Corken HG601 Series, THG601 Series, HG602 Series, THG602 Series Installation, Operation & Maintenance Manual

ORIGINAL INSTRUCTIONS IJ100D

Installation, Operation

& Maintenance Manual

Plain & T-Style Double-Acting Gas Compressors

Models HG601, HG602, THG601 & THG602 Series

Model THG602BE

(T-style )

Model HG601EE

(Plain style)

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

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 one
year from date of installation, provided that the warranty shall not extend beyond twenty-four (24) months from the
date of shipment from Corken. Corken products which fail within the warranty period due to defects in material or
workmanship will be repaired or replaced at Corken’s option, when returned freight prepaid to: Corken, Inc., 3805
N.W. 36th Street, Oklahoma City, Oklahoma 73112.

Parts subject to wear or abuse, such as mechanical seals, blades, piston rings, valves, and packing, and other
parts showing signs of abuse are not covered by this limited warranty. Also, equipment, parts and accessories not
manufactured by Corken but furnished with Corken products are not covered by this limited warranty and purchaser
must look to the original manufacturer’s warranty, if any. This limited warranty is void if the Corken product has been
altered or repaired without the consent of Corken.

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

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

and industrial safety standards.

Contacting The Factory

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

Always include the model number and serial number when ordering parts.

Model No.

Serial No.

Date Purchased

Date Installed

Purchased From

Installed By

2

Table of Contents

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

CHAPTER 1—INSTALLATION OF YOUR COMPRESSOR .............................................6

1.1 Location .................................................................................6

1.2 Foundation ...............................................................................6

1.3 Piping ...................................................................................6

1.4 Liquid Trap ...............................................................................7

1.5 Driver Installation and Flywheels ..............................................................8

1.6 Crankcase Lubrication ......................................................................9

1.7 Crankcase Oil Pressure Adjustment ...........................................................9

1.8 Relief Valves .............................................................................10

1.9 Shutdown/Alarm Devices ...................................................................10

CHAPTER 2—STARTING UP YOUR CORKEN COMPRESSOR .......................................11

2.1 Inspection After Extended Storage ...........................................................11

2.2 Flywheel and V-belt Alignment ..............................................................11

2.3 Compressor Speed and Rotation Direction ....................................................12

2.4 Compressor Cooling ......................................................................12

2.5 Force Feed Cylinder Lubrication (Lubed models only) ............................................12

2.6 Variable Clearance Heads (VCH) .............................................................13

2.7 Startup Check List ........................................................................14

CHAPTER 3—ROUTINE MAINTENANCE CHART ..................................................15

CHAPTER 4—ROUTINE SERVICE AND REPAIR PROCEDURES ......................................15

4.1 Compressor Valves .......................................................................15

4.2 Heads ..................................................................................16

4.3 Piston Rings and Piston Ring Expander Replacement ............................................17

4.4 Pistons .................................................................................17

4.5 Cylinder Replacement .....................................................................18

4.6 Packing Replacement Instructions ...........................................................18

4.7 Bearing Replacement for Crankcase and Connecting Rod ........................................24

4.8 Oil Pump Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

CHAPTER 5—EXTENDED STORAGE PROCEDURES ...............................................27

Compressor Troubleshooting ..................................................................28

Gasket Sets and Repair Kits ...................................................................29

Crankcase and Cylinder Kit Options .............................................................29

APPENDICES

A. Model Number Identification Code ............................................................30

B. Operating Specifications ....................................................................36

C. Outline Dimensions ........................................................................41

D. Assembly Details ..........................................................................45

3

Features and Benefits

Self-lubricating piston and rider rings:
Made of PTFE to ensure extended service life

Cylinder
nameplate

Adapter

Packing cartridge body:
Holds the outer and
middle sets of packing.

Packing cartridge adaptor:
Holds the inner oil wiper
ring set and inner packing

Lifting eye

Crankcase inspection plate

Crankcase
nameplate

Placement of valves:
Make inspection and maintenance simple.

(Optional) Thermostatically controlled crankcase heater:
Assures proper oil viscosity throughout all weather conditions.

Why Corken Compressors
are Special

1/4" Pipe plug

Distance piece:
Ensures greater leakage control

(Optional)
Oil divider valve assembly:
Ensures each cylinder has the
same amount of lubrication.

Oil lter

(Optional) Force-feed lubricator:
Assures proper lubrication of
cylinders and packing when required

Figure 1.1 (THG600 shown)

the crankcase. To further seal the compression chamber,
a crosshead/piston rod design with seals around the
piston rod is required.

Corken industrial gas compressors are unique among
compressors their size. Unlike ordinary lubricated gas
compressors, Corken compressors completely isolate
the pressurized gas in the compression chamber from
the crankcase. While piston rings seal the piston tightly
enough for it to do compression work, they do not provide
enough sealing to isolate the compression chamber from

By utilizing specialized piston-rod sealing systems,
Corken compressors can compress pressurized,
flammable and toxic gases. They can also be used to
compress harmless gases where oil-free compression
or elevated suction pressures are required. With a large
selection of design options available, Corken offers the
most versatile line of small gas compressors in the world.

4

Crankshaft journal, connecting rod
bearings, wrist pins, and crossheads:
Pressure lubricated by an oil pump with oil
ltered by a 10-micron spin on lter.

Heavy-duty cylinder design:
Each cylinder is hydrostatically tested to 1-1/2
times the rated working pressure for maximum

Flywheel

strength. A corrosion resistant coating (MC1002)
is available for all cylinder sizes. MC1002 extends
the life of the cylinder and piston rings.

Inner distance piece
(Barrier 1)

Outer distance piece
(Barrier 2)

Inner oil wiper ring set

Inner packing set

Oil deector ring

Middle packing set

Outer packing set

Variable clearance head:
Enables you to change
the capacity and
BHP requirements.

Heavy-duty crankcase:
A rugged, internally ribbed design,
incorporating heavy-duty main bearings
and four-bolt connecting rods

Corken Horizontal
Gas Compressors

Your new Corken horizontal compressor is a double-acting
reciprocating compressor; however, when an optional blank
valve is used, the compressor is single acting. Corken
horizontal compressors have a large number of configurations
to fit your individual requirements. They are manufactured as
single stage- or two-stage units. For more information on the
various configurations, refer to Appendix A.

5

Chapter 1—Installation Of Your Compressor

1.1 Location

NOTE: Corken compressors are designed to handle
toxic or flammable gases and should be located
outdoors in a well ventilated area.

Proper installation of your compressor is essential for
peak performance and reliable service. The installation
area should be clean, well ventilated and have ample
space to install and maintain your compressor. A
double-acting compressor generates more heat than
a typical single-acting compressor. As a result your
compressor should be located in an area where good
air flow and ventilation can be provided. In extreme
cases, external cooling fans can be used to provide
additional air flow across the cylinders. A minimum of
18 inches clearance between the unit and the nearest
wall is advisable. This space will allow access from all
sides and provide unrestricted air flow for adequate
cooling of the motor and compressor. The unit should
be firmly bolted to a solid, level base.

Corken compressors are designed and manufactured
for outdoor duty. For applications where the compressor
will be subjected to extreme conditions such as corrosive
environments or arctic conditions for extended periods
of time, consult Corken.

Check local safety regulations and building codes to
assure installation will meet local safety standards.

1.2 Foundation

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

1.3 Piping

Proper piping design and installation is as important as a
proper foundation is to a smooth operating compressor.
Improper piping installation will result in undesirable
transmission of compressor vibration to the piping. The
compressor piping should be designed for the rate of
flow anticipated and for minimum pressure drop; in no
case should the piping be smaller than the compressor
nozzle to which it connects. If the length of the line must
exceed 100 ft., the next larger size pipe should be used.
Install a strainer at the compressor inlet. Never install
a shut-off valve in the discharge piping unless a safety
relief valve is placed in the line between the shut-off
valve and the compressor. Remember to consider future
expansion in your pipe sizing and layout.

Noise:

Corken horizontal compressors should not exceed an 85
DBA noise level when properly installed.

Note: The depth of the concrete foundation will

vary based on local soil conditions.

Main beam (C-Beam)

Concrete foundation

Hex nut

&

washer

Figur e 1.2

Cross beam (H-Beam)

3/4″ diameter “J” bolt

DO NOT SUPPORT PIPING WITH THE COMPRESSOR.
Unsupported piping is the most frequent cause of vibration
of the pipe. The best method to minimize transmission of
vibration from the compressor to the piping is to use
flexible connectors (see figure 1.3 for details).

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.

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

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

6

Figure 1.3

Inlet flange

Discharge

flange

Flexible piping

connection

Flexible

piping

connection

Inlet manifold

Discharge manifold

Mounting base

Packing drain tank

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

For vapor recovery applications, be certain to install
a check valve on vapor lines discharging to the liquid
space of the tank.

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

For LP Gas—The National Fire Protection Association
Pamphlet No. 58, Standard for the Storage and Handling
of Liquefied Petroleum Gases.

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

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

1.4 Liquid Trap

Compressors are designed to pressurize gas and not pump
liquids. The entry of even a small amount of liquid into the
compressor will result in serious damage to the compressor.
A liquid trap (scrubber) must be installed in the suction
piping - and discharge line if condensate can drain back to
the compressor - when handling any but the driest of gases.

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

Corken’s liquid trap provides the most thorough liquid
separation (see figure 1.4) and is American Society of
Mechanical Engineers (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 so
the operator can drain the trap using the manual drain
valve at the bottom of the trap. The manual drain valve is
supplied with this trap. NOTE: The liquid level switches
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!

This trap also contains a mist pad. A mist pad is a mesh
of interwoven wire designed to remove fine liquid mists.

7

Relief valve

Outlet

2″ 150 lb

Ball valve

Pressure guage

(0–500 PSI)

Stainless steel

demister pad

1/2″ NPT openings

for sight glass

Outlet

3″ 300 lb

Temperature gauge

(0–250 PSI)

Inlet

3″ 300 lb

Liquid level switches

ANSI flange

1″ 300 lb

Inlet

1″ 300 lb

Stainless steel
demister pad

Inlet

3″ 300 lb

Figur e 1.4

1.5 Driver Installation and Flywheels

Corken compressors may be driven by either electric
motors or internal combustion engines (e.g. gasoline,
diesel, natural gas, etc.). The wiring of an electric
motor is extremely important and must be done by a
competent electrician. Low voltage or improper wiring
of the motor will result in expensive consequences. If
you suspect that you have a low voltage problem, call
your power company.

Humid climates can cause problems with explosion
proof motors. The normal breathing of the motor and
alternating between being warm when running and cool
when stopped can cause moist air to accumulate in
the motor. The moist air inside the motor will condense
and if enough water accumulates, the motor will fail. To
prevent this, make a practice of running the motor at
least once a week on a bright, dry day for an hour or so
without the V-belts. During this period of time, the motor
will heat up and vaporize the condensed moisture.

Manual drain valve

NOTE: No motor manufacturer will guarantee their
explosion proof or totally enclosed (TEFC) motor against
damage from moisture.

Drivers should be selected so the compressor operates
between 400 and 1200 RPM. The unit must not
be operated without the flywheel or severe torsional
imbalances will result that could cause vibration and
a high horsepower requirement. The flywheel should
never be replaced by another pulley unless it has a
higher wk2 value than the flywheel.

NOTE: Never operate a reciprocating compressor
without a flywheel.

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

8

1.6 Crankcase Lubrication

The crankcase of your compressor was drained before
shipment. Before starting the machine, be sure to fill the
crankcase to the full mark on the oil bayonet and not above.
To ensure proper lubrication of the crankcase parts, the
crankcase should be filled through the crankcase inspection
plate (see Fig. 1.6A for the proper oil filling location).

Inspection plate

Inspection plate

gasket

Crankcase

Non-detergent oil is recommended for Corken horizontal
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.
Figure 1.6C shows the recommended oil capacity for the
crankcase. Ensure oil is compatible with the product

being compressed.

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

Fill crankcase

through this opening

Figur e 1.6 A

Use heavy-duty, non-detergent motor oil with rust and
oxidation inhibitors. For viscosity requirements, see
figure 1.6B.

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 65° - 100° F
68 97 20+ 45° - 70° F
46 99 20 35° - 50° F

Texaco®

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

Sun®

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

Figure 1.6B: Oil Selection Chart

Compressor

Model

Approximate Capacity

Quarts Liters

HG/THG600 7 6.6

Figure 1.6C

1.7 Crankcase Oil Pressure
Adjustment

Your Corken compressor is equipped with an
automatically reversible gear type oil pump. It is
essential to ensure the pumping system is primed and
the oil pressure is properly adjusted in order to assure
smooth operation.

Before starting your compressor, check and fill the
crankcase with the proper amount of lubricating oil
(see figure 1.6A for details).

When the compressor is first started, observe the
crankcase oil pressure gauge. If the gauge fails to
indicate pressure within 30 seconds, stop the machine.
Loosen the oil filter and remove the pressure gauge.
Restart the compressor and run it until oil comes out
of the pressure gauge opening or around the filter.
Tighten the filter and reinstall the gauge.

The oil pressure should be about 20 psi (1.4 bars)
minimum for normal service. If the discharge pressure
of the compressor is above 200 psi (14.8 bars), the
oil pressure must be maintained at 25–30 psi (1.7–2.1
bars). A spring-loaded relief valve mounted on the
bearing carrier opposite the flywheel regulates the oil
pressure. As shown in figure 1.7, 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 re-tighten it after making any adjustment (see
figure 1.7 for details).

9

Locknut

the maximum design temperature for the compressor
of 350°F (176°C).

3. Low Suction Pressure Switch: Shuts down the
unit if inlet pressure is not within the preset limit (set
point). In some cases, it is important not to pull a
vacuum because of the potential of pulling oil from the
crankcase into the gas stream.

4. High Discharge Pressure Switch: Shuts down the
unit if the outlet pressure reaches a preset limit (set
point). Both the switch and the compressor have an
operating range. The set point of the pressure switch
should be as follows:

Greater than the normal operating pressure for the

compressor.

Bearing carrier

Oil pressure relief valve

adjustment screw

Oil pressure guage

Figur e 1.7

1.8 Relief Valves

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

1.9 Shutdown/Alarm Devices

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

Less than 90% of the relief valve set point pressure.

Less than the maximum operating pressure of the

compressor.

Midpoint of the pressure switch range.

5. Vibration Switch: Shuts down the unit if vibration
becomes excessive. Recommended for units mounted
to a portable skid.

1. Low Oil Pressure Switch: Shuts down the unit if
crankcase oil pressure falls below 12 psi due to oil
pump failure or low oil level in crankcase. The switch
or the compressor controller must have a 30 second
delay on startup which allows the compressor to build
oil pressure in the crankcase.

2. High Discharge Temperature Switch: This switch
is strongly recommended for all applications. Both
the High Discharge Temperature switch (HDT) and
compressor have an operating pressure range. It is
preferable that the switch set point be 30°F (-1°C)
above the normal discharge temperature, but below

10

Chapter 2—Starting Up Your Corken Compressor

The initial operation of your compressor is the most critical
time it will ever face. READ ALL OF CHAPTER TWO BEFORE
YOU PROCEED WITH THE STARTUP CHECKLIST.

2.1 Inspection After Extended
Storage

If your compressor has been out of service for a long
period of time, you should verify that the cylinder bore
and valve areas are free of rust and other debris. For
valve and/or cylinder head removal instructions, refer to
chapter 4 of this IOM manual.

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

Rotate unit manually to ensure running gear functions
properly. Replace the crankcase inspection plate and
proceed with startup.

2.2 Flywheel and V-belt Alignment

Before working on the drive assembly, make sure the
electrical power is turned off. Always make sure the
driver and compressor are close enough together to
avoid forcing the belts over the flywheel and sheave.
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 loose will cause
excessive vibration while those that are too tight may
cause premature bearing failure (refer to figure 2.2C).

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 straight edge
tool or string is the best method.

Crankshaft key

Align hub with crankshaft key.

Flywheel removal holes

(threaded openings)

Split

Flywheel

Tighten flywheel bolts in an even and progressive manner.

Figure 2.2A (model HG601EE (plain style) shown)

11

NOTE:

1) If you are using five individual V-belts, 1/4 to 3/8 inches (6.4 to 9.5 mm) of movement is normal.

2) If you are using five banded V-belts, movement will be much less due to the stiffness of the banded V-belt design.

Figure 2.2C

The flywheel is mounted on the shaft via a split, tapered
hub and three bolts (see figure 2.2A). These bolts should
be tightened in an even and progressive manner to
the specified torque values listed in figure 2.2B. There
must be a gap between the hub and the flywheel when
installation is complete. Failure to do so will cause the
flywheel to be misaligned. Always check the flywheel run
out before startup and readjust if it exceeds the value
listed in Appendix B.

Hub Size

SF 4.625 (11.7) 12–18 (2.5)

E 6.0 (15. 2) 30–36 (4.9)

J 7.25 (18.4) 75–81 (11.1)

Diameter

in. (cm)

Bolt Torque

Ft·lb (kg·meter)

cooling fans can be used to provide additional air flow
across the cylinders.

WATER COOLED: If your unit has water cooled cylinders
(optional), be sure that the cooling system has been
inspected for leaks and proper circulation. Purge air
from the cooling jackets to eliminate air pockets in the
cooling system. If chilled water systems are used be sure
that water shut-off valves are installed to stop water flow
when compressor stops. Monitor system for any signs of
internal sweating. If internal moisture is detected, water
temperatures and flow rates should be checked. Normal
flow rate for cylinders is approximately 1 - 2 gpm.

2.5 Force Feed Cylinder

Figure 2.2B

2.3 Compressor Speed and

Rotation Direction

The lubrication system of the Corken horizontal
compressor is designed to operate at a minimum of 400
RPM. If lower speeds are necessary, consult the factory.
The maximum speed is 1200 RPM. The crankshaft may
be rotated in either direction.

2.4 Compressor Cooling

AIR COOLED: Double acting units generate a lot of
heat around the valve area. It is very important that
the compressor be located where good air flow and
ventilation can be provided. In extreme cases external

Lubrication (Lubed models only)

An external lubricator is bolted directly to the crankcase
and is driven by a chain inside the crankcase at 80%
of crankshaft speed. To ensure each cylinder receives
the same volume of lubrication, an oil divider valve
assembly is also mounted to the opposite end of
the crankcase (see lubricator assembly details in
Appendix D). Since lubricators supplied with Corken
compressors are made by a number of different
manufacturers, refer to the manufacturer’s instructions
provided with the lubricator for specific details on
priming, adjusting and maintaining your lubricator.
Basic operating instructions and flow rate adjustments
are also listed on the side of the lubricator reservoir.

At the initial setup of your compressor, the lubricator
flow should be set to maximum capacity. After the first
hour, reduce the flow to normal operating levels. Normal

12

NOTE:

1) Since Corken uses more than one vendor when purchasing lubricators, the lubricator shown below and
respective operational instructions may vary from the one used on your compressor.

2) Operational instructions can be found on the side of the lubricator reservoir.

3) Oil used in the reservoir is for lubricating the internal parts of the lubricator only and not the compressor.

4) Depending on the cylinder size, the oil flow rate for the drip tube site glass is three to six drops per minute
during normal operations.

Oil outlet (1/8″)

Mounting stud

Drive shaft

Mounting studs

Reservoir

Oil inlet (1/8″)

Union nut

Drip tube sight glass

Priming button

Flushing unit

Oil ll opening

Lock nut

Reservoir sight glass

Drain plug

Premier lubricator model number P-55U with pump no. 91490 shown above.

operating levels range from three to six drops per minute
depending upon the cylinder size.

NOTE: The lubricator supplied on your CORKEN
compressor must be supplied with oil from an external
supply tank and NOT from the compressor crankcase or
lubricator reservoir.

Oil types: Refer to section 1.6 (crankcase lubrication).

2.6 Variable Clearance Heads (VCH)

Variable clearance head (VCH) assemblies (outboard)
allow adjustment of the compressor when operating
conditions change. By turning the clearance volume

adjusting cup, you can easily change the capacity
and bhp requirements of the cylinder. Normally, the
packager will have already provided at least a preliminary
adjustment of the VCH. If not, you may wish to adjust
the heads for maximum clearance before startup. After
startup, adjust the heads inward to increase the capacity
and bhp of the cylinder to the desired levels.

To adjust the variable clearance heads, follow the steps
below.

1) Remove the VCH adjusting screw nut. Adjustment can
be made while the unit running.

2) Turn the end of the adjusting cup to adjust the cylinder
head end clearance.

13

3) Turning the end of the adjusting cup inward (clockwise)
reduces cylinder head end clearance.

4) Turning the end of the adjusting cup outward
(counterclockwise) increases cylinder head end
clearance.

17. Carefully check for any loose connections or bolts.

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

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

5) Replace the VCH adjustable screw nut and O-ring.

The approximate clearance volume change per turn of
the adjusting bolt is 3%.

2.7 Startup Check List

Please verify each item on this list below before starting
your compressor! Failure to do so may result in a costly
and/or dangerous mistake.

Before Starting the Compressor

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

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

3. Ensure line pressures are within cylinder pressure
ratings.

4. Clean out all piping.

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

6. Check all mounting shims, cylinder and piping supports
to ensure that no twisting forces or other undesired
nozzle forces or torque is applied to the compressor.

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

20. Re-check all of the above.

After Starting Compressor

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

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

3. Verify proper compressor speed.

4. Examine entire system for gas or oil leaks.

5. Note rotation direction.

6. Check start-up voltage drop, running amperage
and voltage.

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

8. Test each shutdown device and record set points.

9. Test or confirm set point on all relief valves. Test all
dump valves, relief valves and unloaders.

10. Check and record all temperatures and pressures
after 30 minutes and 1 hour. Retain records for
future reference.

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

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

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

10. Rotate unit by hand and make certain there is no
wobble or play in the flywheel or sheave.

11. Check crankcase oil level.

12. Drain all liquid traps, separators, etc.

13. Verify proper electrical supply to motor and panel.

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

15. Test piping system for leaks.

16. Purge unit of air before pressurizing with gas. Follow
your company procedures for this operation.

14

Chapter 3—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 adapters and distance pieces

Clean cooling surfaces on compressor and intercooler (if any)

Lubricator supply tank level (if any)

Check belts for correct tension

Inspect valve assemblies
Lubricate motor bearings in accordance with manufacturers’

recommendations
Inspect motor starter contact points

Inspect piston rings

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 ever y 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 star tup.

1

1 1

Chapter 4—Routine Service and Repair Procedures

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

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

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

cover plates to each other. If a valve or gasket is leaking,
it will have a higher operating temperature. NOTE: This
method will not be suitable for two stage compressors if
each stage does not have more than one valve.

Each suction and/or discharge valve assembly is easily
removed as a unit for inspection. If any part of the
valve assembly is broken, the valve assembly should be
replaced. See valve assembly parts details in the Appendix
D for a complete list of part numbers and descriptions.

If a compressor 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 ensure a good seal.

The valve holddown components and valve assemblies
listed in Appendix D show the various specifications
used on horizontal 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, if a compressor valve or valve gasket
is leaking, it will create more heat. On a single stage
compressor, you may be able to compare the operating
temperatures of the two suction or discharge valves and

Model number THG601BBGM 4 FBANSNNN

Valve type = spec 4

15

Valve Inspection and/or Replacement

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

Disassembly of 2.75" Cylinder Size

1. Remove the valve cover plate and O-ring by removing
each of the three bolts.

replaced. Replacement is usually preferable although
repair parts are available. If valve plates are replaced,
seats should also be lapped until they are perfectly
smooth. If more than .005 of an inch must be removed
to achieve a smooth surface, the valve should be
discarded. If plates are replaced without re-lapping
the seat, rapid wear and leakage may occur.

Assembly of 3.25", 4", 5", 6" and 8" Cylinder Sizes

2. After the cover plate and O-ring have been removed,
the valve assembly and valve gasket can be lifted out.

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

Assembly of 2.75" Cylinder Size

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 O-ring and valve cover plate. Torque the
bolts to the value listed in Appendix B. CAUTION: Be
sure the holddown screw has been removed. NOTE:
Gaskets and O-rings are not normally reusable.

4. Check bolts after first week of operation. Re-torque if
necessary. See Appendix B for torque values.

Disassembly of 3.25", 4", 5", 6" and 8" Cylinder Sizes

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

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

3. After the cover plate and O-ring have been removed,
the valve cage, valve assembly and valve gasket can
be lifted out.

4. Inspect valves for breakage, corrosion, debris and
scratches on the valve plate. In many cases, valves
may simply be cleaned and reinstalled. If the valves
show any damage, they should be repaired or

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

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

3. Insert the valve cage.

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

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

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

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

4.2 Heads

A horizontal compressor cylinder head or adjusting cap
seldom require replacement if the compressor is properly
maintained. The primary cause of damage to a cylinder
head and adjusting cap is corrosion and the entry of
solid debris or liquid into the compression chamber.
Improper storage can also result in corrosion damage to
the cylinder heads and adjusting caps (for proper storage
instructions see chapter 5).

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

When reassembling the compressor, make sure the
bolts are re-tightened to the torque values listed in
Appendix B.

16

4.3 Piston Rings and Piston Ring
Expander Replacement

4. Remove the lock nut, washer and shims and pull the
piston off the end of the piston rod. Keep track of which
piston washer and shims came out of each cylinder.

Piston Ring Life - Dry Cylinder Compressor Applicat ions

It is unrealistic to expect the same piston ring life from
a dry cylinder compressor as from a lubricated cylinder
machine because the PTFE rings have greater wear,
particularly under high temperature conditions.

CORKEN uses one of the best PTFE ring formulations
available. The normal life expectancy is approximately
2,200 hours of continuous service within recommended
compression ratios. However, ring life will vary considerably
depending upon piston speed (RPM), ambient temperature,
intermittent service conditions, compression ratio and the
nature of the gas being handled.

The secret to long ring life is operating at a low temperature.
A low ambient temperature and compression ratio along
with better intercooling will provide better ring wear.

Piston Ring Life - Lubricated Cylinder
Compressor Applications

If your compressor is equipped with cylinder lubrication
you can expect considerably longer life from your piston
rings than the dry cylinder units described above.

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

Piston and Piston Ring Expander Replacement

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

2. Remove the cylinder cap (if any) and head.

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

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

4.4 Pistons

As you read the following instructions, refer to
Appendix D for parts details.

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

2. Remove the head (or adjusting screw nut, cylinder
cap, adjusting cup and head - applies to adjustable
head configuration only) as shown in Appendix D.

3. Remove the piston cap and shims by loosening and
removing the piston cap screws holding the piston cap
to the piston. Re-insert two loose screws as shown
in figure 4.3. Using your fingers, pinch the screws
together and pull the piston cap out of the cylinder.

4. Remove the lock nut and thrust washer and pull the
piston out of the cylinder. Then, remove the thrust
washer and shims on the end of the piston rod.

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

6. Measure the thickness of the existing shims.

7. Insert one thrust washer against piston rod shoulder
followed by the same shims (or the same thickness of
shims) as before.

8. Before installing the piston, attach the piston ring
expanders and piston rings to the piston. Then, install
the piston on the piston rod.

Figure 4.3

9. Install a thrust washer and lock nut and tighten the
lock nut to the value listed in Appendix B.

10. Now remove an inboard valve and measure dimension
“Y” on the inboard end of the piston as shown in
Appendix B. If this measurement does not fall within
the tolerances listed in the piston assembly details
(Appendix B), remove the piston and adjust the shims
as necessary. Re-install the piston and tighten the
lock nut to the value listed in Appendix B. Re-measure
the “Y” dimension.

11. After the “Y” dimension is within tolerance, install
the piston cap with the same shim/shims (or same
thickness of shims) as before.

17

12. Torque the piston cap screws to the value listed in
Appendix B.

13. Install the head (or head and adjustable cap ­applies to adjustable head configuration only) as
show in Appendix D. Torque bolts to the value listed
in Appendix B.

14. Now remove an outboard valve and measure
dimension “X” at the outboard end of the piston as
shown in the Appendix B. If this measurement does
not fall within the tolerances in Appendix B, remove
the head (or head and adjustable cap - applies to
adjustable head configuration only) and piston cap
and adjust the shims as necessary. Re-install the
piston cap and tighten the piston cap screws in an
alternating sequence to the values listed in Appendix
B. Re-install the head (or head and adjustable cap

- applies to adjustable head configuration only) and
torque to the value listed in Appendix B. Re-measure
the “X” dimension again.

15. After the “X” dimension is within tolerance, remove
the adjustable cap and install the adjustable cup
followed by the adjustable cap and adjustable screw
nut as shown in Appendix D.

16. Torque the bolts in an alternating sequence to the
values listed in Appendix B.

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

18. Follow standard startup procedures.

1) Keep foreign material out of crosshead bore on
crankcase. Wipe inside of bore with clean rag and
coat bore with oil.

2) Inspect piston rod for cleanliness and coat with oil
before assembly.

3) Before installing adapter and packing cartridge
on piston rod, install packing installation cone
(Corken #3905) over piston rod threads. This
will aid and protect packing during installation.
Failure to use this packing cone could result in
packing damage. Refer to Appendix D for correct
installation of packing.

4) Rotate flywheel/crankshaft by hand several revolutions
to ensure proper fit of all assembled parts.

5) Orient cylinder inlet and outlet to piping installation
to ensure proper valve alignment with system.
Valves must be properly oriented with suction and
discharge piping.

6) For piston installation instructions, see section 4.4.

7) After installing the piston, again, rotate flywheel/
crankshaft by hand several revolutions to ensure
proper fit of all assembled parts.

8) Check crankcase for proper oil level.

9) See start-up procedure in section 2.7. During start­up, listen to the compressor for any unusual noises.
If any problems arise during assembly, please
contact the factory.

4.5 Cylinder Replacement

Cylinders very seldom require replacement if the
compressor is properly maintained. The primary cause
of damage to cylinders is corrosion and the entry of solid
debris or liquid into the compression chamber. Improper
storage can also result in corrosion damage to cylinder
(for proper storage instructions see chapter 5). Damage
can also occur if the piston rings are allowed to wear so
much that the ring expander can reach the cylinder wall.

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.

If the cylinder does become damaged or corroded, use
a hone to smooth the cylinder bore and then polish it
to the value shown in Appendix B. If more than .005 of
an inch must be removed to smooth the bore, replace
the cylinder. Cylinder liners and oversized rings are not
available. OVERBORING THE CYLINDER WILL RESULT
IN GREATLY REDUCED RING LIFE.

When reassembling the compressor, make sure the
bolts are retightened using the torque values listed in
Appendix B.

4.6 Packing Replacement

Instructions

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

For specific construction details and actual part numbers,
consult Appendix D in the back of this Installation,
Operation & Maintenance (IOM) manual. Use instructions
below that apply to the MODEL and SERIAL NUMBER of
your compressor.

18

Cleanliness:

Sealing a reciprocating piston rod is a very difficult task.
In order to create the best seal possible between the
piston rod and the packing, KEEP YOUR HANDS, PARTS
AND TOOLS CLEAN DURING INSTALLATION.

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.

Disassembly of Packing—Plain-style Compressor
Models HG601 and HG602

1. Depressurize and open the compressor before
performing any tasks.

2. Remove the head (along with adjustable head
components, if any), pistons and cylinder.

3. Standard Packing Specification

a. Refer to Appendix D for your particular model of

compressor and note the order in which the parts
are removed.

b. Mark the top of the packing cartridge body to

facilitate later reassembly. Remove the four socket
head bolts that attach the packing cartridge
assembly to the adapter. It is not normally necessar y
to remove the adapter from the crankcase in order
to disassemble or reassemble the packing.

c. Partially insert the bolts in the puller holes in the

outer end of the packing cartridge body and pull
outward to remove the entire packing cartridge
assembly from the adapter and over the piston
rod. If the packing cartridge assembly does not
slide out easily, it may be necessary to alternately
turn the bolts clockwise in the puller holes so
that the bolts engage the adapter and force the
packing cartridge assembly to come out.

d. Remove the outer retainer ring, solid packing breaker

(not included on 6" and 8" cylinders), packing cups,
all packing sets, backup rings, etc. from the cylinder
side of the packing cartridge body.

e. Remove the inner retainer ring, packing washer

and oil wiper ring set from the crankcase side of
the packing cartridge body.

head bolts that attach the packing cartridge cap
to the adapter. It is not normally necessary to
remove the adapter from the crankcase in order to
disassemble or reassemble the packing.

c. Partially insert the bolts in the puller holes in the

outer end of the packing cartridge cap and pull
outward to remove the packing cartridge cap from
the rest of the packing cartridge assembly, adapter
and over the piston rod. If the packing cartridge
cap does not slide out easily, it may be necessary
to alternately turn the bolts clockwise in the puller
holes so that the bolts engage the adapter and
force the packing cartridge cap to come out.

d. Mark the top of the packing cartridge body to

facilitate later reassembly and proper alignment
with the packing cartridge cap. Pull outward to
remove the packing cartridge assembly from the
adapter and piston rod.

i. 2-3/4" and 3-1/4" Cylinders: Using a pair

of flat-bladed screwdrivers or similar tools,
engage the annular groove on the outer end
(cylinder side) of the packing cartridge body
and pry the packing cartridge assembly from
the adapter and over the piston rod.

ii. 4", 5", 6" and 8" Cylinders: Partially insert

the bolts in the puller holes in the outer end of
the packing cartridge body and pull outward
to remove the packing cartridge assembly
from the adapter and over the piston rod. If the
packing cartridge assembly does not slide out
easily, it may be necessary to alternately turn
the bolts clockwise in the puller holes so that
the bolts engage the adapter and force the
packing cartridge assembly to come out.

e. In addition to the packing cartridge cap previously

removed, remove the solid packing breaker (not
included on 6" and 8" cylinders), packing cups,
all packing sets, backup rings, purge packing
cups, cup spacer, packing spacer, oil wiper cup,
oil wiper ring set, etc. from the cylinder side of the
packing cartridge body.

Assembly of Packing—Plain-style Compressor
Models HG601 and HG602

1. Always use new O-rings, packing and oil wiper ring
sets during assembly.

4. Purge Packing Specification

a. Refer to Appendix D for your particular model of

compressor and note the order in which the parts
are removed.

b. Mark the top of the packing cartridge cap to

facilitate later reassembly. Remove the four socket

2. Clean packing cartridge body and parts removed
from it during disassembly process.

3. Standard Packing Specification

a. Refer to Appendix D and note the order in which the

parts are to be installed and their correct orientation.

19

b. Install the oil wiper ring set, packing washer and

inner retainer ring into the crankcase side of the
packing cartridge body.

c. Install the O-ring on the packing spacer, and

install both into the cylinder side of the packing
cartridge body.

d. Install a back-up ring, segmented packing set

(tangent-tangent [TT]) and packing cup with
O-ring into the cylinder side of the packing
cartridge body.

e. Install a back-up ring, a segmented packing set

(radial-tangent [RT]) and packing cup with O-ring
into the cylinder side of the packing cartridge
body. Repeat this process for the remaining RT
packing sets.

f. Install the pressure breaker ring (not included

on 6" and 8" cylinders) and final packing cup
with O-ring into the cylinder side of the packing
cartridge body. Reinstall outer retainer ring.

g. Install a packing installation cone (Part no. 3905)

on threaded end of the piston rod

h. Install a new O-ring inside the adapter.

i. Carefully install the assembled packing cartridge

assembly on the piston rod and insert into the
adapter. Be sure the mark previously made on the
packing cartridge body is oriented up because the
packing cartridge body can only be installed in
one position. Attach the packing cartridge body to
the adapter with the four socket head bolts.

j. Remove the packing installation cone.

k. Replace the cylinder, pistons and cylinder head

(along with adjustable head components, if any).

l. Rotate the unit by hand to insure proper assembly.

4. Purge Packing Specification

a. Refer to Appendix D and note the order in which the

parts are to be installed and their correct orientation.

b. Install oil wiper ring set and oil wiper ring cup into

the cylinder side of the packing cartridge body.

c. Install a biased packing set (tangent-tangent with

springs toward cylinder [TTs]), purge packing
cup with O-ring and cup spacer into the cylinder
side of the packing cartridge body. NOTE: The

6 springs in the biased packing sets are very
small and fit loosely, so extra care is needed to
keep from losing them or having them become
dislodged during assembly.

d. Install a purge packing cup with O-ring and biased

packing set (tangent-tangent with springs toward
crankcase [sTT]) into cylinder side of packing
cartridge body.

e. Install the O-ring on the packing spacer, and

install both into the cylinder side of the packing
cartridge body.

f. Install the back-up ring, segmented packing set

(tangent-tangent [TT]) and packing cup with
the O-ring into the cylinder side of the packing
cartridge body.

g. 2-3/4", 3-1/4" and 4" Cylinders: Each of these

cylinder sizes includes a pressure breaker ring
on the outer end of the packing cartridge
assembly. Also, these cylinder sizes include a
packing cartridge cap into which at least some
of the segmented packing sets (radial-tangent
[RT]) are positioned.

i. Install a back-up ring, segmented packing

set (radial-tangent [RT]) and packing cup with
O-ring into cylinder side of packing cartridge
body. Repeat this process as necessary for
additional RT packing sets until a packing cup
extends partially from the cylinder side of the
packing cartridge body.

ii. Install the pressure breaker ring and packing

cup with O-ring into the packing cartridge cap.

iii. Install a back-up ring, segmented packing

set (radial-tangent [RT]) and packing cup with
O-ring into the packing cartridge cap. Repeat
this process for remaining RT packing sets.

iv. Install the packing cartridge cap on the packing

cartridge body, making sure the previously­made markings on each are aligned. The
portion of the packing cup extending from the
packing cartridge body should extend into the
packing cartridge cap.

v. Insure that the pin extending from the outer

end of packing box cartridge fits into the
corresponding hole in the packing cartridge
cap. NOTE: Some early models did not have

this pin.

h. 5", 6" and 8" Cylinders: Each of these cylinder sizes

includes a flat packing cartridge cap that fits on the
outer end of the packing cartridge body.

i. Install a back-up ring, segmented packing

set (radial-tangent [RT]) and packing cup with
O-ring into the cylinder side of the packing
cartridge body. Repeat this process for
remaining RT packing sets.

20

ii. Position the packing cartridge cap on the

packing cartridge body, making sure the
previously-made markings on each are aligned.
The holes in the packing cap should be aligned
with the corresponding holes in the packing
cartridge body.

i. Install a packing installation cone (Part no. 3905)

on threaded end of the piston rod

j. Install a new O-ring inside the adapter.

k. Carefully install the assembled packing cartridge

assembly with packing cartridge cap on the piston
rod and insert into the adapter. Be sure the marks
previously marked on the packing cartridge body
and cap are oriented up because most packing
cartridge bodies can only be installed in one
position. Attach the packing cartridge cap to the
adapter with the four socket head bolts.

l. Remove the packing installation cone.

m. Replace the cylinder, pistons and cylinder head

(along with adjustable head components, if any).

cartridge assembly from the adapter and over the
piston rod.

a. 2-3/4" and 3-1/4" Cylinders: Using a pair of flat-

bladed screwdrivers or similar tools, engage the
annular groove on the outer end (cylinder side) of the
packing cartridge body and pry the packing cartridge
assembly from the adapter and piston rod.

b. 4", 5", 6" and 8" Cylinders: Partially insert the

bolts in the puller holes in the outer end of the
packing cartridge body and pull outward to remove
the packing cartridge assembly from the adapter
and over the piston rod. If the packing cartridge
assembly does not slide out easily, it may be
necessary to alternately turn the bolts clockwise
in the puller holes so that the bolts engage the
adapter and force the packing cartridge assembly
to come out.

7. Separate the packing cartridge adapter from the
packing cartridge body by removing the four small
socket head screws. Remove the cup spacer by
sliding it out of the packing cartridge body or packing
cartridge adapter.

n. Rotate the unit by hand to insure proper assembly.

Disassembly of Packing—T-style Compressor
Models THG601 and THG602

1. Depressurize and open the compressor before
performing any tasks.

2. Remove the head (along with adjustable head
components, if any), pistons and cylinder.

3. Refer to Appendix D for your particular model of
compressor and note the order in which the parts
are removed.

4. Mark the top of the packing cartridge cap to facilitate
later reassembly. Remove the four socket head bolts
that attach the packing cartridge cap to the adapter.
It is not normally necessary to remove the adapter
from the distance piece or the distance piece from
the crankcase in order to disassemble or reassemble
the packing.

5. Partially insert the bolts in the puller holes in the outer
end of the packing cartridge cap and pull outward
to remove the packing cartridge cap from the rest of
the packing cartridge assembly, adapter and over the
piston rod. If the packing cartridge cap does not slide
out easily, it may be necessary to alternately turn the
bolts clockwise in the puller holes so that the bolts
engage the adapter and force the packing cartridge
cap to come out.

6. Mark the top of the packing cartridge body to facilitate
later reassembly. Pull outward to remove the packing

8. Outer Packing

a. In addition to the packing cartridge cap previously

removed, remove solid packing breaker (not
included on 6" and 8" cylinders), packing cups,
packing sets, backup rings, packing spacer and
purge packing cup, etc. from the cylinder side of
the packing cartridge body.

b. If the packing components are not easily removable,

it may be necessary to use Corken Packing Removal
Tool 4789-X. Referring to Figure 4.6A, orient the
packing cartridge body so that the open end
(cylinder side) faces down, and align the tool with
the center opening of the packing cartridge.

c. Insert Tool 4789-X into the packing cartridge body

until the engagement end of the tool is just above
the purge packing cup. See Figure 4.6B.

d. Press the spring-loaded lever inward so that the

engagement end of the lever moves outward. While
still holding the lever in, place the engagement
ends of the tool and lever in contact with the purge
packing cup, and use a hammer or similar device
to drive the outer packing set from the packing
cartridge body.

9. Middle Packing: Remove the packing cups, packing
sets, backup rings, packing spacer and purge packing
cup, etc. from the crankcase side of the packing
cartridge body. If necessary Packing Removal Tool
4789-X may be used to remove the middle packing
set in a manner similar to the outer packing set.

21

Lever

Engagement end of tool

Step 1 Step 2

Packing removal
tool (4789-X)

Engagement end of lever

Packing cartride body

Packing removal
tool (4789-X)

Push lever in to actuate

Purge packing cup

Purge packing cup

Figure 4.6A: Packing disassembly Figure 4.6B: Packing disassembly

10. Inner Packing: Remove the purge packing cup,
segmented packing, oil wiper cup, oil wiper ring set, etc.
from the cylinder side of the packing cartridge adapter.

Assembly of Packing—T-style Compressor Models
THG601 and THG602

1. Always use new O-rings, packing sets and oil wiper
ring sets during assembly.

2. Clean the packing cartridge body and parts removed
from it during disassembly process.

3. Refer to Appendix D and note the order in which the
parts are to be installed and their correct orientation.

4. Inner Packing: The inner packing set is most easily
assembled using Packing Assembly Tool 4794-X.

a. Set the end plate of the Tool 4794-X on a

horizontal work surface and remove the slotted
clamp of the tool.

Step 1

Packing assembly
tool (4974-X)

Rod

b. Place a purge packing cup and a biased packing

set (TTs) onto the end plate of the tool and over
the rod of the tool. The cylinder side of the packing
should face the end plate of the tool such that the
springs in the biased packing set face toward the
end plate. NOTE: The 6 springs in the biased

packing sets are very small and fit loosely,

Biased packing set (TTs)

22

Purge packing cup

End plate

Figure 4.6C: Packing assembly

Nut

Rod

Step 2 Step 3

Packing assembly
tool (4974-X)

Slotted clamp

Packing cartridge adapter

Packing assembly
tool (4974-X)

Slotted clamp

Wiper ring cup and
inner oil wiper ring set

Purge packing cup and
inner packing set

End plate

Figure 4.6D : Packing assembly

Packing cartridge
body

Step 4

Inner packing set

End plate

Packing cartridge
adapter

Figure 4.6E : Packing assembly

so extra care is needed to keep from losing
them or having them become dislodged during
assembly. Place the oil wiper ring cup and oil

wiper ring set onto the purge packing cup. You
now have a full inner packing set positioned on the
end plate of the tool. See Figure 4.6C.

c. Orient the packing cartridge adapter so that the

open end (cylinder side) faces down. Being careful
not to dislodge the inner packing set previously
placed on the end plate of the tool, position the
packing cartridge adapter over the inner packing
set and end plate of the tool so that the rod of
the tool extends through the packing cartridge
adapter. Place the slotted clamp above the packing
cartridge adapter as shown in Figure 4.6D.

Inner
packing
set

Figure 4.6F : Packing assembly

Cup spacer

Socket head
screw

Packing cartridge
adapter

d. Tighten the nut on the rod of the tool until the

inner packing set is fully drawn into the packing
cartridge adapter. See Figure 4.6E.

e. Invert the packing cartridge adapter with the inner

packing set in it, and remove Tool 4794-X. Slide
the cup spacer into the packing cartridge adapter
so that it engages the inner packing set. See
Figure 4.6F.

f. Place an oil deflector ring inside the cup spacer

so that it is generally concentric with the inner
packing set.

23

5. Middle Packing

a. For compressors set up for pad packing

(Specification Code G), install a purge packing
cup with O-ring and a biased packing set (tangent­tangent with springs toward cylinder [TTs]) into
the crankcase side of the packing cartridge body.
NOTE: The 6 springs in the biased packing sets
are very small and fit loosely, so extra care is
needed to keep from losing them or having them
become dislodged during assembly.

b. Install an O-ring on a packing spacer and install

both into the crankcase side of the packing
cartridge body.

c. Install a backup ring, segmented packing set (tangent-

tangent [TT]) and packing cup with O-ring into the
crankcase side of the packing cartridge body.

d. For compressors set up for purge packing

(Specification Code H), the middle packing set
components are installed in the opposite order
from Specification Code G, so that the springs
are toward the crankcase side of the packing
cartridge body.

e. For both Specification Codes G and H, install the

packing cartridge adapter onto the crankcase
side of the packing cartridge body such that the
cup spacer slides into the crankcase side of the
packing cartridge adapter and engages the middle
packing set to retain it in the packing cartridge
body. Attach the packing cartridge adapter to the
packing cartridge body with the four small socket
head screws.

f. Install a new O-ring on the outside of the packing

cartridge adapter and inside the adapter

g. Install a packing installation cone (Part no. 3905)

on the threaded end of the piston rod.

h. Carefully install the completed packing cartridge

assembly on the piston rod and insert into the
adapter. Be sure the mark previously made on the
packing cartridge body is oriented up because
most packing cartridge bodies can only be
installed in one position.

i. Install the packing cartridge cap in the adapter.

Be sure the mark previously made on the
packing cartridge cap is oriented up because
the packing cartridge cap can only be installed
in one position. On 2-3/4", 3-1/4" and 4"
Cylinders only, insure that the pin extending
from the outer end of the packing box cartridge
fits into the corresponding hole in the packing
cartridge cap.

j. Attach the packing cartridge cap to the adapter

with the four socket head bolts

k. Remove the packing installation cone.

7. Replace the cylinder, pistons and cylinder head (along
with adjustable head components, if any).

8. Rotate unit by hand to insure proper assembly.

4.7 Bearing Replacement for

Crankcase and Connecting Rod

6. Outer Packing

a. Install a purge packing cup with O-ring and biased

packing set (tangent-tangent with springs toward
crankcase [sTT]) into cylinder side of packing
cartridge body.

b. Install an O-ring on a packing spacer, and install

both into cylinder side of packing cartridge body.

c. Install a back-up ring, segmented packing set

(tangent-tangent [TT]) and packing cup with O-ring
into the cylinder side of packing cartridge body.

d. Install a back-up ring, segmented packing set

(radial-tangent [RT]) and packing cup with O-ring
into the cylinder side of packing cartridge body.
Repeat this process for remaining RT packing sets

e. Install a pressure breaker ring (not included on 6"

and 8" cylinders) and final packing cup with O-ring
into the cylinder side of packing cartridge body

1. To replace the crankcase roller bearings, wrist
pin bushing and connecting rod bearings, begin
by removing the head (or head, adjustable cap
and adjustable cup - applies to adjustable head
configuration only), cylinder, pistons, adapter, distance
piece (THG600 only) and crosshead and connecting
rod assemblies.

2. Drain the crankcase and remove the inspection plates.

3. Choose and mark one connecting rod and the
corresponding connecting rod cap to identify them. DO
NOT MIX CONNECTING RODS AND CAPS. Loosen
and remove the connecting rod nuts in order to remove
the crosshead and connecting rod assemblies.

4.7.1 Wrist Pin Bushing Replacement

1. To replace the wrist pin bushing, remove the retainer
rings that position the wrist pin in the crosshead.

2. Press out the wrist pin so the crosshead and
connecting rod may be separated. Inspect the wrist
pin for wear and damage and replace if necessary.

24

Crankcase

Oil seal

Bearing cover

Shim

Bearing cup

Bearing cone

Bearing carrier

Bearing cone

Bearing cup

Bearing carrier

gasket

Backside of

bearing carrier

Drive pin

Spacer

Drive sprocket

Link pin

Make sure this hole is aligned

with the oil-passage hole

on the bearing carrier.

Crankshaft

Flywheel key

Oil-passage hole

Figu re 4.7

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. See
Appendix D for details. Over boring the bushing can
lead to premature failure of the wrist pin bushing
and/or wrist pin.

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

Align slot with the pin located

inside the crankshaft.

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

4.7.2 Replacing Connecting Rod Bearings

The semi-circular connecting rod bearings are easily
replaced by removing the connecting rods. 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. BE
SURE THE PREVIOUSLY MARKED CONNECTING ROD
AND CAP ARE KEPT TOGETHER.

Before reinstalling the crosshead/connecting rod
assemblies, make sure the crankshaft throw and bearing

25

Backside of

oil filter adapter

Crankcase inspection plate:
Fill crankcase with oil through
this opening.

Oil suction

Oil filter

Oil filter adapter

Pin

Align pin with slot
on pump shaft
adapter.

O-ring

Pump shaft
bushing

Spring

Spring guide

Oil pump assembly

O-ring

Pump shaft
adapter

Figure 4.7: Oil Pump Inspection

surface are clean and lubricated. Tighten the connecting
rod nuts to the torque value listed in Appendix B.

4.7.3 Replacing Crankcase Roller Bearings

To inspect the roller bearings, you must remove the
flywheel, flywheel hub, bearing carrier and crankshaft
using the following steps.

1. Remove the flywheel from the crankshaft by removing
the three bolts that holds the flywheel to the hub. After
removal, re-insert the bolts into the three THREADED
flywheel removal holes (see figure 2.2A for details).
Tighten the bolts EVENLY to remove the flywheel from
the flywheel hub.

2. After the flywheel has been removed, remove the hub
from the crankshaft. If the hub will not slide off the
crankshaft easily, gently insert a flat head screw driver
into the split on the hub and lightly tap with a screw
driver. The hub should easily slide off the shaft.

3. Remove the bearing carrier and crankshaft from the
crankcase (see figure 4.7 for details). If corrosion
or pitting is present, the roller bearings should be
replaced. When replacing the roller bearings, always
replace the entire bearing and not just the cup or
the cone. Purchasing extra shims is recommended
as well. For crankcase assembly details, refer to
Appendix D and figure 4.6.

Align slot with
the pin at the end of
the crankshaft.

NOTE: REMOVING AND REPLACING THE BEARING

CONES AND BEARING CUPS (STEPS FOUR AND
FIVE LISTED BELOW) REQUIRES THE SERVICES
OF A PROFESSIONAL MACHINE SHOP. DO NOT
ATTEMPT TO REPLACE THEM IN THE FIELD.

4. To replace the bearings, press out the bearing cup
on the flywheel side of the crankcase and the other
bearing cup located on the bearing carrier. Using a
bearing puller, remove the bearing cones from each
end of the crankshaft.

5. Press one new bearing cup into the bearing
carrier and press the other new bearing cup
into the crankcase (opposite the bearing carrier
side). Press one bearing cone on each end of
the crankshaft. Insert the crankshaft through the
bearing carrier opening. The flywheel side of the
crankshaft should slide through the opening of the
bearing cup and bearing cover. Slowly lower the
opposite end of the crankshaft to the bottom of the
bearing carrier opening.

6. Before installing the bearing carrier, make sure

the slot at the end of the oil pump shaft is
aligned with the pin located at the end of the
crankshaft. Alignment should be either twelve and

six o’clock or nine and three o’clock. Make sure the
gasket for the bearing carrier is installed correctly.
An improperly installed gasket will block the oil
passage (see figure 4.6).

26

7. Push the end of the crankshaft toward the crankcase
and pull back; if a clicking noise or motion is
detected, the crankshaft has too much endplay. See
Appendix B.

8. To reduce endplay, remove the bearing cover located
on the flywheel side of the crankcase and remove a
thin shim. Recheck the endplay after replacing the
bearing cover.

9. When there is no detectable endplay, the shaft
must still be able to rotate. 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 do not over shim. (Appendix B lists
the proper crankshaft endplay). When the crankshaft
can be rotated by hand with proper endplay, the rest
of the compressor may be reassembled.

NOTE: if the crankshaft roller bearings are too tight

or too loose, premature bearing failure will result.

10. Reinstall the flywheel and check the runout as shown
in Appendix B.

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

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

8. As you attach the oil filter adapter to the bearing
carrier, make certain the pin on the back of the oil
filter adapter aligns with the opening on the oil pump
assembly as shown in figure 4.7. When you are sure
the pin is properly aligned, install the oil filter adapter
bolts finger tight. If alignment is correct, the oil filter
adapter will mount flush to the bearing carrier. If it
does not, re-check the pin alignment.

9. Tighten the bolts in an alternating sequence. See
section 1.7 for directions on oil pressure adjustment.

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

Chapter 5—Extended Storage

4.8 Oil Pump Inspection

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

1. To check the oil pump, unbolt the oil filter adapter
and remove the oil pump, spring guide, spring and oil
pump shaft adapter as shown in figure 4.7.

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

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

4. Before reassembling the oil pump mechanism, replace
the O-rings in the oil filter adapter and on the oil pump
shaft adapter (see figure 4.7).

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

Procedures

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

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

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

3. Relieve V-belt tension.

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

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

6. Rotate the flywheel every two weeks if possible.

27

Compressor Troubleshooting

General

In most cases problems with your CORKEN gas
compressor can be solved quite simply. The table below

is an important indicator of the condition of a two-stage
compressor.

If interstage pressure is too high:

• Second stage valves may be broken or leaking.

lists some of the more frequent problems that occur with
reciprocating compressors along with a list of possible

• Second stage piston rings may be worn.

causes. If you are having a problem which is not listed
or if you cannot find the source of the problem, consult

If interstage pressure is too low:

the factory.

• First stage valves may be broken or leaking.

Two-Stage Compressor Trouble Shooting

Two-stage compressors can have problems that never
occur with single-stage machines. Interstage pressure

• First stage piston rings may be worn.

• If suction and/or discharge pressures change, the
interstage pressure will also change.

Compressor Trouble Shooting Guide

Problem Possible Cause

Low Capacity 1, 2, 3, 4
Overheating 1, 2, 3, 5, 6, 11
Knocks, Rattles & Noise 1, 7, 9, 10, 11, 14
Abnormal Piston Ring Wear 1, 3, 5, 6, 11, 14
Product Leaking Through Crankcase Breather 8, 15
Product Leakage 4, 8, 14
Oil Leakage Around Compressor Base 15, 16
No Oil Pressure 17, 18
Excessive Vibration 1, 7, 9, 10, 11, 12, 13, 14, 26
Motor Overheating or Starter Tripping Out 19, 20, 21, 22, 23, 24, 25

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 sheave 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 valves or consult Factory

12. Inadequate compressor base Strengthen, replace or gout

13. Improper foundation or mounting Tighten mounting or rebuild foundation

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

15. Leaking gas blowing oil from crankcase Replace packing

16. Bad oil seal Replace

17. No oil in crankcase Add oil accordingly

18. Oil pump malfunction See "Oil Pressure Adjustment"

19. Low voltage Check line voltage with motor nameplate. Consult Power Company.

20. Motor wired wrong Check wiring diagram

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

22. Wrong power characteristics

23. Wrong size heaters in starter Check and replace according to manufacturer's instructions

24. Compressor overloading Reduce speed

25. Motor shorted out See "Driver Installation"

26. Bad Motor Bearing Lubricate according to manufacturer's instructions.

Voltage, phase and frequency must coincide with motor nameplate.
Consult with Power Company.

28

Gasket Sets and Repair Kits

Gasket Set Part Type Head Type

3582-X Crankcase
3582-X7_ 8" cylinder Standard
3582-X8_ 8" cylinder Adjustable
3582-X5_ 6" cylinder Standard

6" cylinder Adjustable

3582-X6_

3582-X3_ 4" cylinder Standard
3582-X4_ 4" cylinder Adjustable
3582-X1_ 3-1/4" cylinder Standard
3582-X2_ 3-1/4" cylinder Adjustable
3582-X9_ 2-3/4" cylinder Adjustable

Repair kit Part Type

3788-X1 Crankcase
3792-X1_ 8" cylinder
3791-X1_ 6" cylinder
5335-X1_ 5" cylinder
3790 -X1_ 4" cylinder
3789-X1_ 3-1/4" cylinder
3950-X1_ 2-3/4" cylinder

NOTE: The crankcase repair kit includes a gasket set, bearing cups
and cones, connecting rod bearings and wrist pin bushings. The
cylinder repair kits include a gasket set (for adjustable head), piston
rings, expanders, rider ring, oil wiper ring and segmented packing.
The repair kits do not include compressor valves.

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

5" cylinder Standard
5" cylinder Adjustable

Care must be exercised when selecting the cylinder kit
required for a specific application. The proper head type
and piston material must be chosen. To maintain proper
balance, the following piston combinations are required
for two-stage compressors.

Model Size

Piston Material

1st stage 2nd stage

HG602AB 8" x 6" Aluminum Iron
THG602AB 8" x 6" Aluminum Iron
HG602AC 8" x 5" Aluminum Iron
THG602AC 8" x 5" Aluminum Iron
HG602AD 8" x 4" Aluminum Iron
THG602AD 8" x 4" Aluminum Iron
HG602BC 6" x 5" Aluminum Iron
THG602BC 6" x 5" Aluminum Iron
HG602BD 6" x 4" Aluminum Iron
THG602BD 6" x 4" Aluminum Iron
HG602BE 6" x 3-1/4" Aluminum Iron
THG602BE 6" x 3-1/4" Aluminum Iron
HG602BF 6" x 2-3/4" Aluminum Iron
THG602BF 6" x 2-3/4" Aluminum Iron
HG602CD 5" x 4" Iron Iron
THG602CD 5" x 4" Iron Iron
HG602DE 4" x 3-1/4" Iron Iron
THG602DE 4" x 3 -1/4" Iron Iron
HG602DF 4" x 2-3/4" Iron Iron
THG602DF 4" x 2-3/4" Iron Iron
HG602EF 3-1/4" x 2-3/4" Iron Iron
THG602EF 3-1/4" x 2-3/4" Iron Iron

NOTE: Single-stage compressors must use the same material for
each piston.

O-ring Code

A Buna-N
B Neoprene
D Viton

®1

®1

E PTFE

1

Registered trademarks of the DuPont company.

Crankcase and Cylinder Kit Options

Crankcase Options (frame only)

Model Number Lubricator

HG600XXM Not included
THG600XXM Not included
HG600XXL Included
THG600X XL Included

Cylinder Kit Options

Each kit contains all parts required to change from one
cylinder size to another in the field. The crosshead assembly
is not included in the kit. The kits will be assembled "hand
tight' and will include a cylinder nameplate.

Cylinder Kit
Number

Size H ea d Ty p e Piston

3671-X1_ 8" Standard Aluminum
3671-X2_ 8" Standard Iron
3671-X3_ 8" Adjustable Aluminum
3671-X4 _ 8" Adjustable Iron
3528-X1_ 6" Standard Aluminum
3528-X2_ 6" Standard Iron
3528-X3_ 6" Adjustable Aluminum
3528-X4_ 6" Adjustable Iron
5290-X1_ 5" Adjustable Iron
4276-X1_ 4" Standard Iron
4276-X2_ 4" Adjustable Iron
4276-X3 _ 4" Standard Iron
4276-X4_ 4" Adjustable Iron
3523-X1_ 3 -1/4" Standard Iron
3523-X2_ 3 -1/4" Adjustable Iron
3888-X1_ 2-3/4" Adjustable Iron
5290-X1_ 5" Adjustable Iron
5290-X2_ 5" Standard Iron

29

Appendix A—Model Number Identification Code

X

X

XXXXXXXXXXX

X

X

Material

.

.

INDUSTRIAL HORIZONTAL SINGLE CYLINDER COMPRESSORS

Plain Style

BASE MODEL NUMBER

Cylinder size

Approximate shipping weight (lbs.)

HG601A

HG601BXHG601CXHG601DXHG601EXHG601F

8" 6" 5" 4"

730 650 640 630 620 620

3¼

MODEL NUMBER

BASE

" 2¾"

BASE MODEL NUMBER

T-Style

Cylinder size

Approximate shipping weight (lbs.)

SPECIFICATION FIELDS

Packing

Arrangement

Crankcase

Style

Valves

Piston Ring

and Packing

Material

Gasket

Plain style only

T-Style only

Standard lubricating w/external lubricator
Standard lubricating w/ext. lubricator & heater
Standard pressure lubricated crankcase
Standard pressure lubricator w/crankcase heater

Standard suction & discharge valves
Standard valves w/blank valves in both cylinders
Low inlet pressure valves
Low inlet press.valves w/blank valves in both
cylinders
Unloaders
Unloaders w/blank valves in both cylinders
Unloaders with low inlet pressure valves
Unloaders w/low inlet pressure valves & blank
valves in both cylinders

Alloy / Alloy
PTFE / Alloy
PEEK / Alloy

Iron gasket material

THG601A

Standard packing O
Purge packing P
Pad packing G
Purge packing H

Optional Optional NA NA NA NA 4L

Optional Optional NA NA NA NA 4BL

Optional Optional Optional Optional Optional NA 9
Optional Optional Optional Optional Optional NA 9B
Optional Optional NA NA NA NA 9L

Optional Optional NA NA NA NA 9BL

THG601BXTHG601CXTHG601DXTHG601EXTHG601F

8" 6" 5" 4"

780 700 690 680 670 670

Standard

Optional

Standard

Optional

Optional
Optional

Standard

Optional

Standard

Optional

Optional

Standard

Optional

Standard

3¼

" 2¾"

MH

L

LH

M

4

4B

G
F
H

D

Buna-N

O-ring

Material

Intercooler

Flywheel

Protective

Coating

Piston Rod

Coating

Adjustable

Head

NA = Not Available
Neoprene® and Viton® are registered trademarks of the Dupont

Nitrotec® is a registered trademark of TTI Group Ltd

Neoprene®
Viton®
PTFE

No intercooler

No flywheel supplied
Standard flywheel

Coated cylinder only
No coating
Coating on all necessary wetted parts

Nitrotec®

None
Adjustable head

Standard

Optional
Optional
Optional

Standard

Optional

Standard

Optional

Standard

Optional

Standard

Standard Standard Standard Standard Standard NA N

Optional Optional Optional Optional Optional Standard 1

A
B
D
E

N

N
S

C
N

W

N

30

Appendix A—Model Number Identification Code

Gasket

.

.

S

INDUSTRIAL HORIZONTAL TWO CYLINDER, SINGLE-STAGE COMPRESSORS

Plain Style

T-Style

BASE MODEL NUMBER

Cylinder size
Approximate shipping weight (lbs.)

BASE MODEL NUMBER

Cylinder size
Approximate shipping weight (lbs.)

SPECIFICATION FIELDS

Packing

Arrangement

Crankcase

Style

Valves

Piston Ring

and Packing

Material

Plain style only

T-Style only

Standard lubricating w/external lubricator
Standard lubricating w/ext. lubricator & heater
Standard pressure lubricated crankcase
Standard pressure lubricated w/crankcase htr.

Standard suction & discharge valves
Standard valves w/blank valves in both cylinders
Low inlet pressure valves
Low inlet pressure valves w/blank valves in both
cylinders
Unloaders
Unloaders w/blank valves in both cylinders
Unloaders with low inlet pressure valves
Unloaders w/low inlet pressure valves & blank
valves in both cylinders

Alloy / Alloy
PTFE / Alloy
PEEK / Alloy

HG601AA HG601BB HG601CC HG601DD HG601EE HG601FF

8" x 8" 6" x 6" 5" x 5" 4" x 4" 3¼" x 3¼" 2¾" x 2¾"

1,070 910 890 870 845 845

THG601AA THG601BB THG601CC THG601DD THG601EE THG601FF

8" x 8" 6" x 6" 5" x 5" 4" x 4" 3¼" x 3¼" 2¾" x 2¾"

1,170 1,010 990 970 945 945

Standard packing O
Purge packing P
Pad packing G
Purge packing H

Optional Optional NA NA NA NA 4L

Optional Optional NA NA NA NA 4BL

Optional Optional Optional Optional Optional NA 9
Optional Optional Optional Optional Optional NA 9B
Optional Optional NA NA NA NA 9L

Optional Optional NA NA NA NA 9BL

Standard
Optional
Standard
Optional

Optional
Optional
Standard
Optional

Standard
Optional

Optional
Standard
Optional

MODEL NUMBER

BASE XXXXXXXXXXX

L

LH

M

MH

4

4B

G

F

H

Gasket
Material

O-ring

Material

Intercooler

Flywheel

Protective

Coating

Piston Rod

Coating

Adjustable

Head

NA = Not Available
Neoprene® and Viton® are registered trademarks of the Dupont

Nitrotec® is a registered trademark of TTI Group Ltd

Iron gasket material

Buna-N
Neoprene®
Viton®
PTFE

No intercooler

No flywheel supplied
Standard flywheel

Coated cylinder only
No coating
Coating on all necessary wetted parts

Nitrotec®

None
Adjustable heads on both cylinders

tandard

Standard
Optional
Optional
Optional

Standard

Optional
Standard

Optional
Standard
Optional

Standard

Standard Standard Standard Standard Standard NA N

Optional Optional Optional Optional Optional Standard 3

D

A
B

D

E

N

N

S

C
N

W

N

31

Appendix A—Model Number Identification Code

INDUSTRIAL HORIZONTAL TWO CYLINDER, TWO-STAGE COMPRESSORS

XXXXXXXXX

X

9F

.

.

Optional

Unloaders w/blank valves in 1st stage

Plain Style

T-Style

BASE MODEL NUMBER

Cylinder size
Approximate shipping weight (lbs.)

BASE MODEL NUMBER

Cylinder size
Approximate shipping weight (lbs.)

HG602AB HG602AC HG602AD HG602BC HG602BD

8" x 6" 8" x 5" 8" x 4" 6" x 5" 6" x 4"

990 980 970 930 895

THG602AB THG602AC THG602AD THG602BC THG602BD

8" x 6" 8" x 5" 8" x 4" 6" x 5" 6" x 4"

1090 1080 1070 1030 995

SPECIFICATION FIELDS

Packing

Arrangement

Crankcase

Style

Valves

Plain style only

T-Style only

Std. lubricating w/external lubricator
Std. lubricating w/external lube. & heater
Std. pressure lubricated crankcase
Std. pressure lubricated w/crankcase heater

Standard valves w/blank valves in both stages

Low inlet pressure valves
Low inlet pressure valves w/blank valves in both
stages

Standard valves w/blank valves in 1st stage

Low inlet pressure valves w/blank valves in 1st
stage

Standard valves w/blank valves in 2nd stage

Low inlet pressure valves w/blank valves in 2nd
stage
Unloaders

Unloaders w/blank valves in both stages

Unloaders w/low inlet pressure valves
Unloaders w/low inlet pressure valves & blank
valves in both stages

Standard packing O
Purge packing P
Pad packing G
Purge packing H

Standard

Optional

Standard

Optional

Optional
Optional

Standard

Optional

StandardStandard suction & discharge valves

Optional

Optional

Optional

Optional

Optional

Optional

Optional

Optional

Optional

Optional

Optional

MODEL NUMBER

BASE

L

LH

M

MH

4

4B

4L

4BL

4F

4FL

4S

4SL

9

9B

9L

9BL

X

Unloaders w/low inlet pressure valves & blank
valves in 1st stage
Unloaders w/blank valves in 2nd stage
Unloaders w/low inlet pressure valves & blank
valves in 2nd stage

Piston Ring

& Packing

Material

Gasket
Material

O-ring

Material

Intercooler

Flywheel

Protective

Coating

Piston Rod

Coating

Adjustable

Head

NA = Not Available
Neoprene® and Viton® are registered trademarks of the Dupont

Alloy / Alloy
PTFE / Alloy
PEEK / ALLOY

Iron gasket material

Buna-N
Neoprene®
Viton®
PTFE

No intercooler

No flywheel supplied
Standard flywheel

Coated cylinder only
Coating on all necessary wetted parts

Nitrotec®

None
Adjustable head on 1st stage cylnder only
Adjustable head on 2nd stage cylnder only
Adjustable heads on both cylinders

Optional

Optional

Optional

Optional

Standard

Optional

Standard

Standard

Optional
Optional
Optional

Standard

Optional

Standard

Optional
Optional

Standard

Standard

Optional
Optional
Optional

Nitrotec® is a registered trademark of TTI Group Ltd

9FL

9S

9SL

G

F

H

D

A
B
D
E

N

N
S

C

W

N

N

1
2
3

32

Appendix A—Model Number Identification Code

INDUSTRIAL HORIZONTAL TWO CYLINDER, TWO-STAGE COMPRESSORS (cont'd.)

XXXXXXXXX

X

p

p

p

.

.

g

Plain Style

T-Style

BASE MODEL NUMBER

Cylinder size
Approximate shipping weight (lbs.)

BASE MODEL NUMBER

Cylinder size
Approximate shipping weight (lbs.)

SPECIFICATION FIELDS

Packing

Arrangement

Crankcase

Style

Valves

Piston Ring

& Packing

Material

Gasket
Material

O-ring

Material

Intercooler

Flywheel

Protective

Coating

Piston Rod

Coating

Adjustable

Head

NA = Not Available
Neoprene® and Viton® are registered trademarks of the Dupont

Nitrotec® is a registered trademark of TTI Group Ltd

Plain style only

T-Style only

Std. lubricating w/external lubricator
Std. lubricating w/external lube. & heater
Std. pressure lubricated crankcase
Std. pressure lubricated w/crankcase heater

Standard suction & discharge valves

Standard valves w/blank valves in both stages

Low inlet pressure valves
Low inlet pressure valves w/blank valves in both
stages

Standard valves w/blank valves in 1st stage

Low inlet pressure valves w/blank valves in 1st
stage

Standard valves w/blank valves in 2nd stage

Low inlet pressure valves w/blank valves in 2nd
stage
Unloaders

Unloaders w/blank valves in both stages

Unloaders w/low inlet pressure valves
Unloaders w/low inlet pressure valves & blank
valves in both stages
Unloaders w/blank valves in 1st stage
Unloaders w/low inlet pressure valves & blank
valves in 1st stage
Unloaders w/blank valves in 2nd stage
Unloaders w/low inlet pressure valves & blank
valves in 2nd stage

Alloy / Alloy
PTFE / Alloy
PEEK / ALLOY

Iron gasket material

Buna-N
Neoprene®
Viton®
PTFE

No intercooler

No flywheel supplied
Standard flywheel

Coated cylinder only
Coating on all necessary wetted parts

Nitrotec®

None
Adjustable head on 1st stage cylnder only
Adjustable head on 2nd stage cylnder only
Adjustable heads on both cylinders

Standard packing O
Purge packing P
Pad packing G
Purge packing H

HG602BE HG602BF HG602DE HG602DF HG602EF

6" x 3¼" 6" x 2¾" 4" x 3¼" 4" x 2¾" 3¼" x 2¾"

880 880 860 860 845

THG602BE THG602BF THG602DE THG602DF THG602EF

6" x 3¼" 6" x 2¾" 4" x 3¼" 4" x 2¾" 3¼" x 2¾"

980 980 960 960 945

Standard

Optional

Standard

Optional

Optional
Optional

Standard

Optional

Standard

Optional

O

tional Optional NA NA NA 4L

Optional Optional NA NA NA 4BL

Optional

Optional Optional NA NA NA 4FL

Optional

Optional Optional NA NA NA 4SL

Optional NA Optional NA NA 9

Optional NA Optional NA NA 9B

Optional NA Optional NA NA 9L

Optional NA NA NA NA 9BL

Optional NA Optional NA NA 9F

Optional NA NA NA NA 9FL

Optional NA Optional NA NA 9S

Optional NA NA NA NA 9SL

Optional

Standard

Optional

Standard

Standard

Optional
Optional
Optional

Standard

Optional

Standard

Optional
Optional

Standard N

Standard

Optional
Optional
Optional

MH

BASE

L

LH

M

4

4B

4F

4S

G

F

H

D

A
B
D
E

N

N
S

C

W

N

1
2
3

MODEL NUMBER

X

33

Appendix A—Model Number Identification Code

XXXXXXXXXXX

None

N

Optional

LPG HORIZONTAL TWO CYLINDER, SINGLE-STAGE COMPRESSORS

Plain Style

BASE MODEL NUMBER

Cylinders 8" x 8" 6" x 6" 5" x 5" 4" x 4" 3¼" x 3¼" 2¾" x 2¾"

Approx. shipping weight (lbs.) 1070 910 890 870 845 845

HG601AA HG601BB HG601CC HG601DD HG601EE HG601FF

MODEL NUMBER

BASE

T-Style

BASE MODEL NUMBER

Cylinders 8" x 8" 6" x 6" 5" x 5" 4" x 4" 3¼" x 3¼" 2¾" x 2¾"

Approx. shipping weight (lbs.) 1170 1010 990 970 945 945

THG601AA THG601BB THG601DD THG601DD THG601EE THG601FF

SPECIFICATION FIELDS

Packing

Arrangement

Crankcase

Style

Valves

Piston Ring

and Packing

Material

Gasket

Material

O-ring Material

Intercooler No intercooler N

Plain style only

T-Style only

Standard pressure lube M

Standard pressure lube with heater MH

Standard valves 4
Suction valve

PTFE Alloy F

Aluminum gaskets B

Iron/lead gaskets D

Buna-N A

Neoprene® B

Standard packing O

Purge packing P

Pad packing G

Purge packing H

Optional Optional Optional Optional Optional NA 9

Standard

NC

Standard

Optional

Standard

Optional

Standard

Optional

Standard

Standard

NA

Standard

Standard

Optional

Standard

Flywheel

Protective

Coating

Piston Rod

Coating

Adjustable

Head

NA = Not Available NC = No Charge
Neoprene® is a registered trademark of DuPont.

Standard S

No coating N

Nitrotec® N

None NA N

Adjustable heads on both ends Optional Optional Optional Optional Optional Standard 3

Standard

Standard

Standard

Standard

34

35

Appendix B—Operating Specifications

Single-Stage Horizontal Compressors

Single Cylinder
Models

Size 8" 6" 5" 4" 3. 25" 2.75"

Displacement cfm (m3/hr)

400 rpm 68.8 (116.9) 38.4 (65.2) 26.4 (44.9) 16.8 (28.5) 10. 8 (18. 3) 7.6 (12.9)

1200 rpm 207.0 (351.7) 115.0 (195.4) 79.2 (134.4) 49.8 (84.6) 32.2 (54.5) 22.8 (56.0)

Approximate shipping weight lb. (kg.)

HG model 73 0 (331.1) 650 (295.0) 640 (290.3) 630 (285.8) 620 (281.2) 620 ( 281.2)

THG model 780 (353.8) 70 0 (317. 5) 690 (313.0 ) 680 (308.4) 670 (303.9) 670 (303.9)

Two Cylinder
Models

Size 8" x 8" 6" x 6" 5" x 5" 4" x 4" 3.25" x 3.25" 2.75" x 2.75"

Displacement cfm (m3/hr)

400 rpm 138 (234.5) 76.8 (130.5) 52.8 (89.7) 33.2 (56.4) 21.2 (36.0) 14.8 (25.1)

120 0 rpm 414 ( 704) 231 (393) 158.4 (268.8) 99.6 (169.2) 64 (108 .7) 44.4 (75.6)

Approximate shipping weight lb. (kg.)

HG model 1,070 (485.4) 910 (412.8) 890 (403.7) 870 (394.6) 845 (383.3) 845 (383.3)

THG model 1,170 ( 5 30 .7 ) 1,010 (458.1) 99 0 (4 4 9.1) 970 (440.0) 945 (428.7 ) 945 (428.7 )

HG601AX

THG601A X

HG601AA

THG601A A

HG601BX

THG6 01BX

HG601BB

THG6 01BB

HG601CX

THG6 01CX

HG601CC

THG6 01CC

HG601DX

THG6 01DX

HG601DD

THG601DD

HG601EX

THG6 01EX

HG601EE

THG6 01EE

HG601FX

THG6 01FX

HG601FF

THG6 01FF

Two-Stage Horizontal Compressors

Two Cylinder Models

Size 8" x 6" 8" x 5" 8" x 4" 6" x 5" 6" x 4" 6" x 2.75"

Displacement cfm (m3/hr)

400 rpm 68.8 (116.9) 68.8 (116.9) 68.8 (116.9) 38.4 (65.2) 38.4 (65.2) 38.4 (65.2)
120 0 rpm 207. 0 (3 51.7 ) 2 0 7.0 (3 51.7 ) 207. 0 (3 51.7 ) 115.0 (195.4) 115.0 (195.4) 115.0 (195.4)

Approximate shipping weight lb. (kg.)

HG model 99 0 ( 4 4 9.1) 980 (444.5) 970 (440.0) 930 (421.9) 895 (406.0) 880 (399.2)
THG model 1,090 (494.4) 1,080 (489.9) 1,070 (485.4) 1 , 0 3 0 (4 67. 2) 995 (451.3) 980 (444.5)

Two Cylinder Models

Size 6" x 3.25" 5" x 4" 5" x 2.75" 4" x 3.25" 4" x 2.75" 3. 25" x 2.75"

Displacement cfm (m3/hr)

400 rpm 38.4 (65.2) 26.4 (44.9) 26.4 (44.9) 16.8 (28.5) 16.8 (28.5) 10.8 (18.3)
120 0 rpm 79.2 (134.4) 79.2 (134.4) 79.2 (134.4) 49.8 (84.6) 49.8 (84.6) 32.2 (54.5)

Approximate shipping weight lb. (kg.)

HG model 880 (399.2) 880 (399.2) 867 (393.3) 8 6 0 ( 3 90.1) 8 6 0 ( 3 90.1) 845 (383.3)
THG model 980 (444.5) 980 (444.5) 967 (438.6) 960 (435.5) 960 (435.5) 945 (428.7)

HG602AB

THG602AB

HG602BE

THG602BE

HG602 AC

THG602AC

HG602CD

THG602CD

HG602AD

THG602AD

HG602CF

THG602CF

HG602BC

THG602BC

HG602DE

THG602DE

HG602BD

THG602BD

HG602DF

THG602DF

HG602BF

THG602BF

HG602EF

THG602EF

36

Appendix B—Operating Specifications

Cylinder Data

Description

Cylinder Bore in. (mm) 8.0 (203.2) 6.0 (152.4) 5.0 (127 ) 4.0 (101.6) 3.25 (82.6) 2.75 (69.9)

Maximum working pressure
psia (bar g)

Piston ring radial thickness
(minimum) inches (mm)

A B C D E F

300.0 (20.7) 35 0 ( 2 4 .1) 750 (51.7) 1,000.0 (69.0) 1,200.0 (82.8)

0.215 (5.46) 0.155 (3.98) 0.155 (3.98) 0.082 (2.08) 0.082 (2.08) 0.090 (2.29)

Frame Data

Stroke inches (mm) 3.0 (76.2)

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

Maximum motor size hp (kg) 75 (55.9)

Maximum discharge temp °F (°C) 35 0 .0 (176 .7)

Minimum temp °F (°C) -25 (-31.6)

RPM range 400 - 1,200

THG/HG600 Series Clearances and Dimensions

Specification Inches

Piston clearance see figure on page 33

Clearance: connecting rod bearing to crankshaft journal

Clearance: wrist pin to wrist pin bushing (maximum)

Cylinder finish 16 –32 RM S

Clearance: oil pump adapter shaft to bushing (maximum)

Crankshaft end play (cold)

Flywheel runout at O.D. (maximum) 0.020

Clearance: crosshead to crosshead guide bore (maximum) 0.008

Crosshead guide bore finish in crankcase

1

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

1

1

Cylinder Code

1,650. 0

(113 . 8 )

0.0013

0.0033

0.001

0.0036

0.002

0.003

32 RMS (limited

number of small pits

and scratches are

acceptable)

37

Appendix B—Material Specifications (HG600/THG600 Series)

Part Model No. Standard Material Optional Material

Crankcase All Ductile iron ASTM A536, Grade 65-45-12

Adapters All Ductile iron ASTM A536, Grade 65-45-12

Cylinders All Ductile iron ASTM A536, Grade 65-45-12

Cylinder heads (adjustable & standard) All Ductile iron ASTM A536, Grade 65-45-12

Valve caps All Ductile iron ASTM A536, Grade 65-45-12

Crankcase bearing carrier All Gray iron ASTM A48, Class 30

Flanges All Steel slip-on weld

Valve bumper (guard) All Stainless steel

Valve seat All Stainless steel

Valve plates and springs All Stainless steel

Valve gaskets All Iron

Pistons

Pistons 6", 8" Aluminum A356-T6

Piston rod All C-1050 Steel Nitrotec

Crosshead All Gray iron ASTM A48, Class 30

Connecting rod & packing cartridge All Ductile iron ASTM A536, Grade 65-45-12

Piston rings All PTFE (glass and moly filled)

Rider rings All PTFE (glass and moly filled)

Packing: segmented rings All PTFE (carbon filled)

Packing: segmented oil wiper rings All Brass

Connecting rod bearing All Bimetal D-2 Babbit

Crankshaft All Ductile iron ASTM A536, Grade 80-55-06

Wrist pin All C-1018 steel

Wrist pin bushing All Bronze SAE 660

Main bearings All Tapered roller

Inspection plate All Carbon steel

O-rings All Buna-N PTFE, Viton2, Neoprene

Retainer rings All Carbon steel

Lubricator tubing

Lubricator

1

Nitrotec® is a registered trademark of TTI Group Ltd.

2

Viton® and Neoprene® are registered trademarks of the DuPont company.

2.75", 3 . 25",
4", 5"

Lube
models

Lube
models

Steel

Ductile iron A536 Grade
65-45-12 (single stage only)

1

Steel

Force feed with divider block - no flow
shutdown

2

38

Appendix B—Bolt Torque Values

Horizontal Compressor Bolt Torque Values

Cylinder Size 2.75" 3.25" 4" 5" 6" 8"

Connection rod bolt ft•lb 40 40 40 40 40 40

Bearing carrier ft•lb 40 40 40 40 40 40

Bearing cover ft•lb 40 40 40 40 40 40

Crankcase inspection plate ft•lb 8 8 8 8 8 8

Adapter to crankcase or distance piece

Distance piece to crankcase

Cylinder to adapter ft•lb

1

1

Valve cover plate bolt ft•lb CF 35 37 37 37 37

Valve holddown screw ft•lb

2

Piston nut torque ft•lb 150 150 150 150 150 150

Piston screw torque in•lb 100 50 100 100 100 10 0

Valve unloader cap torque ft•lb 25 25 25 25 25 25

Head to cylinder ft•lb

1

Preliminar y tightening: Snug all headbolts in the sequence show. Final tightening: Torque all headbolts in the sequence shown to the value
listed above.

2

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

1

1

65 65 65 65 65 65

65 65 65 65 65 65

65 65 65 65 65 65

40 40 40 40 40 40

65 65 65 65 65 65

Horizontal Compressor Bolt Tightening Sequence

39

Appendix B—Piston Clearance Details

Piston Clearance—Bottom Dead Center (3.25" cylinder shown)

(Y)

Bottom of piston

Adapter

Top of packing

box cartridge

Cylinder

Piston Clearance—Top Dead Center (3.25" cylinder shown)

Adapter

Cylinder

Top of piston cap

Shim washer

Piston body

(X)

Bottom of head

X and Y Dimension–Inches (mm)

Piston Size

2.75" 3.25" 4" 5" 6" 8"

Plain style

Bottom min. clearance (Y) 0.010 (0.25) 0.010 (0.25) 0.010 (0.25) 0.010 (0.25) 0.010 (0.25) 0.010 (0.25)

Bottom max. clearance (Y) 0.020 (0.51) 0.0 20 (0.51) 0.020 (0.51) 0.020 (0 .51) 0.020 (0.51) 0.020 (0.51)

Top min. clearance (X) 0.040 (1.02) 0.083 (2.11) 0.083 (2.11) 0.083 (2.11) 0.083 (2.11) 0.088 (2.24)

Top max. clearance (X) 0.065 (1.65) 0.093 (2.36) 0.093 (2.36) 0.093 (2.36) 0.093 (2.36) 0.098 (2.49)

T-Style

Bottom min. clearance (Y) 0.005 (0.13) 0.005 (0.13) 0.005 (0.13) 0.005 (0.13) 0.005 (0.13) 0.005 (0.13)

Bottom max. clearance ( Y ) 0.015 (0.38) 0.015 (0.38) 0.015 (0.38) 0.015 (0.38) 0.015 (0.38) 0.015 (0.38)

Top min. clearance ( X ) 0.030 (0.76) 0.073 (1. 85) 0 .073 (1.85) 0.073 (1.8 5) 0.073 (1.85) 0.078 (1.98)

Top max. clearance (X) 0.055 (1.46) 0.083 (2.11) 0.083 (2.11) 0.083 (2.11) 0.083 (2.11) 0.088 (2.24)

40

Appendix C—Outline Dimensions

HG601 Series—Plain Style Single Cylinder

2.125"
Diameter shaft

2.124"

0.5" Square keyway

0.78
(1.9)

3.88

7.25

(18.4)

4.88" Diameter holes

9.81

(24.9)

(9.8)

3.38
(8.5)

5.53

(14.0)

Adjustable head

10.09
(25.6)

23.53
(59.7)

A

22.19
(56.1)

6.69

(16.9)

10.06
(25.5)

(Standard head)

Cylinder Size

1.25
(3.1)

A

Nozzle C

10.06
(25.5)

Inches (Centimeters)

B

L

Flange Height

2.75" 23.41 (59.4) 6 .19 (15 . 7 ) — 33. 9 4 ( 8 6.1)

3.25" 22.50 (57.1) 5.0 0 (12.7) 29.31 (74.4) 3 2 .19 (81. 5) 2" slip on

4" 22.69 (57.6) 5.88 (14.9) 30.00 (76.2) 32.81 (83.3) 2" slip on

5" 22.32 (56.7) 5.09 (12.9) 29.26 (74.3) 32.07 (81.5) 2" slip on

6" 22.94 (58.2) 5.94 (15.0) 30.25 (76.8) 33.06 (83.9) 2" slip on

8" 23.63 (60.0) 7. 2 5 ( 18 . 4) 32 .13 ( 81.5) 34.94 (88.7) 3" slip on

a

1.5" 1500 lb. ASA flange not supplied.

NOTE: 1. Standard flywheel (not shown) 5-5V 21.2

2. Jacking screw provided for cylinder support (8" and 6" cylinders only).

C1 (Adjustable head)

C (Standard head)

C

(Adjustable head)

C1

B

B

D

D

Flange Size

a

41

Appendix C—Outline Dimensions

HG601/HG602 Series— Plain Style Double Cylinder

4.88" Diameter holes

0.78
(1.9)

5.53

(14.0)

2.125"
Diameter shaft

2.124"

0.5" Square keyway

10.09
(25.6)

Adjustable head

6.69

(16.9)

7.25

(18.4)

9.81

(24.9)

A

C1 (Adjustable head) C1 (Adjustable head)

C (Standard head) C (Standard head)

3.88
(9.8)

3.38
(8.5)

23.53
(59.7)

A

B

B

1.25
(3.1)

Cylinder Size

A

Nozzle C

L

2.75" 23.41 (59.4) 6 .19 (15 . 7 ) — 33. 9 4 ( 8 6.1)

3.25" 22.50 (57.1) 5.0 0 (12.7) 29.31 (74.4) 3 2 .19 (81. 5) 2" slip on

4" 22.69 (57.6) 5.88 (14.9) 30.00 (76.2) 32.81 (83.3) 2" slip on

5" 22.32 (56.7) 5.09 (12.9) 29.26 (74.3) 32.07 (81.5) 2" slip on

6" 22.94 (58.2) 5.94 (15.0) 30.25 (76.8) 33.06 (83.9) 2" slip on

8" 23.63 (60.0) 7. 2 5 ( 18 . 4) 32 .13 ( 81.5) 34.94 (88.7) 3" slip on

a

1.5" 1500 lb. ASA flange not supplied.

NOTE: 1. Standard flywheel (not shown) 5-5V 21.2

2. Jacking screw provided for cylinder support (8" and 6" cylinders only).

10.06
(25.5)

Inches (Centimeters)

B

Flange Height

10.06
(25.5)

C

(Standard head)

42

D

C1

(Adjustable head)

D

Flange Size

a

Appendix C—Outline Dimensions

THG601 Series—T-Style Single Cylinder

2.125"
Diameter shaft

2.124"

0.5" square keyway

4.88" Diameter holes

0.78
(1.9)

5.53

(14.0)

3.88
(9.8)

10.09

(25.6)

Adjustable

head

7.25

(18.4)

9.81

(24.9)

22.19

(56.1)

3.38

(8.5)

23.53
(59.7)

A

C1 (Adjustable head)

C (Standard head)

B

6.69

(16.9)

Cylinder Size

1.25
(3.1)

Nozzle C

10.06

(25.5)

A

L

2.75" 31.22 (79.3) 6 .19 (15.7 ) — 41.75 (106.0)

3.25" 30 .31 ( 77.0 ) 5 .00 (12.7 ) 3 7.12 ( 94 . 3) 40.00 (10 6.6) 2" slip on

4" 30.50 (77.5) 5.88 (14.9) 37.81 (96.0) 40.62 (103.2) 2" slip on

5" 3 0 .13 ( 76 . 5 ) 5.09 (12.9) 3 7. 07 (9 4 . 2) 3 9.8 8 (101.3) 2" slip on

6" 30 .75 ( 7 8 .1) 5.94 (15.0) 38.06 (96.7) 40.88 (103.8) 2" slip on

8" 31.44 (79.9) 7. 25 (18 . 4 ) 39.94 (101.5) 42.75 (108.6) 3" slip on

a

1.5" 1500 lb. ASA flange not supplied.

NOTE: 1. Standard flywheel (not shown) 5-5V 21.2

2. Jacking screw provided for cylinder support (8" and 6" cylinders only).

10.06
(25.5)

Inches (Centimeters)

B

Flange Height

C

(Standard head)

43

D

C1

(Adjustable head)

B

D

Flange Size

a

Appendix C—Outline Dimensions

(16.9)

THG601/THG602 Series—T-Style Double Cylinder

4.88" Diameter holes

0.78
(1.9)

5.53

(14.0)

2.125"
Diameter shaft

2.124"

0.5" Square keyway

3.88

(9.8)

Adjustable

head

10.09
(25.6)

6.69

7.25

(18.4)

9.813
(24.9)

C1 (Adjustable head)

C (Standard head)

A

1.25
(3.1)

10.06

(25.5)

3.38

(8.5)

10.06
(25.5)

23.53
(59.7)

A

C1 (Adjustable head)

C (Standard head)

B

B

D

Cylinder Size

A

Nozzle C

L

2.75" 31.22 (79.3) 6 .19 (15.7 ) — 41.75 (106.0)

3.25" 30 .31 ( 77.0 ) 5 .00 (12.7 ) 3 7.12 ( 94 . 3) 40.00 (10 6.6) 2" slip on

4" 30.50 (77.5) 5.88 (14.9) 37.81 (96.0) 40.62 (103.2) 2" slip on

5" 3 0 .13 ( 76 . 5 ) 5.09 (12.9) 3 7. 07 (9 4 . 2) 3 9.8 8 (101.3) 2" slip on

6" 30 .75 ( 7 8 .1) 5.94 (15.0) 38.06 (96.7) 40.88 (103.8) 2" slip on

8" 31.44 (79.9) 7. 25 (18 . 4 ) 39.94 (101.5) 42.75 (108.6) 3" slip on

a

1.5" 1500 lb. ASA flange not supplied.

NOTE: 1. Standard flywheel (not shown) 5-5V 21.2

2. Jacking screw provided for cylinder support (8" and 6" cylinders only).

Inches (Centimeters)

B

Flange Height

C

(Standard head)

44

C1

(Adjustable head)

D

Flange Size

a

Appendix D—Cylinder Head Assembly Details (HG600/THG600 Series)

2.75" Cylinder Head

10

Crankcase side

(see packing assembly for details)

Adapter

1

13

12

11

13

2

1

14

3

4

5

6

7

8

9

Available with adjustable head configuration only

Cylinder Head Assembly Bill of Materials for 2.75"

Ref.

Description Part number

no.

1. O-ring 2-232_

a

2. Cylinder 3888 1

3. Adjustable head 3 8 9 9 -1 1

4. O-ring 2-225_

a,f

5. Adjusting cup 3898 1

6. O-ring 2- 2 2 7_

a

7. Adjusting cap 3897 1

8. O-ring 2-127_

a

9. Adjusting screw nut 3665 1

10. Hex head bolt (1/2 - 13 x 1-1/2) 7001-050NC150A 16

11. Nameplate 3698 1

12. Drive screw 7012-006DR019E 2

13. Pipe plug (1/4") 3442 5

14. Adjustable head assembly 3899 -1X 1

– Flange

– Flange gasket

– Flange bolt

b

c

d

Qty. per
cylinder

Head side

O-ring Code

A Buna-N

2

B Neoprene

D Viton

1

1

1

E PTFE

K Kalrez

a

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

b

Use 1-1/2" 15001 ASA weld flange (not provided).

c

Use 1-1/2" ASA flange gasket (not provided).

d

Use 1" - 8 x 3-1/2" hex head bolt (not provided).

e

Registered trademarks of the DuPont company.

f

O-ring code D or K only.

®e

®e

®e

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

1

1

1

10

Torque to 65 ft.-lbs.

45

Appendix D—Cylinder Head Assembly Details (HG600/THG600 Series)

3.25", 4", and 5" Cylinder Head

13

(see packing assembly for details)

Adapter

1

Crankcase side

15

17

16

15

2

3

4

5

1

6

7

18

8

9

10

11

Optional adjustable head configuration

12

Standard head configuration

Head side

14

13

Torque to 65 ft.-lbs.

13

Torque to 65 ft.-lbs.

Cylinder Head Assembly Bill of Materials for 3.25", 4", and 5"

Ref.

Description

no.

1. O-ring 2-236_

3.25" 4" 5"

a

2. Flange 3793-2S 3793-2S 3793-2S 2

3. Hex head bolt (1/2 - 13 x 1-3/4) 70 01-150NC175A 7001-050NC175A 7001-050NC175A 8

4. O-ring 2-231_

a

5. Cylinder 3523 4276 5290 1

6. Adjustable head 3 527-1 3763-1 529 3 -1 1

7. O-ring 2- 2 27_

a

8. Adjusting cup 3664 3775 5295 1

9. O-ring 2-229_

a

10. Adjusting cap 3660 3 7 74 5294 1

11. O-ring 2-127_

a

12. Adjusting screw nut 3665 3665 3665 1

13. Hex head bolt (1/2 - 13 x 1-1/2) 7001-050NC150A 7001-050NC150A 7001-050NC150A 16

14. Head 3527 3763 5293 1

15. Pipe plug (1/4") 3442 3442 3442 4

16. Nameplate 3698 3698 3698 1

17. Drive screw 7012-006SF019E 7012-006SF019E 7012-006SF019E 2

18. Adjustable head assembly 35 27-1X 3 76 3 -1X 5293-1X 1

a

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

b

Registered trademarks of the DuPont company.

c

O-ring code D or K only.

Part number

Size

a

2-242_

a

2-231_

a,c

2-233_

a

2-235_

a

2-127_

2-250 2

a

2-231_

a,c

2-240 _

a

2-242_

a

2-127_

Qty. per
cylinder

2

1

1

1

O-ring Code

A Buna-N

B Neoprene

D Viton

®b

E PTFE

K Kalrez

®b

®b

46

Appendix D—Cylinder Head Assembly Details (HG600/THG600 Series)

6" and 8" Cylinder Head

Adapter (see packing

assembly for details)

13

Crankcase side

15

17

16

2

1

3

4

5

6

1

7

18

8

9

10

11

12

15

23

20
23
22

21

19

14

Optional adjustable head configuration

Standard head configuration

13

Head side

Torque to 65 ft.-lbs.

13

Torque to 65 ft.-lbs.

Cylinder Head Assembly Bill of Materials for 6" and 8"

Ref.

Description

no.

1. O-ring 2-258 _

2. Flange 3793-2S 3794-3S 2

3. Hex head bolt (1/2 - 13 x 1-3/4) 70 01-050NC175A 7001-050NC175A 8

4. O-ring 2-231_

5. Cylinder 3528 3671 1

6. Adjustable head 3 5 32-1 3 6 72-1 1

7. O-ring 2-248_

8. Adjusting cup 3663 3683 1

9. O-ring 2-250_

10. Adjusting cap 3637 3682 1

11. O-ring 2-127_

12. Adjusting screw nut 3665 3665 1

13. Hex head bolt (1/2 - 13 x 1-1/2) 7001-050NC150A 7001-050NC150A 16

14. Head 3532 3672 1

15. Pipe plug (1/4") 3442 3442 4

16. Nameplate 3698 3698 1

17. Drive screw 7012-006SF019E 7012-006SF019E 2

18. Adjustable head assembly 35 3 2-1X 36 72-1X 1

19. Cylinder support assembly (opt.) 3840 -X1 3840 -X1 1

20. Support base 3840 3840 1

21. Support screw 70 01-087NC150E 7001-087NC150E 1

22. Jam nut 2903 2903 2

23. Hex head bolt (3/8-16 x 3/4) 70 01- 037NC075A 7001- 037NC075A 2

Part number

Size

6" 8"

a

a

a,c

a

a

2-266 _

2-242_

2-261_

2-262_

2-127_

a

a

a,c

a

a

Qty. per
cylinder

2

2

1

1

1

O-ring Code

A Buna-N

B Neoprene

D Viton

®b

®b

E PTFE

K Kalrez

a

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

b

Registered trademarks of the
DuPont company.

c

O-ring code D or K only.

®b

47

Appendix D—Valve Holddown Assembly Details (HG600/THG600 Series)

Valve Holddown Assembly (2.75" only) Valve Holddown Assembly

Suction

1

1

Discharge

d

7

(3.25", 4", 5", 6", & 8" only)

d

Suction

7

Discharge

2

3

4

a

6

2

3

5

a

6

8

10

d

9

1

2

3

d

8

9

1

2

3

10

4

a

6

5

a

6

Cylinder Diameter

Ref.

No.

Description

2.75"

Quantit y

per

cylinder

3.25"

Quantit y

per

cylinder

4"

1. Hex head bolt 7001-050NC150A 12 7001-043NC150A 16 7001-043NC150A 16

2. Valve cover plate 3894 4 2205 4 17 6 4 4

3. O-ring 2-224_

b

4 2-14 3 _

b

4 2-235_

b

Suction valve assembly 3900-X (iron) 2 4029-X2 (iron) 2 3807-X (iron) 2

4.

Suction valve assembly N/A — — — 3807-X1 (copper) 2
Suction valve assembly N/A — — — — —
Discharge valve
assembly
Discharge valve

5.
assembly

Discharge valve
assembly

6. Valve gasket 3896

7. Valve cap N/A — 2714 -1

8. O-ring N/A — 2-031_

3901-X (iron) 2 4030-X2 (iron) 2 3808-X (iron lead) 2

— — — — 3808-X1 (copper) 2

— — — — — —

a

4 14 81-2a (iron) 4

d

b

4 2714-1
4 2-031_

2114-2a (iron)

2112-1 (cop p e r )

d

b

9. Holddown screw N /A — 2715 4 2715 4

10. Valve cage N/A — 3569 4 3809 4

11. Actuator N/A — 3689 2 3956 2

12. Unloader spring N/A — 3690 2 3695 2

13. Unloader cap N/A — 259 8 -1 2 2 5 98 -1 2

14. Unloader assembly N/A — 3689 -X1 2 3956-X 2

15. Bolt N/A — 1910 2 1910 2

16. Bal-seal N/A — 2619-X 4 2619 -X 4

17. Unloader piston cap N/A — 2857 2 2857 2

18. Gasket N/A — 2858 2 2858 2

19. Unloader piston N/A — 4205 2 3957 2

a

Included with valve assembly.

b

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

c

Prior to serial number FN (January 1, 1984), use valve cap #2714 and gasket #2716.

d

Quantity = 2 if equipped with unloaders.

e

H2O cylinder requires cage #4311.

f

Registered trademarks of the DuPont company.

Quantit y

per

cylinder

4

4

4
4

48

Appendix D—Valve Holddown Assembly Details (HG600/THG600 Series)

Suction Valve with Unloader

(3.25", 4", 5", 6", & 8" only)

13

d

8

See gure A

9

1

2

3

10

11

12

4

a

6

14

Unloader Piston Assembly Details

Apply Loctite #290

when assembling

Important:

Note seal direction

O-ring Code

A Buna-N

B Neoprene

D Viton

®f

E PTFE

K Kalrez

Figure A

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

®f

®f

15

16

17

18

16

19

Cylinder Diameter

Ref.

No.

Description

5"

Quantit y

per

cylinder

6"

Quantit y

per

cylinder

Quantit y

8"

cylinder

1. Hex head bolt 7001-043NC150A 16 7001-043NC150A 16 7001-043NC150A 16

2. Valve cover plate 1764 4 1764 4 3675 4

3. O-ring 2-235_

b

4 2-235_

b

4 2-242_

b

Suction valve assembly 3856-4X (aluminum) 2 3856-X (aluminum) 2 3710-X (aluminum) 2

4.

Suction valve assembly 3856-4X1 (copper) 2 3856-X1 (copper) 2 3710-X1 (c opper ) 2
Suction valve assembly 3856-4X2 (iron lead) 2 2856-X2 (iron lead) 2 3710-X2 (iron lead) 2
Discharge valve
assembly
Discharge valve

5.
assembly

Discharge valve
assembly

6. Valve gasket 2114 -_

7. Valve cap 2714-1

8. O-ring 2-0 31_

9. Holddown screw 2715 4 2715 4 2715 4

10. Valve cage 357 0 -1 4 3570 -1

3857-4X (aluminum) 2 3857-X (aluminum) 2 3709-X (aluminum) 2

3857-4X1 (copper) 2 3857-X1 (copper) 2 3709-X1 (copper) 2

3857-4X2 (iron) 2 3857-X2 (iron lead) 2 3709-X2 (iron lead) 2

a

d

b

4 2114
4 2714 -1
4 2-031_

a

d

b

e

4 3691
4 2714 -1
4 2-031_

4 3676 4

a

d

b

11. Actuator 3694 2 3694 2 3697 2

12. Unloader spring 5324 2 3695 2 3695 2

13. Unloader cap 2 598-1 2 259 8 -1 2 2598-1 2

14. Unloader assembly 3694-X2 2 3694-X 2 369 7-X 2

15. Bolt 1910 2 1910 2 1910 2

16. Bal-seal 2619-X 4 2619-X 4 2619 -X 4

17. Unloader piston cap 2857 2 2857 2 2857 2

18. Gasket 2858 2 2858 2 2858 2

19. Unloader piston 5323 2 3696 2 2710 2

per

4

4
4
4

49

Appendix D—Valve Assembly Details (HG600/THG600 Series)

2.75" Valve 3.25" Valve

3

Suction

7

Discharge

Suction Discharge

3

7

c

4

c

4

6

9

5

5

9

7

9

5

3

5

9

7

6

3

Cylinder Diameter
Ref.
No.

1.

Description

Suction valve
assembly

b

2.75"

3900 -X

(iron)

Quantit y

per

3.25"

cylinder

2 4029-X2 (iron) 2 3807-X (iron) 2 3856-4X (aluminum) 2

— —

Quantit y

per

cylinder

4"

38 0 7-X1
(copper)

Quantit y

per

cylinder

5"

3856-4X1 (copper) 2

— — — 3856-4X2 (iron) 2

Discharge valve

2.
assembly

3901-X

(iron)

b

— —

2 4030-X2 (iron) 2 3808-X (iron) 2 3857-4X (aluminum) 2

3808 -X1
(copper)

3857-4X (copper) 2

— — — 3857-4X (iron) 2

3. Valve seat 3940 4 — 3832 4 3856-4 4

4. Stud

5.

c

Valve plate

a

(inner)

3828 4 — 3828 4 3920 4

— — 3831 4 3872 4

6. Valve plate (outer)a39 41 4 — 3830 4 3871 4

7. Valve bumper 3939 4 — 3826 4 3857 4

8. Spring button

Spring (inner)

9.

Spring (outer)

10. Repair kit

a

a

a

3804 -X1 4

— — — -

3829

3924 4 —

38 2 9 -1

4 3929 4

(Inconel opt.)

— — — 3928 4

3124-X

(suction)

3125-X

(discharge)

2 3805-X1 4 3146-X1 4

2

11. Blank (not shown)d3943 1 3767 1 3838 1 3768 1

a

These parts included in the repair kit.

b

Valve assembly also includes gaskets (not O-rings) as required
for installation. See valve holddown assembly details.

c

Direction of the stud MUST be as shown.

d

Use when blank valve option is required for reduced capacity.

e

Prior to serial number NN51400 used 3732-X for suction and 3733-X for discharge.

Quantit y

per

cylinder

50

Appendix D—Valve Assembly Details (HG600/THG600 Series)

4", 5", 6" Valve 8" Valve

3

Suction Discharge

7

3

Suction Discharge

7

c

4

c

4

c

4

c

4

5
6

9

5

6

9

8

5

6

6" Only

9

6" Only

9

8

9

9

5
6

7

3

7

3

Cylinder Diameter

Ref.
No.

Description

6"

Quantit y

per

cylinder

6"

Quantit y

per

cylinder

8"

Quantit y

per

cylinder

Quantit y

8"

(15+ psi suction pressure) (0 to 15 psi suction pressure) (15+ psi suction pressure) (0 to 15 psi suction pressure)

Suction valve

1.
assembly

3856-X

(aluminum)

b

3856-X1

(copper)

e

e

2

2

3856-1X

(aluminum)

3856-1X1

(copper)

2

2

3710-X

(aluminum)

3710-X1
(copper)

2

3710-X

(aluminum)

3710-X1
(copper)

2856-X2 (iron) 2 2856-1X2 (iron) 2 3710-X2 (iron) 3710-X2 (iron) 2

Discharge valve

2.
assembly

3857-X

(aluminum)

b

3857-X1
(copper)

2

2

3857-X

(aluminum)

3857-X1
(copper)

2

2

3709 -X

(aluminum)

3709-X1
(copper)

2

3709 -X

(aluminum)

3709-X1
(copper)

3857-X2 (iron) 2 3857-X2 (iron) 2 3709-X2 (iron) 3709-X2 (iron) 2

3. Valve seat 3856 4 3856 4 3834 2 3834 2

4. Stud

5.

c

Valve plate

a

(inner)

3920 4 3920 4 3828 2 3828 2

3872 4 3872 4 3837 2 3837 2

6. Valve plate (outer) 3871 4 3871 4 3836 2 3836 2

7. Valve bumper 3857 4 3857 4 3833 2 3833 2

8. Spring button

Spring (inner)

9.

Spring (outer) 3928 4

10. Repair kit 3146-X1 4 — 4 3 806 -X1 2 380 6 -1X1 2

11. Blank

a

a

d

— — 3835 4 3835 4

3929 4

3951 (suction)

3929 (discharge)

3993 (suction)

3928 (discharge)

4 3829 4 3818 (suction) 2

38 2 9 -1

(Inconel opt.)

4

3829

(discharge)

4

3768 2 3768 2 3769 2 3769 2

per

cylinder

2

2

2

2

2

51

Appendix D—Piston Assembly Details (HG600/THG600 Series)

2.75", 3.25", 4", 5" and 6" Piston Sizes

2

3

4

1

(see connecting rod assembly

Piston rod

details for more information)

NOTE: See Appendix B for piston
clearance specifications.

8" Piston Size

5

6

5

6

7

5

6

5

6

2

8

9

10

11

2

3

4

1

(see connecting rod assembly

Piston rod

for more information)

NOTE: See Appendix B for piston
clearance specifications.

52

7

6

7

2

8

9

10

11

Appendix D—Piston Assembly Details (HG600/THG600 Series)

Piston Assembly Bill of Materials for the 2.75", 3.25", and 4" Piston Sizes

Ref.

Description

No.

Piston assembly

1.

- Iron

2. Thrust washer 3730 2 3730 2 3730 2
Shim washer,
thick

3.
Shim washer, thin 36 0 3 -1 As req. 3 6 0 3 -1 As req. 3 6 0 3 -1 As req.

4. Piston - iron 3889 1 3525 1 4292 1

5. Expander ring 1774 8 1757 4 1776 4

6. Piston ring 3892 8 175 6 4 3781 4

7. Rider ring 3893 1 3 5 74 1 3776 1

8. Lock nut 3604 1 3604 1 3604 1
Shim washer ­thick

9.
Shim washer -

thin

10. Piston cap - iron 3890 1 3561 1 4291 1
Socket head cap

11.
screw

12. Loctite 620 tube

a

Prior to serial number S/N FZ44175 uses 7002-010TP100A. Serial number FZ44175 and later use 7002-025TP100A.

b

Use Loctite retaining compound 620.

7002-025TP062A 6 7002- 010TP100A 4 7002-025TP100A 4

b

2.75" 3.25" 4"

Part No. Qty. Part No. Qt y. Part No. Qty.

3889-X1 1 3525-X1 1 429 2-X1 1

3603 As req. 3603 As req. 3603 As req.

3895 As req. 3731 As req. 3780 As req.

3895-1 As req. 37 31-1 As req. 3780 -1 As req.

3812 1 3812 1 3812 1

Cylinder Diameter

Piston Assembly Bill of Materials for the 5", 6" and 8" Piston Sizes

Ref.

Description

No.

Piston assembly

- Iron

1.
Piston assembly -

Aluminum

2. Thrust washer 3730 2 3730 2 3730 2
Shim washer,
thick

3.
Shim washer, thin 36 0 3 -1 As req. 3 6 0 3 -1 As req. 3 6 0 3 -1 As req.
Piston - iron 5301 1 3530 1 3674 1

4.
Piston - aluminum — 1 3 5 3 0 -1 1 36 74 -1 1

5. Expander ring 5326 6 1753 4 — –

6. Piston ring 5302 6 1752 4 3677 3

7. Rider ring 5303 1 3573 1 3679 2

8. Lock nut 3604 1 3604 1 3604 1
Shim washer ­thick

9.
Shim washer -

thin
Piston cap - iron 5325 1 3562 1 3680 1

10.

Piston cap ­aluminum
Socket head cap

11.
screw

12. Loctite 620 tube

Part No. Qty. Part No. Qt y. Part No. Qty.

7002-025TP100A 4 7002-025TP100A 4 7002-025TP100A 8

b

5" 6" 8"

5301-X1 – 3530-X1 1 3674 - X1 1

— 1 3 5 3 0 -1X1 1 36 74 -1X1 1

3603 As req. 3603 As req. 3603 As req.

5322 As req. 3625 As req. 3681 As req.

53 2 2-1 As req. 3 6 25-1 As req. 36 81-1 As req.

— 1 3 5 62-1 1 3680-1 1

3812 1 3812 1 3812 1

Cylinder Diameter

53

Appendix D—Packing Assembly Details for HG600 Series (Plain Style)

Crankcase side

Cylinder side

2.75" Standard Packing Specification

1

2

5

65 ft. lb.

4

11

O-ring Code

A Buna-N

B Neoprene

D Viton

®e

®e

E PTFE

K Kalrez

®e

TT = Tangent, tangent packing
RT = Radial, tangent packing

3

12

13

4

65 ft. lb.

5

NOTE: Cover the end of the piston rod with packing
cone (part # 3905) before installing packing. For
lubricated compressors, the lubricating quill located
on the adapter must be removed before packing
cartridge can be removed.

6

7

8

2

O-ring locations for adapter

1

2

9

Inner oil wiper ring set

10

Outer packing

15

14

TT

13

16
RT

15

13

16

RT

18

15

13

16

RT

15

13

RT

16

15

17

15

6

Packing Assembly Bill of Materials for 2.75" Standard

Ref

Part No. Description Qt y.

No.

1 2-253 _

2 2-236_

3 3524 Adapter 1

4 7001-050NC150A Hex head bolt (1/2 - 13 x 1-1/2) 16

5 3442 Pipe plug Varies

6 5002-250 Retainer ring 2

7 3631 Packing washer 1

8 3816

9 3891 Packing cartridge 1

10 7002-031NC075AfSocket head bolt (5/16 - 18 X 3/4") 4

11 2-228_

12 3819 Packing spacer 1

a, d

a, d

c

a, d

O-ring 1

O-ring 2

Oil wiper ring set (two per set) 1

O-ring 1

Ref

Part No. Description Qt y.

No.

13 3 811 Back-up ring 5

14 3 814

15

16 3810

b

38 17 Packing cup 6

a, d

2-036_

b

Segmented packing ring
(tangent, tangent - pair)

O-ring 6

Segmented packing ring (radial,
tangent - pair)

17 3 815 Pressure breaker ring 1

18 3810-X3 Packing set 1

a

See detail for O-ring location

b

Direction of packing is impor tant. See packing assembly page for details.

c

Direction of oil wiper ring set is important. See packing assembly
page for details.

d

For O-ring material codes, see O-ring chart.

e

Registered trademarks of the DuPont company.

f

Apply a small amount of loctite #272 to the circumference of the threads.

54

1

4

Appendix D—Packing Assembly Details for HG600 Series (Plain Style)

Crankcase side

Cylinder side

2.75" Purge Packing Specification

4

1

3

2

65 ft. lb.

5

5

NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing.
For lubricated compressors, the lubricating quill located on the adapter must be removed before
packing cartridge can be removed.

O-ring locations for adapter

21

1

2

2

6

7

8

TTs
9

10

11

65 ft. lb.

4

Inner oil wiper ring set

10

12

9

sTT

O-ring Code

13

14

TT

15

16

14

RT

16

17

14

A Buna-N

®e

®e

21

B Neoprene

D Viton

E PTFE

K Kalrez

®e

TT = Tangent, tangent packing
TTs = Biased tangent, tangent with springs on cylinder side
sTT = Biased tangent, tangent with springs on crankcase side
RT = Radial, tangent packing

Packing Assembly Bill of Materials for 2.75" Purge

Ref

Part No. Description Qt y.

No.

1 2-253 _

2 2-236_

3 3524-2 Adapter 1

4 7001-050NC150A Hex head bolt (1/2" - 13 x 1-1/2") 16

5 3442 Pipe plug (1/4") Varies

6 4363 Packing cartridge body 1

7 3816

8 4270 Oil wiper ring cup 1

9 4273

10 4271 Purge packing cup 2

11 4364 Cup spacer 1

12 2-228_

13 4272 Packing spacer 1

14 3 8 11 Back-up ring 5

a, d

a, d

c

O-ring 1

O-ring 3

Oil wiper ring set (two per set) 1

Biased segmented packing set
(tangent, tangent - includes 2 TT
pairs, 2 iron backup rings, and 12

1

springs)

a, d

O-ring 1

Inner packing

Outer packing

16

RT

17

14

Ref

Part No. Description Qt y.

No.

15 3814

38 17 Packing cup 6

16

2-036_

17 3 810

RT

17

16

14

b

16

17

RT

18

Segmented packing ring

16

2

19

(tangent, tangent - pair)

a, d

b

O-ring 8

Segmented packing ring (radial,
tangent - pair)

18 3815 Pressure breaker ring 1

19 4362 Packing cartridge cap 1

Socket head bolt (5/16 - 18 x

20 7002-031NC075A

f

3/4")

21 4273-X3 Packing set 1

a

See detail for O-ring location

b

Direction of packing is impor tant. See packing assembly page for details.

c

Direction of oil wiper ring set is important. See packing assembly
page for details

d

For O-ring material codes, see O-ring chart.

e

Registered trademarks of the DuPont company.

f

Apply a small amount of loctite #272 to the circumference of the threads.

20

1

4

4

55

Appendix D—Packing Assembly Details for HG600 Series (Plain Style)

Crankcase side

Cylinder side

3.25" and 4" Standard Packing Specification

NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing. For lubricated compressors, the lubricating quill
located on the adapter must be removed before packing cartridge can be removed.

1

3

4

2

5

65 ft. lb.

6

7

8

5

65 ft. lb.

Inner oil wiper ring set

4

1

2

9

3.25" adapter

O-ring locations

2

1

10

2

4" adapter

O-ring Code

11

12

A Buna-N

B Neoprene

D Viton

®e

®e

E PTFE

K Kalrez

®e

TT = Tangent, tangent packing
RT = Radial, tangent packing

13

TT

14

15

13

16

RT

15

13

18

Packing Assembly Bill of Materials for 3.25" and 4" Standard

Ref

Part No. Description Qt y.

No.

1 2-253 _

2 2-236_

3

a, d

a, d

O-ring 1

O-ring 2

3524 Adapter (3.25") 1

3762 Adapter (4") 1

4 7001-050NC150A Hex head bolt (1/2 - 13 x 1-1/2) 16

5 3442 Pipe plug Varies

6 5002-250 Retainer ring 2

7 3631 Packing washer 1

8 3816

9

10

11 2-228_

c

Oil wiper ring set (two per set) 1

3594 Packing cartridge (3.25") 1

3764 Packing cartridge (4") 1

Socket head bolt (5/16 - 18 x

7002-031NC075A

7002-025NC062A

a, d

f

3/4") - 3.25"

Socket head bolt (1/4 - 20 x

f

5/8") - 4"

O-ring 1

4

4

Ref
No.

12 3819 Packing spacer 1

13 3 811 Back-up ring 4

14 3 814

15

16 3810

17 3 815 Pressure breaker ring 1

18 3810-X2 Packing set (fits 3.25" & 4") 1

a

See detail for O-ring location

b

Direction of packing is impor tant. See packing assembly page for details.

c

Direction of oil wiper ring set is important. See packing assembly
page for details.

d

For O-ring material codes, see O-ring chart.

e

Registered trademarks of the DuPont company.

f

Apply a small amount of loctite #272 to the circumference of the threads.

Outer packing

16

RT

15

13

16

RT

15

17

15

6

Part No. Description Qt y.

b

Segmented packing ring
(tangent, tangent - pair)

1

38 17 Packing cup 5

a, d

2-036_

b

O-ring 5

Segmented packing ring (radial,
tangent - pair)

3

56

Appendix D—Packing Assembly Details for HG600 Series (Plain Style)

3.25" and 4" Purge Packing Specification

NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing
packing. For lubricated compressors, the lubricating quill located on the adapter must be
removed before packing cartridge can be removed.

1

O-ring locations

2 2

1

3

4

65 ft. lb.

1

2

5

2

5

65 ft. lb.

4

O-ring Code

A Buna-N

B Neoprene

D Viton

®e

E PTFE

K Kalrez

®e

®e

10

9

sTT

12

13

14

TT

15

16

TT = Tangent, tangent packing
TTs = Biased tangent, tangent with springs on cylinder side
sTT = Biased tangent, tangent with springs on crankcase side
RT = Radial, tangent packing

Crankcase side

14

17

RT

6

Inner oil wiper

ring set

16

21

14

7

Outer packing

17

RT

8

Inner packing

16

14

17

RT

3.25" adapter

TTs

9

10

16

21

18

4" adapter

11

16

2

19

20

Cylinder side

Packing Assembly Bill of Materials for 3.25" and 4" Purge

Ref

Part No. Description Q ty.

No.

1 2-253_

2 2-236_

3

a, d

a, d

O-ring 1

O-ring 3

35 24-1 Adapter (3.25") 1

3762-1 Adapter (4") 1

4 7001-050NC150A Hex head bolt (1/2" - 13 x 1-1/2") 16

5 3442 Pipe plug (1/4") Var ie s

4287 Packing cartridge body (3.25") 1

6

4289 Packing car tridge body (4") 1

7 3816

c

Oil wiper ring set (two per set) 1

8 4270 Oil wiper ring cup 1

Biased segmented packing set

9 4273

(tangent, tangent - includes 2 TT
pairs, 2 iron backup rings, and 12
springs)

10 4271 Purge packing cup 2

11 4285 Cup spacer 1

12 2-228_

a, d

O-ring 1

13 4272 Packing spacer 1

14 3 8 11 Back-up ring 4

1

Ref
No.

15 3814

16

17 3 810

18 3815 Pressure breaker ring 1

19

20

21 4273-X2 Packing set (fits 3.25" & 4") 1

a

See detail for O-ring location

b

Direction of packing is impor tant. See packing assembly page for details.

c

Direction of oil wiper ring set is important. See packing assembly
page for details.

d

For O-ring material codes, see O-ring chart.

e

Registered trademarks of the DuPont company.

f

Apply a small amount of loctite #272 to the circumference of the threads.

Part No. Description Q ty.

b

Segmented packing ring (tangent,
tangent - pair)

1

38 17 Packing cup 5

a, d

2-036_

b

O-ring 7

Segmented packing ring (radial,
tangent - pair)

3

4286 Packing car tridge cap (3.25") 1

4288 Packing car tridge cap (4") 1

Socket head bolt (5/16 - 18 X 3/4")

7002-031NC075A

f

- 3.25"

4

7002-010NC075AfSocket head bolt (10 - 24 x 3/4") - 4" 4

57

Crankcase side

Cylinder side

Appendix D—Packing Assembly Details Appendix D—Packing Assembly Details for HG600 Series (Plain Style)

5" Standard Packing Specification

NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing.
For lubricated compressors, the lubricating quill located on the adapter must be removed before
packing cartridge can be removed.

4

2

3

1

65 ft. lb.

5

6

7

8

2

5

65 ft. lb.

Inner oil wiper ring set

4

O-ring Code

A Buna-N

®e

®e

®e

11

12

13

14

TT

15

13

RT

16

15

13

16

B Neoprene

D Viton

E PTFE

K Kalrez

TT = Tangent, tangent packing
RT = Radial, tangent packing

RT

18

15

13

RT

16

O-ring locations

1

2

5" adapter

9

10

Outer packing

15

17

15

6

Packing Assembly Bill of Materials for 5" Standard

Ref

Part No. Description Qt y.

No.

1 2-253_

2 2-236_

3 5291 Adapter 1

4 7001-050NC150A Hex head bolt (1/2 - 13 x 1-1/2) 16

5 3442 Pipe plug Varies

6 5002-250 Retainer ring 2

7 36 31 Packing washer 1

8 3816

9 5304 Packing cartridge 1

10 7002-010NC075AfSocket head bolt (5/16 - 18 X 3/4") 4

11 2-228_

12 3819 Packing spacer 1

13 3 8 11 Back-up ring 4

14 3 814

a, d

a, d

c

a, d

b

O-ring 1

O-ring 2

Oil wiper ring set (two per set) 1

O-ring 1

Segmented packing ring
(tangent, tangent - pair)

Ref

Part No. Description Qt y.

No.

38 17 Packing cup 5

15

16 3810

2-036_

b

a, d

O-ring 5

Segmented packing ring (radial,
tangent - pair)

3

17 3 815 Pressure breaker ring 1

18 3810-X2 Packing set 1

a

See detail for O-ring location

b

Direction of packing is impor tant. See packing assembly page for details.

c

Direction of oil wiper ring set is important. See packing assembly
page for details.

d

For O-ring material codes, see O-ring chart.

e

Registered trademarks of the DuPont company.

f

Apply a small amount of loctite #272 to the circumference of the threads.

1

58

Crankcase side

Cylinder side

Appendix D—Packing Assembly Details

Appendix D—Packing Assembly Details for HG600 Series (Plain Style)

5" Purge Packing Specification

NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing.
For lubricated compressors, the lubricating quill located on the adapter must be removed before
packing cartridge can be removed.

3

2

1

4

65 ft. lb.

5

2

6

5

65 ft. lb.

4

Inner oil wiper ring set

O-ring Code

A Buna-N

B Neoprene

D Viton

®e

®e

E PTFE

K Kalrez

®e

TT = Tangent, tangent packing

10

9

sTT

12

13

14

TT

15

16

14

17

RT

16

14

17
RT

TTs = Biased tangent, tangent with springs on cylinder side
sTT = Biased tangent, tangent with springs on crankcase side

21

RT = Radial, tangent packing

7

8

Outer packing

16

14

17

RT

O-ring locations

1

TTs

9

Inner packing

16

18

2

5" adapter

21

10

16

11

19

20

Packing Assembly Bill of Materials for 5" Purge

Ref

Part No. Description Qty.

No.

1 2-253_

2 2-236_

3 529 1-1 Adapter 1

4 7001-050NC150A Hex head bolt (1/2" - 13 x 1-1/2") 16

5 3442 Pipe plug (1/4") Varies

6 5298 Packing cartridge body 1

7 3816

8 4270 Oil wiper ring cup 1

9 4273

10 4271 Purge packing cup 2

11 4285 Cup spacer 1

12 2-228_

13 4272 Packing spacer 1

14 3 8 11 Back-up ring 4

a, d

a, d

c

O-ring 1

O-ring 2

Oil wiper ring set (two per set) 1

Biased segmented packing set
(tangent, tangent - includes 2 TT
pairs, 2 iron backup rings, and
12 springs)

a, d

O-ring 1

Ref

Part No. Description Qty.

No.

15 3814

16

17 3 810

b

38 17 Packing cup 5

a, d

2-036_

b

Segmented packing ring
(tangent, tangent - pair)

O-ring 7

Segmented packing ring (radial,
tangent - pair)

1

3

18 3815 Pressure breaker ring 1

19 5321 Packing cartridge cap 1

20 7002-010NC075AfSocket head bolt 4

1

21 4273-X2 Packing set 1

a

See detail for O-ring location

b

Direction of packing is impor tant. See packing assembly page for details.

c

Direction of oil wiper ring set is important. See packing assembly
page for details.

d

For O-ring material codes, see O-ring chart.

e

Registered trademarks of the DuPont company.

f

Apply a small amount of loctite #272 to the circumference of the threads.

59

Crankcase side

Cylinder side

Appendix D—Packing Assembly Details for HG600 Series (Plain Style)

6" and 8" Standard Packing Specification

NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing.
For lubricated compressors, the lubricating quill located on the adapter must be removed before
packing cartridge can be removed.

4

1

2

3

65 ft. lb.

5

6

7

5

65 ft. lb.

Inner oil wiper ring set

4

Outer packing

O-ring Code

A Buna-N

B Neoprene

D Viton

®f

®f

E PTFE

K Kalrez

®f

TT = Tangent, tangent packing
RT = Radial, tangent packing

11

12

14

TT

15

13

16

RT

15

13

13

17

8

16

RT

O-ring locations

1

2

2

6" & 8" adapter

9

10

15

16

RT

15

6

13

Packing Assembly Bill of Materials for 6" and 8" Standard

Ref

Part No. Description Qt y.

No.

1 2-253 _

2 2-236_

3

4 7001-050NC150A Hex head bolt (1/2 - 13 x 1-1/2) 16

5 3442 Pipe plug Varies

6 5002-250 Retainer ring 2

7 3631 Packing washer 1

8 3816

9 3533 Packing box cartridge (6" & 8") 1

10 7002-031NC075AgSocket head bolt (5/16 - 18 X 3/4") 4

11 2-228_

12 3819 Packing spacer 1

13 3 811 Back-up ring 4

a, d

a, d, e

O-ring 1

O-ring 2

3529 Adapter (6") 1

3673 Adapter (8") 1

c

a, d

Oil wiper ring set (two per set) 1

O-ring 1

Ref

Part No. Description Qt y.

No.

14 3 814

15

16 3810

b

38 17 Packing cup 4

a, d

2-036_

b

Segmented packing ring
(tangent, tangent - pair)

O-ring 4

Segmented packing ring (radial,
tangent - pair)

17 3 810 -X1 Packing set (6" & 8") 1

a

See detail for O-ring location

b

Direction of packing is impor tant. See packing assembly page for details.

c

Direction of oil wiper ring set is important. See packing assembly
page for details.

d

For O-ring material codes, see O-ring chart.

e

Beginning with serial number NN51397.

f

Registered trademarks of the DuPont company.

g

Apply a small amount of loctite #272 to the circumference of the threads.

60

1

3

Crankcase side

Cylinder side

Appendix D—Packing Assembly Details for HG600 Series (Plain Style)

6" and 8" Purge Packing Specification

NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing.
For lubricated compressors, the lubricating quill located on the adapter must be removed before
packing cartridge can be removed.

4

1

2

3

65 ft. lb.

5

2

6

7

5

65 ft. lb.

4

Inner oil wiper

ring set

O-ring Code

A Buna-N

B Neoprene

D Viton

®e

®e

E PTFE

K Kalrez

®e

TT = Tangent, tangent packing
TTs = Biased tangent, tangent with springs on cylinder side
sTT = Biased tangent, tangent with springs on crankcase side
RT = Radial, tangent packing

10

9

sTT

12

13

14

TT

15

16

20

14

16

17

RT

8

Inner packing

Outer packing

14

17

RT

16

TTs

9

14

1

RT

20

10

17

O-ring locations

2

6" & 8" adapter

11

16

18

19

Packing Assembly Bill of Materials for 6" and 8" Purge

Ref

Part No. Description Qt y.

No.

1 2-253_

2 2-236_

3

4 7001-050NC150A Hex head bolt (1/2" - 13 x 1-1/2") 16

5 3442 Pipe plug (1/4") Varies

6 4268 Packing cartridge body 1

7 3816

8 4270 Oil wiper ring cup 1

9 4273

10 4271 Purge packing cup 2

11 4269 Cup spacer 1

12 2-228_

13 4272 Packing spacer 1

a, d

a, d

O-ring 1

O-ring 2

35 2 9 -1 Adapter (6") 1

36 73-1 Adapter (8") 1

c

Oil wiper ring set (two per set) 1

Biased segmented packing set
(tangent, tangent - includes 2 TT
pairs, 2 iron backup rings, and 12
springs)

a, d

O-ring 1

Ref

Part No. Description Qt y.

No.

14 3 8 11 Back-up ring 4

15 3814

16

17 3 810

b

38 17 Packing cup 4

a, d

2-036_

b

Segmented packing ring
(tangent, tangent - pair)

O-ring 6

Segmented packing ring (radial,
tangent - pair)

1

3

18 4267 Packing cartridge cap 1

19 7002-031NC075AfSocket head bolt 4

20 4273 -X1 Packing set 1

a

1

See detail for O-ring location

b

Direction of packing is impor tant. See packing assembly page for details.

c

Direction of oil wiper ring set is important. See packing assembly
page for details.

d

For O-ring material codes, see O-ring chart.

e

Registered trademarks of the DuPont company.

f

Apply a small amount of loctite #272 to the circumference of the threads.

61

Appendix D—Packing Assembly Details for HG601/HG602 Series (Plain Style)

Inner Oil Wiper Ring Sets

1. Standard Specification

Crankcase

Side

2. Purge Specification

Crankcase

Side

Oil wiper ring set (Radial, Radial)

Radial Cut

(with pin)

Align pin with

hole on backside.

Oil wiper ring set (Radial, Radial)

Part number 3816

Cylinder

Side

Radial Cut

(without pin)

Cylinder

Side

Radial Cut

(with pin)

Align pin with

hole on backside.

Inner Packing Details for Purge Specification Only

Biased Segmented Purge Packing Set (Tangent, Tangent with spring toward cylinder—TTs)

Crankcase

Side

Tangent Cut

(with pin)

Align pin with

hole on backside.

Tangent Cut
(without pin)

Radial Cut

(without pin)

Backup Ring

with 6 springs

Wiper Ring Cup (not included)

Purge Packing Cup

(not included)

Part number 4273

Cylinder

Side

Cup Spacer

(not included)

62

Appendix D—Packing Assembly Details for HG601/HG602 Series (Plain Style)

Outer Packing Details for Standard and Purge Packing Specifications

1. Purge Specification
Biased Segmented Packing Set (Tangent, Tangent with springs toward crankcase—sTT)

Crankcase

Side

Purge Packing Cup

(not included)

2. Standard or Purge Specification

Crankcase

Side

Backup Ring

with 6 Springs

Segmented Packing Set (Tangent, Tangent)

Tangent Cut

(with pin)

Align pin with

hole on backside.

Tangent Cut
(without pin)

O-ring

(not included)

Part number 4273

Cylinder

Side

Purge Packing Spacer

(not included)

Part number 3814

Cylinder

Side

Backup Ring

(not included)

Tangent Cut

(with pin)

Align pin with

hole on backside.

Tangent Cut
(without pin)

3. Standard or Purge Specification

Segmented Packing Set (Radial, Tangent)

Crankcase

Side

Backup Ring

(not included)

Tangent Cut

(with pin)

Align pin with

hole on backside.

Radial Cut

(without pin)

4. Solid Pressure Breaker Ring (applies to 2.75", 3.25", 4", and 5" cylinder sizes only)

Crankcase

Side

Packing Cup

(not included)

Part number 3810

Cylinder

Side

Packing Cup

(not included)

Part number 3815

Cylinder

Side

Breaker Ring

Packing Cup

(not included)

63

Appendix D—Packing Assembly Details for THG600 Series (T-Style)

2

Crankcase side

Cylinder side

NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing.

2.75" Pad Packing Specification

1

4

3

For lubricated compressors, the lubricating quill located on the adapter must be removed before

4

65 ft. lb.

packing cartridge can be removed.

TT = Tangent, tangent packing

1

6

65 ft. lb.

5

TTs = Biased tangent, tangent

sTT = Biased tangent, tangent with

3

RT = Radial, tangent packing

4

with springs on cylinder side

springs on crankcase side

O-ring locations for adapter

1

5

Middle packing

16

TT

17

18

27

19

20

28A

TTs

13

5

4

21

Outer packing

O-ring Code

22*

A Buna-N

®e

®e

®e

18

RT

23

16

18

RT

23

16

24

16

5

B Neoprene

D Viton

E PTFE

K Kalrez

27

*Align pin (item # 22) with the hole on the back side of the packing cartridge cap (item # 25).

Packing Assembly Bill of Materials for 2.75" Pad

Ref

Part No. Description Qty.

No.

1 2-253_
2 4772 Distance piece 1
3 7001-050NC150A Hex head bolt (1/2" - 13 x 1-1/2") 24
4 3442 Pipe plug (1/4") Varies
5 2-236_
6 3524-2 Adapter 1
7 2-231_
8 4778 Packing cartridge adapter 1

9 7002-005NC050AfSocket head bolt 4
10 3816
11 4270 Oil wiper ring cup 1

12 427 3 -1

13 4271 Purge packing cup 3
14 4779 Cup spacer 1
15 1732 Oil deflector ring 1

16

17 3 814

a, d

a, d

a, d

c

O-ring 2

O-ring 3

O-ring 1

Oil wiper ring set (two per set) 1

Biased segmented packing set
(tangent, tangent - includes 1
TT pair, 1 iron backup rings,
and 6 springs)

38 17 Packing cup 6

a, d

2-036_

b

O-ring 8
Segmented packing ring

(tangent, tangent - pair)

3

65 ft. lb.

25*

1

2

7

8

12

27

TTs

13

14

Inner oil wiper

9

10

11

ring set

13

sTT
28B

20

19

Outer packing

18

17

TT

16

Inner packing

27

RT

18

23

16

18

23

RT

16

26

Ref

Part No. Description Qty.

No.

18 3 8 11 Back-up ring 6
19 4272 Packing spacer 1
20 2-228_

a, d

O-ring 1
21 4773 Packing cartridge body 1
22 3253 Pin 1

23 3810

b

Segmented packing ring (radial,

tangent - pair)
24 3815 Pressure breaker ring 1
25 4362 Packing cartridge cap 1
26 7002-031NC075AfSocket head bolt (5/16 - 18 x 3/4") 4
27 4273 -1X3 Packing set 1

28A

4273

28B

a

See detail for O-ring location

b

Direction of packing is impor tant. See packing assembly page for details.

c

Direction of oil wiper ring set is important. See packing assembly
page for details.

d

For O-ring material codes, see O-ring chart.

e

Registered trademarks of the DuPont company.

f

Apply a small amount of loctite #272 to the circumference of the threads.

Biased segmented packing set

(tangent, tangent - includes 2

TT pairs, 2 iron backup rings,

and 12 springs)

15

4

1

64

Appendix D—Packing Assembly Details for THG600 Series (T-Style)

O-ring locations for adapter

5

1

NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing.
For lubricated compressors, the lubricating quill located on the adapter must be removed before
packing cartridge can be removed.

11

12

13

14

15

8

7

1

2

3

19

18

20

5

28A

16

17

20

18

23

20

4

5

6

4

3

1

3

9

10

13

21

18

23

20

18

16

17

18

19

22*

13

28B

18

23

20

23

20

24

20

5

25

26

4

4

*Align pin (item # 22) with the hole on the back side of the packing cartridge cap (item # 25).

Crankcase side

Cylinder side

27

27

27

27

Middle packing

Outer packing

Inner packing

sTT

TT

TTs

sTT

TT

RT

RT

RT

RT

Outer packing

65 ft. lb.

65 ft. lb.

65 ft. lb.

Inner oil wiper ring set

2.75" Purge Packing Specification

TT = Tangent, tangent packing
TTs = Biased tangent, tangent

with springs on cylinder side

sTT = Biased tangent, tangent with

springs on crankcase side

RT = Radial, tangent packing

O-ring Code

A Buna-N

B Neoprene

D Viton

®e

®e

E PTFE

K Kalrez

®e

Packing Assembly Bill of Materials for 2.75" Purge

Ref

Part No. Description Qty.

No.

1 2-253_

a, d

O-ring 2
2 4772 Distance piece 1
3 7001-050NC150A Hex head bolt (1/2" - 13 x 1-1/2") 24
4 3442 Pipe plug (1/4") Varies

a, d

a, d

c

O-ring 3

O-ring 1

Oil wiper ring set (two per set) 1

Biased segmented packing set

(tangent, tangent - includes 1 TT

pair, 1 iron backup rings, and 6

5 2-236_
6 3524-2 Adapter 1
7 2-231_
8 4778 Packing cartridge adapter 1
9 7002-005NC050AfSocket head bolt 4

10 3816
11 4270 Oil wiper ring cup 1

12 4 273 -1

springs)

13 4271 Purge packing cup 3
14 4779 Cup spacer 1
15 17 3 2 Oil deflector ring 1
16 2-228_
17 4272 Packing spacer 2
18 3 8 11 Back-up ring 4

a, d

O-ring 2

3

Ref

Part No. Description Qty.

No.

b

38 17 Packing cup 7
2-036_

a, d

19 3 814

20

21 4773 Packing cartridge body 1
22 3253 Pin 1

23 3810

24 3815 Pressure breaker ring 1

b

25 4362 Packing cartridge cap 1
26 7002-031NC075AfSocket head bolt (5/16 - 18 x 3/4") 4
27 4273-1X3 Packing set 1

28A

4273

28B

a

See detail for O-ring location

b

Direction of packing is impor tant. See packing assembly page for details.

c

Direction of oil wiper ring set is important. See packing assembly
page for details.

d

For O-ring material codes, see O-ring chart.

e

Registered trademarks of the DuPont company.

f

Apply a small amount of loctite #272 to the circumference of the threads.

Segmented packing ring (tangent,
tangent - pair)

O-ring 10

Segmented packing ring (radial,
tangent - pair)

Biased segmented packing set
(tangent, tangent - includes 2 TT
pairs, 2 iron backup rings, and
12 springs)

65

2

4

1

NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing.

1

2

3

Crankcase side

Cylinder side

Appendix D—Packing Assembly Details for THG600 Series (T-Style)

3.25" and 4" Pad Packing Specification

4

4

Middle packing

16

27

TT

17

18

19

20

28A

TTs

13

O-ring Code

A Buna-N

®e

®e

18

®e

RT

23

B Neoprene

D Viton

E PTFE

K Kalrez

TT = Tangent, tangent packing
TTs = Biased tangent, tangent

with springs on cylinder side

sTT = Biased tangent, tangent with

springs on crankcase side

RT = Radial, tangent packing

*Align pin (item # 22) with the hole on the back side of the packing cartridge cap (item # 25).

65 ft. lb.

For lubricated compressors, the lubricating quill located on the adapter must be removed before
packing cartridge can be removed.

O-ring locations

1

65 ft. lb.

6

5

3

1

5

1

4

7

3.25" adapter

4

8

10

11

3

65 ft. lb.

9

12

TTs

4" adapter

13

Inner oil wiper

ring set

18

17

Inner packing

27

TT

18

16

23

RT

16

5

21

Outer packing

22*

16

18

27

RT

23

16

24

16

5

25

13

sTT

28B

20

19

Outer packing

26

5

27

14

15

Packing Assembly Bill of Materials for 3.25" and 4" Pad

Ref

Part No. Description Qt y.

No.

1 2-253_
2 47 72 Distance piece 1
3 70 01-050NC150A Hex head bolt (1/2" - 13 x 1-1/2") 24
4 3442 Pipe plug (1/4") Varies
5 2-236_

6

7 2-231_
8 47 78 Packing cartridge adapter 1

9 7002-005NC050AfSocket head bolt 4
10 3816
11 4270 Oil wiper ring cup 1

12 4273 -1

13 4271 Purge packing cup 3
14 4779 Cup spacer 1
15 173 2 Oil deflector ring 1

16

17 3814

18 3811 Back-up ring 5

a, d

a, d

O-ring 2

O-ring 3
35 24-1 Adapter (3.25") 1
3762-1 Adapter (4") 1

a, d

c

O-ring 1

Oil wiper ring set (two per set) 1

Biased segmented packing set

(tangent, tangent - includes 1 TT pair,

1 iron backup rings, and 6 springs)

38 17 Packing cup 6

a, d

2-036_

b

O-ring 9

Segmented packing ring (tangent,

tangent - pair)

Ref

Part No. Description Qt y.

No.

19 4272 Packing spacer 2
20 2-228 _

21

a, d

O-ring 2
4773 Packing cartridge body (3.25") 1
47 74 Packing cartridge body (4") 1

22 3253 Pin 1

23 3810

b

Segmented packing ring (radial,

tangent - pair)

3

24 3 815 Pressure breaker ring 1

4286 Packing cartridge cap (3.25") 1

25

4288 Packing cartridge cap (4") 1

Socket head bolt (5/16 - 18 X 3/4")
7002-031NC075A

26

f

- 3.25"

4

7002-010NC075AfSocket head bolt (10 - 24 x 3/4") - 4" 4

1

2

27 4273-X 2 Packing set (fits 3.25" & 4") 1

28A

4273

28B

a

See detail for O-ring location

b

Direction of packing is impor tant. See packing assembly page for details.

c

Direction of oil wiper ring set is important. See packing assembly
page for details.

d

For O-ring material codes, see O-ring chart.

e

Registered trademarks of the DuPont company.

f

Apply a small amount of loctite #272 to the circumference of the threads.

Biased segmented packing set
(tangent, tangent - includes 2 TT pairs,
2 iron backup rings, and 12 springs)

1

66

NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing.

1

2

3

Crankcase side

Cylinder side

Appendix D—Packing Assembly Details for THG600 Series (T-Style)

3.25" and 4" Purge Packing Specification

4

65 ft. lb.

4

packing cartridge can be removed.

1

65 ft. lb.

6

5

3

4

Middle packing

4

13

For lubricated compressors, the lubricating quill located on the adapter must be removed before

3

65 ft. lb.

16

28A
sTT

27

O-ring Code

A Buna-N

B Neoprene

D Viton

®e

E PTFE

K Kalrez

TT = Tangent, tangent packing
TTs = Biased tangent, tangent

with springs on cylinder side

sTT = Biased tangent, tangent with

springs on crankcase side

RT = Radial, tangent packing

®e

®e

17

18

19

TT

20

5

21

Outer packing

22*

18

20

23

RT

18

RT

23

27

20

24

20

5

25

26

*Align pin (item # 22) with the hole on the back side of the packing cartridge cap (item # 25).

Packing Assembly Bill of Materials for 3.25" and 4" Purge

Ref

Part No. Description Qty.

No.

1 2-253_

a, d

O-ring 2
2 47 72 Distance piece 1
3 70 01-050NC150A Hex head bolt (1/2" - 13 x 1-1/2") 24
4 3442 Pipe plug (1/4") Varies
5 2-236_

6

7 2-231_

a, d

O-ring 3

35 24-1 Adapter (3.25") 1
3762-1 Adapter (4") 1

a, d

O-ring 1
8 47 78 Packing cartridge adapter 1
9 7002-005NC050AfSocket head bolt 4

10 3816

c

Oil wiper ring set (two per set) 1

11 4270 Oil wiper ring cup 1

Biased segmented packing set

12 4273 -1

(tangent, tangent - includes 1 TT pair,

1 iron backup rings, and 6 springs)

13 4271 Purge packing cup 3
14 4779 Cup spacer 1
15 1732 Oil deflector ring 1
16 2-228_

a, d

O-ring 2

17 4272 Packing spacer 2
18 38 11 Back-up ring 5

19 3814

b

Segmented packing ring (tangent,

tangent - pair)

1

2

Ref
No.

20

21

22 3253 Pin 1

23 3810

24 3815 Pressure breaker ring 1

25

26

27 4 273 -1X2 Packing set (fits 3.25" & 4") 1

28A

28B

a

See detail for O-ring location

b

Direction of packing is impor tant. See packing assembly page for details.

c

Direction of oil wiper ring set is important. See packing assembly
page for details.

d

For O-ring material codes, see O-ring chart.

e

Registered trademarks of the DuPont company.

f

Apply a small amount of loctite #272 to the circumference of the threads.

O-ring locations

1

5

1

5

7

3" adapter

8

10

11

9

Inner oil wiper

TTs

12

4" adapter

27

13

14

ring set

13

sTT

28B

16

17

Outer packing

18

19

TT

Inner packing

18

20

23

RT

20

27

Part No. Description Qty.

38 17 Packing cup 6

a, d

2-036_

O-ring 9
47 74 Packing cartridge body (3.25") 1
4775 Packing cartridge body (4") 1

b

Segmented packing ring (radial,

tangent - pair)

3

4286 Packing car tridge cap (3.25") 1
4288 Packing car tridge cap (4") 1

Socket head bolt (5/16 - 18 X 3/4") ­7002-031NC075A

f

3.25"

4

7002-010NC075AfSocket head bolt (10 - 24 x 3/4") - 4" 4

Biased segmented packing set

4273

(tangent, tangent - includes 2 TT pairs,

1

2 iron backup rings, and 12 springs)

15

67

1

3

2

Appendix D—Packing Assembly Details for THG600 Series (T-Style)

5" Pad Packing Specification

4

65 ft. lb.

NOTE: Cover the end of the piston rod with packing cone
(part # 3905) before installing packing. For lubricated
compressors, the lubricating quill located on the adapter
must be removed before packing cartridge can be removed.

1

O-ring locations

5

1

65 ft. lb.

6

5

4

Middle packing

4

16

TT

17

18

26

19

20

27A

TTs

13

5

3

21

O-ring Code

A Buna-N

®e

®e

Outer packing

B Neoprene

D Viton

E PTFE

K Kalrez

®e

TT = Tangent, tangent packing
TTs = Biased tangent, tangent

with springs on cylinder side

sTT = Biased tangent, tangent with

18

RT

22

16

23

springs on crankcase side

RT = Radial, tangent packing

26

Crankcase side

Packing Assembly Bill of Materials for 5" Pad

Ref

Part No. Description Qty.

No.

1 2-253_
2 4772 Distance piece 1
3 7001-050NC150A Hex head bolt (1/2" - 13 x 1-1/2") 24
4 3442 Pipe plug (1/4") Varie s
5 2-236_
6 5291-1 Adapter 1
7 2-231_
8 4778 Packing cartridge adapter 1

9 7002-005NC050AfSocket head bolt 4
10 3 816
11 4270 Oil wiper ring cup 1

12 4273 -1

13 4271 Purge packing cup 3
14 4779 Cup spacer 1
15 17 3 2 Oil deflector ring 1

16

17 3814

a, d

a, d

a, d

c

O-ring 2

O-ring 3

O-ring 1

Oil wiper ring set (two per set) 1

Biased segmented packing set
(tangent, tangent - includes 1 TT pair,
1 iron backup rings, and 6 springs)

38 17 Packing cup 5

a, d

2-036_

b

O-ring 8
Segmented packing ring (tangent,

tangent - pair)

4

65 ft. lb.

16

24

1

2

3

5" adapter

11

Inner packing

18

22

RT

16

TTs

12

26

13

26

18

13

7

8

9

Inner oil wiper ring set

sTT
27B

20

19

18

Outer packing

17

10

TT

16

25

Cylinder side

Ref

Part No. Description Qty.

No.

18 3 811 Back-up ring 5
19 4272 Packing spacer 2
20 2-228 _

a, d

O-ring 2

21 4776 Packing cartridge body 1

22 3810

b

Segmented packing ring (radial,

tangent - pair)
23 3815 Pressure breaker ring 1
24 5321 Packing cartridge cap 1
25 7002-010NC075AfSocket head bolt 4
26 4273-1X 2 Packing set 1

27A

4273

27B

a

See detail for O-ring location

b

Direction of packing is impor tant. See packing assembly page for details.

c

Direction of oil wiper ring set is important. See packing assembly
page for details.

d

For O-ring material codes, see O-ring chart.

e

Registered trademarks of the DuPont company.

f

Apply a small amount of loctite #272 to the circumference of the threads.

Biased segmented packing set

(tangent, tangent - includes 2 TT pairs,

2 iron backup rings, and 12 springs)

14

15

RT

22

16

3

1

68

1

3

2

Crankcase side

Cylinder side

Appendix D—Packing Assembly Details for THG600 Series (T-Style)

5" Purge Packing Specification

4

4

Middle packing

13

27A

sTT

26

O-ring Code

16

17

18

TT

19

A Buna-N

B Neoprene

D Viton

®e

®e

E PTFE

K Kalrez

®e

TT = Tangent, tangent packing
TTs = Biased tangent, tangent

with springs on cylinder side

sTT = Biased tangent, tangent with

springs on crankcase side

RT = Radial, tangent packing

20

65 ft. lb.

5

NOTE: Cover the end of the piston rod with packing cone
(part # 3905) before installing packing. For lubricated
compressors, the lubricating quill located on the adapter
must be removed before packing cartridge can be removed.

1

65 ft. lb.

6

5

3

4

7

8

4

3

65 ft. lb.

9

Inner oil wiper ring set

21

sTT

13

27B

16

17

Outer packing

Outer packing

18

26

RT

22

20

23

20

25

24

18

1

19

10

11

Inner packing

26

TT

20

O-ring locations

5

5" adapter

26

TTs

12

13

RT

18

22

20

18

RT

22

14

15

20

Packing Assembly Bill of Materials for 5" Purge

Ref

Part No. Description Qty.

No.

1 2-253_
2 4772 Distance piece 1
3 7001-050NC150A Hex head bolt (1/2" - 13 x 1-1/2") 24
4 3442 Pipe plug (1/4") Varies
5 2-236_
6 5291-1 Adapter 1
7 2-231_
8 4778 Packing cartridge adapter 1

9 7002-005NC050AfSocket head bolt 4
10 3 816
11 4270 Oil wiper ring cup 1

12 4273 -1

13 4271 Purge packing cup 3
14 4779 Cup spacer 1
15 17 3 2 Oil deflector ring 1
16 2-228_
17 4272 Packing spacer 2
18 3 811 Back-up ring 5

a, d

a, d

a, d

c

O-ring 2

O-ring 3

O-ring 1

Oil wiper ring set (two per set) 1

Biased segmented packing set
(tangent, tangent - includes 1 TT pair, 1
iron backup rings, and 6 springs)

a, d

O-ring 2

Ref

Part No. Description Qty.

No.

19 3 814

20

b

38 17 Packing cup 5

a, d

2-036_

Segmented packing ring (tangent,
tangent - pair)

O-ring 8

2

21 4776 Packing cartridge body 1

22 3810

b

Segmented packing ring (radial,
tangent - pair)

3

23 3815 Pressure breaker ring 1
24 5321 Packing cartridge cap 1
25 7002-010NC075AfSocket head bolt 4
26 4273-1X 2 Packing set 1

27A

1

4273

27B

a

See detail for O-ring location

b

Direction of packing is impor tant. See packing assembly page for details.

c

Direction of oil wiper ring set is important. See packing assembly
page for details.

d

For O-ring material codes, see O-ring chart.

e

Registered trademarks of the DuPont company.

f

Apply a small amount of loctite #272 to the circumference of the threads.

Biased segmented packing set
(tangent, tangent - includes 2 TT pairs,
2 iron backup rings, and 12 springs)

1

69

Appendix D—Packing Assembly Details for THG600 Series (T-Style)

6" and 8" Pad Packing Specification

1

2

3

4

65 ft. lb.

4

Middle packing

NOTE: Cover the end of the piston rod with packing cone
(part # 3905) before installing packing. For lubricated
compressors, the lubricating quill located on the adapter
must be removed before packing cartridge can be removed.

1

6

65 ft. lb.

3

5

4

7

8

4

O-ring locations

1

5

6" & 8" adapter

10

11

12

TTs

25

65 ft. lb.

16

18

19

17

TT

25

O-ring Code

20

26A

TTs

13

5

21

3

A Buna-N

B Neoprene

D Viton

®e

®e

E PTFE

K Kalrez

®e

TT = Tangent, tangent packing
TTs = Biased tangent, tangent

with springs on cylinder side

sTT = Biased tangent, tangent with

springs on crankcase side

RT = Radial, tangent packing

Crankcase side

Packing Assembly Bill of Materials for 6" and 8" Pad

Ref

Part No. Description Qty.

No.

1 2-253_
2 4772 Distance piece 1
3 7001-050NC150A Hex head bolt (1/2" - 13 x 1-1/2") 24
4 3442 Pipe plug (1/4") Varies
5 2-236_

6

7 2-231_
8 4778 Packing cartridge adapter 1

9 7002-050NC150AfSocket head bolt 4
10 3 816
11 4270 Oil wiper ring cup 1

12 4273 -1

13 4271 Purge packing cup 3
14 4779 Cup spacer 1
15 17 3 2 Oil deflector ring 1
16 3 817 Packing cup 5

a, d

a, d

O-ring 2

O-ring 2
35 2 9 -1 Adapter (6") 1
36 73-1 Adapter (8") 1

a, d

c

O-ring 1

Oil wiper ring set (two per set) 1

Biased segmented packing set

(tangent, tangent - includes 1 TT pair,

1 iron backup rings, and 6 springs)

1

13

14

Inner oil wiper

9

ring set

17

TT

16

Inner packing

25

RT

18

22

16

18

22

RT

16

18

22

23

13

24

sTT

26B

20

19

18

Outer packing

Cylinder side

Ref

Part No. Description Qty.

No.

17 3814

b

Segmented packing ring (tangent,

tangent - pair)
18 3 811 Back-up ring 4
19 4272 Packing spacer 2
20 2-228 _

a, d

O-ring 2
21 4777 Packing cartridge body 1

22 3810

b

Segmented packing ring (radial,

tangent - pair)
23 4267 Packing cartridge cap 1
24 7002-031NC175AfSocket head bolt 4
25 4273-1X1 Packing set 1

26A

4273

26B

a

See detail for O-ring location

b

Direction of packing is impor tant. See packing assembly page for details.

c

Direction of oil wiper ring set is important. See packing assembly
page for details.

d

For O-ring material codes, see O-ring chart.

e

Registered trademarks of the DuPont company.

f

Apply a small amount of loctite #272 to the circumference of the threads.

Biased segmented packing set

(tangent, tangent - includes 2 TT pairs,

2 iron backup rings, and 12 springs)

15

RT

16

2

3

1

70

20

Appendix D—Packing Assembly Details for THG600 Series (T-Style)

6" and 8" Purge Packing Specification

1

2

3

4

65 ft. lb.

4

Middle packing

13

sTT

16

17

18

TT

19

20

5

26A

25

O-ring Code

A Buna-N

B Neoprene

D Viton

®e

®e

E PTFE

K Kalrez

®e

TT = Tangent, tangent packing
TTs = Biased tangent, tangent

with springs on cylinder side

sTT = Biased tangent, tangent with

springs on crankcase side

RT = Radial, tangent packing

Crankcase side

Packing Assembly Bill of Materials for 6" and 8" Purge

Ref

Part No. Description Qty.

No.

1 2-253_
2 4772 Distance piece 1
3 7001-050NC150A Hex head bolt (1/2" - 13 x 1-1/2") 24
4 3442 Pipe plug (1/4") Varies
5 2-236_

6

7 2-231_
8 4778 Packing cartridge adapter 1

9 7002-050NC150AfSocket head bolt 4
10 3 816
11 4270 Oil wiper ring cup 1

12 4273 -1

13 4271 Purge packing cup 3
14 4779 Cup spacer 1
15 17 3 2 Oil deflector ring 1
16 2-228_

a, d

a, d

O-ring 2

O-ring 2
35 2 9 -1 Adapter (6") 1
36 73-1 Adapter (8") 1

a, d

c

O-ring 1

Oil wiper ring set (two per set) 1

Biased segmented packing set
(tangent, tangent - includes 1 TT pair, 1
iron backup rings, and 6 springs)

a, d

O-ring 2

NOTE: Cover the end of the piston rod with packing cone
(part # 3905) before installing packing. For lubricated
compressors, the lubricating quill located on the adapter
must be removed before packing cartridge can be removed.

1

65 ft. lb.

6

3

5

4

7

4

65 ft. lb.

3

Inner oil wiper

9

sTT

26B

13

21

23

24

Ref

Part No. Description Qty.

No.

16

17

Outer packing

17 4272 Packing spacer 2
18 3 811 Back-up ring 4

19 3 814

b

20 3817 Packing cup 5
21 4777 Packing cartridge body 1

22 3810

b

23 4267 Packing cartridge cap 1
24 7002-031NC175AfSocket head bolt 4
25 4273-1X1 Packing set 1

26A

4273

1

26B

a

See detail for O-ring location

b

Direction of packing is impor tant. See packing assembly page for details.

c

Direction of oil wiper ring set is important. See packing assembly
page for details.

d

For O-ring material codes, see O-ring chart.

e

Registered trademarks of the DuPont company.

f

Apply a small amount of loctite #272 to the circumference of the threads.

O-ring locations

1

8

10

5

6" & 8" adapter

TTs

11

12

25

13

ring set

Inner packing

20

18

25

22

RT

20

18

RT

22

18

19

TT

20

Cylinder side

Segmented packing ring (tangent,
tangent - pair)

Segmented packing ring (radial,
tangent - pair)

Biased segmented packing set
(tangent, tangent - includes 2 TT pairs,
2 iron backup rings, and 12 springs)

14

18

22

15

RT

2

3

1

71

Appendix D—Packing Assembly Details for THG600 Series (T-Style)

Inner Oil Wiper Ring Set

Pad or Purge Specification

Crankcase

Side

Inner Packing Details

Pad or Purge Specification

Biased Segmented Packing Set (Tangent, Tangent with springs toward cylinder—TTs)

Crankcase

Side

Radial Cut

(with pin)

Inner Oil Wiper Ring Set (Radial, Radial)

Align pin with

hole on backside.

Radial Cut

(without pin)

Part number 3816

Cylinder

Side

Wiper Ring Cup

(not included)

Part number 4273

Cylinder

Side

Tangent Cut

(with pin)

Align pin with

hole on backside.

Tangent Cut

(without pin)

Backup Ring

with 6 Springs

Purge Packing Cup

(not included)

72

Appendix D—Packing Assembly Details for THG600 Series (T-Style)

Middle Packing Details

1. Pad Specification

Crankcase

Side

2. Pad Specification

Crankcase

Side

Segmented Packing Set (Tangent, Tangent)

Packing Cup

(not included)

Tangent Cut

(with pin)

Align pin with

hole on backside.

Tangent Cut
(without pin)

Back-up Ring

(not included)

Biased Segmented Packing Set (Tangent, Tangent with springs toward cylinder—TTs)

Part number 3814

Cylinder

Side

Part number 4273

Cylinder

Side

Purge Packing Spacer

(not included)

3. Purge Specification

Crankcase

Side

4. Purge Specification

Crankcase

Side

O-ring

(not included)

Tangent Cut

(with pin)

Align pin with

hole on backside.

Tangent Cut
(without pin)

Backup Ring

with 6 Springs

Packing Cup

(not included)

Biased Segmented Packing Set (Tangent, Tangent with springs toward crankcase—TTs)

Packing Cup

(not included)

Backup Ring

with 6 Springs

Tangent Cut

(with pin)

Align pin with

hole on backside.

Tangent Cut

(without pin)

O-ring

(not included)

Segmented Packing Set (Tangent, Tangent)

Part number 4273

Cylinder

Side

Purge Packing Spacer

(not included)

Part number 3814

Cylinder

Side

Backup Ring

(not included)

Tangent Cut

(with pin)

Align pin with

hole on backside.

73

Tangent Cut
(without pin)

Packing Cup

(not included)

Appendix D—Packing Assembly Details for THG600 Series (T-Style)

Outer Packing Details

1. Purge Specification

Crankcase

Side

Purge Packing Cup

2. Pad Specification

Crankcase

Side

Biased Segmented Packing Set (Tangent, Tangent with springs toward crankcase—sTT)

(not included)

Backup Ring

with 6 Springs

Tangent Cut

(with pin)

Align pin with

hole on backside.

Tangent Cut
(without pin)

O-ring

(not included)

Segmented Packing Set (Tangent, Tangent)

Part number 4273

Cylinder

Side

Purge Packing Spacer

(not included)

Part number 3814

Cylinder

Side

Back-up Ring
(not included)

Tangent Cut

(with pin)

Align pin with

hole on backside.

Tangent Cut
(without pin)

3. Pad Specification
Segmented Packing Set (Radial, Tangent)

Crankcase

Side

Back-up Ring
(not included)

Tangent Cut

(with pin)

Align pin with

hole on backside.

Radial Cut

(without pin)

4. Solid Pressure Breaker Ring (applies to 2.75", 3.25", 4", and 5" cylinder sizes only)

Crankcase

Side

Packing Cup

(not included)

Part number 3810

Cylinder

Side

Packing Cup

(not included)

Part number 3815

Cylinder

Side

Breaker Ring

Packing Cup

(not included)

74

75

Appendix D—Connecting Rod Assembly Details for HG600/THG600 Series

2

3

3

1

4

5

6

7

4

Connecting Rod Assembly Bill of Materials

Ref

Part No. Description Q ty.

No.

1. 3536-X Connecting rod assembly 1

2. 172 7

3. 3542 Connecting rod bearing (pair) 1

4. 17 2 6 Connecting rod bolt 4

5. 3 5 41

6. 3590 Wrist pin retainer ring 2

7. 3544-X1 Crosshead assembly 1

8. 3540 Wrist pin 1

9. 3905 Packing cone 1

a

Must be rebored & honed after replacing (1.1256"/1.1252" diameter).

b

Torque connecting rod nuts to 40 ft. lb.

b

a

Connecting rod nut 4

Wrist pin bushing 1

8

6

9

76

Appendix D—Single Cylinder Assembly Details for HG600/THG600 Series

1

2

4

b

5

3

Crankcase

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

a

6

Cylinder Diameter

Ref.

Part Number Description

No.

2.75" 3. 25" 4" 5" 6" 6" 8" 8"

Piston Material

Steel Steel Steel Aluminum Iron Aluminum Iron

Quantity per Compressor

1. 3544-X2 Crosshead assembly 1 1 1 1 1 1 1 1

2. 3864 Balance weight – – 1 1 – 1 1 3

3. 3861 Crosshead cap 1 1 1 1 1 1 1 1

4. 2-253_

c

O-ring 1 1 1 1 1 1 1 1

5. 7001-050NC250Ab1/2 - 13X1-1/2" hex head bolt 8 8 8 8 8 8 8 8

6. 70 01-043NC150Aa716 - 14 x 2-1/2" hex head bolt – – 3 3 – 3 3 9

7. 3812 Loctite 620 tube 1 1 1 1 1 1 1 1

a

O-ring Code

A Buna-N

B Neoprene

D Viton

®d

E PTFE

K Kalrez

®d

®d

Use Loctite retaining compound 620 and torque bolts to 40 ft. lb. when assembling.

b

Torque to 65 ft. lb.

c

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

d

Registered trademarks of the DuPont company.

Note: 3861-X1 single cylinder balance kit includes: (1) 3544-X2, (3) 3864, (1) 3861, (1) 2-253A, (9)
7001-043NC250A, (1) 3812

77

Appendix D—Crankcase Assembly Details for HG600/THG600 Series

Breather cap and ball details

4

Cross section

of bearing carrier shows
lubrication tubing used to
lubricate the crossheads.

Note:
Oil transfer
tubing mounts
inside the
crankcase.

33

34

9

5

3

2

30

34

1

32

8

7

6

10

11

12

13

8

35

34

31

32

30

23

29

28

27

(see lubricator assembly details for more information)

25

26

Optional lubricator available

13

24

33

22

21

20

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

19

14

18

17

16

15

14

78

Appendix D—Crankcase Assembly Details for HG600/THG600 Series

Crankcase Assembly Bill of Materials

Ref

Part No. Description Q ty.

No.

3538 Crankcase 1

3538 -X1

1.

353 8-X2

2. 148 3 Lock pin 1

3. 2796 Breather ball 1

4. 2 -111 A O-ring 1

1279 -X

5.
1279 Breather cap 1

6. 3606 Nameplate 1

7. 7003-004DR019B Drive screw 4

8. 3567 Eyebolt 2

9. 7001-025NC050A Hex head bolt (1/4" - 20 x 1/2") 10

10. 3581 Crankcase inspection plate 1

11. 3582 Inspection plate gasket 1

12. 3583 -X1 Oil bayonet assembly with O-ring 1

13. 2-116 A O-ring 2

14. 7003-025NC037E Phillips head (1/4" x 3/8") 8

15. 3946 Lubricator access cover 1

16. 3947 Lubricator access cover gasket 1

17. 3874 Access cover gasket 1

18. 3875 Access cover 1

Crankcase assembly - HG600M
(without external lubricator)

Crankcase assembly - HG600L
(with external lubricator)

Breather cap assembly
(including O-ring)

1

1

1

Ref

Part No. Description Q ty.

No.

19. 3289 Pipe plug (1/4 NPT flush seal) 1

20. 3823 Pipe plug (3/8" NPT flush seal) 2

21. 3443 Pipe plug (1/2" NPT steel) 1

22. 1275 Oil filter screen 1

23. 1276 Filter screen washer 1

24. 1281 Filter screen screw gasket 1

25. 128 0 Filter screw 1

26. 104 4 Bushing (1/4" NPT x 1/8" NPT) 1

27. 13 02 Oil pressure gauge 1

28. 7001-037NC100A Hex head bolt (3/8 - 16 x 1") 8

29. 3220 -2 X1 Bearing carrier assembly 1

30. R3387 1/4" plastic tubing (specify length) –

31. 3652 Union tee (1/4" T brass) 1

32. R2886 1/4" copper tube (specify length) –

33. 143 5 Tee (1/8" P x 1/4" T x 1/4" T brass) 2

34. 139 9 Male elbow (1/8" P x 1/4" T brass) 3

35. 3643 Pipe plug (1" NPT steel) 1

79

Appendix D—Bearing Carrier Assembly Details for HG600/THG600 Series

Align pin with slot
on pump shaft
adapter.

27

28

6

7

8

9

1

3

2

25

26

5

4

19

21

Align slot with
the pin at the
end of the

22

23

24

crankshaft.

17

12

11

10

20

16

Backside of

bearing carrier

13

14

15

28

18

Make sure oil-passage

hole is not blocked

by the gasket.

Oil

lubrication

tubing

19

29

2

30

Cross section

of bearing carrier shows

lubrication tubing used to lubricate

Backside of

oil filter adapter

31

Oil suction

Note:

When using an external oil cooler, this threaded hole must be plugged using the 1/8″ NPT threaded pipe plug (part number 2590) included

with the 3870-X1 external oil cooler assembly. Otherwise, the oil will not flow through the oil cooler. See external oil cooler assembly details
near the end of this manual.

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

the crossheads.

80

Appendix D—Bearing Carrier Assembly Details for HG600/THG600 Series

Crankcase Assembly Bill of Materials

Ref

Part No. Description Q ty.

No.

1. 1515 -X Closure cap assembly 1

2. 7001-025NC050A Hex head bolt (1/4" - 20 x 1/2") 11

3. 1515 Closure cap 1

4. 1516 Closure body 1

5. 2-218 A O-ring 2

6. 1290 Relief valve adjusting screw 1

7. 2- 0 11A O-ring 1

8. 1291 Adjusting screw locknut 1

9. 1292 Relief valve spring 1

10. 1293 Relief valve ball 1

3220-2 Bearing carrier 1

11.
3220-2X Bearing carrier assembly 1

12. 2131 Bearing carrier gasket 1

13. 173 6 Bearing cup 1

14. 2961-X Air release valve assembly 1

16. 7001-037NC100A Hex head bolt (3/8" - 16 x 1") 8

17. 104 4 Bushing (1/8" x 1/4" NPT) 1

18. 130 2 Oil pressure gauge 1

Ref

Part No. Description Q ty.

No.

19. 1629 Pipe plug (1/16" NPT flush seal) 2

2805 Pump shaft bushing 1

20.
2805-X Pump shaft bushing with tag 1

21. 2-112 A O-ring 1

22. 3219 Pump shaft adapter 1

23. 2852 Oil pump spring 1

24. 2851 Spring guide 1

25. 284 9 -1X

26. 2-228A O-ring 1

27. 4222-X

28. 3289 Pipe plug (1/4" NPT fl. Seal) 2

29. 4222 Oil filter adapter 1

30. 4225 Filter 1

31. 2798

a

Caution: To avoid damage during assembly, refer to Important
Instructions IE400.

a

a

Oil pump assembly 1

Oil filter adapter assembly
(includes pin)

Oil filter adapter pin (included
with 4222-X

1

1

81

Appendix D—Crankshaft Assembly Details for HG600/THG600 Series

15

14

13

12

1

10

7

2

3

4

11

9

Crankcase

(see crankcase assembly for more information)

16

5

6

7

8

Crankshaft Assembly Bill of Materials

Ref

Part No. Description Qt y.

No.

1. 35 37-X1 Crankshaft assembly 1

2. 213 5 Rotor drive pin 1

3. 1737 Bearing cone 1

4. 1736 Bearing cup 1

5. 3638 Spacer 1

6. 3635 Drive sprocket 1

7. 1287 Crankshaft orifice 2

8. 2933 Link pin 1

9. 3503 Flywheel key 1

10. 3537 Crankshaft 1

11. 3580 Bearing cone 1

12. 3579 Bearing cup 1

3589 Bearing adjustment shim (0.005") As req.

13.

35 8 9 -1 Bearing adjustment shim (0.007") As req.

3589-2 Bearing adjustment shim (0.020") As req.

14. 3539 Bearing cover 1

15. 7001-037NC100A Hex head bolt (3/8" - 16 x 1") 4

16. 3526 Oil seal 1

82

Appendix D—Lubricator Assembly Details for HG600/THG600 Series

9

8

7

6

Single cylinder divider

26

b

25

a

21

a

22

7

11

12

13

14

23

15

16

14

7

a

21

a

22

5

24

c

4

10

3

9

8

7

2

d

1

Lubricator Assembly Bill of Materials

Ref

Part No. Description Q ty.

No.

1. 3639-X

2. 3634 Spring clip connecting link 1

3. 3633 Chain 1

4. 1399-1 Elbow (1/8" P x 1/4" T steel) 2

5. 3658-X

6. 14 3 4 -1

7. R2920 1/4" steel tubing (specify length)

8. 3651-1

9. 3656 Quill-check valve 2

10. 1670 -1

11. 3389 Cable tie

12. 3655 Filter 1

13. 104 4

14. 3607

15. 3654 Blow out disc 1

d

Lubricator assembly 1

Divider valve assembly (two
cylinders)

Straight connection (1/8" P x
1/4" T steel)

Female elbow (1/4" P x 1/4" T
steel)

Straight connection (1/4" P x 1/4"
T steel)

Bushing (1/4" NPT x 1/8" NPT
steel)

Nipple (1/8" NPT x 1-1/2",
schedule 80)

1

3

As

req.

2

1

As

req.

1

2

20

19

27

Ref

Part No. Description Q ty.

No.

18

17

16. 2609 Tee (1/8" NPT steel) 1

17. 7101-037NC01A Hex nut (3/8" - 16) 4

18. 72 0 6 -0 37A Lockwasher (3/8") 4

19. 3636 Driven sprocket 1

20. 7006-025NC100A

21. 16 6 9 -1

22. 14 49 -1X

a

a

Set screw (1/4" - 20 x 1" socket
head)

Elbow (1/4" P x 1/4" T steel) 2

Quill assembly 2

23. 2010 Flange gasket 1

24. 7002-010NC200A Socket head (10-24 x 2") 4

25. 2709

26. 3668 -X

b

c

Back check valve 2

Divider valve assembly (single
cylinder)

27. 7 201- 0 37A Washer (3/8") 4

a

Except 2-3/4” cylinder

b

2-3/4” cylinder only

c

Single cylinder units only

d

Optional

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

1

1

83

Appendix D—3870-X1 External Oil Cooler Assembly Details for
HG600/THG600 Series

5

1

Flow

6

(Inlet)

3

5

2

4 (Outlet)

3

11

9

10

Oil lter

Oil lter adapter

7

Oil pressure

guage

10

9

3870-X1 External Oil Cooler Assembly Bill of Materials

Ref

Part No. Description Qty.

No.

1. 3870 External oil cooler 1

2. 7001-037NC 075A Hex HD 3/8-16 X 3/4", GR 5 4

3. 3688 External oil cooler bracket 2

4. 2817 Decal (out) 1

5. 2322-1

6. 2814 Decal (in) 1

7. R 3433 Tube - 1/2 X .035 SAE J525 Specify

Tube elbow - 1/2T X 1/2P
steel

2

8

Ref

Part No. Description Qty.

No.

8. 2021 Nipple - 1/4 X 2-1/2", SCH 80 1

9. 3912-1 Tube str conn - 1/2T X 1/4P ST 2

10. 2063 Tee - 1/4" NPT 2000 LB A105 2

11. 2228 Nipple - 1/4" x 1-1/4", SCH 80 1

Not

shown

a

Must be installed in the center hole on the backside of the oil filter
adapter. See reference #29 on page 80 for details on the backside of
the oil filter adapter (part #4222).

2590

a

Pipe plug - 1/8 NPT flush 1

84

Appendix D—Flywheel Assembly Details for HG600/THG600 Series

Rear view

Flywheel Assembly Bill of Materials

Assembly
Number

3852-X

3852

H J - 2.125

Assembly Name

Flywheel assembly
(flywheel, hub, and three
bolts and washers)

Flywheel: 21.2" O.D., 5
groove

Hub with three bolts and
lockwashers

Front view

85

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.

February 2012