ORIGINAL INSTRUCTIONS
IE101J
Installation, Operation
& Maintenance Manual
Plain Style Compressors for Liquid
Transfer-Vapor Recovery
Model 491-107
Warning: (1) Periodic inspection and maintenance of Corken products is essential. (2) Inspection, maintenance and installation of
Corken products must be made only by experienced, trained and qualified personnel. (3) Maintenance, use and installation of Corken
products must comply with Corken instructions, applicable laws and safety standards. (4) Transfer of toxic, dangerous, flammable or
explosive substances using Corken products is at user’s risk and equipment should be operated only by qualified personnel according
to applicable laws and safety standards.
Solutions beyond products...
Warning
Install, use and maintain this equipment according to Corken’s instructions and all applicable federal, state, local laws
and codes. Periodic inspection and maintenance is essential.
Corken One Year Warranty
CORKEN, INC. warrants that its products will be free from defects in material and workmanship for a period of
one year from date of installation, provided that the warranty shall not extend beyond twenty-four (24) months from
the date of shipment from CORKEN. If a warranty dispute occurs, the DISTRIBUTOR may be required to provide
CORKEN with proof of date of sale. The minimum requirement would be a copy of the DISTRIBUTOR’S invoice to
the customer.
CORKEN products which fail within the warrant period due to defects in material or workmanship will be repaired or
replaced at CORKEN’s option, when returned, freight prepaid to CORKEN, INC., 3805 N.W. 36th St., Oklahoma City,
Oklahoma 73112.
Parts subject to wear or abuse, such as mechanical seals, blades, piston rings, valves and packing, and other parts
showing signs of abuse, neglect or failure to be properly maintained are not covered by this limited warranty. Also,
equipment, parts and accessories not manufactured by CORKEN but furnished with CORKEN products are not
covered by this limited warranty and the purchaser must look to the original manufacturer’s warranty, if any. This
limited warranty is void if the CORKEN product has been altered or repaired without the consent of CORKEN.
All implied warranties, including any implied warranty of merchantability or fitness for a particular purpose, are
expressly negated to the extent permitted by law and shall in no event extend beyond the expressed warranty period.
CORKEN DISCLAIMS ANY LIABILITY FOR CONSEQUENTIAL DAMAGES DUE TO BREACH OF ANY WRITTEN OR
IMPLIED WARRANTY ON CORKEN PRODUCTS. Transfer of toxic, dangerous, flammable or explosive substances
using CORKEN products is at the user’s risk. Experienced, trained personnel in compliance with governmental and
industrial safety standards should handle such substances.
Important notes relating to the European Union (EU) Machinery Directive
Pumps delivered without electric motors are not considered as machines in the EU Machinery Directive. These
pumps will be delivered with a Declaration of Incorporation. The fabricator of the machinery must assure and declare
full compliance with this Directive before the machine in which the pump will be incorporated, or of which it is a part,
is put into service.
Contacting the Factory
Before you contact the factory, note the model number and serial number of your pump. The serial number directs
us to a file containing all information on material specifications and test data applying to your specific pump. When
ordering parts, the Corken service manual or Operations, Installation and Maintenance (IOM) manual should be
consulted for the proper part numbers. ALWAYS INCLUDE THE MODEL NUMBER AND SERIAL NUMBER WHEN
ORDERING PARTS.
The model and serial numbers are shown on the nameplate of the unit. Record this information for future reference.
Model No.
Serial No.
Date Purchased
Date Installed
Purchased From
Installed By
2
Table of Contents
Chapter 1—Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Liquid Transfer By Vapor Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Residual Vapor Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Compressor Construction Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 2—Installing Your Corken Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Foundation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Liquid Traps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Driver Installation / Flywheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6. Crankcase Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.7 Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.8 Truck Mounted Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.9 Shutdown/Alarm Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chapter 3—Starting Up Your Corken Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Inspection After Extended Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Flywheel and V-belt Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Crankcase Oil Pressure Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 Startup Check List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 4—Routine Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Chapter 5—Routine Service and Repair Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 Piston Rings and Piston Ring Expanders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.4 Pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.5 Piston Rod Packing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.6 Cylinder and Packing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.7 Bearing Replacement for Crankcase and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.7.1 Wrist Pin Bushing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.7.2 Replacing Connecting Rod Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.7.3 Replacing Crankcase Roller Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.8 Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Chapter 6—Extended Storage Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1 Repair Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2 Gasket Sets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Appendices
A. Model Number Identification Code and Available Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
B. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
C. Compressor Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
D. Outline Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
E. Parts Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Model 91 and F91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Model 291 and F291. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Model 491 and F491. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Model 691 and F691. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Model D891 and FD891 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
F. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3
Chapter 1—Introduction
Connections:
Available in threaded NPT or Class 300
RF flanges.
High-efficiency valves:
Valves are quiet and highly durable. Special
suction valves tolerating small amounts of
condensate are available.
O-ring seals:
Easy to install O-ring seals head and cylinder.
Ductile iron construction:
Cylinder and head are made of ductile iron
for maximum thermal shock endurance.
Self-lubricating PTFE piston rings:
State-of-the-art piston ring designs to
provide the most cost-effective operation
of compressors for non-lube service. The
step-cut design provides higher efficiencies
during the entire life of the piston ring.
Positively locked piston:
Simple piston design allows end clearance
to be precisely set to provide maximum
efficiency and long life.
Piston rod seals:
Seals constructed of PTFE incorporating
special fillers to maximize leakage control.
Spring loaded seal design self adjusts to
compensate for normal wear.
Nitrotec ®1 coated piston rods:
Impregnated nitride coating provides
superior corrosion and wear resistance.
Cast-iron crosshead:
Durable cast-iron crossheads provide
superior resistance to corrosion and galling.
Pressure-lubricated crankcase with filter:
Self-reversing oil pump ensures proper
lubrication regardless of directional rotation to
main and connecting rod bearings. Standard
10-micron filter ensures long-lasting bearing
life (not available on Model 91).
1
Registered trademark of TTI Group Ltd.
Construction Details—Model F291 Compressor
4
1.1 Liquid Transfer By Vapor
Differential Pressure
gas compressor accomplishes this by withdrawing
vapors from the storage tank, compressing them
and then discharging into the tank being unloaded.
This procedure slightly decreases the storage tank
pressure and increases the pressure in the other tank,
thereby causing the liquid to flow.
Corken LPG/NH3 compressors are designed to transfer
liquefied gases such as butane/propane mixtures
(liquefied petroleum gas or LPG) and Anhydrous Ammonia
(NH3) from one tank to another. Liquefied gases such as
LPG and NH3 are stored in closed containers where both
the liquid and vapor phases are present.
The process of compressing the gas also increases the
temperature, which aids in increasing the pressure in the
tank being unloaded.
1.2 Residual Vapor Recovery
The principle of residual vapor recovery is just the
opposite of liquid transfer. After the liquid has been
transferred, the four-way control valve (or alternate
valve manifolding) is reversed so that the vapors are
drawn from the tank just unloaded and discharged into
the receiving tank. Always discharge the recovered
vapors into the liquid section of the receiving tank.
This will allow the hot, compressed vapors to condense,
preventing an undesirable increase in tank pressure (see
figure 1.2A).
Figure 1.1A: Typical nameplate
(also serves as the packing adjusting screw cover)
There is a piping connection between the vapor
sections of the storage tank and the tank being
unloaded, and there is a similar connection between
the liquid sections of the two tanks. If the connections
are opened, the liquid will seek its own level and
then flow will stop; however, by creating a pressure
in the tank being unloaded which is high enough
to overcome pipe friction and any static elevation
difference between the tanks, all the liquid will be
forced into the storage tank (see figure 1.1B). The
Residual vapor recovery is an essential part of the value
of a compressor. There is an economical limit to the
amount of vapors that should be recovered, however.
When the cost of operation equals the price of the
product being recovered, the operation should be
stopped. For most cases in LP-Gas and Anhydrous
Ammonia services, this point is reached in the summer
when the compressor inlet pressure is 40 to 50 psig
Vapor Line
Pressure difference between
tanks causes liquid to flow out of
the tank car into the storage tank
Vapor Line
Compressor increases
pressure in tank car by
adding vapor
Compressor reduces
pressure in storage tank
by removing vapor
Four Way Valve Position 1
Liquid Line
Figure 1.1B: Liquid transfer by vapor differential pressure.
5
Vapor Line
Liquid line is valved closed
during vapor recovery.
Four Way Valve Position 2
Vapor is
bubbled
through liquid
to help cool and
recondense it
Vapor Line
Removing vapor from
tank causes liquid heel
to boil into vapor
Liquid Line
Figure 1.2A: Residual vapor recovery.
(3.8 to 4.5 bars). A good rule of thumb is not to operate
beyond the point at which the inlet pressure is onefourth the discharge pressure. Some liquids are so
expensive that further recovery may be profitable, but
care should be taken that the ratio of absolute discharge
pressure to absolute inlet pressure never exceeds 7 to
1. Further excavation of very high value products would
require a Corken two-stage gas compressor.
Invariably, there is some liquid remaining in the tank
after the liquid transfer operation. This liquid “heel”
must be vaporized before it can be recovered, so
do not expect the pressure to drop immediately.
Actually, more vapor will be recovered during the first
few minutes while this liquid is being vaporized than
during the same period of time later in the operation.
Remember that more than half of the economically
recoverable product is usually recovered during the
first hour of operation on properly sized equipment.
1.3 Compressor
Construction Features
The Corken liquid transfer-vapor recovery compressor
is a vertical single-stage, single-acting reciprocating
compressor designed to handle flammable gases
like LPG and toxic gases such as ammonia. Corken
compressors can handle these potentially dangerous
gases because the LPG/NH 3 is confined in the
compression chamber and isolated from the crankcase
and the atmosphere. A typical liquid transfer-vapor
recovery compressor package is shown in figure 1.3A.
Figure 1.3A: 107-style compressor mounting.
Corken gas compressors are mounted on oil lubricated
crankcases remaining at atmospheric pressure. Crankshafts
are supported by heavy-duty roller bearings and the
connecting rods ride the crankshaft on journal bearings.
With the exception of the small size model 91 compressor,
all compressor crankcases are lubricated by an automotive
type oil pressure system. An automatically reversible gear
6
type oil pump circulates oil through passages in the
crankshaft and connection rod to lubricate the journal
bearings and wrist pins (see figure 1.3B). Sturdy iron
crossheads transmit reciprocating motion to the piston.
Corken’s automatically reversible oil pump design
allows the machine to function smoothly in either
direction of rotation.
Corken compressors use iron pistons locked to the piston
rod. The standard piston ring material is a glass-filled
PTFE polymer specially formulated for non-lubricated
services. Piston ring expanders are placed behind the
rings to ensure that the piston rings seal tightly against
the cylinder wall.
Figure 1.3C: Compressor sealing system
Suction Valve
Spec 3
Gasket
Adjusting
screw
Relief ball spring
Discharge Valve
All Specs
Gasket
Relief ball
Bolt
Suction valve
seat
Valve plate
Discharge valve
bumper
Valve spring
Figure 1.3B: Pressure lubrication system (not available on Model 91).
Piston rod packing is used to seal the gas in the
compression chamber and prevent crankcase oil from
entering the compressor cylinder. The packing consists
of several PTFE V-rings sandwiched between a male and
female packing ring and held in place by a spring (see
figure 1.3C).
Spacers
Washer
Washer
Valve spring
Spacers
Suction valve
post
Valve plate
Suction valve
bumper
Discharge valve
seat
Valve gasket
Valve gasket
Figure 1.3D: Compressor sealing system
The typical Corken compressor valve consists of a seat,
bumper, one or more spring/s and one or more valve/s
discs or plates as shown in figure 1.3D. Special heattreated alloys are utilized to prolong life of the valve in
punishing non-lubricated services. The valve opens
whenever the pressure on the seat side exceeds the
pressure on the spring side.
7
Chapter 2—Installing Your Corken
Compressor
After leveling and bolting down baseplate and/or skid,
the volume beneath the channel iron baseplate must
be grouted to prevent flexing of the top portion of the
baseplate and the “J” bolt that extends beyond the
foundation. The grout also improves the dampening
capabilities of the foundation by creating a solid interface
between the compressor and foundation.
2.1 Location
NOTE: Compressor must be installed in a well
ventilated area.
See ED410: Compressor Foundation Design for more
information.
Corken compressors are designed and manufactured
for outdoor duty. For applications where the compressor
will be subjected to extreme conditions for extended
periods such as corrosive environments, arctic
conditions, etc., consult Corken. Check local safety
regulations and building codes to assure installation will
meet local safety standards.
2.3 Piping
Proper piping design and installation is as important as
the foundation is to smooth operation of the compressor.
Improper piping installation will result in undesirable
transmission of compressor vibration to the piping.
Corken compressors handling toxic or flammable
gases such as LPG/NH3 should be located outdoors. A
minimum of 18 inches (457.2 mm) clearance between the
compressor and the nearest wall is advised to make it
accessible from all sides and to provide unrestricted air
flow for adequate cooling.
DO NOT SUPPORT PIPING WITH THE COMPRESSOR.
Unsupported piping is the most frequent cause of
vibration of the pipe. The best method to minimize
transmission of vibration from the compressor to the
piping is to use flexible connectors (see figure 2.3A).
NOISE. Corken vertical compressors sizes model 91
through 891 should not exceed an 85 DBA noise level at
a distance of one meter (3.3 ft.) when properly installed.
Flexible
connections
2.2 Foundation
Pipe
support
Proper foundations are essential for a smooth running
compression system. The concrete slab should be
at least 8 inches thick with a 2 inch skirt around the
circumference of the baseplate. The total mass of the
foundation should be approximately twice the weight of
the compressor system (compressor, baseplate, motor,
etc.). For Models 91, 291, 491, and 691, the baseplate
should be secured to the foundation using 1/2" diameter
x 12" long “J” bolts. Use 3/4" x 12" anchor bolts for 891.
Hex nut
Washer
Pipe
support
Grouted
baseplate
Baseplate should
be a maximum
of 4" high
Ground level
NOTE: Be sure to use all anchor holes.
2" minimum
all sides
Flexible
connections
Concrete
foundation
Figure 2.3A: On –107 mountings, the flexible connectors should be
located near the four way valve.
Pipe must be adequately sized to prevent excessive
pressure drop between the suction source and the
compressor as well as between the compressor and the
final discharge point. In most cases, piping should be
at least the same diameter as the suction nozzle on the
compressor. Typically, LPG/NH3 liquid transfer systems
should be designed to limit pressure drops to 20 psi (1.4
bar). Appendix C shows recommended pipe sizes for
each compressor for typical LPG/NH3 installations.
Compressor
baseplate
Grout beneath
base
Concrete foundation
with reinforcements
should be used on
all models
8" minimum
1/2" “J” bolts
12" long
Care must be taken if a restrictive device such as a valve,
pressure regulator, or back-check valve is to be installed
in the compressor’s suction line. The suction line volume
between the restrictive device and the compressor suction
nozzle must be at least ten times the swept cylinder volume.
See Appendix B for details on cylinder and stroke.
NOTE: Locate “J” bolts per compressor outline
dimension drawings .
Figure 2.2A: Recommended foundation details for Corken
compressors 91–691.
8
Hydrostatic relief valve
Back check valve
C
A
D
Vapor line to
rail car
(inbound bulk
transport)
B
Bury or
insulate in
cold climate
areas
E
Vapor line to truck
trailer or tank
(local transport)
Vapor line to gas phase
in storage tank
Vapor line to liquid phase
in storage tank
Service to Perform
4-way Valve Operation
D
A
C
E
Relief valve
4-Way valve
4-Way Valve
Position 2
B
4-Way Valve
Position 1
Valve Position
4-way
A
B
C
D
E
1. Unload tank car
into storage tank
Position
One
Open
Open
Close
Close
Close
2. Recover vapors
from tank car into
storage tank
Position
Two
Close
Open
Open
Close
Close
3. Unload transport
or truck into
storage tank
Position
One
Open
Close
Close
Close
Open
4. Recover vapors
from transport or
truck into storage
tank
Position
Two
Close
Close
Open
Close
Open
5. Load truck or
field tank from
storage tank
Position
Two
Open
Close
Close
Close
Open
6. Load truck or field
tank from tank car
Position
One
Close
Open
Close
Open
Close
7. Equalize between
tank car and
storage tank
without using
vapor pump
—
Open
Open
Close
Open
Open
8. Equalize between
truck or field tank
and storage tank
without using
vapor pump
—
Open
Close
Close
Open
Close
Figure 2.3B: Five valve manifold piping system.
107 style compressors are usually connected using a fivevalve (figure 2.3B) or three-valve manifold (figure 2.3C).
The five-valve manifold allows the storage tank to be
both loaded and unloaded. The three-valve manifold only
allows the storage tank to be loaded. Adequate sizing of
the liquid and vapor lines is essential to limit the pressure
drop in the system to a reasonable level (20 psi or less).
A tank car unloading riser should have two liquid hoses
connected to the car liquid valves. If only one liquid
hose is used, the transfer rate will be slower and there
is a good possibility that the car’s excess flow valve
may close.
Since the heat of compression plays an important part in
rapid liquid transfer, the vapor line from the compressor to
the tank car or other unloading container should be buried
or insulated to prevent the loss of heat and the compressor
should be located as near as possible to the tank being
emptied. In extremely cold climates, if the line from the
storage tank to the compressor is over 15 feet (4.6 meters)
long, it should be insulated to lessen the possibility of
vapors condensing as they flow to the compressor. The
vapor recovery discharge line should not be insulated.
Placing the compressor as close as possible to the tank
The line size helps determine the plant capacity almost
as much as the size of the compressor, and liquid line
sizes are a bigger factor than vapor lines. If the pressure
gauges on the head indicate more than a 15 to 20 psi
(1.0 to 1.4 bars) differential between the inlet and outlet
pressures, the line sizes may be too small or there is too
much piping restriction. The less restriction in the piping,
the better the flow. Appendix C shows recommended
pipe sizes for typical LPG/NH3 compressor installation.
9
Hydrostatic releif valve
Back check valve
C
A
Relief valve
4-Way valve
Vapor line rail car
(in-bound
bulk transfer)
B
Bury or insulate in
cold climate areas
Vapor line to gas
phase in storage
4-way Valve Operation
A
C
Vapor line to liquid
phase in storage
Service to
Perform
1. Unload
tank car into
storage tank
2. Recover
vapors from
tank car into
storage tank
4-Way Valve
Position 2
B
4-way
Valve Position
A
B
C
Position
One
Open
Open
Close
Position
Two
Close
Open
Open
4-Way Valve
Position 1
Figure 2.3C: Three valve manifold piping system.
being unloaded will minimize heat loss from the discharge
line for the best liquid transfer rate.
(see section 2.4). It is of equal importance to protect the
discharge of the compressor from liquid. This may be
done by installing a check valve on the discharge and
designing the piping so liquid cannot gravity-drain back
into the compressor. Make sure to install a check valve
on vapor lines discharging to the liquid space of the tank.
Unloading stationary tanks with a compressor is quite
practical. Delivery trucks and other large containers can
be filled rapidly if the vapor system of the tank to be
filled will permit fast vapor withdrawal, and if the liquid
piping system is large enough. Many older trucks (and
some new ones) are not originally equipped with vapor
excess flow valves large enough to do a good job and
these should be replaced by a suitable size valve. The
liquid discharge should be connected to the tank truck
pump inlet line rather than the often oversized filler valve
connection in the tank head.
All piping must be in accordance with the laws and codes
governing the service. In the United States, the following
codes apply:
For LP-Gas — The National Fire Protection Association
Pamphlet No. 58, Standard for the Storage and Handling
of Liquefied Petroleum Gases.
For Ammonia — The American National Standards
Institute, Inc., K61.1-1999, Storage and Handling of
Anhydrous Ammonia.
It is of extreme importance to prevent the entry of
liquid into the compressor. The inlet of the compressor
should be protected from liquid entry by a liquid trap
10
Install, use and maintain this equipment according to
Corken instructions and all applicable federal, state, and
local laws and previously mentioned codes.
109 and 107 compressor mountings (see Appendix D for
details on standard Corken compressor mountings).
When the compressor will not be under more-or-less
constant observation an automatic trap is recommended.
The automatic trap replaces the float with electrical float
switches. If the liquid level should rise too high, the level
switch will open and disconnect the power to the motor
starter, stopping the compressor. This design ensures
the machine will be protected even when it is not under
close observation and is standard in the 109A and 107A
mounting configurations.
2.4 Liquid Traps
Compressors are designed to pressurize gas, not to pump
liquids. The entry of even a small amount of liquid into the
compressor will result in serious damage to the compressor.
On liquefied gas applications, a liquid trap must be used
to prevent the entry of liquid into the compressor.
Corken’s most sophisticated trap provides the most
thorough liquid separation. This trap is larger and is
ASME code stamped. It contains two level switches, one
for alarm and one for shutdown. In some cases the alarm
switch is used to activate a dump valve (not included
with trap) or sound an alarm for the trap to be manually
drained by the operator. This trap also contains a mist
pad. A mist pad is a mesh of interwoven wire to catch fine
liquid mists. The ASME code trap is standard in the 109B
and 107B mounting configurations.
Corken offers three types of liquid traps for removal of
liquids in the gas stream (see figure 2.4A). The simplest is
a mechanical float trap. As the liquid enters the trap the
gas velocity is greatly reduced, which allows the liquid
to drop out. If the liquid level rises above the inlet, the
float will plug the compressor suction. The compressor
creates a vacuum in the inlet piping and continues to
operate until the operator manually shuts it down. The
trap must be drained and the vacuum-breaker valve
opened before restarting the compressor, to allow the
float to drop back. This type of trap is only appropriate
for use where the operator keeps the compressor under
fairly close observation. This trap is provided with the
Standard Liquid Trap
Standard liquid trap with
mechanical float assembly
and drain valve.
Sizes: • 1-1/4" x 1-1/4" NPT
• 1-1/4" x 1-1/2" NPT
A typical wiring diagram for the liquid level switch is
shown in figure 2.4B.
Automatic Liquid Trap
ASME Automatic Liquid Trap
Automatic liquid trap, with one
NEMA 7 liquid-level switch for
compressor shutdown and
drain valve.
Class 300 RF flange code-stamped
automatic liquid trap with two NEMA 7 liquidlevel switches for compressor shutdown and
alarm. Equipped with relief valve, pressure
gauge, demister pad, and drain valve.
Sizes: • 1-1/4" x 1-1/4" NPT
• 1-1/4" x 1-1/2" NPT
Figure 2.4A: Liquid traps.
11
Sizes: • 1-1/2" x 1-1/2" NPT
• 2" x 2" Class 300 RF flange
2.6. Crankcase Lubrication
Typical Float Switch Wiring Diagram
1 = Common, black
2 = Normally closed, blue
3 = Normally open, red
Non-detergent oil is recommended for Corken vertical
compressors. Detergent oils tend to keep wear particles
and debris suspended in the oil, whereas non-detergent
oils let them settle in the bottom of the crankcase.
When non-detergent oils are not available, detergent
oils may usually be successfully substituted, although
compressors handling ammonia, amine, or imine gases
are notable exceptions. These gases react with the
detergent and cause the crankcase oil to become
corrosive and contaminated. Figures 2.6A and 2.6B show
recommended oil viscosities and crankcase capacities.
Figure 2.4B: Typical float switch wiring diagram.
NOTE: The level switch MUST be removed from
the trap before grounding any welding devices to
the trap or associated piping! Failure to do so will
damage the switch contacts.
Acceptable Crankcase Oil Products
for Corken Compressors
Oil product
Exxon®
If your compressor is equipped with a liquid trap
of other than Corken manufacture, make sure it is
of adequate size to thoroughly remove any liquid
present in the suction stream.
Constant Weight - Non-Detergent - R&O Inhibited
ISO
VI
SAE
Ambient Temp.
TERESSTIC
Mobil®
RARUS 427
Reciprocating
Compressor Oil
DTE Oil Heavy Medium
Dectol R&O Oil
Conoco®
2.5 Driver Installation / Flywheels
Corken vertical compressors may be driven by either
electric motors or combustion engines (gasoline, diesel,
natural gas, etc.). Corken compressors are usually V-belt
driven but they are also suitable for direct drive applications
as well. Direct drive applications require an extended
crankshaft to allow the attachment of a rigid metal coupling.
Dectol R&O Oil
100
68
46
95
95
95
30
20+
20
65° – 100° F
45° – 70° F
35° – 50° F
100
95
30
65° – 100° F
68
46
95
95
20+
20
45° – 70° F
35° – 50° F
100
68
46
98
97
99
30
20+
20
65° – 100° F
45° – 70° F
35° – 50° F
100
68
46
92
97
102
30
20+
20
65° – 100° F
45° – 70° F
35° – 50° F
100
68
46
100
100
100
30
20+
20
65° – 100° F
45° – 70° F
35° – 50° F
Texaco®
Regal R&O Oil
Note: Flexible couplings are not suitable for reciprocating
compressors. Never operate a reciprocating compressor
without a flywheel.
Sun®
SunVis 900 Oil
Drivers should be selected so the compressor operates
between 350 to 825 RPM. The unit must not be operated
without the flywheel or severe torsional imbalances will result
that could cause vibration and high horsepower requirement.
The flywheel should never be replaced by another pulley
unless it has a higher WK 2 value than the flywheel.
Figure 2.6A: Oil selection chart.
A humid climate can cause problems, particularly in
explosion proof motors. The normal breathing of the
motor, and alternating between being warm when running
and being cool when stopped, can cause moist air to be
drawn into the motor. This moist air will condense, and
may eventually add enough water inside the motor to
cause it to fail. To prevent this, make a practice of running
the motor at least once a week on a bright, dry day for an
hour or so without the V-belts. In this period of time the
motor will heat up and vaporize the condensed moisture,
driving it from the motor. No motor manufacturer will
guarantee their explosion proof or totally enclosed
(TEFC) motor against damage from moisture.
Compressor
Model
Approximate
Quarts
Capacity Liters
91
0.9
0.8
291
1.5
1.4
491
3.0
2.8
691/891
7.0
6.6
Figure 2.6B: Oil capacity chart.
Synthetic lubricants are generally not necessary. Please
consult your lubricate supplier if you are considering the
use of synthetic oil. To add oil, remove the name plate
and pour through the opening.
General Notes on Crankcase Oil
Corken gas compressors are used for a wide variety of
gases in a multitude of operating conditions. They are
used in all areas of the world from hot dusty deserts, to
humid coastal areas, to cold arctic climates. No single
crankcase oil or maintenance schedule is right for every
compressor installation. Availability of brands and grades
For installation with engine drivers, thoroughly review
instructions from the engine manufacturer to assure the
unit is properly installed.
12
Viscosity Index
of oil varies from one location to another. These factors
can make it challenging for a Corken compressor user to
select a suitable crankcase oil.
Viscosity Index (VI) is a measure of how much the
oil’s viscosity changes as its temperature changes. A
low viscosity index is an indication that the viscosity
changes more as the temperature changes. A high
viscosity reflects a more stable viscosity, and is generally
preferred for Corken compressors.
It is safe to say that purchasing a quality crankcase oil,
and changing it regularly, is significantly less costly than
the repair bill and downtime associated with a lubrication
failure in any gas compressor. Given the relatively
small volume of oil used in the crankcase of a Corken
compressor, and the critical nature of the services
where these compressors are typically used, selecting
the appropriate high-quality oil is the most economical
choice. It will help ensure the dependability and longevity
of the compressor.
Oil with a low viscosity index tends to thin out as the oil
temperature increases. This can cause lubrication failure
as well as unstable oil pressure. The minimum Viscosity
Index for oils used in Corken compressors is 95 (VI is
a unit-less number). This is particularly important when
operating at high or low temperature extremes, or at a
variety of ambient temperatures (seasonal changes).
Oils to Avoid
Selecting a crankcase oil based on low price or easy
availability is seldom the most economic decision.
Following are oils to avoid.
Pour Point
The pour point of an oil is the lowest temperature at
which the oil flows. At temperatures below the pour
point, the oil is very thick and can’t freely flow to the
compressor’s bearings and other wear surfaces, or even
to the compressor’s oil pump.
• Do not use engine/motor oil with an API Service SA
through SH.
• Do not use any oil with a viscosity index below 95.
In low ambient temperature operation, the oil’s pour point
is critical. An oil should have a pour point at least 15ºF
(8ºC) below the lowest expected ambient temperature.
For example, if the minimum ambient temperature is
expected to be 0ºF (-18ºC), the pour point must be no
higher than -15ºF (-26ºC).
• Do not use any oil with a pour point less than 15ºF
(8ºC) lower than the anticipated minimum ambient
temperature (unless a crankcase oil heater is used).
See below for additional detail on each of these parameters.
Industrial Oils
Do not assume the pour point of an oil is low enough.
Consult the oil’s technical data sheet. Many oils have a
pour point around 0 to 10ºF (-18 to -12ºC) which is too
high for low ambient temperatures. Synthetic oils often
have a lower pour point than conventional oils.
Corken recommends using industrial oils (rather than
engine oil or “motor oil”). Industrial oils have additives
specifically selected and blended for specific purposes.
Many are designed specifically for the conditions
inherent in compressor crankcases. Such industrial
oils are required for Corken compressors operating in
continuous duty or heavily loaded applications.
Engine Oils (Motor Oils)
Engine oils are formulated for use in internal combustion
engines and contain additives that specifically counter
the contaminants created by the combustion of fuel
(soot, CO2, water, etc.). A gas compressor crankcase
is a different environment than an engine crankcase.
Thus, engine oils are not necessarily the best oils to use
in a gas compressor. They are by far the most readily
available oils.
Industrial oils do not receive an API service designation
like an engine oil does.
Critical Oil Characteristics
Viscosity
The viscosity of a crankcase oil is a measure of its
resistance to flow. Viscosity is the most important
physical property of lubricating oil. Oils with higher
viscosity (ISO 100 and ISO 150) are thicker and are
used for higher ambient temperatures. Oils with lower
viscosity (ISO 68, ISO 46, and ISO 32) are thinner and
are used at lower ambient temperatures. However, oils
with a high viscosity index (see below) can be used at
wider ambient temperature range compared to oils with
a lower viscosity index.
If a suitable industrial oil is not available, engine oils can be
used in Corken compressors used in intermittent service.
Heavily loaded compressors or those in continuous duty
service should always use high quality industrial oil. If
engine oil is used, it is critical that the engine oil have an
adequate API Service Grade.
13
API Service
•Oil dilution caused by condensation or other liquids in
the gas stream (see below)
The American Petroleum Institute (API) grades motor
oils (oils designed for use in engines in cars and trucks)
with a two letter classification. Oils with API grades “SA”
through “SH” are obsolete and should never be used
in modern engines or gas compressors. Unfortunately,
motor oils with an “SA” and “SB” ratings are still readily
available at parts stores, service stations, and other
retail outlets at low prices. These are low quality oils and
should NEVER be used in Corken compressors. If motor
oil is used in a Corken compressor, it should have an
API Service of SJ or better. Multigrade motor oils such
as 10W-40 tend to have a higher viscosity index.
•Change in viscosity for any reason (various oil additives
can break down over time)
•Changing ambient temperature may cause the need for
a different viscosity
The oil should be changed as often as necessary
to maintain clean, undiluted oil. Each time the oil is
changed, the oil filter (Corken part number 4225) should
also be changed.
Ammonia Services
Service classification
S=gasoline engine
C=diesel engine
Quality rating
SERVICE S
I
P
•Phillips 66: Ammonia Compressor Oil
•Chevron: Capella P68
NG
RG
•Royal Purple: Uni-Temp
Crankcase Oil Heater Option
VI
ENE
SAE
5W-30
Oils that can be used in ammonia compressors:
N
A
API (American
Petroleum Institute)
Never use a detergent oil in a compressor in ammonia
service. Ammonia will react with the detergent and cause
lubrication failure.
Y C O NSER
Corken offers a crankcase oil heater as an option on
all models except the small model 91. This heater is
available in 110V and 220V versions and is rated for Class
1, Division 1 and 2, Group B, C, D service. The heater
includes a thermostat set at 70°F (21.1°C).
Example of API “Donut” symbol used on motor oil.
Oil suppliers post product data sheets on line that
contain various physical properties of the oil , and the
API Service classification. If there is any doubt, do not
use the oil.
If a crankcase heater is desired, it is best to order the
heater with the compressor (crankcase specification
“MH”). The mounting hole for the heater is not drilled
unless the heater is ordered with the compressor. It is
also possible to order the compressor with the hole
drilled (1" NPT), but without the heater (crankcase
specification “MR”). With this option, a customer can
supply their own heater.
Oil Change Intervals
Oil change intervals can vary significantly depending
on local environmental conditions, the gas being
compressed, and the oil being used. Unless there are
factors that shorten the life of the oil, the following
recommendations apply:
2.7 Relief Valves
An appropriate relief valve must be installed at the
compressor discharge. On Corken 107-style mounted
units a relief valve should be fitted in the piping between
the compressor discharge and the four-way valve (see
figure 1.3A). Relief valves should be made of a material
compatible with the gas being compressed. Local codes
and regulations should be checked for specific relief
valve requirements. Also, relief valves may be required at
other points in the compressor’s system piping.
Conventional oil: 2200 hours or 6 months – whichever
comes first
Synthetic oil:
6000 - 8000 hours* or one year –
whichever comes first
*Oil change intervals in this range should be confirmed via oil analysis.
Factors that shorten the life of the oil:
•Dirty or dusty environmental conditions that cause the
oil to become dirty or discolored
14
2.8 Truck Mounted Compressors
Corken compressors may be mounted on trucks to perform
liquid transfer operations as described in section 1.1. The
compressor should be mounted so the inspection plate is
accessible for packing adjustment. The compressor must
be protected against liquid as explained in section 2.4
and a relief valve must be installed in the discharge piping
before the first downstream shutoff valve.
Figure 2.8C: Outside transport mounting
Three types of mountings are typically used. The inside
mounting (figure 2.8A) drives the compressor directly off
the PTO shaft. The PTO must be selected to drive the
compressor between 400 and 800 RPM. An extended
compressor crankshaft is required so the U-joint yoke
may connect to the compressor without removing the
flywheel. Do not operate the compressor without a
flywheel. Use a U-joint with a splined joint and make sure
the connections are parallel and in line. The U-joint angle
should be less than 15 degrees (see figure 2.8B). Always
use an even number of U-joints.
Figure 2.8D: Top transport mounting.
2.9 Shutdown/Alarm Devices
For many applications, shutdown/alarm switches will
provide worthwhile protection that may prevent serious
damage to your compressor system. All electronic
devices should be selected to meet local code
requirements. Shutdown/alarm devices typically used on
Corken compressors are as follows:
Figure 2.8A: Inside transport mounting.
1. Low Oil Pressure Switch: Shuts down the unit if
crankcase oil pressure falls below 12 psi due to oil
pump failure or low oil level in crankcase. The switch
or the compressor controller must have a 30 second
delay on startup which allows the compressor to
build oil pressure in the crankcase.
2. High Discharge Temperature Switch: This switch
is strongly recommended for all applications. Both
the High Discharge Temperature switch (HDT) and
compressor have an operating pressure range. It is
preferable that the switch set point be midpoint in its
range and 30°F (-1°C) above the normal discharge
temperature, but below the maximum design
temperature for the compressor of 350°F (176.7°C).
Figure 2.8B: U-joint drive for compressor.
Depending on the truck design, the compressor may be
outside or top mounted as shown in figures 2.8C and
2.8D to be V-belt driven. Power is transmitted through
a U-joint drive shaft, jackshaft with two pillow block
bearings, V-belt sheave and V-belts. An idle pulley may
be used under the truck frame.
3. Low Suction Pressure Switch: Shuts down the
unit if inlet pressure is not within the preset limit (set
point). In some cases, it is important not to pull a
vacuum because of the potential of pulling oil from the
crankcase into the gas stream.
4. High Discharge Pressure Switch: Shuts down the
unit if the outlet pressure reaches a preset limit (set
point). Both the switch and the compressor have an
operating range. The set point of the pressure switch
should be as follows:
15
Greater than the normal operating pressure for the
compressor.
bushing and three bolts (refer to figure 3.2A). These bolts
should be tightened in an even and progressive manner until
torqued as specified below. There must be a gap between
the bushing flange and the flywheel when installation is
complete. Always check the flywheel runout before startup
and readjust if it exceeds the value listed in Appendix B.
Less than 90% of the relief valve set point pressure.
Less than the maximum operating pressure of the
compressor.
Midpoint of the pressure switch range.
5. Vibration Switch: Shuts down the unit if vibration
becomes excessive. Recommended for units mounted
to a portable skid.
Bushing Size
Diameter
In. (mm)
Bolt Torque
Ft.-lb. (N•m)
SF
46.25 (1,174.75)
30 (4.1)
E
6.0 (152.40)
60 (8.3)
J
7.25 (184.15)
135 (18.7)
Chapter 3—Starting Up Your
Corken Compressor
NOTE: Before initial startup of the compressor be
sure the principal of using a compressor for liquid
transfer by vapor differential pressure is understood
(see section 1.1). Read this entire chapter, then
proceed with the startup checklist.
3.1 Inspection After
Extended Storage
Figure 3.2A: Flywheel installation.
If your compressor has been out of service for a long period
of time, you should verify the cylinder bore and valve areas
are free of rust and other debris (see chapter 5 of this IOM
manual for valve and/or cylinder head removal instructions).
Tighten the belts until they are taut, but not extremely
tight. Consult your V-belt supplier for specific tension
recommendations. Belts that are too tight may cause
premature bearing failure. Refer to figure 3.2B.
Drain the oil from the crankcase and remove the
nameplate and crankcase inspection plate. Inspect the
running gear for signs of rust and clean or replace parts
as necessary. Replace the crankcase inspection plate
and fill crankcase with the appropriate lubricant. Squirt
oil on the crossheads and rotate the crankshaft by hand
to ensure that all bearing surfaces are coated with oil.
Rotate unit manually to ensure running gear functions
properly. Replace nameplate and proceed with startup.
3.2 Flywheel and V-belt Alignment
Before working on the drive assembly, be sure that the
electric power is disconnected. When mounting new
belts, always make sure the driver and compressor are
close enough together to avoid forcing.
Figure 3.2B: Belt tension.
Improper belt tension and sheave alignment can cause
vibration, excessive belt wear and premature bearing
failures. Before operating your compressor, check alignment
of the V-grooves of the compressor flywheel and driver
sheave. Visual inspection often will indicate if the belts are
properly aligned, but use of a square is the best method.
3.3 Crankcase Oil Pressure
Adjustment
Corken compressor models 291 through 891 are
equipped with an automatically reversible gear type oil
pump (if your compressor is the splash lubricated Model
The flywheel is mounted on the shaft via a split, tapered
16
91, proceed to section 3.4). It is essential to ensure
the pumping system is primed and the oil pressure is
properly adjusted in order to assure smooth operation.
5.Check all mounting shims, cylinder and piping
supports to ensure that no undue twisting forces exist
on the compressor.
Before starting your compressor, check and fill the
crankcase with the proper quantity of lubricating oil.
(Refer to section 2.6)
6. Verify that strainer elements are in place and clean.
When the compressor is first started, observe the
crankcase oil pressure gauge. If the gauge fails to
indicate pressure within 30 seconds, stop the machine
and loosen the oil filter. Restart the compressor and run
until oil comes out and tighten the filter.
8.Check V-belt tension and alignment. Check drive
alignment on direct drive units.
7. Verify that cylinder bore and valve areas are clean.
9. Rotate unit by hand. Check flywheel for wobble or play.
10.Check crankcase oil level.
The oil pressure should be about 20 psi (1.4 bars)
minimum for normal service. If the discharge pressure
is above 200 psi (13.8 bars) the oil pressure must be
maintained at a minimum of 25 psi (1.7 bars). A springloaded relief valve mounted on the bearing housing
opposite the flywheel regulates the oil pressure. As
shown in figure 3.3A, turn the adjusting screw clockwise
to increase the oil pressure and counterclockwise to
lower it. Be sure to loosen the adjusting screw locknut
before trying to turn the screw and tighten it after making
any adjustment.
11.Drain all liquid traps, separators, etc.
12.Verify proper electrical supply to motor and panel.
13.Check that all gauges are at zero level reading.
14.Test piping system for leaks.
15.Purge unit of air before pressurizing with gas.
16.Carefully check for any loose connections or bolts.
17.Remove all stray objects (rags, tools, etc.) from
vicinity of unit.
18.Verify that all valves are open or closed as required.
Oil Pressure
Adjusting
Screw
-
+
19.Double-check all of the above.
After Starting Compressor
1. Verify and note proper oil pressure. Shut down and
correct any problem immediately.
Lock Nut
Oil Pump Cover
Oil Level Bayonet
2.Observe noise and vibration
immediately if excessive.
Oil Pressure Gauge
levels.
Correct
3. Verify proper compressor speed.
Figure 3.3A: Oil pressure adjustment.
3.4 Startup Check List
4. Examine entire system for gas, oil or water levels.
Please verify all of the items on this list before
starting your compressor! Failure to do so may result
in a costly (or dangerous) mistake.
5. Note rotation direction.
6. Check start-up voltage drop, running amperage and
voltage at motor junction box (not at the starter).
Before Starting the Compressor
7. Test each shutdown device and record set points.
1.Become familiar with the function of all piping
associated with the compressor. Know each line’s use!
8. Test all relief valves.
2. Verify that actual operating conditions will match the
anticipated conditions.
9. Check and record all temperatures, pressures and
volumes after 30 minutes and 1 hour.
3.Ensure that line pressures are within cylinder
pressure ratings.
10.After 1 hour running time, tighten all head bolts, valve
holddown bolts, and baseplate bolts. See Appendix B
for torque values.
4. Clean out all piping.
17
Chapter 4—Routine Maintenance Chart
Item to Check
Daily
Weekly
Monthly
Six
Months
Yearly
Crankcase oil pressure
Compressor discharge pressure
Overall visual check
1
Crankcase oil level
Drain liquid from accumulation points
1
2
Drain distance pieces
Clean cooling surfaces on compressor and
intercooler (if any)
Lubricator supply tank level (if any)
Check belts for correct tension
Inspect valve assemblies
Lubricate motor bearings in accordance with
manufacturers’ recommendations
Inspect motor starter contact points
3
Inspect piston rings 1
Change oil every 2,200 hours of operation or every 6 months, whichever occurs first. If the oil is unusually dirty, change it as often as needed to maintain a
clean oil condition. Change replacement filter 4225 with every oil change.
2
Liquid traps should be drained prior to startup.
3
Piston ring life varies greatly, depending on application, gas, and operating pressures. Consult factory for additional recommendations for your specific
application.
1
Chapter 5—Routine Service and
Repair Procedures
scratches on the valve disc. In many cases, valves may
simply be cleaned and reinstalled. If the valves show
any damage, they should be repaired or replaced.
Replacement is usually preferable, although individual
parts are available. If valve discs are replaced, seats
should also be lapped until they are perfectly smooth.
A maximum of .005 inch can be removed during the
lapping process. If more than .005 inch must be removed
to achieve a smooth surface, the valve should be
discarded. If discs are replaced without relapping the
seat, rapid wear and leakage may occur.
CAUTION: Always relieve pressure in the unit
before attempting any repairs. After repair,
the unit should be pressure tested and checked for
leaks at all joints and sealing surfaces.
If routine maintenance is performed as listed in chapter
4, repair service on your Corken gas compressor is
generally limited to replacing valves or piston rings.
When it comes time to order replacement parts, be sure
to consult the part details appendix in the back of this
Installation, Operation & Maintenance (IOM) manual for a
complete list of part numbers and descriptions.
Each suction and/or discharge valve assembly is easily
removed as a unit for inspection. If any part of the valve
assembly is broken, the valve assembly should be replaced.
See valve assembly parts details in the appendices for a
complete list of part numbers and descriptions.
5.1 Valves
If a valve is leaking due to dirt or any other foreign
material that keeps the valve plate and seat from sealing,
the valve may be cleaned and reused. New gaskets and/
or O-rings should be used to assure a good seal.
Test the compressor valves by closing the inlet piping
valves while the unit is running; however, do not allow
the machine to operate in this way very long. If the
inlet pressure gauge does not drop to zero almost
immediately, one or more of the valves is probably either
damaged or dirty. It is possible, of course, that the
pressure gauge itself is faulty.
The valve holddown assemblies and valve assemblies on
the following pages show the various specifications used
on models 91, 291, 491, 691 and 891 compressors. Since
more than one suction valve arrangement is available for
each model of compressor, it is necessary to know your
complete model number so you can identify the valve
Inspect valves for breakage, corrosion, debris, and
18
Valve Inspection and/or Replacement for Models
91 and 291 Compressors
type specification number (see examples listed below).
In most cases for liquid transfer and/or vapor recovery
compressors, the valve type will be spec 3 or 3P.
Before removing and inspecting the valves, begin by
depressurizing and purging (if necessary) the unit.
Model number 491AM 3 FBANSNN
Valve type = spec 3
Disassembly
1. Unscrew the valve cap and remove O-ring.
Model number 691AM 3P FBANSNN
2. With the special wrench supplied with your compressor
at time of purchase, remove the holddown screw.
Valve type = spec 3P
Valve Holddown Assemblies: Depending on your model
of compressor, the valve holddown assembly has all or a
combination of the following:
3.After the holddown screw has been removed, the
valve assembly and valve gasket can be lifted out.
4. Carefully inspect for dirt or broken/damaged parts.
1. Valve cap / cover
5.Inspect valves for breakage, corrosion, debris and
scratches on the valve disc or plate. In many cases,
valves may simply be cleaned and reinstalled. If the
valves show any damage, they should be repaired or
replaced. Replacement is usually preferable although
repair parts are available. If valve plates are replaced,
seats should also be lapped until they are perfectly
smooth. If more than .005 in. must be removed
to achieve a smooth surface, the valve should be
discarded. If plates are replaced without relapping the
seat, rapid wear and leakage may occur.
2. Valve cap O-ring
3. Holddown screw
4. Valve cover plate
5. Valve cover plate bolts
6. Valve cover plate O-ring
7. Valve spacer (model 491 only)
8. Valve cage
9. Valve assembly
Assembly
10.Valve gasket
1. Insert metal valve gasket into the suction and/or
discharge opening of the head. The metal valve
gasket should always be replaced when the valve
is reinstalled.
Valve Assemblies: Depending on your valve specification,
the valve assembly has all or a combination of the following:
1.Gasket
2. Insert cleaned or new valve assembly. Make sure the
suction and discharge valves are in the proper suction
and discharge opening in the head. NOTE: The spec
3 suction valves for a model 91 and 291 compressor
are pre-set so no adjustments to liquid relief pressure
are necessary.
2. Adjusting screw
3. Relief ball spring
4. Relief ball
5. Valve seat
3. Replace the holddown screw and tighten to the value
listed in Appendix B to ensure the valve gasket is
properly seated. NOTE: Gaskets and O-rings are not
normally reusable.
6. Valve plate
7.Spacers
8.Washer
4. Replace the O-ring and valve cap and tighten to the
value listed in Appendix B. O-rings sealing the valve
caps should be replaced.
9. Valve spring
10.Suction valve post
12.Valve gasket
5.Check bolts and valve holddown screws after first
week of operation. Re-torque if necessary. See
Appendix B for torque values.
See valve holddown and valve assembly part details
in the appendix for a complete list of part numbers
and descriptions.
Valve Inspection and/or Replacement for Models
491, 691 and 891 Compressors
11.Valve bumper
Before removing and inspecting the valves, begin by
depressurizing and purging (if necessary) the unit.
19
Disassembly
adjusting screw to set the liquid relief pressure. To set
the liquid relief pressure, the screw bottom must be
tightened to 1.8" from the top of the valve body.
1. Unscrew the valve cap/nut and remove the O-ring
from the coverplate.
8.Check bolts and valve holddown screws after first
week of operation. Re-torque if necessary. See
Appendix B for torque values.
2. Remove the valve cover plate, O-ring and holddown
screw by removing each of the four bolts. NOTE:
Since the holddown screw has been secured with an
impact wrench at the factory, you will probably need
to wait to remove the holddown screw until after the
cover plate has been removed. At this point in time,
the holddown screw can be easily removed from the
cover plate. The holddown screw on model 691 and
891 is most easily removed with the special wrench
supplied with your compressor at time of purchasing.
5.2 Heads
A compressor head very seldom requires replacement
if the compressor is properly maintained. The primary
cause of damage to a head is corrosion and the entry
of solid debris or liquid into the compression chamber.
Improper storage can also result in corrosion damage to
the head (for proper storage instructions see chapter 6).
3. After the cover plate and O-ring have been removed,
the valve spacer (model 491 only), valve cage, valve
assembly and valve gasket can be lifted out.
Many compressor repair operations require removal of the
head. While the compressor is disassembled, special care
should be taken to avoid damage or corrosion to the head. If
the compressor is to be left open for more than a few hours,
bare metal surfaces should be coated with rust preventative.
4.Inspect valves for breakage, corrosion, debris,
and scratches on the valve plate. In many cases,
valves may simply be cleaned and reinstalled. If the
valves show any damage, they should be repaired or
replaced. Replacement is usually preferable although
repair parts are available. If valve plates are replaced,
seats should also be lapped until they are perfectly
smooth. If more than .005 in. must be removed
to achieve a smooth surface, the valve should be
discarded. If plates are replaced without relapping the
seat, rapid wear and leakage may occur.
When reassembling the compressor, make sure the bolts
are retightened as shown in Appendix B.
5.3 Piston Rings and Piston Ring
Expanders
Piston ring life will vary considerably from application to
application. Ring life will improve dramatically at lower
speeds and temperatures.
Assembly
1.Insert metal valve gasket into the suction and/or
discharge opening of the head. The metal valve gasket
should always be replaced when the valve is reinstalled.
1.To replace the piston rings, depressurize the
compressor and purge if necessary.
2. Insert cleaned or new valve assembly. Make sure the
suction and discharge valves are in the proper suction
and discharge opening in the head.
2. Remove the head to gain access to the compressor
cylinder.
3. Insert the valve cage and valve spacer (NOTE: spacer
applies to model 491 compressor only).
3.Loosen the piston head bolts. Remove the piston as
shown in figure 5.3A by pinching two loose bolts together.
4.Replace the O-ring and valve cover plate. Torque
bolts to the value listed in Appendix B. CAUTION: Be
sure the holddown screw has been removed.
5. Insert the holddown screw and tighten to the value
listed in Appendix B to ensure the valve gasket is
properly seated. NOTE: Gaskets and O-rings are not
normally reusable.
6. Replace the O-ring (or gasket) and valve cap/nut and
tighten to the value listed in Appendix B. O-rings
sealing the valve cap should be replaced if they show
signs of wear or damage. Valve caps sealed by flat
metals gaskets should be reinstalled with new gaskets.
Figure 5.3A: Piston removal
4.Piston rings and expanders may then be easily
removed and replaced. Corken recommends replacing
expanders whenever rings are replaced. To determine
if rings should be replaced, measure the radial
thickness and compare it to the chart in Appendix C.
7. NOTE: The Model 491 Spec 3 suction valve has an
20
5.4 Pistons
Models 91, 291, 491, and 691
7. Reinstall the piston platform with the same thickness
of shims as before, BUT DO NOT REINSTALL THE
ROLL PIN.
1. To replace the pistons, depressurize the compressor
and purge if necessary.
8. Install the cylinder and install the piston heads with
new piston rings and expanders.
2.Remove the compressor cylinder and head (see
section 5.2).
9. Now measure dimension “X” shown in the illustration.
If this measurement does not fall within the tolerances
shown in Appendix B, remove the piston, adjust the
shims as necessary and remeasure the “X” dimension.
3. Remove the piston head by loosening and removing
the socket head bolts holding the piston head to the
piston platform (see figure 5.3A).
10.When the piston is properly shimmed, tighten the lock
nut to the torque value shown in Appendix B.
4. Next, remove the lock pin with a pair of needle nose
pliers. The locknut may then be removed and the
piston platform lifted off the end of the piston rod.
11.Now install a new lock pin and lock the piston nut
in place.
5. Check the thrust washer and shims for damage and
replace if necessary.
12.Install the piston head and tighten the socket head
bolts in an alternating sequence.
6. Before installing the new piston, measure the thickness
of the existing shims. For Models 91, 291, and 491, the
shims are placed between the thrust washer and piston
platform. For model 691, the shims are placed between
the platform and piston head (see figures 5.4A and 5.4B).
13.Reinstall the head (see section 5.2) and follow standard
startup procedure. (Note: Some compressors may
have self-locking nuts without roll pins.)
“X” Piston
Clearance
Model 891
1. To replace the pistons, depressurize the compressor
and purge if necessary.
Piston Locknut
Piston Ring Expander
Piston
Lock Pin
Piston Ring
Bolt
2. Remove the cylinder cap, head and cylinder.
3. Remove the piston cap by loosening and removing
the socket head bolts holding the piston cap to the
piston (see figure 5.3A).
Piston Head
Shims
Thrust
Washer
Piston
Platform
4. Next, remove the lock nut and lift the piston off the
end of the piston rod.
Cylinder
5. Check the thrust washer and shims for damage and
replace if necessary.
Piston Rod
Figure 5.4A: Piston cross section model sizes 91 through 491
“X” Piston
Clearance
6. Before installing the new piston, measure the thickness
of the existing shims.
Piston Locknut
Piston Ring Expander
Piston
Lock Pin
Piston Ring
Bolt
7. Replace the cylinder.
8. Install the piston with the same thickness of shims as
before, and with new piston rings and expanders.
Piston Head
Shims
Piston
Platform
9. Now remove a lower valve and measure dimension
“Y” at the bottom of the piston shown in Appendix
E—Piston Assembly Details. If this measurement
does not fall within the tolerances listed in the
piston assembly details (Appendix E), remove the
piston, adjust the shims as necessary and measure
the “Y” dimension.
Cylinder
Piston Rod
Figure 5.4B: Piston cross section model 691
21
15.Replace the previously removed valves. Best results
will be obtained if new valve gaskets are used.
16.Follow standard startup procedures.
5.5 Piston Rod Packing
Adjustment
(Y)
Piston rod packing should be adjusted or replaced
whenever leakage becomes noticeable. Typically, it is a
good idea to replace piston rod packing and piston rings
at the same time. For instructions on replacing the piston
rod packing, see section 5.6.
(Y)
Piston
Piston
NOTE: Packing that cannot be adjusted should be
replaced.
Piston bottom dead center
(X)
(X)
Piston
Piston
Figure 5.5A: Packing adjusting nuts.
5.6 Cylinder and Packing
Replacement
Cylinders very seldom require replacement if the
compressor is properly maintained. The primary
cause of damage to cylinders is corrosion and the
entry of solid debris or liquid into the compression
chamber. Improper storage can also result in corrosion
damage to cylinder (for proper storage instructions
see chapter 6).
Piston top dead center
10.When the piston is properly shimmed, tighten the lock
nut as shown in Appendix B.
If the cylinder does become damaged or corroded, use
a hone to smooth the cylinder bore and then polish it
to the value shown in Appendix B. If more than .005
in. must be removed to smooth the bore, replace the
cylinder. Cylinder liners and oversized rings are not
available. OVERBORING THE CYLINDER WILL RESULT
IN GREATLY REDUCED RING LIFE.
11.Replace the piston cap with the same thickness of
shims as before.
12.Reinstall the piston cap and cylinder head.
13.Now remove an upper valve and measure dimension
“X” at the top of the piston shown in Appendix E—
Piston Assembly Details. If this measurement does
not fall within the tolerances in Appendix E, remove
the cylinder head and piston cap and adjust the shims
as necessary. Repeat the steps and measure the “X”
dimension again.
Many compressor repair operations require removal of
the cylinder. While the compressor is disassembled,
special care should be taken to avoid damage or
corrosion to the cylinder. If the compressor is to be left
open for more than a few hours, bare metal surfaces
should be coated with rust preventative.
14.When the piston cap is properly shimmed, tighten the
socket head bolts in an alternating sequence. Torque
socket head bolt to the values listed in Appendix B.
When reassembling the compressor, make sure the bolts
are retightened to the valves shown in Appendix B.
22
Packing Replacement Instructions
5. Install locking device (part number 1192) into adjusting
screw and cut, leaving 1/8" exposed. Tighten adjusting
screw until plastic locking device engages the first
thread in the crosshead guide.
Caution: Bleed all pressure from the compressor and
piping, and purge (if necessary), before starting to install
new piston rod packing. After repair, the unit should be
pressure tested and checked for leaks at all joints and
gasket surfaces. When the compressor is being used
with toxic, dangerous, flammable or explosive gases,
this pressure and leak testing should be done with air or
a dry, inert gas such as nitrogen.
6. Oil piston rod and install the packing installation cone
(part number 4005) over the threaded end of the
piston rod.
7. Carefully slip the crosshead guide over the piston rod;
otherwise, you may damage the lips of the packing rings.
For simplicity, heads, pistons, and inspection plates are
not shown. For specific construction details and actual
part numbers, consult the appendix in the back of this
IOM manual. Use instructions below that apply to the
MODEL and SERIAL NUMBER of your compressor. Be
careful to arrange packing sets in the proper order.
8. Remove packing installation cone.
9.Install the crosshead guide O-ring, cylinder, piston
and head.
Model 291 Compressor (serial number SS55685
and later)
Model 491 Compressor (serial number XC30633
and later)
Cleanliness:
Prior to installation, inspect all parts for cleanliness
and visible defects. There should be absolutely no
scratches, dings, porosity, or foreign materials on
bearing surfaces, sealing surfaces, and packing
cartridge inner and outer diameters.
(Refer to Appendix E for packing assembly details)
Disassembly of Packing
Workmanship:
1. Depressurize and open the compressor.
Your Corken compressor is a precision piece of equipment
with very close tolerances. Treat it as such. Never beat
on it to get parts in or out.
2. Remove head, pistons and cylinder.
3.Remove cartridge holddown screw with special
wrench supplied with the compressor and packing
box cartridge.
Model 91 Compressor
(Refer to Appendix E for packing assembly details)
4.Loosen adjusting screw and remove retainer ring,
washers, packing spring and old packing from
packing box cartridge.
Disassembly of Packing
1. Depressurize and open the compressor.
2. Remove head, piston, cylinder, inspection plate and
crosshead guide.
Assembly of Packing
1. Clean, and then lightly oil, packing area inside packing
box cartridge.
3.Loosen adjusting screw and remove retainer ring,
washers, packing spring and old packing from
crosshead guide.
2. Slightly thread in adjusting screw.
3.Install packing rings including male and female
packing rings, one at a time, as shown in Appendix E.
Push in each one completely before adding the next
ring. The quantity of packing rings required will vary
due to tolerances; a good rule of thumb is to put in as
many as are removed.
Assembly of Packing
1.Clean, then lightly oil, packing area inside the
crosshead guide.
2.Slightly thread in the adjusting screw into the
crosshead guide.
4. Insert thin packing box washer, packing spring and
thicker washer.
3.Install packing rings including male and female
packing rings one at a time as shown in Appendix E.
Push in each one completely before adding the next
ring. The quantity of packing rings required will vary
due to tolerances; a good rule of thumb is to put in as
many as are removed.
5. Push down on washer and insert retainer ring.
6. Tighten adjusting screw until plastic locking device
(part number 1192) engages the first thread in the
packing box cartridge.
4. Insert thin packing box washer, packing spring and
thicker washer into the top of the crosshead guide.
7. Lubricate piston rod and replace cartridge O-ring.
23
8.Install packing installation cone part number 4005
over the threaded end of the piston rod.
Model 891 Compressor
9. Carefully slip the packing cartridge over the piston rod;
otherwise, you may damage the lips of the packing rings.
Disassembly of Packing (D-Style)
(Refer to Appendix E for packing assembly details)
1. Depressurize and open the compressor.
10.Remove packing installation cone.
2. Remove the cylinder cap, heads, pistons and cylinder.
11.Install and tighten cartridge holddown screw with
special compressor wrench.
3. Remove the packing barrels by prying upwardly under
each one and lifting entire packing barrel/cartridge
assembly up from piston rod.
12.Install cylinder O-ring, cylinder, pistons, and head.
Model 691 Compressor
4. Remove the four socket head screws that hold the
packing box cartridge to the barrel.
(Refer to Appendix E for packing assembly details)
5. Remove segmented packing and cups from barrel.
Disassembly of Packing
6. Remove lower retainer ring, washers, packing spring
and old V-ring packing from packing box cartridge.
1. Depressurize and open the compressor.
2. Remove head, pistons and cylinder.
Assembly of Packing (D-Style)
3.Remove cartridge holddown screw with special
wrench supplied with the compressor and packing
box cartridge.
1. Replace packing as required. The segmented packing
and cups are located in the packing barrel while the
V-ring packing is located in the packing box cartridge.
NOTE: Always use new O-rings when replacing
the packing.
4.Loosen adjusting screw and remove retainer ring,
washers, packing spring and old packing from
packing box cartridge.
2. V-ring packing set:
Assembly of Packing
1. Clean then lightly oil packing area inside packing box
cartridge.
2. Thread in adjusting screw until locking device (part
number 1192) is engaged into first thread of the
packing cartridge.
3.Install packing rings, including male and female
packing rings, one at a time, as shown in Appendix
E. Push in each one completely before adding the
next ring.
NOTE: The instructions below are for packing
specification “J”. Depending on the packing
specification used in your compressor, the
order of assembly for the packing rings, V-ring
packing, washers and packing spring will vary.
Refer to Appendix E to view the V-ring packing
arrangements and follow the order of assembly
and V-ring direction. If you do not know the
packing arrangement used in your compressor,
refer to the model number identification codes
listed in Appendix A.
a. Clean and lightly oil the packing area inside the
packing box cartridge.
4. Insert a packing washer, packing spring, and another
packing washer.
5. Push down on washer and insert retainer ring.
b.Insert the oil deflector ring through the bottom
opening of the packing box cartridge.
6. Oil piston rod and replace cartridge O-ring.
c. Insert the first retainer ring followed by a washer.
7. Install packing installation cone (part number 3905)
over the threaded end of the piston rod.
d. Insert the packing spring followed by another washer.
8. Carefully slip the packing cartridge over the piston
rod; otherwise, you may damage the lips of the
packing rings.
e. Insert a male packing ring followed by four V-rings
and one female packing ring. NOTE: Insert packing
rings and V-rings one at a time. Refer to Appendix
E for the proper direction of the male and female
packing rings and V-rings.
9.Install and tighten cartridge holddown screw with
special compressor wrench.
f. Lastly, insert the final washer. Push in on the
washer and install the second retainer ring.
10. Replace cylinder O-ring, cylinder, pistons and head.
24
5.7.1 Wrist Pin Bushing Replacement
3. Segmented packing:
1. To replace the wrist pin bushing, remove the retainer
rings that position the wrist pin in the crosshead.
NOTE: The instructions below are for packing
specification “J”. Depending on the packing
specification used in your compressor, the order of
assembly for the segmented packing arrangement
(radial or tangent) will vary. Refer to Appendix E
to view the segmented packing arrangements. If
you do not know the packing arrangement used
in your compressor, refer to the model number
identification codes listed in Appendix A.
2.Press out the wrist pin so the crosshead and
connecting rod may be separated. Inspect the wrist
pin for wear and damage and replace if necessary.
3.Press out the old wrist pin bushing and press a
new bushing into the connecting rod. DO NOT
MACHINE THE O.D. OR I.D. OF THE BUSHING
BEFORE PRESSING INTO CONNECTING ROD.
a. Clean the segmented packing cups and the area
inside the packing barrel.
4.Make sure the lubrication hole in the bushing
matches the oil passage in the connecting rod. If
the holes do not align, press out and insert a new
one. Bore the wrist pin bushing I.D. as indicated
on the respective connecting rod assembly details.
These pages are located in Appendix E. Over boring
the bushing can lead to premature failure of the wrist
pin bushing.
b.Insert the segmented packing cups, segmented
packing pairs and backup rings one at a time in
the order shown in Appendix E.
c. Reattach the packing box cartridge to the packing
barrel using the four socket head screws.
4. Install three O-rings on the packing barrel and packing
box cartridge as shown in the D-Style Crosshead
Guide Details in Appendix E.
5. Inspect the oil passage for debris and clean thoroughly
before proceeding.
6. Press the wrist pin back into the crosshead and
wrist pin and reinstall retainer rings. NOTE: The
fit between the wrist pin and bushing is tighter
than ordinary lubricated air compressors and
combustion engines.
5. Install packing installation cone (part number 3905)
over the threaded end of the piston rod.
6. Carefully install barrel/cartridge assemblies over the
piston rods, noting the alignment of the barrels as
they sit on the crosshead guide. The valve scallops
on the barrels must align properly with the valves in
the cylinder.
5.7.2 Replacing Connecting Rod Bearings
Connecting rod bearings are easily replaced by removing
the semicircular bearings. Make sure the indentations
in the connecting rod bearing and connecting rod line
up when installing the new bearings. MAKE SURE
THE ARROW AND/OR ALIGNMENT NOTCH ON
CONNECTING ROD AND CAP ARE ALIGNED.
7. Remove packing installation cone.
8. Replace pistons, cylinders, heads and cylinder cap.
See details in Section 5.3 for proper assembly of
pistons.
Before reinstalling the crosshead/connecting rod
assembly, make sure the crankshaft throw and bearing
surface are clean and lubricated. Tighten the connecting
rod bolts to the torques listed in Appendix B.
9. Rotate unit by hand to ensure proper assembly.
5.7 Bearing Replacement for
Crankcase and Connecting Rod
5.7.3 Replacing Crankcase Roller Bearings
To inspect the roller bearings, remove the flywheel from
the crankshaft and then remove the bearing carrier and
crankshaft from the crankcase. If corrosion or pitting is
present, the roller bearings should be replaced. When
replacing roller bearings, always replace the entire
bearing, not just the cup or the cone.
1. To replace the crankcase roller bearings, wrist pin
bushing and connecting rod bearings, begin by
removing the head, cylinder, piston, crosshead guide
and crosshead assembly.
2. Drain the crankcase and remove the inspection plate(s).
1. To replace the bearings, press the cups out of the
crankcase and bearing carrier and press the cones off
the crankshaft.
3. Before disassembly, choose and mark one connecting
rod and the corresponding connecting rod cap. DO
NOT MIX CONNECTING RODS AND CAPS. Loosen
and remove the connecting rod bolts in order to
remove the crosshead and connecting rod assembly.
2. Press the new bearings into position and reassemble
the crankshaft and bearing carrier to the crankcase.
When reinstalling the bearing carrier, make sure the oil
25
Figure 5.7.3: Bearing carrier replacement.
pump shaft slot is aligned with the pin in the crankshaft.
Make sure to install the bearing carrier gasket so the oil
passage hole is not blocked (see figure 5.7.3).
2. Inspect the gears in the oil pump for corrosion or
pitting and replace if necessary.
3. In order to check the crankshaft endplay, the oil pump
must first be removed (see section 5.8).
3.Inspect the oil pump shaft bushing in the bearing
carrier. If the bushing is corroded, pitted or worn, the
oil pump shaft bushing should be replaced.
4. Press the end of crankshaft towards the crankcase; if
a clicking noise or motion is detected, the crankshaft
has too much endplay. See Appendix B.
4. Before reassembling the oil pump mechanism, replace
the O-rings in the oil pump cover and on the oil pump
adapter shaft (see figure 5.8).
5.To reduce endplay, remove the bearing cover and
remove a thin shim. Recheck the endplay after
replacing the bearing cover.
5. Rotate the drive pin in the crankshaft to a vertical
position for easiest reassembly.
6. Insert the shaft adapter so it engages the drive pin.
6. When there is no detectable endplay, the shaft must
still be able to rotate freely. If the crankshaft sticks
or becomes abnormally warm, then the crankshaft
bearings are too tight. If the crankshaft is too tight,
add more shims, but make sure not to over shim.
(Appendix B lists the proper crankshaft endplay).
When the crankshaft can be rotated freely by hand
with proper endplay, the rest of the compressor can be
reassembled. If the crankshaft roller bearings are too
tight or too loose, premature bearing failure will result.
7. Next, insert the spring, spring guide, and oil pump
assembly. The tang on the oil pump must align with
the slot in the shaft adapter.
8. Install the pump cover so the pin on the case is in the
opening on the oil pump assembly as shown in figure
5.8. When you are sure the pin is properly aligned,
install the cover bolts finger tight.
9.Rotate the crankshaft by hand to ensure smooth
operation. Then rotate it in opposite directions,
listening for a click, which indicates proper alignment
of the oil pump’s pins and slots.
7. Reinstall the flywheel on the crankshaft and check the
run out as shown in Appendix B.
5.8 Oil Pump Inspection
10.Finally, tighten the bolts in an alternating sequence. See
section 3.3 for directions on oil pressure adjustment.
If the compressor operates for a prolonged period with
dirty or contaminated crankcase oil, damage to the oil
pump may result.
1. To check the oil pump, unbolt the pump cover and
remove the oil pump, spring guide, spring, and oil
pump shaft adapter as shown in figure 5.8.
26
Figure 5.8
Chapter 6—Extended Storage
Procedures
3. Operate for a few minutes while fogging oil into the
compressor suction.
4. Relieve V-belt tension.
Following a few simple procedures will greatly minimize
the risk of corrosion and damage. Corken recommends
the following precautions to protect the compressor
during storage:
5.Plug all openings to prevent entry of insects and
moisture. (The cylinders may also be protected by the
use of a vapor phase inhibitor, silica gel, or dry nitrogen
gas. If the silica gel is used, hang a tag on the unit
indicating that it must be removed before start-up.)
1. Drain the crankcase oil and refill with rust inhibiting oil.
6. Store in a dry area, off the ground if possible.
2.When a compressor is returned from long-term
storage, the compressor’s nameplate should be
removed and the new oil poured over the crossheads
to ensure good crosshead lubrication at startup.
7. Rotate the flywheel every two weeks if possible.
8. If possible, store compressor in a climate controlled area.
6.1 Repair Kits
Compressor Repair Kits a
Part Number
Model Number
Suction valve assembly
Discharge valve assembly
Valve cage
Connecting rod bearing (pair)
a
b
3549-X1
90J3, 91J3
3483-1X
3485-X
—
1367
3550-X1
290K3, 291M3
3483-1X (2)
3485-X (2)
—
1367 (2)
3551-X1
490K3, 491M3
2532-1X
2439-X (2)
2448 (4)
1491 (2)
3552-X1
690K3, 690P3
3948-X (2)
3857-X (2)
2797 (4)
1719 (2)
3552-X4
690M3, 691M3
3948-2X (2)
3857-2X (2)
2797 (4)
3542 (2)
Packing set
1452-1X1
1452-1X1 (2)
1452-1X1 (2)
1725-2X (2)
1725-2X (2)
Piston rings
Ring expanders
Gasket set b
O-ring b
O-ring b
O-ring b
Oil seal
Oil seal
Adapter plate gasket
Oil deflector ring
1772 (3)
1775 (3)
2526-XA
—
—
—
3259
—
—
—
1772 (6)
1775 (6)
1281-XA
—
—
—
1278
—
—
—
1773 (6)
1776 (6)
1481-X6A
—
2-242A (2)
2-253A (2)
1507 (490 only)
4438 (491 only)
1486 (2)
—
1739 (6)
1740 (6)
1744-X1A
—
—
—
—
—
—
—
1739 (6)
1740 (6)
1744-X1A
2-261A (2)
—
—
3526
—
—
—
Quantities greater than one are shown in parenthesis.
All repair kits are furnished with Buna-N O-rings which are suitable for LPG and NH3 applications.
27
5578-X3A
891M3
3856-2X (4)
3857-2X (4)
—
3542 (2)
1725-2X,
3810-X1
1739 (8)
1740 (8)
3970-X1A
—
—
—
3526
—
—
1732 (2)
6.2 Gasket Sets
Model 491 Gasket Set (1481-X6A)
Part No. Description
Model 91 Gasket Set (2526-XA)
Part No. Description
Qty
2-235A
O-ring (Buna-N)
2
2526
Crankcase gasket
1
2717
Valve gasket (aluminum)
2
2729
Crankcase inspection plate gasket
1
2-031A
O-ring (Buna-N)
2
2244
Inspection plate gasket
1
2716
Valve cap gasket (aluminum)
2
2725
Bearing carrier gasket
1
Model 291 Gasket Set (1281-XA)
Part No. Description
Qty
1281
Filter screen screw gasket
1
1651
Inspection plate gasket
1
2-113A
O-ring (Buna-N)
2
2-228A
O-ring (Buna-N)
1
2702
Crankcase gasket
1
2716
Valve cap gasket (aluminum)
4
2732
Center headbolt gasket (steel)
2
1190
Adapter plate gasket
2
1285
Bearing carrier gasket
1
2-031A
O-ring (Buna-N)
4
2-135A
O-ring (Buna-N)
2
2-235A
O-ring (Buna-N)
4
2713
Crankcase inspection plate gasket
1
2717
Valve gasket (aluminum)
4
1276
Filter screen
1
2-011A
O-ring
1
2-111A
O-ring
1
2-112A
O-ring
2
2-116A
O-ring
1
Qty
1418
Valve gasket (aluminum)
4
1480
Center headbolt gasket (steel)
2
1488
Inspection plate gasket
1
1511
Crankcase inspection plate gasket
1
2-139A
O-ring (Buna-N)
2
2-228A
O-ring (Buna-N)
1
1281
Filter screen screw gasket
1
1478
Valve cap gasket (steel)
4
1481
Head gasket
1
1489
Crankcase gasket
1
1513
Bearing carrier gasket
1
2-143A
O-ring (Buna-N)
4
2-243A
O-ring (Buna-N)
2
1276
Filter screen
1
2-011A
O-ring
1
2-111A
O-ring
1
2-112A
O-ring
2
2-116A
O-ring
1
Model 691 Gasket Set (1744-X3A)
Part No. Description
28
Qty
1760
Inspection plate gasket
1
2-031A
O-ring (Buna-N)
4
2-231A
O-ring (Buna-N)
2
2-235A
O-ring (Buna-N)
4
2-261A
O-ring (Buna-N)
2
2123
Crankcase inspection plate gasket
2
2131
Bearing carrier gasket
1
2716
Valve cap gasket (aluminum)
4
4127
Lubricator gasket
1
1281
Filter screen screw gasket
1
1761
Crankcase gasket
1
2-228A
O-ring (Buna-N)
1
2-233A
O-ring (Buna-N)
2
2-247A
O-ring (Buna-N)
2
2114
Valve gasket (aluminum)
4
2129
Oil inlet gasket
1
2177
Flange gasket
2
3874
Access cover gasket
2
1276
Filter screen
1
2-011A
O-ring
1
2-112A
O-ring
2
2-116A
O-ring
1
2-218A
O-ring
2
Model 891 Gasket Set (3970-X1A)
Part No. Description
Qty
1281
Filter screen screw gasket
1
1761
Crankcase gasket
1
2-036A
O-ring (Buna-N)
8
2-231A
O-ring (Buna-N)
4
2-238A
O-ring (Buna-N)
2
2114
Valve gasket (aluminum)
8
2131
Bearing carrier gasket
1
4127
Lubricator gasket
1
1760
Inspection plate gasket
1
2-031A
O-ring (Buna-N)
8
2-228A
O-ring (Buna-N)
1
2-235A
O-ring (Buna-N)
8
2-246A
O-ring (Buna-N)
4
2123
Crankcase inspection plate gasket
1
3874
Access cover gasket
2
3906
Gasket spiral wound
2
1276
Filter screen
1
2-011A
O-ring
1
2-112A
O-ring
2
2-116A
O-ring
1
2-118A
O-ring
2
29
Appendix A—Model Number Identification Code and Available Options
Reciprocating Vertical Compressors (Plain Style) LPG and Anhydrous Ammonia Models
Plain Style
(Single
Packed)
Base Model #
Inlet
Outlet
Weight lbs. (kg)
91
3/4" NPT
3/4" NPT
145 (65.8)
Plain Style
(Single
Packed)
Base Model #
Inlet
Outlet
Weight lbs. (kg)
F91
3/4" Class 300 RF
3/4" Class 300 RF
145 (65.8)
291
3/4" NPT
3/4" NPT
190 (86.1)
491
1-1/4" NPT
1-1/4" NPT
300 (136.1)
F291
F491
3/4" Class 300 RF 1-1/4" Class 300 RF
3/4" Class 300 RF 1-1/4" Class 300 RF
190 (86.1)
300 (136.1)
Model Number
Base X X X X X X X X X X
691
2" NPT
1-1/2" NPT
670 (303.9)
F691
2" Class 300 RF
2" Class 300 RF
670 (303.9)
Specification Fields
Packing
Inlet pressure above
Arrangement atmospheric
Crankcase
Style
Splash lubricated
Extended crankshaft
Pressure lubricated
crankcase
Standard crankcase with
heater
Standard crankcase
drilled for heater
Standard
Standard
Optional
NA
Optional
NA
Optional
NA
NA
J
E
NA
Standard
Standard
Standard
M
NA
Optional
Optional
Optional
MH
NA
NA
NA
Optional
MR
NA
Standard
NA
Optional
3
3P
4
4P
Standard
NA
Optional
NA
Liquid relief suction valves
Valves
A
Standard suction and
discharge valve
Piston Ring
and Packing
Material
PTFE piston ring with
PTFE packing material
PTFE piston ring with
Alloy 50 packing material
Gasket
Material
Aluminum gasket
material
Standard
B
O-ring
Material
Buna-N
Neoprene ®1
Standard
Optional
A
B
Intercooler
Not applicable—single
stage
Standard
N
Flywheel
14" flywheel used
in conjunction with
extended crankshaft
Heavy duty flywheel
No flywheel supplied
Standard flywheel
Protective
Coating
Piston Rod
Coating
1
2
Standard
Standard
Standard
NA
NA
NA
NA
Standard
F
NA
Optional
Optional
NA
E
Optional
No charge option
Standard
H
N
S
No coating
Standard
N
Nitrotec ®2
Standard
N
Registered trademark of the DuPont company.
Registered trademark of TTI Group Ltd.
30
Appendix A—Model Number Identification Code and Available Options
Reciprocating Vertical Compressors (D-Style) Double-acting, Single-stage Models
D-Style
(Double
Packed)
Base Model #
Inlet
Outlet
Weight lbs. (kg)
D891
2" weld
2" weld
900 (408.2)
Model Number
Base X X X X X X X X X X
FD891
2" Class 300 RF
2" Class 300 RF
915 (415.0)
Specification Fields
Packing
Packing arranged for padding of
Arrangement distance piece
Standard
J
Crankcase
Style
Pressure lubricated crankcase
Standard crankcase with heater
Standard crankcase drilled for heater
Standard
Optional
Optional
M
MH
MR
Valves
Standard suction and discharge valves
Suction valve unloaders
Standard
Optional
4P
9P
Piston Ring
and Packing
Material
PTFE piston ring with Alloy 50 packing
material
Standard
F
Gasket
Material
Aluminum gasket material
Standard
B
O-ring
Material
Buna-N
Neoprene ®1
Standard
Optional
A
B
Intercooler
Connections
No intercooler—not applicable on single
stage compressors
Standard
N
Flywheel
No flywheel supplied
Standard flywheel
Optional
Standard
N
S
Protective
Coating
No coating
Standard
N
Piston Rod
Coating
Nitrotec ®2 piston rod coating
Standard
N
1
2
Registered trademark of the DuPont company.
Registered trademark of TTI Group Ltd.
31
Appendix B—Specifications for Vertical Single-Acting Models 91–691
Equipment Type and Options
Applications
Single-acting, vertical, reciprocating piston type vapor compressor
Bulk transfer
Tank evacuation
Single packed rod
Vapor recovery
Gas scavenging
NPT or Class 300 RF connections
Features and Benefits
Self-lubricating piston rings:
Non-lubricated operation to minimize oil in gas
NPT or Class 300 RF connections: Versatility for your application
Multiple mounting configurations:
Versatility for your application
High efficiency valves:
Quiet, reliable operation
Reversible oil pump:
Allows operation in either direction
Simplified top down design:
Routine maintenance is minimally invasive
Operating Specifications
Model
91
291
491
691
Bore of cylinder inches (mm)
3.0 (76.2)
3.0 (76.2)
4.0 (101.6)
4.5 (114.3)
Stroke inches (mm)
2.5 (63.5)
2.5 (63.5)
3.0 (76.2)
4.0 (101.6)
4.1 (7.0)
8.2 (13.9)
17.5 (29.7)
29.5 (50.0)
8.4 (14.3)
16.9 (28.7)
36.0 (61.2)
60.7 (103.2)
Piston displacement cfm (m3/hr)
minimum @ 400 RPM
maximum @ 825 RPM
Maximum working pressure psig (bar g)
Maximum brake horsepower (kW)
Maximum rod load lb (kg)
335 (23.1)
1
7.5 (5.6)
15 (11.2)
15 (11.2)
45 (33.6)
3,600 (1,632.9)
3,600 (1,632.9)
4,000 (1,814.4)
7,000 (3,175.1)
Maximum outlet temperature °F (°C)
Maximum flow—propane gpm (m /hr)
3
1
350 (177)
50 (11.4)
101 (22.9)
215 (48.8)
361 (82.0)
These numbers specify pressure-containing abilities of the compressor cylinder and head. For many applications, factors other than the pressure rating will
limit the maximum allowable discharge pressure to lower values. These factors include horsepower, temperature and rod load.
32
Appendix B—Specifications for Vertical Single-Acting Models 91–691
Material Specifications
Part
Model
Standard Material
Head, Cylinder
All
Ductile iron ASTM A536
Crosshead guide crankcase, flywheel, bearing carrier
All
Gray iron ASTM A48, Class 30
Flange
691
Ductile iron ASTM A536
91, 291
17-4 PH stainless steel
491
Ductile iron ASTM A536
691
17-4 PH stainless steel
91, 291
410 stainless steel
491
17-7 PH stainless steel
691
PEEK
91, 291, 691
17-7 PH stainless steel
Valve seat and bumper
Valve plate
Valve spring
491
Inconel
Valve gaskets
None
Soft aluminum
Piston
All
Gray iron ASTM A48, Class 30
Piston rod
None
1045 steel Nitrotec ®1 coated
Crosshead
All
Gray iron ASTM A48, Class 30
91, 291, 491
PTFE, glass and moly filled
691
Alloy 50
Ring expanders
All
302 stainless steel
Packing cartridge, connecting rod
All
Ductile iron ASTM A536
91, 291, 491
PTFE, glass and moly filled
Piston rings
Packing V-rings
1
2
691
Alloy 50
Crankshaft
All
Ductile iron ASTM A536
Connecting rod bearing
All
Bimetal D-2 babbit
Wrist pin
All
C1018 steel
Wrist pin busing
All
Bronze SAE J461
Main bearing
All
Tapered roller
Inspection plate
All
Aluminum
O-rings
All
Buna-N, Neoprene ®2 (optional)
Retainer rings
All
Steel
Misc. gaskets
All
Rubber compositions
Registered trademark of TTI Group Ltd.
Registered trademark of the DuPont company.
33
Appendix B—Specifications for Vertical Single-Acting Models 91–891
Bolt Torque Values (in ft•lb)
Model
91
291
491
691
891
Connecting rod bolt
28
28
30
40
40
Bearing carrier
38
30
26
40
40
Bearing cover
38
30
35
40
40
Crankcase inspection plate
15
13
8
9
9
Crosshead guide
30
25
33
40
65
Cylinder to head 1,2
20
20
33
30
65
—
—
35
37
37
40
40
40
40
40
45
45
45
60
150
Valve cover plate bolt
Valve holddown screw
2
Piston locknut
1
2
Piston screw
50
50
100
100
8
Valve cap with gaskets
40
40
40
40
—
Valve cap with O-rings
25
25
25
25
25
Preliminary tightening – snug all head bolts in the sequence shown. Final torqueing – torque all head bolts in the sequence shown to the listed value.
Retorque to the listed value after 1 hour running time.
10
3
5
7
1
12
11
2
8
6
4
MODEL 891
34
9
Appendix B—Specifications for Vertical Single and Double-Acting
Models 91–891
Clearances and Dimensions for Single-Acting Models
91
291
490
491
691
(M crankcase)
“X” piston clearance figure 5.4A and 5.4B 1
0.020
0.044
0.020
0.044
0.000
0.024
0.020
0.044
0.025
0.040
Clearance from connecting rod bearing to
crankshaft journal
0.001
0.0025
0.001
0.0025
0.001
0.0025
0.0019
0.0035
Clearance from wrist pin to wrist pin
bushing 2
0.0006
0.0011
0.0006
0.0011
0.0006
0.0011
0.0009
0.0015
Model
Maximum cylinder bore diameter
3.009
3.009
4.011
4.515
Cylinder finish (RMS)
16–32
16–32
16–32
16–32
Minimum piston ring radial thickness
0.082
0.082
0.082
0.082
N/A
0.0050
0.0050
0.0050
Crankshaft end play
0.000
0.002
0.000
0.002
0.000
0.002
0.002
0.003
Maximum flywheel runout at O.D.
0.020
0.020
0.020
0.020
Maximum clearance from crosshead to
crosshead guide bore
0.011
0.011
0.012
0.013
Maximum clearance from oil pump
adapter shaft to bushing 2
Crosshead guide bore finish
32 RMS (limited number of small pits and scratches are acceptable)
Clearances and Dimensions for Double-Acting Models
891
Model
“X” piston clearance figure 5.4A and 5.4B 1
0.010/0.020 (bottom)
0.084/0.104 (top)
Clearance from connecting rod bearing to
crankshaft journal
0.0019
0.0035
Clearance from wrist pin to wrist pin
bushing 2
0.0009
0.0015
Maximum cylinder bore diameter
4.515
Cylinder finish (RMS)
16–32
Minimum piston ring radial thickness
0.082
Maximum clearance from oil pump
adapter shaft to bushing 2
0.0050
Crankshaft end play
0.002
0.003
Maximum flywheel runout at O.D.
0.020
Maximum clearance from crosshead to
crosshead guide bore
0.008
Crosshead guide bore finish
1
2
32 RMS (limited number of small pits
and scratches are acceptable)
Clearances should be set with machine cold.
Dimensions for honing are included with new bushings (which must be installed, then honed).
35
Appendix B—Specifications for Vertical Double-Acting Model D891/FD891
Equipment Type and Options
Applications
Double-acting, vertical, reciprocating piston type vapor compressor
Bulk transfer
Double packed rod
Truck, tank,
railcar, barge
unloading
Slip-on weld connections or Class 300 RF flanges
LTVR and
scavenger
applications
Emergency
evacuation
Features and Benefits
Self-lubricating piston rings:
Non-lubricated operation to minimize oil in gas
Multiple materials and configurations:
Versatility for your application
Multiple mounting configurations:
Versatility for your application
High efficiency valves:
Quiet, reliable operation
Reversible oil pump:
Allows operation in either direction
Simplified top down design:
Routine maintenance is minimally invasive
Operating Specifications
Model
D891/FD891
Bore of cylinder inches (mm)
4.5 (114)
Stroke inches (mm)
4.0 (101.6)
Piston displacement cfm (m /hr)
3
minimum @ 400 RPM
56.6 (96.2)
maximum @ 825 RPM
116.8 (198.4)
Maximum working pressure psig (bar g)
450 (31.0)
Maximum brake horsepower (kW)
45 (34)
Maximum rod load lb (kg)
1
7,000 (3,175.2)
Maximum outlet temperature °F (°C)
350 (177)
Maximum flow—propane gpm (m3/hr)
694 (157.6)
These numbers specify pressure-containing abilities of the compressor cylinder and head. For many applications, factors other than the pressure rating will
limit the maximum allowable discharge pressure to lower values. These factors include horsepower, temperature and rod load.
36
Appendix B—Specifications for Vertical Double-Acting Model D891/FD891
Material Specifications
1
Part
Standard Material
Head, cylinder, and cylinder cap
Ductile iron ASTM A536
Crosshead guide
Gray iron ASTM A48, Class 30
Crankcase, flywheel
Gray iron ASTM A48, Class 30
Bearing carrier
Gray iron ASTM A48, Class 30
Flange
ASTM A36 carbon steel (D891 only)
Valve seat, bumper
17-7 PH stainless steel
Valve plate
PEEK
Valve spring
17-7 PH stainless steel
Valve gaskets
Soft aluminum
Piston
Ductile iron ASTM A536
Piston rod
1045 steel, Nitrotec
Crosshead
Ductile iron ASTM A536
Piston rings
PTFE, glass and moly filled
Piston ring expanders
302 stainless steel
Packing cartridge and barrel
Ductile iron ASTM A536
Connecting rod
Ductile iron ASTM A536
Segmented packing
Carbon filled PTFE
V-ring packing
Alloy 50
Crankshaft
Ductile iron ASTM A536
Connecting rod bearing
Bimetal D-2 SAE 12
Wrist pin
C1018 steel or equivalent
Wrist pin bushing
Bronze SAE J461
Main bearing
Tapered roller
Inspection plate
Aluminum
O-rings
Buna-N or Neoprene ®1 (optional)
Retainer rings
Steel
Miscellaneous gaskets
Rubber compositions
Registered trademark of the DuPont company.
37
Appendix C—Compressor Selection
Compressor Mounting Selections
Suction & discharge
pressure gauges
Standard 107 Items
Relief valve connection
Interconnecting piping
•Steel baseplate
•V-belt drive
•Adjustable driver side base
•Enclosed steel guard
•Suction and discharge
pressure gauges
Non-lube, full port,
4-way valve
NEMA 7
liquid level
switch
Enclosed steel
beltguard
40 mesh
suction strainer
Optional driver
•40 Micron strainer
•Non-lube 4-way valve
•Interconnecting piping
•Liquid trap as
specified below
107 Mounting
•Mechanical liquid trap with ball float
107A Mounting
Liquid trap
•Automatic liquid trap with one NEMA 7 liquid
level switch
Drain valve
Steel baseplate
107B Mounting
•Automatic liquid trap with two NEMA 7 liquid
level switches
Adjustable driver slide base
107F Mounting
•107A or 107B with Class 300 RF flanged
components and connections
107TR Mounting
•Must specify 14" flywheel and extended crankshaft
Relief Valve
Standard 109 Items
•Steel baseplate
•V-belt drive
•Adjustable driver side base
•Enclosed steel guard
•Suction and discharge
pressure gauges
Interconnecting piping
Liquid trap
Suction & discharge
pressure guages
•40 Micron strainer
•Non-lube 4-way valve
•Interconnecting piping
•Liquid trap as
specified below
109 Mounting
•Mechanical liquid trap with ball float
Two NEMA 7
liquid level
switches
109A Mounting
•Automatic liquid trap with one NEMA 7 liquid
level switch
Enclosed steel
beltguard
Optional driver
109B Mounting
•Automatic liquid trap with two NEMA 7 liquid
level switches
Drain valve
109F Mounting
Steel baseplate
•109A or 109B with Class 300 RF flanged
components and connections
Adjustable driver slide base
109TR Mounting
•Must specify 14" flywheel and extended crankshaft
38
Appendix C—Compressor Selection
Butane Compressor Selection Table
Service
Small bulk
plants
Unloading
single tank car
or transport
Unloading
two or more
tank cars at
one time or
large transport
with excess
flow valves
of adequate
capacity
Unloading
large tank
cars, multiple
vessels, barges
or terminals
Compressor
Capacity Displacement
gpm 1
cfm
13
17
20
24
23
27
26
30
33
36
39
42
47
50
50
53
53
56
60
63
65
68
71
75
77
81
84
87
91
94
97
94
100
98
107
103
110
113
107
111
119
116
120
124
129
133
137
142
145
150
158
171
184
193
260
359
4
5
6
7
7
8
8
9
10
11
12
13
14
15
15
16
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
30
31
31
32
32
33
34
34
35
36
36
38
39
41
42
43
45
46
47
48
54
58
60
82.1
113.3
Model
RPM
91
91
91
91
291
91
291
291
291
291
291
291
291
291
491
291
491
491
491
491
491
491
491
491
491
491
491
491
491
491
491
691
491
691
491
691
491
491
691
691
491
691
691
691
691
691
691
691
691
691
691
691
691
691
D/FD891
D/FD891
400
505
590
695
345
800
390
435
490
535
580
625
695
735
345
780
370
390
415
435
445
470
490
515
535
560
580
605
625
650
670
400
695
420
740
440
760
780
455
475
825
495
510
530
550
565
585
605
620
640
675
730
785
820
580
800
Driver Sheave
Size Pitch
Diameter
(inches) 2
1,750
RPM
A 3.0
B 3.8
B 4.6
B 5.4
A 3.0
B 6.2
A 3.4
A 3.8
B 4.4
B 4.8
B 5.2
B 5.6
B 6.2
B 6.6
A 3.0
B 7.0
A 3.2
A 3.4
A 3.6
A 3.8
B 4.0
B 4.2
B 4.4
B 4.6
B 4.8
B 5.0
B 5.2
B 5.4
B 5.6
B 5.8
B 6.0
B 4.4
B 6.2
B 4.6
B 6.6
B 4.8
B 6.8
B 7.0
B 5.0
B 5.2
B 7.4
B 5.4
B 5.6
B 5.8
B 6.0
B 6.2
B 6.4
B 6.6
B 6.8
B 7.0
B 7.4
B 8.0
B 8.6
TB 9.0
5V 7.1
5V 9.75
1,450
RPM
B 3.6
B 4.6
B 5.6
B 6.6
A 3.6
B 7.4
B 4.0
B 4.6
B 5.2
B 5.8
B 6.2
B 6.6
B 7.4
B 8.0
A 3.6
B 8.6
A 3.8
B 4.0
B 4.4
B 4.6
B 4.8
B 5.0
B 5.2
B 5.6
B 5.8
B 6.0
B 6.2
B 6.4
B 6.6
B 7.0
B 5.2
B 7.4
B 5.6
B 8.0
B 5.8
B 8.0
B 8.6
B 6.0
B 6.2
B 8.6
A 6.4
B 6.8
B 7.0
A 7.0
­­­­­B 7.4
A 7.4
B 8.0
A 8.2
B 8.6
B 9.4
A 10.6
5V 8.5
5V 11.8
Driver Horsepower
Liquid
Liquid Transfer
Transfer With
Without
Residual Vapor Residual Vapor
Recovery
Recovery
Piping Size 3
100°F
80°F
100°F
80°F
Vapor
Liquid
3
3
3
5
2
5
2
3
3
3
5
5
5
5
5
7-1/2
5
5
5
5
5
5
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
10
10
7-1/2
10
10
10
10
10
10
10
10
15
10
10
10
10
10
10
15
15
15
15
15
15
15
20
25
3
3
3
5
2
5
2
3
3
3
3
5
5
5
5
5
5
5
5
5
5
5
5
5
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
10
7-1/2
10
10
10
10
10
10
10
10
10
10
10
10
10
10
15
15
15
15
20
25
3
3
3
5
2
5
2
3
3
3
5
5
5
5
5
7-1/2
5
5
5
5
5
5
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
10
10
7-1/2
10
10
10
10
10
10
10
10
15
10
10
10
10
10
10
15
15
15
15
15
15
15
20
25
3
3
3
5
2
5
2
3
3
3
3
5
5
5
5
5
5
5
5
5
5
5
5
5
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
10
7-1/2
10
10
10
10
10
10
10
10
10
10
10
10
10
10
15
15
15
15
20
25
3/4
3/4
1
1
1
1
1
1
1
1
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
2
2
2
2
2
2
2
2
2
3
3
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
2
2
2
2
2
2-1/2
2-1/2
2-1/2
2-1/2
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
4
4
4
4
6
6
The capacities shown are based on 70°F, but will vary depending upon piping, fittings used, product being transferred and temperature. The factory can
supply a detailed computer analysis if required.
Driver sheaves: 91 - 2 belts; 291, 491 - 3 belts; 691 - 4 belts.
3
The piping sizes shown are considered minimum. If the length exceeds 100 ft., use the next larger size.
1
2
Consult factory for compressors with higher flows.
39
Appendix C—Compressor Selection
Propane Compressor Selection Table
Service
Small bulk
plants
Unloading
single tank car
or transport
Unloading
two or more
tank cars at
one time or
large transport
with excess
flow valves
of adequate
capacity
Unloading
large tank
cars, multiple
vessels, barges
or terminals
Compressor
Capacity Displacement
gpm 1
cfm
23
29
34
40
39
45
44
50
56
61
66
71
79
84
84
89
89
95
101
106
108
114
119
125
130
136
141
147
152
158
163
163
168
171
179
178
186
193
200
208
215
223
230
237
245
252
260
275
297
319
334
452
623
4
5
6
7
7
8
8
9
10
11
12
13
14
15
15
16
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
30
31
31
32
32
34
35
36
38
39
41
42
43
45
46
47
48
54
58
60
82
113
Model
RPM
91
91
91
91
291
91
291
291
291
291
291
291
291
291
491
291
491
491
491
491
491
491
491
491
491
491
491
491
491
491
491
691
491
691
491
691
691
691
691
691
691
691
691
691
691
691
691
691
691
691
691
D/FD891
D/FD891
400
505
590
695
345
800
390
435
490
535
580
625
695
735
345
780
370
390
415
435
445
470
490
515
535
560
580
605
625
650
670
400
695
420
740
440
455
475
495
510
530
550
565
585
605
620
640
675
730
785
820
580
800
Driver Sheave
Size Pitch
Diameter
(inches) 2
1,750
RPM
A 3.0
B 3.8
B 4.6
B 5.4
A 3.0
B 6.2
A 3.4
A 3.8
B 4.4
B 4.8
B 5.2
B 5.6
B 6.2
B 6.6
A 3.0
B 7.0
A 3.2
A 3.4
A 3.6
A 3.8
B 4.0
B 4.2
B 4.4
B 4.6
B 4.8
B 5.0
B 5.2
B 5.4
B 5.6
B 5.8
B 6.0
B 4.4
B 6.2
B 4.6
B 6.6
B 4.8
B 5.0
B 5.2
B 5.4
B 5.6
B 5.8
B 6.0
B 6.2
B 6.4
B 6.6
B 6.8
B 7.0
B 7.4
B 8.0
B 8.6
TB 9.0
5V 7.1
5V 9.75
1,450
RPM
B 3.6
B 4.6
B 5.6
B 6.6
A 3.6
B 7.4
B 4.0
B 4.6
B 5.2
B 5.8
B 6.2
B 6.6
B 7.4
B 8.0
A 3.6
B 8.6
A 3.8
B 4.0
B 4.4
B 4.6
B 4.8
B 5.0
B 5.2
B 5.6
B 5.8
B 6.0
B 6.2
B 6.4
B 6.6
B 7.0
B 5.2
B 7.4
B 5.6
B 8.0
B 5.8
B 6.0
B 6.2
B 6.4
B 6.8
B 7.0
A 7.0
B 7.4
A 7.4
B 8.0
A 8.2
B 8.6
B 9.4
A 10.6
5V 8.5
5V 11.8
Driver Horsepower
Liquid
Liquid Transfer
Transfer With
Without
Residual Vapor Residual Vapor
Recovery
Recovery
Piping Size 3
100°F
80°F
100°F
80°F
Vapor
Liquid
5
5
5
5
3
7-1/2
5
5
5
5
7-1/2
7-1/2
7-1/2
10
7-1/2
10
7-1/2
7-1/2
10
10
10
10
10
10
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
20
20
20
20
20
20
20
20
25
25
25
30
30
3
5
5
5
3
7-1/2
3
5
5
5
5
5
7-1/2
7-1/2
7-1/2
10
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
10
10
10
10
10
10
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
20
20
20
20
20
25
30
40
3
5
5
5
3
7-1/2
3
3
5
5
5
7-1/2
7-1/2
10
5
10
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
10
10
10
10
15
15
15
15
10
15
10
15
10
15
15
15
15
15
15
15
15
15
15
20
20
20
25
25
30
40
3
5
5
5
3
7-1/2
3
3
5
5
5
5
7-1/2
7-1/2
5
10
5
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
10
10
10
10
15
15
15
10
15
10
15
10
10
10
15
15
15
15
15
15
15
15
15
20
20
20
20
30
30
3/4
3/4
1
1
1
1
1
1
1
1
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
2
2
2
2
2
2
2
2
2
3
3
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
2
2
2
2
2
2-1/2
2-1/2
2-1/2
2-1/2
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
4
4
4
4
6
6
The capacities shown are based on 70°F, but will vary depending upon piping, fittings used, product being transferred and temperature. The factory can
supply a detailed computer analysis if required.
2
Driver sheaves: 91 - 2 belts; 291, 491 - 3 belts; 691 - 4 belts.
3
The piping sizes shown are considered minimum. If the length exceeds 100 ft., use the next larger size.
1
Consult factory for compressors with higher flows.
40
Appendix C—Compressor Selection
Ammonia Compressor Selection Table
Service
Small bulk
plants
Unloading
single tank car
or transport
Unloading
two or more
tank cars at
one time or
large transport
with excess
flow valves
of adequate
capacity
Unloading
large tank
cars, multiple
vessels, barges
or terminals
Compressor
Capacity Displacement
gpm 1
cfm
23
29
34
40
43
46
45
50
56
62
67
72
80
85
85
90
90
96
102
107
110
115
120
126
131
138
142
148
153
160
165
165
170
173
181
180
188
195
203
211
218
226
233
240
248
255
263
278
301
323
338
459
633
4
5
6
7
7
8
8
9
10
11
12
13
14
15
15
16
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
30
31
31
32
32
34
35
36
38
39
41
42
43
45
45
47
48
54
58
60
82
113
Model
RPM
91
91
91
91
291
91
291
291
291
291
291
291
291
291
491
291
491
491
491
491
491
491
491
491
491
491
491
491
491
491
491
691
491
691
491
691
691
691
691
691
691
691
691
691
691
691
691
691
691
691
691
D/FD891
D/FD891
400
505
590
695
345
800
390
435
490
535
580
625
695
735
345
780
370
390
415
435
445
470
490
515
535
560
580
605
625
650
670
400
695
420
740
440
455
475
495
510
530
550
565
585
605
620
640
675
730
785
820
580
800
Driver Sheave
Size Pitch
Diameter
(inches) 2
1,750
RPM
A 3.0
B 3.8
B 4.6
B 5.4
A 3.0
B 6.2
A 3.4
A 3.8
B 4.4
B 4.8
B 5.2
B 5.6
B 6.2
B 6.6
A 3.0
B 7.0
A 3.2
A 3.4
A 3.6
A 3.8
B 4.0
B 4.2
B 4.4
B 4.6
B 4.8
B 5.0
B 5.2
B 5.4
B 5.6
B 5.8
B 6.0
B 4.4
B 6.2
B 4.6
B 6.6
B 4.8
B 5.0
B 5.2
B 5.4
B 5.6
B 5.8
B 6.0
B 6.2
B 6.4
B 6.6
B 6.8
B 7.0
B 7.4
B 8.0
B 8.6
TB 9.0
5V 7.1
5V 9.75
1,450
RPM
B 3.6
B 4.6
B 5.6
B 6.6
A 3.6
B 7.4
B 4.0
B 4.6
B 5.2
B 5.8
B 6.2
B 6.6
B 7.4
B 8.0
A 3.6
B 8.6
A 3.8
B 4.0
B 4.4
B 4.6
B 4.8
B 5.0
B 5.2
B 5.6
B 5.8
B 6.0
B 6.2
B 6.4
B 6.6
B 7.0
B 5.2
B 7.4
B 5.6
B 8.0
B 5.8
B 6.0
B 6.2
B 6.4
B 6.8
B 7.0
A 7.0
B 7.4
A 7.4
B 8.0
A 8.2
B 8.6
B 9.4
A 10.6
5V 8.5
5V 11.8
Driver Horsepower
Liquid
Liquid Transfer
Transfer With
Without
Residual Vapor Residual Vapor
Recovery
Recovery
Piping Size 3
100°F
80°F
100°F
80°F
Vapor
Liquid
5
5
5
5
5
7-1/2
5
5
5
7-1/2
7-1/2
7-1/2
7-1/2
10
7-1/2
10
10
10
10
10
10
10
15
15
15
15
15
15
15
15
15
15
15
15
15
15
20
20
20
20
20
20
20
20
20
25
25
25
25
30
30
40
3
5
5
5
3
5
3
5
5
5
5
5
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
10
10
10
10
10
10
10
15
15
15
15
15
15
15
15
15
15
15
15
15
15
20
20
20
20
20
20
25
25
30
40
3
5
5
5
3
5
3
3
5
5
5
5
7-1/2
7-1/2
5
7-1/2
5
5
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
10
10
10
10
10
10
15
10
15
10
15
10
10
10
15
15
15
15
15
15
15
15
15
15
20
20
20
30
40
3
3
5
5
3
5
3
3
3
5
5
5
5
7-1/2
5
7-1/2
5
5
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
10
10
10
10
10
10
10
15
10
10
10
10
10
15
15
15
15
15
15
15
15
15
20
20
30
30
3/4
3/4
1
1
1
1
1
1
1
1
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
2
2
2
2
2
2
2
2
2
3
3
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
2
2
2
2
2
2-1/2
2-1/2
2-1/2
2-1/2
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
4
4
4
4
6
6
The capacities shown are based on 70°F, but will vary depending upon piping, fittings used, product being transferred and temperature. The factory can
supply a detailed computer analysis if required.
2
Driver sheaves: 91 - 2 belts; 291, 491 - 3 belts; 691 - 4 belts.
3
The piping sizes shown are considered minimum. If the length exceeds 100 ft., use the next larger size.
1
Consult factory for compressors with higher flows.
41
Appendix D—Outline Dimensions
Models 91–691 and F91–F691 Bare with Flywheel
M
M1
Inlet
M
M1
Outlet
S
Model
91, F91
291, F291
491, F491
691, F691
Model
91, F91
291,
F291
491,
F491
691,
F691
A
1-13/16
(46.0)
3-3/8
(85.7)
4-1/8
(104.8)
4-3/4
(120.7)
M*
2-3/8
(60.3)
B
2-3/8
(60.3)
4-1/8
(104.8)
5
(127.0)
5-1/2
(139.7)
M1**
4-1/4
(108.0)
P
3
(76.2)
C
3-11/16
(93.7)
3-11/16
(93.7)
4-11/16
(119.1)
5-3/8
(136.5)
Q
14
(355.6)
16
(406.4)
2-5/8
4-1/4
3
(66.7) (108.0) (76.2)
141
(3,581.4)
16
(406.4)
3-7/8
5-5/8
3
(98.4) (142.9) (76.2)
141
(3,581.4)
6-5/16 6-15/16 3-13/16 19-1/2
(160.3) (176.2) (96.8) (495.3)
D
13/32
(10.3)
7/16
(11.1)
1/2
(12.7)
9/16
(14.3)
E
5/8
(15.9)
25/32
(19.8)
11/16
(17.5)
1
(25.4)
R
1-1/8
(28.6)
S***
1-1/4
(31.8)
T
1/4
(6.4)
1-1/4
(31.8)
1-1/4
(31.8)
1/4
(6.4)
1-3/8
(34.9)
1-1/4
(31.8)
5/16
(7.9)
2-1/8
(54.0)
—
1/2
(12.7)
F
6-1/4
(158.8)
9-13/16
(249.2)
10-11/16
(271.5)
14-1/2
(368.3)
H
25-5/16
(642.9)
25-11/16
(652.5)
29-5/8
(752.5)
39-1/8
(993.8)
J
5
(127.0)
5-3/8
(136.5)
5-7/8
(149.2)
8-1/4
(209.6)
A-belt Groove B-belt Groove
13.2
13.6
2
2
(335.3)
(345.4)
15.2
15.6
3
3
(386.1)
(396.2)
13.21
13.61
2
2
(335.5)
(345.7)
15.2
15.6
3
3
(386.1)
(396.2)
13.21
13.61
2
2
(335.5)
(345.7)
19-1/8
—
—
4
(485.8)
All dimensions are in inches (millimeters).
42
G
3-7/8
(98.4)
12-1/16
(306.4)
13-3/16
(335.0)
14-3/8
(365.1)
K
22-11/16
(576.3)
23-3/8
(593.7)
26-3/16
(665.2)
35-1/16
(890.6)
Appendix D—Outline Dimensions
Models 91 with -107 or -107A Mounting (Model -107A Shown Below)
All dimensions are in inches (millimeters).
43
30-13/16
(782)
Overall
33
(838)
Overall to
optional
relief valve
44
All dimensions are in inches (millimeters).
15 (381)
5-5/16
(135)
23-7/8 (607)
12 (305)
1-1/2
(38)
5
(127)
5/8
(16)
3-9/16
(91)
Liquid drain
1/4" NPT
1-1/4
(32)
6-3/4
(171)
3 (76)
18-3/16
(462)
Strainer
4 (102)
Inlet / Outlet
4-way valve
1" NPT
15-3/4 (400)
9-11/16 (246)
3-7/8
(98)
Suction
Pressure
Gauge
42 (1,067)
Discharge
Pressure
Gauge
Appendix D—Outline Dimensions
Model 291 with 107 Mounting (Motor Frames Up to 215T)
31-13/16
(808)
Overall
33-15/16
(863)
Overall to
optional
relief valve
All dimensions are in inches (millimeters).
45
20 (508)
5-5/16
(135)
26-7/16 (672)
17 (432)
1-1/2
(38)
5
(127)
4-3/8
(111)
1-1/8
(29)
19-3/16
(487)
4
(102)
7-3/4
(197)
1-1/4
(32)
4
(102)
Liquid drain
1/4" NPT
Strainer
Inlet / Outlet
4-way valve
1" NPT
15-3/4 (400)
9-11/16
(246)
3-7/8
(98)
Suction
Pressure
Gauge
42 (1,067)
Discharge
Pressure
Gauge
Appendix D—Outline Dimensions
Model 291 with 107 Mounting (Motor Frames 254T and Up)
5-5/16
(135)
33-5/8
(854)
1-1/2
(38)
Liquid
trap
All dimensions are in inches (millimeters).
46
18 (457)
15 (381)
25-3/4 (654)
5-3/4
(146)
2-1/8
(54)
2-7/16
(62)
1-1/2
(38)
19-1/8
(486)
6
(152)
4
(102)
1-1/4
(32)
7-3/4
(197)
Liquid drain
1/4" NPT
Strainer
Inlet / Outlet
4-way valve
1" NPT
18 (457)
9-7/16
(240)
4
(102)
48 (1,219)
7-1/8
(181
Adjustable motor
slidebase
Electric motor
(optional)
Appendix D—Outline Dimensions
Model 491 with 107 Mounting
Beltguard
All dimensions are in inches (millimeters).
47
17 (432)
29-7/8 (758)
20 (508)
17-1/2 (445)
8-1/4
(210)
43-1/8
(1,095)
Overall
24-1/4
(616)
6
(152)
7-3/4
(197)
4
(102)
Liquid drain
1/4" NPT
Liquid
trap
Strainer
Inlet / Outlet
4-way valve
1" NPT
29-9/16 (750)
19-1/4 (489)
10-1/2
(267)
4-1/8
(105)
Suction
Pressure
Gauge
52 (1,321)
Discharge
Pressure
Gauge
Relief valve
Appendix D—Outline Dimensions
Model 691 with 107 Mounting
Appendix D—Outline Dimensions
Models 91–691 with -109 or -109A Mounting (Model -109A Shown Below)
Model
A
A1
B
C
D
D1
E
F
G
H
91-109, -109A
1-3/16
(30.2)
5-1/4
(133.4)
12
(304.8)
13-5/16
(338.1)
31-1/2
(800.1)
—
1-1/2
(38.1)
15
(381.0)
34
(863.6)
31-3/16
(792.2)
291-109, -109A
5
(127.0)
—
12
(304.8)
15-3/4
(400.1)
39-1/2
(1,003.3)
—
1-1/2
(38.1)
15
(381.0)
42
(1,066.8)
30-7/8
(784.2)
491-109, -109A
5-3/4
(146.1)
—
15
(381.0)
18
(457.2)
45-1/2
(1,155.7)
—
1-1/2
(38.1)
18
(457.2)
48
(1,219.2)
33-5/8
(854.1)
691-109, -109A
8-1/4
(209.6)
—
17
(431.8)
19-1/4
(489.0)
49-1/2
(1,257.3)
19-3/4
(501.7)
1-1/2
(38.1)
20
(508.0)
52
(1,320.8)
43-1/8
(1,095.4)
J
K
L
M
N
P
R
S
T
U
91-109, -109A
5-1/4
(133.4)
28-3/16
(716.0)
3/4"
NPT
2-5/16
(58.7)
3
(76.2)
1-1/4
(31.8)
3-5/8
(92.1)
9-1/2
(241.3)
2-3/4
(69.9)
6-3/4
(171.5)
291-109, -109A
5-1/4
(133.4)
28-1/2
(723.9)
3/4"
NPT
2-11/16
(68.3)
3
(76.2)
1-1/4
(31.8)
3-7/8
(98.4)
9-1/2
(241.3)
4-1/2
(114.3)
6-3/4
(171.5)
491-109, -109A
5-1/4
(133.4)
30-1/8
(766.8)
1-1/4"
NPT
4
(101.6)
4
(101.6)
1-1/4
(31.8)
4-1/16
(103.2)
10-7/8
(276.2)
5.25
(133.4)
8-1/8
(206.4)
691-109, -109A
5-5/8
(142.9)
39-1/8
(993.8)
1-1/2"
NPT
6-3/8
(161.9)
4
(101.6)
1-1/4
(31.8)
4-9/16
(115.9)
21-7/16
(544.5)
4-3/4
(120.7)
7-3/4
(196.9)
Model
All dimensions are in inches (millimeters).
48
Appendix D—Outline Dimensions
Model D891 Bare with Flywheel
5-7/16
(139)
5-7/16
(139)
Suction
valve
unloaders
(optional)
Inlet 2"
slip-on
weld flange
Discharge
2" slip-on
weld flange
1/4"-18 NPT
for drain-both
sides
43
(1,092)
35-5/8
(905)
21.2 (539)
diameter
24-7/16
(621)
2-1/8 (54)
8-1/4
(210)
Four
9/16" (14)
diameter
holes
Crankcase
oil heater
(optional)
5-3/8
(137)
1
(25)
5-3/8
(137)
5-1/2
(140)
9-1/4 (235)
14-1/2 (369)
All dimensions are in inches (millimeters).
49
4-3/4
(121)
5-5/8
(143)
14 (356)
Appendix D—Outline Dimensions
Model FD891 Bare with Flywheel
6
(152)
6
(152)
Suction
pressure
gauge
(optional)
Discharge
pressure
gauge
(optional)
Inlet:
2" Class
300 RF
flange
Outlet:
2" Class
300 RF
flange
Suction
valve
unloaders
(optional)
Compressor
wrench
Crankcase
oil gauge
35-5/8
(905)
21.2
(539)
diameter
43-3/16
(1,097)
2-1/8 (54)
8-1/4
(210)
Four
9/16 (14)
mounting
holes
1
(25)
5-3/8
(137)
Crankcase
oil heater
(optional)
5-3/8
(137)
9-1/2 (235)
14-1/2 (369)
All dimensions are in inches (millimeters).
50
5-1/2
(140)
4-3/4
(121)
14 (356)
48-15/16
(1,243)
overall
7-1/16
(179)
All dimensions are in inches (millimeters).
51
38-13/16 (986)
Overall
30 (762)
41-5/8
(1,057)
Inlet
pressure
gauge
Suction valve
unloaders
(optional)
Inlet:
2" weld
flange
11-3/16
(285)
to outlet
5/16 (7)
to inlet
61 (1,549)
Overall with switch option
56 (1,422)
Adjustable motor
slidebase
Outlet
pressure
gauge
Outlet:
2" weld
flange
Appendix D—Outline Dimensions
Model D891 with 103 Mounting
49-3/16
(1,250)
overall
7-1/16
(180)
All dimensions are in inches (millimeters).
52
39 (991)
Overall
30 (762)
41-5/8
(1,058)
Inlet
pressure
gauge
Inlet:
2" Class 300
RF flange
Suction valve
unloaders
(optional)
5-3/4
(147)
6
(152)
6
(152)
61 (1,550)
Overall with switches
56 (1,423)
Outlet
pressure
gauge
Outlet:
2" Class 300
RF flange
Appendix D—Outline Dimensions
Model FD891 with 103 Mounting
83-3/8
(2,118)
overall
All dimensions are in inches (millimeters).
53
7-1/16
(179)
39 (991)
overall
30 (762)
24-1/16 (611)
19-3/16 (487)
9-7/16
(240)
35-5/8
(905)
46-3/8
(1,178)
Inlet / outlet
four-way valve
2" Class 300
RF flange
9-1/2
(241)
Liquid
level
switches
41
(1,041)
77-3/4
(1,975)
41-13/16 (1,062)
29-3/4 (756)
23-3/4 (603)
3/4
(19)
Suction
pressure
gauge
84 (2,134)
overall
1-1/2" FNPT
connection
Discharge
pressure
gauge
3/4" FNPT
connection
45-13/16
(1,164)
Appendix D—Outline Dimensions
Model FD891 with 107 Mounting
83-3/8
(2,118)
overall
All dimensions are in inches (millimeters).
54
7-1/16
(179)
39 (991)
overall
30 (762)
28-1/2 (724)
19-3/16 (487)
16-7/16 (418)
9-7/16
(240)
9-1/2
(241)
Liquid
level
switches
41
(1,041)
77-3/4
(1,975)
Inlet:
2" Class 300
RF flange
3/4
(19)
35-3/16 (894)
29-3/4 (756)
Suction
pressure
gauge
84 (2,134)
overall
Outlet:
2" weld flange
Discharge
pressure
gauge
41-5/8
(1,057)
Appendix D—Outline Dimensions
Model D891 with 107B Mounting
83-3/8
(2,118)
overall
All dimensions are in inches (millimeters).
55
7-1/16
(179)
39 (991)
overall
30 (762)
24-1/16 (611)
19-3/16 (487)
9-7/16
(240)
35-5/8
(905)
46-3/8
(1,178)
Inlet / outlet
four-way valve
2" Class 300
RF flange
9-1/2
(241)
Liquid
level
switches
41
(1,041)
77-3/4
(1,975)
43-5/16 (1,100)
29-3/4 (756)
23-3/4 (603)
3/4
(19)
Suction
pressure
gauge
84 (2,134)
overall
Discharge
pressure
gauge
Beltguard
1-1/2" FNPT
connection
3/4" FNPT
connection
45-13/16
(1,164)
Appendix D—Outline Dimensions
Model FD891 with 107B Mounting
83-3/8
(2,118)
overall
All dimensions are in inches (millimeters).
56
7-1/16
(179)
39 (991)
overall
30 (762)
19-3/16 (487)
16-7/16 (418)
9-7/16
(240)
41
(1,041)
77-3/4
(1,975)
9-1/2
(241)
Liquid
level
switches
Inlet:
2" Class 300
RF flange
3/4
(19)
35-3/4 (908)
29-3/4 (756)
Suction
pressure
gauge
84 (2,134)
overall
Outlet:
2" Class 300
RF flange
Discharge
pressure
gauge
41-5/8
(1,057)
Appendix D—Outline Dimensions
Model D891 with 109B Mounting
57
Appendix E—Parts Details for 91 and F91 Head and Valve Assembly
91 Head Assembly
Valve Holddown Assemblies
Suction
Spec 3
3
Suction
Spec 4
5
Discharge
All Specs
5
5
1
6
6
6
7
7
7
4
F91 Head Assembly
11
8
11
9
11
10
3
2
Valve Assemblies
Suction Valve
Spec 3
12
13
4
14
15
Suction Valve
Spec 4
CAUTION: Always relieve pressure in the
unit before attempting any repairs.
Discharge Valve
All Specs
WARNING
21
58
16
20
17
17
18
18
19
19
22
23
24
Appendix E—Parts Details for 91 and F91 Head and Valve Assembly
Head and Valve Bill of Materials
Ref
No.
Part No.
Description
2374
Head (model 91)
1
2374-X
Head assembly (model 91, spec 3)
1
2374-X1
Head assembly (model 91, spec 4)
1
2.
4302
Head
(model F91, Class 300 RF flange)
1
3.
7001-037NC100A
Bolt (hex head 3/8"-16 x 1-1/4")
4
4.
2-235_ a
O-ring
1
5.
2714-1
Valve cap
2
6.
2-031_ a
O-ring
2
7.
2715
Holddown screw
2
8.
3483-1X
Suction valve assembly
(aluminum, spec 3)
1
9.
3483-X
Suction valve assembly
(aluminum, spec 4)
1
10.
3485-X
Discharge valve assembly
(aluminum, all specs)
1
11.
2717
Valve gasket (aluminum)
2
12.
5000-77
Retainer ring (spec 3)
1
13.
3977
Suction valve relief housing
(spec 3)
1
14.
1411
Spring (spec 3)
1
15.
1410
Ball (spec 3)
1
16.
3483-1
Suction valve seat (spec 3)
1
17.
3972
Suction valve plate
1
18.
4009
Suction spring
1
19.
3484
Suction valve bumper
1
20.
3483
Suction valve seat (spec 4)
1
21.
3486
Discharge valve bumper
1
22.
4008
Discharge spring
1
23.
3973
Discharge valve plate
1
24.
3485
Discharge valve seat
1
1.
a
b
_ denotes material code. See material code chart for
details.
Registered trademark of the DuPont company.
Qty.
Material Code
A Buna-N
B Neoprene ® b
59
Appendix E—Parts Details for 91 and F91 Head and Valve Assembly
Piston—Bill of Materials
Piston Diameter 3" (7.62 cm)
Ref
No.
1
Part No.
Description
7002-010TP100A
Screw (socket head)
4
7207-010A
Lock washer
4
2.
1983
Head (iron)
1
3.
1775
Ring expander
3
4.
1772
Piston ring
3
5.
1482
Locknut
1
6.
1483
Lock pin
1
7.
1984
Piston platform
1.
2
Qty.
1
1528
Shim washer (thick)
As
Req.
1528-1
Shim washer (thin)
As
Req.
1527
Thrust washer
8.
9.
1
Piston Clearance (Cold) a
3
a
Model
Minimum (x)
Maximum (x)
91
0.020" (0.51 mm)
0.044" (1.12 mm)
The distance from the bottom of the head to the top of the piston.
CAUTION: Always relieve pressure in the unit before attempting
any repairs.
WARNING
4
5
6
7
8
9
Crosshead
assembly
60
Appendix E—Parts Details for 91 and F91 Packing Assembly
Packing—Bill of Materials
14
1
2
3
7
4
5
8
6
13
Ref
No.
Part No.
Description
1.
2242
Cylinder
1
2.
2-235_
O-ring for cylinder
1
3.
5000-137
Retainer ring
1
4.
1012
Washer
1
5.
1628
Packing spring
1
6.
1714
Packing box washer
1
7.
1453-1
Male packing ring
1
8.
1454 b
Packing ring
8
9.
1452-1
Female packing ring
1
10.
2240
Crosshead guide
1
11.
1387-X
Adjusting screw assembly
1
12.
2526
Crankcase gasket
1
13.
1452-1X1
Packing set
1
14.
7001-037NC100A
Bolt (hex head 3/8"-16 x 1")
4
15.
7001-037NC125A
Bolt (hex head 3/8"-16 x 1-1/4")
4
16.
7206-037A
Lock washer (3/8")
4
17.
2243
Inspection plate
1
18.
2244
Inspection plate gasket
1
19.
7012-010NC025B
Screw (Pan HD phillip)
6
20.
1192
Lock device (not shown)
1
a
Qty.
7,8,9
9
Assembly Number
Assembly Name
1132-X2
Crosshead—piston rod assembly
_ denotes material code. See material code chart
for details.
b
The quantity of 1454 packing rings required will
vary due to tolerances. Use cone 4005 for
installation of packing.
c
Registered trademark of the DuPont company.
a
10
Material Code
A Buna-N
B Neoprene ®c
CAUTION: Always relieve pressure in the unit before attempting
any repairs.
WARNING
17
18
20
15
19
11
16
Crosshead
assembly
12
61
Appendix E—Parts Details for 91 and F91 Connecting Rod Assembly
Connecting Rod—Bill of Materials
10
1
Ref
No.
Part No.
Description
1.
1132-X2
Crosshead assembly
1
2.
1498
Retainer ring
2
3.
2505
Wrist pin
1
4.
1846-X a, b
Wrist pin bushing
1
5.
1599 b
Bolt
2
6.
1889-1X
Connecting rod assembly
1
7.
1367
Connecting rod bearing
(pair)
1
8.
2011 b
Dipper
1
9.
1600
Nut
2
10.
4005
Packing installation cone
1
b
b, c
Qty. per
Compressor
After the wrist pin bushing has been pressed into the connecting rod, it
must be honed to .8759/.8756. A hydraulic press and honing machine are
recommended for this step.
b
Included with connecting rod assembly, not sold separately.
c
Torque connecting rod nut to 28 ft. lbs.
a
2
3
Never attempt to separate the piston rod and crosshead. When repair
becomes necessary, the entire crosshead assembly must be replaced.
2
CAUTION: Always relieve pressure in the unit before attempting
any repairs.
WARNING
4
5
5
6
7
Note
alignment
marks
8
9
62
Appendix E—Parts Details for 91 and F91 Flywheel Assembly
1
2
2
2
2
2
2
2
Back Side
Flywheel—Bill of Materials
1
Front Side
63
Ref
No.
Part No.
Description
1.
3271
Flywheel (14" O.D., 2 groove)
1
2.
H SF-1.125
Hub with three bolts and
lockwashers
1
Assembly Number
Assembly Name
3271-X2
Flywheel assembly (flywheel, hub,
and three bolts) standard
Qty.
Appendix E—Parts Details for 91 and F91 Crankcase Assembly
3
23
10
22
17
13
18
19
21
20
13
12
16
15
3
14
56
1
2
3
7
4
11
10
8
9
64
Appendix E—Parts Details for 91 and F91 Crankcase Assembly
Packing—Bill of Materials
Ref
No.
Part No.
Description
1.
3259
Oil seal
2.
1450
Groove pin (1/8" x 1")
1
3.
7001-037NC075A
Hex head (3/8"–16 x 3/4", grade 5)
12
4.
3260
Bearing carrier
1
5.
2796
Breather ball
1
6.
2-111A
O-ring (Buna-N)
1
7.
1279-X
Breather cap
1
8.
2725
Bearing carrier gasket
1
9.
1807
Roll pin (1/8" x 5/8")
1
10.
2718
Bearing cup
2
11.
2723
Oil circulating ring
1
12.
2476
Crankshaft
1
13.
2719
Bearing cone
2
14.
2289
Flywheel key
1
15.
2290
Oil ring retainer washer
1
16.
2554
Crankcase
(capacity: 0.9 quarts, 0.8 liters)
1
17.
1661
Pipe plug (3/8" NPT square or
hex head)
1
18.
2729
Inspection plate gasket
1
19.
2728
Crankcase inspection plate
1
20.
2-112A
O-ring (Buna-N)
1
21.
1368-X1
Oil bayonet assembly (with O-ring)
22.
23.
a
Qty.
1
1
2721
Bearing adjustment shim (0.005)
As
needed
2721-1
Bearing adjustment shim (0.007)
As
needed
2721-2
Bearing adjustment shim (0.020)
As
needed
2720
Bearing cap
1
Assembly Number
Assembly Name
2476-X
Crankshaft assembly with 2476, 2290 and 2719
2476-SX a
Extended crankshaft assembly with 2719 (2) and
2290
3260-X
Bearing carrier assembly with 3260, 2718, 3259,
1279-X, 2-111A, 1450, 2796 and 1807
3271-X2 a
Flywheel assembly 14" - 2 groove with H
SF-1.125 and 3271
Optional equipment.
CAUTION: Always relieve pressure in the unit before attempting
any repairs.
WARNING
65
Appendix E—Parts Details for 291 and F291 Head and Valve Assembly
291 Head Assembly
Valve Holddown Assemblies
Suction
Spec 3
4
Suction
Spec 4
7
7
1
Discharge
All Specs
7
3
8
8
9
9
8
9
6
5
F291 Head Assembly
3
13
10
13
11
13
12
4
2
Valve Assemblies Details
Suction Valve
Spec 3
14
15
16
6
17
5
Suction Valve
Spec 4
Discharge Valve
All Specs
23
CAUTION: Always relieve pressure in the
unit before attempting any repairs.
18
22
19
19
20
20
21
21
WARNING
66
24
25
26
Appendix E—Parts Details for 291 and F291 Head and Valve Assembly
Head and Valve Bill of Materials
Ref
No.
Part No.
Description
2912
Head (model 291)
1
2912-X1
Head assembly
(model 291, spec 3)
1
2912-X2
Head assembly
(model 291, spec 4)
1
4300
Head
(model F291, Class 300 RF flange)
1
7001-037NC100A
Bolt (hex head, 3/8-16 x 1-1/4")
4
7206-037A
Lock washer
4
2731
Center headbolt
2
2732
Gasket (center headbolt)
2
5.
2-235_ a
O-ring
2
6.
2-113_ a
O-ring
1
7.
2714-1
Valve cap
4
8.
2-031_
O-ring
4
9.
2715
Holddown screw
4
10.
3483-1X
Suction valve assembly
(aluminum, spec 3)
2
11.
3483-X
Suction valve assembly
(aluminum, spec 4)
2
12.
3485-X
Discharge valve assembly
(aluminum, all specs)
2
13.
2717
Valve gasket (aluminum)
4
14.
5000-77
Retainer ring (spec 3)
2
15.
3977
Suction valve relief housing
2
16.
1411
Spring (spec 3)
2
17.
1410
Ball (spec 3)
2
18.
3483-1
Suction valve seat (spec 3)
2
19.
3972
Suction valve plate
2
20.
4009
Suction spring
2
21.
3484
Suction valve bumper
2
22.
3483
Suction valve seat (spec 4)
2
23.
3486
Discharge valve bumper
2
24.
4008
Discharge spring
2
25.
3973
Discharge valve plate
2
26.
3485
Discharge valve seat
2
1.
2.
3.
4.
a
_ denotes material code. See material code chart for
details.
b
Registered trademark of the DuPont company.
a
Qty.
Material Code
A
Buna-N
B
Neoprene ®b
67
Appendix E—Parts Details for 291 and F291 Piston Assembly
Piston—Bill of Materials
Piston Diameter 3" (7.62 cm)
Ref
No.
1
Part No.
Description
7002-010TP100A
Screw (socket head)
8
7207-010A
Lock washer
8
2.
1983
Head (iron)
2
3.
1775
Ring expander
6
4.
1772
Piston ring
6
5.
1482
Locknut
2
6.
1483
Lock pin
2
7.
1984
Piston platform
1528
Shim washer (thick)
1.
2
8.
3
Qty.
2
As
req.
1528-1
Shim washer (thin)
9.
1527
Thrust washer
Ref
No.
Assembly
Number
Assembly Name
Qty.
10.
1983-X
Piston assembly
2
2
Piston Clearance (Cold) a
10
a
Model
Minimum
Maximum
291
0.020" (0.51 mm)
0.044" (1.12 mm)
The distance from the bottom of the head to the top of the piston.
CAUTION: Always relieve pressure in the unit before attempting
any repairs.
WARNING
4
5
6
7
8
9
Crosshead
assembly
68
Appendix E—Parts Details for 291 and F291 Packing Assembly
Packing—Bill of Materials
20
1
Description
1.
2913-1
Cylinder
1
2.
2-235_
O-ring (cylinder)
2
3.
5000-137
Retainer ring
2
4.
1012
Washer
2
5.
1628
Packing spring
2
6.
1714
Packing box washer
2
7.
1453-1
Male packing ring
2
8.
1454 b
Packing
16
9.
1452-1
Female packing ring
2
a
Qty.
10.
43­­­98-X
Cartridge holddown screw
2
11.
4394
Packing box cartridge
2
4
12.
1387-X
Adjusting screw
2
13.
2-135_ a
O-ring (packing cartridge)
2
14.
4393
Crosshead guide
1
15.
2702
Crankcase gasket
1
16.
1452-1X1
Packing set
2
17.
1651
Inspection plate gasket
1
18.
1650
Inspection plate
1
10
19.
7003-025NC037E
Screw
(1/4"-20 x 3/8" pan hd phillip)
10
22
20.
7001-037NC100A
Bolt (hex head 3/8"-16 x 1-1/4")
12
21.
7206-037A
Lock washer
12
22.
1192
Locking device (not shown)
1
5
16
7
7,8,9
8
Part No.
2
3
6
Ref
No.
11
9
Assembly Number
Assembly Name
1132-X2
Crosshead—piston rod assembly
_ denotes material code. See material code chart
for details.
The quantity of 1454 packing rings required will
vary due to tolerances. Use cone 4005 for
installation of packing.
c
Registered trademark of the DuPont company.
a
22
12
13
b
14
CAUTION: Always relieve pressure in
the unit before attempting any repairs.
Crosshead
assembly
WARNING
20
21
19
15
Material Code
A Buna-N
B Neoprene ® c
17
18
69
Appendix E—Parts Details for 291 and F291 Connecting Rod Assembly
Connecting Rod—Bill of Materials
9
Ref
No.
Part No.
Description
1.
1132-X2
Crosshead assembly
2
2.
1498
Retainer ring
4
3.
2505
Wrist pin
2
4.
1846-X a, b
Wrist pin bushing
2
5.
1599 b
Bolt
4
6.
1889-X
Connecting rod assembly
2
7.
1367
Connecting rod bearing
(pair)
2
8.
1600 b, c
Nut
4
9.
4005
Packing installation cone
1
b
Qty. per
Compressor
After the wrist pin bushing has been pressed into the connecting rod, it
must be honed to .8759/.8756. A hydraulic press and honing machine are
recommended for this step.
b
Included with connecting rod assembly.
c
Torque connecting rod nut to 28 ft. lbs.
a
1
2
Never attempt to separate the piston rod and crosshead. When repair
becomes necessary, the entire crosshead assembly must be replaced.
3
2
CAUTION: Always relieve pressure in the unit before attempting
any repairs.
WARNING
4
5
5
6
7
Note
alignment
marks
8
70
Appendix E—Parts Details for 291 and F291 Flywheel Assembly
1
2
2
2
2
2
2
2
Back Side
Flywheel—Bill of Materials
1
Front Side
71
Ref
No.
Part No.
Description
1.
2549
Flywheel (16" O.D., 3 groove)
1
2.
H SF-1.250
Hub with three bolts and
lockwashers
1
Qty.
Assembly Number
Assembly Name
2549-X1
Flywheel assembly (flywheel, hub,
and three bolts)—standard
3271-X1
Flywheel assembly for extended crankshaft—
optional
Appendix E—Parts Details for 291 and F291 Crankcase Assembly
1
3
2
4
5
11
10
12
13
14
6
15
16
9
7
17 (Assembly)
2
18
19
8
18
26
28
27
25 24
23
20
22
21
37
44
35
21
38
39 (assembly)
40
34
41
46 9
47
36
48
49
45
50
44
42
33
31
30
32
51
27
29
40
43 (assembly)
72
52
Appendix E—Parts Details for 291 and F291 Crankcase Assembly
Packing Assembly Bill of Materials
Qty.
Ref
No.
Part No.
Description
Oil seal
1
42.
2-228A
O-ring (Buna-N, pump cover)
1
7001-037NC075A
Bolt (hex head, 3/8"-16 x 3/4")
8
43.
4222-X
Oil filter assembly
1
2957
Bearing cover
1
44.
1629
Pipe plug (1/16" NPT, flush seal)
2
Bearing adjustment shim (0.005")
As
needed
45.
7001-037NC100A
Bolt (hex head, 3/8"-16 x 1")
6
46.
2805
Pump shaft bushing
1
Bearing adjustment shim (0.007")
As
needed
47.
2850
Pump shaft adapter
1
As
needed
48.
2852
Oil pump spring
1
49.
2851
Spring guide
1
50.
2849-X
Oil pump assembly (individual
pump parts not available)
1
51.
2798
Pump cover pin with 4222
1
52.
4225
Filter
1
Ref
No.
Part No.
Description
1.
1278
2.
3.
1273
4.
1273-1
1273-2
Bearing adjustment shim (0.020")
5.
1500
Bearing cup
1
6.
1368-X
Oil bayonet
1
7.
2713
Crankcase inspection plate gasket
1
8.
2958
Crankcase inspection plate
1
9.
2-112A
O-ring (Buna-N)
2
10.
2955
Crankcase
1
Assembly Number
Assembly Name
Breather cap assembly with 1279, 2-111A
Qty.
11.
1279
Breather cap
1
1279-X
12.
2-111A
O-ring (Buna-N)
1
1342-X1a
13.
2796
Breather ball
1
Extended crankshaft assembly with 1284 (2),
1286, 1342, 1501, 2590, 2719
14.
1450
Lock pin (1/8" x 1")
1
1368-X1
Oil bayonet assembly with 1368-X, 2-112A
15.
1671
Flywheel key
1
16.
1501
Bearing cone
1
2956-X
17.
1341-X1
Crankshaft assembly with 1284 (2),
1286, 1341, 1501, 2590, 2719
Bearing carrier assembly with 1285, 1290, 1291,
1292, 1293, 1515-X, 2718, 2805, 2806 (2), 2848X, 2849-X, 2850, 2851, 2852, 2956, 2961-X,
2-011A, 2-112A, 2-228A.
1
2957-X
Bearing cover assembly with 2957 and 1278
18.
1284
Crankshaft orifice
2
19.
2719
Bearing cone
1
20.
1286
Pump shaft drive pin
1
21.
2590
Pipe plug (1/8" NPT, flush seal)
2
22.
1280
Filter screen screw
1
23.
1281
Filter screen screw gasket
1
24.
2-116A
O-ring (Buna-N, filter screen)
1
25.
1276
Filter screen washer
1
26.
1275
Oil filter screen
1
27.
3289
Pipe plug (1/4" NPT, flush seal)
2
28.
1661
Pipe plug (3/8" NPT)
1
29.
1290
Relief valve adjusting screw
1
30.
1291
Adjusting screw locknut
1
31.
2-011A
O-ring (Buna-N, relieve valve
adjustment screw)
1
32.
1292
Relief valve spring
1
33.
1293
Relief valve ball
1
34.
2718
Bearing cup
1
35.
2961-X
Air release valve assembly with
2961, 2962, 2963
1
36.
1285
Bearing carrier gasket
1
37.
2956
Bearing carrier
1
38.
2-218A
O-ring
(Buna-N, closure body, 2 required)
2
39.
1515-X
Closure cap assembly including
2-218A (2)
1
40.
7001-025NC050A
Bolt (hex head, 1/4"-20 x 1/2")
10
41.
1302
Oil pressure gauge
1
a
Optional equipment.
CAUTION: Always relieve pressure in the unit before attempting
any repairs.
WARNING
73
Appendix E—Parts Details for 491 and F491 Head and Valve Assembly
491 Head Assembly
5
Valve Holddown Assemblies
Suction
Spec 3
5
Suction
Spec 4
Discharge
All Specs
7
4
1
Suction
8
7
7
9
8
8
9
9
30
30
10
10
11
11
12
12
13
13
103
101
102
14
14
14
30
10
4
Discharge
11
4
6
12
3
13
F491 Head Assembly
5
5
4
2
Suction
Valve Assemblies
Suction Valve
Spec 3
4
Discharge
4
8
6
Suction Valve
Spec 4
24
3
25
Discharge Valve
All Specs
8
26
8
15
15
16
22
27
17
CAUTION: Always relieve pressure in the
unit before attempting any repairs.
17
103
18
19
WARNING
20
74
101
18
19
20
19
102
18
28
20
17
29
21
23
14
14
14
Appendix E—Parts Details for 491 and F491 Head and Valve Assembly
Head and Valve Bill of Materials
Ref
No.
Part No.
Description
1.
3712 a
Head (model 491, ductile iron)
4297
2.
Qty.
Ref
No.
Valve Assembly No.
Assembly Name
1
101.
2438-X
Suction valve assembly—spec 4
Head
(model F491, Class 300 RF flange)
1
102.
2439-X
Discharge valve assembly—all specs
103.
2532-1X
Suction valve assembly—spec 3
3.
2-253_a, b, c
O-ring (model 491)
2
4.
3442
Pipe plug (1/4" NPT)
3
Head Assembly No.
5.
1479
Center head bolt
2
3712-X1 a
b
7005-043NC125A b
6.
7.
8.
Bolt (ferry head, 7/16"-14 x
1-1/4", 490 and 491 prior to serial
#FZ44188)
7005-043NC150Ab
Bolt (ferry head, 7/16"-14 x 1-1/2",
491 serial # FZ44188 and later)
12
1477
Valve screw nut
4
1478
Gasket (steel)
1476
Valve holddown screw
4
10.
1475
Valve cover plate
4
11.
2-143_c
O-ring for cover plate
4
12.
1409d
Valve spacer
4
13.
2448
Cage
4
14.
1418
Valve gasket (aluminum)
15.
2446
Bolt
16.
2438
Suction valve seat
2
17.
2442
Valve plate
4
18.
2445
Spacer (two per valve)
8
19.
3355
Washer
4
20.
1407
Valve spring
4
21.
2440
Suction valve bumper (spec 4)
2
22.
2441
Discharge valve bumper
2
23.
2439
Discharge valve seat
2
24.
2533-1
Adjusting screw
2
25.
1411
Relief ball spring
2
26.
1410
Relief ball
2
27.
2532-1
Suction valve seat
2
28.
2534-1
Suction valve post
2
29.
2447
Suction valve bumper (spec 3)
2
30.
7001-043NC125A
Bolt (hex head, 7/16"-14 x 1-1/4")
16
Valve Specification
491
3
491
4
4297-X1
F491 (Class 300 RF)
3
4297-X2
F491 (Class 300 RF)
4
a
S/N FZ44188 and later.
Not included in head assembly.
_ denotes material code. See material code chart for
details.
d
Place spacers back to back as shown.
e
Registered trademark of the DuPont company.
a
b
c
4
9.
d
3712-X2
12
Model
4
2 or 4
75
Material Code
A
Buna-N
B
Neoprene ®e
Appendix E—Parts Details for 491 and F491 Piston Assembly
Piston—Bill of Materials
Piston Diameter 4" (10.16 cm)
Ref
No.
1
Part No.
Description
7002-025TP125A
Screw (socket head)
16
7207-025A
Lock washer
16
2.
1985
Head (iron)
2
3.
1776
Ring expander
6
4.
1773
Piston ring
6
5.
1482
Locknut
2
6.
1483
Lock pin
2
7.
1986
Piston platform
1528
Shim washer (thick)
1.
2
8.
3
Qty.
2
As
Req.
1528-1
Shim washer (thin)
9.
1527
Thrust washer
Ref
No.
Assembly
Number
Assembly Name
Qty.
10.
1985-X
Piston assembly
2
2
Piston Clearance (Cold) a
10
a
b
Model
Minimum
Maximum
491 b
0.020" (0.51 mm)
0.044" (1.12 mm)
The distance from the bottom of the head to the top of the piston.
For 491 compressor with head O-rings.
CAUTION: Always relieve pressure in the unit before attempting
any repairs.
4
WARNING
5
6
7
8
9
Crosshead
assembly
76
Appendix E—Parts Details for 491 and F491 Packing Assembly
Packing—Bill of Materials
20
1
4
2
3
7
5
6
16
7,8,9
8
Ref
No.
Part No.
Description
1.
3713 a
Cylinder (491 with O-ring)
1
2.
2-243_
O-ring (cylinder)
2
3.
5000-137
Retainer ring
2
4.
1012
Washer
2
5.
1628
Packing spring
2
6.
1714
Packing box washer
2
7.
1453-1
Male packing ring
2
8.
1454 c
Packing ring
16
9.
1452-1
Female packing ring
2
10.
2801-X
Cartridge holddown screw
2
11.
2799
Packing box cartridge
2
12.
1387-X
Adjusting screw
2
13.
2-139_ b
O-ring (packing cartridge)
2
14.
2765 d
Crosshead guide
1
15.
1489
Crankcase gasket
1
16.
1452-1X1
Packing set
2
17.
1488
Inspection plate gasket
1
18.
1487
Inspection plate
1
b
Qty.
19.
7003-025NC037E Screw (1/4"-20 x 3/8")
10
10
20.
7005-043NC125A
Bolt (ferry head, 7/16"-14 x 1-1/4")
12
22
21.
7206-043A
Lock washer (7/16")
6
­­22.
1192
Locking device (not shown)
1
—
3442
Pipe plug (1/4" NPT, not shown)
1
11
9
22
12
Assembly Number
Assembly Name
1384-X
Crosshead assembly
S/N FZ44188 and later.
_ denotes material code. See material code chart
for details.
c
The quantity of 1454 packing rings required will
vary due to tolerances. Use Cone 4005 for packing
installation.
d
Registered trademark of the DuPont company.
a
b
13
14
Material Code
A Buna-N
B Neoprene ® d
Crosshead
assembly
CAUTION: Always relieve pressure in
the unit before attempting any repairs.
20
WARNING
21
19
15
17
18
77
Appendix E—Parts Details for 491 and F491 Connecting Rod Assembly
Connecting Rod—Bill of Materials
9
Ref
No.
Part No.
Description
1.
1384-X
Crosshead assembly
2
2.
1498
Retainer ring
4
3.
1496
Wrist pin
2
4.
1495-X a, b
Wrist pin bushing
2
5.
1492 b
Bolt
4
6.
1490-X
Connecting rod assembly
2
7.
1491
Connecting rod bearing
(pair)
2
8.
1493 b, c
Nut
4
9.
4005
Packing installation cone
1
b
Qty. per
Compressor
After the wrist pin bushing has been pressed into the connecting rod, it
must be honed to .8759/.8756. A hydraulic press and honing machine are
recommended for this step.
b
Included with connecting rod assembly.
c
Torque connecting rod nut to 30 ft. lbs.
a
1
2
Never attempt to separate the piston rod and crosshead. When repair
becomes necessary, the entire crosshead assembly must be replaced.
3
2
CAUTION: Always relieve pressure in the unit before attempting
any repairs.
WARNING
4
5
5
6
7
Note
alignment
marks
8
78
Appendix E—Parts Details for 491 and F491 Flywheel Assembly
1
2
2
2
2
2
2
2
Back Side
Flywheel—Bill of Materials
1
Front Side
79
Ref
No.
Part No.
Description
1.
2549
Flywheel (16" O.D., 3 groove)
1
2.
H SF-1.375
Hub with three bolts and
lockwashers
1
Qty.
Assembly Number
Assembly Name
2549-X
Flywheel assembly (flywheel, hub,
and three bolts)—standard
3271-X1
Flywheel assembly for extended crankshaft—
optional
Appendix E—Parts Details for 491 and F491 Crankcase Assembly
3
1 2
4
11
10
5
12
13
14
6
15
9
7
16
17
2-1
18
8
19
18
26
28
25 24
27
20
23
21
22
37
44
35
21
38
39 (assembly)
40
34
41
46 9
36
47
48
49
50
45
42
44
33
31
30
32
51
27
29
40
43 (assembly)
80
52
Appendix E—Parts Details for 491 and F491 Crankcase Assembly
Packing Assembly Bill of Materials
Qty.
Ref
No.
Part No.
Description
Oil seal
1
42.
2-228A
O-ring (Buna-N, pump cover)
1
7001-037NC075A
Bolt (hex head, 3/8"-16 x 3/4")
4
43.
4222-X
Oil filter assembly (external)
1
7001-031NC075A
Bolt (hex head, 5/16"-18 x 3/4")
6
44.
1629
Pipe plug (1/16" NPT, flush seal)
2
2847-1
Bearing cover
1
45.
7001-037NC100A
Bolt (hex head, 3/8"-16 x 1")
6
46.
2805-X
Pump shaft bushing
1
47.
2850
Pump shaft adapter
1
48.
2852
Oil pump spring
1
49.
2851
Spring guide
1
50.
2849-X
Oil pump assembly (individual
pump parts not available)
1
51.
2798
Pump cover pin with 4222
1
52.
4225
Oil filter
1
Ref
No.
Part No.
Description
1.
4438
2.
2-1.
3.
4.
1504
Bearing adjustment shim (0.005")
As
needed
1504-1
Bearing adjustment shim (0.007")
As
needed
As
needed
1504-2
Bearing adjustment shim (0.020")
5.
1502
Bearing cup
1
6.
1508-X
Oil bayonet
1
7.
1511
Crankcase inspection plate gasket
1
8.
2853
Crankcase inspection plate
1
9.
2-112A
O-ring (Buna-N, oil bayonet and
pump shaft)
2
10.
2803
Crankcase
1
11.
1279
Breather cap
1
12.
2-111A
O-ring (Buna-N, breather cap)
1
13.
2796
Breather ball
1
14.
1450
Lock pin
1
15.
1663
Flywheel key
1
16.
1503
Bearing cone
1
17.
1499-X
Crankshaft assembly with 1284 (2),
1286, 1499, 1501, 1503, 2590
1
18.
1284
Crankcase orifice (2)
2
19.
1501
Bearing cone
1
20.
1286
Pump shaft drive pin
1
21.
2590
Pipe plug
2
22.
1280
Filter screw
1
23.
1281
Filter screen screw gasket
1
24.
2-116A
O-ring (Buna-N, filter screen)
1
25.
1276
Filter screen washer
1
26.
1275
Oil filter screen
1
27.
3289
Pipe plug
2
28.
1661
Plug (3/8" NPT)
1
29.
1290
Relief valve adjusting screw
1
30.
1291
Adjusting screw locknut
1
31.
2-011A
O-ring (Buna-N, relief valve
adjusting screw)
1
32.
1292
Relief valve spring
1
33.
1293
Relief valve ball
1
34.
1500
Bearing cup
1
35.
2961-X
Air release valve assembly with
2961, 2962, 2963
1
36.
1513
Bearing carrier gasket
1
37.
2804
Bearing carrier
1
38.
2-218A
O-ring (Buna-N, closure body, 2)
2
39
1515-X
Closure cap assembly
1
40.
7001-025NC050A
Bolt (hex head, 1/4"-20 x 1/2")
11
41.
1302
Oil pressure gauge
1
a
Qty.
Assembly Number
Assembly Name
1279-X
Breather cap assembly with 1279, 2-111A
1499-SX a
Extended crankshaft assembly with 1284 (2),
1286, 1499-S, 1501, 1503, 2590
1508-X1
Oil bayonet assembly with 1508-X, 2-112A
2804-X
Bearing carrier assembly with 1290, 1291, 1292,
1293, 1500, 1513, 1515-X, 1629 (2), 2590, 2804,
2849-X, 2850, 2851, 2852, 2961-X, 2-011A,
2-112A, 2-228A, 4222-X
2847-1X
Bearing cover assembly with 2847-1, 4438
Optional equipment.
CAUTION: Always relieve pressure in the unit before attempting
any repairs.
WARNING
81
Appendix E—Parts Details for 691 and F691 Head and Valve Assembly
691 Head Assembly
7
Valve Holddown Assemblies
Suction
Spec 3
8
3
Suction
Spec 4
10
1
5
Discharge
All Specs
10
11
10
11
12
11
12
12
13
5
13
13
14
9
14
14
4
15
7
15
15
6
16
16
F691 Head Assembly
8
16
2
Suction Valve
Spec 3
9
101
102
103
17
17
17
Valve Assemblies
18
19
20
21
6
Suction Valve
Spec 4
22
23
104
WARNING
26
82
29
30
24
25
101
31
30
24
CAUTION: Always relieve pressure in the
unit before attempting any repairs.
Discharge Valve
All Specs
102
26
25
104
26
103
27
104
24
27
27
28
29
31
17
17
17
25
Appendix E—Parts Details for 691 and F691 Head and Valve Assembly
Head and Valve Bill of Materials
Ref
No.
Part No.
Description
1.
3458 a
Head (model 691)
4299
2.
Qty.
Ref
No.
Valve Assembly No.
Assembly Name
1
101.
3948-2X
Suction valve assembly—spec 3
Head
(model F691, Class 300 RF flange)
1
102.
3856-2X
Suction valve assembly—spec 4
103.
3857-2X
Discharge valve assembly—all specs
104.
3146-X2
Valve repair kit—all specs
(suction and discharge)
3.
2144-2
Flange (2" NPT, suction)
1
4.
2144-1.5
Flange (1-1/2" NPT, discharge)
1
5.
2-231_ b
O-ring
2
6.
2-261_ b
O-ring (model 691 head)
2
Head Assembly No.
7.
7001-043NC150A
Bolt (hex head, 7/16"-14 x 1-1/2")
8
3458-X
8.
2136
Center head bolt
2
9.
7005-050NC150A
Bolt (ferry head, 1/2"-13 x 1-1/2")
12
2714
Valve cap
4
2714-1
Valve cap (grooved for O-ring)
4
11.
2-031_ b
O-ring (valve cap)
4
12.
2715
Holddown screw
4
13.
7001-043NC137A
Bolt (hex head, 7/16"-14 x 1-3/8")
16
14.
1764
Valve cover plate
4
15.
2-235_ b
O-ring (cover plate)
4
16.
2797
Valve cage
4
17.
2114
Valve gasket (aluminum)
4
18.
5000-77
Retainer ring
2
19.
3977
Suction valve relief housing (spec 3)
2
20.
1411
Spring
2
21.
1410
Relief ball
2
22.
3948
Valve seat (spec 3)
2
23.
2534-1
Suction valve post (spec 3)
2
24.
4230
Inner valve plate
2
25.
4229
Outer valve plate
2
26.
3929
Inner valve spring
2
27.
3928
Outer valve spring
2
28.
3949-1
Valve bumper (spec 3)
2
Valve bumper (spec 3)
4
10.
29.
3857-1
Valve bumper (spec 4)
6
30.
3920
Valve stud
4
31.
3856
Valve seat
2
Model
Valve Specification
691
3
S/N NQ51455 and later. Earlier models use gasket
#2177.
b
_ denotes material code. See material code chart for
details.
c
Registered trademark of the DuPont company.
a
83
Material Code
A
Buna-N
B
Neoprene ®c
Appendix E—Parts Details for 691 and F691 Piston Assembly
Piston—Bill of Materials
Piston Diameter 4.5" (11.43 cm)
Ref
No.
1
Part No.
Description
7002-025TP125A
Screw (socket head)
16
7207-025A
Lock washer
16
2.
1987
Head, iron
2
3.
1740
Ring expander
6
4.
1739
Piston ring
6
5.
1482
Locknut
2
6.
1483
Lock pin
2
1735
Shim washer (thick)
1735-1
Shim washer (thin)
8.
1986
Piston platform
Ref
No.
Assembly
Number
Assembly Name
Qty.
9.
1987-X1
Piston assembly
2
1.
7.
2
Qty.
As
Req.
2
Piston Clearance (Cold) a
9
3
a
Model
Minimum
Maximum
691
0.025" (0.64 mm)
0.040" (1.02 mm)
The distance from the bottom of the head to the top of the piston.
CAUTION: Always relieve pressure in the unit before attempting
any repairs.
WARNING
4
5
6
7
8
Crosshead
assembly
84
Appendix E—Parts Details for 691 and F691 Packing Assembly
Packing—Bill of Materials
1
23
2
3
22
4
6
5
7
8
6
17
7,8,9
10
9
15
21
Ref
No.
Part No.
Description
1.
3457
Cylinder (model 691)
1
2.
2-247_
O-ring (cylinder)
2
3.
1749-X
Cartridge holddown screw
2
4.
5000-175
Retainer ring
2
5.
1731
Packing spring
2
6.
1728
Packing washer
2
7.
1724
Male packing ring
2
8.
1725-2
Packing ring
8
9.
1723
Female packing ring
2
10.
2407
Packing box cartridge
2
11.
2-233_ a
O-ring (packing cartridge)
2
12.
1748
Cartridge plate
2
13.
5000-350
Retainer ring
2
14.
2405
Crosshead guide
1
15.
1722-X
Adjusting screw
2
16.
1761
Crankcase gasket
1
17.
1725-2X
Packing set
2
18.
1760
Inspection plate gasket
1
19.
1721
Inspection plate
1
20.
7003-025NC037E
Screw (1/4"-20 x 3/8")
10
­21.
1192
Locking device (for adjusting
screw, not shown)
2
22.
2893
Locking device cartridge holddown
screw (not shown)
2
23.
7005-050NC175A
Bolt
16
24.
7206-050A
Lock washer
16
a
Qty.
11
14
Assembly Number
Assembly Name
2405-X
Crosshead guide assembly with 1748 (2), 2405,
5000-350 (2)
3544-X4
Crosshead assembly “M” style
_ denotes material code. See material code chart
for details.
c
The quantity of 1454 packing rings required will
vary due to tolerances. Use Cone 4005 for packing
installation.
d
S/N XC30633 and later.
e
Registered trademark of the DuPont company.
a
12
13
A
Buna-N
B
Neoprene ® d
CAUTION: Always relieve pressure in
the unit before attempting any repairs.
23
WARNING
24
20
Crosshead
assembly
Material Code
19
18
16
85
Appendix E—Parts Details for 691 and F691 Connecting Rod Assembly
Connecting Rod—Bill of Materials
9
1
2
3
2
a
b
c
Ref
No.
Part No.
1.
3544-X4
Crosshead assembly
2
2.
3590
Retainer ring
4
3.
3540
Wrist pin
2
4.
3541-X a, c
Wrist pin bushing
2
5.
1726 a
Bolt
8
6.
3785-X1
Connecting rod assembly
2
7.
3542 a
Connecting rod bearing (pair)
2
8.
1727 a, b
Nut
8
9.
4692
Packing installation cone
1
Spec M Only
Description
Qty. per
Compressor
Included with connecting rod assembly
Torque connecting rod nut to 40 ft. lbs.
After the wrist pin bushing has been pressed into the connecting rod, it
must be honed to 1.1263/1.1259 (Spec M ONLY). A hydraulic press and
honing machine are recommended for this step.
Never attempt to separate the piston rod and crosshead. When repair
becomes necessary, the entire crosshead assembly must be replaced.
4
CAUTION: Always relieve pressure in the unit before attempting
any repairs.
5
5
WARNING
7
6
Note
alignment
marks
8
8
86
Appendix E—Parts Details for 691 and F691 Flywheel Assembly
1
2
2
2
2
2
2
2
Back Side
Flywheel—Bill of Materials
1
Front Side
87
Ref
No.
Part No.
Description
1.
1762
Flywheel (19.5" O.D., 4 groove)
1
2.
H E-2.125
Hub with three bolts and
lockwashers
1
Assembly Number
Assembly Name
1762-X
Flywheel assembly (flywheel, hub,
and three bolts)—standard
Qty.
Appendix E—Parts Details for 691 and F691 Crankcase Assembly
14
13
15
12
19
4
16
17
18
11
10
27
8
7
3
26
9
6
3
20
23
22
21
24
25
2
1
30
28
4
36
37
38
35
31
29
5
49
39
40
34
33
32
27
47
59
(Includes all
parts shown
except #50
and #51)
46
48
Inside of
Bearing Carrier
55
54
13
45
44
52
43
41
53
58
51
42
50
32
56
53
Oil Passage Hole
Important! Line up hole in
gasket with oil passage hole.
57
53
48
Pump Cover Oil/Filter Adapter
41
58
Pumpside of adapter shown for
proper orientation of cover and
location of pump cover pin.
88
Appendix E—Parts Details for 691 and F691 Crankcase Assembly
Packing—Bill of Materials
Ref
No.
Part No.
Description
Qty.
Ref
No.
Part No.
Description
Qty.
1.
1737
Bearing cone
1
44.
2851
Spring guide
1
2.
3638-1
Spacer
1
45.
2852
Oil pump spring
1
3.
1284
Crankshaft orifice
2
46.
3219
Pump shaft adapter
1
4.
2197
Drive pin
1
47.
2805-X b
Pump shaft bushing
1
5.
2933
Link pin
1
48.
1629
Pipe plug (1/16" NPT, flush seal)
1
6.
3786
Crankshaft
1
49.
1736
Bearing cup
1
7.
3503
Flywheel key
1
50.
1302
Oil pressure gauge
1
8.
3580
Bearing cone
1
51.
1044
Bushing (1/8" x 1/4" NPT)
1
9.
3786-X1
Crankshaft assembly
1
52.
3220-2
Bearing carrier
1
3289
Pipe plug (1/4" NPT, flush seal)
4
10.
7001-031NC075A
Bolt (hex head, 5/16"–18 x 3/4")
6
53.
11.
2122
Inspection cover
1
54.
2131
Bearing carrier gasket
1
12.
2123
Gasket (inspection cover)
1
55.
2961-X
Air release valve assembly
1
13.
2-112A
O-ring, Buna-N
2
56.
2590
Pipe plug (1/8" NPT, flush seal)
1
14.
3225-X1
Oil bayonet assembly (with O-ring)
1
57.
4225
Filter
1
15.
2126
Breather ball
1
16.
3579
Bearing cup
1
58.
2798
Pump cover pin
(included with 4222-X)
1
3589
Bearing adjustment shim (.005")
As
needed
59.
3220-2X
Bearing carrier assembly M3 style
1
3589-1
Bearing adjustment shim (.007")
As
needed
Assembly Number
Assembly Name
3589-2
Bearing adjustment shim (.020")
As
needed
3221-X1
Crankcase assembly (M3, 4, 8, 9) without
lubrication (not shown)
18.
3539
Bearing cover
1
19.
3526
Oil seal
1
20.
1280
Filter screw
1
21.
1281
Gasket (filter)
1
22.
2-116A
O-ring (Buna-N)
1
23.
1276
Washer
1
24.
1275
Oil filter screen
1
25.
3443
Pipe plug (1/2" NPT, steel)
1
26.
3221
Crankcase
1
27.
7001-037NC100A
Bolt
(hex head, 3/8"–16 x 1", grade 5)
12
28.
3875
Access cover
1
29.
7003-025NC037E
Screw (1/4"–20 x 3/8")
4
30.
3874
Gasket, access cover
1
31.
1515-X
Closure cap assembly
1
32.
7001-025NC050A
Bolt (hex head, 1/4"–20 x 1/2")
11
33.
1515
Closure cap
1
34.
1516
Closure body
1
35.
2-218A
O-ring (Buna-N)
2
36.
1290
Relief valve adjusting screw
1
37.
2-011A
O-ring (Buna-N)
1
38.
1291
Adjusting screw locknut
1
39.
1292
Relief valve spring
1
40.
1293
Relief valve ball
1
41.
4222-X a
Oil filter adapter assembly
(with pin)
1
42.
2-228A
O-ring (Buna-N)
1
43.
2849-1X a
Oil pump assembly
1
17.
a
b
Caution: To avoid damage during assembly, refer to installation Instruction
Manual IE400.
Must be rebored and honed after replacing (0.876"/0.875" diameter).
CAUTION: Always relieve pressure in the unit before attempting
any repairs.
WARNING
89
Appendix E—Parts Details for D891 and FD891 Head and Valve Assembly
891 Head
4
Valve Holddown
Assembly (4-1/2")
Valve Holddown
Assembly (4-1/2")
Suction
Discharge
1
2
5
5
6
6
7
7
14
14
14
14
8
8
8
2
3
8
D891
cover
plate
D891
cover
plate
9
9
FD891
cover
plate
10
FD891
cover
plate
10
3
CAUTION: Always relieve pressure in the
unit before attempting any repairs.
11
11
13
13
WARNING
Head and Valve Bill of Materials
Ref
No.
1.
2.
3.
Part No.
Description
3923
3924
2-246__ a
Cylinder cap
Cylinder head (4-1/2")
O-ring
Bolt (hex head, 1/2"–13 x 1-3/4",
grade 5, torque to 65 ft•lbs)
Valve cap
O-ring
Holddown screw
Valve cover plate (model D891)
Valve cover plate (model FD891)
O-ring
Valve cage
Valve assembly (4-1/2", suction)
Valve assembly (4-1/2", discharge)
Valve gasket
Bolt (hex head, 7/16"–14 x 1-1/2",
torque to 37 ft•lbs)—model FD891
Bolt (hex head, 7/16"–14 x 1-1/2",
torque to 37 ft•lbs)—model D891
Valve seat (4-1/2")
Stud
Valve plate (inner)
Valve plate (outer)
Inner spring
Outer spring
Valve bumper (4-1/2")
Valve repair kit
4.
7001-050 NC175A
5.
6.
7.
9.
10.
11.
12.
13.
2714-1
2-031__ a
2715
1764
4854
2-235__ a
3570-1
3856-2X
3857-2X
2114 b
14.
7001-043 NC150A
15.
16.
17.
18.
19.
20.
21.
22.
3856
3920
4230 c
4229 c
3929 c
3928 c
3857-1
3146-X2
8.
Valve Assemblies (4-1/2")
Qty.
Suction Valve
Spec 4
1
2
2
Discharge Valve
All Specs
15
21
16
12
8
8
8
8
4
8
8
4
4
8
17
28
21
16
19
18
20
22
22
19
17
20
18
15
32
8
8
8
8
2
2
8
1
_ denotes material code. See material code chart
for details.
Included with valve assembly.
c
Included with valve repair kit.
d
Registered trademark of the DuPont company.
a
b
90
Material Code
A
Buna-N
B
Neoprene ® d
Appendix E—Parts Details for D891 and FD891 Piston
1
Piston—Bill of Materials
Piston Diameter 4.5" (11.43 cm)
2
3
Ref
No.
Part No.
Description
1.
7002-025TP100A
Screw (orlo, gr. 8, torque to 8 ft•lbs)
4
2.
3927
Piston cap
1
2902
Shim washer (thick)
2902-1
Shim washer (thin)
4.
1739
Piston rings
4
5.
1740
Expander ring
4
6.
3604
Lock nut (torque to 150 ft•lbs)
1
7.
3730
Thrust washer
2
8.
3925
Piston (4-1/2" diameter)
1
3603
Shim washer (thick)
3603-1
Shim washer (thin)
10.
3812
Loctite tube (620, not shown)
Ref
No.
Assembly Number
Assembly Name
11.
3925-X1
Piston assembly
3.
4
5
9.
4
5
4
5
Qty.
As
req.
As
req.
1
Piston Clearance (Cold) a
Model
4
D891
5
a
b
6
Top (X)
Minimum a
Top (X)
Maximum a
Bottom (Y)
Minimum b
Bottom (Y)
Maximum b
0.084"
(2.13 mm)
0.104"
(2.64 mm)
0.010"
(0.25 mm)
0.020"
(0.51 mm)
The distance from the bottom of the head to the top of the piston.
The distance from the bottom of the piston to the top of the packing barrel.
Model D891 Piston Clearance
7
Piston
Piston
X
X
8
Y
Y
Piston
Piston
Piston bottom dead center
Piston top dead center
Model FD891 Piston Clearance
9
7
Piston
WARNING
Piston
X
CAUTION: Always relieve
pressure in the unit before
attempting any repairs.
X
Crosshead
assembly
Y
Y
Piston
Piston top dead center
91
Piston
Piston bottom dead center
Appendix E—Parts Details for D891 and FD891 Crosshead Guide
D891 Cylinder
FD891 Cylinder
1
1
Valve openings
Valve openings
6
5
4
3
3
Valve openings
3
Valve openings
3
2
2
7
14
Crosshead Guide—Bill of Materials
13
Ref
No.
14
13
8
3
Packing barrels
and cartridges
(For parts details,
see D891 packing
assembly).
1.
3
12
4
10
11
Description
3922
Cylinder (model D891)
1
4851
Cylinder
(model FD891, Class 300 RF flange)
1
O-ring for cylinder
2
Pipe plug (1/4" NPT)
3
Bolt (hex head, 1/2"—13 x 1-3/4",
grade 5, model D891)
18
Bolt (hex head, 1/2"–13 x 1-3/4",
grade 5, model FD891)
14
2.
2-246_
3.
3442
4.
4
Part No.
a
7001-050NC175A
5.
3793-2S
Flange
(inlet / outlet, model D891 only)
2
6.
2-231_ a
O-ring (flange, model D891 only)
2
7.
3253
Roll pin
1
8.
2405-1
Crosshead guide
1
9.
1761
Gasket (crankcase)
1
10.
1760
Gasket (inspection cover)
1
11.
1721
Inspection cover
1
12.
7012-010NC025B
Bolt (phillip head, 10"–24 x 1/4")
10
13.
2-231_ a
O-ring
2
14.
2-238_
O-ring
2
a
_ denotes material code. See material code chart
for details.
b
Registered trademark of the DuPont company.
a
9
CAUTION: Always relieve pressure in the
unit before attempting any repairs.
WARNING
92
Qty.
Material Code
A
Buna-N
B
Neoprene ® b
Appendix E—Parts Details for D891 and FD891 Packing
Packing—Bill of Materials
Specification “J”
1
2
3
4
5
6
Radial
Tangent
7
4
5
6
Radial
Tangent
7
18
Upper
Segmented
Packing
Set
4
5
6
Radial
Tangent
Ref
No.
Part No.
Description
1.
3926
Packing barrel (4-1/2")
2
2.
2-238_ a, c
O-ring
2
3.
3906
Crush gasket
2
4.
3817
Packing cup (Not included in
3810-X1 packing set)
8
5.
2-036_ a, d
O-ring (cup)
8
6.
3810
Segmented packing
(radial—tangent) pair
6
6.1.
3814
Segmented packing
(tangent—tangent) pair
2
7.
3811
Back-up ring
8
8.
7002-025TP100A
Screw (socket head, 1/4"–20 x 1")
8
9.
3885
Cartridge
2
10.
2-231_ a
O-ring
4
11.
1732 b
Oil deflector ring
2
12.
5000-175
Retainer ring
4
13.
1728
Washer
6
14.
1731
Spring
2
15.
1724
Packing ring (male)
2
16.
1725-2
V-ring packing
8
17.
1723
Packing ring (female)
2
18.
3810-X1e
Packing set (segmented)
2
19.
1725-2X
Packing set (V-ring)
2
7
Identification of Packing Specification
Example: Model Number FD891 J M4PFBANSNN
Packing Spec
4
5
6.1
Tangent
Tangent
7
10
11
12
V-ring
Packing
Direction
15
Piston (Pressure) Side
Align pin
with hole
Tangent Cut
(without pin)
Tangent Cut
(with pin)
Back-up
ring
Back-up
ring
Align pin
with hole
To Crankcase
15
IMPORTANT: Identify and line up the rings before installing. Be sure they face
the way shown here and that the pin and hole are aligned when assembled.
16
a
_ denotes material code. See material code chart for
Material Code
details.
A Buna-N
Deflector ring is loose within the packing cartridge
until fitted on the piston rod. Must be put in from
B Neoprene ® f
the bottom of the cartridge.
c
Insert O-ring into the groove in the bottom of the barrel.
d
Starting with S.N. NN51397.
e
Packing cup O-ring not included in packing set.
f
Registered trademark of the DuPont company.
b
17
16
17
Piston (Pressure) Side
To Crankcase
13
19
Lower
V-ring
Packing
Set
Segmented packing for
Specification “J”
Tangent Cut
(with pin)
Lower Packing
Specification
“J”
13
14
Segmented Packing for
Specification “J”
Radial Cut
(without pin)
8
9
Qty.
To Crankcase
13
CAUTION: Always relieve pressure in the unit before attempting
any repairs.
12
WARNING
93
Appendix E—Parts Details for D891 and FD891 Connecting Rod Assembly
Connecting Rod—Bill of Materials
9
1
2
3
2
Ref
No.
Part No.
Description
1.
3544-X3
Crosshead assembly
2
2.
3590
Retainer ring
4
3.
3540
Wrist pin
2
4.
3541-X a, c
Wrist pin bushing
2
5.
1726 a
Bolt
8
6.
3785-X1
Connecting rod assembly
2
7.
3542
Connecting rod bearing
(pair)
2
8.
1727 a, b
Nut
8
9.
3905
Packing installation cone
1
a
a
Qty. per
Compressor
Included with connecting rod assembly
Torque connecting rod nut to 40 ft. lbs.
c
After the wrist pin bushing has been pressed into the connecting rod, it
must be honed to 1.1263/1.1259. A hydraulic press and honing machine are
recommended for this step.
a
b
Never attempt to separate the piston rod and crosshead. When repair
becomes necessary, the entire crosshead assembly must be replaced.
4
5
5
CAUTION: Always relieve pressure in the unit before attempting
any repairs.
WARNING
7
6
Note
alignment
marks
8
8
94
Appendix E—Parts Details for D891 and FD891 Flywheel Assembly
1
2
2
2
2
2
2
2
Back Side
Flywheel—Bill of Materials
1
Front Side
95
Ref
No.
Part No.
Description
1.
3852
Flywheel (21.2" O.D., 5 groove)
1
2.
H J-2.125
Hub with three bolts and
lockwashers
1
Assembly Number
Assembly Name
3852-X
Flywheel assembly (flywheel, hub,
and three bolts)
Qty.
Appendix E—Parts Details for D891 and FD891 Crankcase Assembly
14
13
15
12
19
4
16
17
18
11
10
27
8
7
3
26
9
6
3
20
23
22
21
24
25
2
1
30
28
4
36
37
38
35
31
29
5
49
39
40
34
33
32
27
47
59
(Includes all
parts shown
except #50
and #51)
46
48
Inside of
Bearing Carrier
55
54
13
45
44
52
43
41
53
58
51
42
50
32
56
53
Oil Passage Hole
Important! Line up hole in
gasket with oil passage hole.
57
53
48
Pump Cover Oil/Filter Adapter
41
58
Pumpside of adapter shown for
proper orientation of cover and
location of pump cover pin.
96
Appendix E—Parts Details for D891 and FD891 Crankcase Assembly
Packing Assembly Bill of Materials
Ref
No.
Part No.
Description
Qty.
Ref
No.
Part No.
Description
Qty.
1.
1737
Bearing cone
1
44.
2851
Spring guide
1
2.
3638-1
Spacer
1
45.
2852
Oil pump spring
1
3.
1284
Crankshaft orifice
2
46.
3219
Pump shaft adapter
1
4.
2197
Drive pin
1
47.
2805 b
Pump shaft bushing
1
5.
2933
Link pin
1
48.
1629
Pipe plug (1/16" NPT, flush seal)
1
6.
3786
Crankshaft
1
49.
1736
Bearing cup
1
7.
3503
Flywheel key
1
50.
1302
Oil pressure gauge
1
8.
3580
Bearing cone
1
51.
1044
Bushing (1/8" x 1/4" NPT)
1
9.
3786-X1
Crankshaft assembly
1
52.
3220-2
Bearing carrier
1
3289
Pipe plug (1/4" NPT, flush seal)
4
10.
7001-031NC075A
Bolt (hex head, 5/16"–18 x 3/4")
6
53.
11.
2122
Inspection cover
1
54.
2131
Bearing carrier gasket
1
12.
2123
Gasket (inspection cover)
1
55.
2961-X
Air release valve assembly
1
13.
2-112A
O-ring (Buna-N)
2
56.
2590
Pipe plug (1/8" NPT, flush seal)
1
14.
3225-X1
Oil bayonet assembly (with O-ring)
1
57.
4225
Filter
1
15.
2126
Breather ball
1
16.
3579
Bearing cup
1
58.
2798
Pump cover pin (included with
4222-X)
1
3589
Bearing adjustment shim (.005")
As
needed
59.
3220-2X
Bearing carrier assembly M3 style
1
3589-1
Bearing adjustment shim (.007")
As
needed
Assembly Number
Assembly Name
3589-2
Bearing adjustment shim (.020")
As
needed
3221-X1
Crankcase assembly (M3, 4, 8, 9) without
lubrication (not shown)
18.
3539
Bearing cover
1
19.
3526
Oil seal
1
20.
1280
Filter screw
1
21.
1281
Gasket (filter)
1
22.
2-116A
O-ring (Buna-N)
1
23.
1276
Washer
1
24.
1275
Oil filter screen
1
25.
3443
Pipe plug (1/2" NPT, steel)
1
26.
3221
Crankcase
1
27.
7001-037NC100A
Bolt
(hex head, 3/8"–16 x 1", grade 5)
12
28.
3875
Access cover
1
29.
7003-025NC037E
Screw (1/4"–20 x 3/8")
4
30.
3874
Gasket (access cover)
1
31.
1515-X
Closure cap assembly
1
32.
7001-025NC050A
Bolt (hex head, 1/4"–20 x 1/2")
11
33.
1515
Closure cap
1
34.
1516
Closure body
1
35.
2-218A
O-ring (Buna-N)
2
36.
1290
Relief valve adjusting screw
1
37.
2-011A
O-ring (Buna-N)
1
38.
1291
Adjusting screw locknut
1
39.
1292
Relief valve spring
1
40.
1293
Relief valve ball
1
41.
4222-X a
Oil filter adapter assembly
(with pin)
1
42.
2-228A
O-ring (Buna-N)
1
43.
2849-1X a
Oil pump assembly
1
17.
a
b
Caution: To avoid damage during assembly, refer to installation Instruction
Manual IE400.
Must be rebored and honed after replacing (0.876"/0.875" diameter).
CAUTION: Always relieve pressure in the unit before attempting
any repairs.
WARNING
97
Appendix F—Troubleshooting
In most cases, problems with your Corken gas compressor
can be solved quite simply. This chart lists some of the
more frequent problems that occur with reciprocating
Problem
Low capacity
Overheating
Knocks, rattles and noise
Oil in cylinder
Abnormal piston-ring wear
Product leaking through crankcase breather
Product leakage
Oil leakage around compressor base
No oil pressure
Excessive vibration
Motor overheating or starter tripping out
Ref.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
compressors along with a list of possible causes. If you
are having a problem which is not listed, or if you cannot
find the source of the problem, consult the factory.
Possible Cause
1, 2, 3, 4
1, 2, 3, 5, 6, 11, 15
1, 7, 9, 10, 11, 14
8, 14
1, 3, 5, 6, 11, 14, 15
8, 14
4, 8, 14
16, 17
18, 19
1, 7, 9, 10, 11, 12, 13, 25, 27
20, 21, 22, 23, 24, 25, 26, 27
Possible Causes
What To Do
Valves broken, stuck or leaking
Piston ring worn
Inlet strainer clogged
Leaks in piping
Inlet or ambient temperature too high
Compression ratio too high
Loose flywheel or belt
Worn piston-rod packing
Worn wrist pin or wrist-pin bushing
Worn connecting-rod bearing
Unbalanced load
Inadequate compressor base
Improper foundation or mounting
Loose valve, piston or packing
Dirty cooling fins
Leaking gas blowing oil from crankcase
Bad oil seal
No oil in crankcase
Oil-pump malfunction
Inspect and clean or repair
Inspect and replace as necessary
Clean or replace screen as necessary
Inspect and repair
Consult factory
Check application and consult factory
Tighten
Replace
Replace
Replace
Inspect valve or consult factory
Strengthen, replace or grout
Tighten mounting or rebuild foundation
Tighten or replace as necessary
Clean weekly
Tighten packing
Replace
Add oil
See oil-pressure adjustment
Check line voltage with motor nameplate. Consult power
company
Check wiring diagram
Replace with correct size
Voltage, phase and frequency must coincide with motor
nameplate. Consult with power company.
Check and replace according to manufacturer’s instructions
Reduce speed
See driver installation
Lubricate according to manufacturer’s instructions
20.
Low voltage
21.
22.
Motor wired wrong
Wire size too small for length or run
23.
Wrong power characteristics
24.
25.
26.
27.
Wrong size of heaters in starter
Compressor overloading
Motor shorted out
Bad motor bearing
98
Solutions beyond products...
CORKEN, INC. • A Unit of IDEX Corporation
3805 N.W. 36th St., Oklahoma City, OK 73112
Phone (405) 946-5576 • Fax (405) 948-7343
Visit our website at http://www.corken.com
or e-mail us at cocsalesdept@idexcorp.com
@CorkenInc
Printed in the U.S.A.
March 2018
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