327 UNION, 90_, swivel, 3/4”1
12 106150 FILTER, air, 3/4”npt 1
13 238985 TANK, surge, 1–1/2”1
See 307707 for parts
14 180783 BRACKET, angle 3
15 51A796 ELBOW, 90_, sst, 1–1/2”1
16 51B381 HOSE, material, 1–1/2 x 4”1
17 100057 SCREW, hex hd, 5/16 x 18–3/4”2
18 100214 WASHER, lock, 5/16”2
19 516830 NIPPLE, pipe, 3/4”npt 2
20 166466 TEE, pipe, 3/4”npt 1
21 C19260 PLUG, pipe, 3/4”npt 1
22 107141 VALVE, ball, air, 3/4”npt 1
23 180187 REGULATOR, air, 3/4”npt 1
See 308168 for parts
24 100960 GAUGE, air, 0–200 psi, 1/4 npt 1
25 214956 HOSE, air, 3/4 x 2”1
26 100627 NIPPLE, pipe, 3/4”npt 2
27 224040 VALVE, runaway, 3/4”npt 1
See 308201 for parts
28 214849 LUBRICATOR, air, 3/4”npt 1
29 C19515 ELBOW, street, 3/4”npt 1
30 618097 HEADER, surge tank discharge,1–1/2”1
31 618237 FRAME, wall mount, left hand 1
32 243749 PUMP, 3:1 King, sst 1
(used on 96A647 and 96A894)
See 309136 for parts
243747 PUMP, 4:1 King, sst 1
(used on 96A785 and 96A900)
See 309136 for parts
33 C19126 SCREW, hex hd, 3/8 x 1–3/4”4
34 C19213 WASHER, lock, 3/8”4
35 100307 NUT, hex, 3/8”4
36 515551 VALVE, double union, sst, 1”npt 1
37 516772 NIPPLE, sst, 1”x 4”1
38 208997 REGULATOR, standard, sst 1
(used on 96A647 and 96A785)
See 307107 for parts
224486 REGULATOR, low shear, sst 1
(used on 96A894 and 96A900)
See 307107 for parts
39 515992 BUSHING, reducer, sst, 1–1/4x1”npt 2
(used on 96A647 and 96A785)
516306 BUSHING, reducer, sst, 1–1/2x1”npt 2
(used on 96A894 and 96A900)
40 516037 ELBOW, street, 90_, sst, 1–1/4”npt 2
41 515983 BUSHING, reducer, sst, 2x1–1/4”npt 2
42 518312 ADAPTOR, tube, 1–1/2 x 1 ”2
43 516581 SCREW, hex hd, 5/8 x 3/4”3
44 100128 WASHER, lock, 5/8”3
45 100127 NUT, hex, 5/8”3

20 310562
Parts
Right Hand Mount Dual Filter Models: 96A907 and 96A926
3:1 and 4:1 Ratio, King Pumps
TI0830
TI0830
TI0830
Model 96A907 Shown
1
2
3
4
5,6
7,17,18
2
4
5,6
8
9
5,6
10
11
12
5,6
13
14
15
16
19 20 21 22 23 24 25 26 27 26,29 28
30 31
32
33,
34,
35
36
37
38,
39
40,
41,
42
414043,44,45