Corken D791, T791, T891, D891 Installation, Operation & Maintenance Manual

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IJ110 E

Installation, Operation

& Maintenance Manual

D and T-Style Double-Acting Gas Compressors

Models D791, T791, D891 and T891

Model D891

Compressor Package

Model T891

Compressor

Warning: (1) Periodic inspection and maintenance of Corken products is essential. (2) Inspection, maintenance and installation of Corken products must be made only by experienced, trained and qualified personnel. (3) Maintenance, use and installation of Corken products must comply with Corken instructions, applicable laws and safety standards (such as NFPA Pamphlet 58 for LP-Gas and ANSI K61.1-1972 for Anhydrous Ammonia). (4) Transfer of toxic, dangerous, flammable or explosive substances using Corken products is at user’s risk and equipment should be operated only by qualified personnel according to applicable laws and safety standards.

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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 inspection 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., 3805 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

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Table of Contents

FEATURES AND BENEFITS .....................................................................4

CHAPTER 1—INSTALLING YOUR CORKEN COMPRESSOR ..........................................5

1.1 Location .................................................................................5

1.2 Foundation ...............................................................................5

1.3 Piping ...................................................................................5

1.4 Liquid Trap ...............................................................................6

1.5 Driver Installation/Flywheels .................................................................6

1.6 Crankcase Lubrication ......................................................................6

1.7 Purging, Padding, Venting and Draining of Distance Pieces .........................................7

1.8 Relief Valves ..............................................................................8

1.9 Shutdown/Alarm Devices ....................................................................8

CHAPTER 2—STARTING UP YOUR CORKEN COMPRESSOR ........................................9

2.1 Inspection After Extended Storage ............................................................9

2.2 Flywheel and V-belt Alignment ...............................................................9

2.3 Crankcase Oil Pressure Adjustment ...........................................................9

2.4 Startup Check List ........................................................................10

CHAPTER 3—ROUTINE MAINTENANCE CHART ..................................................11

CHAPTER 4—ROUTINE SERVICE AND REPAIR PROCEDURES ......................................12

4.1 Valve s ..................................................................................12

4.2 Heads ..................................................................................13

4.3 Piston Rings and Piston Ring Expanders ......................................................13

4.4 Piston Replacement .......................................................................13

4.5 Piston Rod Packing Adjustment .............................................................14

4.6 Cylinder and Packing Replacement ..........................................................14

4.7 Bearing Replacement for Crankcase and Connecting Rod ........................................17

4.8 Oil Pump Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

CHAPTER 5—EXTENDED STORAGE PROCEDURES ...............................................19

APPENDICES

A. Vertical Double-Acting Model Number Identification Code .........................................20

B. Vertical Double-Acting Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

C. Outline Dimensions ........................................................................24

D. Troubleshooting ...........................................................................32

E. Assembly Details ..........................................................................34

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Features and Benefits

High-efficiency valves:

Corken valves offer quiet operation and high durability in oil-free gas applications.

Ductile iron construction:

All cylinders and heads are ductile iron for maximum thermal shock endurance.

Self-lubricating PTFE piston rings:

Corken provides a variety of state-of-the-art piston ring designs to provide the most cost-effective operation of compressors for non-lube service. The step-cut design provides higher efficiencies during the entire life of the piston ring.

Upper packing

(Segmented)

Upper distance piece

Positively locked pistons:

Simple piston design allows end clearance to be precisely set to provide maximum efficiency and long life.

Self-lubricating piston rod seals:

Seals constructed of PTFE incorporating special fillers to ensure no oil carry over and maximize leakage control. Spring loaded seal design self adjusts to compensate for normal wear.

Nitride-coated piston rods:

Impregnated nitride coating provides superior corrosion and wear resistance.

Adjustable packing screw: Ensures maximum sealing capacity during the life of the packing (T791 and T891 models only).

Cast iron crossheads:

Durable cast iron crossheads provide superior resistance to corrosion and galling.

Pressure-lubricated crankcase with filter:

Self-reversing oil pump ensures proper lubrication regardless of directional rotation to main and connecting rod bearings. Standard 10-micron filter ensures long-lasting bearing life.

Middle packing (V-ring)

Lower distance piece

Oil deflector ring

Lower packing (V-ring)

Construction details: Model T891 compressor

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Chapter 1—Installing Your Corken Compressor

Ground level

Note: The depth of the concrete foundation will

1.1 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 will be subjected to extreme conditions for extended periods such as corrosive environments, arctic conditions, etc., consult Corken. Check local safety regulations and building codes to assure installation will meet local safety standards.

Corken compressors handling toxic or flammable gases such as LPG/NH3 should be located outdoors in

a well ventilated area. 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 should not exceed an 85 DBA noise level when properly installed.

Concrete foundation

be at least the same diameter as the suction nozzle on the compressor.

vary based on local soil conditions.

Figure 1.2: Recommended foundation details

Main beam (C-Beam)

Cross beam (H-Beam)

Hex nut

washer

3/4″ diameter “J” bolt

for Corken compressors

1.2 Foundation

Proper foundations are essential for a smooth running compression system. Corken recommends the compressor be attached to a concrete slab at least 8 inches thick with a 2 inch skirt around the circumference of the steel structural skid. The steel structural skid should be securely anchored into the foundation by 3/4 inch diameter “J” bolts that are 8 inches long. The total mass of the foundation should be approximately twice the weight of the compressor system (compressor, baseplate, motor, etc.). See figure 1.2 for details.

For a more detailed explanation of a proper fou ndation design, please refer to ED410, Important Instructions for Compressor Foundation Design.

1.3 Piping

Proper piping design and installation is as important as a proper foundation is to a smooth operating compressor. Improper piping installation will result in undesirable transmission of compressor vibration to the piping.

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 1.3 for details).

If a restrictive device such as a valve, pressure regulator, or back-check valve is to be installed in the compressor’s suction line, care must be taken. The suction line volume between the restrictive device and the compressor suction nozzle must be at least ten times the swept cylinder volume.

On liquefied gas applications such as LPG/NH3, it is of extreme importance to prevent the entry of liquid into the compressor. Installing a liquid trap on the inlet side will prevent liquid from entering the compressor (see section 1.4).

It is of equal importance to protect the discharge side of the compressor from liquid entry. This may be done by installing a check valve on the discharge side of the compressor and using a piping design that does not allow liquid to gravity drain into the compressor.

Flexible connector

Pipe support

Steel structural skid

Concrete

foundation

Flexible connector

Pipe support

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

Figure 1.3: Flexible connectors should be used to minimize

transmission of vibration to the piping.

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For vapor recovery applications, be certain 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. 58, Standard for the Storage and Handling of Liquefied Petroleum Gases.

For Ammonia—The American National Standards Institute, Inc., K61.1-1989, Storage and Handling of Anhydrous Ammonia.

Corken’s liquid trap provides the most thorough liquid separation (see figure 1.4) 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 designed to remove fine liquid mists. The ASME code trap is standard in the 109B and 107B mounting configurations.

NOTE: The liquid 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.

Copies of these are available from NFPA, 60 Baterymarch Street, Boston, Mass, 02110 and ANSI, 1430 Broadway, New York, N.Y., 10018. Install, use and maintain this equipment according to Corken instructions and all applicable federal, state, and local laws and previously mentioned codes. Other laws may apply in different industries and applications.

1.4 Liquid Trap

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.

On liquefied gas applications, a liquid trap must be used to prevent the entry of liquid into the compressor.

If your compressor is equipped with a liquid trap not manufactured by Corken, make sure it is adequately sized; otherwise it may not be able to remove the liquid entrained in the suction stream.

1.5 Driver Installation/Flywheels

Corken vertical compressors may be driven by either electric motors or combustion engines (gasoline, diesel, natural gas, etc.).

Note: Never operate a reciprocating compressor without a flywheel.

Drivers should be selected so the compressor operates between 400 and 900 RPM. The unit must not be operated without the flywheel or severe torsional imbalances will result that could cause vibration and a high horsepower requirement. The flywheel should never be replaced by another pulley unless it has a higher wk2 value than the flywheel.

Humid climates can cause problems with explosion proof motors. The normal breathing of the motor and alternating between being warm when running and 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. During this period of time, the motor will heat up and vaporize the condensed moisture. No motor manufacturer will guarantee their explosion proof or totally enclosed (TEFC) motor against damage from moisture.

Figure 1.4: ASME automatic liquid trap

For installation with engine drivers, thoroughly review instructions from the engine manufacturer to assure the unit is properly installed.

1.6 Crankcase Lubrication

To ensure proper lubrication of the crankcase parts before startup, the crankcase should be filled through the nameplate inspection opening.

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Non-detergent oil is recommended for Corken vertical compressors. Detergent oils tend to keep wear particles and debris suspended in the oil, whereas non-detergent oils let them settle in the bottom of the crankcase. When non-detergent oils are not available, detergent oils may usually be successfully substituted, although compressors handling ammonia, amine, or imine gases are notable exceptions. These gases react with the detergent and cause the crankcase oil to become corrosive and contaminated. Figures 1.6A and 1.6B show recommended oil viscosities and crankcase capacities. Ensure oil is compatible with the product being compressed.

Synthetic lubricants are generally not necessary. Please consult your lubricant supplier if you are considering the use of synthetic oil.

1.7 Purging, Padding, Venting and Draining of Distance Pieces

The key to leakage control and oil-free operation of Corken compressors is the distance piece. The distance piece is integral with the crosshead guide and forms the upper portion of it. Distance pieces are equipped with tapped holes to allow purging, padding, venting, and draining (see Figure 1.7). Proper connections to

and from these tapped holes are essential for optimum compressor performance.

Corrosive gases should be prevented from entering the crankcase, since even small amounts of gas leakage into the crankcase can seriously contaminate the crankcase oil. To prevent this contamination, the distance piece may be purged, padded, or vented using a clean, noncorrosive gas like dry air or nitrogen.

Purging:

Purging of the distance piece controls leakage of process gas to the atmosphere. Process gas leakage into the distance piece is quickly diluted by the purge gas and swept away. The purge gas should be vented to a safe release area, flare, compressor’s inlet, or treatment facility, depending on the gas and local regulations.

When purging, it is critical to maintain the proper pressure loading across each set of packing. The higher pressure should be on the open side of the “V”, which is also the side with the spring.

Moisture, oil, or condensate can be removed from the distance piece with the purge gas by using the lower distance piece connection (drain location) as the purge gas outlet connection.

Acceptable Crankcase Oil Products for Corken

Compressors

Constant Weight - Non-Detergent - R&O Inhibited

Oil product ISO VI SAE Ambient Temp.

Exxon®

TERESSTIC 100 95 30 65° - 100° F 68 95 20+ 45° - 70° F 46 95 20 35° - 50° F

Mobil®

RARUS 427 Reciprocating 100 95 30 65° - 100° F Compressor Oil DTE Oil Heavy Medium 64 95 20+ 45° - 100° F Dectol R&O Oil 44 95 20 35° - 50° F

Conoco®

Dectol R&O Oil 100 98 30 35° - 50° F 68 97 20+ 45° - 70° F 46 99 20 35° - 50° F

Texaco®

Regal R&O Oil 100 92 30 65° - 100° F 68 97 20+ 45° - 70° F 46 102 20 35° - 50° F

Sun®

SunVis 900 Oil 100 100 30 65° - 100° F 68 100 20+ 45° - 70° F 46 100 20 35° - 50° F

Figure 1.6A: Oil selection chart

Upper Distance Piece

Drain Plug

Lower Distance Piece

Drain Plug

Compressor

Model

Approximate

Quarts

791, 891 7.0 6.6

Figure 1.6B: Oil capacity char t

Capacity

Liters

Figure 1.7: Distance piece details

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Corken offers Purge Kits which include the necessary regulator, valves, fittings, etc. Consult the factory or see Important Instruction, item number IE210, for details.

devices should be selected to meet local code requirements. Shutdown/alarm devices typically used on Corken compressors are as follows:

Padding (Buffering):

If purging is not practical, the distance piece can be pressurized with a static pressure. This is called padding or buffering. Padding is done at a pressure above the compressor’s suction pressure using a clean noncorrosive gas like dry air or nitrogen. The higher pressure in the distance piece tends to reduce the process gas leakage to the atmosphere. A small amount of purge gas will likely get into the process gas. A pressure regulator can be used to maintain proper distance piece pressure.

When padding, it is critical to maintain the proper pressure loading across each set of packing. The higher pressure should be on the open side of the “V”, which is also the side with the spring.

Venting:

The distance piece can also simply be vented to an appropriate release area, flare, or treatment facility. This is sometimes useful for indoor installations.

Draining:

Since some oil will pass the lower packing set, regular draining of the distance piece is essential to maintain oil-free operation (See Figure 1.7). Corken recommends draining the distance piece once a week for units in continuous-duty operation. Installing a drain cock to the distance piece drain will help simplify draining of the distance piece.

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 if the normal discharge temperature is exceeded. This is strongly recommended for all applications. Typically, the set point is about 30°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.

Highly Corrosive Gases:

The compressor should be blocked from the system via valves on the suction and discharge piping, then purged with dry inert gas before being shut down. Experience has proven this significantly lowers corrosion damage to the machine.

1.8 Relief Valves

An appropriate relief valve must be installed on the discharge side of the compressor. On Corken 107-style mounted units, a relief valve should be fitted in the piping between the compressor discharge and the fourway valve. 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.

1.9 Shutdown/Alarm Devices

For many applications, shutdown/alarm switches will provide worthwhile protection that may prevent serious damage to your compressor system. All electronic

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Chapter 2—Starting Up Your Corken Compressor

NOTE: Read this entire chapter, then proceed with the startup checklist.

2.1 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. For valve and/or cylinder head removal instructions, refer to chapter 4 of this IOM manual.

Drain the oil from the crankcase and remove the nameplate and crankcase inspection plate. Inspect the running gear for signs of rust and clean or replace parts as necessary. Replace the crankcase inspection plate and fill crankcase with the appropriate lubricant through the nameplate inspection opening. Squirt oil on the crossheads and rotate the crankshaft by hand to ensure that all bearing surfaces are coated with oil.

Rotate unit manually to ensure running gear functions properly. Replace nameplate and proceed with startup.

Figure 2.2A: Flywheel installation

2.2 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 hub and three bolts (see figure 2.2A). These bolts should be tightened in an even and progressive manner to the specified torque values listed below. There must be a gap between the bushing flange and the flywheel when installation is complete. Always check the flywheel runout before startup and readjust if it exceeds the value listed in Appendix B.

Hub Size

SF 4.625 (11.7) 12-18 (1.7–2.5) 22 (3.1)

Diameter

in. (cm)

E 6.0 (15. 2) 30-36 (4.1–4.9) 22 (3.1)

J 7.25 (18.4) 75-81 (10.3 –11.1) 109 (15 .1)

Bolt Torque

Ft-lb (kg-meter)

Set Screw

Torque Ft-lb

(kg-meter)

Figure 2.2B: 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 2.2B.

2.3 Crankcase Oil Pressure Adjustment

Your Corken compr essor is equipped with an automatic ally reversible gear type oil pump. 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 amount 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. Loosen the oil filter and remove the pressure gauge. Restart the compressor and run it until oil comes out of the pressure gauge opening or around the filter. Tighten the filter and reinstall the gauge.

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The oil pressure should be about 20 psi (1.4 bars) minimum for normal service. If the compressor 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 springloaded relief valve mounted on the bearing housing opposite the flywheel regulates the oil pressure. As shown in figure

2.3, 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 retighten it after making any adjustment.

Oil pressure relief valve and adjustment screw

10. Rotate unit by hand and make certain there is no wobble or play.

11. Check crankcase oil level.

12. Drain all liquid traps, separators, etc.

13. Verify proper electrical supply to motor and panel.

14. Check all gauges and confirm a zero level reading.

15. Test piping system for leaks.

16. Purge unit of air before pressurizing with gas.

17. Carefully check for any loose connections or bolts.

18. Remove all stray objects (rags, tools, etc.) from vicinity of the unit.

Oil lter

Oil pressure gauge

Figure 2.3: Oil pressure adjustment

Breather cap

2.4 Startup Check List

Please verify each item on this list below before starting your compressor! Failure to do so may result

in a costly (or dangerous) mistake.

Before Starting the Compressor

1. Become familiar with the function of all piping associated with the compressor. Know each line’s use!

2. Make certain actual operating conditions will match the anticipated conditions.

3. Ensure line pressures are within cylinder pressure ratings.

4. Clean out all piping.

5. Ensure all distance piece openings are tubed or plugged as desired.

6. Check all mounting shims, cylinder and piping supports to ensure that no undue twisting forces exist on the compressor.

19. Confirm all valves are open or closed as required.

20. Double-check all of the above.

After Starting Compressor

1. Verify and note proper oil pressure. Shut down and correct any problems immediately.

2. Observe noise and vibration levels. Correct immediately if excessive.

3. Verify proper compressor speed.

4. Examine entire system for gas or oil leaks.

5. Note rotation direction.

6. Check start-up voltage drop, running amperage and voltage at motor junction box (not at the starter).

7. Verify proper lubrication rate (lubed units only).

8. Test each shutdown device and record set points.

9. Test or confirm set point on all relief valves.

10. Check and record all temperatures, pressures and volumes after 30 minutes and 1 hour.

11. After 1 hour running time, tighten all head bolts, valve holddown bolts, and baseplate bolts. See Appendix B for torque values.

7. Make certain strainer elements are in place and clean.

8. Make certain cylinder bore and valve areas are clean.

9. Check V-belt tension and alignment or drive alignment on direct drive units.

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Chapter 3—Routine Maintenance Chart

Item to Check Daily Weekly Monthly

Six

Months

Year l y

Crankcase oil pressure

Compressor discharge pressure

Overall visual check

Crankcase oil level

Drain liquid from accumulation points

2 2

Drain distance pieces

Clean cooling surfaces on compressor and intercooler (if any)

Lubricator supply tank level (if any)

Check belts for correct tension

Inspect valve assemblies

Lubricate motor bearings in accordance with manufacturers' recommendations

Inspect motor starter contact points

Inspect piston rings

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 star tup.

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Chapter 4—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 3, 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.

4.1 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 damaged or dirty. However, it is possible for the pressure gauge itself to be faulty.

In most cases, if a valve or gasket is leaking, it will create more heat. On a single-stage compressor, you may be able to compare the operating temperatures of the two suction or discharge valves and cover plates to each other. If a valve or gasket is leaking, it will have a higher operating temperature. NOTE: This method will not be suitable for two-stage compressors if each stage does not have more than one valve.

Valve Inspection and/or Replacement

Before removing and inspecting the valves, begin by depressurizing and purging (if necessary) the unit.

Disassembly

1. Unscrew the valve cap and remove the O-ring.

2. Remove the valve cover plate, O-ring and holddown screw by removing each of the four bolts. The holddown screw is easily removed with the special wrench supplied with your compressor.

3. After the cover plate and O-ring have been removed, the 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. Replacement is usually preferable although repair parts are available. If valve plates are replaced, seats should also be lapped until they are perfectly smooth. If more than .005 of an inch 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

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 Appendix E for a complete list of part numbers and descriptions.

If a valve is leaking due to dirt or any other foreign material that keeps the valve plate and seat from sealing, the valve may be cleaned and reused. New valve gaskets and 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 791 and 891 compressors. Since more than one suction valve arrangement is available for each model of compressor, it is necessary to know your complete model number so you can identify the valve type specification number (see example listed below).

Model number D891AM 4 FBANSNN

Valve type = spec 4

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.

2. Insert cleaned or new valve assembly. Make sure the suction and discharge valves are in the proper suction and discharge opening in the head.

3. Insert the valve cage.

4. Replace the O-ring and valve cover plate. Torque the bolts to the value listed in Appendix B. CAUTION: Be sure the holddown screw has been removed.

5. To ensure the valve gasket is properly seated, insert the holddown screw and tighten to the value listed in Appendix B. NOTE: Gaskets and O-rings are not normally reusable.

6. Replace the O-ring and valve cap and tighten to the value listed in Appendix B.

7. Check bolts and valve holddown screws after first week of operation. Re-torque if necessary. See Appendix B for torque values.

Page 13

4.2 Heads

A compressor cylinder cap and head very seldom requires replacement if the compressor is properly maintained. The primary cause of damage to a cylinder cap or 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 cylinder cap and heads (for proper storage instructions see chapter 5).

Many compressor repair operations require removal of the cylinder cap and heads. While the compressor is disassembled, special care should be taken to avoid damage or corrosion. 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 per the torque values listed in Appendix B.

rings should be replaced, measure the radial thickness and compare it to the chart in Appendix B.

4.4 Piston Replacement

1. To replace the pistons, depressurize the compressor and purge if necessary.

2. Remove the compressor cylinder cap, head and cylinder (see section 4.2).

3. Remove the piston cap by loosening and removing the socket head bolts holding the piston cap to the piston (see figure 4.3).

4. Next, remove the lock nut and lift the piston off the end of the piston rod.

5. Check the thrust washer and shims for damage and replace if necessary.

4.3 Piston Rings and Piston Ring Expanders

Figure 4.3: Piston cap 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 cylinder cap and heads to gain access to the compressor cylinder.

3. Loosen the piston cap bolts and remove the piston cap as shown in figure 4.3 by pinching two loose bolts together.

4. Remove the lock nut and lift the piston off the end of the piston rod.

5. Piston rings and expanders may then be easily removed and replaced. Corken recommends replacing expanders whenever rings are replaced. To determine if

6. Before installing the new piston, measure the thickness of the existing shims.

7. Replace the cylinder.

8. Install the piston with the same thickness of shims as before, and with new piston rings and expanders.

9. Now remove a lower valve and measure dimension “Y” at the bottom of the piston shown in Appendix E— Piston Assembly Details. If this measurement does not fall within the tolerances listed in the piston assembly details (Appendix E), remove the piston, adjust the shims as necessary and remeasure the “Y” dimension.

10. When the piston is properly shimmed, tighten the lock nut as shown in Appendix B.

11. Replace the piston cap with the same thickness of shims as before.

12. Reinstall the piston cap and cylinder head.

13. Now remove an upper valve and measure dimension “X” at the top of the piston shown in Appendix E— Piston Assembly Details. If this measurement does not fall within the tolerances in Appendix E, remove the cylinder head and piston cap and adjust the shims as necessary. Repeat the steps and measure the “X” dimension again.

14. When the piston cap is properly shimmed, tighten the socket head bolts in an alternating sequence. Torque socket head bolt to the values listed in Appendix B.

15. Replace the previously removed valves. Best results will be obtained if new valve gaskets are used.

16. Follow standard startup procedures.

Page 14

4.5 Piston Rod Packing Adjustment

Piston rod packing should be adjusted or replaced whenever leakage becomes noticeable. Adjust packing by tightening packing nuts as shown in Figure 4.5.

Packing Replacement Instructions

For specific construction details and actual part numbers, consult Appendix E in the back of this Installation, Operation & Maintenance (IOM) manual. Use instructions below and on the following pages that apply to the MODEL and SERIAL NUMBER of your compressor. Be careful to arrange packing sets in the proper order.

CAUTION: Before installing the new piston rod packing, bleed all pressure from the compressor and piping and purge if necessary. After the new piston rod packing has been installed, the unit should be pressure tested and checked for leaks at all joints and gasket surfaces. When the compressor is being used with toxic, dangerous, flammable or explosive gases, this pressure and leak testing should be done with air or a dry, inert gas such as nitrogen.

Figure 4.5: Packing adjusting nuts (models T791 and T891 only)

NOTE: Compressor models D791 and D891 do not have adjustable packing nuts so the packing sets on models D791 and D891 are not adjustable, the piston rod packing should be replaced whenever leakage becomes noticeable.

Typically, it is a good idea to replace piston rod packing and piston rings at the same time. For instructions on replacing the piston rod packing, see section 4.6.

4.6 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 5).

If the cylinder does become damaged or corroded, use a hone to smooth the cylinder bore and then polish it to the value shown in Appendix B. If more than .005 of an inch 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 using the torque values listed in Appendix B.

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 is a precision piece of equipment with very close tolerances. Treat it as such. Never beat on it to get parts in or out.

Packing Configuration

The packing for these compressors includes segmented packing in a packing barrel at the lower end of the cylinder and V-ring packing in a packing box cartridge below the segmented packing.

Refer to Appendix E for packing assembly details. Note the arrangement of the particular packing sets for the model of machine that you have.

4.6.1 Model D791 and D891 Compressors (D-Style)

On Models D791 and D891, there is one set of V-ring packing in a packing box cartridge attached to the packing barrel. The packing box cartridge holds the segmented packing inside the barrel.

Disassembly of Packing (D-Style)

1. Depressurize and open the compressor.

2. Remove the cylinder cap, heads, pistons and cylinder.

3. Remove the packing barrels by prying upwardly under each one and lifting entire packing barrel/cartridge assembly up from piston rod.

Page 15

4. Remove the four socket head screws that hold the packing box cartridge to the barrel.

a. Clean the segmented packing cups and the area

inside the packing barrel.

5. Remove segmented packing and cups from barrel.

6. Remove lower retainer ring, washers, packing spring and old V-ring packing from packing box cartridge.

Assembly of Packing (D-Style)

1. Replace packing as required. The segmented packing and cups are located in the packing barrel while the V-ring packing is located in the packing box cartridge.

NOTE: Always use new O-rings when replacing the packing.

2. V-ring packing set:

NOTE: The instructions below are for packing

specification “J”. Depending on the packing specification used in your compressor, the order of assembly for the packing rings, V-ring packing, washers and packing spring will vary. Refer to Appendix E to view the V-ring packing arrangements and follow the order of assembly and V-ring direction. If you do not know the packing arrangement used in your compressor, refer to the model number identification codes listed in Appendix A.

b. Insert the segmented packing cups, segmented

packing pairs and backup rings one at a time in the order shown in Appendix E.

c. Reattach the packing box cartridge to the packing

barrel using the four socket head screws.

4. Install three O-rings on the packing barrel and packing box cartridge as shown in the D-Style Crosshead Guide Assembly Details in Appendix E.

5. Install packing installation cone part number 3905 over the threaded end of the piston rod.

6. Carefully install barrel/cartridge assemblies over the piston rods, noting the alignment of the barrels as they sit on the crosshead guide. The valve scallops on the barrels must align properly with the valves in the cylinder.

7. Remove packing installation cone.

8. Replace pistons, cylinders, heads and cylinder cap. See details in Section 4.4 for proper assembly of pistons.

9. Rotate unit by hand to ensure proper assembly.

a. Clean and lightly oil the packing area inside the

packing box cartridge.

b. Insert the oil deflector ring through the bottom

opening of the packing box cartridge.

c. Insert the first retainer ring followed by a washer.

d. Insert the packing spring followed by another

wa sher.

e. Insert a male packing ring followed by four V-rings

and one female packing ring. NOTE: Insert

packing rings and V-rings one at a time. Refer to Appendix E for the proper direction of the male and female packing rings and V-rings.

f. Lastly, insert the final washer. Push in on the

washer and install the second retainer ring.

3. Segmented packing:

NOTE: The instructions below are for packing

specification “J”. Depending on the packing specification used in your compressor, the order of assembly for the segmented packing arrangement (radial or tangent) will vary. Refer to Appendix E to view the segmented packing arrangements. If you do not know the packing arrangement used in your compressor, refer to the model number identification codes listed in Appendix A.

4.6.2 Model T791 and T891 Compressors (T-Style)

On Models T791 and T891 there are two sets of V-ring packing in a separate packing box cartridge held in the crosshead guide by a cartridge holddown screw. A packing adapter holds the segmented packing inside the packing barrel.

Disassembly of Packing (T-Style)

1. Depressurize and open the compressor.

2. Remove the cylinder cap, heads, pistons and cylinder.

3. Remove the packing barrels.

4. Remove the four socket head screws that hold packing adapter to the barrel.

5. Remove segmented packing and cups from barrel.

6. Remove cartridge holddown screws with special wrench supplied with the compressor, and remove cages and packing box cartridges.

7. On the lower V-ring packing set, remove adjusting screw, washers, packing spring and old packing from each packing box cartridge.

8. On the middle V-ring packing set, remove upper retainer ring, washers, packing spring and old packing from each packing box cartridge.

Page 16

Assembly of Packing (T-Style)

1. Replace packing as required. The segmented packing and cups are located in the packing barrel while the V-ring packing is located in the packing box cartridge.

NOTE: Always use new O-rings when replacing the packing.

2. Lower V-ring packing set:

NOTE: The instructions below are for packing

specification “G”. Depending on the packing specification used in your compressor, the order of assembly for the packing rings, V-ring packing, washers and packing spring will vary. Refer to Appendix E to view the V-ring packing arrangements and follow the order of assembly and V-ring direction. If you do not know the packing arrangement used in your compressor, refer to the model number identification codes listed in Appendix A.

e. Lastly, push in on the washer and insert the third

retainer ring.

f. Install two O-rings on the packing box cartridge as

shown in the T-Style Crosshead Guide Assembly Details in Appendix E.

4. Segmented packing:

NOTE: The instructions below are for packing

specification “G”. Depending on the packing specification used in your compressor, the order of assembly for the segmented packing arrangement (radial or tangent) will vary. Refer to Appendix E to view the segmented packing arrangements. If you do not know the packing arrangement used in your compressor, refer to the model number identification codes listed in Appendix A.

a. Clean the segmented packing cups and the area

inside the packing barrel.

a. Clean and lightly oil the packing area inside the

packing box cartridge.

b. Insert the first retainer ring followed by a washer

through the bottom of the packing box cartridge.

c. Insert the packing spring followed by another

wa sher.

d. Insert a male packing ring followed by four V-rings

and one female packing ring. NOTE: Insert

packing rings and V-rings one at a time. Refer to Appendix E for the proper direction of the packing rings and V-rings.

e. Lastly, install and tightened the adjusting screw

until the PTFE locking device located on the side of the adjusting screw is engaged with the first thread of the packing box cartridge. DO NOT OVER TIGHTEN! The PTFE locking device should engage (slightly bent) the first thread but not break off.

3. Middle V-ring packing set:

a. Clean and lightly oil the packing area inside the

packing box cartridge.

b. Insert the second retainer ring followed by a washer

through the top of the packing box cartridge.

c. Insert a female packing ring followed by four

V-rings and one male packing ring. NOTE: Insert

packing rings and V-rings one at a time. Refer to Appendix E for the proper direction of the male and female packing rings and V-rings.

d. Insert a washer and a packing spring followed by

another washer.

b. Insert the segmented packing cups, segmented

packing pairs and backup rings one at a time in the order shown in Appendix E.

c. Reattach the packing adapter to the packing barrel

using the four socket head screws.

d. Install two O-rings on the packing barrel as shown

in the T-Style Crosshead Guide Assembly Details in Appendix E.

5. Install packing installation cone part number 3905 over the threaded end of the piston rod.

6. Before installing the packing box cartridge over the packing cone and piston rod, you must insert the oil deflector ring through the side opening of the packing box cartridge. The oil deflector ring should rest on top of the lower packing set. Make sure the oil deflector ring is centered over the piston rod opening before sliding packing cartridge over the installation cone and piston rod.

7. Install cages.

8. Install and tighten holddown screws with special wrench.

9. Install packing barrels, noting the alignment of the barrels as they sit on the crosshead guide. The valve scallops on the barrels must align properly with the valves in the cylinder.

10. Remove packing installation cone.

11. Replace cylinder, pistons, heads and cylinder cap. See details in Section 4.4 for proper assembly of pistons.

12. Rotate unit by hand to ensure proper assembly.

Page 17

4.7 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 cylinder cap, heads, cylinder, pistons, crosshead guide and crosshead assemblies.

2. Drain the crankcase and remove the inspection plates.

4. Make sure the lubrication hole in the bushing matches the oil passage in the connecting rod. If the holes do not align, drill out the bushing through the connecting rod lubricant passage with a long drill. Bore the wrist pin bushing I.D. as indicated. See Appendix E for details. 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.

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.

4.7.1 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 a new bushing into the connecting rod. DO NOT MACHINE THE O.D. OR I.D. OF THE BUSHING BEFORE PRESSING INTO CONNECTING ROD.

6. Press the wrist pin back into the crosshead and wrist pin bushing and reinstall retainer rings. NOTE: The fit between the wrist pin and bushing is tighter than lubricated air compressors and combustion engines.

4.7.2 Replacing Connecting Rod Bearings

Connecting rod bearings are easily replaced by removing the semicircular bearings. Make sure the indentations in the connecting rod bearing and connecting rod line up when installing the new bearings. MAKE SURE THE ARROW AND/OR ALIGNMENT NOTCH ON CONNECTING ROD AND CAP ARE ALIGNED.

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 torque values listed in Appendix B.

Figure 4.7: Bearing carrier replacement

Page 18

4.7.3 Replacing Crankcase Roller Bearings

To inspect the roller bearings, remove the flywheel from the crankshaft and then remove the bearing carrier and crankshaft from the crankcase. If corrosion or pitting is present, the roller bearings should be replaced. When replacing roller bearings, always replace the entire bearing and 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.

2. Press the new bearings into position and reassemble the crankshaft and bearing carrier to the crankcase. When reinstalling the bearing carrier, make sure the oil pump shaft slot is aligned with the pin in the crankshaft. Make sure to install the bearing carrier gasket so the oil passage hole is not blocked (see figure 4.7).

3. In order to check the crankshaft endplay, the oil pump must first be removed (see section 4.8).

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 or too loose, premature bearing failure will result.

7. Reinstall the oil pump and flywheel and check the run out as shown in Appendix B.

4.8 Oil Pump Inspection

If the compressor operates for a prolonged period with dirty or contaminated crankcase oil, damage to the oil pump and bearings may result.

1. To check the oil pump, unbolt the pump cover and remove the oil pump, spring guide, spring and oil pump shaft adapter as shown in figure 4.8.

2. Inspect the gears in the oil pump for corrosion or pitting and replace if necessary.

3. Check the oil pump shaft bushing in the bearing carrier. If the bushing is corroded, pitted or worn, the oil pump shaft bushing should be replaced. Inspect and replace other parts as necessary.

4. Before reassembling the oil pump mechanism, replace the O-rings in the oil pump cover and on the oil pump adapter shaft (see figure 4.8).

5. Rotate the drive pin in the crankshaft to a vertical position for easiest reassembly.

Figure 4.8: Oil pump inspection

Page 19

6. Insert the shaft adapter so it engages the drive pin.

Chapter 5—Extended Storage

7. Next, insert the spring, spring guide and oil pump assembly. The pin on the oil pump must align with the slot in the shaft adapter.

8. Install the pump cover so the pin on the case is in the opening on the oil pump assembly as shown in figure 4.8. When you are sure the pin is properly aligned, install the cover bolts finger tight. If alignment is correct, the pump cover will mount flush to the bearing carrier. If it does not, re-check the pin alignment.

9. Tighten the bolts in an alternating sequence. See section 2.3 for directions on oil pressure adjustment.

10. Finally, 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.

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. Drain the crankcase oil and refill with rust inhibiting oil.

2. Operate for a few minutes while fogging oil into the compressor suction.

3. Relieve V-belt tension.

4. Plug all openings to prevent entry of insects and moisture. (The cylinders may also be protected by the use of a vapor phase inhibitor, silica gel, or dry nitrogen gas. If the silica gel is used, hang a tag on the unit indicating that it must be removed before start-up.)

5. Store in a dry area and off the ground if possible.

6. Rotate the flywheel every two weeks if possible.

Page 20

XXXXXXXXX

hydraulic unloader

unloaders and pilot valve

speed unloading

MODEL NUMBER

Aluminum gasket material

intercooler

NA = Not Available NC = No Charge Option

Registered trademarks of the DuPont company.

Standard

Appendix A—Industrial Vertical Double Acting Model Number Identification Code (D-Style)

BASE MODEL NUMBER D791 D891

Inlet 2" weld 2" weld

Outlet 2" weld 2" weld

Intercooler connection 2" weld NA

Approximate shipping weight (lbs.) 930 900

SPECIFICATION FIELDS

Packing

Arrangement

Crankcase

Style

Valves

Packing arranged for padding of distance piece J

Packing arranged for venting of distance piece K

Atmospheric inlet or light vacuum service R

Pressure lubricated crankcase M

Std. crankcase with crankcase heater MH

Std. crankcase with cylinder lubricator Charge option Charge option L

Std. crankcase with cylinder lubricator and heater Charge option Charge option LH

Standard suction and discharge valves 4

Standard suction & discharge valves w/ light springs No charge option No charge option 4L

Loadless start through suction valve unloaders and

Constant speed unloading through suction valve

Combination control: loadless starting and constant

Suction valve unloaders Charge option Charge option 9

Spec 4 valves w/MC1002 corrosion resistant coating NC NA 4C*

Spec 9 valves w/MC1002 corrosion resistant coating Charge option NA 9C*

Standard

No charge option

Standard

Charge option

Standard

Charge option Charge option 7(a)

Charge option Charge option 8(b)

Charge option Charge option 78(a)(b)

BASE

Piston Ring

and Packing

Material

O-ring Material

Intercooler

Connections

Flywheel

Protective

Coating

Piston Rod

Coating

PTFE piston ring and packing material Standard Standard F

Same as F with the addition of K-ring spacers Charge option Charge option FK

Alloy 50 piston rings and packing material Charge option Charge option G

Same as G with the addition of K-Ring spacers Charge option Charge option GK

PEEK piston ring and alloy 50 packing material Charge option Charge option H

Same as H with the addition of K-Ring spacers Charge option Charge option HK

Aluminum gasket material B

Copper gasket material C

Iron-lead gasket material D

Buna-N A

Neoprene®

Viton®

PTFE and Kalrez®

Weld flanges only, no intercooler Standard NA F

Not applicable - single stage compressor, no

No flywheel supplied N

Standard flywheel S

Coated cylinder only C

No coating N

Coating on all necessary wetted parts W*

Nitride Standard

Charge option Charge option

Standard

No charge optionGasket Material

No charge option

Standard

No charge option

NA Standard N

No charge option

Standard

Charge option

Standard

Charge option

*Must select Protective Coating Option "W" when selecting valve option "4C", or "9C" for the D791 (a) 1 = up to 200 psi or 2 = above 200 psi (discharge pressure) (b) 1 = 30 to 70 psi or 2 = 71 to 150 psi or 3 = 151 to 500 psi (discharge pressure)

Page 21

XXXXXXXXX

hydraulic unloader

unloaders and pilot valve

speed unloading

MODEL NUMBER

Aluminum gasket material

intercooler

NA = Not Available NC = No Charge Option

Registered trademarks of the DuPont company.

Standard

Appendix A—Industrial Vertical Double Acting Model Number Identification Code (T-Style)

BASE MODEL NUMBER T791 T891

Inlet 2" weld 2" weld

Outlet 2" weld 2" weld

Intercooler connection 2" weld NA

Approximate shipping weight (lbs.) 1,030 1,000

SPECIFICATION FIELDS

Packing

Arrangement

Crankcase

Style

Valves

Packing arranged for padding of distance piece G

Packing arranged for purging of distance piece H

Atmospheric inlet or light vacuum service F

Pressure lubricated crankcase M

Std. crankcase with crankcase heater MH

Std. crankcase with cylinder lubricator Charge option Charge option L

Std. crankcase with cylinder lubricator and heater Charge option Charge option LH

Standard suction and discharge valves 4

Standard suction & discharge valves w/ light springs No charge option No charge option 4L

Loadless start through suction valve unloaders and

Constant speed unloading through suction valve

Combination control: loadless starting and constant

Suction valve unloaders Charge option Charge option 9

Spec 4 valves w/MC1002 corrosion resistant coating NC NA 4C*

Spec 9 valves w/MC1002 corrosion resistant coating Charge option NA 9C*

Standard

No charge option

Standard

Charge option

Standard

Charge option Charge option 7(a)

Charge option Charge option 8(b)

Charge option Charge option 78(a)(b)

BASE

Piston Ring

and Packing

Material

Gasket Material

O-ring Material

Intercooler

Connections

Flywheel

Protective

Coating

Piston Rod

Coating

PTFE piston ring and packing material Standard Standard F

Same as F with the addition of K-ring spacers Charge option Charge option FK

Alloy 50 piston rings and packing material Charge option Charge option G

Same as G with the addition of K-Ring spacers Charge option Charge option GK

PEEK piston ring and alloy 50 packing material Charge option Charge option H

Same as H with the addition of K-Ring spacers Charge option Charge option HK

Aluminum gasket material B

Copper gasket material C

Iron-lead gasket material D

Buna-N A

Neoprene®

Viton®

PTFE and Kalrez®

Weld flanges only, no intercooler Standard NA F

Not applicable - single stage compressor, no

No flywheel supplied N

Standard flywheel S

Coated cylinder only C

No coating N

Coating on all necessary wetted parts W*

Nitride Standard N

Charge option Charge option

Standard

No charge option

Standard

No charge option

NA Standard N

No charge option

Standard

Charge option

Standard

Charge option

*Must select Protective Coating Option "W" when selecting valve option "4C", or "9C" for the T791 (a) 1 = up to 200 psi or 2 = above 200 psi (discharge pressure) (b) 1 = 30 to 70 psi or 2 = 71 to 150 psi or 3 = 151 to 500 psi (discharge pressure)

Page 22

Appendix B—Vertical Double-Acting Specifications

Equipment Type & Options

Double-acting, vertical, reciprocating piston type compressor Two-stage configuration (model 791 only) Double packed rod (models D791 & D891); triple packed rod (models T791 & T891) Slip-on weld connections

Features & 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

Material Specifications

Part Standard Material Optional Material

Head, cylinder, cylinder cap Ductile iron ASTM A536

Crosshead guide

Gray iron ASTM A48, Class 30Crankcase, flywheel

Bearing carrier

Flange ASTM A36 carbon steel

Valve seat, bumper 17-7 PH stainless steel

Valve plate 410 stainless steel PEEK

Valve spring 17-7 PH stainless steel

Valve gaskets Soft aluminum Copper, iron-lead

Piston Ductile iron ASTM A536

Piston rod 1045 steel, Nitrotec

Crosshead Ductile iron ASTM A536

Piston rings PTFE, glass and moly filled Alloy 50, PEEK

Piston ring expanders 302 stainless steel

Packing cartridge and barrel

Connecting rod

Segmented packing rings Carbon-filled PTFE

V-ring packing Filled reinforced PTFE

Crankshaft Ductile iron ASTM A536

Connecting rod bearing Bimetal SAE 12 babbit

Wrist pin C1018 steel or equivalent

Wrist pin bushing Bronze SAE J461

Main bearing Tapered roller

Inspection plate Aluminum

O-rings Buna-N PTFE, Viton®1, Neoprene

Retainer rings Steel

Miscellaneous gaskets Rubber compositions

Registered trademarks of the DuPont company.

Ductile iron ASTM A536

®1

Page 23

Appendix B—Vertical Double-Acting Specifications

Specifications and Performance

Specification D791 D891 T791 T891

Bore of cylinder, inches (mm) first stage second stage

Stroke, inches (mm) 4.0 (101.6) 4.0 (101.6) 4.0 (101.6) 4.0 (101.6)

Piston displacement, cfm (m3/hr) minimum @ 400 RPM maximum @ 900 RPM

Maximum working pressure, psig (bar g) first stage second stage

Maximum brake horsepower, kW 45 (34) 45 (34) 45 (34) 45 (34)

Maximum rod load, lb (kg) 7,000 (3,175.2) 7,000 (3,175.2) 7,000 (3,175.2) 7,000 (3,175.2)

Maximum outlet temperature °F (°C) 350 (177 ) 350 (177 ) 350 (177 ) 350 (177)

Bare unit weight, lb (kg) 900 (408.2) 85 5 (3 8 7. 8) 1,060 (480.8) 1,015 (460.4)

6 (152.4)

3.25 (82.5)

51. 2 (87. 0 )

115.3 (196.0)

350 ( 24.1) 600 (41.3)

4.5 (113 ) —

56.6 (96.2)

127.6 (216.8)

46 5 ( 3 2 .1)

—

6 (152.4)

3.25 (82.5)

51. 2 (87. 0 )

115.3 (196.0)

350 ( 24.1)

600 (41.3)

4.5 (113 ) —

56.6 (96.2)

127.6 (216.8)

46 5 ( 3 2 .1)

—

791 & 891 Bolt Torque Values

Specification ft•lb

Connecting rod bolt 40

Bearing carrier 40

Bearing cover 40

Crankcase inspection plate 9

Crosshead guide 65

Cylinder to head

Valve cover plate bolt 37

Valve holddown screw

Piston lock nut torque 150

Piston screw torque 8

Valve cap torque 25

Preliminar y tightening—snug all head bolts in the sequence shown. Final torqueing—torque all head bolts in the sequence shown to the listed value.

Retorque to the listed value after 2–5 hours running time.

Dimensions for honing are included with new bushings (which must be installed, then honed).

1,2

791 & 891 Clearances and Dimensions

Specification Inches

Piston clearance (see Appendix E)

Clearance: connecting rod bearing to

crankshaft journal

Clearance: wrist pin to wrist pin

bushing (maximum)

Cylinder bore diameter (maximum)—

Single stage 891

Cylinder bore diameter (maximum)— First stage 791 Second stage 791

Cylinder finish 16–32 RMS

Piston ring radial thickness (minimum) Single stage 891 First stage 791 Second stage 791

Clearance: oil pump adapter shaft to

bushing (maximum)

Crankshaft end play (cold)

Flywheel runout at O.D. (maximum) 0.020

Clearance: crosshead to crosshead

guide bore (maximum)

Crosshead guide bore finish

0.0013

0.0033

0.001

4.515

6.018

3.260

0.082

0.15 5

0.082

0.0036

0.002

0.003

0.008

32 RMS

(limited

number of

small pits and

scratches are

acceptable)

Page 24

1st stage

Appendix C—Outline Dimensions

Model D791 (Two Stage) Bare Compressor with Flywheel

21-3/16

(53.8)

2nd stage outlet (2" weld flange)

5-5/8

(14.3)

(50.8)

4 (10.2)

2-9/16 (6.5)

1st stage

(2" weld

flange)

inlet

35-5/8

(90.5)

42-7/8

(108.9)

(116.8)

Adjustable head

Suction valve

unloaders

(optional)

1st stage inlet

(2" weld flange)

1/4” NPT

31-3/8

(79.7)

8-1/4

(21)

outlet

(2" weld

flange)

drain

2-1/8

(5.4)

15 (38.1)

4-3/4

(12.1)

5-1/2

(14.1)

13-7/16

(34.1)

14-1/2 (36.8)

Inches (Centimeters)

Crankcase

oil heater

(optional)

1 (2.5)

Four 9/16 (1.4)

diameter

holes

5-3/8

(13.7)

5-3/8

(13.7)

Page 25

Appendix C—Outline Dimensions

Model D891 (Single Stage) Bare with Flywheel

21.2"

(53.8)

(2" weld

flange)

1/4" NPT drain

2-1/8"

(5.3)

Inlet

8-1/4" (20.9)

35-5/8"

(90.4)

valve unloaders

43-1/4" (109.9)

Suction

(optional)

Inlet

(2" weld

flange)

Inlet

pressure

guage

24-15/32"

(62.1)

5-1/2" (13.9)

Outlet

pressure

gauge

Outlet

(2" weld

flange)

Crankcase heater

(optional)

5-5/8" (14.3)

13-1/4"

(33.6)

4-3/4" (12.0)

5-1/2" (13.9)

(2.5)

Inches (Centimeters)

9-16" (1.4)

Hole Diameter

5-3/8" (13.6)

10-1/4"

(26.0)

Page 26

Appendix C—Outline Dimensions

Model D891 (Single Stage) with 103 Mounting

(2″ weld flange)

Inlet

Inches (Centimeters)

″ weld flange)

Outlet

(2″ weld flange)

Inlet

Page 27

Appendix C—Outline Dimensions

Model D891 (Single Stage) with 107B Mounting

Inches (Centimeters)

Page 28

Appendix C—Outline Dimensions

Model D891 (Single Stage) with 109B Mounting

(1.91)

3/4

(60.96)

(5 7.1 5 )

22-1/2

(17.96)

Inches (Centimeters)

(23.07)

9-3/32

7-1/16

3-23/32

(9.45)

3-21/32

(9.31)

Crankcase

oil drain

28 -15/16

5-15/16

(15. 09)

(2 7.1 5)

(73.51)

10-11/16

Belt guard

(16.49)

6-1/2

High liquid level

shutdown switch

1/2" NPT

High liquid level

alarm switch

1/2" NPT

79 -13/32

(201.69)

(172.72)

40 -15 /16

(103.99)

34 -15 /16

(88.75)

2" NPT pipe away

Relief valve

weld neck flange

(1.4 3)

9/16

Drain valve

1" NPT

(1.4 3)

9/16

2" 300# RF

Inlet

FLOW

(31.75)

12-1/2

(68.58)

30-5/64

(7 6.41)

(114 . 3 0)

pressure switch

(optional)

Low oil

pressure

gauge

Inlet

CORKEN

unloaders (optional)

(160.02)

CORKEN CORKEN

Suction valve

(182.88)

Crankcase

(optional)

heater

(13.92)

5-1/2

Outlet 2" weld flange

Outlet pressure gauge

Adjustable driver

slide base

eight 3/4"

anchor

bolts

Use

41-21/ 32

(10 5. 81)

Electric motor driver

Page 29

21-3/16

weld flange)

Appendix C—Outline Dimensions

Model T791 (Two Stage) Bare Compressor with Flywheel

2nd stage

outlet (2″

weld flange)

5-5/8

(14)

4 (10)

2-9/16 (7)

1st stage

weld flange)

inlet (2″

43-5/8

(111 )

50-7/8

(129)

Suction valve

weld flange)

(137)

39-3/8

(100)

unloaders

(optional)

1st stage

inlet (2″

1/4″ NPT

upper

distance

piece

Adjustable

head

1st stage

outlet (2″

1/4″ NPT

lower

distance

piece

(54)

20 (51)

2-1/8 (5)

15 (38)

4-3/4

(12)

5-1/2 (14)

13-3/4 (35)

14-1/2 (37)

Crankcase

oil heater (optional)

Inches (Centimeters)

8-1/4

(21)

1 (3)

Four 9/16″ (1.4)

diameter holes

5-3/8

(14)

5-3/8

(14)

Page 30

Appendix C—Outline Dimensions

Model T891 (Single Stage) Bare Compressor with Flywheel

5-5/8

(14.3)

Inlet

(2″ weld flange)

43-5/8

(110.8)

Suction valve

unloaders

(optional)

Inlet

(2″ weld flange)

1/4″ upper

distance

51-1/4

(130.1)

piece

5-7/16 (13.9)

Outlet (2″

weld flange)

1/4″ NPT

lower

distance

piece

21-3/16

(53.8)

(50.8)

2-1/8 (5.4)

4-3/4 (12.1)

15 (38.2)

5-1/2 (14.1)

13-5/8 (34.5)

14-1/2 (36.9)

Inches (Centimeters)

Crankcase

oil heater (optional)

8-1/4

(21)

1 (2.5)

Four 9/16″ (1.4)

diameter holes

5-3/8

(13.6)

5-3/8

(13.6)

Page 31

Appendix C—Outline Dimensions

Model T891 (Single Stage) with 103 Mounting

(17.78)

(1.91)

3/4

(17.78)

(2″ weld flange)

Beltguard

Inlet

Suction valve unloaders

22-1/2 (57.15)

24 (60.96)

connections

Purge

5-3/4

(3.81)

1-1/2

(1/4″)

(5.08)

Pressure gauge

(Inlet)

(2″ weld flange)

Inlet

Crankcase

oil drain

3-9/16

(9.13)

126.10

49-5/8

(78.74)

Inches (Centimeters)

10 (25.40)

(15.24)

(10.21)

(145.34)

57-1/4

(14.61)

(optional)

Suction valve unloaders

(optional)

(13.92)

5-1/2

Low oil pressure switch

18 (45.72)

(optional)

56 (142.24)

36 (91.44)

Adjustable driver slide base

anchor bolts

Use six 3/4″

Crankcase heater

(optional)

Electric motor driver

Purge connections

(1/4″)

(2″ weld flange)

Outlet

(outlet)

(13.92)

5-1/2

Pressure gauge

Page 32

Appendix D—Troubleshooting

In most cases, problems with your Corken gas compressor can be solved quite simply. This chart lists some of the more frequent problems that occur with reciprocating

Problem Possible Cause

Low capacity 1, 2, 3, 4, 8, 15, 17 Overheating 1, 2, 3, 5, 6, 11, 16 Knocks, rattles and noise 1, 7, 9, 10, 11, 15 Oil in cylinder 8, 12, 15 Abnormal piston-ring wear 1, 3, 5, 6, 11, 15, 16 Product leaking through crankcase breather 8, 15 Product leakage 4, 8, 15, 17 Oil leakage around compressor base 17, 18, 19, 20 No oil pressure 19, 20 Excessive vibration 1, 7, 9, 10, 11, 13, 14, 28 Motor overheating or starter tripping out 21, 22, 23, 24, 25, 26, 27, 28

Ref. Possible Causes What To Do

1. Valves broken, stuck or leaking Inspect and clean or repair

2. Piston ring worn Inspect and replace as necessary

3. Inlet strainer clogged Clean or replace screen as necessar y

4. Leaks in piping Inspect and repair

5. Inlet or ambient temperature too high Consult factory

6. Compression ratio too high Check application and consult factory

7. Loose flywheel or belt Tighten

8. Worn piston-rod packing Replace

9. Worn wrist-pin or wrist-pin bushing Replace

10. Worn connecting-rod bearing Replace

11. Unbalanced load Inspect valve or consult factor y

12. Oil in distance piece Tighten packing nut — drain weekly

13. Inadequate compressor base Strengthen, replace or grout

14. Improper foundation or mounting Tighten mounting or rebuild foundation

15. Loose valve, piston or packing Tighten or replace as necessary

16. Dirty cooling fins Clean weekly

17. 4-way control valve not lubricated Inspect and lubricate

18. Leaking gas blowing oil from crankcase Tighten packing

19. Bad oil seal Replace

20. No oil in crankcase Add oil

21. Oil-pump malfunction See oil pressure adjustment

22. Low voltage Check line voltage with motor nameplate. Consult power company

23. Motor wired wrong Check wiring diagram

24. Wire size too small for length of run Replace with correct size

25. Wrong power characteristics Voltage, phase and frequency must coincide with motor nameplate.

26. Wrong size of heaters in starter Check and replace according to manufacturer’s instructions

27. Compressor overloading Reduce speed

28. Motor shorted out See driver installation

29. Bad motor bearing Lubricate according to manufacturer’s instructions

compressors along with a list of possible causes. If you are having a problem which is not listed, or if you cannot find the source of the problem, consult the factory.

Consult with power company.

Two-Stage Compressor Troubleshooting

Two-stage compressors can have problems that never occur with single-stage machines. Interstage pressure is an important indicator of the condition of a twostage compressor. If interstage pressure is too high:

1. Second stage valves may be broken or leaking.

2. Second stage piston rings may be worn. If interstage pressure is too low:

1. First stage valves may be broken or leaking.

2. First stage piston rings may be worn.

Another cause for high interstage pressure is a low compression ratio. Two-stage machines should not be used in applications where the compression ratio is below 5. To use two-stage compressors in this kind of situation results in rapid ring wear, machine imbalance and excessive horsepower. If you think you have a problem in this area, consult factory.

Page 33

Page 34

Appendix E—D791 and T791 Head and Valve Holddown Assembly Details

Head

First Stage Holddown Assembly (6")

Suction with Unloader Suction (Standard)

See gure A

First Stage Holddown

Assembly (6")

Discharge

CAUTION: Always relieve pressure in the unit before attempting any repairs.

Unloader Piston Assembly Details

Apply Loctite #290

when assembling

Important:

Note seal direction

Figure A

14 (6") 14-1 (3-1/4" )

Second Stage Holddown Assembly (3-1/4")

Suction with Unloader Suction (Standard)

See gure A

27 28

Second Stage Holddown

Assembly (3-1/4")

Discharge

Page 35

Appendix E—D791 and T791 Head and Valve Holddown Assembly Details

First Stage Valve Assembly (6")

Suction Discharge

38 39

Ref

Part No. Description

No.

1. 3665 Adjusting screw nut

2. 2 -127

3. 3867 Cylinder cap

4. 2-250

5. 3663 Adjusting cup

6. 2-24 8

7. 3876 Cylinder head (6")

8. 2-258 O-ring

9. 7001-050 -NC150A

10. 3877 Cylinder head (3-1/4")

11. 2-236

12. 25 98-1

13. 2-031

14. 3696

14-1. 2618

15. 2715 Holddown screw

16. 7001-043-NC150A

17. 176 4 Valve cover plate

18. 2-235

19. 35 70 -1 Valve cage

20. 3694

21. 3695

22. 3694-X Unloader assembly (6")

23. 3732-X Suction valve assembly (6")

24. 2 114

25. 27 14-1 Valve cap

26. 3733-X Discharge valve assembly (6")

27. 2205 Valve cover plate

28. 2-14 3

29. 3569 Valve cage

30. 3689

O-ring

Bolt (1/2–13x1-1/2" hex hd gr 5)(Torque to 65 ft•lbs)

O-ring Unloader cap O-ring Unloader piston (6") Unloader piston (3-1/4")

Bolt (7/16–14x1-1/2" hex hd)(Torque to 37 ft•lbs)

O-ring

Actuator Spring

Valve gasket

O-ring

Actuator

38 39

Second Stage Valve Assembly (3-1/4")

Suction Discharge

Ref

Part No. Description

No.

31. 3690

32. 3689 -X Unloader assembly (3-1/4")

33. 2438-X Suction valve assembly (3-1/4")

34. 1418 -2

35. 2439-X Discharge valve assembly (3-1/4")

36. 3827 Valve seat (6")

37. 3828 Stud

38. 3830

39. 3831

40. 3829

41. 3805-X1 Valve repair kit

42. 3826 Valve bumper (6")

43. 2446 Bolt

44. 2438 Suction valve seat (3-1/4")

45. 2442 Valve plate

46. 2445

47. 3355 Washer

48. 1407 Spring

49. 2440 Suction valve bumper (3-1/4")

50. 2441 Discharge valve bumper (3-1/4")

51. 2439 Discharge valve seat (3-1/4")

52. 1910

53. 2619 -X

54. 2857

55. 2858

_ denotes O-ring code. See O-ring chart for details.

Included with valve assembly.

Included with unloader assembly.

Included with valve repair kit.

Install spacers back to back.

Registered trademark of the DuPont company.

Spring

Valve gasket

Outer valve plate Inner valve plate Spring

Spacer (two per valve)

Bolt Unloader piston seal assembly Unloader piston cap Gasket

O-ring Code

A Buna-N B Neoprene D Viton E PTFE K Kalrez

®f

Page 36

Appendix E—D891 and T891 Head and Valve Holddown Assembly Details

Head Holddown Assembly (4-1/2")

CAUTION: Always relieve pressure in the unit before attempting any repairs.

Suction with Unloader Suction (Standard)

See gure A

Holddown Assembly (4-1/2")

Discharge

Unloader Assembly Part Details

Apply Loctite #290

when assembling

Important:

Note seal direction

Figure A

Valve Assemblies (4-1/2")

Suction Valve Discharge Valve

23 24

Page 37

Appendix E—D891 and T891 Head and Valve Holddown Assembly Details

Compressor Head and Valve Bill of Materials

Ref

Part No. Description

No.

1. 3923 Cylinder cap

2. 3 924 Cylinder head (4-1/2")

3. 2-246

4. 7001-050 NC150A

5. 259 8 -1

6. 2-031

7. 3696

O-ring Bolt (1/2 - 13 x 1-1/2" hex head Gr 5)

(Torque to 65 ft•lbs)

Unloader cap O-ring Unloader piston

8. 2715 Holddown screw

9. 7001-043 NC150A

Bolt (7/16 - 14 x 1-1/2" hex head)( Torque to 37 ft•lbs)

10. 176 4 Valve cover plate

11. 2-235

O-ring

12. 3570 -1 Va lve cage

13. 3694

14. 3695

Actuator Spring

15. 3694-X Unloader assembly (4-1/2")

16. 3732-X Suction valve assembly (4-1/2")

17. 2114

Valve gasket

Ref

Part No. Description

No.

18. 2714-1 Valve cap

19. 3569 Valve cag e

20. 3733 -X Discharge valve assembly (4-1/2")

21. 3827 Valve seat (4-1/2")

22. 3828 Stud

23. 3830

24. 3 831

25. 3829

Valve plate (outer) Valve plate (inner) Spring

26. 3826 Valve bumper (4-1/2")

27. 3805-X1 Valve repair kit

28. 1910

29. 2619-X

30. 2857

31. 2858

_ denotes O-ring code. See O-ring chart below for details.

Included with valve assembly

Included with unloader assembly

Included with valve repair kit.

Registered trademark of the DuPont company.

Bolt Unloader piston seal assembly Unloader piston cap Gasket

O-ring Code

A Buna-N

B Neoprene

D Viton

®e

E PTFE

K Kalrez

®e

Page 38

(

)

Appendix E—D791, T791, D891 and T891 Piston Assembly Details

Piston Assembly Bill of Materials

Part No.

Ref.

D/T791 1st Stage

No.

10. 3812 (not shown) Loctite tube (620) 1

MC1002 coated piston and cap available. Add “C” to end of a standard par t number (e.g. 3562C)

3879-X1 (6")

1. 7002-025-TP100A 7002-010-TP100A 7002-025-TP100A

2. 3562

5. 1753 1757 1740 Expander ring 4

6. 3604

7. 3730 Thrust washer 2

8. (6" diameter)

3625 3731 2902 Shim washer (thick)

3625-1 3731-1 2902-1 Shim washer (thin)

1752 1756 1739 Piston rings

1752-3 1756-3 1739-3 Peek rings (opt.)

3879a

D/T791 2nd

Stage

388 4 -X1 (3-1/4")

3561

3884a

(3-1/4" diameter)

3603 Shim washer (thick)

3603-1 Shim washer (thin)

D/T891

3925-X1 (4-1/2")

3927

3925a

(4-1/2" diameter)

Description Qty

Screw, orlo gr. 8 (torque to 8 ft•lbs)

Piston cap 1

Lock nut (torque to 150 ft•lbs)

Piston 1

req.

41752-2 1756-4 1739-2 Alloy 50 rings (opt.)

req.

Piston Rod

Piston Clearance (Cold)

Model (Y) Bottom Min.c(Y) Bottom Max.c(X) Top Min.

D791/D891 0.010" (0.25 mm) 0.020" (0.50 mm) 0.084" (2.13 mm) 0.104" (2.64 mm)

T791/T891 0.005" (0.13 mm) 0.015" (0.38 mm) 0.089" (2.26 mm) 0.109" (2.77 mm)

The distance from the bottom of the head to the top of the piston.

The distance from the bottom of the piston to the top of the packing barrel.

CAUTION: Always relieve pressure in the unit before attempting any repairs.

(X) (

Piston

) (Y)

Piston

(X) Top Max.

Piston

Piston bottom dead center

Piston top dead center

Page 39

Appendix E—D791, T791, D891 and T891 Connecting Rod and Crosshead Assembly Details

Note

alignment

marks

Connecting Rod and Crosshead Assembly

Bill of Materials

Ref

Part No. Description

No.

354 4-X3 Crosshead assembly (D791, D891)

354 4-X9 Crosshead assembly (T791, T891)

3544-X10

2. 3590 Retainer ring

3. 1726

5. 1727

6. 3540 Wrist pin

7. 3541

8. 3542

Included with connecting rod assembly

Torque connecting rod nut to 40 ft. lbs.

Must be rebored after replacing (1.1258/1.1254 dia.)

Not sold separately

Never attempt to separate the piston rod and crosshead. When repair becomes necessary, the entire crosshead assembly must be replaced.

3785-X1 Connecting rod assembly

a,d

3785

a,b

a,c

Crosshead assembly—coated piston rod (T791, T891)

Bolt

Connecting rod

Nut

Wrist pin bushing

Connecting rod bearing

CAUTION: Always relieve pressure in the unit before attempting

any repairs.

Page 40

Appendix E—D791 and D891 Packing Assembly Details

Specification “K”Specification “J”

Upper

Segmented

Packing

Set

5.1

3 4

Radial

Tangent

Radial

Tangent

Radial

Tangent

Tangent Tangent

3 4

Radial

Tangent

Radial

Tangent

Radial

Tangent

Tangent Tangent

Upper

Segmented

Packing

Set

Lower V-ring

Packing

Set

V-ring Packing Direction

Lower Packing

Specification

“J”

To Crankcase

Lower Packing

Specification

“K”

To Crankcase

Lower V-ring

Packing

Set

Page 41

Appendix E—D791 and D891 Packing Assembly Details

Segmented Packing for

Segmented packing for

Upper

Segmented

Packing

Set

Specification “R”

3 4

5.1

3 4

5.1

3 4

5.1

Tan g ent Tan g ent

Packing Assembly Bill of Materials

Ref

Part No. Description

No.

3886 Packing barrel (3-1/4")(791 second stage)

3887 Packing barrel (6")(791 rst stage) 3926 Packing barrel (4-1/2")(891 only)

2. 3906 Crush gasket

3. 3817

4. 2-036_

a,c,d

5. 3810

5.1. 3814

6. 3811 Back-up ring

7. 7002-025OC100A Screw (1/4-20 x 1" socket head)

8. 3885 Cartridge

9. 1732

10. 5000-175 Retainer ring

11. 172 8 Washer

12. 1731 Spring

13. 1724 Male packing ring

14. 17 25 V-ring packing

15. 1723 Female packing ring

16. 3810-X1

17. 1725 -2X V-ring packing set

Identification of Packing Specification

Example: Model Number D891 K M4FBA

Packing Spec.

Specification “J” & “K”

Piston (Pressure) Side

Packing cup (Not included in 3810-X1 packing set)

Cup O-ring Segmented packing

(radial—tangent) pair Segmented packing

(tangent—tangent) pair

Oil deector ring

Segmented packing set

Specification “J”, “K”, & “R”

Piston (Pressure) Side

17 Lower V-ring

Packing

Set

V-ring

Packing

Direction

Lower Packing

Specification

“R”

To Crankcase

O-ring Code

A Buna-N B Neoprene D Viton E PTFE K Kalrez

®e

Radial Cut

(without pin)

Tangent Cut

(with pin)

Back-up

ring

To Crankcase

Align pin

with hole

Tangent Cut (without pin)

Tangent Cut

(with pin)

Back-up

ring

To Crankcase

IMPORTANT: Identify and line up the rings before installing. Be sure they face the way shown here and that the pin and hole are aligned when assembled.

_ denotes O-ring code. See O-ring chart for details.

Deflector ring is loose within the packing cartridge until fitted on the piston rod. Must be put in from the bottom of the cartridge.

Starting with S.N. NN51397.

Packing cup O-ring not included in packing set.

Registered trademark of the DuPont company.

Align pin

with hole

Page 42

Appendix E—T791 and T891 Packing Assembly Details

Specification “H”Specification “G”

Upper

Segmented

Packing

Set

Middle

V-ring

Packing

Set

11 13

14 15

3 4

5 6 3 4 5 6 3 4 5

6 3

4 7

Radial Tangent

Tangent Tangent

Upper

Segmented

Packing

Set

V-ring Packing Direction

Middle Packing

Specification

“G”

Middle Packing

Specification

“H”

2 3 4

5 6

3 4 5

6 3

4 5

6 3 4

Radial

Tangent

Radial

Tangent

Radial

Tangent

Tangent Tangent

15 14 13

Packing

Middle

V-ring

Set

19 Lower V-ring

Packing

Set

To Crankcase

Lower Packing

Specification

“G”

To Crankcase

PTFE Locking Device

To Crankcase

Lower Packing

Specification

To Crankcase

“H”

16 20

10 11

Lower

V-ring

Packing

Set

PTFE Locking Device

Page 43

Appendix E—T791 and T891 Packing Assembly Details

Segmented Packing for

Segmented packing for

Upper

Segmented

Packing

Set

Middle

V-ring

Packing

Set

Specification “F”

2 3

4 7 6 3 4 7 6 3 4

6 3 4

14 15

Tangent Tangent

V-ring

Packing

Direction

Middle Packing

Specification

“F”

To Crankcase

Lower Packing

Specification

“F”

Packing Assembly Bill of Materials

Ref

Part No. Description

No.

3886 Packing barrel (3-1/4")(791 second stage)

3887 Packing barrel (6")(791 rst stage) 3926 Packing barrel (4-1/2")(891 only)

2. 3906 Crush gasket

3. 3817

4. 2-036_

a,c,d

5. 3810

6. 3811 Back-up ring

7. 3814

8. 4748 Packing adapter

9. 7002-025OC100A Screw (1/4-20 x 1" socket head)

10. 5000-175 Retainer ring

11. 172 8 Washer

12. 1731 Spring

13. 1724 Male packing ring

14. 17 25 V-ring packing

15. 1723 Female packing ring

16. 474 6 Cartridge

17. 1722-X Adjusting screw

18. 3810-X1

19. 172 5 -2X V-ring packing set

20. 1732 Oil deector ring

Identification of Packing Specification

Example: Model Number T891 G L4FBDNSNC

Packing Spec.

Specification “F” & “G”

Piston (Pressure) Side

Radial Cut

(without pin)

Tangent Cut

(with pin)

Back-up

ring

Packing cup (Not included in 3810-X1 packing set)

Cup O-ring Segmented packing

(radial—tangent) pair

Segmented packing (tangent—tangent) pair

Segmented packing set

Specification “F”, “G”, & “H”

Piston (Pressure) Side

Tangent Cut

Align pin

with hole

(without pin)

Tangent Cut

(with pin)

Back-up

ring

Align pin with hole

Lower

V-ring

Packing

Set

PTFE Locking Device

To Crankcase

O-ring Code

A Buna-N B Neoprene D Viton

®e

E PTFE K Kalrez

®e

To Crankcase

IMPORTANT: Identify and line up the rings before installing. Be sure they face the way shown here and that the pin and hole are aligned when assembled.

_ denotes O-ring code. See O-ring chart for details.

Deflector ring is loose within the packing cartridge until fitted on the piston rod. Must be put in from the bottom of the cartridge.

Starting with S.N. NN51397.

Packing cup O-ring not included in packing set.

Registered trademark of the DuPont company.

Page 44

Appendix E—D791 Crosshead Guide Assembly Details

Crosshead Guide Bill of Materials

Ref

Part No. Description Qty

No.

1. 3866 Cylinder 1

2. 3442 Pipe plug (1/4" NPT) 10

3. 1054 Drain valve (lubricated models) 1

Packing barrels and cartridges (For parts details, see D791 packing on previous pages).

4. 1071 Nipple (1/4" x close) 1

5. 2-258_

5-1. 2-236_

6. 7001-050NC175A

7. 3793-2S Flange (inlet/outlet) 4

8. 2-231_

9. 3253 Roll pin 1

10. 240 5 -1 Crosshead guide 1

11. 10 64 Elbow (1/4" NPT) 1

12. 7005-050175A Bolt (1/2" 13 x 1-3/4" ferry head) 16

13. 1761 Gasket (crankcase) 1

14. 176 0 Gasket (inspection cover) 1

15. 1721 Inspection cover 1

16. 7012-010NC025B Bolt (10 - 24 x 1/4" Phillips hd.) 10

17. 2-231_

O-ring for cylinder (1st stage) 1

O-ring for cylinder (2nd stage) 1

Bolt (1/2" - 13 x 1-3/4" hex head gr 5)

O-ring for ange 4

O-ring 2

O-ring Code

A Buna-N

B Neoprene

D Viton

E PTFE

K Kalrez

_ denotes O-ring code. See O-ring chart above for details.

Registered trademark of the DuPont company.

CAUTION: Always relieve pressure in the unit before attempting any repairs.

NOTE: Packing barrel installation:

1. Use packing installation cone #3905 on the piston rod.

2. Insert small barrel first, use finger holes to align slinger ring on to the rod. Slip the packing barrel into place.

3. Align pin with slot in large packing barrel.

4. Slip large packing barrel in place.

®b

Page 45

Appendix E—D891 Crosshead Guide Assembly Details

Crosshead Guide Bill of Materials

Ref

Part No. Description Qty

No.

1. 3922 Cylinder 1

2. 3442 Pipe plug (1/4" NPT) 6

3. 1054 Drain valve (lubricated models) 1

Packing barrels and cartridges (For parts details, see D891 packing on previous pages).

4. 1071 Nipple (1/4" x close) 1

5. 2-24 6_

6. 7001-050NC175A

7. 3793-2S Flange (inlet/outlet) 2

8. 2-231_

9. 3253 Roll pin 1

10. 240 5 -1 Crosshead guide 1

11. 10 64 Elbow (1/4" NPT) 1

12. 7005-050175A Bolt (1/2" 13 x 1-3/4" ferry head) 16

13. 1761 Gasket (crankcase) 1

14. 176 0 Gasket (inspection cover) 1

15. 1721 Inspection cover 1

16. 7012-010NC025B Screw (10 - 24 x 1/4" Phillips hd.) 10

17. 2-231_

O-ring for cylinder 2

Bolt (1/2"- 13 x 1-3/4" hex head gr 5)

O-ring for ange 2

O-ring 2

O-ring Code

A Buna-N

B Neoprene

D Viton

E PTFE

K Kalrez

_ denotes O-ring code. See O-ring chart above for details.

Registered trademark of the DuPont company.

CAUTION: Always relieve pressure in the unit before attempting any repairs.

NOTE: Packing barrel installation:

1. Use packing installation cone #3905 on the piston rod.

2. Insert small barrel first, use finger holes to align slinger ring on to the rod. Slip the packing barrel into place.

3. Align pin with slot in large packing barrel.

4. Slip large packing barrel in place.

®b

Page 46

Appendix E—T791 Crosshead Guide Assembly Details

Crosshead Guide Bill of Materials

Ref

Part No. Description Qty

No.

1. 3866 Cylinder 1

2. 3442 Pipe plug (1/4" NPT) 16

3. 1054 Drain valve (lubricated models) 1

4. 1071 Nipple (1/4" x close) 1

5. 2-258_

5-1. 2-236_

6. 7001-050NC175A

7. 3793-2S Flange (inlet/outlet) 4

8. 2-231_

9. 3253 Roll pin 1

10. 1716 - 4 Crosshead guide 1

11. 7005-050175A Bolt (1/2" 13 x 1-3/4" ferry head) 16

12. 1748 Cartridge plate 2

13. 5000-350 Retainer ring 2

14. 1761 Gasket (crankcase) 1

15. 176 0 Gasket (inspection cover) 1

16. 1721 Inspection cover 1

17. 7012-010NC025B Bolt (10 - 24 x 1/4" Phillips hd.) 10

18. 2-238_

19. 1749 Cartridge holddown screw 2

20. 4747 Cage 2

21. 2-233_

22. 17 32 Oil deector ring 2

O-ring for cylinder (1st stage) 1

O-ring for cylinder (2nd stage) 1

Bolt (1/2" 13 x 1-3/4" hex head gr 5)

O-ring for ange 4

O-ring 2

Packing barrels

and cartridges (For parts details, see T791 packing on previous pages).

5-1

O-ring Code

A Buna-N

B Neoprene

D Viton

E PTFE

K Kalrez

_ denotes O-ring code. See O-ring chart above for details.

Registered trademark of the DuPont company.

CAUTION: Always relieve pressure in the unit before attempting any repairs.

NOTE: Packing barrel installation:

1. Use packing installation cone #3905 on the piston rod.

2. Insert small barrel first, use finger holes to align slinger ring on to the rod. Slip the packing barrel into place.

3. Align pin with slot in large packing barrel.

4. Slip large packing barrel in place.

®b

Page 47

Appendix E—T891 Crosshead Guide Assembly Details

Crosshead Guide Bill of Materials

Ref

Part No. Description Qty

No.

1. 3922 Cylinder 1

2. 3442 Pipe plug (1/4" NPT) 12

3. 1054 Drain valve (lubricated models) 1

Packing barrels and cartridges (For parts details, see T891 packing on previous pages).

4. 1071 Nipple (1/4" x close) 1

5. 2-24 6_

6. 7001-050NC175A

7. 3793-2S Flange (inlet/outlet) 2

8. 2-231_

9. 3253 Roll pin 1

10. 1716 - 4 Crosshead guide 1

11. 7005-050175A Bolt (1/2" 13 x 1-3/4" ferry head) 16

12. 1748 Cartridge plate 2

13. 5000-350 Retainer ring 2

14. 1761 Gasket (crankcase) 1

15. 176 0 Gasket (inspection cover) 1

16. 1721 Inspection cover 1

17. 7012-010NC025B Bolt (10 - 24 x 1/4" Phillips hd.) 10

18. 2-238_

19. 1749 Cartridge holddown screw 2

20. 4747 Cage 2

21. 2-233_

22. 17 32 Oil deector ring 2

O-ring for cylinder 2

Bolt (1/2" 13 x 1-3/4" hex head gr 5)

O-ring for ange 2

O-ring 2

O-ring Code

A Buna-N

B Neoprene

D Viton

E PTFE

K Kalrez

_ denotes O-ring code. See O-ring chart above for details.

Registered trademark of the DuPont company.

CAUTION: Always relieve pressure in the unit before attempting any repairs.

NOTE: Packing barrel installation:

1. Use packing installation cone #3905 on the piston rod.

2. Insert small barrel first, use finger holes to align slinger ring on to the rod. Slip the packing barrel into place.

3. Align pin with slot in large packing barrel.

4. Slip large packing barrel in place.

®b

Page 48

except #52 and #53)

Adapter

location of pump cover pin.

Appendix E—Crankcase Assembly Details

63 (Pipe plug on under side of

crankcase is not shown)

(Includes all parts shown

Inside of

Bearing Carrier

Oil Passage Hole

Important! Line up hole in

gasket with oil passage hole.

Pump Cover Oil/Filter

Pumpside of adapter shown for

proper orientation of cover and

Page 49

Appendix E—Crankcase Assembly Details

Crankcase Assembly Bill of Materials

Ref

Part No. Description

No.

1. 1737 Bearing cone

2. 3638 Spacer

3. 3635 Drive sprocket

4. 1284 Crankshaft orifice

5. 213 5 Drive pin

6. 2933 Link pin

7. 3786 Crankshaft

8. 3503 Flywheel key

9. 3580 Bearing cone

10. 3786 -X1 Crankshaft assembly

11. 7001-031N C075A Bolt (5/16 - 18 x 3/4" hex head)

12. 2122 Inspection cover

13. 2123 Gasket, inspection cover

14. 2-112 _

O-ring

15. 3225-X1 Oil bayonet assembly (w/O-ring)

16. 2126 Breather ball

17. 3579 Bearing cup

3589 Bearing adjustment shim (.005")

35 8 9-1 Bearing adjustment shim (.007")

18.

3589-2 Bearing adjustment shim (.020")

19. 3539 Bearing cover

20. 3526 Oil seal

21. 1280 Filter screw

22. 1281 Gasket, filter

23. 2-116 _

O-ring

24. 1276 Washer

25. 1275 Oil filter screen

26. 3443 Pipe plug (1/2" NPT steel)

27. 3221 Crankcase

28. 7001-037NC100A Bolt (3/8 - 16 x 1" hex head Gr. 5)

29. 3875 Access cover

30. 7003-025NC037E Screw (1/4 - 20 x 3/8")

31. 38 74 Gasket (access cover)

32. 1515 -X Closure cap assembly

33. 7001-025NC050A Bolt (1/4 - 20 x 1/2" hex head)

34. 1515 Closure cap

35. 1516 Closure body

36. 2-118 _

O-ring

37. 129 0 Relief valve adjusting screw

38. 2-011 _

O-ring

39. 1291 Adjusting screw locknut

40. 129 2 Relief valve spring

41. 1293 Relief valve ball

42. 4222-X

43. 2-228 _

44. 284 9 -1X

Oil filter adapter assembly (w/pin)

O-ring

Oil pump assembly

45. 28 51 Spring guide

46. 2852 Oil pump spring

Ref

Part No. Description

No.

47. 3219 Pump shaft adapter

48. 2-112 _

49. 2805-X

O-ring

Pump shaft bushing

50. 162 9 Pipe plug (1/16 NPT fl. seal)

51. 173 6 Bearing cup

52. 13 02 Oil pressure gauge

53. 104 4 Bushing (1/8 x 1/4 NPT)

54. 3220-2 Bearing carrier

55. 3289 Pipe plug (1/4 NPT fl. seal)

56. 2131 Bearing carrier gasket

57. 2961-X Air release valve assembly

58. 2590 Pipe plug (1/8 NPT fl. seal)

59. 4225 Filter

60. 2798 Pump cover pin (included w/4222-X)

61. 3220-2X Bearing carrier assembly

62. 4222 Oil filter adapter

63. 3289 Pipe plug (1/4" x 18 NPTF x 7/8")

Assembly Number

Assembly Name

3221-X1 Crankcase assembly (M, 4, 8, 9) without lubricator

3221-X2 Crankcase assembly (M7, 78) without lubricator

3221-X3 Crankcase assembly (L, 4, 8, 9) with lubricator

3221-X4 Crankcase assembly (L7, 78) with lubricator

O-ring Code

A Buna-N

B Neoprene

D Viton

®b

E PTFE

K Kalrez

Must be rebored and honed after replacing (0.876"/0.875" diameter)

Caution: To avoid damage during assembly, refer to installation Instruction Manual IE400.

_ denotes O-ring code. See O-ring chart above for details.

Registered trademark of the DuPont company.

®b

CAUTION: Always relieve pressure in the unit before attempting any repairs.

Page 50

Back Side

Front Side

Appendix E—Flywheel Assembly Details

Flywheel Assembly Bill of Materials

Assembly Number

3852-X

3852 Flywheel: 21.2" O.D., 5 groove

H J - 2 .12 5

Assembly Name

Flywheel assembly (flywheel, hub, and three bolts)

Hub with three bolts and lockwashers

Page 51

Page 52

Solutions beyond products...

CORKEN, INC. • A Unit of IDEX Corporation

3805 NW 36th Street, Oklahoma City, OK 73112

Phone (405) 946-5576 • Fax (405) 948-7343

Visit our website at www.corken.com

or e-mail us at cocsalesdept@idexcorp.com

@CorkenInc

Printed in the U.S.A.

January 2019

Corken D791, T791, T891, D891 Installation, Operation & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual