E1016 Installation, Operation & Maintenance Manual Liquid Transfer-Vapor Recovery Compressors Solutions beyond products... = CORKEN.Warning Install, use and maintain this equipment according to Corken, Inc. instructions and all applicable federal, state, local laws and codes, and NFPA Pamphlet 58 for LP-Gas or ANSI K61.1-1989 for Anhydrous Ammonia. Periodic inspec tion and maintenance is essential Corken One Year Limited Warranty Corken, Inc. warrants that its products will be free from defects in material and workmanship for a period of 12 months following date of purchase from Corken. Corken products which fail within the warranty period due to defects in material or workmanship will be repaired or replaced at Corken’s option, when returned freight prepaid to: Corken, Inc., 9805 N.W. 36th Street, 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 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 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. Such substances should be handled by experienced, trained personnel in compliance with governmental and industrial safety standards. Contacting The Factory For your convenience, the model number and serial number are given on the compressor nameplate. Space is provided below for you to keep a written record of this information. Always include the model number and serial number when ordering parts. Model No. Serial No, Date Purchased Date Installed Purchased From Installed By IMPORTANT NOTE TO CUSTOMERS! CORKEN, INC. does not recommend ordering parts from general descriptions in this manual. To minimize the possibility of receiving incorrect parts for your machine, Corken strongly recommends you order parts according to part numbers in the Corken Service Manual and/or Installation, Operation, & Maintenance (1M) Manual. If you do not have the appropriate service manual pages, call or write Corken with model number and serial number from the nameplate on your compressor.TABLE OF CONTENTS CHAPTER 1—INTRODUCTION .. 1.1. Liquid Transfer by Vapor Differential Pressure 1.2 Residual Vapor Recovery : 1.3 Compressor Construction Features « CHAPTER 2-INSTALLING YOUR CORKEN COMPRESSOR. . 24 Location ... 2.2 Foundation. 23 Piping a 2.4 Liquid Traps . 2.10 2.5 Driver installation / Flywheels : voeeeeeee fier WD 2.6 Crankcase Lubrication. 12 27 Relief Valves 12 2.8 Truck Mounted Compressors 12 2.9 Shutdown/Alarm Devices 13 CHAPTER 3—STARTING UP YOUR CORKEN COMPRESSOR PAGE 14 3.1 Inspection After Extended Storage 14 3.2 Flywheel and V-belt Alignment : 14 3.3 Crankcase Oil Pressure Adjustment . 4 3.4 Startup Checklist 15 CHAPTER 4—ROUTINE MAINTENANCE CHART . . -PAGE 16 CHAPTER 5—ROUTINE SERVICE AND REPAIR PROCEDURES . cee - PAGE 17 51 Valves 7 5.2 Head 19 5.3 Piston Rings and Piston Ring Expanders 19 5.4 Pistons 19 5.5 Piston Rod Packing Adjustment . +20 5.6 Cylinder and Packing Replacement . +20 5.7 Bearing Replacement for Grankcase and Gonnecting Rod - 222 5.7.1 Wrist Pin Bushing Replacement : . 222 5.7.2 Replacing Connecting Rod Bearings. 222 5.7.9 Replacing Roller Bearings ...... 222 5.8 Oil Pump Inspection .......... 223 5.9 Servicing the Four-Way Valve : cette eettteeeeennaeees 224 CHAPTER 6 EXTENDED STORAGE PROCEDURES. ........ssscsessicsecseeeuesuesressees PAGE 25 APPENDICES A. Model Number and Mounting Identification Code... . . 26-27 B. Operating and Material Specifications, Bolt Torque Values, Clearance and Dimensions 28-33 CC. Compressor Selection Mounting Selections . 234 NeButane.... ec. 235 Propane 36 Ammonia. . 37 D. Outline Dimensions. 38-48 E, Troubleshooting. 49 F Model 91 and F91 Parts Details, 50-57 G. Model 291 and F291 Parts Details 0.2... : 58-65 H. Model 490, 491, and F491 Parts Details... coe 66-73 1. Model 691 and Fé91 Parts Details .......... : 74-81 J. Model Dast Parts Details = 82-89Chapter 1—Introduction Threaded and ANSI flanges: Compressors are availabe n ether threaded NPT, —— ANSI, or DIN flanged connections. High-efficiency valves: Corken valves offer quit operation and high ‘lurabilty in oi-toe gas applications. Specially designed suction valves which tolerate small ‘amounts of condensate are used in quid transter- vapor recovery compressors. O-ring head gaskets: Easy to install O-ing head gaskets providing highly reliale seals, Ductile iron construction: Alloyinders and heads are ductile iron for maximum thermal shock endurance. Solt-lubricating PTFE piston rings: Corken provides a vary of state-of-the-art piston ring designs to provide the most cost-effective ‘operation of compressors for nor-iube service. The Step-out design provides higher efcienoiee during the entire life ofthe piston ring, Positively locked pistons Simple piston design allows ond clearance to be precisely sotto provide maximum aficieney and rong te. Selt-lubricating piston rod Seale constructed of PTFE incorporating special filers to ensure no oll carryover and maximize leakage control. Spring loaded seal design sett adjusts to compensate for normal wear Nitride-coated piston rods: Impregnated nitride coating provides superior Corrosion and wear resistance. Nameplate: Serves as packing adjusting screw cover (S96 Figure 114). Castiron crosshead: Durable cast iron erossheads prove superior resistance to corrosion and galling Pressure-lubricated crankcase with fiter: Selfreversing ol pump ensures proper lubrication — regardless of directional ration to main and Connecting rod bearings. Standard 10-micronfiter ensures long-lasting bearing Iie (not avaliable on Model 81). Construction Detals—Model F201 CompressorCORKEN. GAS COMPRESSOR ‘CRANKCASE CAPACITY 2 OTS. ( LT). PAT WO3 95,027 ‘READ INSTRUCTIONS BEFORE OPERATING. INO INSTRUCTION BOOK WAS RECEIVED, WRITE THE FACTORY. MooeL ‘SERIAL NO. (ONLAHOMA CTY OF WADE IN USA 906 CORE RE Figure 1.18: Typical Namepiate (Also Serves as the Packing Adjusting Screw Cover) 1.1 Liquid Transfer By Vapor Differential Pressure Corken LPG/NH; compressors are designed to transfer liquefied gases such as butane/propane mixtures (liquefied petroleum gas or LPG) and Anhydrous Ammonia (NH) from one tank to another. Liquefied gases such as LPG & NH, are stored in closed containers where both the liquid and vapor phases are present There is a piping connection between the vapor sections of the storage tank and the tank being unloaded, and there is 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 1.18). The gas compressor accomplishes ‘COMPRESSOR INCREASES PRESSURE IN TANK CAR BY ADDING VAPOR. this by withdrawing vapors from the storage tank, compressing them and then discharging into the tank to be unloaded. This procedure slightly decreases the storage tank pressure and increases the pressure in the other tank, thereby causing the liquid to flow. 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 1.24), 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 (8.8 to 4.5, VAPOR LINES macs CAUSES CUD TOFLOW: “WAY VALVE OPERATION "TANKS CAUSES LIQUID TO FLOW 1 OPERATY ‘OUT OF THE TANK GAR TO. auld une ~ "THe STORAGE TANK ronda Four-Way Valve Position 1 mucr70 schanoe Frou Coumnesson Coameseon Figure 1.18: Liquid transter by vapor differential pressureVAPORUINES ‘VAPOR 6 BUBBLED THROUGH ‘isuiprowe coc sx — nesonoense — ENON VAPOR FROM TANK var “eway VALE OPERATION cal wove TO LIQUID LINE IS VALVED CLOSED Sok erTOWFOR une varon neSOWERY 1 RSE Four-Way Valve Position 2 sro ieSenos rn Beeson eoaratsioe Figur 1.24: Rasue Vapr Recovery Serre bars). A good rule of thumb is not to operate beyond the point at which the inlet pressure is one-fourth 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 duting the first few minutes hile this liquid is being vaporized than that during the same period of time later in the operation. Remember that more than haif 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, 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 1.3. Corken gas compressors are mounted on oil lubricated crankcases that remain at atmospheric pressure. ‘lL PRESSURE GAUOE Figure 1.24: 107-Style Compressor Mounting 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 type cil pump circulates oil through passages in the crankshaft and connection rod to lubricate the journal bearings and wrist pins (see figure 1.38). Sturdy iron crossheads transmit reciprocating motion to the piston,Corken's automatically reversible oil pump design cYLNOER allows the machine to function smoothly in either son direction of rotation, MALE PACING Corken compressors use iron pistons that are locked me {o the piston rod. The standard piston ring material is a vam glass-filed PTFE polymer specially formulated for non- Fue mcena lubricated services. Piston ring expanders are placed me behind the rings to ensure that the piston rings seal pach tightly against the cylinder wall. ‘owsTmG sone 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 stow R00 of several PTFE V-rings sandwiched between a male and female packing ring and held in place by a spring (see ‘ossneao GUDE figure 1.30). ‘The typical Corken compressor valve consists of a seat Figure 130° Compressor Sealing System bumper, one or more spring/s and one or more valve/s discs or plates as shown in figure 1.80. Special heat- treated 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. risvon rst INO aus racona Fl LB connects foo cnossnean 4 isroN noo P= i= sveren SOUR Fae 1.20; Suton end Discharge Volvos on Hi weknn iu 1 CRANKSHAFT Figure 1.28: Pressure Lubecation Systom (Not Available on Model 91)Chapter 2—Installing Your Corken Compressor 2.4 Location NOTE: Compressor must be installed in a well ventilated area. Corken compressors are designed and manufactured for ‘outdoor duty. For applications where the compressor willbe 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. Corken compressors handling toxic or flammable gases such as LPG/NH; should be located outdoors. A minimum of 18 inches (45 cm) 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. NOISE. Corken vertical compressors sizes modal 91 through 891 should not exceed an 85 DBA noise level when properly installed. 2.2 Foundation Proper foundations are essential for a smooth running compression system. Corken recommends the compressor be attached to a concrete slab at least 8 in. thick with a 2 in. skirt around the circumference of the baseplate. The baseplate should be securely anchored into the foundation by 1/2 in. diameter “J” bolts 12 in. long. Four bolts should be used for models 91, 291, and 491. Six bolts should be used for model 691. The total mass of the foundation should be approximately twice the weight ofthe compressor system (compressor, baseplate, motor, etc) Alter leveling and bolting down baseplate, 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. (On some of the longer baseplates, such as with the 691-107, a3 in. hole can be cut in the baseplate for filing the middle section of the baseplate with grout. ‘See ED410 Compressor Foundation Design, 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. HEX NUT _ WASHER, COMPRESSOR 2 MIN BASEPLATE 4 ALL SIDES “_anour seneara i —pase | conencrerownoxrion Eos ora O53] 12 9 pours Pte tone so Locare-s" Botts PER COMPRESSOR OUTLINE Figure 2.24: Recommended Foundation Details lor Corken Compressors 91 - 691 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 2.34) 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/NH, liquid transfer systems should be designed to limit pressure drops to 20 psi (1.3. bar). Appendix C shows recommended pipe sizes for each compressor for typical LPG/NH, installations. RIGID PIPING Figure 2.24: On -107 mountings, the fexible con actors should be located near the four way vat,Care must be taken ifa restrictive device such as a valve, pressure reguiator, 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. 4107 style compressors are usually connected using a five- valve (figure 2.38) or three-valve manifold (figure 2.30). 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). 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 (2.07 to 2.40 bars) differential between the inlet and outlet pressures, the line sizes are too small or there is some fitting or excess flow valve creating too much restriction. The less restriction in the piping, the better the flow. Appendix C shows recommended pipe sizes for typical LPG/NH, compressor installation ‘VAPOR UNE 70 TRUCK OR TRAILER LOADING VAPOR LINE TO VAPOR SECRON OF STORAGE |\\ varontime To Lau pHase FOR VAPOR RECOVERY’ A tank car unloading riser should have two liquid hoses connected to the car liquid valves. If only one liquid hose isused, 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 possibilty of vapors condensing as they flow to the compressor. The vapor recovery discharge line is better not insulated Placing the compressor as close as possible to the tank being unloaded will minimize heat loss from the discharge line for the best liquid transfer rate. Unioading stationary tanks with a compressor is quite practical. Delivery trucks and other large containers can be filed rapidly if the vapor system of the tank to be filed will permit fast vapor withdrawal, and if the quid piping system. is large enough. Many older trucks (and some new ones) are not originally equipped with vapor excess flow valves ‘SERVICE TO PERFOR VALWE POSTION 1. bad Taw Caro Postion) Opa | Open | Goss | Goss [Goss ‘Storage Tink ‘One Recover vapors Fan THR] Postion] ORGS | Open | Opa | Case | Oe Carnes storaga Ta "wo ‘Daa Farepart or aK | Poon} Opan | Cbs] Goes | Goss POR no Storage Tak ‘One Rover pas Wor Waepar | Postion] Gas | Cs | Opa | Case [ORS ortuaceta Storage Tank | Two Lad Tuk Or Ftd Tak | Poon] Opa | Cos | Ce | ose Opa from Stage Tak. Two. Lead tak or FRE Tn] Potion] RSE | Open | GS | Opn | Oca 7 Eq Baoan Tk CaF ‘a | Open | Coes | Open POR ‘ad Strage Tank Wirout ‘sng vapor Pump. gato Beton TuKOr ‘psn | Css | Gos | Opn Poa Fs Tarkan Sage Tank \ibout Use Vapor Pap Figure 2.9B: Five-Valve Manifold Piping System 9OPERATION OF VALVES. “SERUCETO PERFOR VALVE POSTION TOT aR CIT Poston} Opa | Opa | CRS ‘Storage Tank ‘ne 7 Racover Vapors fom Tait | Poston} ose | Opa | Opa (Gz rio stage Te we Figure 2.2C: Three-Valve Manifold Peing System large enough to do a good job and these should be replaced by a suitable size valve. The liquid cischarge should be Connected to the tank truck pump inlet line rather than the often oversized filler valve connection in the tank head. It's 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 (see section 2.4). itis 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 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. 68, Standard for the Storage and Handling of Liquefied Petroleum Gases. For Ammonia - The American National Standards Institute, Inc., K611-1989, Storage and Handling of Anhydrous Ammonia. Copies of these are available from NFPA, 60 Baterymarch Street, Boston, Mass, 02110 and ANSI, 1430 Broadway, New York, NY., 10018. Install, use and maintain this equipment according to Corken instructions and all applicable federal, state, and local laws and previously mentioned codes. 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 offers three types of liquid traps for removal of entrained liquids. The simplest is a mechanical float trap (see figure 2.44). As the liquid enters the trap the gas velocity is greatly reduced, which allows the entrained 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 oniy appropriate for use where the operator keeps the compressor under fairly close observation. This trap is provided with the 409 and 107 compressor packages (see Appendix C for details on standard Corken compressor packages). When the compressor will not be under more-or-less constant observation an automatic trap is recommended BALL FLOAT Figure 24: Mechanical Trap 10(Gee figure 2.48). The automatic trap replaces the float with electrical float switches. Ifthe 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 108A and 407A mounting configurations. Corken's most sophisticated trap provides the most thorough liquid separation (see figure 2.4C). 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 disentrain fine liquid mists. The ASME code trap is standard in the 109B and 107B mounting configurations. ‘A typical wiring diagram for the liquid level switch is shown in figure 2.4D. 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. Figure 2.48: Automatic Liquid Trap It your compressor is equipped with a liquid trap of other than Corken manufacture, make sure it i of adequate size to thoroughly remove any liquid entrained in the suction stream. ‘Typical Float Switch Wiring Diagram ‘Common, black lormally closed, blue lormally open, red w u oun stop 3 | +t, Tt | tt Figure 2.40: Typical Float Switch Wiring Diagram Krewe vatve \—— mer bh — ot wow caver swircH vou LeveL aan STH ee oe mal Figure 2.40: ASME Automatic Liquid Trap "2.5 Driver Installation / Flywheels Corken vertical compressors may be driven by either electric motors or combustion engines (gasoline, diesel, rratural 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. NOTE: Flexible couplings are not suitable for reciprocating compressors. Never operate a reciprocating compressor without a flywheel. 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 wk2 value than the flywheel. 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. For installation with engine drivers, thoroughly review instructions from the engine manufacturer to assure the Unit is properly installed, 2.6. Crankcase Lubrication Non-detergent oll 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 lls may usually be successfully substituted, although ‘compressors handling ammonia, amine, orimine gases are notable exceptions. These gases react with the detergent and cause the crankcase oll to become corrosive and contaminated. figures 2.6 and 2.6B shaw recommended oil viscosities and crankcase capacities. Synthetic lubricants are generally not necessary. Please consult your lubricate supplier if you are considering the use of synthetic oll ‘Acceptable Crankease Oil Products for Corken Compressors Constant Weight -Non-Detergent-R&O Inhibited product s0 | wi | sat | ambient temp. Enone TERESSTIC we BO | 95 | 2054870 F as) as [20a SF Mobi RARUS 427 Racprocaing | 100] 98 | 30] 6-100" Compressor 0 ‘TE Ol Hen Madi ae ae as ecto! R80 OF Fa Conoc0o Dectal B&O OF 100 [ee 8 | oT | We [as T0F a6) oof | 36 BO Texaco egal F&O i oo [ eo | OE 8) of | We [ae 45) woe [20 [36 BO Sune Suivi 00 07 00 [A000 | aor 0 | 100] 20+ | a- 70°F 46) 00 | 20 | 36° BOF Figure 2.64; Of Selection Chart Compressor | Approximate | Capacity Model Quarts Liters, 1 09 08 291 15 14 491 3.0 28 691 70 66 Figure 2.68: O¥ Capacity Chart 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, 2.8 Truck Mounted Compressors Corken compressors are 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. 12Three types of mountings are typically used. The inside mounting (figure 2.84) 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 2.88). Always use an even number of U-joints. Depending on the truck design, the compressor may be ‘outside or top mounted as shown in figures 2.8 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. 2.9 Shutdown/Alarm Devices For many applications, shutdown/alarm switches will provide worthwhile protection that may prevent serious ‘damageto your compressor system. Allelectronic devices should be selected to meet local code requirements. Shutdown/alarm devices typically used on Corken ‘compressors are: 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 High Temperature Switch—shuts down the unit it the normal discharge temperature Is exceeded. This is strongly recommended for all applications. Typically, the set point is about 80°F (-1°C) above the normal discharge temperature. Low Suction, High Discharge Pressure Switch—shuts down the unit if inlet or outlet pressures are not within preset limits. Vibration Switch—shuts down the unit if vibration becomes excessive. Recommended for units mounted on portable skids Figure 2.88: inside Transport Mounting COMPRESSOR FLYWHEEL se waxMUM = POWER FF TAKEOFF uP Jot -YOKES PARALLEL. [EXTENDED CRANKSHAFT SHArTS PARALLEL Figure 2.88: U.jont Drive for Compressor Figure 2.80: Top Transport Mounting 18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 If your compressor has been out of service for a long period of time, you should verify that 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), 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 fil 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 cil 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. 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, The flywheel is mounted on the shaft via a split, tapered bushing and three bolts. 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 it exceeds the value listed in Appendix B. Diameter Bolt Torque In. (cm) Ft-Ib. (kg-meter) SF 4.628 (11.7) 30 (4.1) E 6.0 (15.2) 60 (8.3) J 7.25 (18.4) 195 (18.7) aN I Figure 3.28: Belt Tension Tighten the belts so that 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 3.28. 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 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. Before starting your compressor, check and fill the crankcase with the proper quantity of lubricating oil 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. 14Remove the pressure gauge. Restart the compressor and run it until oil comes out of the pressure gauge ‘opening. Reinstall the gauge. The oil pressure should be about 20 psi (1.4 bars) minimum for normal service. If the discharge pressure is above 200 psi (14.8 bars) the oil pressure must be maintained at a minimum of 25 psi (1.7 bars). A spring-loaded relief valve mounted on the bearing housing opposite the flywheel regulates the oil pressure. As shown in figure 3.34, 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 ‘OIL LEVEL BAYONET Figure 2.24: Oil Pressure Adjustment 3.4 Startup Check List Please verity all of the items on this list before starting your compressor! Failure to do so may result in a costly (or dangerous) mistake. Before Starting the Compressor 1. Become familiarwith the function ofallpipingassociated with the compressor. Know each line's use! 2. Verify that actual operating conditions will match the anticipated conditions. 3. Ensure that line pressures are within cylinder pressure ratings. 4. Clean out all piping, 8. Check all mounting shims, cylinder and piping supports to ensure that no undue twisting forces exist on the compressor. Verify that strainer elements are in place and clean. Verify that cylinder bore and valve areas are clean. Check V-belt tension and alignment. Check drive alignment on direct drive units. Rotate unit by hand. Check flywheel for wobble or play. Check crankcase oil level. 9. 10. 411. Drain all liquid traps, separators, etc. 12, 18. 14, Verity proper electrical supply to motor and panel Check that all gauges are at zero level reading Test piping system for leaks. 15, 16. Purge unit of air before pressurizing with gas. 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. 19. Double-check all of the above. After Starting Compressor Verity and note proper oil pressure. Shut down and correct any problem immediately. Observe noise and vibration immediately if excessive. levels. Correct Verity proper compressor speed. Examine entire system for gas, oil or water levels. Note rotation direction, Check start-up voltage drop, running amperage and voltage at motor junction box (not at the starter). Test each shutdown device and record set points. Test all relief valves. Check and record all temperatures, pressures and volumes after 30 minutes and 1 hour. 10. After + hour running time, tighten all head bolts, valve holddown bolts, and baseplate bolts. See Appendix B for torque values. 16Chapter 4—Routine Maintenance Chart Item to Check Daily | Weekly | Monthly [Six Months | Yearly Crankease oil pressure x ‘Compressor discharge pressure x Overall visual check x Crankcase cil level Drain liquid from accumulation points xe Clean cooling surfaces on compressor x Lubricator supply tank level if any) x Check belts for correct tension x Inspect valve assemblies x Lubricate motor bearings in accordance with ‘manufacturers’ recommendations Inspect motor starter contact points x Piston rings . x Piston ring life varies greatly, depending on application, gas, and operating pressures. Consult factory for additional recommendations for your specific application. 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 “Liquid traps should be drained prior to startup. 16Chapter 5—Routine Service and Repair Procedures 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 gasket 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. 5.1 Valves 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. Inspect valves for breakage, corrosion, and scratches on the valve disc and debris. In many cases, valves may simply be cleaned and reinstalled. Ifthe 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. If more than ,00S in, 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, 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 lst of part numbers and descriptions. Ifa valve is leaking due to dirt or any other foreign material that keeps the valve plate and seat from sealing, the vaive may be cleaned and reused. New gaskets and/ ‘or O-rings should be used to assure a good seal. ‘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, itis necessary to know your ‘complete model number so you can identify the valve type specification number (see example listed below). Model number 491At Valve type = spec In most cases for liquid transfer and/or vapor recovery compressors, the valve type will be spec. 3. Valve Holddown Assemblies: Depending on your model of compressor, the vaive holddown assembly has all or a combination of the following: Valve cap Valve cap O-ring Holddown screw Valve cover plate Valve cover plate bolts Valve cover plate O-ring Valve spacer (model 481 oniy) Valve cage SPrNPHeepe Valve assembly 410. Valve gasket Valve Assemblies: Depending on yourvalve specification, the valve assembly has all or a combination of the following Gasket Adjusting screw Relief ball spring Relief ball Valve seat Valve plate Spacers Washer Valve spring Suction valve post . Valve bumper 12. Valve gasket See valve holddown and valve assembly part details in the appendix for a complete list of part numbers and descriptions. Valve Inspection andlor Replacement for Models 91 and 291 Compressors Before removing and inspecting the valves, begin by depressurizing and purging (if necessary) the unit. wDisassembly 1. Unscrew the valve cap and remove O-ring. 2. Withthespecialwrenchsuppliedwithyourcompressor at time of purchase, remove the holddown screw. After the holddown screw has been removed, the valve assembly and vaive gasket can be lifted out. Carefully inspect for dirt or broken/damaged parts. Inspect valves for breakage, corrosion, debris and scratches on the vahe 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 perfectiy ‘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. 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. 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. 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 Replace the O-ring (or gasket) and valve cap and tighten to the value listed in Appendix B. O-rings sealing the valve caps should be replaced. Check bolts and valve holddown screws after first week of operation. Re-torque if necessary. See ‘Appendix B for torque values. Valve Inspection and/or Replacement for Models 491, 691 and 891 Compressors Before removing and inspecting the valves, begin by depressurizing and purging (if necessary) the unit. Disassembly 1. Unscrew the valve cap/nut and remove the gasket from the coverplate. Remove the valve cover plate, O-ring and holddown ‘screw by removing each of the four bolts, NOTE: Sinoe the holddown sorew 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. 3. After the cover plate and O-ring have been removed, the valve spacer (model 431 only), valve cage, valve assembly and valve gasket can be lifted out 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. Replacementis 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 .006 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. 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. Insert cleaned or new valve assembly. Make sure the suction and discharge valves are in the proper suction and discharge opening in the head. Insert the valve cage and valve spacer (NOTE: spacer applies to model 491 compressor only). 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. 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. 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. NOTE: Spec 3 suction valves have an adjusting screw to set the liquid relief pressure. To set the liquid relief pressure, tighten the adjusting screw until it bottoms, then back out 3/4 turn, Check bolts and valve holddown screws after first week of operation. Re-torque if necessary. See ‘Appendix B for torque values. 18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). 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. When reassembling the compressor, make sure the bolts are retightened as shown in Appendix B. 5.3 Piston Rings and Piston Ring Expanders j Figure 5.24: Piston Removal Piston ring life will vary considerably from application to application. Ring life will improve dramatically at lower speeds and temperatures, 1. To replace the piston rings, depressurize the compressor and purge if necessary. 2, Remove the head to gain access to the compressor cylinder. 3. Loosen the piston head bolts. Remove the piston as shown in figure 5.3A by pinching two loose bolts together. 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 B. 5.4 Pistons 1. Toreplace the pistons, depressurize the compressor and purge if necessary, Remove the compressor cylinder and head (see section 5.2). Remove the piston head by loosening and removing the socket head bolts holding the piston head to the piston platform (see figure 5.34). Next, remove the roll pin with a pair of needle nose pliers. The castellated nut may then be removed and the piston platform lifted off the end of the piston rod. Check the thrust washer and shims for damage and replace if necessary. Before installing the new piston, measure the thickness of the existing shims. For Models 91 through 491, the shims are placed between the thrust washer and piston platform. For model 681, the shims are placed between the platform and piston head (see figures 5.44 and 5.48), Reinstall the piston platform with the same thickness. of shims as before, BUT DO NOT REINSTALL THE ROLL PIN, Replace the cylinder and install the piston heads with new piston rings and expanders, 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, 10. When the piston is properly shimmed, tighten the castellated nut as shown in Appendix B. 11. Now install a new roll pin to lock the castellated piston nut in place. x IsTOM (SEE APP.) L piston mean —/ TaRust WASHER PIsTON CrLuNDER, PuATFonM Figure 8.48: Piston Cross Section ‘Model Sizes 01 Through 491 19PISTON PLATFORM ~PISTONROD / CYLINDER ‘sams igure $48: Piston Cross Section ‘Mode! 694 12. Install the piston head and tighten the socket head bolts in an alternating sequence. 13. Reinstallthehead (see section5.2)andfollowstandard startup procedure. (Note: Some compressors may have self-locking nuts without roll pins.) 5.5 Piston Rod Packing Adjustment Piston rod packing should be adjusted or replaced whenever leakage becomes noticeable. Typically, it is 1 good idea to replace piston rod packing and piston rings at the same time. For instructions on adjusting and replacing the piston rod packing, see section 5.6. NOTE: Inspection of the rod packing is generally not productive, since packing that cannot be adjusted to an acceptable leakage rate should be replaced. | J UU LULU J nove mus crease ‘witr oi tHROUGH TONTENTGTURN THIS OPENING. Figure 5.54: 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) If the cylinder does become damaged or corroded, use @ hone to smooth the cylinder bore and then polish it to the value shown in Appendix 8. 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. 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 When reassembling the compressor, make sure the bolts are retightened as shown in Appendix B. Packing Replacement Instructions 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 o explosive gases, this pressure and leak testing should be done with air or a dry, inert gas such as nitrogen, 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. Cleanliness: Sealing a reciprocating piston rod is a very difficult task. Keep all parts, tools and your hands clean during installation. Your new packing needs every chance it can get, so keep it clean. Workmanship: Your Corken compressor isa precision piece of equipment with very close tolerances. Treat it as such. Never beat on it to get parts in or out. Model 91 Compressor (Refer to Appendix F for packing assembly details) Disassembly of Packing 1. Depressurize and open the compressor. 20Remove head, piston, cylinder, inspection plate and crosshead guide. Loosen adjusting screw and remove retainer ring, washers, packing spring and old packing from crosshead guide. Assembly of Packing 1. Clean, then lightly oil, packing area inside the crosshead guide. Slightly thread in the adjusting screw into the crosshead guide. Install packing rings including male and female packing rings one at a time as shown in Appendix F. 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. Insert thin packing box washer, packing spring and thicker washer into the top of the crosshead guide. Tighten adjusting screw until plastic locking device engages the first thread in the crosshead guide. ll piston rod and install the packing installation cone (part number 4005) over the threaded end of the piston rod. Carefully slip the crosshead guide over the piston rod; otherwise, you may damage the lips of the packing rings. Remove packing installation cone. Install the crosshead guide O-ring, cylinder, piston and head. Model 291 Compressor (serial no. SS55685 and later) Model 491 Compressor (serial no. XC30633 and later) (Refer to Appendix G or H for packing assembly details) Disassembly of Packing 1 Depressurize and open the compressor. 2, Remove head, pistons and cylinder. 3. Remove cartridge holddown screw with special wrench supplied with the compressor and packing box cartridge. 4, Loosen adjusting screw and remove retainer ring, washers, packing spring and old packing from packing box cartridge. Assembly of Packing 1 Clean, and then lightly cil, packing area inside Packing box cartridge. 2. Slightly thread in adjusting screw. Install packing rings including male and female packing rings, one at a time, as shown in Appendix Gor H. Push in each one completely before adding the next ring. The quantity of packing rings required will vary due to tolerances; @ good rule of thumb is to put in as many as are removed. 4. Insert thin packing box washer, packing spring and thicker washer. 5. Push down on washer and insert retainer ring. 6. Tighten adjusting screw until plastic locking device engages the first thread in the packing box cartridge 7. Oilpiston rod and replace cartridge O-ring 8. Install packing installation cone part number 4005 ‘over the threaded end of the piston rod. 9. Carefully slip the packing cartridge over the piston rod; otherwise, you may damage the lips of the packing rings. 40. Remove packing installation cone. 11, Install and tighten cartridge holddown screw with special wrench. 12. Install cylinder O-ring, cylinder, pistons and head. Model 691 Compressor (Refer to Appendix | for packing assembly details) Disassembly of Packing 1, Depressurize and open the compressor. 2. Remove head, pistons and cylinder. 3. Remove cartridge holddown screw with special wrench supplied with the compressor and packing box cartridge. 4, Loosen adjusting screw and remove retainer ring, washers, packing spring and old packing from packing box cartridge. Assembly of Packing 1. Clean then lightly oil packing area inside packing box cartridge. 2. Thread in adjusting screw until locking device 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 |. Push in each one completely before adding the next ring 4, Insert a packing washer, packing spring and another packing washer. 24Push down on washer and insert retainer ring. 6. Oil piston rod and replace cartridge O-ring, 7. Install packing installation cone part number 3905 over the threaded end of the piston rod. 8. Carefully slip the packing cartridge over the piston rod; otherwise, you may damage the lips of the Packing rings. 9. Install and tighten cartridge holddown screw with special wrench, 10. Replace cylinder O-ring, cylinder, pistons and head. Model D891 Compressor (Refer to Appendix J for packing assembly details) Disassembly of Packing 1. Depressurize and open the compressor. 2, Remove the cylinder cap, heads, pistons and cylinder. 3. To remove the packing barrels, pry upward under ‘each one and lift entire barrel/cartridge assembly up from piston rod. 4. Remove the four socket head screws that hold the packing cartridge to the barrel Assembly of Packing 1. Replace packing as required. The segmented packing and cups are in the barrel. The V-ring packing is in the cartridge. Note the arrangement of the particular packing set for the model machine you have. 2. Reattach the cartridges to the barrels using the four socket head screws. 3. Install cartridge barrel assemblies, noting the alignment of the barrels as they sit on the crosshead guide. The valve scallops on the barrels must align Property with the valves of the cylinder. 4, Replace cylinder, pistons, heads and cap. See piston assembly details for proper clearance values. 6. Rotate unit by hand to ensure proper assembly. 5.7 Bearing Replacement for Crankcase and Connecting Rod 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). 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. 5.7.4 Wrist Pin Bushing Replacement 1. To replace the wrist pin bushing, remove the retainer rings that position the wrist pin in the crosshead, 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 anew bushing into the connecting rod. DO NOT MACHINE THE O.D. OR |.D. OF THE BUSHING BEFORE PRESSING INTO CONNECTING ROD. 4, Make sure the lubrication hole in the bushing matches. the oil passage in the connecting rod. If the holes do rot align, aril out the bushing through the connecting od lubricant passage with a long dril. Bore the wrist pin bushing ILD. as indicated on the respective connecting rod assembly details. These pages are located in the appendices. Over boring the bushing can lead to premature failure of the wrist pin bushing, 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. 5.7.2 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 instaling the new bearings. MAKE SURE THE ARROW AND/OR ALIGNMENT NOTCH ON CONNECTING ROD AND CAP ARE ALIGNED. 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. 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 ‘rom the crankcase. if corrosion or pitting is present, the roler bearings should be replaced. When replacing roller bearings, always replace the entre bearing, not just the cup or the cone. 1. To replace the bearings, press the cups out of the crankcase and bearing carrier and press the cones off the crankshaft.Figure 5.8.28: Bearing Carier Replacement 2, Press the new bearings into position and reassemble the crankshaft and bearing carriar to the crankcase. When reinstalling the bearing carrier, make sure the oll pump shaft slot is aligned with the pin in the crankshaft. Make sure to install the bearing carrier gasket so the oll passage hole is not blocked (see figure 5.6.3A). 3. In order to check the crankshaft endplay, the oil Pump must first be removed (see section 5.8). 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. 5. To reduce endplay, remove the bearing cover and remove a thin shim, Recheck the endplay after replacing the bearing cover. 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 may be reassembled, If the crankshaft roller bearings are too tight of too loose, premature bearing failure will result, 7. Reinstall the flywheel on the crankshaft and check the run out as shown in Appendix B. 5.8 Oil Pump Inspection If the compressor operates for a prolonged period with dirty or contaminated crankcase oil, damage to the oil pump may result. 10, OIL PASSAGE HOLE To check the oil pump, unbolt the pump cover and remove the oll pump, spring guide, spring and oil Pump shaft adapter as shown in figure 5.8A, Inspect the gears in the oil pump for corrosion or pitting and replace if necessary. Check the oil pump shaft bushing in the bearing caarrier. If the bushing is corroded, pitted or worn, the oil pump shaft bushing should be replaced. Before reassembling the oll pump mechanism, replace the O-rings in the oll pump cover and on the oil pump adapter shaft (see figure 5.8A). Rotate the drive pin in the crankshaft to a vertical position for easiest reassembly. Insert the shaft adapter so it engages the drive pin. Next, insert the spring, spring guide and oll pump assembly. The tang on the oil pump must align with the slot in the shaft adapter. Install the pump cover so the pin on the case is in the ‘opening on the oil pump assembly as shown in figure 5.8A. When you are sure the pin is properly aligned, install the cover bolts finger tight. 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. Finally tighten the bolts in an altemating sequence. See section 3.3 for directions on oil pressure adjustment. 23.LOCATE OIL FILTER ADAPTER AS SHOWN ALIGN TANG (OIL PUMP ASSEMBLY) \WITW SLOT (PUMP SHAT ADAPTER) om |\ PIN(PUMP COVER) MusT / FALLIN GROOVED AREA (OIL PUMP ASSEMBLY) Nove: FOR COMPRESSORS WITHOUT OW FLIER ASSEMBLIES. USE OPTIONAL PUMP COVER ASSEMBLY INSTRUCTIONS ARE THE SAME AS ABOVE, Figure 6.84 ic | 1. Remove the hex nut, indicator plate and handle from 5.9 Servicing the Four-Way Valve theta teat Unlike older units, new Corken compressors mounted in > the -107 arrangement are being supplied with anon-lube four-way valve. No maintenance is normally required on this valve. If you have reason to disassemble the valve, please follow the instructions below (see figures 5.98, and 5.98). Remove the four hex head bolts and the cap from the body. The cap should be rotated unti free; do not pry. Inspect cap for wear and damage (see figure 5.9C). CAUTION: Always Relieve Pressure In The Unit Before Attempting Any Repairs. Before Disassembly: 1. Record the position marks on the end of the rotor shaft. 2. Record the positions of the handle stops on the cap. NOTE: A small amount of silicone grease applied to each part before assembly facilitates assembly if allowed. Disassembly Refer to the drawing for item description. Figure 5.94 Figure 5.98oy Figure 5.96 3. Remove the body O-ring, stem O-ring, cap O-ring, and top rotor washer and discard. Remove the rotor and four seals as a unit from the body. IMPORTANT: Because of the close tolerance, care must be taken to remove the rotor on its axis to prevent damage to the rotor and body. Rotating the handle with a lifting action will help remove the rotor as shown in figure 5.9D. Figure §.9D Discard the four seals. Inspect the rotor for wear and damage. Remove the bottom rotor washer and discard. Inspect the body for wear and damage. Assembly Refer to figure 5.9B. Have the repair kit laid out. 1. 2. Place the new bottom rotor washer into the body. Assemble the four seals and O-rings onto the appropriate surfaces of the rotor. Assemble the rotor and seal assembly into the body. IMPORTANT: Because of the close tolerance, care must be taken to press the rotor on its axis to prevent damage to the rotor and body. A ring compressor is helpful. Be sure that the rotor is bottomed in the body. Rotate the rotor so that the position marks on the end of the rotor shaft are the same as recorded before disassembly. Assemble the new top rotor washer and cap O-ring, onto the shoulder of the rotor. Assemble the new stem O-ring and the body O-ring into their grooves in the rotor and body. 7. Place the cap over the rotor shaft. 8. Rotate the rotor so the position of the handle stops on. the cap is the same as recorded before disassembly. 9. Assemble the four hex head bolts through the cap and into the body. Be sure that the body O-ring is in the proper position and tighten the hex head bolts. 10. Reassemble the handle, indicator plate and hex nut. Be sure that the handle is assembled so that the stop on the handle mates with the stops on the cap, Chapter 6 Extended Storage Procedures Following a few simple procedures will greatly minimize the risk of the unit becoming corroded and damaged. Corken recommends the following precautions to protect the compressor during storage: 1 2. Drain the crankcase oil and refill with rust inhibiting oil. Operate for a few minutes while fogging oil into the compressor suction. Relieve V-balt tension. Plug all openings to prevent entry of insects and moisture. (The cylinders may also be protected by the Use of a vapor phase inhibitor, sca 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.) Store in a dry area, off the ground if possible. Rotate the flywheel every two weeks if possible. 25Appendix A Vertical Single-Acting Model Number Identification Code Model Number Base XXXXXKXXXX Base Model 9 291 481 601 Inet gvannet | aver ner | svar net | 2° NPT Outlet sve ner | aver neT | sve ner | 1-172" NPT Base Modsl Fo Fe01 Fat Foot Inet vans! | 7a” ast | 1-174" ANSI| 2" ANSI Outiet ava" anst | ava" anst | v4" aNst| 2" ANSI Packing Arrangemant | Pressurized int Standard A ‘Splash ubrcated Standard | NA WA wa [3 crankcase Sy Extensed crankshatt_| Extra cost | Extracost | Exiracost| NA | E rankoase Sie Pressure lubricated WA | Standard_| Standerd | Standard | M Standard withheater [WA | Extracost | Extra cost | Extra cost | MH ves Liquid relief suction Standard 3 Standard vaives No extra cost 4 Piston Rings and Packing [PE Sanene E Alloy 50 Extra Cost 6 Aluminum Standard 8 Gasket Materia Copper No extra cost c Lead-iron No extra cost D O-rings Buna-N Standare a Neoprene®! No extra cost 8 Viton? Extra cost D Teton" Extra cost E Intercooler None NVA for single stage compressor N “4° fywheel used with lo onan extended crankshaft Ne charge wa Le Fiywhnee! Heavy duty Extra cost | Extra cost | Evra cost | Extracost | H No fiywhea! No extra cost N Standard 14" ‘Standard 8 Protective Coating | No coating Standard N Piston Rod Goatng | MBO sareae a Chrome oxide Extra cost ° 1 Teflon®, Neoprene, and Viton® are registered trademarks ofthe DuPont company. ‘See Appand C for mounting options 26Appendix A Vertical Single-Acting Model Number Identification Code Base Moc Nani Demi Medel Number inlet Connection 2" Weld Base XXXXXXXXXX air Connection > Wed Sip WAHT 0) 0 Pacing ig | Packing arangod for padding of dtance pleco | Standad | J Grankoase | esse cated Sanaa | Style ‘Standard with heater Extra cost | MH ve Tiandardsocon and charge vanes Sandee Suction vave uloades Extra cost Piston Rng fd Packing | Tene: standard | wt Ceska Metal | Anam Saad | 8 O-rna Sara Sandra [A Matoial ——_ Neoprena™ octarge |B Tricor | WAT ange tage compressor Sanda [6 Fywnost [No fwheot proved Noga [| _N Standard yhoo! standaé |S Prive a wove standae Piston Rod Beton Nitec standard | | Tefion® and Neoprene® are registored trademarks of the DuPont company. Mounting Selections 103 Mounting includes: Stee! baseplate, adjustable driver slide base, V-belt drive and enclosed steel belt guard. Pressure gauges are ‘mounted on the compressor 107 Mounting includes: Steel basoplata, mechanical Iguid rap, nov lube #-way vale, inleconnocing plang, Samer adjustable dver side base, V-balt ve and enclosed steel bolt quard, Pressure gauges are mounted on the compressor. TOTA Mounting inclides: All items on the 107 replacing the mechanical float the iquid trap witha NEMA 7 Hquid level Switch. 1078 Mounting includes: Al tems on the 107 replacing the liquid trap witha larger ASME code iquid trap with 2 NEMA liquid Yevel ‘sultches ea fr alarm and shutdown, *107TR Mounting includes: Al iams on the TO7 setup fo ba used asa Wranaporl uni Nola tha tha Gompressar must have the opional 14” flywheel and extanded crankshaft to use thie mounting ? "109 Mounting includes: Steel baseplate, mechanical iquid Wap, Hferconnecing piping, adjustable Grver side base, V-belt dive and enclosed stoel belt guard. Pressure gauges are mounted onthe compressor “109A Mounting inoludes: All tems on the 109 replacing the mechanical float n tha hquid Wap with a NEMAT Tiguid level with. "1098 Mounting inoludes: All Reme on the 709 replacing the hquid trap with a larger ASME code liquid Wrap with 2 NEMA T liquid vel ‘sultches eat fr alarm and shutdown.» “T09TR Mounting includes: Al tame on the 109 S81 up To ba uBad as a angport Uni. Nola the Comprassor must have the opiional ‘ywheel and evtanced crankshaft to use this mounting 23 2 Nol sutable for 691 ® Discharge reliet valves are required but not included in these mountings. arAppendix B—Vertical Single-Acting Specifications Models 91-691 Equipment Type & Options Applications Single packed rod NPT or 3004 ANSI connections SSingle-acting, vertical, reciprocating piston type vapor compressor Bulk transfer Vapor recovery Tank evacuation Features and Benefits Gas scavenging ‘Self-lubricating piston rings: Non-lubricated operation to minimize oil in gas NPT or 300# ANSI 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 Specifications ‘Model Number Specification 4 291 434 69 Bore of cylinder inches (mm) 3.0 (76.2) 3.0 (762) 40 (101.6) [45 (114.3) ‘Stroke inches (mmm) 2.5 (63.5) 2.5 (63.5) 3.0 (762) 4.0 (101.6) Piston displacement cfm (hr) minimum @ 400 RPM 4068) 8.0 (13.6) 172292) | 292496) maximum @ 625 RPM 83 (14.1) 16.5 (28.0) | 35.5603) | 60.2 (102.3) Maximum working pressure psig (bar g)" 335 (23-1), Maximum brake horsepower (kW) 7568) 15(11) 15.(1) 35 (26.1) Maximum tod load Ib (ka) 3,600 (1,632.9) | 8,600 (1,692.9) | 4,000 (1,614.4) | 7,000 (3,175.1) Maximum outlet temperature °F (°C) 350 (177) Bare unit weight Ib (ka) 715 (62.3) 760 (72.6) | 260(117.9) | 625 (283.5) Maximum flow—propane gpm (m2/ht) 50 (11.4) 101 (22.9) 215 (48.8) 361 (62.0) ! These numbers speci pressure-containing abies ofthe compressor cylinder and head. For many applications, factors other than the pres ‘ure rating wil lt the maximum allowable discharge pressure o lower values. These factors Include horsepower, lemperature and rod oad 28Appendix B—Vertical Single-Acting Specifications Models 91-691 Material Specifications Part Model Standard Material Optional Material Head, Cylinder Al Ductile iron ASTM A536 None Crosshead guide crankcase, flywheel, | All Gray iron ASTM A48, Class 30 | None bearing carrier Flange 691 Ductile iron ASTM A536 Steel weld flange 91, 287 17-4 PH stainless steel Valve seat & bumper | 491 Ductile iron ASTM A536 None 691 17-4 PH stainless steel 91, 251 “410 stainless steel Valve plate 491 47-7 PH stainless steel None 651 “410 stainless steel Vane spring 91, 201, 691 | 17-7 PH stainless steel None 491 Inconel Valve gaskets Al Soft aluminum Iron-lead, Copper Piston Al Gray iron ASTM A48, Class 30_| None Piston rod All (C1050 steel Nitrotec coated | Chrome oxide Crosshead All Gray iron ASTM 48, Class 30__| None Piston rings All PTFE, glass and moly filed Alloy 50 Ring expanders All 302 stainless steel None Head gasket All O-ring, Buna-N Tefion®™, Viton®?, Neoprene®? Packing cartridge, | All Ductile iron ASTM A536 None connecting rod Packing rings All Teflon®, glass and moly filed | Alloy 50 Crankshaft All Ductile iron ASTM A536 None Con. rod bearing | All Bimetal D-2 Babbit None Wrist pin All C1018 steel None Wrist pin busing | All Bronze SAE 660 None Main bearing Al Tapered roller None Inspection plate | All ‘Aluminum None Oxrings Al Buna-N PTFE, Viton®?, Neoprene®™ Retainer rings All Steel None Misc. gaskets All Coroprene None ‘Tefion®, Viton® and Neoprene® are registred trademarks ofthe DuPont company. 29Appendix B—Vertical Single-Acting Specifications Bolt Torque Values Vave crank. cyt | vaive | Hold | Piston Vaive valve conn. case To | cover | Down | Lock cap cap Rod |Bearing| Bearing | Inspec | X-Head| Head | Plate | serow | Nut Torque | Torque Bott | carrier | Cover | Plate | Guide | (1.2) | Bo | 2 | Torque (1 Gaskets) (wi O-Rings) Model | feib | fete | tei | em | fet | tei | stem | tei | tte ftelb feb | 2 | a | se | 1% | 2 | 2% | — 40 | 45 40 25 ‘ov_| 28 [a0 | 90 | 12 | 25 | 20 | — 40 | 45 40 2 an | 30 | 2s | a | 8 | 3 | = | = | «0 | «5 40) 25 | 40 | ao | 4 | @ | 40 | 30 | a7 | «0 | 0 40 25 1 Preliminary tohtening — snug al head bots inthe sequence shown. Final orqueing — oraue al head bots inthe sequence shown (othe listed valve 2 Rotorque to te isfod valve afer 2 ~ 5 hours running time. 10 ©Appendix B—Vertical Single-Acting Specifications Clearances and Dimensions 1 291 491 691 (M crankcase) *Clearance: “X’ piston 0.020 0.020) (0.00070.020 0.000/0.015 figure 5.4 & 5.48 044 0.044 0.024/0.044 0.012/0.007 Clearance: connecting rod bearing 0.0005 ‘0.0005 0.0005 0.0019 to crankshaft journal 0.0025 0.0025 0.0025 0.0035 Clearance: wrist pin to wrist pin 0.0008 ‘0.0009 0.0008 0.0020 bushing” (max) Cylinder bore diameter (max) 3.008) 3.008) 4011 4515 Cylinder finish (RMS) 16-32 16-32 16-32 16-32 Piston ring radial thickness (min) 0.082 0.082 0.082 0.082 Clearance: oil pump adapter shaft 0.0050 0.0050 0.0050 0.0050 to bushing” (max) Crankshaft end play (cold) 0.000 0.000 0.000 0.002) 0.002 0.002 0.002 0.003 Flywheel runout at O.D. (max) 0.020 0.020) 0.020 0.020) Clearance: crosshead to crosshead oon oon 012 0.013 guide bore (max) Crosshead guide bore finish {32 RMS (limited number of small pits and scratches are acceptable) ‘Dimensions for honing are included with new bushings (which must be installed, then honed) (Clearance should bo set with machine cola 3Appendix B—Vertical Single-Acting Specifications Model D891 Equipment Type & Options Applications Double-acting, vertical, reciprocating piston type vapor compressor Bulk transfer. Double packed rod Slip-on weld connections Truck, tank, railcar, barge unloading 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 Features and Benefits Bore of oylinder inches (mm) 4.5 (113) ‘Stroke inches (mm) 4.0 (101.6) Piston displacement cfm (m®/hr) minimum @ 400 RPM 56.6 (96.2) maximum @ 825 RPM 113.2 (192.0) Maximum working pressure psig (bar g) 465 (82.1) Maximum brake horsepower (kW) 45 (4) Maximum rod Toad Ib (ka) 7,000 (8.175.2) Maximum outlet temperature °F (°C) 350 (177) Bare unit weight Ib (ka) 855 (387.8) Maximum fiow—propane gpm (m3/hr) 694 (157.6)Appendix B—Vertical Single-Acting Specifications Model D891 Material Specifications Part Standard Material Optional Material Head, cylinder Ductile iron ASTM AB36 Distance piece Crosshead guide Crankcase, flywheel Bearing carrier Gray iron ASTM A48, Class 30 Flange ‘ASTM AS6 carbon steel Valve seat, bumper 17-7 PH stainless steel Valve plate 410 stainless steel Valve spring 17-7 PH stainless steel Valve gaskets Soft aluminum ‘Copper, iron-lead Piston Ductile iron ASTM A536 Piston rod ‘C1050 steel, Nitrotec Crosshead Gray iron ASTM AaB, Class 30 Piston rings Teflon®, glass and moly filed Alloy 50 Piston ring expanders 302 stainless steel Head gasket ‘O-ring, Buna-N Tefion®?, Viton®", Neoprene®! ‘Adapter plate Packing cartridge Connecting rod Ductile iron ASTM A536 Packing rings Teflon®", glass and moly filed Alloy 50 Crankshaft Dustile iron ASTM A536 Connecting rod bearing Bimetal D-2 Babbit Wrist pin C1018 Steel Wrist pin bushing Bronze SAE 660 Main bearing Tapered roller Inspection piate ‘Aluminum O-rings Buna-N Tefion®, Viton®, Neoprene®! Retainer rings Steel Miscellaneous gaskets Coroprene "Teflon®, Viton® and Neoprene® are registred trademarks ofthe DuPont company. 33Appendix C—Compressor Selection Compressor Mounting Selections itereonnetng ing Inet ressue gauge Out pressure gauge ee nahi ‘ae Sn met domes Optional divor ‘scion strainer Lula wep —__ ‘Stee baseplate ‘Adjusiabe diverse base stpeaan gee Intcconmecting wging ute resevre gauge NEMA 7 — ay < eel, gud Vent t ute {+109 onl an ‘st risen sow = mic! ops NPT inlet. [ Ste! Baseplate Adjustable crv slide base Standard 107 Items Steel baseplate V-Belt drive Adjustable driver slide base Enclosed stee! belt guard Inlet and outlet pressure gauges 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 Automatic liquid trap with one NEMA 7 liquid level switch 1078 Mounting ‘Automatic liquid trap with two NEMA 7 liquid level switches Standard 109 Items Steel baseplate V-Belt drive Adjustable driver slide base Enclosed steel belt guard Inlet and outlet pressure gauges interconnecting piping Liquid trap as specified below 109 Mounting Mechanical liquid trap with ball float 109A Mounting Automatic liquid trap with one NEMA 7 liquid level switch 1098 Mounting Automatic liquid trap with two NEMA 7 liquid level switchesAppendix C—Compressor Selection Butane Compressor Selection Table "The capacities shown are based on 70°F. but wil vary depending upon piping, ings used, product being transferred and temperature actory ean supply a detaled computor analysis i required. 2 Driver sheaves: 91 (2 bel): 290, 21, 490, 491 (9 bes); 690, 691 (4 belts). 5 The piping sizes shown are considered minimum. I the length excoeds 100 fe, use the next larger size. NOTE: Please consult factory for compressors wth higher fos. Driver Horsepower Tiquie Liquid Transfer | Transfer & Without Residual | Residual Driver Sheave Size | Vapor Vapor (Capacity Displacement|__Compressor_| Pitch Diameter Gnches)2|_Recovery_| Recovery | _ Piping Size? Service gpm | cfm _{~Model_| RPM [1,750 RPM [1,450 RPM | 100°F | 60°F | f00°F | 60°F | Vapor | Liquid "2 4 Pao} ago | ase | a] a] 3 | 3] aa] ve small 7 5 ar |sos| ase | ace | a | 3 | 3 | a | am | 04 bulk 20 6 a | so | asc | aso | 3 | 3 | 2 | a | a | av plants a 7 ot feos | sss | Bee | 5 | 5 | 5 | 5 | i |i 2a 7 zoo.21 | ss | azo | ase | 2 | 2 | 2 | 2 | a | sae ar @ 3 [ves] Bez | Bra | 5 | 5 | 8s | 3 | 1 [72 2 8 ze0,21 | a0 | Ase | Bao | 2 | 2 | 2 | 2 | 1 | ie 30 8 200,201 | 45 | age | eae | 9 | a | 3 | 3 | 4 | 42 33 so | 290201 | #90 | Bas | ps2 | 3 | 3 | 3) 3] 4 | 2 Unieaaing 38 un | 290,201 | 535) sas | psa | 3 | 3 | 3) 3) 1 | 2 single tank | _30 s2__| 200201 | 580 | ps2 | ps2 | 5 | 3 | s | 3s |i | 2 ‘eat oF 42 32] 290,201 | as | aso | asa | s | 5 | s | 8 | vm] 2 ‘anspor ar | 20201 | eos | Be2 | Bra | 5 | 5 | 5 | 5 | tue] 2 50 1s | zaoza1 | 735 | Bee | Bao | 5 | 5 | 5 | 5 | 144 | ove 50 1s | aaast | gas | Aso | Ase | 5 | 5 | 5 | 5 | 144 | ove 53 1s | 290,201 | 720 | Bro | Bae |rae| 5 | rve| 5 | 144 | pve 53 se__| aoo,401 | a0 | _as2 | asa _|'s | 5 | os | 5 | vim | 210 56 | aa0.4or [390 | Asa | Bao [5 | 5 | 5 | 5 | Mal 3 60 ra | agoranr | ms | ase | aca | 5 | s | s | 5 [aaa] 2 « so | aaoaor | acs | aaa | ave | s | s | s | 5 | tum] o 65 2 «| 490,41 | as | aac | eas | 5 | 5 | 5 | 5 | 14a] 3 os 2 | 40a | ao | Baz | g50 | 5 | 5 | 5 | 5 | tal 8 Unicading n ze__| as0,4 | a0 | Bas | 52 |rve| 5 | re) 5 | rel 3 ‘two oF 5 | 490,41] sis) B46 | B56 | rz} 5 | rae) 5 | wie] 3 more tank 7 2 | 490,491] 505 | Bas | ase |r| eve! re |r42| wie) 3 cars at at 26 | 490,491 | 580 | B50 | B60 | 742 | rve| 72 |7-42| 144) 3 ‘one time a4 26 | 490,401 | 580 | B52 | Be2 | ro] rve| re |r) ia) 3 cor large. ar ar | ag0,41 | sos | asa | sea |r| rye! m2 |r) tae) 3 transport at 2s__| 490,401 | 2s | ase | 66 | ru | rve| re |r| ri 3 with excess [94 29 | 490,401 | 50 | asa | e709 | 10 | rve} 1 (ra) 12] = fowvanes | or 30 | 490,401 | sro | B60 so | r2| wo |rae| ie] s ofadequate | 94 30 | eso.en | 200) Bas | as2 | rue! rve| rae |rai2| wiz) 3 capacity 100 at | 490,41 | 695 | Bez | Bra | 10 | eve! to |ra2| riz) 3 98 ai | ea0,ea1 | 420 | Bae | ps6 | 10 | 742! 10 |rve| 42! @ 107 so__| 90,41 | v0 | B66 | sao | i | wo | w | io | rl 3 105 32 | 690,61 | 440] B48 | B58 | 10 | rvel 10/742) 112] 3 m0 as | as0,a1 | 70 | aoa | eao | 1 | wo | wo | wo | m2| 2 13 a — | 400,401 | 70 | 70 | aes | 10 | wo | to | wo | 2] 3 107 a |asoen | a5 | aso | aco | 10 | 0 | 1 | 0 | 2] 3 m 35 | eae | 475 | B52 | 862 | 1 | w | 1 | wo 12) 3 13 36 | 40.41 | aes | Bra | Bee | 15 | wo | ts | 1 | tz] 3 6 36__| 90,6 | 25 | asa | asa | 10 | wo | 1 | i | r2| 5 120 38 | e90,61 | 810) B56 | Bee | 10 | 10 | 10) 10) M2] 4 Unloading | 124 39 | 690,61 | 530 | B58 | Bro | 10 | w | 0 | 0 | 142) 4 large 19 a | es0,6 | 50 | seo | azo | 1 | w | w | wo | rm] 4 Tank ears, cy 42 | cone | ses | pez | aza | 1 | w | w | |) 2 | 4 rmuttiple 17 43 | eo0,60 | sas | Be | ava | 10 | w | w | wo | 2 | 4 vessels, 1 45__| 690,601 | 05 | see | 830 | i5 | wo | ws | | 2 | 4 barges or 745) 46) eoo.ea1 | oxo) Bos % | w [1 [to] 2 fe terminals 150 at |esc.en | cx | Bro | ase | 5 | | t |) 2 | 4 158 4% | 90,60 | 57 | Bra | Bae | 5 | | ts is 2 | 4 im s1 | 690,61 | 70 | ao | pos | is | 5 | te is 2 | 4 184 53 | 690,601 | 705 | Bas 5 | | 5 | a5 | 2 | 4 303, co__| eso,6n | a0 | taco | awe | is | is | as | is | 2 | a 280 32.1 Daai | 80] —sv71} vas) 20 | 20 | 20) 20) a | 6 30 1133 oasi_| aco | svers | sve | 25 | 25 | ms | 5 | 3 | 6 Th 35Appendix C—Compressor Selection Propane Compressor Selection Table Driver Horsepower Tiquid iquic Transfer | Transfer & Without Residual | Residual Driver Sheave Size || Vapor Vapor Capacity Displacement|_Compressor_| Pitch Diameter inches)®, Recovery _| Recovery | Piping Size? Service ‘gpm! cfm___| “Model _| RPM [1,750 RPM [1,450 RPM |100'F | 80°F | T00°F | 80°F | Vapor | Liquid 2 4 a pao, ago | ase | 5 | 3] a} 3] aa | ue ‘small 2 5 a |sos| ase | ass | s | s | 5 | 5 | am | 14 bulk 24 6 a [so | eis | ass | 5 | 5 | 5 | 5 | 4 | a1 plants 0 1 si | os | B54 | see | 5 | 5 | 5 | 5 | 4 | rae 29 1 zor | as | azo | ase | 3 | 3 | 3 | 3 | 4 |r 35 e ‘1 | ves | Bez | Bra rae | mam] re fre} 1 | 12 “8 8 zw,201} a0 | asa | aso | 5s | a | a | 3 | 4 | ae 50 8 200,201 | ass | ass | pas | 5 | 5 | a | 3 | 4 |r 56 so | 290,281 | 400 | Baa | ps2 | 5 | 5 | 5] 5] 4 | 2 Unioaaing et iw goon | sas | ae | asa | s | s | s | s | i | 2 single ark | ~ 66 1] 200,201 | sao [852 | Ba> [7m] s | 8 | s | 1 | 2 caror nm ss | aa.201 | 2s | B56 | pes |rv2| 5 | re] 5 | wa] 2 transport ca v4 | 200,201 | 005 | Bez | eza | rae | ri2| ri lrae| ive] 2 ea 15 | peo.za1 | 735 | Bee | Ba0 | 1 | rvz| wo |rve| vv | ove e4 1s | ag0aar | os | Ago | Ase |rve|rvz| 5 | 5 | ve | ove 89 16 | 200,201 | 730 | B70 | Bae | 1 | 10 | 10 | 10 | +4 | 2472 80, s6__| 490,401 | o70 | azz | aza_| rv | rve| rve| 5 | sa | 240 95 7 | 40,491 | 390 [ASA | B40 [rie | me] m2 |r| val 3 101 we | aqaor | as | ase | pea |v | m2] rae |ra| va! 3 108 so | ao0,4or | 435 | ase | eae | wo | 72| 72 |r| v4] 3 08 zo | aaoaar | 44s | B40 | Bas | wo | ru2| ri |rae|ise| 3 4 zt | avoaor | avo | B42 | B50 | wo | rx2| ri |rvel| ive] 3 Unioading ua ze | aso.aa1 | as0 | Baa | B52 | wo | 10 | re |rve| vel two oF 25, za | 490,491 | 5:5 | Bae | B56 | 10 | 10 | 10 |rvel aw] a more tank 130 2 | ao0,aor | sas. | pas | asa | 15 | 1 | wo | 10 fave] 3 cars at 138 25 | ao0,aor | 560 | B50 | B60 | 15 | 1 | 1 | 10 fw] a fone time “1 26 | avoaai | sso | B52 | B62 | 15 | 1 | 1 | 0 | sm] 3 orlarge ur zr | avoaai | 60s | psa | ssa | as | wo | ws | to foam] 3 transport 152 ps | 4o0.4o1 | os | ese | ase | is | is | is | os |ive| 3 with excess | “58 zo | ao0-aar | oso | B58 | 870 [as [is | ws [as [awe] flow valves. | 163 30 | av0,aa1 | sro | Boo 3 | | se fs fia] s ofadequate | 163 30 | exo.ea1 | 400 | Baa | ase | ws | a | w | 10 five] 3 capacity 168 a | as0.4a1 | 695 | Bez | ara | as | is | as fas fre] 3 m a1 | 600,801 | 20 | Bas | as6 | as | 15 | 1 | 10 |r| a +78 so__| aeo.aar | 20 | Bes | a0 | 5 | 5 | 5 | 5 || 5 178 | ew-ea1 | 40 | B48 | B58 | 15 | 15 | 1 | 10 [te] 3 188 sa | eao'ear | ass | ps0 | sso | is | 5s | us | 0 fia] 3 93 as | coosar | as. | B52 | B52 | as | is | is | 10 fil 3 200 26__| coo.ear | sos | esa | soa | a5 | 5 | is | 5 | ive| 3 208 38 [euoeor | 510 | B56 | Bee [zo [ws | = [1 [iw] 4 215 ss | wo.ea1 | sao. | Bse | Bzo0 | 2 | | ws | 5 fiwe| 4 223 4 | ss0.691 | 550 | Beo | azo | 20 | 15 | a | as foal 4 200 42 | 60,601 | 565 | Be2 | Bra | 20 | 5 | | ts | 2 | 4 Unioading — |_2a7 43__| 60.so1 | 585 | pea | ara | 20 | 15 | 5 | as | 2 | large 2s as | s00-ea1 | 605 | B65 | 880 | 20 | 15 | 15 [1s [2 | @ tank cars, 282 4s | 620,601 | s20 | Bas zo | 2} s || 2 | 4 ‘multiple 260 a7 | 600,01 | 10 | B70 | ase | 20 | mo | ao | as | 2 | 4 vessos, 275 ae | eo0.ea1 | ors. | gra | Bae | 25 | 2 | 2 | 20 | 2 | 4 bargos or zor sa | ewo.e0r | 730 | Bao | Boa | a | wo | w | 20 | 2 | 4 terminals 31g se | cxo.eat | 785 | Bae 2 | | 2 |2| 2 | 4 338 50___| 690.691 | a0 | rea0 | awe | a0 | 25 | 25 | 20 | 2 | 4 452 [a Daer | 880 | —sv7_ | sves | a0 | 90 | 30 | 90] 9 | 6 623 13, paer_| 800 | svo7s | svite a | «| so] 3 | 6 1 The capacities shown are based on 70°F, but will vary depending upon piping, tings used, product being transferred and temperature, The factory can supply a detailed computer analysis roquired. 2 Driver sheaves: 91 (2 bets); 280, 291, 490, 491 (3 bets) 690, 691 (4 bets). ° The piping sizes shown are consisered minimum. Ifthe length exceeds 100 f, use the next larger size, NOTE: Please consul factory for compressors with higher lows.Appendix C—Compressor Selection Ammonia Compressor Selection Table Driver Horsepower Tiquie Tiguie Transfer | Transfer & Without Residual | Residual Driver Sheave Size | Vapor Vapor (Capacity Displacement|__Compressor_| Pitch Diameter (inches)®| Recovery _| Recovery _| Piping Size? Service gpm | cfm _{Model_| RPM | 1,750 RPM (1,450 RPM ‘BOF | 00°F | 60°F | Vapor | Liquid 2 4 oy} 400] Aaa | Age a >a) 3) aa) wa small 20 5 or | sos| ase | aac s | s | 3 | a4 | sm bulk a4 6 or | so | a4o | ase s|sj)s | | sw plants 40 7 ot | oo | B54 | B56 s|s|s |i |r 43 7 200,201 | sas | aso | age a3 }3 is] |i 46 @ a [ves | Bez | Bra ss) 3s | a |e 6 8 200,201 | 390 | Aaa | B40 3|3a]3]4 |r 50 8 200,201 | 05 | Aas | Bas s|a]3a] 4 |e 56 so | 20,201 | 400 | Baa | B52 s|sj/3]1]2 Unieaaing e | 290,201 | 535 | as | B58 s|s|s]a] 2 single tank | _67 s2__| 200,201 | 580 | B52 | Bee s|sis |i] 2 ‘eat oF 2 32] 290.20 | as | Bsa | 860 5 |-s | s | iwa) 2 ‘anspor 80 v4 | 20.201 | 00s | Be2 | Bra ra| rie) 5 | ve] 2 85 1s | za0.zs1 | 735 | Bee | Bao rae | re | rare | ve | ove 85 1s | aaogst | aes | Ago | Age me] os | 5 | ie | ove 90 16 | 290,201 | 730 | Bro | Bas rare | rie | rare | ve | are 90 s6__| ao0,401 | 370 | as2 | Aas wie| 5 | 5 | ve | ove 96 i? | 490,491 [390 | A34 | B40 Te) 5 | 5 | tel 3 ae re | agolanr | ms | age | Baa rae | rae | rae | va] 8 107 xo | agoaor | aos | Age | Bae rae | rue |r| cua] 8 0 2 | 400,41 | as | Bac | B48 rae | ra |r| ue | 3 15 2 | 490,41 | ao | B42 | B50 rae | rie | rare | iva] 3 Unloading |_120 ze | as0.41 | 0 | Bas | B52 30 | rave | rar | a8 | 3 ‘two oF 26 | 490,401 | sis | Bae | B56 30 | rae | rare | le | 3 moretank | 131 24 | 490,401 | 505 | Bas | B58 wo | 10 742) te] 3 cars at 198 2 | 490,401 | 580 | B50 | B60 wo | 10 742) +48] 3 ‘one time 12 26 | 490,401 | 580 | B52 | Bo2 wo | 10 742) 4a] 3 cor large. 148 27 | 490,41 | sos | asa | Boa wo | wo | wo | ta] 2 transport 153, 28__| 490,401 | sos | ass | B66 so | 0 | wo | 2] 2 with excess [ie 29 | 490,401 | 50 | sa | 870 3 | 10 | 0) i428 flowvaies | 165 30 | 490,401 | sro | B60 ws | 1 | wo |r| ofadequate | 165 30 | eso.e1 | 400 | Bae | B52 ws | 1 | w | 2] 3 capacity 170 si | 490,401 | 695 | Be2 | Bra as | is | wo | wi] 3 173 ai | 690,601 | 420 | Bas | B56 1 | 1 | 0 | 12] 3 sat s2__| 490,401 | 740 | B66 | B80 ss | ws | 5 | ti] 3 180 32 | 690,681 | 440] B48 | B58 1s | 10) 10) M2) s 188 at | esojen | ass | aso | geo as | wo | wo | ra] 2 195 as | conan | 475 | as2 | B62 as | 1 | wo | 2] 3 203 26__| eso.en | aos | asa | aoa as | 15 | | i] ait ze eoeat | sic) B56) Boe a6 [so tie a 28 39 | eso.et | 50 | B58 | Bro ws | i | is | we] 4 226 41 | x06 | 580 | Beo | Azo as | is | is | tie] 4 203 42 | 90,601 | 585 | B62 | Bra w|i i 2 | 4 Unloading | 240 43 | 690,601 | 585 | Bes | Ard a) 5) i | 2 | 4 large 248 45__| es0,601 | sos | ses | B30 aol is jis | 2 | a Tank ears, 255 45 690,601 | 620 | B68 20] is] 8] 2} a rmuttiple 263 a7 | eo0,601 | 540 | B70 | Aa a] wifi | 2 | 4 vessels, 278 43 | cones | os | Bra | B86 a) w|i | 2 | 4 barges or sot sa | eoo,e1 | 70 | Bao | Boa zw | 2} | 2 | 4 terminals 328 53 | eso.et | 75 | Bao 2 | 2 |2| 2 | 4 336 60__| 690,61 | a0 | Taso | Aros 2 | 2 || 2 | @ 50 #2, ast | sao) sv7i | svas | 40 | a0 | a0 | a0) 3 | 6 633 113 oset_|_ 800 | svers | sviie 4 | 4% | 3%) 3 | 6 1 The capacities shown aro based on 70°F, but wil vary depending upon piping, fitings used, product being transfered and tomporature. Tho factory can supply @ detailed computer analysis i required. 2 Driver sheaves: 91 (2 belts); 200, 201, 400, 41 (2 belts); 690, 691 (4 bets). 5 The piping sizes shown are considered minimum. ifthe length exceeds 100 f, use the next larger size NOTE: Please consul factory for compressors with higher ows. 37Appendix D—Outline Dimensions Models 91-691 and F91-F691 Bare with Flywheel L tint ir toute pettefitin a £ + mm a T — k i | een bee + b-c—b-c + D hole diameter 6 ~ F bes Outline Dimensions—Inches (Centimeters) Model A B c D E F GS H J K onror | MME] Ba | SHIM [Teme | 5 | Gm | 7 | BST | 8 | eet 46) | (6.0) (9.4) _| (1.03) | (1.59) | 59) | (98) | (64.3) | (127) | (676) poirmi) $28 | #18 | S16 | tome | 5 [etané | te [asta] sae | 20-88 (es) | (105) | 4) | (tt) | (159) | 249) | 04) | (65.2) | (19.7) | (69.4) wire) 8 | 5 [te] 12 | ihe [won| te | zene | 5-78 | 26-016 (10.5) | (12.7) | 1.9) | (1.27) | (1.75) | 7.2) | 34) | 75.4) | (14.9) | (66.5) 691, Feat 4-3/4 5 5-3/8 9/6 1 4 14-3/8 | 39-1/8 a4 35-1/8 . 2a) | v4.0) | (37) | a5) | (25) | @56) | (5.6) | (99.4) | (21.0) | (69.2) “PD” Flywheel Pitch Diameter Model tc ue Mm | Mi P Q R s T__| A-belt |Groove |B-belt | Groove 91, F91 9/4 | 3/4-300 Ib | 2-3/8 | 4-1/4 3 14 | 1-4/8 1-1/4) 1/4 | 13.2 2 13.6 2 NPT| ANSI (6.0) | (10.8) | (7.6)_| (5.6) | (2.8) | (8.2) | (0.63) | (33.5) (34.5) 291, F291) 3/4 | 3/4-300 Ib |2-11/16] 4-1/4 3 16 | 1-1/4 1-1/4] 1/4 | 15.2 3 15.6 3 NPT| ANSI (6.8) | (10.8) | (7.6) | (40.6) | (3.2) | (3.2) | (0.63) | (38.6) (39.6) 14! 13.21 2 13.6" 2 (35.6) (33.5) (34.5) 491, F491] 1-1/4 |1-1/4-300 Ib] 3-7/8 | 5-5/8 3 16 | 1-3/8) 1-1/4] 546 | 15.2 3 15.6 3 NPT| ANSI (9.9) | (14.3) | (7.6) | (40.6) | (3.5) | (3.2) | (0.79) | (38.6) (39.6) 14! 13.21 2 13.6" 2 (35.6) (33.5) (34.5) 691, Fe91| 22 | 2-300 Ib | 6-3/8 |6-15/16|3-13/16] 19-1/2 | 2-1/8 | — v2 = — |194/8 4 NPT| ANSI (16.1) | (176) | (9.7) | (49.5) | (5.4) (1.27) (48.5) Optional fywheot 2 Optional flanges: 1-114" 1-112" NPT, 1-14" 1-112" or 2* Wold * 9, 291, 499, 691 only =F, F291, F401, F601 only 38Appendix D—Outline Dimensions Models 91-691 with 103 Mounting __ Intake prossure guage Discharge pressure ‘gauge Pe [5% ti ‘Aajstable bese Use 412" anchor bots K L e c ot ! . Outline Dimensions —Inches (Centimeters) Model A 8 ¢ D E F é 91-408 2 15 WAR 30 7174 3 51/4 (90.4) (28.1) (69.8) (76.2) (1) 7) (13.94) vortoa| 15 3112 34 1-1/4 3 5 (20.5) (28.1) (600) (66.4) (2) 7.6) (127) wos) 18 37-12 40 1/4 4 5-1/4 (98.1) (45.7) (€53) (101.5) (32) (10.2) (13.3) corte)? 20 39-172 a2 1474 4 55 (33.2) 08) | (100.3) (708.7) a2) (10.2) (140) Outline Dimensions —Inches (Centimeters) Model a J K L 0 N ortog | 2811716 26-378 +1576 775 Davi6 wa (729) (67.0) (12.5) 97) 68) NPT porsog | 2822/82 26-6/16 415716 7-3/4 Bvt6 aA (729) (67.0) (12.5) (197) (6.2) NPT worsoa | e116 30-3716 5/4 10 15/16 aA (65.6) (76.7) (14.6) 25.4) (10.0) NPT corsa | 18 29-178 3.25 9.25 6-5/8 2 (1095) (294) 1.0) 23.5) (16.2) NPT 39Appendix D—Outline Dimensions Models 91 with -107 or -107A Mounting (model -107A shown below) Discharge ( va aie NPT ii opening for Liaid 31-116 wap tonk = Teiolueve tov vain Bottguard hears (4620, a 7 16916 J} . 4207) N TG {0 ta meeto Li ae! Lene (6.36) att i sla 71) 1-418 x30 , ar (330) ] | ae ane 22 28 49) 021) Ausable driver Uee for THe) an = Se CED She ase anon oly (S048), ean) 12 (6001) = cto) 34 (0636) Inches (Centimeters) * Dimensions apply to -107A mounting onlyAppendix D—Outline Dimensions Model 291 with -107 or -107A Mounting (model -107A shown below) Fourway et Susonyane Dacha cere prtsie “crt” "ease wet” "Swege’ eterno an wave \ OO \ ae ener =, Sk iat span z (cio) 30-1916 E way | HE at LE JU Inches (Centimeters) * Dimensions apply to -107A mounting only sears S a) SL | (Cys (EX x oon & f (ee Say Cay) 3 Om Ik Mews 792) On as S |Peete° \ T ‘i £ | vseiet 5-58 spans 2 Ee an ae ai GSS, momen Stes ea 8 (tay ee, esa . easy we OH (fo 8) wen) t0) «woko0) 4aAppendix D—Outline Dimensions Model 491 with -107 or -107A Mounting (model -107A shown below) n igh sche epoca sch Hl ‘crn y SENT eno Bogus inane thee we ie A same er een ; ase 2 a, ws \ ‘eave t ters " brane 734 (1888)' 5g) Caeawe [ot “on Fe tpt eal ioe G78) | L (ay ’ |: ar anne Nees t ae (1ctey | BN8 me su ae tear (1334-+—> 48.72) Inches (Contimetors) * Dimensions eppiy to 107A mounting only 42Appendix D—Outline Dimensions Model 691 with -107 or -107A Mounting (model -107A shown below) 8 in, NPT Teuray”Hstpossr gauge Out resie cae | contevane _vartvale Pete ni Lisi a ‘i a use + \ | = iS bran | wave ; | - i i] G) t Po r th rguaiane aar ] | me | ° sia nchor tots | D. u c - é : Inches (Centimeters) Outline Dimensions—Inches (Centimeters) Model K 8 € D E F 6 H J aia | 17 | am [te0a [412 | 20 | 62 | 4344 | 5am 691-107, -107 eo) | asx) | a2 | 601 | Ba | Goa | 32 | cx | 4 Outline Dimensions —Inches (Centimeters) Model K U ™ N ° P a R 3 4 | ia | 14 [eae] 72a | 29 [i042 | 214 | 6 691-107, -107 cot) | 62) | e639 | war | a6 | 730) | 66) | 61.0 | 150 * Dimensions apply 10 107A mounting only 43Appendix D—Outline Dimensions Model 91-691 with -109 or 109A Mounting (model -109A shown below) Int pressure gauge a ute possi vu | — control Laud Vent mn re uk en oy ite “ta whe | (1096 ony SP\ Eee G8 som j Outi , - sane Fat guars NET int. 4 MD > = Pi Z| op 8 i > fl i f ab c 1 P > s Outline Dimensions—inches (Centimeters) Model A Al B c D ot E F GS H J or-109, 109 | T816| S14 | 12 [AesHe[at-e | — fave | 15 | 84 [State | S174 : 6.7_| 13.4) | G05) | 3.) | @oo) a. | 31) | 66.4) | (792) | (13.3) 5 = 12 15-3/4 | 39-1/2 = 1-1/2 15 42 | 30-7/8 | 5-1/4 281-108-1098) v2 | _— | @os) | oo) |aoos)| — | @@ | an |(106.27| (re) | (19.9) saa] — | 15 | 1 [asv2][ — [tae] 13 | 48 [aaa] 5a 491-109, 109A) 146) | — | a.» | an [arse | — | @@ | asn |(r219)| 57 | (19.9) aia | — | 7 [1974 |ao7@ [i984 [112 | 20 | 62 [as-ane] 5172 091-108, 109A) aoc) | — | aa-2 | c48.8) | (125.7) | (50.1) | a) | (0.8) | (192) | (09.6) | (14.0 ‘Ouiline Dimensions—Inches (Centimeters) Model K L M N Pp R s T u o1-109, 00a | 28076 | 34 [286 | 3 14 | 35/6 | 912 | 20/8 | 69/4 (71.6) NPT 6.9) (7.6) (3.2) (9.2) (24.1) (6.9) (17.1) portoa, toon | 28:12 [am [a-tie[ 8 | 1-14 | ore | 9 | 412) 6-04 (72.4) NPT (6.8) (7.6) (3.2) (9.9) (24.1) (11.4) (17.1) wortoa, ion | OOU8 [4-1] 4 4) 14) 4 ~| 1042 | 525 | 7-3/4 (76.5) NPT (10.2) (10.2) (3.2) (10.2) (26.7) (13.3) (19.7) qertoa, aoa | O88 [4-12 | 698 [4 | tm | 4-18 [at7ie | 7-14 | 7-3 93) | net | (61) | (102) | @2) | (104) | 44) | (a4) | (19.7)Appendix D—Outline Dimensions Model! D891 Bare with Flywheel sucton sur san vacuneeies (9) 0 ‘coure ee, wt ite oust ‘enue Loewe aa pressure “| att es et tatoo ene ten ot anes alr ‘crore aessor ‘con son] tate oaoe tao. ae) aes ewig 838] Be save Hole Diameter (196) | (186) 33" owe — sey Inches (Centimeters) 45Appendix D—Outline Dimensions Model D891 with 103 Mounting ‘Suction valve urlcaders (opsanal 5. S12 (4309) (1392) Outlet _ Pressure gauge Outlet “2 Weld fenge Crankcase heater Electic motor ‘optional “Saver / ] Ol ie, (EX by Betouas (BR lratease) | oo i CE) rN ri (66.36) _ io go! ee J o/ [ or ] ul : Sa [aha wae cay [ran 2 | (824) (102 —<— | aaa . 7: er) 3.916 10. (45.72) 36. (07.78) ei (0.05) (25.40) 6 e149) (142.24)Appendix D—Outline Dimensions Mode! D891 with 107B Mounting Optional under soenoid valve \ tae Fouvaay valve optint wasn? sgl Lid tap valve unleadors Optional . igh discharge tempertie atch Lik ° \. Opening fe optional tag ' felt valet 12 NPT Bett guard x N ee Electr motor ver \ epics | 0 ° ae Crankease erin I Cf sy Lt t D cs Foyt onan Yeu lade (7 ya Peet S| sae 4 W sar" | Me ne x Srehta | y z At Outline Dimensions —Inches (Centimeters) Model A B c D E F G H i so1-107B 32 | 1ae | Sie) 7 ae | 7186 | S212) 23-118 | 2d ge | 49 | @4 | a78 | 09) | 199) | @9 | 69.1) | 61 Outline Dimensions—Inches (Centimeters) Model J K L N ° a R s s91-1078 in | esd | Terie | 6 e176 | 36-58 | 29 | 10-378 wr) | @22) | ors) | (152) | (1729 | 20 | 737 | e739) Outline Dimensions—inches (Centimeters) Model T U v Ww x Y¥ Zz at eo1-1078 6 9 ote | 27 | sorae | 45 63 72 (52) | @29) | @3o | (a6) | (ras) | (1143) | (1600) | (182.9) a7Appendix D—Outline Dimensions Model D891 with 109B Mounting Rett valve 2 NPT—pipe away Z pt stan 5 x s vao nade ae S| | ute ml u pressure | "pane ptt int z bigh discharge F200 DRE lonperstre ech Weld neck ange wet N iS ange Fy 4 / ett \ f / =} Lowell Eloctiomotor oes 3 volte =] pressure switch driver Viel rua! | 9 fas oll-H " , { of Drain vatve | - : Her hy A EF it mal ‘ | ao Bi op pals me ooo fy \ 8 I Crankase e © ‘oll drain s ° —Ile x Outline Dimensions—inches (Centimeters) Model A B c D E F G H 0891-109B 1-5/16, 2 5-3/4 16 7 20 1-13/16 12-1/2 eo | ey | ose | goo | a7 | 6oe | a7 | era Outline Dimensions—inches (Centimeters) Model 1 J L N oO P Q R D891-109B 77-9/16 66-3/16 6 39-18 27-178 39-13/16 | 8-7/8 4-1/8 i973) | (eas) | 52) | @24 | 689) | (torr) | e259 | (05) ‘Outline Dimensions—Inches (Centimeters) Model s T u v we x Y Zz D891-109B 1-1/4 7-3/8 18 28-38 24-3/4 65-1/2 68 14-1/2 (3.2) (18.7) (45.7) (72.1) (62.8) (166.3) (172.7) (36.8)Appendix E—Troubleshooting Inmostcases, problems with yourCorkengas compressor compressors along with a list of possible causes. If you can be solved quite simply. This chart lists some of the are having a problem which is not listed, or if you cannot more frequent problems that occur with reciprocating find the source of the problem, consult the factory. Problem Possible Cause ‘Low capacity 1.2.3.4, 16 ‘Overheating 1.2.8,5,6, 11,15 ‘Knocks, rattl6s and nowse 1,7, 9, 10, 11, 14 Oil in cylinder 2.14 ‘Abnormal piston-ring wear 1, 25,611, 14, 15 Product leaking through crankcase breather | 6. 14 Product leakage 4.8, 14,16 Oil leakage around compressor base 17.18 No oll pressure 78,20 Excessive vibration 1. 7,9, 10, 11,12, 15,28 ‘Mator overheating or starter Wipping out 21, 22, 23, 24, 25, 26, 27, 2B Ret. | Possible Causes What To Do. 7.__| Valves broken, stuok or leaking Tnspact and Glean or repair 2.__ | Piston ring worn Inspact and replace as necessary 2. | nat strainer clogged Clean or replace screen as necessary 4. | Leaks in piping Inspact and repair 5. | Inlat or ambient temparature too high Consult factory 6. | Comprassion ratio too high ‘Chack application and consult factory 7._| Loose flywheel or belt Tighten '8._| Wom piston-rod packing Replace ‘8. | Worn wrist pin or wrist-pin bushing Replace 70.__| Worn connecting-rod bearing Replace 1._| Unbalanced load Inspact valve or consul factory 72._| Inadequate comprassor base ‘Strengthen, replace or grout 73.__|_Improper foundation or mounting “Tighten mounting or rebuild foundation 14. | Loose vaive, piston or packing Tighten oF replace as necessary 38._| Dirty cooling fins Clean weekly 76.__| 4-way control valve not lubricated Inspect and lubricate 7._| Leaking gas blowing oil from crankcase __| Tighten packing 78._| Bad oll seal Replace 79._| No oll in crankcase ‘Add oi 20._|Oipump maifunction ‘See oll-pressure adjustment 21. | Low vottage. Check line voltage with motor nameplate. Consult power company 22._| Motor wired wrong, ‘Check wiring diagram, 23._| Wire size too small for length or run Replace with correct size 24,_| Wrong power characteristics Voltage, phase and frequency must coincide with motor nameplate. Consult with power company. 25._| Wrong size of heaters in starter ‘Chack and replace according to manufacturer's Instructions 26._| Compressor overloaaing Fleduce speed 27._| Motor shorted out ‘Seo river installation 28._| Bad motor bearing Lubricate according to manufacturers Instructions 49Appendix F—91 and F91 Head and Valve Assembly Details 91 Head Assembly. “ff Ts A Ile F91 Head Assembly Valve Holddown Assemblies Valve Assemblies ‘Suction Valve Discharge Vale ‘spec 4 ‘AL Specs,Appendix F—91 and F91 Head and Valve Assembly Details Head and Valve Bill of Materials Ref | Part No._| No. Description 1. | 2378 Head modal 91 2374-xe Head assy. for model 91 (spec 3) 2374-Xt Head assy. for model 91 (spec 4) 2.__| 4902 Head model F91 (ANSI flange) 3.__| 7001-087 NC100A | Bol, 3/8-16 x 1" Gr5 hex head 4_| 2-235.© O-ring | 27144 Valve cap 6. | 20315 Oring 7._| 2715 Holddown screw 3. | 9483-4X Suetion valve assy. (spec 3) 3483-1X12 ‘Same as above but with copper gaskets 3483-120 ‘Same as above but with iron-lead gaskets 3 | 3aasx ‘Suction valve assy. (spec 4) 3483-X19 ‘Same as above but with copper gaskets 3483-x2 Same as above but with iron-lead gaskets 10. | 3485-X Discharge valve assy. (al specs) 3485-X19 ‘Same as above but with copper gaskets 3485-X20 ‘Same as above but with iron-lead gaskets 11. [277 Valve gasket (aluminum) 27i74b Valve gasket (copper) 2717-20 Valve gasket (iron-lead) 12._| 5000-77 Retainer ring (spec 3) 13. | so77 Suction valve relief housing 14. [1414 ‘Spring (spec 3) 15. | 1410 Ball (spec 3) 16._| 3483-7 Suction valve seat (Spee 8) 17__| 3972 Suction valve plate (spec 3) 18._| 4009 ‘Suction spring (spec 3) 19. | 3484 Suction valve bumper (spec 3) 20. | 3483 Suction valve seat (spec 4) a1. | 3972 ‘Suction valve plate (spec 4) 22. | 4009 ‘Suction spring (spec 4) 23. | a4ad Suction valve bumper (spec 4) 2a. | 3486 Discharge valve bumper 25.__| 4008 Discharge spring 26.__| 9973 Discharge valve plate 27._| 3485 Discharge valve seat O-ring Code opine A | Buna-N « _ denotes O-ring code. See O-ring chart o theft for details B | Neoprene®] © Roatstored trademarks of tho DuPont company CAUTION: Always Relieve Pressure In The Unit Before Attempting Any Repairs. 51Appendix F—91 and F91 Piston Assembly Details Piston Assembly Number 1983-X Bill of Materials, Piston Diameter 3” (7.62 cm) Ref | Part No. | No. Description Qty 7. | 7002-0100C700A | Screw, socket head 4 7207-0108 Lock washer 4 2. 1983 Head, iron 1 3. 4775, Ring expander 3 4 1772 Piston ring 3 5. 1482 Locknut 1 6. | 1480 Lock pin 1 7. 1984 Piston platform 1 a | 1628 ‘Shim washer, thick As 4528-1 Shim washer, thin eg, 9 1527, Thrust washer 1 Piston Clearance (Cold)* Model Minimum Maximum 1 10.020" (0.51 mm) 0.044" (1.12 mm) ae Piston Rod 5 The eistance rom the boom ofthe ead tothe top ofthe piston, CAUTION: Always Relieve Prossure In Tho Unit Before Attompling Any Reps.Appendix F—91 and F91 Packing Assembly Details Packing Assembly Bill of Materials Ref | Part No. | No. Description Qty 4.__| 2242 Cylinder 1 2.__| 2-235 * | Oxting for cylinder 1 3,__| 8000-137 | Retainer ring 1 4__| 1012 Washer 1 | 1628 Packing spring 7 6 | i714 Packing box washer 1 7. | 1453-1 | Male packing ring 7 | 14542 | Packing ring 8 8_| 1452-1 | Female packing ring 1 10._| 2240 Crosshead guides 1 11._| 1387 Adjusting screw 1 12.__| 2526 Crankcase gasket 1 13.__ | 1452-1X1 | Packing set 1 Number | Name Assembly | Assembly 1192:X2_| Crosshead - piston-rod assembly 1452-1X1_| Packing set with 1452-1, 1459-1, 1454 (8),1626, 1714 *1452-2X1 | Packing set (alloy 50) with 1452-1, 1453-1,1454-2 (8), 1626, 1714 ‘O-ring Code ‘A | Buna-N B | Neoprene® * Optional equipment Any Repairs. 2 _ denotes O-ring code. S00 O-1ing chart above for details » The quantity of 1454 packing rings required will vary due to {olerances. Use cone 4005 for instalation of packing « Rogisered trademarks ofthe DuPont comps. CAUTION: Aways Roliove Pressure In The Unit Before Attempting 53Appendix F—91 and F91 Connecting Rod Assembly Details Connecting Rod Assembly Bill of Materials Ret | Part No. | No. Description 4_|-1132-K2 Crosshead assembly 2 | 1498 Retainer ring 3. | 2505 Wrist pin 4___| 1846-%82 | Wrist pin bushing | 1599° Bolt 6 | 18895 Connecting rod assembly 7__| 1889-1 Connecting roc a i367 Connecting rod bearing 3 [zone Dipper 1o._| 160056 Nut ® Must be rebored after replacing (0.8754/0.8751 dia) ° Included with connecting rod assembly © Torque connecting rod nut 1 28. bs. "Noverattomptto separate te piston rod and crossicad. hon repair becomes necessary, eerie crosshead assem mus b= replaced. CAUTION: Amays Relieve Pressure In The Unit Before Attempting Any Repairs.Appendix F—91 and F91 Flywheel Assembly Details Back Side Flywheel Assembly Bill of Materials ‘Assembly | Assembly Number | Name 3271-X2__| Flywheel assembly Flywheel: 14” 0.D., 2 groove (# 3271) Hub with three blots and lockwashers (fH SF-1.125) Front Side 55Appendix F—91 and F91 Crankcase Assembly DetailsAppendix F—91 and F91 Crankcase Assembly Details Crankcase Assembly Bill of Materials Ref | Part No. | No. Description 1 | 3259 Oil seal 2. [1483 Roll pin - 1/8 x1" 3,__| 7001-037NCO7SA | Hex head 2/6-16 x 9/4", Gr5 4._[ 9260 Bearing carrier 5._| 2796 Breather ball 6 | 1979. (O-ring (part of bearing cap assembly) 7._| 1279-x Breather cap assembly (with O-ting- ref.no. 6) a__| 2725 Bearing carrier gasket 9. | 1807 Roll pin - 1/8 x 5/8" 10._| 2718 Bearing cup 11._| 2723 il circulating ring 12._| 2476 Crankshaft 13._ | 2719 Bearing cone 14, | 2289 Flywheel key 15._ | 2290 Oil ring retainer washer 16._| 2554 Crankcase 17. | 1661 Pipe plug - 3/8 NPT sq. or hex 18._| 2729 Inspection plate gasket 19._ | 2728 Crankcase inspection plate 20. | 24124 (Oring 21. | 1368-X1 Oil bayonet assembly (with O-ring) 22, | 2721 Bearing adjustment shim (0.005) 2721-1 Bearing adjustment shim (0.007) 2721-2 Bearing adjustment shim (0.020) 23 [ 2720 Bearing cap ‘Assembly | Assembly Number | Name 2476-X | Crankshaft assembly with 2476, 2280 and 2718 2476-SX_|_ Extended crankshaft assembly with2719 (2) and 2290, (optional) 3260-X | Beating carrier assembly with 3260, 2718, 3259, 41279-X, 2-111, 1483, 2796 and 1807 3271-X28_| Flywheel assembly 14" - 2 groove with H SF-1.125 and $271 8 Not shown, not part ofthe crankcase assombly Crankcase capacity: 0.9 quarts (0.8 ters) CAUTION: Always Relieve Pressure In The Unit Before Attempting Any Repairs. 37Appendix G—291 and F291 Head and Valve Assembly Details 291 Head Assembly Valve Holddown Assemblies Valve Assemblies Details _ ac “ CO, Sy eo” oo. 58Appendix G—291 and F291 Head and Valve Assembly Details Head and Valve Bill of Materials Ref | Part No. | No. Description 1. | 2912 Head model 251 2s12-x1 Head assy. for model 291 (spec 3) 2812-X2 Head assy. for model 291 (spec 4) 2. | 4300 Head model F291 (ANSI flange) 3,__| 7001-087 NC100A | Bolt, 3/8-16 x 1" Gr hex head 4. | 273i Genter headbolt 2732 Gasket for center headbolt 5 | 22358 O-ring 6 [213 ‘Orting 7.__| 2714-1 Valve cap a__[ 20318 O-ring 9 [2715 Holddown screw 10. | 3483-4X Suetion valve assy. (spec 3) 3483-1X12 ‘Same as above but with copper gaskets 3483-1X24 ‘Same as above but with iron-lead gaskets 11, | 3483-X ‘Suction valve assy. (spec 4) 3483-X12 ‘Same as above but with copper gaskets 3483-X22 ‘Same as above but with iron-lead gaskets 72, | 3485-x Discharge valve assy. (all specs) 3485-X12 ‘Same as above but with copper gaskets 3485-X22 ‘Same as above but with iron-lead gaskets 13. | 2717 Valve gasket (aluminum) 2717-18 Valve gasket (copper) 2717-28 Valve gasket (iron-lead) 14. [5000-77 Retainer ring (spec 3) 15._| 397 ‘Suction vaive relief housing 16._|_ 1411 Spring (Spec 3) 17__| 1410 Ball (spec 3) 16. | 3483-1 Suction valve seat (Spec 9) 19. | 3972 Suetion valve plate (spec 3) 20._ | 4008 Suction spring (spec 3) a1. | 34a4 ‘Suction valve bumper (spec 8) 22. | 3483 ‘Suction valve seat (spec 4) 23. | 3972 ‘Suction vaive plate (spec 4) 24. | 4008 ‘Suction spring (spec 4) 25, | 3484 ‘Suction valve bumper (spec 4) 26._ | 3486 Discharge valve bumper 27._| 4008 Discharge spring 28._| 3973 Discharge valve plate 29._[ 3485 Discharge valve seat O-ring Code serene denotes O-ring code. See O-ring chart othe et for deta. A] Buna-N © Registered trademarks ofthe DuPont company. B | Neoprene™= CAUTION: Always Reliove Pressuro In Tho Unit Before Attompting Any Repairs. 59Appendix G—291 and F291 Piston Assembly Details t- Piston Assembly Number 1983-X Bill of Materials, Piston Diameter 3” (7.62 cm) Ref | Part No. | No. Description Qty 1. | 7002-0100G100A | Screw, socket head 4 7207-0108 Lock washer 4 2_| 1983 Head, iron 1 3. 4775, Ring expander 3 4__[ 177 Piston ting 3 5 | 1482 Locknut 1 6 | 1488 Lock pin 1 7. 1984 Piston platform 1 8. 1528 ‘Shim washer, thick As 1528-1 ‘Shim washer, thin Reg. 9. 1527 Thrust washer 1 Piston Clearance (Cold)= Model Minimum Maximum 291 0.020" (0.51 mm) 0.044" (1.12 mm) The distance from the bottom ofthe head tothe top ofthe piston, CAUTION: Always Relieve Pressure In The Unit Before Attempting Any Repairs.Appendix G—291 and F291 Packing Assembly Details Packing Assembly Bill of Materials Ref | Part No. | No. Description Qty 4. | 2913-4 | Oylinder 4 2.__| 2-236 ® | O-ring for cylinder 2 3, | 5000-197 | Retainer ring 2 4_[1012 | Washer 2 | 1626 | Packing spring 2 6 | 1714 _| Packing box washer | 2 7. | 1453-1 | Male packing ring 2 & | 14542 | Packing 6 9_| 1452-1 | Female packing ring [2 10. | 4398 | Cartridge holddown | 2 sorew 11._| 4394 | Packing box cartridge | 2 12. | 1387 __| Adjusting screw 2 13. | 2135 | O-ring 2 (packing cartridge) 14. [4383 | Crosshead guide 7 15.__| 2702 | Crankease gasket 1 16.__| 1452-1X1 | Packing set 2 not | 1192 | Locking device 4 shown ‘Assembly | Assembly Number __| Name aty 1192-X2__| Crosshead assembly 2 1452-1X1_| Packing set with 1452-1, 1453-1, 1454 (6), 1628, 1714 | 2 O-ring Code A] Buna-N B | Neoprene®> denotes O-ring code. Soe O-ring chart above for details ® The quantity of 454 packing rings required wil vary due to {olerances. Use Cone 4008 for instalation of packing. © Rogistered trademarks of the DuPont company. Picton Rod CAUTION: Always Relieve Pressure In The Unit Before Attompting Any Repairs. 6Appendix G—291 and F291 Connecting Rod Assembly Details Connecting Rod Assembly Bill of Materials Ret | Part No. | No. Description 1.__| 1192-28 | Crosshead assembly 2. | 1498 Retainer ring 3_| 2505 Wrist pin 4__| 1846%2 | Wrist pin bushing 5__| 159° Bolt 6. | 1889 Connecting rod assembly 7__| 1889 Connecting rod a | 13676 Connecting rod bearing 9. | 16008© Nut Altompling Any Repairs. ° Must be rebored after replacing (0.875410.8761 dia) ° Included with connecting rod assembly © Torque connecting rod nut 1 28. bs. "Never attomp! fo separate the piston rod and crosshead. When repair becomes necessary, the entre crsshead assembly must be replied. CAUTION: Almays Relieve Pressure In The Unit BeforeAppendix G—291 and F291 Flywheel Assembly Details Flywheel Assembly Bill of Materials ‘Assembly | Assembly Number 2549-X1_| Flywheel assembly (fH SF-1.250)Appendix G—291 and F291 Crankcase Assembly DetailsAppendix G—291 and F291 Crankcase Assembly Details Crankcase Assembly Bill of Materials Ret] Part ‘Assombly | Assombly No.| No. Description Number” | Name a [378 Oi seal T2TOX | Brealer Gap ASST wih ETB, ETT 2. | roo:-oarNcoreA | Bot, 98-1874, hax head 1347-7 | Crankshaft assembly with 1264 (2), 1266, 1347, 3] 267 Bearing cover 1501, 2590. 2719 a | zr Bearing acjusimaet Sits (00057) TSAERT | Bato erankanal assay Wi THA) TOBE, ves Bearing acstmert shi 0.007") 1342, 1501, 2560, 2719 12732 Bearing adustment shim (0.0207) TS6SXT | Oi bayonst assonbiy with 1368.% SABA 51500 Bearing cup TS192X7 | Fycaulie unioader assembly (up f> 200 ps) 6. | 1369. Or bayonst ‘ees 7 [aria Crankcasa inpection pate gasket TaTSDE™ | Tiyrauhe unioader assembly 8._| 2858 Grankcase inspection pate (200 psi & aboveySpec 7. 78 ony) 9. | 21128 ina WSIEX | Closure cap assembly nclcing 2-278A 40. | 205 Srankonse (poe, 4,6, 9 oniy) nae Breaer cap ZEIGT | Fiyuheelassembiy, 16° OD. 3 geove wih 2. [Bi ‘xing (breather cap) 2549 and 2218 (not part of erankoase 13. | 2795 rear ball ssemb) rot shown) 14. [1489 Lock pinV8 x7 Z55EK | Bearing carer assembly with 1285, 1290, 15 38. [ 461 Feel ker 1202, 1203, 1515-X, 2718, 2805, 2606 2), 2848 X, 16.1504 Bearing cone 2849-X, 2860, 2851, 2852, 2956, 2961-K,2011-A, i | 1980 Crankshaft assembly with 1254 @), 2er12A, 2.2260, 1286, 1941, 1501, 2590, 2719 Z55T-X | ‘Baarng Cover asSombvy wih 2057 ae 1378 18. | 1204 Crankshaft orifice @) 2061-X ‘Arr reloase valve assembly with 2961, 2962, 5963, 0. [ari Bearing cone BaTiXI | Fiywhosl assembly, 4° 0.0.2 groove with S218 and 20. | 1286 Pump shalt dive pin 3271 (not part of crankcase assenbiy) (nt shown) 21. | 2500 Pipe plug — 1/8 NPT, flush seal “4252-% | Oi titer assembly with 4222, 4225, 2708, C200 22. [1280 iter serean sere (Standard on a maces starting dahuary 1, 1983) za. | 1281 Fir screen screw gasket 2a. | 2-116K Ong titer sreer) ® Optional equoment 25. | 1276 Fit screen washer CGrankcase capacity: 15 quarts (14 ters) 28. | 127 Oi er screen zr | 3289 Pie plug ~ 1/4 NBT, Hush seal CAUTION: Always Rolove Pressure In The Unt Before Attompting 25. 1061 Pie plug a6 NPT ‘Any Repairs 29. [1200 Feb! vave adjusting sere 20_| 1291 Adjusting screw tocknut 31. | BONA ‘Orrng feieve vale equstnentSereu) a. | 1202 ale vave Spnng 3. | 1209 ole! vavo ball 3a | aria Bearing cup 35. | 2009-X ‘Ar rloase val assembly ‘wan 2001, 2962, 2063 36. | as Boaving caioe gasket 37. | 2056 Bearing carior 3a. | 22188 ‘O-ing losure Baa) @ equa (Spee, 4,8, 9 oni | sEX Closure cap ascambly nauding 221A (Spee 3.4.8, 9 only) WD ToOT-GRENGOSGA | Bor, 174-20. 172, hax haa a1. | 1a02 Oi prossure gauge a2. | 2.2988 ‘-zng pump cover a9. | 4220 Oi iter assembly a. | 1629 Pipe plug — 1716 NBT. sh seal 35. | 7001-G37NETOOA | Bot, 5-16. 1, hex head 36. | 2805 um saft bashing a7. | 2850 Pump shaft adaptor 26. | 2652 ‘iL pum spring 39. | 2051 Spring auide 0. | 2640 i pump assembly (ndvigual pump pars not avalabio) i | ar98 ump cover pn wth 2546 % 2040.X Pump cover natu pi) wa anes iter 65Appendix H—490, 491, and F491 Head and Valve Assembly Details 490 and 491 Head Assembly Valve Holddown Assemblies Lr Sr om Sustion Valve Suction Valve Discharge Valve ‘Spec Speed AAI Specs,Appendix H—490, 491, and F491 Head and Valve Assembly Details Compressor Head and Valve Bill of Materials 1._| anat ‘Head—ductile iron (491) 10%. | 2438-X ‘Suction valve assembly 2. | 37129 ‘Head —ductila iron (491) (see ref. no. 7, 17, 18, 19, 20, 21(2). 3. | 4207 Head —ANS| flanged (F491) z PRP PH 42974 Head flanged - Din spec. only (F492)| 2438-0 ‘Same as 2438-% 4 | 1481 Head gasket (490 and 491) Dee ee ith Sooper geshes [pass in on but wh fro goats pe plug —| 102. | 2439-X ‘Discharge valve assembly 7_| 14798 Cenier head bolt (Gee ref. no. 7, 17, 18, 20, 21(2),, @ | 14804° Center head boit gasket (copper) 22, 26, 25) 1480 Genter head bolt gasket (Stee) BK ‘Same a5 2830 '7005-043NC150A° Bolt, 7/16-14 x 1-1/2" ferry head but with iron-lead gaskets {491 serial # F244188 and later) 103.| 2532-9 ‘Suction valve assembly (spec. 3) a. [etd ‘O-ring for cover plate 2014-x2t 4st 4 15. | 14097 Valve spacer 2914 xa 491 a 141848 \Valve gasket (copper) 4297-xa1 Fast 3 1418-22 Valve gasket (iron), 4297-X2) Fagt 4 48. | 2446 Bolt ‘4297-1X1 Fag2 3 21. | east ‘Spacer (two par valve) 20. | 9355 Washer O-ring Code: 23. | 1407, Valve spring A | Buna-N 24. | 2440 ‘Suction valve bumper B | Neoprene®9 ate a to cere ae em ate Sos icc at tom oe Snes a cenawape cane tna Ra rane oa vt orAppendix H—490, 491, and F491 Piston Assembly Details Piston Assembly Number 1985-X Bill of Materials Piston Diameter 4" (10.16 cm) Ref | Part No. | No. Description Qty 7. | 7002-02500725A | Screw, socket head 3 7207-0258 Lock Washer a 2. 1985, Head, iron 1 3. 1776 Ring expander 3 4. 1773, Piston ring 3 5. | 1482 Locknut 1 6. 1483, Lock pin 1 7. 1986 Piston platform 1 3 | 1528 ‘Shim washer, thick As 1528-1 ‘Shim washer, thin Rea. o_[ 1827 Thrust washer 1 Piston Clearance (Cold)* ° For 491 compressor with fat gaskot © For 491 compressor with head O-rings. Model Minimum Maximum 490 0.000" (0.00 mm) 0.024" (0.61 mm) _— Pision Ros | 497 —— agi 0.020" (0.57 mm 0.044" (1-72 mm) ® The datance from the bottom ofthe head to the top ofthe piston CAUTION: Always Relive Pressure In The Unit Before Attempting Any Repairs.Appendix H—490, 491, and F491 Packing Assembly Details Packing Assembly Bill of Materials Ref | Part No. | No. Description Qty 4. [3713 [Cylinder (491 w/O-ring)|_14 2.__| 2-243 ® | O-ring for cylinder 2 3, | 5000-197 | Retainer ring 2 4.1012 | Washer 2 | 1626 _| Packing spring 2 6 | 1714 _| Packing box washer | 2 7. | 1453-1 | Male packing ring 2 @_| 1454° | Packing ring 6 9 | 1452-1 | Female packing ring | 2 40. | 2801 | Cartridge holddown | 2 screw 11._| 2799 | Packing box cartridge | 2 12._| 1387__| Adjusting screw 2 13. | 2-139 | O-ing 2 {packing cartridge) 14. | 27657 | Crosshead guide 7 15. | 1489___| Crankcase gasket 1 16.__ | 1452-1X1 | Packing set 2 not | 1192 | Locking device 4 shown ‘Assembly | Assembly Number | Name 1984-X__| Crosshead assembly 1452-1X1_| Packing set with 1452-1, 1453-1, 1454 (6), 1628, 1714 (O-ring Code A] Buna-N B | Neoprene®* » SIN F244168 ond later "denotes O-ring code. See O-ing chart above for deals © The quantity of 1454 packing rings required wil vary due to lolerances. Use Cone 4008 for packing instalation. 4 SIN XC20630 and later © Registered trademarks of the DuPont company. CAUTION: Always Relieve Pressure In The Unit Before ‘Attompting Any Repairs. 9Appendix H—490, 491, and F491 Connecting Rod Assembly Details Note ligament smacks Connecting Rod Assembly Bill of Materials Ref | Part No. | No. Description 1. | 1384-X Crosshead assembly 2 | 1498 Retainer ring 3.__| 1496 Waist pin 4__| 1495-X80 | Wrist pin bushing 5__| 14922 Bolt 6 | 1490-% Connecting rod assembly 7__| 14908 Connecting rod 8 | 149° Connecting rod bearing 9 | 14930© Nut 2 Must be rebored after replacing (0.8754/0.8791 di) ° Included with connecting rod assembly ° Torgue connecting rod nut © 90 fb. "Never attempt to separate te piston rod and crosshead. Ven repair ‘becomes necessary, the entro crosshead assembly must bo replaced. ‘CAUTION: Almays Relieve Prossure In The Unit Botore Attempting Any Repairs.Appendix H—490, 491, and F491 Flywheel Assembly Details Flywheel Assembly Bill of Materials ‘Assembly | Assembly Number | Name 2549-X | Flywheel assembly Flywheel: 16” 0.D., 8 groove (Ht 2549) Hub with three blots and lockwashers (# HSF-1.375) Front Side aAppendix H—490, 491, and F491 Crankcase Assembly DetailsAppendix H—490, 491, and F491 Crankcase Assembly Details Crankcase Assembly Bill of Materials fhe eee agi su ecieersae a7. | 1498. Crankshaft assembly with 1284 (2) 1808-X1_| Oi bayonet assembly with 1508-X,2-1124 1a98-5K Extended crankshant assembly with (Spec. 3, 4. 8, 9 only) CSnae aa ta] fame cates tao ors 7a. [188 rankcase orcs @) crankcase assembly (ot shown) =e ere = eae ae za, [1296 Bun staf ae 2550, 25042546 % 2549, 2550, 205,295, io _| ead = jes [Bs ee a a 25. | 1276 Filter screen washer 2 Optional equipment — O-ring 4 7001-050 NC150A Bolt, 1/2 - 13 x 1-1/2" hex head Gr 5 (Torque to 65 ftelbs) 3. | a7iat ‘Valve cap 6. 2-037_© O-ring 7p eri Foldcown Serew 8. 1764 Valve cover plate 9. | 2-235_> O-ring 10. 3570-1 ‘Valve cage 11. 3732-X ‘Suction valve assembly (6") 12._| 3733-X Discharge valve assembly (6°) ‘O-ring Code 73.) ata Valve gasket AL Bra N 14, | 7001-043 NCTSOA | Bolt, 7/16 - 14 x 1-1/2" hox head (Torque to 37 ftelbs) 5 | Neoprene®? 75. | 3827 Valve seat (6) = Ince wih vo assembly 15__| 3827 vane 2 foncios Ong code So0 ng 17.__| 880° Valve plate, outer Inoue wh vale pal A 18._| 9831° Valve plate, inner ‘Registered trademarks ofthe DuPont 19. 3829° ‘Spring company. 20. | 3826 Valve bumper (6°) CAUTION: Always relieve pressure in the 21. | 9605-x1 Valve repair kit (ist stage) lun Before atompting any repair. 82Appendix J—D891 Piston Assembly Details Piston Assembly Number 3925-X1 Bill of Materials Piston Diameter 4.5" (11.43 cm) Ref | Part No. _|_ No. Description aty 1. | 7002-025 TPIO0A | Screw, orlo gr. 6 4 (Torque to 8 ttelbs) 2. | 3927 Piston cap i 3. | 2902 ‘Shim washer (thick) AS rea. 3002-1 ‘Shim washer (thin) As req 4 | 3604 Look nut (Torque to 150 ftebs|_1 5 | 8730 Thrust washer 2 6_| 3925 Piston cap 1 7. | 1739 Piston rings (PTFE) 4 1799-2 Piston rings (Alloy) 4 1739-3 Piston rings (PEEK) 4 &__| 1740 Expander ring 4 3603 ‘Shim washer (thick) AS req. 3603-1 ‘Shim washer (thin) As req Loctite tube - 620 | 3812 1 ‘Top Max. Bottom Min. | Bottom Max. (0.070" (0.25 mm)] 0.020" (0.50 mm) ® The distance fom the bottom ofthe head tothe top ofthe piston 2 The distance from the bottom of the piston othe top ofthe crosshead guide, CAUTION: Always Relieve Pressure In The Unit Before Attompling Ary Repairs. 8 > Piston Rod — 10. i Piston Clearance (Cold) Model | Top Min? D891 | 0.084" (2.13 mm) |0.104" (2.64 mm) 83Appendix J—D891 Crosshead Guide Assembly Details id ° Crosshead Guide Bill of Materials Ref | Part No. | No. Descript aty 1. | 3922 Cylinder 1 2 | 1054 Drain valve 1 (lubricated models) 3 | 1071 Nipple, 1/4” x close 1 4 | 2286 = (O-ring for cylinder 2 5__| 3442 Pipe plug, 1/4" NPT 3 6. | 7007-O50NCITEA | Bolt, 1/2" 19x 1-3/4" 24 hex head gr 5 7_| 3793-28 Flange (inlet/outlet) 2 wis 6 [8 | 22018 ‘O-ring for flange 2 9. | 3253 Roll pin 1 10._| 2405-1 Crosshead guide 1 a1 | 1064 Elbow, 1/4" NPT 1 12._| 9974 Tag 1 73._| 1761 Gasket, crankcase 1 34. | 1760 Gasket, inspection cover | 1 15__| 1721 Inspection cover 1 76._[ 7072-O10NCO25B | Bott, 10-24 x 1/4" Philip hd. | 10 O-ring Code ‘A Buna-N B | Neoprene = denotes O-ring code. See O-ring chart above for deta. ® Registored trademarks of the DuPont company. CAUTION: AMays Relieve Pressure In The Unit Betore Attempting Any Repairs Nore: Packing barre instllaton: 1. Use packing installation cone #905 on the piston rod. 2. Insert small barre! fst, uso finger holes to aig singer rng on to the rod. Sip tie packing barre into place. 4, Align pin with slot lage packing barre 4. Slip large packing bare in place. a4Appendix J—D891 Packing Assemb| TK 7 Packing Direction 8 Tee 5 Bm Tax 4 2 4 10 - 1 nore Ne Ne Ne a 10 12014 P 18. ua Bd nd 120014" | NOTE: Use instalation Cone b»»>d 10 QI 43005 over piston 10d when Instaling packing. CAUTION: Aways Relieve Prassura In The Unit Before Aiempting Any Repairs, O-ring Code ‘A | Buna-N B | Neoprene®® ly Details Packing Assembly Bill of Materials Ref | Part No. | No. Description 1. | 3926 Packing barrel - 4-1/2" 2. 3885 Cartridge 3. 1732 Oil slinger ring 4. | 5000-175 ‘Snap ring 5. 3906 Crush gasket 6. | 3617 Packing cup (Not included in 3810-X1 packing set) 7. [3810 ‘Segmented packing (radial - tangent) pair 8. | 3814 ‘Segmented packing {tangent - tangent) pair 3 [sari Back-up ring 10. | 1728 Washer 44._| 1731 ‘Spring 12. | 1724 Male packing ring 13. | 1725 Packing ring 14. [1723 Female packing ring 15. | 2-238_4¢ O-ring 16. | 2-231_4 O-ring 17._ | 7002-G35OCIOOK | Screw, 7420xT” socket head 16. | 1725-X Packing set 79. | 610-x1= Packing set 20. | 2-036 4¢ Cup O-ring 2 aenotes Ong code, Seo O-ig chet for dears 4 Singer rings loose whi the packing carrie unt fied on the piston rod Must be put n om the Baton of to cartridge « Insert tem 17 into the groove nthe botom ofthe bare. 4 Starting with SN. NNSS07 © Packing cup O-ring nt inluded in packing so. 1 Registered racomars of he DuPor company. Identification of Packing Specification Example: Model Number D891 a M4FBA Packing Spec. ‘Segmented packing align pin wh hole 33810 SPEC“ 8% Qc crmnae Rd Cut Tangent Cut Backup (oot pin) (wipe) tng ‘Segmented packing align pin wth hole 33814 SPEC“ 8% ren rom so) 6) —ceem TTongert Cut Tangent Cut Back-up (wet pin) (wit pe) tng IMPORTANT: Identty and tne up the rings before installing. Be sure ‘ey face the way shown here and iat the pin and hole are aligned when assembled 85Appendix J—D891 Connecting Rod Assembly Details Connecting Rod Assembly Bill of Materials Ret | Part No. | No. Description 1. | 3548-X3 Crosshead assembly 2. | 3590 Retainer ring 3. | 3540 Wiist pin 4__| 3541-325 | Wrist pin bushing 3. | 1726? Bolt 6 | 3785-K Connecting rod assembly 7__| s765* Connecting rod @_| 35428 Connecting rod bearing a | 17a78e Nut ® Included with connecting rod assembly ° Torque connecting rod nut 1 40 ft. bs. © Must be rebored after replacing (1.1256I1.252 da.) "Never attempt to separate te piston rod and crosshead. When repair \ becomes necessary, the entre crasshead assembly must bo replaced. Note alignment CAUTION: Always Relieve Pressure In The Unit Bofore ‘marks Attempting Any Repairs. onAppendix J—D891 Flywheel Assembly Details Flywheel Assembly Bill of Materials ‘Assembly Number ‘Assembly Name ‘3852-X Flywheel assembly Flywheel: 21.2” 0.0., (# HE-2.125)Appendix J—D891 Crankcase Assembly Details 6 fs al pats shown ‘except #52 and #53)Appendix J—D891 Crankcase Assembly Details Crankcase Assembly Bill of Materials Ret] Part Ret | Part No. | No. Description Wo. | No. Descriotion Pan Bearing cone 55. | 3260 Pipe plug, 11 NBT sear 2 88 Spacer 36.) 2a ‘Bearing carer gasket S| eas Dive sprocket 7 2050 ‘Ar elase valve assombiy a 1284 Crankshaft ois | 2500 ipa plug. 1/8 NET fl Seal 5. | 2135 Dive pin 55, | 425 Fier 6. | 2839 Tink pn 60. | 2768 Pump cover pin included WARE) 7 ara Crankshal ei | 32202 ‘Bearing cater assay | 3508 Fiywhesl Koy o._| 3580 Beang cone ‘Assembly ] Assembly 10 | a7a6%1 Crankshalt assembly Number” | Name 1. | 7001-0SiNGOTEA | Bot, 5/16 - 1 x /4" hax oad SSD — | Har aScemby DEBT ony va. | eee Inspection Gover az Fiywhoal 512°, SV. 5 grove 13. | 2123, Gasket, mepection cover ae Flywheel hub type J2 - 1/8 bore (D897 only) 14. [2.2108 On “rez Feet 19 1/2" AB, 4 groove 18. | 8225X4 Oil bayonat assemby (wO-ring) '3221-K77 | Crankoase assembly (M3, 4, 6, 9) without lubrication 16. [2126 Breather bal 3221 Xe" | Crankcase assembly (M7, 76) wheat hibrcaton a7. | 3573) Bearing Cup S221 X34 _| Crankcase assomby (U3, 4,8. 9 without hbricaton| 16. | 3580 Boar ausimant shin (005) SETAE Grankcnse essen (7.78) wih ubreaon 25897 Bearing agustment shim (007°) 25892 Bearing adusiment shim (020°) Not shown 7a a0 Benoa © Must bo rebored and honed aftr replacing (0.87610 875" ameter) sof asa Sin © Caution: To avoid damage during assembly, refer o instalation 20. | 3826 Gtseal— Instruction Maal 1400. za. [281 Gok, Hae CAUTION: Amays Reiove Prossure In The Unt Botore Attempting za. | 210A ‘O-ing any Repos za. | 1276 ‘Washer 25. | 127 Oi iter seen 26. [aaa Pipe plug, V2" NPT steel zr] oz21 Crankease 28. | 7001-OS7NGTOOR | Bot. 98 - 16x T haxhoad Ges 20. 3876 ‘enass cover 30. | 7003-OBSNCOBTE | Screw. 14 - 0x3 31. | 3878 Gasket antess cover se. | 1515 Closure cap asseribhy 3. | 700%-OBSNODEGA | Bot, 178 20 x V2" nex head sa | 1515 Closure cap 35. | 1516 Closure body 36. | 218A Ong si. | 1200 Fbet vane agusing seve 8. | 2011 o so. | 1201 ‘Ajsting sarew tocknut 30. | 1292 Relief vave spring ai. | 1209 bet vave ball 2, | 42225 Oi fife adapter asserby (wi) aa. | 226A Ong aa, | amo ‘Oi purip assem a5. | 2851 Spring guide a6. | 2852 Oi pump spring a7. | azi9 Pump shaft adapter aa. | 2-112 Oring ao | Basa Purp shai bashing 0. | 1820 Pipe plug, 716 NBT TL seal Bi. [1738 Bearing cup 2. | 1902 Oi pressure gauge a. | 108a Bushing, 178 «1/4 NBT oa. | oze07 Bearing carrier 89Solutions beyond products... = CORKEN EEX CORKEN, INC. # A Unit of IDEX Corporation 3805 N.W. 36th St., Oklahoma City, OK 73112 USA. Phone (405) 946-5576 (800) 631-4929 Fax (405) 948-7343 Visit our website at http://www.corken.com or e-mail us at info.corken@idexcorp.com Printed in the U.S.A. November 2006