Corken F291, F491, F91, 91, 291 Installation, Operation & Maintenance Manual

IE101H

Installation, Operation

& Maintenance Manual

Liquid Transfer-Vapor Recovery Compressors

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 qualied 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, ammable or explosive substances using Corken products is at user’s risk and
equipment should be operated only by qualied personnel according to applicable laws and safety standards.

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 WA RRANTY OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE, ARE EXPRESSLY NEGATED TO THE EXTENT PERMITTED BY LAW AND
SHALL IN NO EVENT EXTEND BEYOND THE EXPRESSED WARRANTY PERIOD.

Corken disclaims any liability for consequential damages due to breach of any written or implied warranty on Corken
products. Transfer of toxic, dangerous, flammable or explosive substances using Corken products is at the user’s
risk. Such substances should be handled by experienced, trained personnel in compliance with governmental and
industrial safety standards.

Contacting The Factory

For your convenience, the model number and serial number are given on the compressor nameplate. Space is
provided below for you to keep a written record of this information.

ALWAYS INCLUDE THE MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS.

Model No.

Serial No.

Date Purchased

Date Installed

Purchased From

Installed By

IMPORTANT NOTE TO CUSTOMERS!

CORKEN, INC. does not recommend ordering parts from general descriptions in this manual. To minimize
the possibility of receiving incorrect parts for your machine, Corken strongly recommends you order parts
according to part numbers in the Corken Service Manual and/or Installation, Operation, & Maintenance
(IOM) Manual. If you do not have the appropriate service manual pages, call or write Corken with model
number and serial number from the nameplate on your compressor.

2

Table of Contents

CHAPTER 1—INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 4

1.1 Liquid Transfer by Vapor Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 Residual Vapor Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3 Compressor Construction Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CHAPTER 2—INSTALLING YOUR CORKEN COMPRESSOR .................................... PAGE 8

2.1 Location .................................................................................8

2.2 Foundation ...............................................................................8

2.3 Piping ...................................................................................8

2.4 Liquid Traps .............................................................................10

2.5 Driver Installation / Flywheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.6 Crankcase Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.7 Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.8 Truck Mounted Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.9 Shutdown/Alarm Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

CHAPTER 3—STARTING UP YOUR CORKEN COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 14

3.1 Inspection After Extended Storage ...........................................................14

3.2 Flywheel and V-belt Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.3 Crankcase Oil Pressure Adjustment ..........................................................14

3.4 Startup Checklist .........................................................................15

CHAPTER 4—ROUTINE MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 16

CHAPTER 5—ROUTINE SERVICE AND REPAIR PROCEDURES .................................PAGE 17

5.1 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5.2 Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.3 Piston Rings and Piston Ring Expanders ......................................................19

5.4 Pistons .................................................................................19

5.5 Piston Rod Packing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.6 Cylinder and Packing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.7 Bearing Replacement for Crankcase and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.7.1 Wrist Pin Bushing Replacement ........................................................22

5.7.2 Replacing Connecting Rod Bearings ....................................................22

5.7.3 Replacing Roller Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.8 Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.9 Servicing the Four-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

CHAPTER 6—EXTENDED STORAGE PROCEDURES ......................................... PAGE 25

APPENDICES

A. Repair Kits and Gasket Sets .............................................................26–27

B. Model Number and Mounting Identification Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28–29

C. Operating and Material Specifications, Bolt Torque Values, Clearance and Dimensions . . . . . . . . . . . . . . 30–35

D. Compressor Selection

Mounting Selections .................................................................36

Butane ............................................................................37

Propane ...........................................................................38

Ammonia ..........................................................................39

E. Outline Dimensions ....................................................................40–50

F. Troubleshooting ..........................................................................51

G. Model 91 and F91 Parts Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52–59

H. Model 291 and F291 Parts Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 – 67

I. Model 490, 491, and F491 Parts Details ....................................................68–75

J. Model 691 and F691 Parts Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76–83

K. Model D891 Parts Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84–93

3

Chapter 1—Introduction

Threaded and ANSI flanges:

Compressors are available in either threaded NPT,
ANSI, or DIN flanged connections.

High-efficiency valves:

Corken valves offer quiet operation and high
durability in oil-free gas applications. Specially
designed suction valves which tolerate small
amounts of condensate are used in liquid transfer­vapor recovery compressors.

O-ring head gaskets:

Easy to install O-ring head gaskets providing highly
reliable seals.

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.

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.

Nameplate:

Serves as packing adjusting screw cover (see
figure 1.1A).

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 (not available on
Model 91).

Construction Details—Model F291 Compressor

4

Compressor reduces
pressure in storage tank
by removing vapor

Compressor increases
pressure in tank car by
adding vapor

Pressure difference between
tanks causes liquid to flow out of
the tank car into the storage tank

Four Way Valve Position 1

Vapor Line

Vapor Line

Liquid Line

Figure 1.1A: Typical Nameplate

(Also Serves as the Packing Adjusting Screw Cover)

1.1 Liquid Transfer By Vapor
Differential Pressure

Corken LPG/NH3 com pres sors are designed to
transfer liquefied gases such as butane/propane
mixtures (liquefie d petrole um gas or LPG) and
Anhydrous Ammonia (NH3) from one tank to another.
Liquefied gases such as LPG & NH3 are stored in
closed containers where both the liquid and vapor
phases are present.

this by withdrawing vapors from the storage tank,
compressing them and then discharging into the tank
to be unloaded. This procedure slightly decreases the
storage tank pressure and increases the pressure in
the other tank, thereby causing the liquid to flow.

The process of compressing the gas also increases the
temperature, which aids in increasing the pressure in the
tank being unloaded.

1.2 Residual Vapor Recovery

The principle of residual vapor recovery is just the
opposite of liquid transfer. After the liquid has been
transferred, the four-way control valve (or alternate
valve manifolding) is reversed so that the vapors are
drawn from the tank just unloaded and discharged into
the receiving tank. Always discharge the recovered
vapors into the liquid section of the receiving tank.
This will allow the hot, compressed vapors to condense,
preventing an undesirable increase in tank pressure (see
figure 1.2A).

There is a piping connection between the vapor
sections of the storage tank and the tank being
unloaded, and there is a similar connection between the
liquid sections of the two tanks. If the connections are
opened, the liquid will seek its own level and then flow
will stop; however, by creating a pressure in the tank
being unloaded which is high enough to overcome pipe
friction and any static elevation difference between the
tanks, all the liquid will be forced into the storage tank
(see figure 1.1B). The gas compressor accomplishes

Residual vapor recovery is an essential part of the value
of a compressor. There is an economical limit to the
amount of vapors that should be recovered, however.

When the cost of operation equals the price of the product
being recovered, the operation should be stopped.
For most cases in LP Gas and Anhydrous Ammonia
services, this point is reached in the summer when the
compressor inlet pressure is 40 to 50 psig (3.8 to 4.5
bars). A good rule of thumb is not to operate beyond

Figure 1.1B: Liquid transfer by vapor differential pressure

5

Vapor is
bubbled
through liquid to
help cool and
recondense it

Removing vapor from
tank causes liquid heel
to boil into vapor

Liquid line is valved closed
during vapor recovery.

Four Way Valve Position 2

Liquid Heel

Vapor Line

Vapor Line

Figure 1.2A: Residual Vapor Recovery

the point at which the inlet pressure is one-fourth the
discharge pressure. Some liquids are so expensive that
further recovery may be profitable, but care should be
taken that the ratio of absolute discharge pressure to
absolute inlet pressure never exceeds 7 to 1. Further
excavation of very high value products would require a
Corken two-stage gas compressor.

Invariably, there is some liquid remaining in the tank
after the liquid transfer operation. This liquid “heel”
must be vaporized before it can be recovered, so do not
expect the pressure to drop immediately. Actually, more
vapor will be recovered during the first few minutes
while this liquid is being vaporized than that during the
same period of time later in the operation. Remember
that more than half of the economically recoverable
product is usually recovered during the first hour of
operation on properly sized equipment.

1.3 Compressor
Construction Features

The Corken liquid transfer-vapor recovery compressor
is a vertical single-stage, single-acting reciprocating
compressor designed to handle flammable gases like LPG
and toxic gases such as ammonia. Corken compressors
can handle these potentially dangerous gases because
the LPG/NH3 is confined in the compression chamber
and isolated from the crankcase and the atmosphere.
A typical liquid transfer-vapor recovery compressor
package is shown in figure 1.3A.

Figure 1.3A: 107-Style Compressor Mounting

Corken gas compressors are mounted on oil lubricated
crankcases that remain at atmospheric pressure.
Crankshafts are supported by heavy-duty roller bearings
and the connecting rods ride the crankshaft on journal
bearings. With the exception of the small size model 91
compressor, all compressor crankcases are lubricated by
an automotive type oil pressure system. An automatically
reversible gear type oil pump circulates oil through

6

Gasket

Adjusting
screw

Relief ball spring

Relief ball

Suction valve
seat

Valve plate

Spacers
Washer

Spacers

Washer

Valve spring

Suction valve
post

Suction valve
bumper

Valve gasket

Gasket

Bolt

Discharge valve
bumper

Valve spring

Valve plate

Discharge valve
seat

Valve gasket

Suction Valve

Spec 3

Discharge Valve

All Specs

passages in the crankshaft and connection rod to
lubricate the journal bearings and wrist pins (see figure

1.3B). Sturdy iron crossheads transmit reciprocating
motion to the piston.

Corken’s automatically reversible oil pump design
allows the machine to function smoothly in either
direction of rotation.

Corken compressors use iron pistons that are locked
to the piston rod. The standard piston ring material is a
glass-filled PTFE polymer specially formulated for non­lubricated services. Piston ring expanders are placed
behind the rings to ensure that the piston rings seal
tightly against the cylinder wall.

Piston rod packing is used to seal the gas in the
compression chamber and prevent crankcase oil from
entering the compressor cylinder. The packing consists
of several PTFE V-rings sandwiched between a male and
female packing ring and held in place by a spring (see
figure 1.3C).

The typical Corken compressor valve consists of a seat,
bumper, one or more spring/s and one or more valve/s
discs or plates as shown in figure 1.3D. Special heat­treated alloys are utilized to prolong life of the valve in
punishing non-lubricated services. The valve opens
whenever the pressure on the seat side exceeds the
pressure on the spring side.

Figure 1.3C: Compressor Sealing System

Figure 1.3B: Pressure Lubrication System

(Not Available on Model 91)

Figure 1.3D: Suction and Discharge Valves

7

Ground level

Concrete

foundation

Baseplate should be

a maximum of 4″ high

Grouted
baseplate

Pipe support

Pipe support

Flexible connections

Flexible connections

Chapter 2—Installing Your Corken Compressor

2.1 Location

NOTE: Compressor must be installed in a well
ventilated area.

Corken compressors are designed and manufactured for
outdoor dut y. For applications where the compress or 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. A minimum of 18
inches (45 cm) clearance between the compressor and the
nearest wall is advised to make it accessible from all sides
and to provide unrestricted air flow for adequate cooling.

NOISE. Corken vertical compressors sizes model 91
through 891 should not exceed an 85 DBA noise level
when properly installed.

2.2 Foundation

Proper foundations are essential for a smooth running
compression system. Corken recommends the compressor
be attached to a concrete slab at least 8 in. thick with a 2
in. skirt around the circumference of the baseplate. The
baseplate should be securely anchored into the foundation
by 1/2 in. diameter “J” bolts 12 in. long. Four bolts should

be used for models 91, 291, and 491. Six bolts should
be used for model 691. The total mass of the foundation

should be approximately twice the weight of the compressor
system (compressor, baseplate, motor, etc.).

After leveling and bolting down baseplate, the volume
beneath the channel iron baseplate must be grouted
to prevent flexing of the top portion
of the baseplate and the “J” bolt that
extends beyond the foundation. The
grout also improves the dampening
capabilities of the foundation by
creating a solid interface between the
compressor and foundation.

2” MIN.

ALL SIDES

8” MIN.

HEX NUT

WASHER

NOTE:
LOCATE “J” BOLTS PER
COMPRESSOR OUTLINE
DIMENSION DRAWINGS.

Figure 2.2A: Recommended Foundation Details

for Corken Compressors 91 - 691

COMPRESSOR
BASEPLATE

GROUT BENEATH
BASE

CONCRETE FOUNDATION
WITH REINFORCEMENTS
SHOULD BE USED ON ALL
MODELS

1/2” “J” BOLTS
12” LONG

smooth operation of the 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 2.3A).

Pipe must be adequately sized to prevent excessive pressure
drop between the suction source and the compressor as
well as between the compressor and the final discharge
point. In most cases, piping should be at least the same
diameter as the suction nozzle on the compressor. Typically,
LPG/NH

liquid transfer systems should be designed to

3

limit pressure drops to 20 psi (1.3 bar). Appendix D shows
recommended pipe sizes for each compressor for typical
LPG/NH3 installations.

On some of the longer baseplates, such
as with the 691–107, a 3 in. hole can be
cut in the baseplate for filling the middle
section of the baseplate with grout.

See ED410 (Compressor Foundation
Design).

2.3 Piping

Proper piping design and installation
is as important as the foundation is to

Figure 2.3A: On –107 mountings, the flexible

connectors should be located near the four way valve.

8

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

107 style compressors are usually connected using a five­valve (figure 2.3B) or three-valve manifold (figure 2.3C).
The five-valve manifold allows the storage tank to be
both loaded and unloaded. The three-valve manifold only
allows the storage tank to be loaded. Adequate sizing of
the liquid and vapor lines is essential to limit the pressure
drop in the system to a reasonable level (20 psi or less).

The line size helps determine the plant capacity almost
as much as the size of the compressor, and liquid line
sizes are a bigger factor than vapor lines. If the pressure
gauges on the head indicate more than a 15 to 20 psi
(2.07 to 2.40 bars) differential between the inlet and outlet
pressures, the line sizes are too small or there is some
fitting or excess flow valve creating too much restriction.
The less restriction in the piping, the better the flow.
Appendix D shows recommended pipe sizes for typical
LPG/NH3 compressor installation.

A tank car unloading riser should have two liquid hoses
connected to the car liquid valves. If only one liquid hose
is used, the transfer rate will be slower and there is a good
possibility that the car’s excess flow valve may close.

Since the heat of compression plays an important part in
rapid liquid transfer, the vapor line from the compressor to
the tank car or other unloading container should be buried
or insulated to prevent the loss of heat and the compressor
should be located as near as possible to the tank being
emptied. In extremely cold climates, if the line from the
storage tank to the compressor is over 15 feet (4.6 meters)
long, it should be insulated to lessen the possibility of
vapors condensing as they flow to the compressor. The
vapor recovery discharge line is better not insulated.
Placing the compressor as close as possible to the tank
being unloaded will minimize heat loss from the discharge
line for the best liquid transfer rate.

Unloading stationary tanks with a compressor is quite
practical. Delivery trucks and other large containers can be
filled rapidly if the vapor system of the tank to be filled will
permit fast vapor withdrawal, and if the liquid piping system
is large enough. Many older trucks (and some new ones) are
not originally equipped with vapor excess flow valves large

SERVICE TO PERFORM

1. Unload Tank Car in to
Storage Tank

2. Recover Vapors from Tank
Car into Storage Tank

3. Unload Transport or Truck
into Storage Tank

4. Recover Vapors from
Transport or Truck into
Storage Tank

5. Load Truck or Field Tank
from Storage Tank

6. Load Truck or Field Tank
from Tank Car

7. Equalize Between Tank Car
and Storage Tank without
using Vapor Pump

8. Equalize Between Truck or
Field Tank and Storage Tank
without using Vapor Pump

Figure 2.3B: Five-Valve Manifold Piping System

9

VALVE POSITION

4- WAY A B C D E

Position

Position

Position

Position

Position

Position

Open Open Close Close Close

One

Close Open Open Close Close

Two

Open Close Close Close Open

One

Close Close Open Close Open

Two

Open Close Close Close Open

Two

Close Open Close Open Close

One

— Open Open Close Open Open

— Open Close Close Open Close

SERVICE TO PERFORM

1. Unload Tank Car into
Storage Tank

2. Recover Vapors from
Tank Car into Storage
Tan k

Figure 2.3C: Three-Valve Manifold Piping System

4-WAY A B C

Position

One

Position

Two

VALVE POSITION

Open Open Close

Close Open Open

enough to do a good job and these should be replaced
by a suitable size valve. The liquid discharge should be
connected to the tank truck pump inlet line rather than the
often oversized filler valve connection in the tank head.

2.4 Liquid Traps

Compressors are designed to pressurize gas, not to
pump liquids. The entry of even a small amount of
liquid into the compres sor will result in serious damage
to the compressor.

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

Corken offers three types of liquid traps for removal of
entrained liquids. The simplest is a mechanical float trap
(see figure 2.4A). As the liquid enters the trap the gas
velocity is greatly reduced, which allows the entrained
liquid to drop out. If the liquid level rises above the
inlet, the float will plug the compressor suction. The
compressor creates a vacuum in the inlet piping and
continues to operate until the operator manually shuts it
down. The trap must be drained and the vacuum-breaker
valve opened before restarting the compressor, to allow
the float to drop back. This type of trap is only appropriate
for use where the operator keeps the compressor under
fairly close observation. This trap is provided with the
109 and 107 compressor packages (see Appendix D for
details on standard Corken compressor packages).

When the compressor will not be under more-or-less
constant observation an automatic trap is recommended

It is of extreme importance to prevent the entry of
liquid into the compressor. The inlet of the compressor
should be protected from liquid entry by a liquid trap
(see section 2.4). It is of equal importance to protect
the discharge of the compressor from liquid. This may
be done by installing a check valve on the discharge
and designing the piping so liquid cannot gravity­drain back into the compressor. Make sure to install
a check valve on vapor lines discharging to the liquid
space of the tank.

All piping must be in accordance with the laws and codes
governing the service. In the United States, the following
codes apply:

For LP Gas – The National Fire Protection Association
Pamphlet No. 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.

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.

Figure 2.4A: Mechanical Trap

10

(see figure 2.4B). The automatic trap replaces the float with
electrical float switches. If the liquid level should rise too
high, the level switch will open and disconnect the power
to the motor starter, stopping the compressor. This design
ensures the machine will be protected even when it is not
under close observation and is standard in the 109A and
107A mounting configurations.

If your compressor is equipped with a liquid trap
of other than Corken manufacture, make sure it is
of adequate size to thoroughly remove any liquid
entrained in the suction stream.

Corken’s most sophisticated trap provides the most
thorough liquid separation (see figure 2.4C). This trap is
larger and is ASME code stamped. It contains two level
switches, one for alarm and one for shutdown. In some
cases the alarm switch is used to activate a dump valve
(not included with trap) or sound an alarm for the trap
to be manually drained by the operator. This trap also
contains a mist pad. A mist pad is a mesh of interwoven
wire to disentrain fine liquid mists. The ASME code trap is
standard in the 109B and 107B mounting configurations.

A typical wiring diagram for the liquid level switch is
shown in figure 2.4D.

NOTE: The level switch MUST be removed from
the trap before grounding any welding devices to
the trap or associated piping! Failure to do so will
damage the switch contacts.

Typical Float Switch Wiring Diagram

(1) = Common, black
(2) = Normally closed, blue
(3) = Normally open, red

Figure 2.4D: Typical Float Switch Wiring Diagram

Figure 2.4B: Automatic Liquid Trap Figure 2.4C: ASME Automatic Liquid Trap

11

2.5 Driver Installation / Flywheels

Corken vertical compressors may be driven by either
electric motors or combustion engines (gasoline, diesel,
natural gas, etc.). Corken compressors are usually
V-belt driven but they are also suitable for direct drive
applications as well. Direct drive applications require an
extended crankshaft to allow the attachment of a rigid
metal coupling.

NOTE: Flexible couplings are not suitable for
reciprocating compressors. Never operate a
reciprocating compressor without a flywheel.

Drive rs shoul d b e s e l e c t e d s o the compressor oper ates
between 350 to 825 RPM. The unit must not be
operated without the flywheel or severe torsional
imbalances will result that could cause vibration and
high horsepower requirement. The flywheel should
never be replaced by another pulley unless it has a
higher wk2 value than the flywheel.

A humid climate can cause problems, particularly in
explosion proof motors. The normal breathing of the
motor, and alternating between being warm when running
and being cool when stopped, can cause moist air to be
drawn into the motor. This moist air will condense, and
may eventually add enough water inside the motor to
cause it to fail. To prevent this, make a practice of running
the motor at least once a week on a bright, dry day for an
hour or so without the V-belts. In this period of time the
motor will heat up and vaporize the condensed moisture,
driving it from the motor. No motor manufacturer will
guarantee their explosion proof or totally enclosed
(TEFC) motor against damage from moisture.

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 2.6A: Oil Selection Chart

Compressor

Model

Approximate

Quarts

Capacity Liters

91 0.9 0.8

291 1.5 1.4

491 3.0 2.8

691 7. 0 6.6

Figure 2.6B: Oil Capacity Chart

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

2.6. Crankcase Lubrication

Non-detergent oil is recommended for Corken vertical
compressors. Detergent oils tend to keep wear particles
and debris suspended in the oil, whereas non-detergent
oils let them settle in the bottom of the crankcase.
When non-detergent oils are not available, detergent
oils may usually be successfully substituted, although
compressors handling ammonia, amine, or imine gases
are notable exceptions. These gases react with the
detergent and cause the crankcase oil to become
corrosive and contaminated. Figures 2.6A and 2.6B show
recommended oil viscosities and crankcase capacities.

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

2.7 Relief Valves

An appropriate relief valve must be installed at the
compressor discharge. On Corken 107-style mounted
units a relief valve should be fitted in the piping
between the compressor discharge and the four-way
valve (see figure 1.3A). Relief valves should be made of
a material compatible with the gas being compressed.
Local codes and regulations should be checked for
specific relief valve requirements. Also, relief valves
may be required at other points in the compressor’s
system piping.

2.8 Truck Mounted Compressors

Corken compressors are may be mounted on trucks to
perform liquid transfer operations as described in section

1.1. The compressor should be mounted so the inspection
plate is accessible for packing adjustment. The compressor
must be protected against liquid as explained in section 2.4
and a relief valve must be installed in the discharge piping
before the first downstream shutoff valve.

12

Three types of mountings are typically used. The inside
mounting (figure 2.8A) drives the compressor directly off
the PTO shaft. The PTO must be selected to drive the
compressor between 400 and 800 RPM. An extended
compressor crankshaft is required so the U-joint yoke
may connect to the compressor without removing the
flywheel. Do not operate the compressor without a
flywheel. Use a U-joint with a splined joint and make
sure the connections are parallel and in line. The U-joint
angle should be less than 15 degrees (see figure 2.8B).
Always use an even number of U-joints.

Depending on the truck design, the compressor may be
outside or top mounted as shown in figures 2.8C and

2.8D to be V-belt driven. Power is transmitted through
a U-joint drive shaft, jackshaft with two pillow block
bearings, V-belt sheave and V-belts. An idle pulley may
be used under the truck frame.

2.9 Shutdown/Alarm Devices

For many applications, shutdown/alarm switches will
provide worthwhile protection that may prevent serious
damage to your compressor system. All electronic devices
should be selected to meet local code requirements.
Shutdown/alarm devices typically used on Corken
compressors are:

Figure 2.8A: Inside Transport Mounting

Figure 2.8B: U-joint Drive for Compressor

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.

Figure 2.8C: Outside Transport Mounting

Figure 2.8D: Top Transport Mounting

13

Chapter 3—Starting Up Your Corken Compressor

NOTE: Before initial startup of the compressor be
sure the principal of using a compressor for liquid
transfer by vapor differential pressure is understood
(see section 1.1). Read this entire chapter, then
proceed with the startup checklist.

3.1 Inspection After
Extended Storage

If your compressor has been out of service for a long
period of time, you should verify that the cylinder bore
and valve areas are free of rust and other debris (see
chapter 5 of this IOM manual for valve and/or cylinder
head removal instructions).

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

Figure 3.2A: Flywheel Installation

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

3.2 Flywheel and V-belt Alignment

Before working on the drive assembly, be sure that the
electric power is disconnected. When mounting new
belts, always make sure the driver and compressor are
close enough together to avoid forcing.

Improper belt tension and sheave alignment can cause
vibration, excessive belt wear and premature bearing
failures. Before operating your compressor, check alignment
of the V-grooves of the compressor flywheel and driver
sheave. Visual inspection often will indicate if the belts are
properly aligned, but use of a square is the best method.

The flywheel is mounted on the shaft via a split, tapered
bushing a nd three bolts. These bolts shou ld be tighte ned in
an even and progressive manner until torqued as specified
below. There must be a gap between the bushing flange
and the flywheel when installation is complete. Always

check the flywheel runout before startup and readjust
if it exceeds the value listed in Appendix C.

Bushing Size

SF 4.625 (11.7) 30 (4.1)

E 6.0 (15.2) 60 (8.3)

J 7.25 (18.4) 135 (18 .7 )

Diameter

In. (cm)

Bolt Torque

Ft.-lb. (kg-meter)

Figure 3.2B: 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 3.2B.

3.3 Crankcase Oil Pressure
Adjustment

Corken compressor models 291 through 891 are
equipped with an automatically reversible gear type oil
pump (if your compressor is the splash lubricated Model
91, proceed to section 3.4). It is essential to ensure
the pumping system is primed and the oil pressure is
properly adjusted in order to assure smooth operation.

Before starting your compressor, check and fill the
crankcase with the proper quantity of lubricating oil.

When the compressor is first started, observe the
crankcase oil pressure gauge. If the gauge fails to
indicate pressure within 30 seconds, stop the machine.

14

Remove the pressure gauge. Restart the compressor

Oil Pressure Gauge

Oil Level Bayonet

Lock Nut

Oil Pressure

Adjusting

Screw

+

-

Oil Pump Cover

and run it until oil comes out of the pressure gauge
opening. Reinstall the gauge.

The oil pressure should be about 20 psi (1.4 bars) minimum
for normal service. If the discharge pressure is above 200
psi (14.8 bars) the oil pressure must be maintained at a
minimum of 25 psi (1.7 bars). A spring-loaded relief valve
mounted on the bearing housing opposite the flywheel
regulates the oil pressure. As shown in figure 3.3A, turn
the adjusting screw clockwise to increase the oil pressure
and counterclockwise to lower it. Be sure to loosen the
adjusting screw locknut before trying to turn the screw and
tighten it after making any adjustment.

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

9. Rotate unit by hand. Check flywheel for wobble or play.

10. Check crankcase oil level.

11. Drain all liquid traps, separators, etc.

12. Verify proper electrical supply to motor and panel.

13. Check that all gauges are at zero level reading.

14. Test piping system for leaks.

15. Purge unit of air before pressurizing with gas.

16. Carefully check for any loose connections or bolts.

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

18. Verify that all valves are open or closed as required.

19. Double-check all of the above.

Figure 3.3A: Oil Pressure Adjustment

3.4 Startup Check List

Please verify all of the items on this list before
starting your compressor! Failure to do so
may result in a costly (or dangerous) mistake.

Before Starting the Compressor

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

2. Verify that actual operating conditions will match the
anticipated conditions.

3. Ensure that line pressures are within cylinder
pressure ratings.

4. Clean out all piping.

After Starting Compressor

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

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

3. Verify proper compressor speed.

4. Examine entire system for gas, oil or water levels.

5. Note rotation direction.

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

7. Test each shutdown device and record set points.

8. Test all relief valves.

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

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

5. Check all mounting shims, cylinder and piping
supports to ensure that no undue twisting forces exist

on the compressor.

6. Verify that strainer elements are in place and clean.

7. Verify that cylinder bore and valve areas are clean.

15

Chapter 4—Routine Maintenance Chart

Item to Check Daily Weekly Monthly

Six

Months

Yearly

Crankcase oil pressure

Compressor discharge pressure

Overall visual check

Crankcase oil level

Drain liquid from accumulation points

3

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

1

Inspect valve assemblies

Lubricate motor bearings in accordance with
manufacturers' recommendations

Inspect motor starter contact points

Inspect piston rings

1

Piston ring life varies greatly, depending on application, gas, and operating pressures. Consult factory for additional recommendations for
your specific application.

2

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.

3

Liquid traps should be drained prior to startup.

1

1 1

16

Chapter 5—Routine Service and Repair Procedures

CAUTION: Always relieve pressure in the unit before
attempting any repairs. After repair, the unit should
be pressure tested and checked for leaks at all joints
and gasket surfaces.

If routine maintenance is performed as listed in chapter
4, repair service on your Corken gas compressor is
generally limited to replacing valves or piston rings.
When it comes time to order replacement parts, be sure
to consult the part details appendix in the back of this
Installation, Operation & Maintenance (IOM) manual for a
complete list of part numbers and descriptions.

5.1 Valves

Test the compressor valves by closing the inlet piping valves
while the unit is running; however, do not allow the machine
to operate in this way very long. If the inlet pressure gauge
does not drop to zero almost immediately, one or more of
the valves is probably either damaged or dirty. It is possible,
of course, that the pressure gauge itself is faulty.

Inspect valves for breakage, corrosion, and scratches on
the valve disc and debris. In many cases, valves may simply
be cleaned and reinstalled. If the valves show any damage,
they should be repaired or replaced. Replacement is usually
preferable, although individual parts are available. If valve
discs are replaced, seats should also be lapped until they
are perfectly smooth. If more than .005 in. must be removed
to achieve a smooth surface, the valve should be discarded.
If discs are replaced without relapping the seat, rapid wear
and leakage may occur.

Valve Holddown Assemblies: Depending on your model
of compressor, the valve holddown assembly has all or a
combination of the following:

1. Valve cap

2. Valve cap O-ring

3. Holddown screw

4. Valve cover plate

5. Valve cover plate bolts

6. Valve cover plate O-ring

7. Valve spacer (model 491 only)

8. Valve cage

9. Valve assembly

10. Valve gasket

Valve Assemblies: Depending on your valve specification,
the valve assembly has all or a combination of the following:

1. Gasket

2. Adjusting screw

3. Relief ball spring

4. Relief ball

Each suction and/or discharge valve assembly is easily
removed as a unit for inspection. If any part of the valve
a s se m bl y i s b r ok e n , t h e va l v e a s s e mb ly s ho u l d b e re p l ac e d.
See valve assembly parts details in the appendices 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 gaskets and/
or O-rings should be used to assure a good seal.

The valve holddown assemblies and valve assemblies on
the following pages show the various specifications used
on models 91, 291, 491, 691 and 891 compressors. Since
more than one suction valve arrangement is available for
each model of compressor, it is necessary to know your
complete model number so you can identify the valve
type specification number (see example listed below).
In most cases for liquid transfer and/or vapor recovery
compressors, the valve type will be spec. 3.

Model number 491AM 3 FBANSNN

Valve type = spec 3

5. Valve seat

6. Valve plate

7. Spacers

8. Washer

9. Valve spring

10. Suction valve post

11. Valve bumper

12. Valve gasket

See valve holddown and valve assembly part details
in the appendix for a complete list of part numbers
and descriptions.

Valve Inspection and/or Replacement for Models 91
and 291 Compressors

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

17

Disassembly

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

2. With the special wrench supplied with your compressor
at time of purchase, remove the holddown screw.

3. After the holddown screw has been removed, the
valve assembly and valve gasket can be lifted out.

the holddown screw has been secured with an impact
wrench at the factory, you will probably need to wait to
remove the holddown screw until after the cover plate
has been removed. At this point in time, the holddown
screw can be easily removed from the cover plate. The
holddown screw on model 691 and 891 is most easily
removed with the special wrench supplied with your
compressor at time of purchasing.

4. Carefully inspect for dirt or broken/damaged parts.

5. Inspect valves for breakage, corrosion, debris and
scratches on the valve disc or plate. In many cases,
valves may simply be cleaned and reinstalled. If the
valves show any damage, they should be repaired or
replaced. Replacement is usually preferable although
repair parts are available. If valve plates are replaced,
seats should also be lapped until they are perfectly
smooth. If more than .005 in. must be removed
to achieve a smooth surface, the valve should be
discarded. If plates are replaced without relapping the
seat, rapid wear and leakage may occur.

Assembly

1. Insert metal valve gasket into the suction and/or discharge
opening of the head. The metal valve gasket should
always be replaced when the valve is reinstalled.

2. Insert cleaned or new valve assembly. Make sure the
suction and discharge valves are in the proper suction and
discharge opening in the head. NOTE: The spec 3 suction
valves for a model 91 and 291 compressor are pre-set so
no adjustments to liquid relief pressure are necessary.

3. After the cover plate and O-ring have been removed,
the valve spacer (model 491 only), valve cage, valve
assembly and valve gasket can be lifted out.

4. Inspect valves for breakage, corrosion, debris and
scratches on the valve plate. In many cases, valves may
simply be cleaned and reinstalled. If the valves show
any damage, they should be repaired or replaced.
Replacement is usually preferable although repair
parts are available. If valve plates are replaced, seats
should also be lapped until they are perfectly smooth.
If more than .005 in. must be removed to achieve a
smooth surface, the valve should be discarded. If
plates are replaced without relapping the seat, rapid
wear and leakage may occur.

Assembly

1. Insert metal valve gasket into the suction and/or discharge
opening of the head. The metal valve gasket should
always be replaced when the valve is reinstalled.

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. Replace the holddown screw and tighten to the value
listed in Appendix C to ensure the valve gasket is
properly seated. NOTE: Gaskets and O-rings are not
normally reusable.

4. Replace the O-ring (or gasket) and valve cap and
tighten to the value listed in Appendix C. O-rings
sealing the valve caps should be replaced.

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

Valve Inspection and/or Replacement for Models
491, 691 and 891 Compressors

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

Disassembly

1. Unscrew the valve cap/nut and remove the gasket
from the coverplate.

2. Remove the valve cover plate, O-ring and holddown
screw by removing each of the four bolts. NOTE: Since

3. Insert the valve cage and valve spacer (NOTE: spacer
applies to model 491 compressor only).

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

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

6. Replace the O-ring (or gasket) and valve cap/nut and
tighten to the value listed in Appendix C. O-rings sealing
the valve cap should be replaced if they show signs of
wear or damage. Valve caps sealed by flat metals
gaskets should be reinstalled with new gaskets.

7. NOTE: Spec 3 suction valves have an adjusting screw
to set the liquid relief pressure. To set the liquid relief
pressure, tighten the adjusting screw until it bottoms,
then back out 3/4 turn.

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

18

5.2 Heads

5.4 Pistons

A compressor head very seldom requires replacement if
the compressor is properly maintained. The primary cause
of damage to a head is corrosion and the entry of solid
debris or liquid into the compression chamber. Improper
storage can also result in corrosion damage to the head
(for proper storage instructions see chapter 6).

Many compressor repair operations require removal
of the head. While the compressor is disassembled,
special care should be taken to avoid damage or
corrosion to the head. If the compressor is to be left
open for more than a few hours, bare metal surfaces
should be coated with rust preventative.

When reassembling the compressor, make sure the bolts
are retightened as shown in Appendix C.

5.3 Piston Rings and
Piston Ring Expanders

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

2. Remove the compressor cylinder and head (see
section 5.2).

3. Remove the piston head by loosening and removing
the socket head bolts holding the piston head to the
piston platform (see figure 5.3A).

4. Next, remove the roll pin with a pair of needle nose
pliers. The castellated nut may then be removed and the
piston platform lifted off the end of the piston rod.

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

6. Before installing the new piston, measure the thickness
of the existing shims. For Models 91 through 491, the
shims are placed between the thrust washer and
piston platform. For model 691, the shims are placed
between the platform and piston head (see figures

5.4A and 5.4B).

7. Reinstall the piston platform with the same thickness
of shims as before, BUT DO NOT REINSTALL THE

ROLL PIN.

Figure 5.3A: Piston Removal

Piston ring life will vary considerably from application to
application. Ring life will improve dramatically at lower
speeds and temperatures.

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

2. Remove the head to gain access to the compressor
cylinder.

3. Loosen the piston head bolts. Remove the piston
as shown in figure 5.3A by pinching two loose
bolts together.

4. Piston rings and expanders may then be easily
removed and replaced. Corken recommends
replacing expanders whenever rings are replaced.
To determine if rings should be replaced, measure
the radial thickness and compare it to the chart in
Appendix C.

8. Replace the cylinder and install the piston heads with
new piston rings and expanders.

9. Now measure dimension “X” shown in the illustration.
If this measurement does not fall within the tolerances
shown in Appendix C, remove the piston, adjust the
shims as necessary and remeasure the “X” dimension.

10. When the piston is properly shimmed, tighten the
castellated nut as shown in Appendix C.

11. Now install a new roll pin to lock the castellated piston
nut in place.

Figure 5.4A: Piston Cross Section

Model Sizes 91 Through 491

19

Figure 5.4B: Piston Cross Section

Model 691

ch amb er. Im pr op er s to ra ge ca n als o r es ul t in co rr os io n
damage to cylinder (for proper storage instructions
see chapter 6).

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 C. If more than .005
in. must be removed to smooth the bore, replace the
cylinder. Cylinder liners and oversized rings are not
available. OVERBORING THE CYLINDER WILL RESULT
IN GREATLY REDUCED RING LIFE.

Many compressor repair operations require removal of the
cylinder. While the compressor is disassembled, special
care should be taken to avoid damage or corrosion to
the cylinder. If the compressor is to be left open for more
than a few hours, bare metal surfaces should be coated
with rust preventative.

12. Install the piston head and tighten the socket head
bolts in an alternating sequence.

13. Reinstall the head (see section 5.2) and follow standard
startup procedure. (Note: Some compressors may
have self-locking nuts without roll pins.)

5.5 Piston Rod Packing Adjustment

Piston rod packing should be adjusted or replaced
whenever leakage becomes noticeable. Typically, it is
a good idea to replace piston rod packing and piston
rings at the same time. For instructions on adjusting and
replacing the piston rod packing, see section 5.6.

NOTE: Inspection of the rod packing is generally not
productive, since packing that cannot be adjusted to an
acceptable leakage rate should be replaced.

When reassembling the compressor, make sure the bolts
are retightened as shown in Appendix C.

Packing Replacement Instructions

Caution: Bleed all pressure from the compressor and piping,
and purge (if necessary), before starting to install new piston
rod packing. After repair, the unit should be pressure tested
and checked for leaks at all joints and gasket surfaces.
When the compressor is being used with toxic, dangerous,
flammable or explosive gases, this pressure and leak testing
should be done with air or a dry, inert gas such as nitrogen.

For simplicity, heads, pistons, and inspection plates are
not shown. For specific construction details and actual
part numbers, consult the appendix in the back of this
IOM manual. Use instructions below that apply to the
MODEL and SERIAL NUMBER of your compressor. Be
careful to arrange packing sets in the proper order.

Cleanliness:

Sealing a reciprocating piston rod is a very difficult
task. Keep all parts, tools and your hands clean during
installation. Your new packing needs every chance it can
get, so keep it clean.

Figure 5.5A: Packing Adjusting Nuts

5.6 Cylinder and

Packing Replacement

Cylinders very seldom require replacement if the
compressor is properly maintained. The primary
cause of damage to cylinders is corrosion and the
entry of solid debris or liquid into the compression

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.

Model 91 Compressor

(Refer to Appendix G for packing assembly details)

Disassembly of Packing

1. Depressurize and open the compressor.

2. Remove head, piston, cylinder, inspection plate and
crosshead guide.

20

3. Loosen adjusting screw and remove retainer ring,
washers, packing spring and old packing from
crosshead guide.

Assembly of Packing

1. Clean, then lightly oil, packing area inside the
crosshead guide.

2. Slightly thread in the adjusting screw into the
crosshead guide.

3. Install packing rings including male and female packing
rings one at a time as shown in Appendix G. Push
in each one completely before adding the next ring.
The quantity of packing rings required will vary due to
tolerances; a good rule of thumb is to put in as many as
are removed.

2. Slightly thread in adjusting screw.

3. Install packing rings including male and female
packing rings, one at a time, as shown in Appendix H
or I. Push in each one completely before adding the
next ring. The quantity of packing rings required will
vary due to tolerances; a good rule of thumb is to put
in as many as are removed.

4. Insert thin packing box washer, packing spring and
thicker washer.

5. Push down on washer and insert retainer ring.

6. Tighten adjusting screw until plastic locking device
engages the first thread in the packing box cartridge.

7. Oil piston rod and replace cartridge O-ring.

4. Insert thin packing box washer, packing spring and
thicker washer into the top of the crosshead guide.

5. Tighten adjusting screw until plastic locking device
engages the first thread in the crosshead guide.

6. Oil piston rod and install the packing installation cone
(part number 4005) over the threaded end of the
piston rod.

7. Carefully slip the crosshead guide over the piston
rod; otherwise, you may damage the lips of the
packing rings.

8. Remove packing installation cone.

9. Install the crosshead guide O-ring, cylinder, piston
and head.

Model 291 Compressor (serial no. SS55685 and later)

Model 491 Compressor (serial no. XC30633 and later)

(Refer to Appendix H or I for packing assembly details)

Disassembly of Packing

1. Depressurize and open the compressor.

8. Install packing installation cone part number 4005
over the threaded end of the piston rod.

9. Carefully slip the packing cartridge over the piston
rod; otherwise, you may damage the lips of the
packing rings.

10. Remove packing installation cone.

11. Install and tighten cartridge holddown screw with
special wrench.

12. Install cylinder O-ring, cylinder, pistons and head.

Model 691 Compressor

(Refer to Appendix J for packing assembly details)

Disassembly of Packing

1. Depressurize and open the compressor.

2. Remove head, pistons and cylinder.

3. Remove cartridge holddown screw with special
wrench supplied with the compressor and packing
box cartridge.

2. Remove head, pistons and cylinder.

3. Remove cartridge holddown screw with special
wrench supplied with the compressor and packing
box cartridge.

4. Loosen adjusting screw and remove retainer ring,
washers, packing spring and old packing from packing
box cartridge.

Assembly of Packing

1. Clean, and then lightly oil, packing area inside packing
box cartridge.

4. Loosen adjusting screw and remove retainer ring,
washers, packing spring and old packing from packing
box cartridge.

Assembly of Packing

1. Clean then lightly oil packing area inside packing box
cartridge.

2. Thread in adjusting screw until locking device is
engaged into first thread of the packing cartridge.

3. Install packing rings, including male and female packing
rings, one at a time, as shown in Appendix J. Push in
each one completely before adding the next ring.

21

4. Insert a packing washer, packing spring and another
packing washer.

removing the head, cylinder, piston, crosshead guide
and crosshead assembly.

5. Push down on washer and insert retainer ring.

6. Oil piston rod and replace cartridge O-ring.

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

8. Carefully slip the packing cartridge over the piston
rod; otherwise, you may damage the lips of the
packing rings.

9. Install and tighten cartridge holddown screw with
special wrench.

10. Replace cylinder O-ring, cylinder, pistons and head.

Model D891 Compressor

(Refer to Appendix K for packing assembly details)

Disassembly of Packing

1. Depressurize and open the compressor.

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

3. To remove the packing barrels, pry upward under
each one and lift entire barrel/cartridge assembly up
from piston rod.

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

Assembly of Packing

1. Replace packing as required. The segmented packing
and cups are in the barrel. The V-ring packing is in
the cartridge. Note the arrangement of the particular
packing set for the model machine you have.

2. Reattach the cartridges to the barrels using the four
socket head screws.

3. Install cartridge barrel assemblies, noting the
alignment of the barrels as they sit on the crosshead
guide. The valve scallops on the barrels must align
properly with the valves of the cylinder.

4. Replace cylinder, pistons, heads and cap. See piston
assembly details for proper clearance values.

5. Rotate unit by hand to ensure proper assembly.

5.7 Bearing Replacement for

2. Drain the crankcase and remove the inspection plate(s).

3. Before disassembly, choose and mark one connecting
rod and the corresponding connecting rod cap. DO
NOT MIX CONNECTING RODS AND CAPS. Loosen and
remove the connecting rod bolts in order to remove the
crosshead and connecting rod assembly.

5.7.1 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.

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 on the respective
connecting rod assembly details. These pages are
located in the appendices. Over boring the bushing can
lead to premature failure of the wrist pin bushing.

5. Inspect the oil passage for debris and clean thoroughly
before proceeding.

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

5.7.2 Replacing Connecting Rod Bearings

Connecting rod bearings are easily replaced by removing
the semicircular bearings. Make sure the indentations
in the connecting rod bearing and connecting rod line
up when 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 torques listed in Appendix C.

Crankcase and Connecting Rod

1. To replace the crankcase roller bearings, wrist pin
bushing and connecting rod bearings, begin by

5.7.3 Replacing Crankcase Roller Bearings

To inspect the roller bearings, remove the flywheel from
the crankshaft and then remove the bearing carrier and
crankshaft from the crankcase. If corrosion or pitting is

22

Figure 5.6.3A: Bearing Carrier Replacement

present, the roller bearings should be replaced. When
replacing roller bearings, always replace the entire bearing,
not just the cup or the cone.

1. To replace the 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 5.6.3A).

3. In order to check the crankshaft endplay, the oil pump
must first be removed (see section 5.8).

4. Press the end of crankshaft towards the crankcase; if
a clicking noise or motion is detected, the crankshaft
has too much endplay. See Appendix C.

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 C 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.

5.8 Oil Pump Inspection

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

1. To check the oil pump, unbolt the pump cover and
remove the oil pump, spring guide, spring and oil
pump shaft adapter as shown in figure 5.8A.

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.

4. Before reassembling the oil pump mechanism, replace
the O-rings in the oil pump cover and on the oil pump
adapter shaft (see figure 5.8A).

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

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

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

8. Install the pump cover so the pin on the case is in the
opening on the oil pump assembly as shown in figure

5.8A. When you are sure the pin is properly aligned,
install the cover bolts finger tight.

9. Rotate the crankshaft by hand to ensure smooth
operation. Then rotate it in opposite directions,
listening for a click, which indicates proper alignment
of the oil pump’s pins and slots.

7. Reinstall the flywheel on the crankshaft and check the
run out as shown in Appendix C.

10. Finally, tighten the bolts in an alternating sequence. See
section 3.3 for directions on oil pressure adjustment.

23

Figure 5.8A

5.9 Servicing the Four-Way Valve

Unlike older units, new Corken compressors mounted in
the –107 arr a nge m e nt a r e bei n g s upp l i e d w i t h a non - lub e
four-way valve. No maintenance is normally required on
this valve. If you have reason to disassemble the valve,
please follow the instructions below (see figures 5.9A
and 5.9B).

CAUTION: Always Relieve Pressure In The Unit
Before Attempting Any Repairs.

Before Disassembly:

1. Record the position marks on the end of the rotor shaft.

2. Record the positions of the handle stops on the cap.

NOTE: A small amount of silicone grease applied
to each part before assembly facilitates assembly
if allowed.

Disassembly

Refer to the drawing for item description.

1. Remove the hex nut, indicator plate and handle from
the rotor shaft.

2. Remove the four hex head bolts and the cap from the
body. The cap should be rotated until free; do not pry.
Inspect cap for wear and damage (see figure 5.9C).

Figure 5.9A

Figure 5.9B

24

Figure 5.9C

6. Assemble the new stem O-ring and the body O-ring
into their grooves in the rotor and body.

7. Place the cap over the rotor shaft.

8. Rotate the rotor so the position of the handle stops on
the cap is the same as recorded before disassembly.

9. Assemble the four hex head bolts through the cap
and into the body. Be sure that the body O-ring is in
the proper position and tighten the hex head bolts.

3. Remove the body O-ring, stem O-ring, cap O-ring,
and top rotor washer and discard.

4. Remove the rotor and four seals as a unit from the
body. IM P O R TA N T: Because of the close tolerance,
care must be taken to remove the rotor on its axis to
prevent damage to the rotor and body. Rotating the
handle with a lifting action will help remove the rotor
as shown in figure 5.9D.

Figure 5.9D

5. Discard the four seals. Inspect the rotor for wear
and damage.

6. Remove the bottom rotor washer and discard. Inspect
the body for wear and damage.

Assembly

Refer to figure 5.9B. Have the repair kit laid out.

1. Place the new bottom rotor washer into the body.

10. Reassemble the handle, indicator plate and hex nut.
Be sure that the handle is assembled so that the stop
on the handle mates with the stops on the cap.

Chapter 6
Extended Storage Procedures

Following a few simple procedures will greatly minimize the
risk of the unit becoming corroded and damaged. Corken
recommends the following precautions to protect the
compressor during storage:

1. 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, off the ground if possible.

6. Rotate the flywheel every two weeks if possible.

2. Assemble the four seals and O-rings onto the
appropriate surfaces of the rotor.

3. Assemble the rotor and seal assembly into the
body. IMPORTANT: Because of the close tolerance,
care must be taken to press the rotor on its axis
to prevent damage to the rotor and body. A ring
compressor is helpful. Be sure that the rotor is
bottomed in the body.

4. Rotate the rotor so that the position marks on the
end of the rotor shaft are the same as recorded
before disassembly.

5. Assemble the new top rotor washer and cap O-ring,
onto the shoulder of the rotor.

25

Appendix A—Repair Kits and Gasket Sets

Compressor Repair Kits

Part Number 3549-X1 3550-X1 3551-X1 3552-X1 3552-X2 5578-X2A

Model Number 90J3, 91J3 290K3, 291M3 490K3, 491M3 690K3, 690P3 690M3, 691M3 891M3

Suction valve assembly 3483-1X 3483-1X (2)

Discharge valve assembly 3485-X 3485-X (2)

Valve cage — — 2448 (4)

Connecting rod bearing (pair) 1367 1367 (2)2 1491 (2)

Packing set 1452-1X1 1452-1X1 (2)

Piston rings 1772 (3)

Ring expanders 1775 (3)

Gasket set

O-ring

O-ring

O-ring

1

1

1

1

2526-XA

— — — — 2-261A (2)

— — 2-242A (2)

— — 2-253A (2)

2

2

1

1772 (6)

1775 (6)

1281-XA

Oil seal 3259 1278 1507 (490 only) — 3526 3526

Oil seal — — 4438 (491 only) — — —

Adapter plate gasket — — 1486 — — —

1

All repair kits are furnished with Buna-N O-rings which are suitable for LPG and NH3 applications

2

Quantities larger than 1 are shown in parenthesis

2

2

2

2

2

1

2532-1X 3948-X (2)

2439-X (2)

1452-1X1 (2)

1773 (6)

1776 (6)

1481-X6A

2

2

2

2

1, 2

1, 2

2

2

1

3857-X (2)

2797 (4)

1719 (2)

1725-2X (2)

1739 (6)

1740 (6)

1744-X1A

2

2

2

2

2

2

1

2

3948-X (2)

3857-X (2)

2797 (4)

3542 (2)

1725-2X (2)

1739 (6)

1740 (6)

1744-X1A

2

2

2

2

1, 2

2

2

3732-X

3733-X

3542 (2)

2

1725-2X,

3810-X1

1739 (8)

1740 (8)

1

3970-X1A

— — —

— — —

—

—

2

2

2

Four-Way Valve Repair Kits

Description Trim Part Number Connection Sizes

3122-X 1"

Four-Way Valve Repair Kits PTFE and Buna-N trim

3123-X 1¼"

3130-X 2"

Gasket Sets

Model 91 Gasket Set (2526-XA)

Part
Number

2-235A O-ring, Buna-N 2

2526 Crankcase gasket 1

2717 Valve gasket, aluminum 2

2729 Crankcase inspection plate gas 1

2-031A O-ring, Buna-N 2

2244 Inspection plate gasket 1

2716 Valve cap gasket, aluminum 2

2725 Bearing carrier gasket 1

Description Quantity

Model 291 Gasket Set (1281-XA)

Part
Number

1281 Filter screen screw gasket 1

1651 Inspection plate gasket 1

2-113A O-ring, Buna-N 2

2-228A O-ring, Buna-N 1

2702 Crankcase gasket 1

2716 Valve cap gasket, aluminum 4

2732 Center headbolt gasket - steel 2

1190 Adapter plate gasket 2

1285 Bearing carrier gasket 1

2-031A O-ring, Buna-N 4

2-135A O-ring, Buna-N 2

2-235A O-ring, Buna-N 4

2713 Crankcase inspection plate gas 1

2717 Valve gasket, aluminum 4

Description Quantity

26

Appendix A—Repair Kits and Gasket Sets (continued)

Model 491 Gasket Set (1481-X6A) Model 691 Gasket Set (1744-X3A)

Part
Number

1418 Valve gasket, aluminum 4

1480 Center headbolt gasket - steel 2

1488 Inspection plate gasket 1

1511 Crankcase inspection plate gas 1

2-139A O-ring, Buna-N 2

2-228A O-ring, Buna-N 1

1281 Filter screen screw gasket 1

1478 Valve cap gasket, steel 4

1481 Head gasket 1

1489 Crankcase gasket 1

1513 Bearing carrier gasket 1

2-143A O-ring, Buna-N 4

2-243A O-ring, Buna-N 2

Description Quantity

Model 891 Gasket Set (3970-X1A)

Part
Number

1281 Filter screen screw gasket 1

1761 Crankcase gasket 1

2-036A O-ring, Buna-N 8

2-231A O-ring, Buna-N 4

2-238A O-ring, Buna-N 2

2114 Valve gasket, aluminum 8

2131 Bearing carrier gasket 1

4127 Lubricator gasket 1

1760 Inspection plate gasket 1

2-031A O-ring, Buna-N 8

2-228A O-ring, Buna-N 1

2-235A O-ring, Buna-N 8

2-246A O-ring, Buna-N 4

2123 Crankcase inspection plate gas 1

3874 Access cover gasket 2

3906 Gasket spiral wound 2

Description Quantity

Part
Number

1760 Inspection plate gasket 1

2-031A O-ring, Buna-N 4

2-231A O-ring, Buna-N 2

2-235A O-ring, Buna-N 4

2-261A O-ring, Buna-N 2

2123 Crankcase inspection plate gas 2

2131 Bearing carrier gasket 1

2716 Valve cap gasket, aluminum 4

4127 Lubricator gasket 1

1281 Filter screen screw gasket 1

1761 Crankcase gasket 1

2-228A O-ring, Buna-N 1

2-233A O-ring, Buna-N 2

2-247A O-ring, Buna-N 2

2114 Valve gasket, aluminum 4

2129 Oil inlet gasket 1

2177 Flange gasket 2

3874 Access cover gasket 2

Description Quantity

27

Appendix B
Vertical Single-Acting Model Number Identification Code

Base Model 91 291 491 691

Inlet 3/4" NPT 3/4" NPT 1-1/4" NPT 2" NPT

Outlet 3/4" NPT 3/4" NPT 1-1/4" NPT 1-1/2" NPT

Base Model F91 F291 F491 F691

Inlet 3/4" ANSI 3/4" ANSI 1-1/4" ANSI 2" ANSI

Outlet 3/4" ANSI 3/4" ANSI 1-1/4" ANSI 2" ANSI

Packing Arrangement Pressurized inlet Standard A

Splash lubricated Standard N/A N/A N/A J

Extended crankshaft Extra cost Extra cost Extra cost N/A E
Crankcase Style

Standard with heater N/A Extra cost Extra cost Extra cost MH

Pressure lubricated N/A Standard Standard Standard M

Model Number

Base X X X X X X X X X X

Liquid relief suction Standard 3

Valves
Standard valves No extra cost 4

Piston Rings and Packing
Alloy 50 Extra Cost G

Aluminum Standard B

Gasket Material Copper No extra cost C

Lead-iron No extra cost D

Buna-N Standard A

O-ring Material
Viton®1 Extra cost D

PTFE Extra cost E

Intercooler None N/A for single stage compressor N

14" fly wheel used with
extended crankshaft

Flywheel Heavy duty Extra cost Extra cost Extra cost Extra cost H

Neoprene®1 No extra cost B

PTFE Standard F

No charge N/A E

No flywheel No extra cost N

Standard flywheel Standard S

Protective Coating No coating Standard N

Piston Rod Coating
Chrome oxide Extra cost C

1

Registered trademark of the DuPont company.

See Appendix D for mounting options.

Nitrotec Standard N

28

Appendix B
Vertical Double-Acting Model Number Identification Code

Base Model Number D891

Inlet Connection 2" Weld

Outlet Connection 2" Weld

Ship Weight (lb) 900

Packing
Arrangement

Crankcase Pressure lubricated Standard M
Style

Standard with heater Extra cost MH

Standard suction and discharge valves Standard 4

Valves
Suction valve unloaders Extra cost 9

Piston Ring
and Packing PTFE Standard F
Material

Gasket Material Aluminum Standard B

O-ring Buna-N Standard A
Material

Neoprene®1 No charge B

Intercooler N/A for single stage compressor Standard N

Packing arranged for padding of distance piece Standard J

Model Number

Base X X X X X X X X X X

Flywheel No flywheel provided No charge N

Standard flywheel Standard S

Protective
Coating

Piston Rod
Coating

1

Registered trademark of the DuPont company.

None Standard N

Nitrotec Standard N

Mounting Selections

103 Mounting includes: Steel baseplate, adjustable driver slide base, V-belt drive and enclosed steel belt guard. Pressure gauges are

mounted on the compressor.

107 Mounting includes: Steel baseplate, mechanical liquid trap, non-lube 4-way valve, interconnecting piping, strainer, adjustable driver slide

base, V-belt drive and enclosed steel belt guard. Pressure gauges are mounted on the compressor.

107A Mounting includes: All items on the 107 replacing the mechanical float in the liquid trap with a NEMA 7 liquid level switch.

107B Mounting includes: All items on the 107 replacing the liquid trap with a larger ASME code liquid trap with 2 NEMA 7 liquid level

switches set for alarm and shutdown.

107TR Mounting includes: All items on the 107 set up to be used as a transport unit. Note that the compressor must have the optional 14”

flywheel and extended crankshaft to use this mounting.

109 Mounting includes: Steel baseplate, mechanical liquid trap, interconnecting piping, adjustable driver slide base, V-belt drive and

enclosed steel belt guard. Pressure gauges are mounted on the compressor.

109A Mounting includes: All items on the 109 replacing the mechanical float in the liquid trap with a NEMA7 liquid level switch.

109B Mounting includes: All items on the 109 replacing the liquid trap with a larger ASME code liquid trap with 2 NEMA 7 liquid level

switches set for alarm and shutdown.

109TR Mounting includes: All items on the 109 set up to be used as a transpor t unit. Note the compressor must have the optional 14”

flywheel and extended crankshaft to use this mounting.

2

Not suitable for 691 or D891.

3

Discharge relief valves are required but not included in these mountings.

3

2

3

3

3

2,3

29

Appendix C—Vertical Single-Acting Specifications

Models 91– 691

Equipment Type & Options

Single-acting, vertical, reciprocating piston type vapor compressor
Single packed rod
NPT or 300# ANSI connections

Applications

Bulk transfer
Vapor recovery
Tank evacuation
Gas scavenging

Features and Benefits

Self-lubricating piston rings: Non-lubricated operation to minimize oil in gas
NPT or 300# ANSI connections: Versatility for your application
Multiple mounting configurations: Versatility for your application
High efficiency valves: Quiet, reliable operation
Reversible oil pump: Allows operation in either direction
Simplified top down design: Routine maintenance is minimally invasive

Specifications

Specification

Bore of cylinder inches (mm) 3.0 (76.2) 3.0 (76.2) 4.0 (101.6) 4.5 (114.3)
Stroke inches (mm) 2.5 (63.5) 2.5 (63.5) 3.0 (76.2) 4.0 (101.6)

3

Piston displacement cfm (m
minimum @ 400 RPM
maximum @ 825 RPM
Maximum working pressure psig (bar g)
Maximum brake horsepower (kW) 7. 5 (5 .6 ) 15 (11) 15 (11) 35 (26.1)
Maximum rod load lb (kg) 3,600 (1,632.9) 3,600 (1,632.9) 4,000 (1,814.4) 7,000 (3,175.1)
Maximum outlet temperature °F (°C) 350 (177)
Bare unit weight lb (kg) 115 (52.2) 160 (72.6) 260 (117.9) 625 (283.5)
Maximum flow—propane gpm (m

1

These numbers specify pressure-containing abilities of the compressor cylinder and head. For many applications, factors other than the
pressure rating will limit the ma ximum allowable discharge pressure to lower values. These factors include horsepower, temperature and rod
load.

/hr)

1

3

/hr) 50 (11. 4) 101 (22.9) 215 (48.8) 361 (82.0)

91 291 491 691

4.0 (6.8)

8.3 (14.1)

8.0 (13.6) 16.5

Model Number

(28.0)

335 (23.1)

17.2 (29.2) 35.5
(60.3)

29.2 (49.6)

60.2 (102.3)

30

Appendix C—Vertical Single-Acting Specifications

Models 91– 691 Material Specifications

Part Model Standard Material Optional Material

Head, Cylinder All Ductile iron ASTM A536 None
Crosshead guide
crankcase, flywheel,
bearing carrier
Flange 691 Ductile iron ASTM A536 Steel weld flange

Valve seat & bumper

Valve plate

Valve spring

Valve gaskets All Soft aluminum Iron-lead, Copper
Piston All Gray iron ASTM A48, Class 30 None
Piston rod All C1050 steel Nitrotec coated Chrome oxide
Crosshead All Gray iron ASTM 48, Class 30 None
Piston rings All PTFE, glass and moly filled Alloy 50
Ring expanders All 302 stainless steel None
Head gasket All O-ring, Buna-N PTFE, Viton
Packing cartridge,
connecting rod
Packing rings All PTFE, glass and moly filled Alloy 50
Crankshaft All Ductile iron ASTM A536 None
Con. rod bearing All Bimetal D-2 babbit None
Wrist pin All C1018 steel None
Wrist pin busing All Bronze SAE 660 None
Main bearing All Tapered roller None
Inspection plate All Aluminum None
O-rings All Buna-N PTFE, Viton
Retainer rings All Steel None
Misc. gaskets All Coroprene None

1

Registered trademark of the DuPont company.

All Gray iron ASTM A48, Class 30 None

91, 291 17-4 PH stainless steel
491 Ductile iron ASTM A536 None
691 17-4 PH stainless steel
91, 291 410 stainless steel
491 17-7 PH stainless steel None
691 410 stainless steel
91, 291, 691 17-7 PH stainless steel None
491 Inconel

All Ductile iron ASTM A536 None

®1

, Neoprene

®1

, Neoprene

®1

®1

31

Appendix C—Vertical Single-Acting Specifications

Bolt Torque Values

Valve

Crank-

Conn.

Rod
Bolt

Model

91 28 38 38 15 30 20 — 40 45 50 40 25

291 28 30 30 13 25 20 — 40 45 50 40 25

491 30 26 35 8 33 33 35 40 45 10 0 40 25

691 40 40 40 9 40 30 37 40 60 100 40 25

1

Preliminary tightening – snug all head bolts in the sequence shown. Final torqueing – torque all head bolts in the sequence shown to the listed value.

2

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

ft•lb

Bearing

Carrier

ft•lb

Bearing

Cover

ft•lb

case

Inspec

Plate

ft•lb

X-Head

Guide

ft•lb

Cyl. to

Head

(1.2 )

ft•lb

Valve

Cover

Plate

Bolt

ft•lb

Hold­down

Screw

2

ft•lb

Piston

Lock

Nut

Torque

ft•lb

Piston
Screw

Torque

in•lb

Valve Cap

Torque

(w/

Gaskets)

ft•lb

Valve Cap

Torque

(w/

O-rings)

ft•lb

32

Appendix C—Vertical Single-Acting Specifications

Clearances and Dimensions

91 291 491

**Clearance: “X” piston figure 5.4A &

5.4B

Clearance: connecting rod bearing to

crankshaft journal

Clearance: wrist pin to wrist pin

bushing* (max)

0.020

0.044

0.0005

0.0025

0.020

0.044

0.0005

0.0025

0.000/0.020

0.024/0.044

0.0005

0.0025

0.0009 0.0009 0.0009 0.0020

Cylinder bore diameter (max) 3.009 3.009 4 .011 4.515
Cylinder finish (RMS) 16 -32 16-32 16-32 16-32
Piston ring radial thickness (min) 0.082 0.082 0.082 0.082
Clearance: oil pump adapter shaft to

bushing* (max)

Crankshaft end play (cold)

0.0050 0.0050 0.0050 0.0050

0.000

0.002

0.000

0.002

0.000

0.002
Flywheel runout at O.D. (max) 0.020 0.020 0.020 0.020
Clearance: crosshead to crosshead

guide bore (max)

0.011 0.011 0.012 0.013

Crosshead guide bore finish 32 RMS (limited number of small pits and scratches are acceptable)

*

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

**

Clearance should be set with machine cold.

691/D891

(M crankcase)

0.000/0.015

0.012/0.027

0.0019

0.0035

0.002

0.003

33

Appendix C—Vertical Double-Acting Specifications

Model D891

Equipment Type & Options

Double-acting, vertical, reciprocating piston type vapor compressor
Double packed rod
Slip-on weld connections

Applications

Bulk transfer
Truck, tank, railcar, barge unloading
LTVR and scavenger applications
Emergency evacuation

Features and Benefits

Self-lubricating piston rings: Non-lubricated operation to minimize oil in gas
Multiple materials and configurations: Versatility for your application
Multiple mounting configurations: Versatility for your application
High efficiency valves: Quiet, reliable operation
Reversible oil pump: Allows operation in either direction
Simplified top down design: Routine maintenance is minimally invasive

Operating Specifications

Bore of cylinder inches (mm) 4.5 (113)
Stroke inches (mm) 4.0 (101.6)
Piston displacement cfm (m3/hr)
minimum @ 400 RPM 56.6 (96.2)
maximum @ 825 RPM 113.2 (192.0)
Maximum working pressure psig (bar g) 465 (32.1)
Maximum brake horsepower (kW) 45 (34)
Maximum rod load lb (kg) 7,000 (3,175.2)
Maximum outlet temperature °F (°C) 350 (177)
Bare unit weight lb (kg) 855 (387.8)
Maximum flow—propane gpm (m3/hr) 694 (157.6)

34

Appendix C—Vertical Double-Acting Specifications

Model D891 Material Specifications

Part Standard Material Optional Material

Head, cylinder Ductile iron ASTM A536
Distance piece
Crosshead guide Gray iron ASTM A48, Class 30
Crankcase, flywheel
Bearing carrier
Flange ASTM A36 carbon steel
Valve seat, bumper 17-7 PH stainless steel
Valve plate 410 stainless steel
Valve spring 17-7 PH stainless steel
Valve gaskets Soft aluminum Copper, iron-lead
Piston Ductile iron ASTM A536
Piston rod C1050 steel, Nitrotec
Crosshead Gray iron ASTM A48, Class 30
Piston rings PTFE, glass and moly filled Alloy 50
Piston ring expanders 302 stainless steel
Head gasket O-ring, Buna-N PTFE, Viton®1, Neoprene
Adapter plate
Packing cartridge Ductile iron ASTM A536
Connecting rod
Packing rings PTFE, glass and moly filled Alloy 50
Crankshaft Ductile iron ASTM A536
Connecting rod bearing Bimetal D-2 Babbit
Wrist pin C1018 Steel
Wrist pin bushing Bronze SAE 660
Main bearing Tapered roller
Inspection plate Aluminum
O-rings Buna-N PTFE, Viton®1, Neoprene
Retainer rings Steel
Miscellaneous gaskets Coroprene

1

Registered trademark of the DuPont company.

®1

®1

35

Inlet pressure gauge

NEMA 7
liquid level
switch
(107A only)
1-1/2" NPT

Outlet pressure gauge

Appendix D—Compressor Selection

Compressor Mounting Selections

Standard 107 Items

Steel baseplate
V-Belt drive
Adjustable driver slide base
Enclosed steel belt guard
Inlet and outlet pressure gauges
40 Micron strainer
Non-lube 4-way valve
Interconnecting piping
Liquid trap as specified below

107 Mounting

Mechanical liquid trap with ball float

107A Mounting

Automatic liquid trap with one NEMA 7
liquid level switch

107B Mounting

Automatic liquid trap (ASME code) with
two NEMA 7 liquid level switches

Standard 109 Items

Steel baseplate
V-Belt drive
Adjustable driver slide base
Enclosed steel belt guard
Inlet and outlet pressure gauges
Interconnecting piping
Liquid trap as specified below

109 Mounting

Mechanical liquid trap with ball float

109A Mounting

Automatic liquid trap with one NEMA 7
liquid level switch

109B Mounting

Automatic liquid trap (ASME code) with
two NEMA 7 liquid level switches

36

Appendix D—Compressor Selection

Butane Compressor Selection Table

Driver Horsepower
Liquid Liquid
Transfer Transfer
& Without
Residual Residual
Driver Sheave Size Vapor Vapor
Capacity Displacement Compressor Pitch Diameter (inches)
Service gpm1 cfm Model RPM 1,750 RPM 1,450 RPM 100°F 80°F 100°F 8 0°F Vapor Liquid

13 4 91 400 A 3.0 A 3.6 3 3 3 3 3/4 1-1/4
Small 17 5 91 505 A 3.8 B 4.6 3 3 3 3 3/4 1-1/4
bulk 20 6 91 590 B 4.6 B 5.6 3 3 3 3 1 1-1/4
plants 24 7 91 695 B 5.4 B 6.6 5 5 5 5 1 1-1/2
23 7 290, 291 345 A 3.0 A 3.6 2 2 2 2 1 1-1/2
27 8 91 795 B 6.2 B 7.4 5 5 5 5 1 1-1/2
26 8 290, 291 390 A 3.4 B 4.0 2 2 2 2 1 1-1/2
30 9 290, 291 435 A 3.8 B 4.6 3 3 3 3 1 1-1/2
33 10 290, 291 490 B 4.4 B 5.2 3 3 3 3 1 2
Unloading 36 11 290, 291 535 B 4.8 B 5.8 3 3 3 3 1 2
single tank 39 12 290, 291 580 B 5.2 B 6.2 5 3 5 3 1 2
car or 42 13 290, 291 625 B 5.6 B 6.6 5 5 5 5 1-1/4 2
transport 47 14 290, 291 695 B 6.2 B 7.4 5 5 5 5 1-1/4 2
50 15 290, 291 735 B 6.6 B 8.0 5 5 5 5 1-1/4 2-1/2
50 15 490, 491 345 A 3.0 A 3.6 5 5 5 5 1-1/4 2-1/2
53 16 290, 291 780 B 7.0 B 8.6 7-1/2 5 7-1/2 5 1-1/4 2-1/2
53 16 490, 491 370 A 3.2 A 3.8 5 5 5 5 1-1/4 2-1/2
56 17 490, 491 390 A 3.4 B 4.0 5 5 5 5 1-1/4 3
60 18 490, 491 415 A 3.6 B 4.4 5 5 5 5 1-1/4 3
63 19 490, 491 435 A 3.8 B 4.6 5 5 5 5 1-1/4 3
65 20 490, 491 445 B 4.0 B 4.8 5 5 5 5 1-1/4 3
68 21 490, 491 470 B 4.2 B 5.0 5 5 5 5 1-1/4 3
Unloading 71 22 490, 491 490 B 4.4 B 5.2 7-1/2 5 7-1/2 5 1-1/4 3
two or 75 23 490, 491 515 B 4.6 B 5.6 7-1/2 5 7-1/2 5 1-1/4 3
more tank 77 24 490, 491 535 B 4.8 B 5.8 7-1/2 7-1/2 7-1/2 7-1/2 1-1/4 3
cars at 81 25 490, 491 560 B 5.0 B 6.0 7-1/2 7-1/2 7-1/2 7-1/2 1-1/4 3
one time 84 26 490, 491 580 B 5.2 B 6.2 7-1/2 7-1/2 7-1/2 7-1/2 1-1/4 3
or large 87 27 490, 491 605 B 5.4 B 6.4 7-1/2 7-1/2 7-1/2 7-1/2 1-1/4 3
transport 91 28 490, 491 625 B 5.6 B 6.6 7-1/2 7-1/2 7-1/2 7-1/2 1-1/2 3
with excess 94 29 490, 491 650 B 5.8 B 7.0 10 7-1/2 10 7-1/2 1-1/2 3
flow valves 97 30 490, 491 670 B 6.0 10 7-1/2 10 7-1/2 1-1/2 3
of adequate 94 30 690, 691 400 B 4.4 B 5.2 7-1/2 7-1/2 7-1/2 7-1/2 1-1/2 3
capacity 100 31 490, 491 695 B 6.2 B 7.4 10 7-1/2 10 7-1/2 1-1/2 3
98 31 690, 691 420 B 4.6 B 5.6 10 7-1/2 10 7-1/2 1-1/2 3
107 32 490, 491 740 B 6.6 B 8.0 10 10 10 10 1-1/2 3
103 32 690, 691 440 B 4.8 B 5.8 10 7-1/2 10 7-1/2 1-1/2 3
110 33 490, 491 760 B 6.8 B 8.0 10 10 10 10 1-1/2 3
113 34 490, 491 780 B 7.0 B 8.6 10 10 10 10 1-1/2 3
107 34 690, 691 455 B 5.0 B 6.0 10 10 10 10 1-1/2 3
111 35 690, 691 475 B 5.2 B 6.2 10 10 10 10 1-1/2 3
119 36 490, 491 825 B 7.4 B 8.6 15 10 15 10 1-1/2 3
116 36 690, 691 495 B 5.4 A 6.4 10 10 10 10 1-1/2 3
120 38 690, 691 510 B 5.6 B 6.8 10 10 10 10 1-1/2 4
Unloading 124 39 690, 691 530 B 5.8 B 7.0 10 10 10 10 1-1/2 4
large 129 41 690, 691 550 B 6.0 A 7.0 10 10 10 10 1-1/2 4
tank cars, 133 42 690, 691 565 B 6.2 B 7.4 10 10 10 10 2 4
multiple 137 43 690, 691 585 B 6.4 A 7.4 10 10 10 10 2 4
vessels, 142 45 690, 691 605 B 6.6 B 8.0 15 10 15 10 2 4
barges or 145 46 690, 691 620 B 6.8 15 10 15 10 2 4
terminals 150 47 690, 691 640 B 7.0 A 8.2 15 10 15 10 2 4
158 48 690, 691 675 B 7.4 B 8.6 15 15 15 15 2 4
171 54 690, 691 730 B 8.0 B 9.4 15 15 15 15 2 4
184 58 690, 691 785 B 8.6 15 15 15 15 2 4
193 60 690, 691 820 TB 9.0 A 10.6 15 15 15 15 2 4
260 82.1 D891 580 5V 7.1 5V 8.5 20 20 20 20 3 6
359 113.3 D891 800 5V 9.75 5V 11.8 25 25 25 25 3 6

1

The capacities shown are based on 70°F, but will vary depending upon piping, fittings used, product being transferred and temperature. The
factory can supply a detailed computer analysis if required.

2

Driver sheaves: 91 (2 belts); 290, 291, 490, 491 (3 belts); 690, 691 (4 belts).

3

The piping sizes shown are considered minimum. If the length exceeds 100 ft., use the next larger size.
NOTE: Please consult factory for compressors with higher flows.

2

Recovery Recovery Piping Size

3

37

Appendix D—Compressor Selection

Propane Compressor Selection Table

Driver Horsepower
Liquid Liquid
Transfer Transfer
& Without
Residual Residual
Driver Sheave Size Vapor Vapor
Capacity Displacement Compressor Pitch Diameter (inches)
Service gpm1 cfm Model RPM 1,750 RPM 1,450 RPM 100°F 80°F 100°F 8 0°F Vapor Liquid

23 4 91 400 A 3.0 A 3.6 5 3 3 3 3/4 1-1/4
Small 29 5 91 505 A 3.8 B 4.6 5 5 5 5 3/4 1-1/4
bulk 34 6 91 590 B 4.6 B 5.6 5 5 5 5 1 1-1/4
plants 40 7 91 695 B 5.4 B 6.6 5 5 5 5 1 1-1/2
39 7 290, 291 345 A 3.0 A 3.6 3 3 3 3 1 1-1/2
45 8 91 795 B 6.2 B 7.4 7-1/2 7-1/2 7-1/2 7-1/2 1 1-1/2
44 8 290, 291 390 A 3.4 B 4.0 5 3 3 3 1 1-1/2
50 9 290, 291 435 A 3.8 B 4.6 5 5 3 3 1 1-1/2
56 10 290, 291 490 B 4.4 B 5.2 5 5 5 5 1 2
Unloading 61 11 290, 291 535 B 4.8 B 5.8 5 5 5 5 1 2
single tank 66 12 290, 291 580 B 5.2 B 6.2 7-1/2 5 5 5 1 2
car or 71 13 290, 291 625 B 5.6 B 6.6 7-1/2 5 7-1/2 5 1-1/4 2
transport 79 14 290, 291 695 B 6.2 B 7.4 7-1/2 7-1/2 7-1/2 7-1/2 1-1/4 2
84 15 290, 291 735 B 6.6 B 8.0 10 7-1/2 10 7-1/2 1-1/4 2-1/2
84 15 490, 491 345 A 3.0 A 3.6 7-1/2 7-1/2 5 5 1-1/4 2-1/2
89 16 290, 291 780 B 7.0 B 8.6 10 10 10 10 1-1/4 2-1/2
89 16 490, 491 370 A 3.2 A 3.8 7-1/2 7-1/2 7-1/2 5 1-1/4 2-1/2
95 17 490, 491 390 A 3.4 B 4.0 7-1/2 7-1/2 7-1/2 7-1/2 1-1/4 3
101 18 490, 491 415 A 3.6 B 4.4 10 7-1/2 7-1/2 7-1/2 1-1/4 3
106 19 490, 491 435 A 3.8 B 4.6 10 7-1/2 7-1/2 7-1/2 1-1/4 3
108 20 490, 491 445 B 4.0 B 4.8 10 7-1/2 7-1/2 7-1/2 1-1/4 3
114 21 490, 491 470 B 4.2 B 5.0 10 7-1/2 7-1/2 7-1/2 1-1/4 3
Unloading 119 22 490, 491 490 B 4.4 B 5.2 10 10 7-1/2 7-1/2 1-1/4 3
two or 125 23 490, 491 515 B 4.6 B 5.6 10 10 10 7-1/2 1-1/4 3
more tank 130 24 490, 491 535 B 4.8 B 5.8 15 10 10 10 1-1/4 3
cars at 136 25 490, 491 560 B 5.0 B 6.0 15 10 10 10 1-1/4 3
one time 141 26 490, 491 580 B 5.2 B 6.2 15 10 10 10 1-1/4 3
or large 147 27 490, 491 605 B 5.4 B 6.4 15 10 15 10 1-1/4 3
transport 152 28 490, 491 625 B 5.6 B 6.6 15 15 15 15 1-1/2 3
with excess 158 29 490, 491 650 B 5.8 B 7.0 15 15 15 15 1-1/2 3
flow valves 163 30 490, 491 670 B 6.0 15 15 15 15 1-1/2 3
of adequate 163 30 690, 691 400 B 4.4 B 5.2 15 15 10 10 1-1/2 3
capacity 168 31 490, 491 695 B 6.2 B 7.4 15 15 15 15 1-1/2 3
171 31 690, 691 420 B 4.6 B 5.6 15 15 10 10 1-1/2 3
179 32 490, 491 740 B 6.6 B 8.0 15 15 15 15 1-1/2 3
178 32 690, 691 440 B 4.8 B 5.8 15 15 10 10 1-1/2 3
186 34 690, 691 455 B 5.0 B 6.0 15 15 15 10 1-1/2 3
193 35 690, 691 475 B 5.2 B 6.2 15 15 15 10 1-1/2 3
200 36 690, 691 495 B 5.4 B 6.4 15 15 15 15 1-1/2 3
208 38 690, 691 510 B 5.6 B 6.8 20 15 15 15 1-1/2 4
215 39 690, 691 530 B 5.8 B 7.0 20 15 15 15 1-1/2 4
223 41 690, 691 550 B 6.0 A 7.0 20 15 15 15 1-1/2 4
230 42 690, 691 565 B 6.2 B 7.4 20 15 15 15 2 4
Unloading 237 43 690, 691 585 B 6.4 A 7.4 20 15 15 15 2 4
large 245 45 690, 691 605 B 6.6 B 8.0 20 15 15 15 2 4
tank cars, 252 46 690, 691 620 B 6.8 20 20 15 15 2 4
multiple 260 47 690, 691 640 B 7.0 A 8.2 20 20 20 15 2 4
vessels, 275 48 690, 691 675 B 7.4 B 8.6 25 20 20 20 2 4
barges or 297 54 690, 691 730 B 8.0 B 9.4 25 20 20 20 2 4
terminals 319 58 690, 691 785 B 8.6 25 20 25 20 2 4
334 60 690, 691 820 TB 9.0 A 10.6 30 25 25 20 2 4
452 82 D891 580 5V 7.1 5V 8.5 30 30 30 30 3 6
623 113 D891 800 5V 9.75 5V 11.8 40 40 30 3 6

1

The capacities shown are based on 70°F, but will vary depending upon piping, fittings used, product being transferred and temperature. The
factory can supply a detailed computer analysis if required.

2

Driver sheaves: 91 (2 belts); 290, 291, 490, 491 (3 belts); 690, 691 (4 belts).

3

The piping sizes shown are considered minimum. If the length exceeds 100 ft., use the next larger size.
NOTE: Please consult factory for compressors with higher flows.

2

Recovery Recovery Piping Size

3

38

Appendix D—Compressor Selection

Ammonia Compressor Selection Table

Driver Horsepower
Liquid Liquid
Transfer Transfer
& Without
Residual Residual
Driver Sheave Size Vapor Vapor
Capacity Displacement Compressor Pitch Diameter (inches)
Service gpm1 cfm Model RPM 1,750 RPM 1,450 RPM 100°F 80°F 100°F 8 0°F Vapor Liquid

23 4 91 400 A 3.0 A 3.6 5 3 3 3 3/4 1-1/4
Small 29 5 91 505 A 3.8 B 4.6 5 5 5 3 3/4 1-1/4
bulk 34 6 91 590 B 4.6 B 5.6 5 5 5 5 1 1-1/4
plants 40 7 91 695 B 5.4 B 6.6 5 5 5 5 1 1-1/2
43 7 290, 291 345 A 3.0 A 3.6 5 3 3 3 1 1-1/2
46 8 91 795 B 6.2 B 7.4 7-1/2 5 5 5 1 1-1/2
45 8 290, 291 390 A 3.4 B 4.0 5 3 3 3 1 1-1/2
50 9 290, 291 435 A 3.8 B 4.6 5 5 3 3 1 1-1/2
56 10 290, 291 490 B 4.4 B 5.2 5 5 5 3 1 2
Unloading 62 11 290, 291 535 B 4.8 B 5.8 7-1/2 5 5 5 1 2
single tank 67 12 290, 291 580 B 5.2 B 6.2 7-1/2 5 5 5 1 2
car or 72 13 290, 291 625 B 5.6 B 6.6 7-1/2 5 5 5 1-1/4 2
transport 80 14 290, 291 695 B 6.2 B 7.4 7-1/2 7-1/2 7-1/2 5 1-1/4 2
85 15 290, 291 735 B 6.6 B 8.0 10 7-1/2 7-1/2 7-1/2 1-1/4 2-1/2
85 15 490, 491 345 A 3.0 A 3.6 7-1/2 7-1/2 5 5 1-1/4 2-1/2
90 16 290, 291 780 B 7.0 B 8.6 10 7-1/2 7-1/2 7-1/2 1-1/4 2-1/2
90 16 490, 491 370 A 3.2 A 3.8 10 7-1/2 5 5 1-1/4 2-1/2
96 17 490, 491 390 A 3.4 B 4.0 10 7-1/2 5 5 1-1/4 3
102 18 490, 491 415 A 3.6 B 4.4 10 7-1/2 7-1/2 7-1/2 1-1/4 3
107 19 490, 491 435 A 3.8 B 4.6 10 7-1/2 7-1/2 7-1/2 1-1/4 3
110 20 490, 491 445 B 4.0 B 4.8 10 7-1/2 7-1/2 7-1/2 1-1/4 3
115 21 490, 491 470 B 4.2 B 5.0 10 7-1/2 7-1/2 7-1/2 1-1/4 3
Unloading 120 22 490, 491 490 B 4.4 B 5.2 15 10 7-1/2 7-1/2 1-1/4 3
two or 126 23 490, 491 515 B 4.6 B 5.6 15 10 7-1/2 7-1/2 1-1/4 3
more tank 131 24 490, 491 535 B 4.8 B 5.8 15 10 10 7-1/2 1-1/4 3
cars at 138 25 490, 491 560 B 5.0 B 6.0 15 10 10 7-1/2 1-1/4 3
one time 142 26 490, 491 580 B 5.2 B 6.2 15 10 10 7-1/2 1-1/4 3
or large 148 27 490, 491 605 B 5.4 B 6.4 15 10 10 10 1-1/4 3
transport 153 28 490, 491 625 B 5.6 B 6.6 15 10 10 10 1-1/2 3
with excess 160 29 490, 491 650 B 5.8 B 7.0 15 15 10 10 1-1/2 3
flow valves 165 30 490, 491 670 B 6.0 15 15 15 10 1-1/2 3
of adequate 165 30 690, 691 400 B 4.4 B 5.2 15 15 10 10 1-1/2 3
capacity 170 31 490, 491 695 B 6.2 B 7.4 15 15 15 10 1-1/2 3
173 31 690, 691 420 B 4.6 B 5.6 15 15 10 10 1-1/2 3
181 32 490, 491 740 B 6.6 B 8.0 15 15 15 15 1-1/2 3
180 32 690, 691 440 B 4.8 B 5.8 15 15 10 10 1-1/2 3
188 34 690, 691 455 B 5.0 B 6.0 20 15 10 10 1-1/2 3
195 35 690, 691 475 B 5.2 B 6.2 20 15 10 10 1-1/2 3
203 36 690, 691 495 B 5.4 B 6.4 20 15 15 10 1-1/2 3
211 38 690, 691 510 B 5.6 B 6.8 20 15 15 10 1-1/2 4
218 39 690, 691 530 B 5.8 B 7.0 20 15 15 15 1-1/2 4
226 41 690, 691 550 B 6.0 A 7.0 20 15 15 15 1-1/2 4
233 42 690, 691 565 B 6.2 B 7.4 20 15 15 15 2 4
Unloading 240 43 690, 691 585 B 6.4 A 7.4 20 20 15 15 2 4
large 248 45 690, 691 605 B 6.6 B 8.0 20 20 15 15 2 4
tank cars, 255 45 690, 691 620 B 6.8 25 20 15 15 2 4
multiple 263 47 690, 691 640 B 7.0 A 8.2 25 20 15 15 2 4
vessels, 278 48 690, 691 675 B 7.4 B 8.6 25 20 15 15 2 4
barges or 301 54 690, 691 730 B 8.0 B 9.4 25 20 20 15 2 4
terminals 323 58 690, 691 785 B 8.6 30 25 20 20 2 4
338 60 690, 691 820 TB 9.0 A 10.6 30 25 20 20 2 4
459 82 D891 580 5V 7.1 5V 8.5 40 30 30 30 3 6
633 113 D891 800 5V 9.75 5V 11.8 40 40 30 3 6

1

The capacities shown are based on 70°F, but will vary depending upon piping, fittings used, product being transferred and temperature. The
factory can supply a detailed computer analysis if required.

2

Driver sheaves: 91 (2 belts); 290, 291, 490, 491 (3 belts); 690, 691 (4 belts).

3

The piping sizes shown are considered minimum. If the length exceeds 100 ft., use the next larger size.
NOTE: Please consult factory for compressors with higher flows.

2

Recovery Recovery Piping Size

3

39

M

M1

L

L1

L

L1

M

M1

S***

Appendix E—Outline Dimensions

Models 91–691 and F91–F691 Bare with Flywheel

Outline Dimensions—Inches (Centimeters)

Model A B C D E F G H J K

91, F91

1-13/16 2-3/8 3-11/16 13/32 5/8 6-1/4 3-7/8 25-5/16 5 22-11/16

(4.6) (6.0) (9.4) (1.03) (1.59) (15.9) (9.8) (64.3) (12.7) (57.6)

291, F291

3-3/8 4-1/8 3-11/16 13/32 5/8 9-13/16 12 25-13/16 5-3/8 23-3/8

(8.6) (10.5) (9.4) (1.11) (1.59) (24.9) (30.4) (65.2) (13.7) (59.4)

491, F491

4-1/8 5 4-11/16 1/2 11/16 10-11/16 13 29-11/16 5-7/8 26-3/16

(10.5) (12.7) (11.9) (1.27) (1.75) (27.2) (33.1) (75.4) (14.9) (66.5)

691, F691
(12.1) (14.0) (13.7) (1.5) (2.5) (35.6) (35.6) (99.4) (21.0) (89.2)

4-3/4 5 5-3/8 9/16 1 14 14-3/8 39-1/8 8-1/4 35-1/8

“PD” Flywheel Pitch Diameter
Model L* L1** M* M1** P Q R S*** T A-belt Groove B-belt Groove

91, F91 3/4 3/4-300 lb 2-3/8 4-1/4 3 14 1-1/8 1-1/4 1/4 13.2 2 13.6 2
NPT ANSI (6.0) (10.8) (7.6) (35.6) (2.8) (3.2) (0.63) (33.5) (34.5)
291, F291 3/4 3/4-300 lb 2-11/16 4-1/4 3 16 1-1/4 1-1/4 1/4 15.2 3 15.6 3
NPT ANSI (6.8) (10.8) (7.6) (40.6) (3.2) (3.2) (0.63) (38.6) (39.6)
14

1

13.21 2 13.61 2
(35.6) (33.5) (34.5)
491, F491 1-1/4 1-1/4-300 lb 3-7/8 5-5/8 3 16 1-3/8 1-1/4 5/16 15.2 3 15.6 3
NPT ANSI (9.9) (14.3) (7.6) (40.6) (3.5) (3.2) (0.79) (38.6) (39.6)
14

1

13.21 2 13.61 2
(35.6) (33.5) (34.5)
691, F691 2

2

2-300 lb 6-3/8 6-15/16 3-13/16 19-1/2 2-1/8 — 1/2 — — 19-1/8 4

NPT ANSI (16.1) (17.6) (9.7) (49.5) (5.4) (1.27) (48.5)

1

Optional flywheel

2

Optional flanges: 1-1/4", 1-1/2" NPT, 1-1/4", 1-1/2" or 2" Weld

* 91, 291, 491, 691 only
** F91, F291, F491, F691 only
*** With extended crankshaft option only

40

Appendix E—Outline Dimensions

Models 91–691 with 103 Mounting

Outline Dimensions—Inches (Centimeters)

Model A B C D E F G

91-103
(30.4) (38.1) (69.8) (76.2) (3.1) (7.6) (13.34)

291-103
(30.5) (38.1) (80.0) (86.4) (3.2) (7.6) (12.7)

491-103
(38.1) (45.7) (95.3) (101.6) (3.2) (10.2) (13.3)

691-103
(43.2) (50.8) (100.3) (106.7) (3.2) (10.2) (14.0)

Model H J K L M N

91-103
(72.9) (67.0) (12.5) (19.7) (6.8) NPT

291-103
(72.9) (67.0) (12.5) (19.7) (6.8) NPT

491-103
(85.6) (76.7) (14.6) (25.4) (10.0) NPT

691-103
(109.5) (99.4) (21.0) (23.5) (16.2) NPT

12 15 27-1/2 30 1-1/4 3 5-1/4

12 15 31-1/2 34 1-1/4 3 5

15 18 37-1/2 40 1-1/4 4 5-1/4

17 20 39-1/2 42 1-1/4 4 5.5

Outline Dimensions—Inches (Centimeters)

28-11/16 26-3/8 4-15/16 7.75 2-11/16 3/4

28-22/32 26-6/16 4-15/16 7-3/4 2-11/16 3/4

33-11/16 30-3/16 5-3/4 10 3-15/16 3/4

43-1/8 39-1/8 8.25 9.25 6-3/8 2

41

Appendix E—Outline Dimensions

Models 91 with -107 or -107A Mounting (model -107A shown below)

* Dimensions apply to -107A mounting only

Inches (Centimeters)

42

CORKEN

AUTOMATIC LIQUID TRAP

IN

CORKEN

CORKEN CORKEN

Appendix E—Outline Dimensions

Model 291 with -107 or -107A Mounting (model -107A shown below)

* Dimensions apply to -107A mounting only

Inches (Centimeters)

43

CORKENCORKEN

IN

CORKEN

AUTOMATIC LIQUID TRAP

Appendix E—Outline Dimensions

Model 491 with -107 or -107A Mounting (model -107A shown below)

* Dimensions apply to -107A mounting only

Inches (Centimeters)

44

1-1/4 in. NPT

four way

control valve

O

M N

S

RP

K

L

Q D

C

Appendix E—Outline Dimensions

Model 691 with -107 or -107A Mounting (model -107A shown below)

Inches (Centimeters)

Outline Dimensions—Inches (Centimeters)

Model A B C D E F G H J

691-107, -107A

8-1/4 17 49-1/2 19-3/4 1-1/2 20 52 43-1/4 5-1/2

(21.0) (43.1) (126) (50.1) (3.8) (50.8) (132) (110) (14)

Outline Dimensions—Inches (Centimeters)

Model K L M N O P Q R S

691-107, -107A

4 1-1/4 1/4 2-11/16* 7-3/4 29 10-1/2 24-1/4 6

(10.1) (3.2) (0.63) (6.8)* (19.6) (73.0) (26.6) (61.0) (15.0)

* Dimensions apply to -107A mounting only

45

Appendix E—Outline Dimensions

Model 91–691 with -109 or -109A Mounting (model -109A shown below)

Outline Dimensions—Inches (Centimeters)

Model A A1 B C D D1 E F G H J

91-109, -109A
(3.7) (13.4) (30.5) (33.8) (80.0) (3.8) (38.1) (86.4) (79.2) (13.3)

291-109, -109A

(12.7) — (30.5) (40.0) (100.3) — (3.8) (38.1) (106.7) (78.4) (13.3)

491-109, -109A

(14.6) — (38.1) (45.7) (115.6) — (3.8) (45.7) (121.9) (85.7) (13.3)

691-109, -109A

(30.0) — (43.2) (48.8) (125.7) (50.1) (3.8) (50.8) (132) (109.6) (14.0)

Model K L M N P R S T U

91-109, -109A

(71.6) NPT (5.9) (7.6) (3.2) (9.2) (24.1) (6.9) (17.1)

291-109, -109A

(72.4) NPT (6.8) (7.6) (3.2) (9.9) (24.1) (11.4) (17.1)

491-109, -109A

(76.5) NPT (10.2) (10.2) (3.2) (10.2) (26.7) (13.3) (19.7)

691-109, -109A

(99.3) NPT (16.1) (10.2) (3.2) (10.4) (54.4) (18.4) (19.7)

1-3/16 5-1/4 12 13-5/16 31-1/2 — 1-1/2 15 34 31-3/16 5-1/4

5 — 12 15-3/4 39-1/2 — 1-1/2 15 42 30-7/8 5-1/4

5-3/4 — 15 18 45-1/2 — 1-1/2 18 48 33-3/4 5-1/4

8-1/4 — 17 19-1/4 49-1/2 19-3/4 1-1/2 20 52 43-3/16 5-1/2

Outline Dimensions—Inches (Centimeters)

28-3/16 3/4 2-5/16 3 1-1/4 3-5/8 9-1/2 2-3/4 6-3/4

28-1/2 3/4 2-11/16 3 1-1/4 3-7/8 9-1/2 4-1/2 6-3/4

30-1/8 1-1/4 4 4 1-1/4 4 10-1/2 5.25 7-3/4

39-1/8 1-1/2 6-3/8 4 1-1/4 4-1/8 21-7/16 7-1/4 7-3/4

46

Suction

valve unloaders

(optional)

Inlet

2" Weld or

NPT flange

9-16" (1.4)

Hole Diameter

Outlet

2" Weld or

NPT flange

Crankcase heater

(optional)

2-1/8"

(5.3)

8-1/4"
(20.9)

35-5/8"

(90.4)

43-1/4"
(109.9)

1/4" NPT drain

24-15/32"

(62.1)

21.2"

(53.8)

5-5/8"
(14.3)

13-1/4"

(33.6)

4-3/4"
(12.0)

1"

(2.5)

5-1/2"
(13.9)

5-3/8"
(13.6)

10-1/4"

(26.0)

5-3/8"
(13.6)

5-1/2"

(13.9)

5-1/2"
(13.9)

Appendix E—Outline Dimensions

Model D891 Bare with Flywheel

Inches (Centimeters)

47

Inlet

2" Weld or

NPT flange

Outlet

2" Weld or

NPT flange

Appendix E—Outline Dimensions

Model D891 with 103 Mounting

Inches (Centimeters)

48

Appendix E—Outline Dimensions

Model D891 with 107B Mounting

Inches (Centimeters)

49

Appendix E—Outline Dimensions

Model D891 with 109B Mounting

Inches (Centimeters)

50

Appendix F—Troubleshooting

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

Problem Possible Cause

Low capacity 1, 2, 3, 4, 16

Overheating 1, 2, 3, 5, 6, 11, 15

Knocks, rattles and noise 1, 7, 9, 10, 11, 14

Oil in cylinder 8, 14

Abnormal piston-ring wear 1, 3, 5, 6, 11, 14, 15

Product leaking through crankcase breather 8, 14

Product leakage 4, 8, 14, 16

Oil leakage around compressor base 17, 18

No oil pressure 19, 20

Excessive vibration 1, 7, 9, 10, 11, 12, 13, 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 necessary

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 factory

12. Inadequate compressor base Strengthen, replace or grout

13. Improper foundation or mounting Tighten mounting or rebuild foundation

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

15. Dirty cooling fins Clean weekly

16. 4-way control valve not lubricated Inspect and lubricate

17. Leaking gas blowing oil from crankcase Tighten packing

18. Bad oil seal Replace

19. No oil in crankcase Add oil

20. Oil-pump malfunction See oil-pressure adjustment

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

22. Motor wired wrong Check wiring diagram

23. Wire size too small for length or run Replace with correct size

24. Wrong power characteristics Voltage, phase and frequency must coincide with motor nameplate.
Consult with power company.

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

26. Compressor overloading Reduce speed

27. Motor shorted out See driver installation

28. 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.

51

5

7

6

5

7

6

11 1111

5

7

6

1098

Suction

Spec 3

Suction

Spec 4

Discharge

All Specs

Suction Valve

Spec 3

Suction Valve

Spec 4

Discharge Valve

All Specs

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

1

3

4

3

2

4

Appendix G—91 and F91 Head and Valve Assembly Details

Valve Holddown Assemblies91 Head Assembly

F91 Head Assembly

Valve Assemblies

52

Appendix G—91 and F91 Head and Valve Assembly Details

Head and Valve Bill of Materials

Ref
No.

Part No. Description

2374 Head model 91

1.

2374 -X

a

Head assy. for model 91 (spec 3)

2374 -X1 Head assy. for model 91 (spec 4)

2. 4302 Head model F91 (ANSI flange)

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

4. 2-235_

c

O-ring

5. 2714-1 Valve cap

6. 2-031_

c

O-ring

7. 2715 Holddown screw
3483-1X Suction valve assy. (spec 3)

8.

3483-1X1
3483-1X 2

b

b

Same as above but with copper gaskets
Same as above but with iron-lead gaskets

3483-X Suction valve assy. (spec 4)

9.

3483-X1
3483-X2

b

b

Same as above but with copper gaskets
Same as above but with iron-lead gaskets

3485-X Discharge valve assy. (all specs)

10.

3485-X1
3485-X2

b

b

Same as above but with copper gaskets
Same as above but with iron-lead gaskets

2717 Valve gasket (aluminum)

11.

2717-1
2717-2

b

b

Valve gasket (copper)
Valve gasket (iron-lead)

12. 5000-77 Retainer ring (spec 3)

13. 3977 Suction valve relief housing (spec 3)

14. 1411 Spring (spec 3)

15. 1410 Ball (spec 3)

16. 3 483-1 Suction valve seat (spec 3)

17. 3972 Suction valve plate (spec 3)

18. 4009 Suction spring (spec 3)

19. 3484 Suction valve bumper (spec 3)

20. 3483 Suction valve seat (spec 4)

21. 3972 Suction valve plate (spec 4)

22. 4009 Suction spring (spec 4)

23. 3484 Suction valve bumper (spec 4)

24. 3486 Discharge valve bumper

25. 4008 Discharge spring

26. 3973 Discharge valve plate

27. 3485 Discharge valve seat

a

O-ring Code

A Buna-N

B Neoprene

®d

Not shown.

b

Optional

c

_ denotes O-ring code. See O-ring char t to the left for details.

d

Registered trademark of the DuPont company.

CAUTION: Always Relieve Pressure In The Unit Before Attempting Any Repairs.

53

5

6

7

8

9

Piston Rod

4

3

2

1

Appendix G—91 and F91 Piston Assembly Details

Piston Assembly Number 1983-X Bill of Materials
Piston Diameter 3" (7.62 cm)

No.

1.

Ref

Part No. Description Qty

7002-010OC100A Screw, socket head 4

7207-010A Lock washer 4

2. 1983 Head, iron 1

3. 17 75 Ring expander 3

4. 1772 Piston ring 3

5. 1482 Locknut 1

6. 14 8 3 Lock pin 1

7. 1984 Piston platform 1

8.

1528 Shim washer, thick

1528 -1 Shim washer, thin

As

Req.

9. 1527 Thrust washer 1

Piston Clearance (Cold)

Model Minimum Maximum

a

91 0.020" (0.51 mm) 0.044" (1.12 mm)

a

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

CAUTION: Always Relieve Pressure In The Unit Before Attempting Any Repairs.

54

Piston Rod

1

2

3

4

13

5

6

7,8,9

7

8

9

10

11

12

Appendix G—91 and F91 Packing Assembly Details

Packing Assembly Bill of Materials

Ref
No.

Part No. Description Qty

1. 2242 Cylinder 1

2. 2-235_

a

O-ring for cylinder 1

3. 5000-137 Retainer ring 1

4. 1012 Washer 1

5. 1628 Packing spring 1

6. 1714 Packing box washer 1

7. 1453-1 Male packing ring 1

8. 14 5 4

9. 1452-1 Female packing ring 1

b

Packing ring 8

10. 2240 Crosshead guides 1

11. 1387 Adjusting screw 1

12. 2526 Crankcase gasket 1

13. 1452-1X1 Packing set 1

Assembly
Number

Assembly Name

113 2-X 2 Crosshead - piston-rod assembly

Packing set (alloy 50) with 1452-1,

1452-2X1

O-ring Code

d

1453-1, 1454-2 (8), 1626, 1714

A Buna-N

B Neoprene

a

_ denotes O-ring code. See O-ring char t above for details.

b

The quantity of 1454 packing rings required will vary due to
tolerances. Use cone 4005 for installation of packing.

c

Registered trademark of the DuPont company.

d

Optional equipment

CAUTION: Always Relieve Pressure In The Unit Before Attempting
Any Repairs.

®c

55

5

Note

alignment

marks

8

1

4

2

5

9

10

6, 7

3

2

Appendix G—91 and F91 Connecting Rod Assembly Details

Connecting Rod Assembly Bill of Materials

Ref
No.

Part No. Description

1. 1132-X 2 Crosshead assembly

2. 1498 Retainer ring

3. 2505 Wrist pin

4. 1846 -X

5. 159 9

b

a,b

Wrist pin bushing
Bolt

6. 1889 -1X Connecting rod assembly

7. 1889-1

8. 13 67

9. 2011

10. 1600

a

Must be rebored after replacing (0.8754/0.8751 dia.)

b

Included with connecting rod assembly

c

Torque connecting rod nut to 28 ft. lbs.

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

CAUTION: Always Relieve Pressure In The Unit Before Attempting
Any Repairs.

b

b

b

b,c

Connecting rod
Connecting rod bearing
Dipper
Nut

56

Back Side

Front Side

Appendix G—91 and F91 Flywheel Assembly Details

Flywheel Assembly Bill of Materials

Assembly Number Assembly Name

Flywheel assembly

3271-X2

3271

H SF-1.125

(flywheel, hub, and
three bolts)

Flywheel: 14" O.D.,
2 groove

Hub with three
bolts and
lockwashers

57

17

3

23

22

10

13

13

12

1

2

3

4

5

6

7

15

16

14

8

9

10

11

18

20

19

3

21

Appendix G—91 and F91 Crankcase Assembly Details

58

Appendix G—91 and F91 Crankcase Assembly Details

Crankcase Assembly Bill of Materials

Ref No. Part No. Description

1. 3259 Oil seal

2. 1483 Roll pin - 1/8 x 1"

3. 7001-037NC075A Hex head 3/8-16 x 3/4", Gr 5

4. 3260 Bearing carrier

5. 2796 Breather ball

6. 1279-X O-ring (part of bearing cap assembly)

7. 1279-X Breather cap assembly (with O-ring - ref. no. 6)

8. 2725 Bearing carrier gasket

9. 1807 Roll pin - 1/8 x 5/8"

10. 2718 Bearing cup

11. 2723 Oil circulating ring

12. 2476 Crankshaft

13. 2719 Bearing cone

14. 2289 Flywheel key

15. 2290 Oil ring retainer washer

16. 2554

a

17. 1661 Pipe plug - 3/8 NPT sq. or hex

18. 2729 Inspection plate gasket

19. 2728 Crankcase inspection plate

20. 2-112_

c

21. 1368-X1 Oil bayonet assembly (with O-ring)

2721 Bearing adjustment shim (0.005)

22.

2721-1 Bearing adjustment shim (0.007)
2721-2 Bearing adjustment shim (0.020)

23. 2720 Bearing cap

Crankcase

O-ring

Other Assemblies

Assembly
Number

2476-X Crankshaft assembly with 2476, 2290 and 2719
2476-SX

3260-X

3271-X2

O-ring Code

A Buna-N

B Neoprene

a

Crankcase capacity: 0.9 quarts (0.8 liters)

b

Optional

c

_ denotes O-ring code. See O-ring char t above for details.

d

Registered trademark of the DuPont company.

CAUTION: Always Relieve Pressure In The Unit Before Attempting Any Repairs.

Assembly Name

b

Extended crankshaft assembly with 2719 (2) and 2290, (optional)
Bearing carrier assembly with 3260, 2718, 3259, 1279-X, 2-111,

1483, 2796 and 1807

b

Flywheel assembly 14" - 2 groove with H SF-1.125 and 3271

®c

59

Suction

Spec 3

Suction

Spec 4

Discharge

All Specs

Suction Valve

Spec 3

Suction Valve

Spec 4

Discharge Valve

All Specs

7

9

8

7

9

8

13 1313

7

9

8

121110

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

2

3

1

6

5

4

2

3

6

5

4

Appendix H—291 and F291 Head and Valve Assembly Details

Valve Holddown Assemblies291 Head Assembly

F291 Head Assembly

Valve Assemblies Details

60

Appendix H—291 and F291 Head and Valve Assembly Details

Head and Valve Bill of Materials

Ref
No.

Part No. Description

2912 Head model 291

1.

2912-X1 Head assy. for model 291 (spec 3)
2912-X 2 Head assy. for model 291 (spec 4)

2. 4300 Head model F291 (ANSI flange)

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

4.

5. 2-235_

6. 2-113 _

2731 Center headbolt
2732 Gasket for center headbolt

b

b

O-ring
O-ring

7. 2714-1 Valve cap

8. 2-031_

b

O-ring

9. 2715 Holddown screw
3483-1X Suction valve assy. (spec 3)

10.

3483-1X1
3483-1X 2

a

a

Same as above but with copper gaskets
Same as above but with iron-lead gaskets

3483-X Suction valve assy. (spec 4)

11.

3483-X1
3483-X2

a

a

Same as above but with copper gaskets
Same as above but with iron-lead gaskets

3485-X Discharge valve assy. (all specs)

12.

3485-X1
3485-X2

a

a

Same as above but with copper gaskets
Same as above but with iron-lead gaskets

2717 Valve gasket (aluminum)

13.

2717-1
2717-2

a

a

Valve gasket (copper)
Valve gasket (iron-lead)

14. 5000-77 Retainer ring (spec 3)

15. 3977 Suction valve relief housing

16. 1411 Spring (spec 3)

17. 1410 Ball (spec 3)

18. 3483-1 Suction valve seat (spec 3)

19. 3972 Suction valve plate (spec 3)

20. 4009 Suction spring (spec 3)

21. 3484 Suction valve bumper (spec 3)

22. 3483 Suction valve seat (spec 4)

23. 3972 Suction valve plate (spec 4)

24. 4009 Suction spring (spec 4)

25. 3484 Suction valve bumper (spec 4)

26. 3486 Discharge valve bumper

27. 4008 Discharge spring

28. 3973 Discharge valve plate

29. 3485 Discharge valve seat

a

O-ring Code

A Buna-N

B Neoprene

®c

Optional

b

_ denotes O-ring code. See O-ring char t to the left for details.

c

Registered trademark of the DuPont company.

CAUTION: Always Relieve Pressure In The Unit Before Attempting Any Repairs.

61

5

6

7

8

9

Piston Rod

4

3

2

1

Appendix H—291 and F291 Piston Assembly Details

Piston Assembly Number 1983-X Bill of Materials
Piston Diameter 3" (7.62 cm)

Ref

Part No. Description Qty

No.

7002-010OC100A Screw, socket head 4

1.
7207-010A Lock washer 4

2. 1983 Head, iron 1

3. 1775 Ring expander 3

4. 1772 Piston ring 3

5. 1482 Locknut 1

6. 14 8 3 Lock pin 1

7. 1984 Piston platform 1
1528 Shim washer, thick

8.
1528 -1 Shim washer, thin

As

Req.

9. 1527 Thrust washer 1

Piston Clearance (Cold)

a

Model Minimum Maximum

291 0.020" (0.51 mm) 0.044" (1.12 mm)

a

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

CAUTION: Always Relieve Pressure In The Unit Before Attempting Any Repairs.

62

1

2

4

5

6

16

10

11

3

13

Piston Rod

12

15

14

7

8

9

7,8,9

17

18

19

Appendix H—291 and F291 Packing Assembly Details

Packing Assembly Bill of Materials

Ref
No.

Part No. Description Qty

1. 2 913 -1 Cylinder 1

a

2. 2-235_

O-ring for cylinder 2

3. 5000-137 Retainer ring 2

4. 1012 Washer 2

5. 1628 Packing spring 2

6. 1714 Packing box washer 2

7. 1453-1 Male packing ring 2

8. 14 5 4

b

Packing 6

9. 145 2-1 Female packing ring 2

10. 4 3 9 8

Cartridge holddown
screw

2

11. 4394 Packing box cartridge 2

12. 1387 Adjusting screw 2

13. 2-135 _

a

O-ring (packing
cartridge)

14. 4393 Crosshead guide 1

15. 2702 Crankcase gasket 1

16. 1452-1X1 Packing set 2

17. 1651

Inspection plate
gasket

2

1

18. 1650 Inspection plate 1

19.

not
shown

Other Assemblies

Assembly
Number

7003­025NC037E

1/4-20x3/8" 4

119 2 Locking device 4

Assembly Name Qty

113 2-X 2 Crosshead assembly 2

1452-1X1

Packing set with 1452-1,
1453-1, 1454 (8), 1628, 1714

2

63

O-ring Code

A Buna-N

B Neoprene

a

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

b

The quantity of 1454 packing rings
required will vary due to tolerances.
Use Cone 4005 for installation of
packing.

c

Registered trademark of the
DuPont company.

CAUTION: Always Relieve Pressure
In The Unit Before Attempting Any
Repairs.

®c

5

1

4

2

5

9

6, 7

3

2

Note

alignment

marks

8

Appendix H—291 and F291 Connecting Rod Assembly Details

Connecting Rod Assembly Bill of Materials

Ref
No.

1. 1132-X 2

Part No. Description

a

Crosshead assembly

2. 1498 Retainer ring

3. 2505 Wrist pin

4. 1846 -X

5. 159 9

a,b

b

Wrist pin bushing
Bolt

6. 18 89-X Connecting rod assembly

7. 18 89

8. 13 67

9. 1600

a

Must be rebored after replacing (0.8754/0.8751 dia.)

b

Included with connecting rod assembly

c

Torque connecting rod nut to 28 ft. lbs.

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

CAUTION: Always Relieve Pressure In The Unit Before Attempting
Any Repairs.

b

b

b,c

Connecting rod
Connecting rod bearing
Nut

64

Back Side

Front Side

Appendix H—291 and F291 Flywheel Assembly Details

Flywheel Assembly Bill of Materials

Assembly Number Assembly Name

Flywheel assembly

2549-X1

2549

H SF-1.250

(flywheel, hub, and
three bolts)

Flywheel: 16" O.D.,
3 groove

Hub with three
bolts and
lockwashers

65

1

2

4

3

5

6

15

26

25

24

23

22

21

20

10

18

28

27

16

17 (Assembly)

18

19

37

21

44

38

39 (assembly)

40

41

7

9

11

12
13
14

2

8

35

34

45

36

44

47

46

9

48

49

50

42

51

27

40

43 (assembly)

52

29

30

31

32

33

Appendix H—291 and F291 Crankcase Assembly Details

66

Appendix H—291 and F291 Crankcase Assembly Details

Crankcase Assembly Bill of Materials Other Assemblies

Ref

Part No. Description

No.

1. 1278 Oil seal

2. 7001- 037NC075A Bolt, 3/8-16 x 3/4, hex head

3. 2957 Bearing cover
1273 Bearing adjustment shim (0.005")

4.

127 3-1 Bearing adjustment shim (0.007")
1273 -2 Bearing adjustment shim (0.020")

5. 1500 Bearing cup

6. 1368 -X Oil bayonet

7. 2713 Crankcase inspection plate gasket

8. 2958 Crankcase inspection plate

9. 2 -112 _

10. 2955

11. 1279 Breather cap

12. 2-111_

a,b

c

O-ring
Crankcase

c

O-ring (breather cap)

13. 2796 Breather ball

14. 14 83 Lock pin - 1/8 x 1"

15. 1671 Flywheel key

16. 1501 Bearing cone

17. 1341-X1

Crankshaft assembly with 1284 (2), 1286,
1341, 1501, 2590, 2719

18. 1284 Crankshaft orifice (2)

19. 2719 Bearing cone

20. 128 6 Pump shaft drive pin

21. 2590 Pipe plug - 1/8 NPT, flush seal

22. 1280 Filter screen screw

23. 1281 Filter screen screw gasket

24. 2-116 _

c

O-ring (filter screen)

25. 1276 Filter screen washer

26. 1275 Oil filter screen

27. 3289 Pipe plug - 1/4 NPT, flush seal

28. 1661 Pipe plug - 3/8 NPT

29. 1290 Relief valve adjusting screw

30. 1291 Adjusting screw locknut

31. 2- 011_

c

O-ring (relieve valve adjustment screw)

32. 1292 Relief valve spring

33. 1293 Relief valve ball

34. 2718 Bearing cup

35. 2961-X

Air release valve assembly with 2961,
2962, 2963

36. 1285 Bearing carrier gasket

37. 2956 Bearing carrier

38. 2-218 _

39. 1515-X

c

O-ring (closure body) (2 required) (Spec
3, 4, 8, 9 only)

Closure cap assembly including 2-218A(2)
(Spec 3, 4, 8, 9 only)

40. 7001-025NC050A Bolt, 1/4-20 x 1/2, hex head

41. 1302 Oil pressure gauge

42. 2-228_

c

O-ring (pump cover)

43. 4222-X Oil filter assembly

44. 1629 Pipe plug - 1/16 NPT, flush seal

45. 7001-037NC100A Bolt, 3/8-16 x 1, hex head

46. 2805 Pump shaft bushing

47. 2850 Pump shaft adapter

48. 2852 Oil pump spring

49. 28 51 Spring guide

50. 2849-X

2798 Pump cover pin with 2848-X

51.
2848-X Pump cover (includes pin)

Oil pump assembly (individual pump
parts not available)

52. 4225 Filter

Assembly
Number

Assembly Name

1279 -X Breather cap assembly with 1279, 2-111A

1341-X1

1342-X1

Crankshaft assembly with 1284 (2), 1286, 1341, 1501,
2590, 2719

Extended crankshaft assembly with 1284 (2), 1286,

a

1342, 1501, 2590, 2719

136 8-X1 Oil bayonet assembly with 1368-X, 2-112A

1515-X

Closure cap assembly including 2-218A (2) (Spec 3, 4,
8, 9 only)

Bearing carrier assembly with 1285, 1290, 1291,

2956-X

1292, 1293, 1515-X, 2718, 2805, 2806 (2), 2848-X,
2849-X, 2850, 2851, 2852, 2956, 2961-X, 2011-A,

2-112A, 2-228A.
29 57-X Bearing cover assembly with 2957 and 1278
2961-X Air release valve assembly with 2961, 2962, 2963

3271-X1

3271 (not part of crankcase assembly) (not shown)

Flywheel assembly, 14" O.D. 2 groove with 3218 and

a

O-ring Code

A Buna-N

B Neoprene

a

Optional equipment

b

Crankcase capacity: 1.5 quarts (1.4 liters)

c

_ denotes O-ring code. See O-ring char t above for details.

d

Registered trademark of the DuPont company.

CAUTION: Always Relieve Pressure In The Unit Before Attempting
Any Repairs.

®d

67

10

11

12

33

13

14

15

16

103

17

11

27

28

29

30

20

21
22

21
22

21

22

23

31

32

17

11

18

19

20

23

24

17

11

18

25

23

20

26

17

10

11

12

33

13

14

15

16

101

17

10

11

12

33

13

14

15

16

102

17

Suction

Spec 3

Suction
Spec 4

Discharge

All Specs

Suction Valve

Spec 3

103

Suction Valve

Spec 4

101

Discharge Valve

All Specs

102

7

8

Suction

Discharge

9

7

8

1

4 (prior to FZ44188)

6

7

6

Suction

Discharge

9

7

2

5

7

Suction

Discharge

9

7

3

5

6

Appendix I—490, 491, and F491 Head and Valve Assembly Details

490 and 491 Head Assembly

491 Head Assembly

Valve Holddown Assemblies

Valve Assemblies

F491 Head Assembly

68

Appendix I—490, 491, and F491 Head and Valve Assembly Details

Compressor Head and Valve Bill of Materials

Ref

Part No. Description

No.

1. 2914

2. 3712

3. 4297 Head—ANSI flanged (F491)

4. 14 81

5. 2-253_

6. 3442 Pipe plug—1/4" NPT

7. 1479

8.

9.

10. 1477 Valve screw nut

11. 1478 Gasket (steel)

12. 1476 Valve holddown screw

13. 1475 Valve cover plate

14. 2-143 _

15. 140 9

16. 2448 Cage

17.

18. 2446 Bolt

19. 2438 Suction valve seat

20. 2442 Valve plate

21. 2445

22. 3355 Washer

23. 1407 Valve spring

24. 2440 Suction valve bumper

25. 24 41 Discharge valve bumper

26. 2439 Discharge valve seat

27. 2 533 -1 Adjusting screw

28. 1411 Relief ball spring

29. 1410 Relief ball

30. 25 32-1 Suction valve seat

31. 25 34-1 Suction valve post

32. 24 47 Suction valve bumper

33. 7001-043NC125A Bolt (7/16-14 x 1-1/4” hex head)

d

e

42 97-1 Head flanged - Din spec. only (F492)

c

b,c,e

c

c

148 0-1

c

148 0

7005-043NC125A

7005-043NC150A

a

1478-1

1478 -2 Gasket (iron)

b

f

1418 Valve gasket (aluminum)

a

1418 -1

a

1418-2

f

Head—ductile iron (491)

Head—ductile iron (491)

Head gasket (490 and 491)

O-ring (491)

Center head bolt

Center head bolt gasket (copper)

Center head bolt gasket (steel)

Bolt, 7/16-14 x 1-1/4" ferry head (490 &

c

491 prior to serial # FZ44188)

Bolt, 7/16-14 x 1-1/2" ferry head (491

c

serial # FZ44188 and later)

Gasket (copper)

O-ring for cover plate

Valve spacer

Valve gasket (copper)

Valve gasket (iron)

Spacer (two per valve)

Ref

Valve Assembly No. Assembly Name

No.

2438-X

2438-X1

2438-X 2

2439-X

2439-X1

2439-X 2

25 32-1X

25 32-1X1

25 32-1X 2

d

d

e

e

a

a

a

a

a

a

101.

102.

103.

Head Assembly No. Model Valve Specification

2914-X2

2914-X4

3712-X1

3712-X2

42 97-X1 F491 3

42 97-X2 F491 4

42 97-1X1 F492 3

42 97-1X2 F492 4

Suction valve assembly (see ref. no.
7, 17, 18, 19, 20, 21(2), 22, 23, 24)

Same as 2438-X but with copper
gaskets

Same as 2438-X but with iron-lead
gaskets

Discharge valve assembly (see ref.
no. 7, 17, 18, 20, 21(2), 22, 26, 25)

Same as 2439-X but with copper
gaskets

Same as 2439-X but with iron-lead
gaskets

Suction valve assembly (spec. 3)
with aluminum

Same as 2532-1X but with copper

Same as 2532-1X but with iron-lead

491 4

491 3

491 3

491 4

O-ring Code

A Buna-N

B Neoprene

a

Optional equipment

b

_ denotes O-ring code. See O-ring char t above for details.

c

Not included in Head Assembly.

d

Prior to S/N FZ44188.

e

S/N FZ44188 and later.

f

Place spacers back to back as shown.

g

Registered trademark of the DuPont company.

CAUTION: Always Relieve Pressure In The Unit Before
Attempting Any Repairs.

®g

69

5

6

7

8

9

Piston Rod

4

3

2

1

Appendix I—490, 491, and F491 Piston Assembly Details

Piston Assembly Number 1985-X Bill of Materials
Piston Diameter 4" (10.16 cm)

Ref

Part No. Description Qty

No.

Piston Clearance (Cold)

a

b

c

7002-025OC125A Screw, socket head 8

1.
7207-025A Lock Washer 8

2. 1985 Head, iron 1

3. 1776 Ring expander 3

4. 1773 Piston ring 3

5. 1482 Locknut 1

6. 14 8 3 Lock pin 1

7. 1986 Piston platform 1
1528 Shim washer, thick

8.
1528 -1 Shim washer, thin

9. 1527 Thrust washer 1

a

Model Minimum Maximum

490

b

491

c

491

The distance from the bottom of the head to the top of the piston.
For 491 compressor with flat gasket.
For 491 compressor with head O-rings.

0.000" (0.00 mm) 0.024" (0.61 mm)

0.020" (0.51 mm) 0.044" (1.12 mm)

As

Req.

CAUTION: Always Relieve Pressure In The Unit Before Attempting Any Repairs.

70

7

8

9

1

4

16

10

11

3

2

13

Piston Rod

12

15

14

5

6

7,8,9

17

18

19

Appendix I—490, 491, and F491 Packing Assembly Details

Packing Assembly Bill of Materials

Ref
No.

1. 3713

2. 2-243_

3. 5000-137 Retainer ring 2

4. 1012 Washer 2

5. 1628 Packing spring 2

6. 1714 Packing box washer 2

7. 1453-1 Male packing ring 2

8. 14 5 4

9. 145 2-1 Female packing ring 2

10. 2801

11. 2799

12. 1387 Adjusting screw 2

13. 2-139 _

14. 2765

15. 1489 Crankcase gasket 1

16. 1452-1X1 Packing set 2

17. 1488

18. 1487 Inspection plate 1

19.

not
shown

Part No. Description Qty

a

Cylinder (491 w/O­ring)

b

c

O-ring for cylinder 2

Packing ring 6

Cartridge holddown
screw

Packing box
cartridge

b

O-ring (packing
cartridge)

d

Crosshead guide 1

Inspection plate
gasket

7003­025NC037E

1/4-20x3/8" 4

119 2 Locking device 4

1

2

2

2

1

71

Additional Assembly

Assembly
Number

138 4-X Crosshead assembly

Assembly Name

O-ring Code

A Buna-N

B Neoprene

a

S/N FZ44188 and later

b

_ denotes O-ring code. See O-ring char t
above for details

c

The quantity of 1454 packing rings
required will vary due to tolerances. Use
Cone 4005 for packing installation.

d

S/N XC30633 and later

e

Registered trademark of the DuPont
company.

CAUTION: Always Relieve Pressure In
The Unit Before Attempting Any Repairs.

®e

5

1

4

2

5

9

6, 7

3

2

Note

alignment

marks

8

Appendix I—490, 491, and F491 Connecting Rod Assembly Details

Connecting Rod Assembly Bill of Materials

Ref
No.

Part No. Description

1. 1384-X Crosshead assembly

2. 1498 Retainer ring

3. 1496 Wrist pin

4. 1495-X

5. 1492

b

a,b

Wrist pin bushing
Bolt

6. 14 9 0 -X Connecting rod assembly

7. 14 9 0

8. 14 91

9. 1493

a

Must be rebored after replacing (0.8754/0.8751 dia.)

b

Included with connecting rod assembly

c

Torque connecting rod nut to 30 ft. lbs.

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

CAUTION: Always Relieve Pressure In The Unit Before Attempting
Any Repairs.

b

b

b,c

Connecting rod
Connecting rod bearing
Nut

72

Back Side

Front Side

Appendix I—490, 491, and F491 Flywheel Assembly Details

Flywheel Assembly Bill of Materials

Assembly Number Assembly Name

Flywheel assembly

2549-X

2549

H SF-1.375

(flywheel, hub, and
three bolts)

Flywheel: 16" O.D.,
3 groove

Hub with three
bolts and
lockwashers

73

1

2

3

4

5

6

10

11

12
13
14

15

16

17

18

19

18

21

20

26

25

24

23

22

28

27

35

34

37

21

44

38

39 (assembly)

40

41

45

36

44

47

48

49

50

42

46

9

51

27

40

43 (assembly)

52

29

30

31

32

33

7

9

2-1

8

Appendix I—490, 491, and F491 Crankcase Assembly Details

74

Appendix I—490, 491, and F491 Crankcase Assembly Details

Crankcase Assembly Bill of Materials

Ref

Part No. Description

No.

1. 4438 Oil seal

2. 7001-037NC075A Hex head bolt 3/8-16 x 3/4

2-1. 7001-031NC075A Hex head bolt 5/16-18 x 3/4

3. 2847-1 Bearing cover

1504 Bearing adjustment shim (0.005")

4.

1504-1 Bearing adjustment shim (0.007")

1504-2 Bearing adjustment shim (0.020")

5. 1502 Bearing cup

6. 1508-X Oil bayonet

7. 1511 Crankcase inspection plate gasket

8. 2853 Crankcase inspection plate

9. 2-112_

10. 2803

c

b

O-ring (oil bayonet & pump shaft)

Crankcase

11. 1279 Breather cap

12. 2-111_

c

O-ring (breather cap)

13. 2796 Breather ball

14. 1483 Lock pin

15. 1663 Flywheel key

16. 1501 Bearing cone

1499-X

17.
1499-SX

Crankshaft assembly with 1284 (2),
1286, 1499, 1501, 1503, 2590

Extended crankshaft assembly with 1284
(2),1286, 1499-S, 1501, 1503, 2590

18. 1284 Crankcase orifice (2)

19. 1503 Bearing cone

20. 1286 Pump shaft drive pin

1459 Crankshaft plug (depends on design)

21.
2590 Pipe plug (depends on design)

22. 1280 Filter screw

23. 1281 Filter screen screw gasket

24. 2-116_

c

O-ring (filter screen)

25. 1276 Filter screen washer

26. 1275 Oil filter screen

27 3289 Pipe plug

28. 1661 Plug 3/8" NPT

29. 1290 Relief valve adjusting screw

30. 1291 Adjusting screw locknut

31. 2-011_

c

O-ring (relief valve adjusting screw)

32. 1292 Relief valve spring

33. 1293 Relief valve ball

34. 1500 Bearing cup

35. 2961-X

Air release valve assembly with 2961,
2962, 2963

36. 1513 Bearing carrier gasket

37. 2804 Bearing carrier

38. 2-218_

c

O-ring (closure body) (2) (Spec. 3, 4, 8,
9 only)

39 1515-X Closure cap assembly

40. 7001-025NC050A Hex head bolt 1/4-20 x 1/2

41. 1302 Oil pressure gauge

Ref

Part No. Description

No.

42. 2-228_

c

O-ring (pump cover)

43. 4222-X Oil filter assembly - external

44. 1629 1/16" NPT pipe plug, flush seal

45. 7001-037NC100A Hex head bolt 3/8-16 x 1

46. 2805-X Pump shaft bushing

47. 2850 Pump shaft adapter

48. 2852 Oil pump spring

49. 2851 Spring guide

50. 2849-X

2798 Pump cover pin with 2848-X

51.
2848-X Pump cover (includes pin)

Oil pump assembly (individual pump
parts not available)

52. 4225 Oil filter

Other Assemblies

Assembly
Number

1279 -X Breather cap assembly with 1279, 2-111A

149 9-X

1499-SX

1508-X1 Oil bayonet assembly with 1508-X, 2-112A

1515-X

2804-X

28 47-1X Bearing cover assembly with 2847-1, 3855

3271-X

O-ring Code

A Buna-N

B Neoprene

a

Optional equipment

b

Crankcase capacity: 3 quar ts (2.8 liters)

c

_ denotes O-ring code. See O-ring char t above for details.

d

Registered trademark of the DuPont company.

CAUTION: Always Relieve Pressure In The Unit Before Attempting
Any Repairs.

Assembly Name

Crankshaft assembly with 1284 (2), 1286, 1499, 1501,
1503, 2590

Extended crankshaft assembly with 1284 (2), 1286,

a

1499-S, 1501, 1503, 2590

Closure cap assembly including 2-218A (2), (Spec. 3,
4, 8, 9 only)

Bearing carrier assembly with 1290, 1291, 1292,
1293, 1500, 1513, 1515-X, 1629 (2), 2590, 2804,
2849-X, 2850, 2851, 2852, 2961-X, 2-011A, 2-112A,
2-228A, 4222-X

Flywheel assembly with 3271, 3217 (not part of

a

crankcase assembly (not shown)

®d

75

12

13

14

20

21

22
23

24

25

26

27

28

29

30

33

32

26

27

104

28

29

31

15

16

17

18

101

19

12

13

14

15

16

17

18

102

19

12

13

14

15

16

17

18

103

19

Suction

Spec 3

Suction

Spec 4

Discharge

All Specs

Suction Valve

Spec 3

Suction Valve

Spec 4

Discharge Valve

All Specs

31

32

28

29

104

26

27

31

104

11.2

8

4.1

5

7

2

5

8

4

9

6

11.1

11

8

4.1

5

1

10

5

8

4

9

9

3

11.2

7

Appendix J—691 and F691 Head and Valve Assembly Details

690 Head Assembly

691 Head Assembly

Valve Holddown Assemblies

F691 Head Assembly

76

Valve Assemblies

Appendix J—691 and F691 Head and Valve Assembly Details

Head and Valve Bill of Materials

Ref

Part No. Description

No.

1. 1743 Head (690)

2. 3458

d

Head (691)

3. 4299 F691 head

2144-2 Flange (suction) 2" NPT

4.

4.1

5. 2-231_

6.

7. 2-261_

2144-2S

c

Flange 2" weld

214 4-1.5 Flange (discharge) 1-1/2" NPT

214 4-1.5S

a

b

1744

b,c

1744-1

a

c

Flange 1-1/2" Weld

O-ring

Head gasket (690)

Head gasket grafoil

O-ring for head (691)

8. 7001-043 NC150A Bolt, 7/16-14 x 1-1/2" hex head

9. 213 6 Center head bolt

1625 Center head bolt gasket (aluminum)

10.

1625 -1

1625 -2

c

c

Center head bolt gasket (copper)

Center head bolt gasket (iron-lead)

11. 7005-043 NC125A Bolt, 7/16-14 x 1-1/4" ferry head

11.1 7006-043A Reg. lockwasher 7/16"

11. 2 7005-050 NC150A Bolt, 1/2-13 x 1-1/2" ferry head

2714 Valve cap

12.
2714-1 Valve cap, grooved for O-ring

13.

2-031_

c

2716

2716-1

2716-2

a

c

c

O-ring for valve cap

Gasket (aluminum) for valve cap

Gasket (copper) for valve cap

Gasket (iron) for valve cap

14. 2715 Holddown screw

15. 7001-043 NC137A Bolt, 7/16-14 x 1-3/8" hex head

16. 176 4 Valve cover plate

17. 2-235_

a

O-ring (cover plate)

18. 2797 Valve cage

2114 Valve gasket (aluminum)

19.

2114-1

2114-2

c

c

Valve gasket (copper)

Valve gasket (iron)

20. 5000-77 Retainer ring

21. 3977 Suction valve relief housing (spec 3)

22. 1411 Spring

23. 1410 Relief ball

24. 3948 Valve seat (spec. 3)

25. 25 34-1 Suction valve post (spec 3)

26. 3872 Inner valve plate

27. 3871 Outer valve plate

28. 3929 Inner valve spring

29. 3928 Outer valve spring

30. 3949 Valve bumper (spec. 3)

31. 3857 Valve bumper

32. 3920 Valve stud

33. 3856 Valve seat

Ref

Valve Assembly No. Assembly Name

No.

Suction valve assembly (spec. 3)
(includes valve gasket)

Same as above but with copper
gasket

Same as above but with iron-lead
gasket

Suction valve assembly (includes
valve gasket)

Same as above but with copper
gasket

Same as above but with iron-lead
gasket

Discharge valve assembly (includes
valve gasket)

Same as above but with copper
gasket

Same as above but with iron-lead
gasket

101.

102.

103.

394 8-X

3948-X1

394 8-X 2

3856-X

3856-X1

2255-X2

3857-X

3857-X1

3857-X2

c

c

c

c

c

c

104. 3146-X1 Valve repair kit (suction & discharge)

Other Assemblies

Head Assembly Number Models Valve Specification

1743-X 690 3

3458-X 691 3

O-ring Code

A Buna-N

B Neoprene

a

_ denotes O-ring code. See O-ring char t above for details.

b

Not included in head assembly.

c

Optional.

d

S/N NQ51455 and later. Earlier models use gasket #2177.

e

Registered trademark of the DuPont company.

®e

77

5

6

7

8

Piston Rod

4

3

2

1

Appendix J—691 and F691 Piston Assembly Details

Piston Assembly Number 1987-X1 Bill of Materials
Piston Diameter 4.5" (11.43 cm)

Ref

Part No. Description Qty

No.

1. 7002-025TP125A Screw, socket head 8
7207-025A Lock washer 8

2. 1987 Head, iron 1

3. 1740 Ring expander 3

4. 1739 Piston ring 3

5. 1482 Locknut 1

6. 14 8 3 Lock pin 1

7. 173 5 Shim washer, thick As
173 5-1 Shim washer, thin

8. 19 86 Piston platform 1

Piston Clearance (Cold)

a

Req.

Model Minimum Maximum

690 0.000" (0.00 mm) 0.012" (0.30 mm)

691 0.015" (0.38 mm) 0.027" (0.68 mm)

a

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

CAUTION: Always Relieve Pressure In The Unit Before Attempting Any Repairs.

78

7

8

9

1

2

3

4

17

5

6

10

15

11

Piston Rod

13

12

16

14

7,8,9

18

19

20

Appendix J—691 and F691 Packing Assembly Details

Packing Assembly Bill of Materials

Ref
No.

1. 3457 Cylinder 1

2. 2- 247_

3. 1749

4. 5000-175 Retainer ring 2

5. 1731 Packing spring 2

6. 17 28 Packing washer 2

7. 1724 Male packing ring 2

8. 1725 Packing ring 4

9. 1723 Female packing ring 2

10. 2407 Packing box cartridge 2

11. 2-233_

12. 174 8 Cartridge plate 2

13. 5000-350 Retainer ring 2

14. 2405 Crosshead guide 1

15. 1722 Adjusting screw 2

16. 1761 Crankcase gasket 1

17. 1725-2X Packing set 2

18. 1760

19. 1721 Inspection plate 1

20.

not
shown

not
shown

Part No. Description Qty

a

a

7003­025NC037E

119 2

2893

O-ring for cylinder 2
Cartridge holddown
screw

O-ring (packing
cartridge)

Inspection plate gas­ket

Screw-1/4-20x3/8" 4

Locking device for
adj. screw
Locking device
cartridge holddown
screw

2

2

1

4

79

Other Assemblies

Assembly
Number

1717-X1 Crosshead assembly “P” style

2405-X

3544-X4 Crosshead assembly “M” style

Assembly Name

Crosshead guide assembly with
1748 (2), 2405, 5000-350 (2)

O-ring Code

A Buna-N

B Neoprene

a

_ denotes O-ring code. See O-ring char t
above for details.

b

Registered trademark of the DuPont
company.

CAUTION: Always Relieve Pressure In The
Unit Before Attempting Any Repairs.

®b

1

2

3

8

7

3

9

6

4,5

Note

alignment

marks

6

2

Appendix J—691 and F691 Connecting Rod Assembly Details

Connecting Rod Assembly Bill of Materials

Ref
No.

1. 1717-X1 3544-X4 Crosshead assy.

2. 1498 3590 Retainer ring

3. 1718 3540 Wrist pin

4. 149 5 -X

5. 1726

6. 1720 -X 3785-X1 Conn. rod assy.

7. 172 0

8. 1719

9. 172 7

a

Must be rebored after replacing (0.8754/0.8751 dia.)

b

Included with connecting rod assembly

c

Torque connecting rod nut to 40 ft. lbs.

d

Must be rebored after replacing (1.1256/1.252 dia.)

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

CAUTION: Always Relieve Pressure In The Unit Before
Attempting Any Repairs.

Part Number

Spec. K,P
Only

a,b

b

b

b

b,c

Spec. M
Only

3541-X
172 6

3785
3542
172 7

b,d

b

b

b

b,c

Description

Wrist pin bushing
Bolt

Connecting rod
Conn. rod bearing
Nut

80

Back Side

Front Side

Appendix J—691 and F691 Flywheel Assembly Details

Flywheel Assembly Bill of Materials

Assembly Number Assembly Name

Flywheel assembly

176 2-X

176 2

H E-2.125

(flywheel, hub, and
three bolts)

Flywheel: 19.5"
O.D., 4 groove

Hub with three
bolts and
lockwashers

81

1

2

3

4

5

6

7

10

4

30

54

29

31

52

53

27

8

21

17

16

37

38

39

41

40

15

14

18

19

20

22

23

24

25

26

9

11

12

13

5

33

34

35

43

44

45

46

47

48

42

51

49

56

50

36

32

59

33

60

55

42

28

55

61

(Includes all parts shown

except #52 and #53)

50

58

Inside of

Bearing Carrier

Pump Cover Oil/Filter Adapter

Oil Passage Hole

Important! Line up hole in

gasket with oil passage hole.

Pumpside of adapter shown for

proper orientation of cover and

location of pump cover pin.

57

55

60

28

Appendix J—691 and F691 Crankcase Assembly Details

82

Appendix J—691 and F691 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. 2135 Drive pin

6. 2933 Link pin

7. 3786 Crankshaft

8. 3503 Flywheel key

9. 3580 Bearing cone

10. 3786-X1 Crankshaf t assembly

11. 70 01-0 31N C075A Bolt, 5/16 - 18 x 3/4" hex head

12. 2122 Inspection cover

13. 2123 Gasket, inspection cover

14. 2-210_

d

O-ring

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

16. 2126 Breather ball

17. 3579 Bearing cup

3589 Bearing adjustment shim (.005")

18.

35 89-1 Bearing adjustment shim (.007")

3589-2 Bearing adjustment shim (.020")

19. 3539 Bearing cover

20. 3526 Oil seal

21. 128 0 Filter screw

22. 1281 Gasket, filter

23. 2-116 _

d

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. 3 874 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. 2-218 _

d

O-ring

37. 12 90 Relief valve adjusting screw

38. 2- 011 _

d

O-ring

39. 1291 Adjusting screw locknut

40. 1292 Relief valve spring

41. 1293 Relief valve ball

42. 4222-X

43. 2-228_

44. 28 49-1X

c

d

c

Oil filter adapter assembly (w/pin)

O-ring

Oil pump assembly

45. 2851 Spring guide

46. 2852 Oil pump spring

47. 3 219 Pump shaf t adapter

Ref

Part No. Description

No.

48. 2-11 2_

49. 2805-X_

d

d

O-ring

Pump shaft bushing

50. 1629 Pipe plug, 1/16 NPT fl. seal

51. 1736 Bearing cup

52. 13 02 Oil pressure gauge

53. 1044 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. 2 961-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 M3 style

Additional Assembly

Assembly
Number

3221-X1

O-ring Code

A Buna-N

B Neoprene

a

Not shown

b

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

c

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

d

_denotes O-ring code. See O-ring chart above for details.

e

Registered trademark of the DuPont company.

CAUTION: Always Relieve Pressure In The Unit Before Attempting
Any Repairs.

Assembly Name

a

Crankcase assembly (M3, 4, 8, 9) without lubrication

®e

83

1

2

3

2

3

4

15

16

17
18

19

20

Suction

Valve

Discharge

Valve

21

20

16

17

18

19

15

21

5

6

7

14

8

9

10

11

13

8

5

6

7

14

9

10

12

13

Appendix K—D891 Head and Valve Assembly Details

O-ring Code

A Buna-N

B Neoprene

891 Head Valve Holddown

Assembly (4-1/2")

®d

Valve Holddown

Assembly (4-1/2")

DischargeSuction

Compressor Head and Valve Bill of Materials

Ref

Part No. Description

No.

1. 3923 Cylinder cap

2. 3924 Cylinder head (4-1/2")

3. 2 - 2 4 6 __

4. 7001-050 NC150A

5. 2714-1 Valve cap

6. 2 - 0 3 1 __

7. 2715 Holddown screw

8. 176 4 Valve cover plate

9. 2 - 2 3 5 __

10. 3570-1 Valve cage

11. 3732-X Suction valve assembly (4-1/2")

12. 3733-X Discharge valve assembly (4-1/2")

13. 2114

14. 7001-043 NC150A

15. 3827 Valve seat (4-1/2")

16. 3828 Stud

17. 3830

18. 3831

19. 3829

20. 3826 Valve bumper (4-1/2")

21. 3805-X1

a

c

c

c

b

b

b

c

O-ring
Bolt, 1/2 - 13 x 1-1/2" hex head

Gr 5 (Torque to 65 ft•lbs)

O-ring

O-ring

Valve gasket
Bolt, 7/16 - 14 x 1-1/2" hex head

(Torque to 37 ft•lbs)

Valve plate, outer
Valve plate, inner
Spring

Valve repair kit (1st stage)

84

Valve Assemblies (4-1/2")

a

Included with valve assembly

b

_ denotes O-ring code. See O-ring char t above for details.

c

Included with valve repair kit.

d

Registered trademark of the DuPont company.

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

1

2

3

4

5

4

5

4

5

4

5

6

7

8

9

Piston
Rod

9

Piston top dead center

Piston bottom dead center

Piston

Piston

Piston

Piston

Appendix K—D891 Piston Assembly Details

Ref.

No.

1. 7002-025-TP100A Screw, orlo gr. 8 (torque to 8 ft•lbs) 4

2. 3927 Piston cap 1

3.

4.

5. 1740 Expander ring 4

6. 3604 Lock nut (torque to 150 ft•lbs) 1

7. 3730 Thrust washer 2

8.

9.

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

Piston Clearance (Cold)

Model Top Min.

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

a

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

b

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.

Part No.

D891

Description Qty

3925-X1 (4-1/2")

2902 Shim washer, thick

2902-1 Shim washer, thin

1739 Piston rings

1739-3 Peek rings—opt.

3925

(4-1/2" diameter)

Piston 1

3603 Shim washer, thick

3603-1 Shim washer, thin

a

Top Max.

a

Bottom Min.

b

Bottom Max.

As

req.

41739-2 Alloy 50 rings—opt.

As

req.

b

Piston Assembly Bill of Materials

85

17

17

12

12

13

14

15

16

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

Appendix K—D891 Crosshead Guide Assembly Details

86

Appendix K—D891 Crosshead Guide Assembly Details

Crosshead Guide Bill of Materials

Ref

Part No. Description Qty

No.

1. 3922 Cylinder 1

2. 1054

3. 1071 Nipple, 1/4" x close 1

4. 2-246_

a

5. 3442 Pipe plug, 1/4" NPT 3

6. 7001-050NC175A

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

8. 2-231_

a

9. 3253 Roll pin 1

10. 24 0 5 -1 Crosshead guide 1

11. 1064 Elbow, 1/4" NPT 1

12. 3 974 Ta g 1

13. 1761 Gasket, crankcase 1

14. 176 0

15. 1721 Inspection cover 1

16. 7012-010NC025B

Drain valve (lubricated
models)

O-ring for cylinder 2

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

O-ring for flange 2

Gasket, inspection
cover

Bolt, 10 - 24 x 1/4"
Phillip hd.

1

24

1

10

O-ring Code

A Buna-N

B Neoprene

a

_ denotes O-ring code. See O-ring char t above for details.

b

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 #905 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

87

1

2

3

4
5

6

7

4
5

6

7

4
5

6

7

4
5

6.1

7

8

9

10

12

13

14

13

15

16

17

13

12

19

18

V-ring Packing Direction

Lower Packing

Specification

“J”

Lower Packing

Specification

“K”

15

16

17

17

16

15

To Crankcase

To Crankcase

12

13

14

13

15

16

17

13

12

19

Radial

Tangent

Radial

Tangent

Radial

Tangent

Tangent
Tangent

Upper

Segmented

Packing

Set

Lower

V-ring

Packing

Set

Lower
V-ring

Packing

Set

1

2

3

4
5

6

7

4
5

6

7

4
5

6

7

4
5

6.1

7

8

9

10

18

Radial

Tangent

Radial

Tangent

Radial

Tangent

Tangent
Tangent

Upper

Segmented

Packing

Set

11

11

Appendix K—D891 Packing Assembly Details

Specification “K”Specification “J”

88

V-ring

Packing

Direction

Lower Packing

Specification

“R”

15

16

17

To Crankcase

18

Upper

Segmented

Packing

Set

6.1

1

2

3

4
5

7

4
5

7

4
5

7

4
5

6.1

7

11

8

9

10

6.1

6.1

Tangent
Tangent

Tangent
Tangent

Tangent
Tangent

Tangent
Tangent

12

13

14

13

15

16

17

13

12

19

Lower

V-ring

Packing

Set

To Crankcase

Piston (Pressure) Side

Radial Cut

(without pin)

Segmented Packing for
Specification “J” & “K”

Tangent Cut

(with pin)

Back-up

ring

To Crankcase

Piston (Pressure) Side

Tangent Cut
(without pin)

Segmented packing for

Specification “J”, “K”, & “R”

Tangent Cut

(with pin)

Back-up

ring

Align pin

with hole

Align pin
with hole

Appendix K—D891 Packing Assembly Details

Specification “R”

Packing Assembly Bill of Materials

Ref

Part No. Description

No.

1. 3926 Packing barrel (4-1/2")

2. 2-238_

3. 3906 Crush gasket

4. 3817

5. 2-036 _

6. 3 810

6.1. 3814

7. 3811 Back-up ring

8. 70 02-025OC100A Screw, 1/4-20 x 1" socket head

9. 3885 Cartridge

10. 2-231_

11. 173 2

12. 5000-175 Retainer ring

13. 172 8 Washer

14. 1731 Spring

15. 1724 Male packing ring

16. 172 5 V-ring packing

17. 1723 Female packing ring

18. 3810-X1

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

Packing Spec.

a,c

O-ring

Packing cup (Not included in 3810-X1

a,d

packing set)
Cup O-ring
Segmented packing

(radial—tangent) pair
Segmented packing

(tangent—tangent) pair

a

b

e

O-ring
Oil deflector ring

Segmented packing set

Identification of Packing Specification

Example: Model Number D891 J M4FBA

O-ring Code

A Buna-N
B Neoprene

D Viton

E PTFE
K Kalrez

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.

a

_ denotes O-ring code. See O-ring char t for details.

b

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

c

Inser t O-ring into the groove in the bottom of the barrel.

d

Starting with S.N. NN51397.

e

®f

®f

®f

Packing cup O-ring not included in packing set.

f

Registered trademark of the DuPont company.

89

1

2

3

8

7

3

9

6

4,5

Note

alignment

marks

6

2

Appendix K—D891 Connecting Rod Assembly Details

Connecting Rod Assembly Bill of Materials

Ref
No.

1. 3544-X3 Crosshead assembly

2. 3590 Retainer ring

3. 3540 Wrist pin

4. 3541-X

5. 1726

6. 3785-X

7. 3785

8. 3542

9. 1727

a

Included with connecting rod assembly

b

Torque connecting rod nut to 40 ft. lbs.

c

Must be rebored after replacing (1.1256/1.252 dia.)

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

CAUTION: Always Relieve Pressure In The Unit Before Attempting
Any Repairs.

Part No. Description

a,b

b

a

a

a

a,c

Wrist pin bushing
Bolt
Connecting rod assembly
Connecting rod
Connecting rod bearing
Nut

90

Back Side

Front Side

Appendix K—D891 Flywheel Assembly Details

Flywheel Assembly Bill of Materials

Assembly Number Assembly Name

Flywheel assembly

3852-X

3852

H J-2.125

(flywheel, hub, and
three bolts)

Flywheel: 21.2"
O.D., 5 groove

Hub with three
bolts and
lockwashers

91

1

2

3

4

5

6

7

10

4

30

54

29

31

52

53

27

8

21

17

16

37

38

39

41

40

15

14

18

19

20

22

23

24

25

26

9

11

12

13

5

33

34

35

43

44

45

46

47

48

42

51

49

56

50

36

32

59

33

60

55

42

28

55

61

(Includes all parts shown

except #52 and #53)

50

58

Inside of

Bearing Carrier

Pump Cover Oil/Filter Adapter

Oil Passage Hole

Important! Line up hole in

gasket with oil passage hole.

Pumpside of adapter shown for

proper orientation of cover and

location of pump cover pin.

57

55

60

28

Appendix K—D891 Crankcase Assembly Details

92

Appendix K—D891 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. 2135 Drive pin

6. 2933 Link pin

7. 3786 Crankshaft

8. 3503 Flywheel key

9. 3580 Bearing cone

10. 3786-X1 Crankshaft assembly

11. 7001-031NC075A Bolt, 5/16 - 18 x 3/4" hex head

12. 2122 Inspection cover

13. 2123 Gasket, inspection cover

14. 2-210_

d

O-ring

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

16. 2126 Breather ball

17. 3579 Bearing cup

3589 Bearing adjustment shim (.005")

18.

2589-1 Bearing adjustment shim (.007")

2589-2 Bearing adjustment shim (.020")

19. 3539 Bearing cover

20. 3526 Oil seal

21. 1280 Filter screw

22. 1281 Gasket, filter

23. 2-116_

d

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. 3874 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. 2-218_

d

O-ring

37. 1290 Relief valve adjusting screw

38. 2-011_

d

O-ring

39. 1291 Adjusting screw locknut

40. 1292 Relief valve spring

41. 1293 Relief valve ball

42. 4222-X

43. 2-228_

44. 2849-1X

c

d

c

Oil filter adapter assembly (w/pin)

O-ring

Oil pump assembly

45. 2851 Spring guide

46. 2852 Oil pump spring

47. 3219 Pump shaft adapter

Ref

Part No. Description

No.

48. 2-112_

49. 2805-X

d

b

O-ring

Pump shaft bushing

50. 1629 Pipe plug, 1/16 NPT fl. seal

51. 1736 Bearing cup

52. 1302 Oil pressure gauge

53. 1044 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

Additional Assembly

Assembly
Number

3221-X1

O-ring Code

A Buna-N

B Neoprene

a

Not shown

b

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

c

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

d

_denotes O-ring code. See O-ring chart above for details.

e

Registered trademark of the DuPont company.

CAUTION: Always Relieve Pressure In The Unit Before Attempting
Any Repairs.

Assembly Name

a

Crankcase assembly (M3, 4, 8, 9) without lubrication

®e

93

94

95

Corken, Inc. • A Unit of IDEX Corporation

3805 N.W. 36th St., Oklahoma City, OK 73112

Phone [phone] • Fax [phone]

Visit our website at http://www.corken.com

or e-mail us at [e-mail]

Printed in the U.S. A.

July 2009