Installation, Operation & Maintenance Manual: Liquid Transfer-Vapor Recovery Compressors

IE101H
Installation, Operation
& Maintenance Manual
Liquid Transfer-Vapor Recovery Compressors
Warning: (1) Periodic inspection and maintenance of Corken products is essential. (2) Inspection, maintenance and installation of Corken
products must be made only by experienced, trained and 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.
Downloaded from www.Manualslib.com manuals search engine

Warning
Install, use and maintain this equipment according to Corken, Inc. instructions and all applicable federal, state, local
laws and codes, and NFPA Pamphlet 58 for LP-Gas or ANSI K61.1-1989 for Anhydrous Ammonia. Periodic inspection
and maintenance is essential.
Corken One Year Limited Warranty

Corken, Inc. warrants that its products will be free from defects in material and workmanship for a period of 12
months following date of purchase from Corken. Corken products which fail within the warranty period due to defects
in material or workmanship will be repaired or replaced at Corken’s option, when returned freight prepaid to Corken,
Inc., 3805 N.W. 36th Street, Oklahoma City, Oklahoma 73112.
Parts subject to wear or abuse, such as mechanical seals, blades, piston rings, valves, and packing, and other
parts showing signs of abuse are not covered by this limited warranty. Also, equipment, parts and accessories not
manufactured by Corken but furnished with Corken products are not covered by this limited warranty and purchaser
must look to the original manufacturer’s warranty, if any. This limited warranty is void if the Corken product has been
altered or repaired without the consent of Corken.
All implied warranties, including any implied warranty of merchantability or fitness

for a particular purpose, are expressly negated to the extent permitted by law and
shall in no event extend beyond the expressed warranty period.
Corken disclaims any liability for consequential damages due to breach of any written or implied warranty on Corken
products. Transfer of toxic, dangerous, flammable or explosive substances using Corken products is at the user’s
risk. Such substances should be handled by experienced, trained personnel in compliance with governmental and
industrial safety standards.
Contacting The Factory

For your convenience, the model number and serial number are given on the compressor nameplate. Space is
provided below for you to keep a written record of this information.
Always include the model number and serial number when ordering parts.
Model No.
Serial No.
Date Purchased
Date Installed
Purchased From
Installed By
Important Note to Customers!

CORKEN, INC. does not recommend ordering parts from general descriptions in this manual. To minimize
the possibility of receiving incorrect parts for your machine, Corken strongly recommends you order parts
according to part numbers in the Corken Service Manual and/or Installation, Operation, & Maintenance
(IOM) Manual. If you do not have the appropriate service manual pages, call or write Corken with model
number and serial number from the nameplate on your compressor.
2
Table of Contents
Chapter 1—introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
1.1 Liquid Transfer by Vapor Differential Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Residual Vapor Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Compressor Construction Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 2—Installing your corken compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
2.1 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Foundation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Liquid Traps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 Driver Installation / Flywheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6 Crankcase Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.7 Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.8 Truck Mounted Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.9 Shutdown/Alarm Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 3—Starting up your corken compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 14
3.1 Inspection After Extended Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Flywheel and V-belt Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Crankcase Oil Pressure Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Startup Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chapter 4—Routine Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 16
Chapter 5—Routine Service and Repair Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 17
5.1 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2 Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3 Piston Rings and Piston Ring Expanders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.4 Pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.5 Piston Rod Packing Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.6 Cylinder and Packing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.7 Bearing Replacement for Crankcase and Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.7.1 Wrist Pin Bushing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.7.2 Replacing Connecting Rod Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.7.3 Replacing Roller Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.8 Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.9 Servicing the Four-Way Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Chapter 6—Extended Storage Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 25
Appendices
A. Repair Kits and Gasket Sets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–27
B. Model Number and Mounting Identification Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28–29
C. Operating and Material Specifications, Bolt Torque Values, Clearance and Dimensions. . . . . . . . . . . . . . 30–35
D. Compressor Selection
Mounting Selections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Butane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Propane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Ammonia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
E. Outline Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–50
F. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
G. Model 91 and F91 Parts Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52–59
H. Model 291 and F291 Parts Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60–67
I. Model 490, 491, and F491 Parts Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68–75
J. Model 691 and F691 Parts Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76–83
K. Model D891 Parts Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84–93
3
Chapter 1—Introduction
Threaded and ANSI flanges:
Compressors are available in either threaded NPT,
ANSI, or DIN flanged connections.
High-efficiency valves:
Corken valves offer quiet operation and high
durability in oil-free gas applications. Specially
designed suction valves which tolerate small
amounts of condensate are used in liquid transfer-
vapor recovery compressors.
O-ring head gaskets:

Easy to install O-ring head gaskets providing highly
reliable seals.
Ductile iron construction:

All cylinders and heads are ductile iron for maximum
thermal shock endurance.
Self-lubricating PTFE piston rings:

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

Simple piston design allows end clearance to be
precisely set to provide maximum efficiency and
long life.
Self-lubricating piston rod seals:

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

Impregnated nitride coating provides superior
corrosion and wear resistance.
Nameplate:
Serves as packing adjusting screw cover (see
figure 1.1A).
Cast iron crossheads:

Durable cast iron crossheads provide superior
resistance to corrosion and galling.
Pressure-lubricated crankcase with filter:

Self-reversing oil pump ensures proper lubrication
regardless of directional rotation to main and
connecting rod bearings. Standard 10-micron filter
ensures long-lasting bearing life (not available on
Model 91).
Construction Details—Model F291 Compressor
4
this by withdrawing vapors from the storage tank,
compressing them and then discharging into the tank
to be unloaded. This procedure slightly decreases the
storage tank pressure and increases the pressure in
the other tank, thereby causing the liquid to flow.
The process of compressing the gas also increases the

temperature, which aids in increasing the pressure in the
tank being unloaded.
Figure 1.1A: Typical Nameplate
(Also Serves as the Packing Adjusting Screw Cover)
1.2 Residual Vapor Recovery

1.1 Liquid Transfer By Vapor The principle of residual vapor recovery is just the
Differential Pressure opposite of liquid transfer. After the liquid has been
transferred, the four-way control valve (or alternate
Corken LPG/NH 3 compressors are designed to valve manifolding) is reversed so that the vapors are
transfer liquefied gases such as butane/propane drawn from the tank just unloaded and discharged into
mixtures (liquefied petroleum gas or LPG) and the receiving tank. Always discharge the recovered
Anhydrous Ammonia (NH 3) from one tank to another. vapors into the liquid section of the receiving tank.
Liquefied gases such as LPG & NH 3 are stored in This will allow the hot, compressed vapors to condense,
closed containers where both the liquid and vapor preventing an undesirable increase in tank pressure (see
phases are present. figure 1.2A).
There is a piping connection between the vapor Residual vapor recovery is an essential part of the value
sections of the storage tank and the tank being of a compressor. There is an economical limit to the
unloaded, and there is a similar connection between the amount of vapors that should be recovered, however.
liquid sections of the two tanks. If the connections are
opened, the liquid will seek its own level and then flow When the cost of operation equals the price of the product
will stop; however, by creating a pressure in the tank being recovered, the operation should be stopped.
being unloaded which is high enough to overcome pipe For most cases in LP Gas and Anhydrous Ammonia
friction and any static elevation difference between the services, this point is reached in the summer when the
tanks, all the liquid will be forced into the storage tank compressor inlet pressure is 40 to 50 psig (3.8 to 4.5
(see figure 1.1B). The gas compressor accomplishes bars). A good rule of thumb is not to operate beyond
Compressor increases
pressure in tank car by
adding vapor
Vapor Line
Pressure difference between

Vapor Line
tanks causes liquid to flow out of

the tank car into the storage tank
Compressor reduces
pressure in storage tank
by removing vapor
Four Way Valve Position 1 Liquid Line

Figure 1.1B: Liquid transfer by vapor differential pressure
5
Vapor Line
Liquid line is valved closed

during vapor recovery.
Removing vapor from Vapor is
Vapor Line
tank causes liquid heel bubbled
to boil into vapor through liquid to
help cool and
recondense it
Liquid Heel
Four Way Valve Position 2
Figure 1.2A: Residual Vapor Recovery
the point at which the inlet pressure is one-fourth the

discharge pressure. Some liquids are so expensive that
further recovery may be profitable, but care should be
taken that the ratio of absolute discharge pressure to
absolute inlet pressure never exceeds 7 to 1. Further
excavation of very high value products would require a
Corken two-stage gas compressor.
Invariably, there is some liquid remaining in the tank

after the liquid transfer operation. This liquid “heel”
must be vaporized before it can be recovered, so do not
expect the pressure to drop immediately. Actually, more
vapor will be recovered during the first few minutes
while this liquid is being vaporized than that during the
same period of time later in the operation. Remember
that more than half of the economically recoverable
product is usually recovered during the first hour of
operation on properly sized equipment.
1.3 Compressor
Construction Features Figure 1.3A: 107-Style Compressor Mounting
The Corken liquid transfer-vapor recovery compressor
is a vertical single-stage, single-acting reciprocating Corken gas compressors are mounted on oil lubricated
compressor designed to handle flammable gases like LPG crankcases that remain at atmospheric pressure.
and toxic gases such as ammonia. Corken compressors Crankshafts are supported by heavy-duty roller bearings
can handle these potentially dangerous gases because and the connecting rods ride the crankshaft on journal
the LPG/NH3 is confined in the compression chamber bearings. With the exception of the small size model 91
and isolated from the crankcase and the atmosphere. compressor, all compressor crankcases are lubricated by
A typical liquid transfer-vapor recovery compressor an automotive type oil pressure system. An automatically
package is shown in figure 1.3A. reversible gear type oil pump circulates oil through
6
passages in the crankshaft and connection rod to
lubricate the journal bearings and wrist pins (see figure
1.3B). Sturdy iron crossheads transmit reciprocating
motion to the piston.
Corken’s automatically reversible oil pump design

allows the machine to function smoothly in either
direction of rotation.
Corken compressors use iron pistons that are locked

to the piston rod. The standard piston ring material is a
glass-filled PTFE polymer specially formulated for non-
lubricated services. Piston ring expanders are placed
behind the rings to ensure that the piston rings seal
tightly against the cylinder wall.
Piston rod packing is used to seal the gas in the

compression chamber and prevent crankcase oil from
Figure 1.3C: Compressor Sealing System
entering the compressor cylinder. The packing consists
of several PTFE V-rings sandwiched between a male and
female packing ring and held in place by a spring (see
figure 1.3C).
The typical Corken compressor valve consists of a seat, Suction Valve

bumper, one or more spring/s and one or more valve/s Spec 3
discs or plates as shown in figure 1.3D. Special heat- Gasket
treated alloys are utilized to prolong life of the valve in
punishing non-lubricated services. The valve opens
Adjusting Discharge Valve
whenever the pressure on the seat side exceeds the screw All Specs
pressure on the spring side.
Relief ball spring
Gasket
Relief ball
Bolt
Suction valve
seat
Discharge valve
Valve plate bumper
Valve spring
Spacers
Washer
Washer
Valve spring Spacers
Suction valve Valve plate

post
Suction valve Discharge valve
bumper seat
Valve gasket Valve gasket
Figure 1.3D: Suction and Discharge Valves
Figure 1.3B: Pressure Lubrication System

(Not Available on Model 91)
7
Chapter 2—Installing Your Corken Compressor
2.1 Location 2” Min.
HEx Nut
Compressor
Washer Baseplate
all sides
NOTE: Compressor must be installed in a well
ventilated area. Grout Beneath
base
Corken compressors are designed and manufactured for
Concrete foundation
outdoor duty. For applications where the compressor will be with reinforcements
subjected to extreme conditions for extended periods such should be used on all
models
as corrosive environments, arctic conditions, etc., consult
8” Min.
Corken. Check local safety regulations and building codes 1/2” “J” Bolts
to assure installation will meet local safety standards. 12” Long
Corken compressors handling toxic or flammable gases such Note:

as LPG/NH3 should be located outdoors. A minimum of 18 Locate “J” Bolts Per
inches (45 cm) clearance between the compressor and the compressor outline
dimension drawings.
nearest wall is advised to make it accessible from all sides
and to provide unrestricted air flow for adequate cooling. Figure 2.2A: Recommended Foundation Details
for Corken Compressors 91 - 691
Noise. Corken vertical compressors sizes model 91
smooth operation of the compressor. Improper piping
through 891 should not exceed an 85 DBA noise level
installation will result in undesirable transmission of
when properly installed.
compressor vibration to the piping.
2.2 Foundation DO NOT SUPPORT PIPING WITH THE COMPRESSOR.

Unsupported piping is the most frequent cause of
Proper foundations are essential for a smooth running vibration of the pipe. The best method to minimize
compression system. Corken recommends the compressor transmission of vibration from the compressor to the
be attached to a concrete slab at least 8 in. thick with a 2 piping is to use flexible connectors (see figure 2.3A).
in. skirt around the circumference of the baseplate. The
baseplate should be securely anchored into the foundation Pipe must be adequately sized to prevent excessive pressure
by 1/2 in. diameter “J” bolts 12 in. long. Four bolts should drop between the suction source and the compressor as
be used for models 91, 291, and 491. Six bolts should well as between the compressor and the final discharge
be used for model 691. The total mass of the foundation point. In most cases, piping should be at least the same
should be approximately twice the weight of the compressor diameter as the suction nozzle on the compressor. Typically,
system (compressor, baseplate, motor, etc.). LPG/NH3 liquid transfer systems should be designed to
limit pressure drops to 20 psi (1.3 bar). Appendix D shows
After leveling and bolting down baseplate, the volume recommended pipe sizes for each compressor for typical
beneath the channel iron baseplate must be grouted LPG/NH3 installations.
to prevent flexing of the top portion
of the baseplate and the “J” bolt that
extends beyond the foundation. The
grout also improves the dampening Flexible connections Flexible connections
capabilities of the foundation by
creating a solid interface between the
compressor and foundation.
Pipe support
On some of the longer baseplates, such Pipe support
as with the 691–107, a 3 in. hole can be Baseplate should be
a maximum of 4″ high
cut in the baseplate for filling the middle Grouted
section of the baseplate with grout. baseplate
See ED410 (Compressor Foundation Concrete Ground level

Design). foundation
2.3 Piping
Proper piping design and installation Figure 2.3A: On –107 mountings, the flexible
is as important as the foundation is to connectors should be located near the four way valve.
8
Care must be taken if a restrictive device such as a valve, A tank car unloading riser should have two liquid hoses
pressure regulator, or back-check valve is to be installed connected to the car liquid valves. If only one liquid hose
in the compressor’s suction line. The suction line volume is used, the transfer rate will be slower and there is a good
between the restrictive device and the compressor possibility that the car’s excess flow valve may close.
suction nozzle must be at least ten times the swept
cylinder volume. Since the heat of compression plays an important part in
rapid liquid transfer, the vapor line from the compressor to
107 style compressors are usually connected using a five- the tank car or other unloading container should be buried
valve (figure 2.3B) or three-valve manifold (figure 2.3C). or insulated to prevent the loss of heat and the compressor
The five-valve manifold allows the storage tank to be should be located as near as possible to the tank being
both loaded and unloaded. The three-valve manifold only emptied. In extremely cold climates, if the line from the
allows the storage tank to be loaded. Adequate sizing of storage tank to the compressor is over 15 feet (4.6 meters)
the liquid and vapor lines is essential to limit the pressure long, it should be insulated to lessen the possibility of
drop in the system to a reasonable level (20 psi or less). vapors condensing as they flow to the compressor. The
vapor recovery discharge line is better not insulated.
The line size helps determine the plant capacity almost Placing the compressor as close as possible to the tank
as much as the size of the compressor, and liquid line being unloaded will minimize heat loss from the discharge
sizes are a bigger factor than vapor lines. If the pressure line for the best liquid transfer rate.
gauges on the head indicate more than a 15 to 20 psi
(2.07 to 2.40 bars) differential between the inlet and outlet Unloading stationary tanks with a compressor is quite
pressures, the line sizes are too small or there is some practical. Delivery trucks and other large containers can be
fitting or excess flow valve creating too much restriction. filled rapidly if the vapor system of the tank to be filled will
The less restriction in the piping, the better the flow. permit fast vapor withdrawal, and if the liquid piping system
Appendix D shows recommended pipe sizes for typical is large enough. Many older trucks (and some new ones) are
LPG/NH3 compressor installation. not originally equipped with vapor excess flow valves large
Valve Position
Service to Perform
4-way A B C D E
1. Unload Tank Car into Position
Open Open Close Close Close
Storage Tank One
2. Recover Vapors from Tank Position
Close Open Open Close Close
Car into Storage Tank Two
3. Unload Transport or Truck Position
Open Close Close Close Open
into Storage Tank One
4. Recover Vapors from
Position
Transport or Truck into Close Close Open Close Open
Two
Storage Tank
5. Load Truck or Field Tank Position
Open Close Close Close Open
from Storage Tank Two
6. Load Truck or Field Tank Position
Close Open Close Open Close
from Tank Car One
7. Equalize Between Tank Car
and Storage Tank without — Open Open Close Open Open
using Vapor Pump
8. Equalize Between Truck or
Field Tank and Storage Tank — Open Close Close Open Close
without using Vapor Pump
Figure 2.3B: Five-Valve Manifold Piping System
9
2.4 Liquid Traps
Compressors are designed to pressurize gas, not to
pump liquids. The entry of even a small amount of
liquid into the compressor will result in serious damage
to the compressor.
On liquefied gas applications, a liquid trap must be used

to prevent the entry of liquid into the compressor.
Corken offers three types of liquid traps for removal of

entrained liquids. The simplest is a mechanical float trap
(see figure 2.4A). As the liquid enters the trap the gas
velocity is greatly reduced, which allows the entrained
liquid to drop out. If the liquid level rises above the
inlet, the float will plug the compressor suction. The
Service to Perform
Valve Position compressor creates a vacuum in the inlet piping and
4-way A B C continues to operate until the operator manually shuts it
1. Unload Tank Car into Position down. The trap must be drained and the vacuum-breaker
Open Open Close
Storage Tank One
valve opened before restarting the compressor, to allow
2. Recover Vapors from
Position the float to drop back. This type of trap is only appropriate
Tank Car into Storage Close Open Open
Tank
Two for use where the operator keeps the compressor under
fairly close observation. This trap is provided with the
Figure 2.3C: Three-Valve Manifold Piping System 109 and 107 compressor packages (see Appendix D for
details on standard Corken compressor packages).
enough to do a good job and these should be replaced
by a suitable size valve. The liquid discharge should be When the compressor will not be under more-or-less
connected to the tank truck pump inlet line rather than the constant observation an automatic trap is recommended
often oversized filler valve connection in the tank head.
It is of extreme importance to prevent the entry of

liquid into the compressor. The inlet of the compressor
should be protected from liquid entry by a liquid trap
(see section 2.4). It is of equal importance to protect
the discharge of the compressor from liquid. This may
be done by installing a check valve on the discharge
and designing the piping so liquid cannot gravity-
drain back into the compressor. Make sure to install
a check valve on vapor lines discharging to the liquid
space of the tank.
All piping must be in accordance with the laws and codes

governing the service. In the United States, the following
codes apply:
For LP Gas – The National Fire Protection Association

Pamphlet No. 58, Standard for the Storage and Handling
of Liquefied Petroleum Gases.
For Ammonia – The American National Standards

Institute, Inc., K61.1-1989, Storage and Handling of
Anhydrous Ammonia.
Copies of these are available from NFPA, 60 Baterymarch

Street, Boston, Mass, 02110 and ANSI, 1430 Broadway,
New York, N.Y., 10018. Install, use and maintain this
equipment according to Corken instructions and all
applicable federal, state, and local laws and previously
mentioned codes.
Figure 2.4A: Mechanical Trap
10
(see figure 2.4B). The automatic trap replaces the float with If your compressor is equipped with a liquid trap
electrical float switches. If the liquid level should rise too of other than Corken manufacture, make sure it is
high, the level switch will open and disconnect the power of adequate size to thoroughly remove any liquid
to the motor starter, stopping the compressor. This design entrained in the suction stream.
ensures the machine will be protected even when it is not
under close observation and is standard in the 109A and
107A mounting configurations.
Corken’s most sophisticated trap provides the most

Typical Float Switch Wiring Diagram
thorough liquid separation (see figure 2.4C). This trap is
(1) = Common, black
larger and is ASME code stamped. It contains two level
(2) = Normally closed, blue
switches, one for alarm and one for shutdown. In some
(3) = Normally open, red
cases the alarm switch is used to activate a dump valve
(not included with trap) or sound an alarm for the trap
to be manually drained by the operator. This trap also
contains a mist pad. A mist pad is a mesh of interwoven
wire to disentrain fine liquid mists. The ASME code trap is
standard in the 109B and 107B mounting configurations.
A typical wiring diagram for the liquid level switch is Figure 2.4D: Typical Float Switch Wiring Diagram
shown in figure 2.4D.
NOTE: The level switch MUST be removed from

the trap before grounding any welding devices to
the trap or associated piping! Failure to do so will
damage the switch contacts.
Figure 2.4B: Automatic Liquid Trap Figure 2.4C: ASME Automatic Liquid Trap
11
2.5 Driver Installation / Flywheels Acceptable Crankcase Oil Products for Corken
Compressors
Corken vertical compressors may be driven by either
Constant Weight - Non-Detergent - R&O Inhibited
electric motors or combustion engines (gasoline, diesel,
natural gas, etc.). Corken compressors are usually Oil product ISO VI SAE Ambient Temp.
V-belt driven but they are also suitable for direct drive Exxon®
applications as well. Direct drive applications require an Teresstic 100 95 30 65° - 100° F
extended crankshaft to allow the attachment of a rigid 68 95 20+ 45° - 70° F
metal coupling. 46 95 20 35° - 50° F
Mobil®
RARUS 427 Reciprocating 100 95 30 65° - 100° F
Note: Flexible couplings are not suitable for
Compressor Oil
reciprocating compressors. Never operate a DTE Oil Heavy Medium 64 95 20+ 45° - 100° F
reciprocating compressor without a flywheel. Dectol R&O Oil 44 95 20 35° - 50° F
Conoco®
Drivers should be selected so the compressor operates Dectol R&O Oil 100 98 30 35° - 50° F
between 350 to 825 RPM. The unit must not be 68 97 20+ 45° - 70° F
46 99 20 35° - 50° F
operated without the flywheel or severe torsional Texaco®
imbalances will result that could cause vibration and Regal R&O Oil 100 92 30 65° - 100° F
high horsepower requirement. The flywheel should 68 97 20+ 45° - 70° F
never be replaced by another pulley unless it has a 46 102 20 35° - 50° F
higher wk2 value than the flywheel. Sun®
SunVis 900 Oil 100 100 30 65° - 100° F
68 100 20+ 45° - 70° F
A humid climate can cause problems, particularly in 46 100 20 35° - 50° F
explosion proof motors. The normal breathing of the
Figure 2.6A: Oil Selection Chart
motor, and alternating between being warm when running
and being cool when stopped, can cause moist air to be
drawn into the motor. This moist air will condense, and Compressor Approximate
may eventually add enough water inside the motor to Capacity Liters
Model Quarts
cause it to fail. To prevent this, make a practice of running 91 0.9 0.8
the motor at least once a week on a bright, dry day for an
hour or so without the V-belts. In this period of time the 291 1.5 1.4
motor will heat up and vaporize the condensed moisture, 491 3.0 2.8
driving it from the motor. No motor manufacturer will 691 7.0 6.6
guarantee their explosion proof or totally enclosed
Figure 2.6B: Oil Capacity Chart
(TEFC) motor against damage from moisture.
For installation with engine drivers, thoroughly review

instructions from the engine manufacturer to assure the
2.7 Relief Valves
unit is properly installed. An appropriate relief valve must be installed at the
compressor discharge. On Corken 107-style mounted
units a relief valve should be fitted in the piping
2.6. Crankcase Lubrication between the compressor discharge and the four-way
Non-detergent oil is recommended for Corken vertical valve (see figure 1.3A). Relief valves should be made of
compressors. Detergent oils tend to keep wear particles a material compatible with the gas being compressed.
and debris suspended in the oil, whereas non-detergent Local codes and regulations should be checked for
oils let them settle in the bottom of the crankcase. specific relief valve requirements. Also, relief valves
When non-detergent oils are not available, detergent may be required at other points in the compressor’s
oils may usually be successfully substituted, although system piping.
compressors handling ammonia, amine, or imine gases
are notable exceptions. These gases react with the
detergent and cause the crankcase oil to become
2.8 Truck Mounted Compressors
corrosive and contaminated. Figures 2.6A and 2.6B show Corken compressors are may be mounted on trucks to
recommended oil viscosities and crankcase capacities. perform liquid transfer operations as described in section
1.1. The compressor should be mounted so the inspection
Synthetic lubricants are generally not necessary. Please plate is accessible for packing adjustment. The compressor
consult your lubricate supplier if you are considering the must be protected against liquid as explained in section 2.4
use of synthetic oil. and a relief valve must be installed in the discharge piping
before the first downstream shutoff valve.
12
Three types of mountings are typically used. The inside
mounting (figure 2.8A) drives the compressor directly off
the PTO shaft. The PTO must be selected to drive the
compressor between 400 and 800 RPM. An extended
compressor crankshaft is required so the U-joint yoke
may connect to the compressor without removing the
flywheel. Do not operate the compressor without a
flywheel. Use a U-joint with a splined joint and make
sure the connections are parallel and in line. The U-joint
angle should be less than 15 degrees (see figure 2.8B). Figure 2.8A: Inside Transport Mounting
Always use an even number of U-joints.
Depending on the truck design, the compressor may be

outside or top mounted as shown in figures 2.8C and
2.8D to be V-belt driven. Power is transmitted through
a U-joint drive shaft, jackshaft with two pillow block
bearings, V-belt sheave and V-belts. An idle pulley may
be used under the truck frame.
2.9 Shutdown/Alarm Devices

For many applications, shutdown/alarm switches will
provide worthwhile protection that may prevent serious
damage to your compressor system. All electronic devices
should be selected to meet local code requirements. Figure 2.8B: U-joint Drive for Compressor
Shutdown/alarm devices typically used on Corken
compressors are:
Low Oil Pressure Switch: Shuts down the unit if crankcase

oil pressure falls below 12 psi due to oil pump failure or
low oil level in crankcase.
High Temperature Switch: Shuts down the unit if the

normal discharge temperature is exceeded. This is
strongly recommended for all applications. Typically,
the set point is about 30°F (-1°C) above the normal
discharge temperature.
Low Suction, High Discharge Pressure Switch: Shuts Figure 2.8C: Outside Transport Mounting
down the unit if inlet or outlet pressures are not within
preset limits.
Vibration Switch: Shuts down the unit if vibration

becomes excessive. Recommended for units mounted
on portable skids.
Figure 2.8D: Top Transport Mounting
13
Chapter 3—Starting Up Your Corken Compressor
NOTE: Before initial startup of the compressor be
sure the principal of using a compressor for liquid
transfer by vapor differential pressure is understood
(see section 1.1). Read this entire chapter, then
proceed with the startup checklist.
3.1 Inspection After

Extended Storage
If your compressor has been out of service for a long
period of time, you should verify that the cylinder bore
and valve areas are free of rust and other debris (see
chapter 5 of this IOM manual for valve and/or cylinder
head removal instructions). Figure 3.2A: Flywheel Installation
Drain the oil from the crankcase and remove the

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

properly. Replace nameplate and proceed with startup.
3.2 Flywheel and V-belt Alignment

Before working on the drive assembly, be sure that the
electric power is disconnected. When mounting new
belts, always make sure the driver and compressor are
Figure 3.2B: Belt Tension
close enough together to avoid forcing.
Improper belt tension and sheave alignment can cause Tighten the belts so that they are taut, but not extremely
vibration, excessive belt wear and premature bearing tight. Consult your V-belt supplier for specific tension
failures. Before operating your compressor, check alignment recommendations. Belts that are too tight may cause
of the V-grooves of the compressor flywheel and driver premature bearing failure. Refer to figure 3.2B.
sheave. Visual inspection often will indicate if the belts are
properly aligned, but use of a square is the best method.
3.3 Crankcase Oil Pressure
The flywheel is mounted on the shaft via a split, tapered
bushing and three bolts. These bolts should be tightened in Adjustment
an even and progressive manner until torqued as specified Corken compressor models 291 through 891 are
below. There must be a gap between the bushing flange equipped with an automatically reversible gear type oil
and the flywheel when installation is complete. Always pump (if your compressor is the splash lubricated Model
check the flywheel runout before startup and readjust 91, proceed to section 3.4). It is essential to ensure
if it exceeds the value listed in Appendix C. the pumping system is primed and the oil pressure is
properly adjusted in order to assure smooth operation.
Diameter Bolt Torque
Bushing Size Before starting your compressor, check and fill the
In. (cm) Ft.-lb. (kg-meter)
SF 4.625 (11.7) 30 (4.1) crankcase with the proper quantity of lubricating oil.
E 6.0 (15.2) 60 (8.3) When the compressor is first started, observe the
J 7.25 (18.4) 135 (18.7) crankcase oil pressure gauge. If the gauge fails to
indicate pressure within 30 seconds, stop the machine.
14
Remove the pressure gauge. Restart the compressor 8. Check V-belt tension and alignment. Check drive
and run it until oil comes out of the pressure gauge alignment on direct drive units.
opening. Reinstall the gauge.
9. Rotate unit by hand. Check flywheel for wobble or play.
The oil pressure should be about 20 psi (1.4 bars) minimum
for normal service. If the discharge pressure is above 200 10. Check crankcase oil level.
psi (14.8 bars) the oil pressure must be maintained at a
minimum of 25 psi (1.7 bars). A spring-loaded relief valve 11. Drain all liquid traps, separators, etc.
mounted on the bearing housing opposite the flywheel
regulates the oil pressure. As shown in figure 3.3A, turn 12. Verify proper electrical supply to motor and panel.
the adjusting screw clockwise to increase the oil pressure
and counterclockwise to lower it. Be sure to loosen the 13. Check that all gauges are at zero level reading.
adjusting screw locknut before trying to turn the screw and
14. Test piping system for leaks.
tighten it after making any adjustment.
15. Purge unit of air before pressurizing with gas.
16. Carefully check for any loose connections or bolts.
17. Remove all stray objects (rags, tools, etc.) from vicinity
- of unit.
+
Oil Pressure
Adjusting 18. Verify that all valves are open or closed as required.
Screw
19. Double-check all of the above.
Lock Nut
After Starting Compressor
Oil Pump Cover
Oil Level Bayonet 1. Verify and note proper oil pressure. Shut down and
correct any problem immediately.
Oil Pressure Gauge
2. Observe noise and vibration levels. Correct immediately
Figure 3.3A: Oil Pressure Adjustment if excessive.
3. Verify proper compressor speed.
3.4 Startup Check List 4. Examine entire system for gas, oil or water levels.
Please verify all of the items on this list before 5. Note rotation direction.
starting your compressor! Failure to do so
may result in a costly (or dangerous) mistake. 6. Check start-up voltage drop, running amperage and
voltage at motor junction box (not at the starter).
Before Starting the Compressor
7. Test each shutdown device and record set points.
1. Become familiar with the function of all piping associated
with the compressor. Know each line’s use! 8. Test all relief valves.
2. Verify that actual operating conditions will match the 9. Check and record all temperatures, pressures and
anticipated conditions. volumes after 30 minutes and 1 hour.
3. Ensure that line pressures are within cylinder 10. After 1 hour running time, tighten all head bolts, valve
pressure ratings. holddown bolts, and baseplate bolts. See Appendix C
for torque values.
4. Clean out all piping.
5. Check all mounting shims, cylinder and piping

supports to ensure that no undue twisting forces exist
on the compressor.
6. Verify that strainer elements are in place and clean.
7. Verify that cylinder bore and valve areas are clean.
15
Chapter 4—Routine Maintenance Chart
Six
Item to Check Daily Weekly Monthly Yearly
Months
Crankcase oil pressure
Compressor discharge pressure
Overall visual check
Crankcase oil level 2 2
Drain liquid from accumulation points 3
Drain distance pieces

Clean cooling surfaces on compressor and
intercooler (if any)
Lubricator supply tank level (if any)
1
Check belts for correct tension
Inspect valve assemblies
Lubricate motor bearings in accordance with
manufacturers' recommendations
Inspect motor starter contact points
Inspect piston rings1 1 1
1 Piston ring life varies greatly, depending on application, gas, and operating pressures. Consult factory for additional recommendations for
your specific application.
2 Change oil every 2,200 hours of operation or every 6 months, whichever occurs first. If the oil is unusually dirty, change it as often as needed
to maintain a clean oil condition. Change replacement filter 4225 with every oil change.
3 Liquid traps should be drained prior to startup.
16
Chapter 5—Routine Service and Repair Procedures
CAUTION: Always relieve pressure in the unit before Valve Holddown Assemblies: Depending on your model
attempting any repairs. After repair, the unit should of compressor, the valve holddown assembly has all or a
be pressure tested and checked for leaks at all joints combination of the following:
and gasket surfaces.
1. Valve cap
If routine maintenance is performed as listed in chapter
4, repair service on your Corken gas compressor is 2. Valve cap O-ring
generally limited to replacing valves or piston rings.
When it comes time to order replacement parts, be sure 3. Holddown screw
to consult the part details appendix in the back of this
Installation, Operation & Maintenance (IOM) manual for a 4. Valve cover plate
complete list of part numbers and descriptions.
5. Valve cover plate bolts
5.1 Valves 6. Valve cover plate O-ring
Test the compressor valves by closing the inlet piping valves 7. Valve spacer (model 491 only)
while the unit is running; however, do not allow the machine
to operate in this way very long. If the inlet pressure gauge 8. Valve cage
does not drop to zero almost immediately, one or more of
9. Valve assembly
the valves is probably either damaged or dirty. It is possible,
of course, that the pressure gauge itself is faulty. 10. Valve gasket
Inspect valves for breakage, corrosion, and scratches on Valve Assemblies: Depending on your valve specification,
the valve disc and debris. In many cases, valves may simply the valve assembly has all or a combination of the following:
be cleaned and reinstalled. If the valves show any damage,
they should be repaired or replaced. Replacement is usually 1. Gasket
preferable, although individual parts are available. If valve
discs are replaced, seats should also be lapped until they 2. Adjusting screw
are perfectly smooth. If more than .005 in. must be removed
to achieve a smooth surface, the valve should be discarded. 3. Relief ball spring
If discs are replaced without relapping the seat, rapid wear
and leakage may occur. 4. Relief ball
Each suction and/or discharge valve assembly is easily 5. Valve seat

removed as a unit for inspection. If any part of the valve
6. Valve plate
assembly is broken, the valve assembly should be replaced.
See valve assembly parts details in the appendices for a 7. Spacers
complete list of part numbers and descriptions.
8. Washer
If a valve is leaking due to dirt or any other foreign
material that keeps the valve plate and seat from sealing, 9. Valve spring
the valve may be cleaned and reused. New gaskets and/
or O-rings should be used to assure a good seal. 10. Suction valve post
The valve holddown assemblies and valve assemblies on 11. Valve bumper
the following pages show the various specifications used
on models 91, 291, 491, 691 and 891 compressors. Since 12. Valve gasket
more than one suction valve arrangement is available for
See valve holddown and valve assembly part details
each model of compressor, it is necessary to know your
in the appendix for a complete list of part numbers
complete model number so you can identify the valve
and descriptions.
type specification number (see example listed below).
In most cases for liquid transfer and/or vapor recovery
compressors, the valve type will be spec. 3.
Valve Inspection and/or Replacement for Models 91
and 291 Compressors
Model number 491AM 3 FBANSNN Before removing and inspecting the valves, begin by
Valve type = spec 3 depressurizing and purging (if necessary) the unit.
17
Disassembly the holddown screw has been secured with an impact
wrench at the factory, you will probably need to wait to
1. Unscrew the valve cap and remove O-ring.
remove the holddown screw until after the cover plate
2. With the special wrench supplied with your compressor has been removed. At this point in time, the holddown
at time of purchase, remove the holddown screw. screw can be easily removed from the cover plate. The
holddown screw on model 691 and 891 is most easily
3. After the holddown screw has been removed, the removed with the special wrench supplied with your
valve assembly and valve gasket can be lifted out. compressor at time of purchasing.
4. Carefully inspect for dirt or broken/damaged parts. 3. After the cover plate and O-ring have been removed,
the valve spacer (model 491 only), valve cage, valve
5. Inspect valves for breakage, corrosion, debris and assembly and valve gasket can be lifted out.
scratches on the valve disc or plate. In many cases,
valves may simply be cleaned and reinstalled. If the 4. Inspect valves for breakage, corrosion, debris and
valves show any damage, they should be repaired or scratches on the valve plate. In many cases, valves may
replaced. Replacement is usually preferable although simply be cleaned and reinstalled. If the valves show
repair parts are available. If valve plates are replaced, any damage, they should be repaired or replaced.
seats should also be lapped until they are perfectly Replacement is usually preferable although repair
smooth. If more than .005 in. must be removed parts are available. If valve plates are replaced, seats
to achieve a smooth surface, the valve should be should also be lapped until they are perfectly smooth.
discarded. If plates are replaced without relapping the If more than .005 in. must be removed to achieve a
seat, rapid wear and leakage may occur. smooth surface, the valve should be discarded. If
plates are replaced without relapping the seat, rapid
Assembly wear and leakage may occur.
1. Insert metal valve gasket into the suction and/or discharge
Assembly
opening of the head. The metal valve gasket should
always be replaced when the valve is reinstalled. 1. Insert metal valve gasket into the suction and/or discharge
opening of the head. The metal valve gasket should
2. Insert cleaned or new valve assembly. Make sure the always be replaced when the valve is reinstalled.
suction and discharge valves are in the proper suction and
discharge opening in the head. NOTE: The spec 3 suction 2. Insert cleaned or new valve assembly. Make sure the
valves for a model 91 and 291 compressor are pre-set so suction and discharge valves are in the proper suction
no adjustments to liquid relief pressure are necessary. and discharge opening in the head.
3. Replace the holddown screw and tighten to the value 3. Insert the valve cage and valve spacer (NOTE: spacer
listed in Appendix C to ensure the valve gasket is applies to model 491 compressor only).
properly seated. NOTE: Gaskets and O-rings are not
normally reusable. 4. Replace the O-ring and valve cover plate. Torque
bolts to the value listed in Appendix C. CAUTION: Be
4. Replace the O-ring (or gasket) and valve cap and sure the holddown screw has been removed.
tighten to the value listed in Appendix C. O-rings
sealing the valve caps should be replaced. 5. Insert the holddown screw and tighten to the value
listed in Appendix C to ensure the valve gasket is
5. Check bolts and valve holddown screws after first properly seated. NOTE: Gaskets and O-rings are not
week of operation. Re-torque if necessary. See normally reusable.
Appendix C for torque values.
6. Replace the O-ring (or gasket) and valve cap/nut and
Valve Inspection and/or Replacement for Models tighten to the value listed in Appendix C. O-rings sealing
the valve cap should be replaced if they show signs of
491, 691 and 891 Compressors wear or damage. Valve caps sealed by flat metals
Before removing and inspecting the valves, begin by gaskets should be reinstalled with new gaskets.
depressurizing and purging (if necessary) the unit.
7. NOTE: Spec 3 suction valves have an adjusting screw
Disassembly to set the liquid relief pressure. To set the liquid relief
1. Unscrew the valve cap/nut and remove the gasket pressure, tighten the adjusting screw until it bottoms,
from the coverplate. then back out 3/4 turn.
2. Remove the valve cover plate, O-ring and holddown 8. Check bolts and valve holddown screws after first
screw by removing each of the four bolts. NOTE: Since week of operation. Re-torque if necessary. See
Appendix C for torque values.
18
5.2 Heads 5.4 Pistons
A compressor head very seldom requires replacement if 1. To replace the pistons, depressurize the compressor
the compressor is properly maintained. The primary cause and purge if necessary.
of damage to a head is corrosion and the entry of solid
debris or liquid into the compression chamber. Improper 2. Remove the compressor cylinder and head (see
storage can also result in corrosion damage to the head section 5.2).
(for proper storage instructions see chapter 6).
3. Remove the piston head by loosening and removing
Many compressor repair operations require removal the socket head bolts holding the piston head to the
of the head. While the compressor is disassembled, piston platform (see figure 5.3A).
special care should be taken to avoid damage or
corrosion to the head. If the compressor is to be left 4. Next, remove the roll pin with a pair of needle nose
open for more than a few hours, bare metal surfaces pliers. The castellated nut may then be removed and the
should be coated with rust preventative. piston platform lifted off the end of the piston rod.
When reassembling the compressor, make sure the bolts 5. Check the thrust washer and shims for damage and
are retightened as shown in Appendix C. replace if necessary.
6. Before installing the new piston, measure the thickness

5.3 Piston Rings and of the existing shims. For Models 91 through 491, the
shims are placed between the thrust washer and
Piston Ring Expanders piston platform. For model 691, the shims are placed
between the platform and piston head (see figures
5.4A and 5.4B).
7. Reinstall the piston platform with the same thickness

of shims as before, BUT DO NOT REINSTALL THE
ROLL PIN.
8. Replace the cylinder and install the piston heads with

new piston rings and expanders.
9. Now measure dimension “X” shown in the illustration.

If this measurement does not fall within the tolerances
shown in Appendix C, remove the piston, adjust the
shims as necessary and remeasure the “X” dimension.
Figure 5.3A: Piston Removal
10. When the piston is properly shimmed, tighten the
Piston ring life will vary considerably from application to castellated nut as shown in Appendix C.
application. Ring life will improve dramatically at lower
speeds and temperatures. 11. Now install a new roll pin to lock the castellated piston
nut in place.
1. To replace the piston rings, depressurize the
compressor and purge if necessary.
2. Remove the head to gain access to the compressor

cylinder.
3. Loosen the piston head bolts. Remove the piston

as shown in figure 5.3A by pinching two loose
bolts together.
4. Piston rings and expanders may then be easily

removed and replaced. Corken recommends
replacing expanders whenever rings are replaced.
To determine if rings should be replaced, measure
the radial thickness and compare it to the chart in
Appendix C.
Figure 5.4A: Piston Cross Section
Model Sizes 91 Through 491
19
chamber. Improper storage can also result in corrosion
damage to cylinder (for proper storage instructions
see chapter 6).
If the cylinder does become damaged or corroded, use

a hone to smooth the cylinder bore and then polish it
to the value shown in Appendix C. If more than .005
in. must be removed to smooth the bore, replace the
cylinder. Cylinder liners and oversized rings are not
available. OVERBORING THE CYLINDER WILL RESULT
IN GREATLY REDUCED RING LIFE.
Many compressor repair operations require removal of the

cylinder. While the compressor is disassembled, special
care should be taken to avoid damage or corrosion to
the cylinder. If the compressor is to be left open for more
Figure 5.4B: Piston Cross Section than a few hours, bare metal surfaces should be coated
Model 691 with rust preventative.
12. Install the piston head and tighten the socket head When reassembling the compressor, make sure the bolts
bolts in an alternating sequence. are retightened as shown in Appendix C.
13. Reinstall the head (see section 5.2) and follow standard
Packing Replacement Instructions
startup procedure. (Note: Some compressors may
have self-locking nuts without roll pins.) Caution: Bleed all pressure from the compressor and piping,
and purge (if necessary), before starting to install new piston
rod packing. After repair, the unit should be pressure tested
5.5 Piston Rod Packing Adjustment and checked for leaks at all joints and gasket surfaces.
When the compressor is being used with toxic, dangerous,
Piston rod packing should be adjusted or replaced
flammable or explosive gases, this pressure and leak testing
whenever leakage becomes noticeable. Typically, it is
should be done with air or a dry, inert gas such as nitrogen.
a good idea to replace piston rod packing and piston
rings at the same time. For instructions on adjusting and For simplicity, heads, pistons, and inspection plates are
replacing the piston rod packing, see section 5.6. not shown. For specific construction details and actual
part numbers, consult the appendix in the back of this
NOTE: Inspection of the rod packing is generally not
IOM manual. Use instructions below that apply to the
productive, since packing that cannot be adjusted to an
MODEL and SERIAL NUMBER of your compressor. Be
acceptable leakage rate should be replaced.
careful to arrange packing sets in the proper order.
Cleanliness:
Sealing a reciprocating piston rod is a very difficult
task. Keep all parts, tools and your hands clean during
installation. Your new packing needs every chance it can
get, so keep it clean.
Workmanship:
Your Corken compressor is a precision piece of equipment
with very close tolerances. Treat it as such. Never beat
on it to get parts in or out.
Figure 5.5A: Packing Adjusting Nuts
Model 91 Compressor
5.6 Cylinder and (Refer to Appendix G for packing assembly details)
Packing Replacement Disassembly of Packing

1. Depressurize and open the compressor.
Cylinders very seldom require replacement if the
compressor is properly maintained. The primary 2. Remove head, piston, cylinder, inspection plate and
cause of damage to cylinders is corrosion and the crosshead guide.
entry of solid debris or liquid into the compression
20
3. Loosen adjusting screw and remove retainer ring, 2. Slightly thread in adjusting screw.
washers, packing spring and old packing from
crosshead guide. 3. Install packing rings including male and female
packing rings, one at a time, as shown in Appendix H
Assembly of Packing or I. Push in each one completely before adding the
next ring. The quantity of packing rings required will
1. Clean, then lightly oil, packing area inside the
vary due to tolerances; a good rule of thumb is to put
crosshead guide.
in as many as are removed.
2. Slightly thread in the adjusting screw into the
4. Insert thin packing box washer, packing spring and
crosshead guide.
thicker washer.
3. Install packing rings including male and female packing
5. Push down on washer and insert retainer ring.
rings one at a time as shown in Appendix G. Push
in each one completely before adding the next ring.
6. Tighten adjusting screw until plastic locking device
The quantity of packing rings required will vary due to
engages the first thread in the packing box cartridge.
tolerances; a good rule of thumb is to put in as many as
are removed. 7. Oil piston rod and replace cartridge O-ring.
4. Insert thin packing box washer, packing spring and 8. Install packing installation cone part number 4005
thicker washer into the top of the crosshead guide. over the threaded end of the piston rod.
5. Tighten adjusting screw until plastic locking device 9. Carefully slip the packing cartridge over the piston
engages the first thread in the crosshead guide. rod; otherwise, you may damage the lips of the
packing rings.
6. Oil piston rod and install the packing installation cone
(part number 4005) over the threaded end of the 10. Remove packing installation cone.
piston rod.
11. Install and tighten cartridge holddown screw with
7. Carefully slip the crosshead guide over the piston special wrench.
rod; otherwise, you may damage the lips of the
packing rings. 12. Install cylinder O-ring, cylinder, pistons and head.
8. Remove packing installation cone. Model 691 Compressor
9. Install the crosshead guide O-ring, cylinder, piston (Refer to Appendix J for packing assembly details)
and head.
Disassembly of Packing
Model 291 Compressor (serial no. SS55685 and later) 1. Depressurize and open the compressor.
Model 491 Compressor (serial no. XC30633 and later)
2. Remove head, pistons and cylinder.
(Refer to Appendix H or I for packing assembly details)
3. Remove cartridge holddown screw with special
Disassembly of Packing wrench supplied with the compressor and packing
1. Depressurize and open the compressor. box cartridge.
2. Remove head, pistons and cylinder. 4. Loosen adjusting screw and remove retainer ring,
washers, packing spring and old packing from packing
3. Remove cartridge holddown screw with special box cartridge.
wrench supplied with the compressor and packing
box cartridge. Assembly of Packing
1. Clean then lightly oil packing area inside packing box
4. Loosen adjusting screw and remove retainer ring, cartridge.
washers, packing spring and old packing from packing
box cartridge. 2. Thread in adjusting screw until locking device is
engaged into first thread of the packing cartridge.
Assembly of Packing
1. Clean, and then lightly oil, packing area inside packing 3. Install packing rings, including male and female packing
box cartridge. rings, one at a time, as shown in Appendix J. Push in
each one completely before adding the next ring.
21
4. Insert a packing washer, packing spring and another removing the head, cylinder, piston, crosshead guide
packing washer. and crosshead assembly.
5. Push down on washer and insert retainer ring. 2. Drain the crankcase and remove the inspection plate(s).
6. Oil piston rod and replace cartridge O-ring. 3. Before disassembly, choose and mark one connecting
rod and the corresponding connecting rod cap. DO
7. Install packing installation cone part number 3905 NOT MIX CONNECTING RODS AND CAPS. Loosen and
over the threaded end of the piston rod. remove the connecting rod bolts in order to remove the
crosshead and connecting rod assembly.
8. Carefully slip the packing cartridge over the piston
rod; otherwise, you may damage the lips of the 5.7.1 Wrist Pin Bushing Replacement
packing rings.
1. To replace the wrist pin bushing, remove the retainer
9. Install and tighten cartridge holddown screw with rings that position the wrist pin in the crosshead.
special wrench.
2. Press out the wrist pin so the crosshead and
10. Replace cylinder O-ring, cylinder, pistons and head. connecting rod may be separated. Inspect the wrist
pin for wear and damage and replace if necessary.
Model D891 Compressor
3. Press out the old wrist pin bushing and press a new
(Refer to Appendix K for packing assembly details) bushing into the connecting rod. DO NOT MACHINE THE
O.D. OR I.D. OF THE BUSHING BEFORE PRESSING
Disassembly of Packing INTO CONNECTING ROD.
1. Depressurize and open the compressor.
4. Make sure the lubrication hole in the bushing matches
2. Remove the cylinder cap, heads, pistons and cylinder. the oil passage in the connecting rod. If the holes do
not align, drill out the bushing through the connecting
3. To remove the packing barrels, pry upward under rod lubricant passage with a long drill. Bore the
each one and lift entire barrel/cartridge assembly up wrist pin bushing I.D. as indicated on the respective
from piston rod. connecting rod assembly details. These pages are
located in the appendices. Over boring the bushing can
4. Remove the four socket head screws that hold the lead to premature failure of the wrist pin bushing.
packing cartridge to the barrel.
5. Inspect the oil passage for debris and clean thoroughly
Assembly of Packing before proceeding.
1. Replace packing as required. The segmented packing
6. Press the wrist pin back into the crosshead and
and cups are in the barrel. The V-ring packing is in
wrist pin and reinstall retainer rings. NOTE: The
the cartridge. Note the arrangement of the particular
fit between the wrist pin and bushing is tighter
packing set for the model machine you have.
than ordinary lubricated air compressors and
combustion engines.
2. Reattach the cartridges to the barrels using the four
socket head screws.
5.7.2 Replacing Connecting Rod Bearings
3. Install cartridge barrel assemblies, noting the Connecting rod bearings are easily replaced by removing
alignment of the barrels as they sit on the crosshead the semicircular bearings. Make sure the indentations
guide. The valve scallops on the barrels must align in the connecting rod bearing and connecting rod line
properly with the valves of the cylinder. up when installing the new bearings. MAKE SURE THE
ARROW AND/OR ALIGNMENT NOTCH ON CONNECTING
4. Replace cylinder, pistons, heads and cap. See piston ROD AND CAP ARE ALIGNED.
assembly details for proper clearance values.
Before reinstalling the crosshead/connecting rod
5. Rotate unit by hand to ensure proper assembly. assembly, make sure the crankshaft throw and bearing
surface are clean and lubricated. Tighten the connecting
5.7 Bearing Replacement for rod bolts to the torques listed in Appendix C.
Crankcase and Connecting Rod 5.7.3 Replacing Crankcase Roller Bearings

To inspect the roller bearings, remove the flywheel from
1. To replace the crankcase roller bearings, wrist pin
the crankshaft and then remove the bearing carrier and
bushing and connecting rod bearings, begin by
crankshaft from the crankcase. If corrosion or pitting is
22
Figure 5.6.3A: Bearing Carrier Replacement
present, the roller bearings should be replaced. When

replacing roller bearings, always replace the entire bearing,
5.8 Oil Pump Inspection
not just the cup or the cone. If the compressor operates for a prolonged period with
dirty or contaminated crankcase oil, damage to the oil
1. To replace the bearings, press the cups out of the pump may result.
crankcase and bearing carrier and press the cones off
the crankshaft. 1. To check the oil pump, unbolt the pump cover and
remove the oil pump, spring guide, spring and oil
2. Press the new bearings into position and reassemble pump shaft adapter as shown in figure 5.8A.
the crankshaft and bearing carrier to the crankcase.
When reinstalling the bearing carrier, make sure 2. Inspect the gears in the oil pump for corrosion or
the oil pump shaft slot is aligned with the pin in the pitting and replace if necessary.
crankshaft. Make sure to install the bearing carrier
gasket so the oil passage hole is not blocked (see 3. Check the oil pump shaft bushing in the bearing
figure 5.6.3A). carrier. If the bushing is corroded, pitted or worn, the
oil pump shaft bushing should be replaced.
3. In order to check the crankshaft endplay, the oil pump
must first be removed (see section 5.8). 4. Before reassembling the oil pump mechanism, replace
the O-rings in the oil pump cover and on the oil pump
4. Press the end of crankshaft towards the crankcase; if adapter shaft (see figure 5.8A).
a clicking noise or motion is detected, the crankshaft
has too much endplay. See Appendix C. 5. Rotate the drive pin in the crankshaft to a vertical
position for easiest reassembly.
5. To reduce endplay, remove the bearing cover and
remove a thin shim. Recheck the endplay after 6. Insert the shaft adapter so it engages the drive pin.
replacing the bearing cover.
7. Next, insert the spring, spring guide and oil pump
6. When there is no detectable endplay, the shaft must assembly. The tang on the oil pump must align with
still be able to rotate freely. If the crankshaft sticks the slot in the shaft adapter.
or becomes abnormally warm, then the crankshaft
8. Install the pump cover so the pin on the case is in the
bearings are too tight. If the crankshaft is too tight,
opening on the oil pump assembly as shown in figure
add more shims, but make sure not to over shim.
5.8A. When you are sure the pin is properly aligned,
(Appendix C lists the proper crankshaft endplay).
install the cover bolts finger tight.
When the crankshaft can be rotated freely by hand
with proper endplay, the rest of the compressor may 9. Rotate the crankshaft by hand to ensure smooth
be reassembled. If the crankshaft roller bearings operation. Then rotate it in opposite directions,
are too tight or too loose, premature bearing failure listening for a click, which indicates proper alignment
will result. of the oil pump’s pins and slots.
7. Reinstall the flywheel on the crankshaft and check the 10. Finally, tighten the bolts in an alternating sequence. See
run out as shown in Appendix C. section 3.3 for directions on oil pressure adjustment.
23
Figure 5.8A
5.9 Servicing the Four-Way Valve 1. Remove the hex nut, indicator plate and handle from
the rotor shaft.
Unlike older units, new Corken compressors mounted in
the –107 arrangement are being supplied with a non-lube 2. Remove the four hex head bolts and the cap from the
four-way valve. No maintenance is normally required on body. The cap should be rotated until free; do not pry.
this valve. If you have reason to disassemble the valve, Inspect cap for wear and damage (see figure 5.9C).
please follow the instructions below (see figures 5.9A
and 5.9B).
CAUTION: Always Relieve Pressure In The Unit

Before Attempting Any Repairs.
Before Disassembly:
1. Record the position marks on the end of the rotor shaft.
2. Record the positions of the handle stops on the cap.
NOTE: A small amount of silicone grease applied

to each part before assembly facilitates assembly
if allowed.
Disassembly
Refer to the drawing for item description.
Figure 5.9A Figure 5.9B
24
6. Assemble the new stem O-ring and the body O-ring
into their grooves in the rotor and body.
7. Place the cap over the rotor shaft.
8. Rotate the rotor so the position of the handle stops on

the cap is the same as recorded before disassembly.
9. Assemble the four hex head bolts through the cap

and into the body. Be sure that the body O-ring is in
Figure 5.9C the proper position and tighten the hex head bolts.
3. Remove the body O-ring, stem O-ring, cap O-ring, 10. Reassemble the handle, indicator plate and hex nut.
and top rotor washer and discard. Be sure that the handle is assembled so that the stop
on the handle mates with the stops on the cap.
4. Remove the rotor and four seals as a unit from the
body. IMPORTANT: Because of the close tolerance,
care must be taken to remove the rotor on its axis to Chapter 6
prevent damage to the rotor and body. Rotating the
handle with a lifting action will help remove the rotor
Extended Storage Procedures
as shown in figure 5.9D. 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.
Figure 5.9D
3. Relieve V-belt tension.
5. Discard the four seals. Inspect the rotor for wear
and damage. 4. Plug all openings to prevent entry of insects and
moisture. (The cylinders may also be protected by the
6. Remove the bottom rotor washer and discard. Inspect use of a vapor phase inhibitor, silica gel, or dry nitrogen
the body for wear and damage. gas. If the silica gel is used, hang a tag on the unit
indicating that it must be removed before start-up.)
Assembly
5. Store in a dry area, off the ground if possible.
Refer to figure 5.9B. Have the repair kit laid out.
6. Rotate the flywheel every two weeks if possible.
1. Place the new bottom rotor washer into the body.
2. Assemble the four seals and O-rings onto the

appropriate surfaces of the rotor.
3. Assemble the rotor and seal assembly into the

body. IMPORTANT: Because of the close tolerance,
care must be taken to press the rotor on its axis
to prevent damage to the rotor and body. A ring
compressor is helpful. Be sure that the rotor is
bottomed in the body.
4. Rotate the rotor so that the position marks on the

end of the rotor shaft are the same as recorded
before disassembly.
5. Assemble the new top rotor washer and cap O-ring,

onto the shoulder of the rotor.
25
Appendix A—Repair Kits and Gasket Sets
Compressor Repair Kits
Part Number 3549-X1 3550-X1 3551-X1 3552-X1 3552-X2 5578-X2A
Model Number 90J3, 91J3 290K3, 291M3 490K3, 491M3 690K3, 690P3 690M3, 691M3 891M3
2 2 2
Suction valve assembly 3483-1X 3483-1X (2) 2532-1X 3948-X (2) 3948-X (2) 3732-X
2
Discharge valve assembly 3485-X 3485-X (2) 2439-X (2)2 3857-X (2)2 3857-X (2)2 3733-X
2
Valve cage — — 2448 (4) 2797 (4)2 2797 (4)2 —
2
Connecting rod bearing (pair) 1367 1367 (2)2 1491 (2) 1719 (2)2 3542 (2)2 3542 (2)2
1725-2X,
Packing set 1452-1X1 1452-1X1 (2)2 1452-1X1 (2)2 1725-2X (2)2 1725-2X (2)2
3810-X1
2
Piston rings 1772 (3) 1772 (6)2 1773 (6)2 1739 (6)2 1739 (6)2 1739 (8)2
2 2 2 2 2
Ring expanders 1775 (3) 1775 (6) 1776 (6) 1740 (6) 1740 (6) 1740 (8)2
Gasket set1 2526-XA1 1281-XA1 1481-X6A1 1744-X1A1 1744-X1A1 3970-X1A
1
O-ring — — — — 2-261A (2)1, 2 —
1
O-ring — — 2-242A (2)1, 2 — — —
O-ring1 — — 2-253A (2)1, 2 — — —
Oil seal 3259 1278 1507 (490 only) — 3526 3526
Oil seal — — 4438 (491 only) — — —
Adapter plate gasket — — 1486 — — —
1 All repair kits are furnished with Buna-N O-rings which are suitable for LPG and NH3 applications
2 Quantities larger than 1 are shown in parenthesis
Four-Way Valve Repair Kits

Description Trim Part Number Connection Sizes
3122-X 1"
Four-Way Valve Repair Kits PTFE and Buna-N trim 3123-X 1¼"
3130-X 2"
Gasket Sets
Model 91 Gasket Set (2526-XA) Model 291 Gasket Set (1281-XA)
Part Part
Description Quantity Description Quantity
Number Number
2-235A O-ring, Buna-N 2 1281 Filter screen screw gasket 1
2526 Crankcase gasket 1 1651 Inspection plate gasket 1
2717 Valve gasket, aluminum 2 2-113A O-ring, Buna-N 2
2729 Crankcase inspection plate gas 1 2-228A O-ring, Buna-N 1
2-031A O-ring, Buna-N 2 2702 Crankcase gasket 1
2244 Inspection plate gasket 1
2716 Valve cap gasket, aluminum 4
2716 Valve cap gasket, aluminum 2
2732 Center headbolt gasket - steel 2
2725 Bearing carrier gasket 1
1190 Adapter plate gasket 2
2-031A O-ring, Buna-N 4
2713 Crankcase inspection plate gas 1
2717 Valve gasket, aluminum 4
26
Appendix A—Repair Kits and Gasket Sets (continued)
Model 491 Gasket Set (1481-X6A) Model 691 Gasket Set (1744-X3A)
Part Part
Description Quantity Description Quantity
Number Number
1418 Valve gasket, aluminum 4 1760 Inspection plate gasket 1
1480 Center headbolt gasket - steel 2 2-031A O-ring, Buna-N 4
1488 Inspection plate gasket 1 2-231A O-ring, Buna-N 2
1511 Crankcase inspection plate gas 1 2-235A O-ring, Buna-N 4
2-139A O-ring, Buna-N 2 2-261A O-ring, Buna-N 2
2-228A O-ring, Buna-N 1 2123 Crankcase inspection plate gas 2
1281 Filter screen screw gasket 1 2131 Bearing carrier gasket 1
1478 Valve cap gasket, steel 4 2716 Valve cap gasket, aluminum 4
1481 Head gasket 1 4127 Lubricator gasket 1
1489 Crankcase gasket 1 1281 Filter screen screw gasket 1
1513 Bearing carrier gasket 1 1761 Crankcase gasket 1
2129 Oil inlet gasket 1
Model 891 Gasket Set (3970-X1A) 2177 Flange gasket 2
Part 3874 Access cover gasket 2
Description Quantity
Number
1281 Filter screen screw gasket 1
1761 Crankcase gasket 1
4127 Lubricator gasket 1
1760 Inspection plate gasket 1
2123 Crankcase inspection plate gas 1
3874 Access cover gasket 2
3906 Gasket spiral wound 2
27
Appendix B
Vertical Single-Acting Model Number Identification Code
Base Model 91 291 491 691

Model Number
Inlet 3/4" NPT 3/4" NPT 1-1/4" NPT 2" NPT Base X X X X X X X X X X
Outlet 3/4" NPT 3/4" NPT 1-1/4" NPT 1-1/2" NPT
Base Model F91 F291 F491 F691
Inlet 3/4" ANSI 3/4" ANSI 1-1/4" ANSI 2" ANSI
Outlet 3/4" ANSI 3/4" ANSI 1-1/4" ANSI 2" ANSI
Packing Arrangement Pressurized inlet Standard A
Splash lubricated Standard N/A N/A N/A J

Extended crankshaft Extra cost Extra cost Extra cost N/A E
Crankcase Style
Pressure lubricated N/A Standard Standard Standard M
Standard with heater N/A Extra cost Extra cost Extra cost MH
Liquid relief suction Standard 3

Valves
Standard valves No extra cost 4
PTFE Standard F
Piston Rings and Packing
Alloy 50 Extra Cost G
Aluminum Standard B
Gasket Material Copper No extra cost C
Lead-iron No extra cost D
Buna-N Standard A
Neoprene ®1 No extra cost B
O-ring Material
Viton®1 Extra cost D
PTFE Extra cost E
Intercooler None N/A for single stage compressor N
14" flywheel used with

No charge N/A E
extended crankshaft
Flywheel Heavy duty Extra cost Extra cost Extra cost Extra cost H
No flywheel No extra cost N
Standard flywheel Standard S
Protective Coating No coating Standard N
Nitrotec Standard N
Piston Rod Coating
Chrome oxide Extra cost C
1Registered trademark of the DuPont company.
See Appendix D for mounting options.
28
Appendix B
Vertical Double-Acting Model Number Identification Code
Base Model Number D891 Model Number
Inlet Connection 2" Weld Base X X X X X X X X X X
Outlet Connection 2" Weld
Ship Weight (lb) 900
Packing
Packing arranged for padding of distance piece Standard J
Arrangement
Crankcase Pressure lubricated Standard M

Style Standard with heater Extra cost MH
Standard suction and discharge valves Standard 4

Valves
Suction valve unloaders Extra cost 9
Piston Ring
and Packing PTFE Standard F
Material
Gasket Material Aluminum Standard B
O-ring Buna-N Standard A

Material Neoprene ®1 No charge B
Intercooler N/A for single stage compressor Standard N
Flywheel No flywheel provided No charge N

Standard flywheel Standard S
Protective
None Standard N
Coating
Piston Rod
Nitrotec Standard N
Coating
1 Registered trademark of the DuPont company.
Mounting Selections
103 Mounting includes: Steel baseplate, adjustable driver slide base, V-belt drive and enclosed steel belt guard. Pressure gauges are
mounted on the compressor.3
107 Mounting includes: Steel baseplate, mechanical liquid trap, non-lube 4-way valve, interconnecting piping, strainer, adjustable driver slide
base, V-belt drive and enclosed steel belt guard. Pressure gauges are mounted on the compressor.
107A Mounting includes: All items on the 107 replacing the mechanical float in the liquid trap with a NEMA 7 liquid level switch.
107B Mounting includes: All items on the 107 replacing the liquid trap with a larger ASME code liquid trap with 2 NEMA 7 liquid level
switches set for alarm and shutdown.
107TR Mounting includes: All items on the 107 set up to be used as a transport unit. Note that the compressor must have the optional 14”
flywheel and extended crankshaft to use this mounting.2
109 Mounting includes: Steel baseplate, mechanical liquid trap, interconnecting piping, adjustable driver slide base, V-belt drive and
enclosed steel belt guard. Pressure gauges are mounted on the compressor.3
109A Mounting includes: All items on the 109 replacing the mechanical float in the liquid trap with a NEMA7 liquid level switch.3
109B Mounting includes: All items on the 109 replacing the liquid trap with a larger ASME code liquid trap with 2 NEMA 7 liquid level
switches set for alarm and shutdown.3
109TR Mounting includes: All items on the 109 set up to be used as a transport unit. Note the compressor must have the optional 14”
flywheel and extended crankshaft to use this mounting.2,3
2 Not suitable for 691 or D891.
3 Discharge relief valves are required but not included in these mountings.
29
Appendix C—Vertical Single-Acting Specifications
Models 91–691
Equipment Type & Options Applications
Single-acting, vertical, reciprocating piston type vapor compressor Bulk transfer
Single packed rod Vapor recovery
NPT or 300# ANSI connections Tank evacuation
Gas scavenging
Features and Benefits

Self-lubricating piston rings: Non-lubricated operation to minimize oil in gas
NPT or 300# ANSI connections: Versatility for your application
Multiple mounting configurations: Versatility for your application
High efficiency valves: Quiet, reliable operation
Reversible oil pump: Allows operation in either direction
Simplified top down design: Routine maintenance is minimally invasive
Specifications
Model Number
Specification
91 291 491 691
Bore of cylinder inches (mm) 3.0 (76.2) 3.0 (76.2) 4.0 (101.6) 4.5 (114.3)
Stroke inches (mm) 2.5 (63.5) 2.5 (63.5) 3.0 (76.2) 4.0 (101.6)
Piston displacement cfm (m3/hr)
minimum @ 400 RPM 4.0 (6.8) 8.0 (13.6) 16.5 17.2 (29.2) 35.5 29.2 (49.6)
maximum @ 825 RPM 8.3 (14.1) (28.0) (60.3) 60.2 (102.3)
Maximum working pressure psig (bar g)1 335 (23.1)
Maximum brake horsepower (kW) 7.5 (5.6) 15 (11) 15 (11) 35 (26.1)
Maximum rod load lb (kg) 3,600 (1,632.9) 3,600 (1,632.9) 4,000 (1,814.4) 7,000 (3,175.1)
Maximum outlet temperature °F (°C) 350 (177)
Bare unit weight lb (kg) 115 (52.2) 160 (72.6) 260 (117.9) 625 (283.5)
Maximum flow—propane gpm (m3/hr) 50 (11.4) 101 (22.9) 215 (48.8) 361 (82.0)
1 These numbers specify pressure-containing abilities of the compressor cylinder and head. For many applications, factors other than the
pressure rating will limit the maximum allowable discharge pressure to lower values. These factors include horsepower, temperature and rod
load.
30
Models 91–691 Material Specifications
Part Model Standard Material Optional Material
Head, Cylinder All Ductile iron ASTM A536 None
Crosshead guide
crankcase, flywheel, All Gray iron ASTM A48, Class 30 None
bearing carrier
Flange 691 Ductile iron ASTM A536 Steel weld flange
91, 291 17-4 PH stainless steel
Valve seat & bumper 491 Ductile iron ASTM A536 None
691 17-4 PH stainless steel
91, 291 410 stainless steel
Valve plate 491 17-7 PH stainless steel None
691 410 stainless steel
91, 291, 691 17-7 PH stainless steel None
Valve spring
491 Inconel
Valve gaskets All Soft aluminum Iron-lead, Copper
Piston All Gray iron ASTM A48, Class 30 None
Piston rod All C1050 steel Nitrotec coated Chrome oxide
Crosshead All Gray iron ASTM 48, Class 30 None
Piston rings All PTFE, glass and moly filled Alloy 50
Ring expanders All 302 stainless steel None
Head gasket All O-ring, Buna-N PTFE, Viton®1, Neoprene®1
Packing cartridge,
All Ductile iron ASTM A536 None
connecting rod
Packing rings All PTFE, glass and moly filled Alloy 50
Crankshaft All Ductile iron ASTM A536 None
Con. rod bearing All Bimetal D-2 babbit None
Wrist pin All C1018 steel None
Wrist pin busing All Bronze SAE 660 None
Main bearing All Tapered roller None
Inspection plate All Aluminum None
O-rings All Buna-N PTFE, Viton®1, Neoprene®1
Retainer rings All Steel None
Misc. gaskets All Coroprene None
31
Bolt Torque Values
Valve
Crank- Valve Hold- Piston Valve Cap Valve Cap
Conn. case Cyl. to Cover down Lock Piston Torque Torque
Rod Bearing Bearing Inspec X-Head Head Plate Screw Nut Screw (w/ (w/
Bolt Carrier Cover Plate Guide (1.2) Bolt 2 Torque Torque Gaskets) O-rings)
Model ft•lb ft•lb ft•lb ft•lb ft•lb ft•lb ft•lb ft•lb ft•lb in•lb ft•lb ft•lb
91 28 38 38 15 30 20 — 40 45 50 40 25
291 28 30 30 13 25 20 — 40 45 50 40 25
491 30 26 35 8 33 33 35 40 45 100 40 25
691 40 40 40 9 40 30 37 40 60 100 40 25
1 Preliminary tightening – snug all head bolts in the sequence shown. Final torqueing – torque all head bolts in the sequence shown to the listed value.
2 Retorque to the listed value after 2 – 5 hours running time.
32
Clearances and Dimensions
691/D891
91 291 491
(M crankcase)
**Clearance: “X” piston figure 5.4A & 0.020 0.020 0.000/0.020 0.000/0.015
5.4B 0.044 0.044 0.024/0.044 0.012/0.027
Clearance: connecting rod bearing to 0.0005 0.0005 0.0005 0.0019
crankshaft journal 0.0025 0.0025 0.0025 0.0035
Clearance: wrist pin to wrist pin
0.0009 0.0009 0.0009 0.0020
bushing* (max)
Cylinder bore diameter (max) 3.009 3.009 4.011 4.515
Cylinder finish (RMS) 16-32 16-32 16-32 16-32
Piston ring radial thickness (min) 0.082 0.082 0.082 0.082
Clearance: oil pump adapter shaft to
0.0050 0.0050 0.0050 0.0050
bushing* (max)
0.000 0.000 0.000 0.002
Crankshaft end play (cold)
0.002 0.002 0.002 0.003
Flywheel runout at O.D. (max) 0.020 0.020 0.020 0.020
Clearance: crosshead to crosshead
0.011 0.011 0.012 0.013
guide bore (max)
Crosshead guide bore finish 32 RMS (limited number of small pits and scratches are acceptable)
* Dimensions for honing are included with new bushings (which must be installed, then honed).
** Clearance should be set with machine cold.
33
Appendix C—Vertical Double-Acting Specifications
Model D891
Equipment Type & Options Applications
Double-acting, vertical, reciprocating piston type vapor compressor Bulk transfer
Double packed rod Truck, tank, railcar, barge unloading
Slip-on weld connections LTVR and scavenger applications
Emergency evacuation
Features and Benefits

Self-lubricating piston rings: Non-lubricated operation to minimize oil in gas
Multiple materials and configurations: Versatility for your application
Multiple mounting configurations: Versatility for your application
High efficiency valves: Quiet, reliable operation
Reversible oil pump: Allows operation in either direction
Simplified top down design: Routine maintenance is minimally invasive
Operating Specifications
Bore of cylinder inches (mm) 4.5 (113)
Stroke inches (mm) 4.0 (101.6)
Piston displacement cfm (m3/hr)
minimum @ 400 RPM 56.6 (96.2)
maximum @ 825 RPM 113.2 (192.0)
Maximum working pressure psig (bar g) 465 (32.1)
Maximum brake horsepower (kW) 45 (34)
Maximum rod load lb (kg) 7,000 (3,175.2)
Maximum outlet temperature °F (°C) 350 (177)
Bare unit weight lb (kg) 855 (387.8)
Maximum flow—propane gpm (m3/hr) 694 (157.6)
34
Appendix C—Vertical Double-Acting Specifications
Model D891 Material Specifications
Part Standard Material Optional Material
Head, cylinder Ductile iron ASTM A536
Distance piece
Crosshead guide Gray iron ASTM A48, Class 30
Crankcase, flywheel
Bearing carrier
Flange ASTM A36 carbon steel
Valve seat, bumper 17-7 PH stainless steel
Valve plate 410 stainless steel
Valve spring 17-7 PH stainless steel
Valve gaskets Soft aluminum Copper, iron-lead
Piston Ductile iron ASTM A536
Piston rod C1050 steel, Nitrotec
Crosshead Gray iron ASTM A48, Class 30
Piston rings PTFE, glass and moly filled Alloy 50
Piston ring expanders 302 stainless steel
Head gasket O-ring, Buna-N PTFE, Viton®1, Neoprene®1
Adapter plate
Packing cartridge Ductile iron ASTM A536
Connecting rod
Packing rings PTFE, glass and moly filled Alloy 50
Crankshaft Ductile iron ASTM A536
Connecting rod bearing Bimetal D-2 Babbit
Wrist pin C1018 Steel
Wrist pin bushing Bronze SAE 660
Main bearing Tapered roller
Inspection plate Aluminum
O-rings Buna-N PTFE, Viton®1, Neoprene®1
Retainer rings Steel
Miscellaneous gaskets Coroprene
35
Appendix D—Compressor Selection
Compressor Mounting Selections
Inlet pressure gauge Outlet pressure gauge
Standard 107 Items
Steel baseplate
V-Belt drive
Adjustable driver slide base
Enclosed steel belt guard
NEMA 7 Inlet and outlet pressure gauges
liquid level 40 Micron strainer
switch
(107A only)
Non-lube 4-way valve
1-1/2" NPT Interconnecting piping
Liquid trap as specified below
107 Mounting
Mechanical liquid trap with ball float
107A Mounting
Automatic liquid trap with one NEMA 7
liquid level switch
107B Mounting
Automatic liquid trap (ASME code) with
two NEMA 7 liquid level switches
Standard 109 Items

Steel baseplate
V-Belt drive
Adjustable driver slide base
Enclosed steel belt guard
Inlet and outlet pressure gauges
Interconnecting piping
Liquid trap as specified below
109 Mounting
Mechanical liquid trap with ball float
109A Mounting
Automatic liquid trap with one NEMA 7
liquid level switch
109B Mounting
Automatic liquid trap (ASME code) with
two NEMA 7 liquid level switches
36
Butane Compressor Selection Table
Driver Horsepower
Liquid Liquid
Transfer Transfer
& Without
Residual Residual
Driver Sheave Size Vapor Vapor
Capacity Displacement Compressor Pitch Diameter (inches)2 Recovery Recovery Piping Size 3
Service gpm1 cfm Model RPM 1,750 RPM 1,450 RPM 100°F 80°F 100°F 80°F Vapor Liquid
13 4 91 400 A 3.0 A 3.6 3 3 3 3 3/4 1-1/4
Small 17 5 91 505 A 3.8 B 4.6 3 3 3 3 3/4 1-1/4
bulk 20 6 91 590 B 4.6 B 5.6 3 3 3 3 1 1-1/4
plants 24 7 91 695 B 5.4 B 6.6 5 5 5 5 1 1-1/2
23 7 290, 291 345 A 3.0 A 3.6 2 2 2 2 1 1-1/2
27 8 91 795 B 6.2 B 7.4 5 5 5 5 1 1-1/2
26 8 290, 291 390 A 3.4 B 4.0 2 2 2 2 1 1-1/2
30 9 290, 291 435 A 3.8 B 4.6 3 3 3 3 1 1-1/2
33 10 290, 291 490 B 4.4 B 5.2 3 3 3 3 1 2
Unloading 36 11 290, 291 535 B 4.8 B 5.8 3 3 3 3 1 2
single tank 39 12 290, 291 580 B 5.2 B 6.2 5 3 5 3 1 2
car or 42 13 290, 291 625 B 5.6 B 6.6 5 5 5 5 1-1/4 2
transport 47 14 290, 291 695 B 6.2 B 7.4 5 5 5 5 1-1/4 2
50 15 290, 291 735 B 6.6 B 8.0 5 5 5 5 1-1/4 2-1/2
50 15 490, 491 345 A 3.0 A 3.6 5 5 5 5 1-1/4 2-1/2
53 16 290, 291 780 B 7.0 B 8.6 7-1/2 5 7-1/2 5 1-1/4 2-1/2
53 16 490, 491 370 A 3.2 A 3.8 5 5 5 5 1-1/4 2-1/2
56 17 490, 491 390 A 3.4 B 4.0 5 5 5 5 1-1/4 3
60 18 490, 491 415 A 3.6 B 4.4 5 5 5 5 1-1/4 3
63 19 490, 491 435 A 3.8 B 4.6 5 5 5 5 1-1/4 3
65 20 490, 491 445 B 4.0 B 4.8 5 5 5 5 1-1/4 3
68 21 490, 491 470 B 4.2 B 5.0 5 5 5 5 1-1/4 3
Unloading 71 22 490, 491 490 B 4.4 B 5.2 7-1/2 5 7-1/2 5 1-1/4 3
two or 75 23 490, 491 515 B 4.6 B 5.6 7-1/2 5 7-1/2 5 1-1/4 3
more tank 77 24 490, 491 535 B 4.8 B 5.8 7-1/2 7-1/2 7-1/2 7-1/2 1-1/4 3
cars at 81 25 490, 491 560 B 5.0 B 6.0 7-1/2 7-1/2 7-1/2 7-1/2 1-1/4 3
one time 84 26 490, 491 580 B 5.2 B 6.2 7-1/2 7-1/2 7-1/2 7-1/2 1-1/4 3
or large 87 27 490, 491 605 B 5.4 B 6.4 7-1/2 7-1/2 7-1/2 7-1/2 1-1/4 3
transport 91 28 490, 491 625 B 5.6 B 6.6 7-1/2 7-1/2 7-1/2 7-1/2 1-1/2 3
with excess 94 29 490, 491 650 B 5.8 B 7.0 10 7-1/2 10 7-1/2 1-1/2 3
flow valves 97 30 490, 491 670 B 6.0 10 7-1/2 10 7-1/2 1-1/2 3
of adequate 94 30 690, 691 400 B 4.4 B 5.2 7-1/2 7-1/2 7-1/2 7-1/2 1-1/2 3
capacity 100 31 490, 491 695 B 6.2 B 7.4 10 7-1/2 10 7-1/2 1-1/2 3
98 31 690, 691 420 B 4.6 B 5.6 10 7-1/2 10 7-1/2 1-1/2 3
107 32 490, 491 740 B 6.6 B 8.0 10 10 10 10 1-1/2 3
103 32 690, 691 440 B 4.8 B 5.8 10 7-1/2 10 7-1/2 1-1/2 3
110 33 490, 491 760 B 6.8 B 8.0 10 10 10 10 1-1/2 3
113 34 490, 491 780 B 7.0 B 8.6 10 10 10 10 1-1/2 3
107 34 690, 691 455 B 5.0 B 6.0 10 10 10 10 1-1/2 3
111 35 690, 691 475 B 5.2 B 6.2 10 10 10 10 1-1/2 3
119 36 490, 491 825 B 7.4 B 8.6 15 10 15 10 1-1/2 3
116 36 690, 691 495 B 5.4 A 6.4 10 10 10 10 1-1/2 3
120 38 690, 691 510 B 5.6 B 6.8 10 10 10 10 1-1/2 4
Unloading 124 39 690, 691 530 B 5.8 B 7.0 10 10 10 10 1-1/2 4
large 129 41 690, 691 550 B 6.0 A 7.0 10 10 10 10 1-1/2 4
tank cars, 133 42 690, 691 565 B 6.2 B 7.4 10 10 10 10 2 4
multiple 137 43 690, 691 585 B 6.4 A 7.4 10 10 10 10 2 4
vessels, 142 45 690, 691 605 B 6.6 B 8.0 15 10 15 10 2 4
barges or 145 46 690, 691 620 B 6.8 15 10 15 10 2 4
terminals 150 47 690, 691 640 B 7.0 A 8.2 15 10 15 10 2 4
158 48 690, 691 675 B 7.4 B 8.6 15 15 15 15 2 4
171 54 690, 691 730 B 8.0 B 9.4 15 15 15 15 2 4
184 58 690, 691 785 B 8.6 15 15 15 15 2 4
193 60 690, 691 820 TB 9.0 A 10.6 15 15 15 15 2 4
260 82.1 D891 580 5V 7.1 5V 8.5 20 20 20 20 3 6
359 113.3 D891 800 5V 9.75 5V 11.8 25 25 25 25 3 6
1 The capacities shown are based on 70°F, but will vary depending upon piping, fittings used, product being transferred and temperature. The
factory can supply a detailed computer analysis if required.
2 Driver sheaves: 91 (2 belts); 290, 291, 490, 491 (3 belts); 690, 691 (4 belts).
3 The piping sizes shown are considered minimum. If the length exceeds 100 ft., use the next larger size.
NOTE: Please consult factory for compressors with higher flows.
37
Propane Compressor Selection Table
Driver Horsepower
Liquid Liquid
Transfer Transfer
& Without
Residual Residual
23 4 91 400 A 3.0 A 3.6 5 3 3 3 3/4 1-1/4
Small 29 5 91 505 A 3.8 B 4.6 5 5 5 5 3/4 1-1/4
bulk 34 6 91 590 B 4.6 B 5.6 5 5 5 5 1 1-1/4
plants 40 7 91 695 B 5.4 B 6.6 5 5 5 5 1 1-1/2
39 7 290, 291 345 A 3.0 A 3.6 3 3 3 3 1 1-1/2
45 8 91 795 B 6.2 B 7.4 7-1/2 7-1/2 7-1/2 7-1/2 1 1-1/2
44 8 290, 291 390 A 3.4 B 4.0 5 3 3 3 1 1-1/2
50 9 290, 291 435 A 3.8 B 4.6 5 5 3 3 1 1-1/2
56 10 290, 291 490 B 4.4 B 5.2 5 5 5 5 1 2
Unloading 61 11 290, 291 535 B 4.8 B 5.8 5 5 5 5 1 2
single tank 66 12 290, 291 580 B 5.2 B 6.2 7-1/2 5 5 5 1 2
car or 71 13 290, 291 625 B 5.6 B 6.6 7-1/2 5 7-1/2 5 1-1/4 2
transport 79 14 290, 291 695 B 6.2 B 7.4 7-1/2 7-1/2 7-1/2 7-1/2 1-1/4 2
84 15 290, 291 735 B 6.6 B 8.0 10 7-1/2 10 7-1/2 1-1/4 2-1/2
84 15 490, 491 345 A 3.0 A 3.6 7-1/2 7-1/2 5 5 1-1/4 2-1/2
89 16 290, 291 780 B 7.0 B 8.6 10 10 10 10 1-1/4 2-1/2
89 16 490, 491 370 A 3.2 A 3.8 7-1/2 7-1/2 7-1/2 5 1-1/4 2-1/2
95 17 490, 491 390 A 3.4 B 4.0 7-1/2 7-1/2 7-1/2 7-1/2 1-1/4 3
101 18 490, 491 415 A 3.6 B 4.4 10 7-1/2 7-1/2 7-1/2 1-1/4 3
106 19 490, 491 435 A 3.8 B 4.6 10 7-1/2 7-1/2 7-1/2 1-1/4 3
108 20 490, 491 445 B 4.0 B 4.8 10 7-1/2 7-1/2 7-1/2 1-1/4 3
114 21 490, 491 470 B 4.2 B 5.0 10 7-1/2 7-1/2 7-1/2 1-1/4 3
Unloading 119 22 490, 491 490 B 4.4 B 5.2 10 10 7-1/2 7-1/2 1-1/4 3
two or 125 23 490, 491 515 B 4.6 B 5.6 10 10 10 7-1/2 1-1/4 3
more tank 130 24 490, 491 535 B 4.8 B 5.8 15 10 10 10 1-1/4 3
cars at 136 25 490, 491 560 B 5.0 B 6.0 15 10 10 10 1-1/4 3
one time 141 26 490, 491 580 B 5.2 B 6.2 15 10 10 10 1-1/4 3
or large 147 27 490, 491 605 B 5.4 B 6.4 15 10 15 10 1-1/4 3
transport 152 28 490, 491 625 B 5.6 B 6.6 15 15 15 15 1-1/2 3
with excess 158 29 490, 491 650 B 5.8 B 7.0 15 15 15 15 1-1/2 3
flow valves 163 30 490, 491 670 B 6.0 15 15 15 15 1-1/2 3
of adequate 163 30 690, 691 400 B 4.4 B 5.2 15 15 10 10 1-1/2 3
capacity 168 31 490, 491 695 B 6.2 B 7.4 15 15 15 15 1-1/2 3
171 31 690, 691 420 B 4.6 B 5.6 15 15 10 10 1-1/2 3
179 32 490, 491 740 B 6.6 B 8.0 15 15 15 15 1-1/2 3
178 32 690, 691 440 B 4.8 B 5.8 15 15 10 10 1-1/2 3
186 34 690, 691 455 B 5.0 B 6.0 15 15 15 10 1-1/2 3
193 35 690, 691 475 B 5.2 B 6.2 15 15 15 10 1-1/2 3
200 36 690, 691 495 B 5.4 B 6.4 15 15 15 15 1-1/2 3
208 38 690, 691 510 B 5.6 B 6.8 20 15 15 15 1-1/2 4
215 39 690, 691 530 B 5.8 B 7.0 20 15 15 15 1-1/2 4
223 41 690, 691 550 B 6.0 A 7.0 20 15 15 15 1-1/2 4
230 42 690, 691 565 B 6.2 B 7.4 20 15 15 15 2 4
Unloading 237 43 690, 691 585 B 6.4 A 7.4 20 15 15 15 2 4
large 245 45 690, 691 605 B 6.6 B 8.0 20 15 15 15 2 4
tank cars, 252 46 690, 691 620 B 6.8 20 20 15 15 2 4
multiple 260 47 690, 691 640 B 7.0 A 8.2 20 20 20 15 2 4
vessels, 275 48 690, 691 675 B 7.4 B 8.6 25 20 20 20 2 4
barges or 297 54 690, 691 730 B 8.0 B 9.4 25 20 20 20 2 4
terminals 319 58 690, 691 785 B 8.6 25 20 25 20 2 4
334 60 690, 691 820 TB 9.0 A 10.6 30 25 25 20 2 4
452 82 D891 580 5V 7.1 5V 8.5 30 30 30 30 3 6
623 113 D891 800 5V 9.75 5V 11.8 40 40 30 3 6
38
Ammonia Compressor Selection Table
Driver Horsepower
Liquid Liquid
Transfer Transfer
& Without
Residual Residual
23 4 91 400 A 3.0 A 3.6 5 3 3 3 3/4 1-1/4
Small 29 5 91 505 A 3.8 B 4.6 5 5 5 3 3/4 1-1/4
bulk 34 6 91 590 B 4.6 B 5.6 5 5 5 5 1 1-1/4
plants 40 7 91 695 B 5.4 B 6.6 5 5 5 5 1 1-1/2
43 7 290, 291 345 A 3.0 A 3.6 5 3 3 3 1 1-1/2
46 8 91 795 B 6.2 B 7.4 7-1/2 5 5 5 1 1-1/2
45 8 290, 291 390 A 3.4 B 4.0 5 3 3 3 1 1-1/2
50 9 290, 291 435 A 3.8 B 4.6 5 5 3 3 1 1-1/2
56 10 290, 291 490 B 4.4 B 5.2 5 5 5 3 1 2
Unloading 62 11 290, 291 535 B 4.8 B 5.8 7-1/2 5 5 5 1 2
single tank 67 12 290, 291 580 B 5.2 B 6.2 7-1/2 5 5 5 1 2
car or 72 13 290, 291 625 B 5.6 B 6.6 7-1/2 5 5 5 1-1/4 2
transport 80 14 290, 291 695 B 6.2 B 7.4 7-1/2 7-1/2 7-1/2 5 1-1/4 2
85 15 290, 291 735 B 6.6 B 8.0 10 7-1/2 7-1/2 7-1/2 1-1/4 2-1/2
85 15 490, 491 345 A 3.0 A 3.6 7-1/2 7-1/2 5 5 1-1/4 2-1/2
90 16 290, 291 780 B 7.0 B 8.6 10 7-1/2 7-1/2 7-1/2 1-1/4 2-1/2
90 16 490, 491 370 A 3.2 A 3.8 10 7-1/2 5 5 1-1/4 2-1/2
96 17 490, 491 390 A 3.4 B 4.0 10 7-1/2 5 5 1-1/4 3
102 18 490, 491 415 A 3.6 B 4.4 10 7-1/2 7-1/2 7-1/2 1-1/4 3
107 19 490, 491 435 A 3.8 B 4.6 10 7-1/2 7-1/2 7-1/2 1-1/4 3
110 20 490, 491 445 B 4.0 B 4.8 10 7-1/2 7-1/2 7-1/2 1-1/4 3
115 21 490, 491 470 B 4.2 B 5.0 10 7-1/2 7-1/2 7-1/2 1-1/4 3
Unloading 120 22 490, 491 490 B 4.4 B 5.2 15 10 7-1/2 7-1/2 1-1/4 3
two or 126 23 490, 491 515 B 4.6 B 5.6 15 10 7-1/2 7-1/2 1-1/4 3
more tank 131 24 490, 491 535 B 4.8 B 5.8 15 10 10 7-1/2 1-1/4 3
cars at 138 25 490, 491 560 B 5.0 B 6.0 15 10 10 7-1/2 1-1/4 3
one time 142 26 490, 491 580 B 5.2 B 6.2 15 10 10 7-1/2 1-1/4 3
or large 148 27 490, 491 605 B 5.4 B 6.4 15 10 10 10 1-1/4 3
transport 153 28 490, 491 625 B 5.6 B 6.6 15 10 10 10 1-1/2 3
with excess 160 29 490, 491 650 B 5.8 B 7.0 15 15 10 10 1-1/2 3
flow valves 165 30 490, 491 670 B 6.0 15 15 15 10 1-1/2 3
of adequate 165 30 690, 691 400 B 4.4 B 5.2 15 15 10 10 1-1/2 3
capacity 170 31 490, 491 695 B 6.2 B 7.4 15 15 15 10 1-1/2 3
173 31 690, 691 420 B 4.6 B 5.6 15 15 10 10 1-1/2 3
181 32 490, 491 740 B 6.6 B 8.0 15 15 15 15 1-1/2 3
180 32 690, 691 440 B 4.8 B 5.8 15 15 10 10 1-1/2 3
188 34 690, 691 455 B 5.0 B 6.0 20 15 10 10 1-1/2 3
195 35 690, 691 475 B 5.2 B 6.2 20 15 10 10 1-1/2 3
203 36 690, 691 495 B 5.4 B 6.4 20 15 15 10 1-1/2 3
211 38 690, 691 510 B 5.6 B 6.8 20 15 15 10 1-1/2 4
218 39 690, 691 530 B 5.8 B 7.0 20 15 15 15 1-1/2 4
226 41 690, 691 550 B 6.0 A 7.0 20 15 15 15 1-1/2 4
233 42 690, 691 565 B 6.2 B 7.4 20 15 15 15 2 4
Unloading 240 43 690, 691 585 B 6.4 A 7.4 20 20 15 15 2 4
large 248 45 690, 691 605 B 6.6 B 8.0 20 20 15 15 2 4
tank cars, 255 45 690, 691 620 B 6.8 25 20 15 15 2 4
multiple 263 47 690, 691 640 B 7.0 A 8.2 25 20 15 15 2 4
vessels, 278 48 690, 691 675 B 7.4 B 8.6 25 20 15 15 2 4
barges or 301 54 690, 691 730 B 8.0 B 9.4 25 20 20 15 2 4
terminals 323 58 690, 691 785 B 8.6 30 25 20 20 2 4
338 60 690, 691 820 TB 9.0 A 10.6 30 25 20 20 2 4
459 82 D891 580 5V 7.1 5V 8.5 40 30 30 30 3 6
633 113 D891 800 5V 9.75 5V 11.8 40 40 30 3 6
39
Appendix E—Outline Dimensions
Models 91–691 and F91–F691 Bare with Flywheel
L M M L
L1 M1 M1 L1
S***
Outline Dimensions—Inches (Centimeters)

Model A B C D E F G H J K
1-13/16 2-3/8 3-11/16 13/32 5/8 6-1/4 3-7/8 25-5/16 5 22-11/16
91, F91
(4.6) (6.0) (9.4) (1.03) (1.59) (15.9) (9.8) (64.3) (12.7) (57.6)
3-3/8 4-1/8 3-11/16 13/32 5/8 9-13/16 12 25-13/16 5-3/8 23-3/8
291, F291
(8.6) (10.5) (9.4) (1.11) (1.59) (24.9) (30.4) (65.2) (13.7) (59.4)
4-1/8 5 4-11/16 1/2 11/16 10-11/16 13 29-11/16 5-7/8 26-3/16
491, F491
(10.5) (12.7) (11.9) (1.27) (1.75) (27.2) (33.1) (75.4) (14.9) (66.5)
4-3/4 5 5-3/8 9/16 1 14 14-3/8 39-1/8 8-1/4 35-1/8
691, F691
(12.1) (14.0) (13.7) (1.5) (2.5) (35.6) (35.6) (99.4) (21.0) (89.2)
“PD” Flywheel Pitch Diameter

Model L* L1** M* M1** P Q R S*** T A-belt Groove B-belt Groove
91, F91 3/4 3/4-300 lb 2-3/8 4-1/4 3 14 1-1/8 1-1/4 1/4 13.2 2 13.6 2
NPT ANSI (6.0) (10.8) (7.6) (35.6) (2.8) (3.2) (0.63) (33.5) (34.5)
291, F291 3/4 3/4-300 lb 2-11/16 4-1/4 3 16 1-1/4 1-1/4 1/4 15.2 3 15.6 3
NPT ANSI (6.8) (10.8) (7.6) (40.6) (3.2) (3.2) (0.63) (38.6) (39.6)
141 13.21 2 13.61 2
(35.6) (33.5) (34.5)
491, F491 1-1/4 1-1/4-300 lb 3-7/8 5-5/8 3 16 1-3/8 1-1/4 5/16 15.2 3 15.6 3
NPT ANSI (9.9) (14.3) (7.6) (40.6) (3.5) (3.2) (0.79) (38.6) (39.6)
141 13.21 2 13.61 2
(35.6) (33.5) (34.5)
691, F691 22 2-300 lb 6-3/8 6-15/16 3-13/16 19-1/2 2-1/8 — 1/2 — — 19-1/8 4
NPT ANSI (16.1) (17.6) (9.7) (49.5) (5.4) (1.27) (48.5)
1 Optional flywheel * 91, 291, 491, 691 only
2 Optional flanges: 1-1/4", 1-1/2" NPT, 1-1/4", 1-1/2" or 2" Weld ** F91, F291, F491, F691 only
*** With extended crankshaft option only
40
Models 91–691 with 103 Mounting

Model A B C D E F G
12 15 27-1/2 30 1-1/4 3 5-1/4
91-103
(30.4) (38.1) (69.8) (76.2) (3.1) (7.6) (13.34)
12 15 31-1/2 34 1-1/4 3 5
291-103
(30.5) (38.1) (80.0) (86.4) (3.2) (7.6) (12.7)
15 18 37-1/2 40 1-1/4 4 5-1/4
491-103
(38.1) (45.7) (95.3) (101.6) (3.2) (10.2) (13.3)
17 20 39-1/2 42 1-1/4 4 5.5
691-103
(43.2) (50.8) (100.3) (106.7) (3.2) (10.2) (14.0)

Model H J K L M N
28-11/16 26-3/8 4-15/16 7.75 2-11/16 3/4
91-103
(72.9) (67.0) (12.5) (19.7) (6.8) NPT
28-22/32 26-6/16 4-15/16 7-3/4 2-11/16 3/4
291-103
(72.9) (67.0) (12.5) (19.7) (6.8) NPT
33-11/16 30-3/16 5-3/4 10 3-15/16 3/4
491-103
(85.6) (76.7) (14.6) (25.4) (10.0) NPT
43-1/8 39-1/8 8.25 9.25 6-3/8 2
691-103
(109.5) (99.4) (21.0) (23.5) (16.2) NPT
41
Models 91 with -107 or -107A Mounting (model -107A shown below)
Inches (Centimeters)
* Dimensions apply to -107A mounting only
42
Model 291 with -107 or -107A Mounting (model -107A shown below)
AUTOMATIC LIQUID TRAP

CORKEN
CORKEN
IN
CORKEN
CORKEN
43
AUTOMATIC LIQUID TRAP

CORKEN
IN
CORKEN
CORKEN
44
1-1/4 in. NPT

four way
control valve
P R
O
K
M N Q D
L C

Model A B C D E F G H J
8-1/4 17 49-1/2 19-3/4 1-1/2 20 52 43-1/4 5-1/2
691-107, -107A
(21.0) (43.1) (126) (50.1) (3.8) (50.8) (132) (110) (14)

Model K L M N O P Q R S
4 1-1/4 1/4 2-11/16* 7-3/4 29 10-1/2 24-1/4 6
691-107, -107A
(10.1) (3.2) (0.63) (6.8)* (19.6) (73.0) (26.6) (61.0) (15.0)
45
Model 91–691 with -109 or -109A Mounting (model -109A shown below)

Model A A1 B C D D1 E F G H J
1-3/16 5-1/4 12 13-5/16 31-1/2 — 1-1/2 15 34 31-3/16 5-1/4
91-109, -109A
(3.7) (13.4) (30.5) (33.8) (80.0) (3.8) (38.1) (86.4) (79.2) (13.3)
5 — 12 15-3/4 39-1/2 — 1-1/2 15 42 30-7/8 5-1/4
291-109, -109A
(12.7) — (30.5) (40.0) (100.3) — (3.8) (38.1) (106.7) (78.4) (13.3)
5-3/4 — 15 18 45-1/2 — 1-1/2 18 48 33-3/4 5-1/4
491-109, -109A
(14.6) — (38.1) (45.7) (115.6) — (3.8) (45.7) (121.9) (85.7) (13.3)
8-1/4 — 17 19-1/4 49-1/2 19-3/4 1-1/2 20 52 43-3/16 5-1/2
691-109, -109A
(30.0) — (43.2) (48.8) (125.7) (50.1) (3.8) (50.8) (132) (109.6) (14.0)

Model K L M N P R S T U
28-3/16 3/4 2-5/16 3 1-1/4 3-5/8 9-1/2 2-3/4 6-3/4
91-109, -109A
(71.6) NPT (5.9) (7.6) (3.2) (9.2) (24.1) (6.9) (17.1)
28-1/2 3/4 2-11/16 3 1-1/4 3-7/8 9-1/2 4-1/2 6-3/4
291-109, -109A
(72.4) NPT (6.8) (7.6) (3.2) (9.9) (24.1) (11.4) (17.1)
30-1/8 1-1/4 4 4 1-1/4 4 10-1/2 5.25 7-3/4
491-109, -109A
(76.5) NPT (10.2) (10.2) (3.2) (10.2) (26.7) (13.3) (19.7)
39-1/8 1-1/2 6-3/8 4 1-1/4 4-1/8 21-7/16 7-1/4 7-3/4
691-109, -109A
(99.3) NPT (16.1) (10.2) (3.2) (10.4) (54.4) (18.4) (19.7)
46
Model D891 Bare with Flywheel
Suction 5-1/2" 5-1/2"

valve unloaders (13.9) (13.9)
(optional)
Inlet
2" Weld or
NPT flange
Outlet
2" Weld or
NPT flange
1/4" NPT drain
43-1/4"
(109.9) Crankcase heater
(optional)
35-5/8"
(90.4)
24-15/32"
(62.1)
21.2"
(53.8)
8-1/4"
2-1/8" (20.9)
(5.3)
5-5/8" 4-3/4" 5-1/2" 1"

(14.3) (12.0) (13.9) (2.5)
9-16" (1.4) 5-3/8" 5-3/8"
Hole Diameter (13.6) (13.6)
13-1/4"
(33.6) 10-1/4"
(26.0)
47
Model D891 with 103 Mounting
NPT flange
2" Weld or
Inlet
NPT flange
2" Weld or
Outlet
48
Model D891 with 107B Mounting
49
Model D891 with 109B Mounting
50
Appendix F—Troubleshooting
In most cases, problems with your Corken gas compressor compressors along with a list of possible causes. If you
can be solved quite simply. This chart lists some of the are having a problem which is not listed, or if you cannot
more frequent problems that occur with reciprocating find the source of the problem, consult the factory.
Problem Possible Cause

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

1. Valves broken, stuck or leaking Inspect and clean or repair
2. Piston ring worn Inspect and replace as necessary
3. Inlet strainer clogged Clean or replace screen as necessary
4. Leaks in piping Inspect and repair
5. Inlet or ambient temperature too high Consult factory
6. Compression ratio too high Check application and consult factory
7. Loose flywheel or belt Tighten
8. Worn piston-rod packing Replace
9. Worn wrist pin or wrist-pin bushing Replace
10. Worn connecting-rod bearing Replace
11. Unbalanced load Inspect valve or consult factory
12. Inadequate compressor base Strengthen, replace or grout
13. Improper foundation or mounting Tighten mounting or rebuild foundation
14. Loose valve, piston or packing Tighten or replace as necessary
15. Dirty cooling fins Clean weekly
16. 4-way control valve not lubricated Inspect and lubricate
17. Leaking gas blowing oil from crankcase Tighten packing
18. Bad oil seal Replace
19. No oil in crankcase Add oil
20. Oil-pump malfunction See oil-pressure adjustment
21. Low voltage Check line voltage with motor nameplate. Consult power company
22. Motor wired wrong Check wiring diagram
23. Wire size too small for length or run Replace with correct size
24. Wrong power characteristics Voltage, phase and frequency must coincide with motor nameplate.
Consult with power company.
25. Wrong size of heaters in starter Check and replace according to manufacturer’s instructions
26. Compressor overloading Reduce speed
27. Motor shorted out See driver installation
28. Bad motor bearing Lubricate according to manufacturer’s instructions
51
Appendix G—91 and F91 Head and Valve Assembly Details
91 Head Assembly Valve Holddown Assemblies
Suction Suction Discharge
3 Spec 3 Spec 4 All Specs
5 5
5
1
6 6
6
7 7
F91 Head Assembly

11 8 11 9 11 10
3
2
Valve Assemblies
Suction Valve
Spec 3
12
13
4
14
15
Suction Valve Discharge Valve
Spec 4 All Specs
24
16 20
17 21
25
18 22
26
19 23 27
52
Appendix G—91 and F91 Head and Valve Assembly Details
Head and Valve Bill of Materials
Ref
Part No. Description
No.
2374 Head model 91
1. 2374-Xa Head assy. for model 91 (spec 3)
2374-X1 Head assy. for model 91 (spec 4)
2. 4302 Head model F91 (ANSI flange)
3. 7001-037 NC100A Bolt, 3/8-16 x 1" Gr.5 hex head
4. 2-235_c O-ring
5. 2714-1 Valve cap
6. 2-031_c O-ring
7. 2715 Holddown screw
3483-1X Suction valve assy. (spec 3)
8. 3483-1X1b Same as above but with copper gaskets
3483-1X2b Same as above but with iron-lead gaskets
3483-X Suction valve assy. (spec 4)
9. 3483-X1b Same as above but with copper gaskets
3483-X2b Same as above but with iron-lead gaskets
3485-X Discharge valve assy. (all specs)
10. 3485-X1b Same as above but with copper gaskets
3485-X2b Same as above but with iron-lead gaskets
2717 Valve gasket (aluminum)
11. 2717-1b Valve gasket (copper)
2717-2b Valve gasket (iron-lead)
12. 5000-77 Retainer ring (spec 3)
13. 3977 Suction valve relief housing (spec 3)
14. 1411 Spring (spec 3)
15. 1410 Ball (spec 3)
16. 3483-1 Suction valve seat (spec 3)
17. 3972 Suction valve plate (spec 3)
18. 4009 Suction spring (spec 3)
19. 3484 Suction valve bumper (spec 3)
20. 3483 Suction valve seat (spec 4)
24. 3486 Discharge valve bumper
25. 4008 Discharge spring
26. 3973 Discharge valve plate
27. 3485 Discharge valve seat
a Not shown.
O-ring Code b Optional
c_
A Buna-N denotes O-ring code. See O-ring chart to the left for details.
d Registered trademark of the DuPont company.
B Neoprene®d
CAUTION: Always Relieve Pressure In The Unit Before Attempting Any Repairs.
53
Appendix G—91 and F91 Piston Assembly Details
Piston Assembly Number 1983-X Bill of Materials

Piston Diameter 3" (7.62 cm)
Ref
4 Part No. Description Qty
No.
7002-010OC100A Screw, socket head 4
5 1.
7207-010A Lock washer 4
6
2. 1983 Head, iron 1
3. 1775 Ring expander 3
7 4. 1772 Piston ring 3
5. 1482 Locknut 1
6. 1483 Lock pin 1
8
7. 1984 Piston platform 1
9
1528 Shim washer, thick As
8.
1528-1 Shim washer, thin Req.
9. 1527 Thrust washer 1
Piston Clearance (Cold)a

Model Minimum Maximum
Piston Rod 91 0.020" (0.51 mm) 0.044" (1.12 mm)
a The distance from the bottom of the head to the top of the piston.
54
Appendix G—91 and F91 Packing Assembly Details
Packing Assembly Bill of Materials
Ref
Part No. Description Qty
No.
1. 2242 Cylinder 1
2. 2-235_ a O-ring for cylinder 1
3. 5000-137 Retainer ring 1
4. 1012 Washer 1
5. 1628 Packing spring 1
1 6. 1714 Packing box washer 1
7. 1453-1 Male packing ring 1
8. 1454b Packing ring 8
2
9. 1452-1 Female packing ring 1
10. 2240 Crosshead guides 1
3
11. 1387 Adjusting screw 1
7 4 12. 2526 Crankcase gasket 1
13. 1452-1X1 Packing set 1
5 Assembly
Assembly Name
8 Number
6 1132-X2 Crosshead - piston-rod assembly
13
Packing set (alloy 50) with 1452-1,
1452-2X1d
1453-1, 1454-2 (8), 1626, 1714
7,8,9
O-ring Code
9
A Buna-N
B Neoprene®c
a _ denotes O-ring code. See O-ring chart above for details.
10 b The quantity of 1454 packing rings required will vary due to
tolerances. Use cone 4005 for installation of packing.
c Registered trademark of the DuPont company.
d Optional equipment
CAUTION: Always Relieve Pressure In The Unit Before Attempting

Any Repairs.
11
Piston Rod
12
55
Appendix G—91 and F91 Connecting Rod Assembly Details
1 2
3
2
Connecting Rod Assembly Bill of Materials

Ref
4 Part No. Description
No.
1. 1132-X2 Crosshead assembly
2. 1498 Retainer ring
5 3. 2505 Wrist pin
4. 1846-Xa,b Wrist pin bushing
5
5. 1599b Bolt
6. 1889-1X Connecting rod assembly
7. 1889-1b Connecting rod
8. 1367b Connecting rod bearing
9. 2011b Dipper
10. 1600b,c Nut
a Must be rebored after replacing (0.8754/0.8751 dia.)
b Included with connecting rod assembly
c Torque connecting rod nut to 28 ft. lbs.

6, 7 8 Never attempt to separate the piston rod and crosshead. When repair
Note becomes necessary, the entire crosshead assembly must be replaced.
alignment
marks CAUTION: Always Relieve Pressure In The Unit Before Attempting
Any Repairs.
9
10
56
Appendix G—91 and F91 Flywheel Assembly Details
Back Side
Flywheel Assembly Bill of Materials

Assembly Number Assembly Name
Flywheel assembly
3271-X2 (flywheel, hub, and
three bolts)
Flywheel: 14" O.D.,
3271
2 groove
Hub with three
H SF-1.125 bolts and
lockwashers
Front Side
57
Appendix G—91 and F91 Crankcase Assembly Details
3
23
22
10
17
13
18
19
21
20
13
12
16
15
3
14
7
56
4
3
2
1
11
10
9
8
58
Appendix G—91 and F91 Crankcase Assembly Details
Crankcase Assembly Bill of Materials
Ref No. Part No. Description
1. 3259 Oil seal
2. 1483 Roll pin - 1/8 x 1"
3. 7001-037NC075A Hex head 3/8-16 x 3/4", Gr 5
4. 3260 Bearing carrier
5. 2796 Breather ball
6. 1279-X O-ring (part of bearing cap assembly)
7. 1279-X Breather cap assembly (with O-ring - ref. no. 6)
8. 2725 Bearing carrier gasket
9. 1807 Roll pin - 1/8 x 5/8"
10. 2718 Bearing cup
11. 2723 Oil circulating ring
12. 2476 Crankshaft
13. 2719 Bearing cone
14. 2289 Flywheel key
15. 2290 Oil ring retainer washer
16. 2554a Crankcase
17. 1661 Pipe plug - 3/8 NPT sq. or hex
18. 2729 Inspection plate gasket
19. 2728 Crankcase inspection plate
20. 2-112_ c O-ring
21. 1368-X1 Oil bayonet assembly (with O-ring)
2721 Bearing adjustment shim (0.005)
22. 2721-1 Bearing adjustment shim (0.007)
2721-2 Bearing adjustment shim (0.020)
23. 2720 Bearing cap
Other Assemblies
Assembly
Assembly Name
Number
2476-X Crankshaft assembly with 2476, 2290 and 2719
2476-SXb Extended crankshaft assembly with 2719 (2) and 2290, (optional)
Bearing carrier assembly with 3260, 2718, 3259, 1279-X, 2-111,
3260-X
1483, 2796 and 1807
3271-X2b Flywheel assembly 14" - 2 groove with H SF-1.125 and 3271
O-ring Code
A Buna-N
B Neoprene®c
a Crankcase capacity: 0.9 quarts (0.8 liters)
b Optional
c_ denotes O-ring code. See O-ring chart above for details.
59
2
Appendix H—291 and F291 Head and Valve Assembly Details

Spec 3 Spec 4 All Specs
4 7 7
1
3 7
8 8
8
9 9
F291 Head Assembly

13 10 13 11 13 12
3 4
2
Valve Assemblies Details
Suction Valve
Spec 3
14
15
16
6
17
5 Suction Valve Discharge Valve

Spec 4 All Specs
26
18 22
19 23
27
20 24
28
21 25 29
60
Appendix H—291 and F291 Head and Valve Assembly Details
Ref
No.
2912 Head model 291
1. 2912-X1 Head assy. for model 291 (spec 3)
2912-X2 Head assy. for model 291 (spec 4)
2. 4300 Head model F291 (ANSI flange)
3. 7001-037 NC100A Bolt, 3/8-16 x 1" Gr.5 hex head
2731 Center headbolt
4.
2732 Gasket for center headbolt
5. 2-235_b O-ring
6. 2-113_b O-ring
7. 2714-1 Valve cap
8. 2-031_b O-ring
3483-1X Suction valve assy. (spec 3)
10. 3483-1X1a Same as above but with copper gaskets
3483-1X2a Same as above but with iron-lead gaskets
3483-X Suction valve assy. (spec 4)
11. 3483-X1a Same as above but with copper gaskets
3483-X2a Same as above but with iron-lead gaskets
3485-X Discharge valve assy. (all specs)
12. 3485-X1a Same as above but with copper gaskets
3485-X2a Same as above but with iron-lead gaskets
13. 2717-1a Valve gasket (copper)
2717-2a Valve gasket (iron-lead)
14. 5000-77 Retainer ring (spec 3)
15. 3977 Suction valve relief housing
16. 1411 Spring (spec 3)
17. 1410 Ball (spec 3)
18. 3483-1 Suction valve seat (spec 3)
22. 3483 Suction valve seat (spec 4)
27. 4008 Discharge spring
28. 3973 Discharge valve plate
29. 3485 Discharge valve seat
a Optional
O-ring Code b_ denotes O-ring code. See O-ring chart to the left for details.
A Buna-N c Registered trademark of the DuPont company.
B Neoprene®c CAUTION: Always Relieve Pressure In The Unit Before Attempting Any Repairs.
61
Appendix H—291 and F291 Piston Assembly Details

Ref
4 Part No. Description Qty
No.
5
1.
6
7 4. 1772 Piston ring 3
5. 1482 Locknut 1
6. 1483 Lock pin 1
8 7. 1984 Piston platform 1
9 1528 Shim washer, thick As
8.

291 0.020" (0.51 mm) 0.044" (1.12 mm)
Piston Rod a The distance from the bottom of the head to the top of the piston.
62
Appendix H—291 and F291 Packing Assembly Details
Ref
No.
1. 2913-1 Cylinder 1
2. 2-235_a O-ring for cylinder 2
4. 1012 Washer 2
6. 1714 Packing box washer 2
1 7. 1453-1 Male packing ring 2
8. 1454b Packing 6
2 Cartridge holddown
10. 4398 2
screw
4
11. 4394 Packing box cartridge 2
3
5
O-ring (packing
13. 2-135_a 2
6 16
cartridge)
7 14. 4393 Crosshead guide 1
7,8,9 15. 2702 Crankcase gasket 1
10
Inspection plate
17. 1651 1
8 gasket
18. 1650 Inspection plate 1
7003-
19. 1/4-20x3/8" 4
11 025NC037E
not
1192 Locking device 4
shown
9
Other Assemblies
Assembly
Assembly Name Qty
12 Number
1132-X2 Crosshead assembly 2
13 14
Packing set with 1452-1,
1452-1X1 2
1453-1, 1454 (8), 1628, 1714
O-ring Code
A Buna-N
Piston Rod
B Neoprene®c
a _ denotes O-ring code. See O-ring
chart above for details.
19 b The quantity of 1454 packing rings
required will vary due to tolerances.

Use Cone 4005 for installation of
packing.
18 c Registered trademark of the
17 DuPont company.
15
CAUTION: Always Relieve Pressure
In The Unit Before Attempting Any
Repairs.
63
Appendix H—291 and F291 Connecting Rod Assembly Details
1 2
3
2

Ref
No.
1. 1132-X2a Crosshead assembly
4
3. 2505 Wrist pin
5 5. 1599b Bolt
6. 1889-X Connecting rod assembly
5
7. 1889b Connecting rod
9. 1600b,c Nut
Never attempt to separate the piston rod and crosshead. When repair
becomes necessary, the entire crosshead assembly must be replaced.

6, 7 8
Any Repairs.
Note
alignment
marks
64
Appendix H—291 and F291 Flywheel Assembly Details
Back Side

Flywheel assembly
2549-X1 (flywheel, hub, and
three bolts)
Flywheel: 16" O.D.,
2549
3 groove
Hub with three
lockwashers
Front Side
65
Appendix H—291 and F291 Crankcase Assembly Details
1 3 11
2 4
5 10
12
6 13
14
15
9 16
7 17 (Assembly)
2
18
19
8
18
28 26
25 24 20
27 23 21
22
37
44
35 21
38
39 (assembly)
34
40
41
46 9
47
36 48
49
45 50
44 42
33
32
31
51
30
29 27
40
43 (assembly) 52
66
Appendix H—291 and F291 Crankcase Assembly Details
Crankcase Assembly Bill of Materials Other Assemblies
Ref Assembly
Part No. Description Assembly Name
No. Number
1. 1278 Oil seal 1279-X Breather cap assembly with 1279, 2-111A
2. 7001-037NC075A Bolt, 3/8-16 x 3/4, hex head Crankshaft assembly with 1284 (2), 1286, 1341, 1501,
3. 2957 Bearing cover 1341-X1
2590, 2719
1273 Bearing adjustment shim (0.005") Extended crankshaft assembly with 1284 (2), 1286,
4. 1273-1 Bearing adjustment shim (0.007") 1342-X1a
1342, 1501, 2590, 2719
1273-2 Bearing adjustment shim (0.020") 1368-X1 Oil bayonet assembly with 1368-X, 2-112A
5. 1500 Bearing cup Closure cap assembly including 2-218A (2) (Spec 3, 4,
6. 1368-X Oil bayonet 1515-X
8, 9 only)
7. 2713 Crankcase inspection plate gasket Bearing carrier assembly with 1285, 1290, 1291,
8. 2958 Crankcase inspection plate 1292, 1293, 1515-X, 2718, 2805, 2806 (2), 2848-X,
9. 2-112_c O-ring 2956-X
2849-X, 2850, 2851, 2852, 2956, 2961-X, 2011-A,
a,b
10. 2955 Crankcase 2-112A, 2-228A.
11. 1279 Breather cap 2957-X Bearing cover assembly with 2957 and 1278
c
12. 2-111_ O-ring (breather cap) 2961-X Air release valve assembly with 2961, 2962, 2963
13. 2796 Breather ball Flywheel assembly, 14" O.D. 2 groove with 3218 and
14. 1483 Lock pin - 1/8 x 1" 3271-X1a
3271 (not part of crankcase assembly) (not shown)
Crankshaft assembly with 1284 (2), 1286, O-ring Code
17. 1341-X1
1341, 1501, 2590, 2719 A Buna-N
18. 1284 Crankshaft orifice (2)
19. 2719 Bearing cone B Neoprene®d
20. 1286 Pump shaft drive pin a Optional equipment
21. 2590 Pipe plug - 1/8 NPT, flush seal b Crankcase capacity: 1.5 quarts (1.4 liters)
c _ denotes O-ring code. See O-ring chart above for details.
22. 1280 Filter screen screw
23. 1281 Filter screen screw gasket
24. 2-116_c O-ring (filter screen)
25. 1276 Filter screen washer
Any Repairs.
26. 1275 Oil filter screen
27. 3289 Pipe plug - 1/4 NPT, flush seal
28. 1661 Pipe plug - 3/8 NPT
29. 1290 Relief valve adjusting screw
30. 1291 Adjusting screw locknut
c
31. 2-011_ O-ring (relieve valve adjustment screw)
32. 1292 Relief valve spring
33. 1293 Relief valve ball
34. 2718 Bearing cup
Air release valve assembly with 2961,
35. 2961-X
2962, 2963
O-ring (closure body) (2 required) (Spec
38. 2-218_c
3, 4, 8, 9 only)
Closure cap assembly including 2-218A(2)
39. 1515-X
(Spec 3, 4, 8, 9 only)
40. 7001-025NC050A Bolt, 1/4-20 x 1/2, hex head
41. 1302 Oil pressure gauge
42. 2-228_c O-ring (pump cover)
43. 4222-X Oil filter assembly
44. 1629 Pipe plug - 1/16 NPT, flush seal
45. 7001-037NC100A Bolt, 3/8-16 x 1, hex head
46. 2805 Pump shaft bushing
47. 2850 Pump shaft adapter
48. 2852 Oil pump spring
49. 2851 Spring guide
Oil pump assembly (individual pump
50. 2849-X
parts not available)
2798 Pump cover pin with 2848-X
51.
2848-X Pump cover (includes pin)
52. 4225 Filter
67
Appendix I—490, 491, and F491 Head and Valve Assembly Details
490 and 491 Head Assembly Valve Holddown Assemblies
7 7 Spec 3 Spec 4 All Specs
10
6 8 8
11 10 10
1
Suction 12 11 11
12 12
33
13 33 33
13 13
Discharge 14
14 14
9 15
15 15
4 (prior to FZ44188)
16
16 16
491 Head Assembly
7 7
103 101 102
6
2
Suction 17 17
17
Valve Assemblies
Discharge Suction Valve
Spec 3
103 11
9
27 Suction Valve Discharge Valve

5
Spec 4 All Specs
28 101 102
11
11
F491 Head Assembly 29
18 18
7 7
30
6
19 25
3 20
Suction
20 23
21
22
22 21
23 22
21
31 23 20
32 24 26
Discharge
9
17 17 17
68
Appendix I—490, 491, and F491 Head and Valve Assembly Details
Compressor Head and Valve Bill of Materials
Ref Ref
Part No. Description Valve Assembly No. Assembly Name
No. No.
1. 2914d Head—ductile iron (491) Suction valve assembly (see ref. no.
2438-X
2. 3712e Head—ductile iron (491) 7, 17, 18, 19, 20, 21(2), 22, 23, 24)
Same as 2438-X but with copper
3. 4297 Head—ANSI flanged (F491) 101. 2438-X1a
gaskets
4297-1 Head flanged - Din spec. only (F492)
Same as 2438-X but with iron-lead
4. 1481c Head gasket (490 and 491) 2438-X2a
gaskets
5. 2-253_b,c,e O-ring (491)
Discharge valve assembly (see ref.
6. 3442 Pipe plug—1/4" NPT 2439-X
no. 7, 17, 18, 20, 21(2), 22, 26, 25)
7. 1479c Center head bolt Same as 2439-X but with copper
102. 2439-X1a
1480-1c Center head bolt gasket (copper) gaskets
8.
1480c Center head bolt gasket (steel) 2439-X2a
Same as 2439-X but with iron-lead
gaskets
Bolt, 7/16-14 x 1-1/4" ferry head (490 &
7005-043NC125Ac Suction valve assembly (spec. 3)
491 prior to serial # FZ44188) 2532-1X
9. with aluminum
Bolt, 7/16-14 x 1-1/2" ferry head (491
7005-043NC150Ac 103.
2532-1X1a Same as 2532-1X but with copper
serial # FZ44188 and later)
10. 1477 Valve screw nut 2532-1X2a Same as 2532-1X but with iron-lead
11. 1478 Gasket (steel)
1478-1a Gasket (copper) Head Assembly No. Model Valve Specification
1478-2 Gasket (iron) 2914-X2d 491 4
12. 1476 Valve holddown screw 2914-X4d 491 3
13. 1475 Valve cover plate 3712-X1e 491 3
14. 2-143_b O-ring for cover plate 3712-X2e 491 4
15. 1409f Valve spacer 4297-X1 F491 3
16. 2448 Cage 4297-X2 F491 4
1418 Valve gasket (aluminum) 4297-1X1 F492 3
17. 1418-1a Valve gasket (copper) 4297-1X2 F492 4
1418-2a Valve gasket (iron)
18. 2446 Bolt O-ring Code
19. 2438 Suction valve seat
A Buna-N
20. 2442 Valve plate
B Neoprene®g
21. 2445f Spacer (two per valve)
a Optional equipment
22. 3355 Washer
b_ denotes O-ring code. See O-ring chart above for details.
23. 1407 Valve spring c Not included in Head Assembly.
24. 2440 Suction valve bumper d Prior to S/N FZ44188.
e S/N FZ44188 and later.
f Place spacers back to back as shown.
26. 2439 Discharge valve seat g Registered trademark of the DuPont company.
27. 2533-1 Adjusting screw
28. 1411 Relief ball spring CAUTION: Always Relieve Pressure In The Unit Before
Attempting Any Repairs.
29. 1410 Relief ball
30. 2532-1 Suction valve seat
31. 2534-1 Suction valve post
32. 2447 Suction valve bumper
33. 7001-043NC125A Bolt (7/16-14 x 1-1/4” hex head)
69
Appendix I—490, 491, and F491 Piston Assembly Details

Ref
4 No.
1.
5 7207-025A Lock Washer 8
6 2. 1985 Head, iron 1
4. 1773 Piston ring 3
7
5. 1482 Locknut 1
6. 1483 Lock pin 1
8 7. 1986 Piston platform 1
9 8.

490
0.000" (0.00 mm) 0.024" (0.61 mm)
Piston Rod 491b
491c 0.020" (0.51 mm) 0.044" (1.12 mm)
b For 491 compressor with flat gasket.
c For 491 compressor with head O-rings.
70
Appendix I—490, 491, and F491 Packing Assembly Details
Ref
No.
Cylinder (491 w/O-
1. 3713a 1
ring)
2. 2-243_b O-ring for cylinder 2
4. 1012 Washer 2
6. 1714 Packing box washer 2
7. 1453-1 Male packing ring 2
8. 1454c Packing ring 6
1
Cartridge holddown
10. 2801 2
4 screw
2 Packing box
11. 2799 2
3 5 cartridge
6 16
7 O-ring (packing
13. 2-139_b 2
cartridge)
7,8,9
14. 2765d Crosshead guide 1
10 15. 1489 Crankcase gasket 1
8
Inspection plate
17. 1488 1
11 gasket
18. 1487 Inspection plate 1
7003-
9 19. 1/4-20x3/8" 4
025NC037E
not
1192 Locking device 4
12 shown
Additional Assembly
13
14 Assembly
Assembly Name
Number
1384-X Crosshead assembly
O-ring Code
Piston Rod A Buna-N
B Neoprene®e
a S/N FZ44188 and later
19
b_ denotes O-ring code. See O-ring chart
above for details
c The quantity of 1454 packing rings
18
required will vary due to tolerances. Use
17
15 Cone 4005 for packing installation.
d S/N XC30633 and later
e Registered trademark of the DuPont
company.

CAUTION: Always Relieve Pressure In

The Unit Before Attempting Any Repairs.
71
Appendix I—490, 491, and F491 Connecting Rod Assembly Details
1 2
3
2

Ref
4 No.
1. 1384-X Crosshead assembly
5 3. 1496 Wrist pin
5 5. 1492b Bolt
6. 1490-X Connecting rod assembly
7. 1490b Connecting rod
9. 1493b,c Nut
becomes necessary, the entire crosshead assembly must be replaced.
6, 7 8
Note CAUTION: Always Relieve Pressure In The Unit Before Attempting
alignment Any Repairs.
marks
72
Appendix I—490, 491, and F491 Flywheel Assembly Details
Back Side

Flywheel assembly
2549-X (flywheel, hub, and
three bolts)
Flywheel: 16" O.D.,
2549
3 groove
Hub with three
lockwashers
Front Side
73
Appendix I—490, 491, and F491 Crankcase Assembly Details
3 11
1 2 4 10
5
6 12
13
14
9 15
7 16
17
2-1
8 18
19
18
28 26 20
25 24 21
27 23
22
37
44
35 21
38
34 39 (assembly)
40
41
46 9
47
36 48
49
45 50
44 42
33
32
31
51
30
29 27
40
43 (assembly) 52
74
Appendix I—490, 491, and F491 Crankcase Assembly Details
Ref Ref
Part No. Description Part No. Description
No. No.
c
1. 4438 Oil seal 42. 2-228_ O-ring (pump cover)
2. 7001-037NC075A Hex head bolt 3/8-16 x 3/4 43. 4222-X Oil filter assembly - external
2-1. 7001-031NC075A Hex head bolt 5/16-18 x 3/4 44. 1629 1/16" NPT pipe plug, flush seal
3. 2847-1 Bearing cover 45. 7001-037NC100A Hex head bolt 3/8-16 x 1
1504 Bearing adjustment shim (0.005") 46. 2805-X Pump shaft bushing
4. 1504-1 Bearing adjustment shim (0.007") 47. 2850 Pump shaft adapter
1504-2 Bearing adjustment shim (0.020") 48. 2852 Oil pump spring
5. 1502 Bearing cup 49. 2851 Spring guide
6. 1508-X Oil bayonet Oil pump assembly (individual pump
50. 2849-X
7. 1511 Crankcase inspection plate gasket parts not available)
8. 2853 Crankcase inspection plate 2798 Pump cover pin with 2848-X
51.
9. 2-112_ c
O-ring (oil bayonet & pump shaft) 2848-X Pump cover (includes pin)
10. 2803 b
Crankcase 52. 4225 Oil filter
11. 1279 Breather cap

c
Other Assemblies
12. 2-111_ O-ring (breather cap)
Assembly
13. 2796 Breather ball Assembly Name
Number
14. 1483 Lock pin
1279-X Breather cap assembly with 1279, 2-111A
Crankshaft assembly with 1284 (2), 1286, 1499, 1501,
16. 1501 Bearing cone 1499-X
1503, 2590
Crankshaft assembly with 1284 (2), Extended crankshaft assembly with 1284 (2), 1286,
1499-X 1499-SX
a
1286, 1499, 1501, 1503, 2590 1499-S, 1501, 1503, 2590
17.
Extended crankshaft assembly with 1284 1508-X1 Oil bayonet assembly with 1508-X, 2-112A
1499-SX
(2),1286, 1499-S, 1501, 1503, 2590
Closure cap assembly including 2-218A (2), (Spec. 3,
18. 1284 Crankcase orifice (2) 1515-X
4, 8, 9 only)
Bearing carrier assembly with 1290, 1291, 1292,
20. 1286 Pump shaft drive pin 1293, 1500, 1513, 1515-X, 1629 (2), 2590, 2804,
2804-X
1459 Crankshaft plug (depends on design) 2849-X, 2850, 2851, 2852, 2961-X, 2-011A, 2-112A,
21. 2-228A, 4222-X
2590 Pipe plug (depends on design)
22. 1280 Filter screw 2847-1X Bearing cover assembly with 2847-1, 3855
23. 1281 Filter screen screw gasket Flywheel assembly with 3271, 3217 (not part of
3271-Xa
c crankcase assembly (not shown)
24. 2-116_ O-ring (filter screen)
25. 1276 Filter screen washer
26. 1275 Oil filter screen O-ring Code
27 3289 Pipe plug A Buna-N
28. 1661 Plug 3/8" NPT B Neoprene®d
a Optional equipment
30. 1291 Adjusting screw locknut b Crankcase capacity: 3 quarts (2.8 liters)
c
31. 2-011_ O-ring (relief valve adjusting screw) c _ denotes O-ring code. See O-ring chart above for details.
34. 1500 Bearing cup Any Repairs.
Air release valve assembly with 2961,
35. 2961-X
2962, 2963
c O-ring (closure body) (2) (Spec. 3, 4, 8,
38. 2-218_
9 only)
39 1515-X Closure cap assembly
40. 7001-025NC050A Hex head bolt 1/4-20 x 1/2
41. 1302 Oil pressure gauge
75
Appendix J—691 and F691 Head and Valve Assembly Details
9 Suction Suction Discharge
8
Spec 3 Spec 4 All Specs
4 10
1 12 12
5
13 12 13
14 13 14
14
5 15 15
15
16 16
11.1 4.1 16
11
6 8 17 17
17
691 Head Assembly 18 18
8 9 18
4
2
5
101 102 103
19 19 19
5
11.2
4.1 Valve Assemblies
8 Suction Valve
Spec 3
7 20
21
22
F691 Head Assembly 23
Suction Valve Discharge Valve
9 Spec 4 All Specs
3 24
33
31
25
32
32
26
26
28
27
27
104 29
104
28 28 104
11.2 26
29 29
27
7 30 31 31
76
Appendix J—691 and F691 Head and Valve Assembly Details
Ref Ref
Part No. Description Valve Assembly No. Assembly Name
No. No.
1. 1743 Head (690) Suction valve assembly (spec. 3)
3948-X
2. 3458
d
Head (691) (includes valve gasket)
Same as above but with copper
3. 4299 F691 head 101. 3948-X1c
gasket
2144-2 Flange (suction) 2" NPT
4. c c Same as above but with iron-lead
2144-2S Flange 2" weld 3948-X2
gasket
2144-1.5 Flange (discharge) 1-1/2" NPT
4.1 Suction valve assembly (includes
2144-1.5S
c
Flange 1-1/2" Weld 3856-X
valve gasket)
a
5. 2-231_ O-ring c Same as above but with copper
b 102. 3856-X1
1744 Head gasket (690) gasket
6. b,c
1744-1 Head gasket grafoil c Same as above but with iron-lead
2255-X2
a gasket
7. 2-261_ O-ring for head (691)
Discharge valve assembly (includes
8. 7001-043 NC150A Bolt, 7/16-14 x 1-1/2" hex head 3857-X
valve gasket)
9. 2136 Center head bolt
c Same as above but with copper
1625 Center head bolt gasket (aluminum) 103. 3857-X1
gasket
c
10. 1625-1 Center head bolt gasket (copper) c Same as above but with iron-lead
c 3857-X2
1625-2 Center head bolt gasket (iron-lead) gasket
11. 7005-043 NC125A Bolt, 7/16-14 x 1-1/4" ferry head 104. 3146-X1 Valve repair kit (suction & discharge)
11.1 7006-043A Reg. lockwasher 7/16"
11.2 7005-050 NC150A Bolt, 1/2-13 x 1-1/2" ferry head Other Assemblies
2714 Valve cap Head Assembly Number Models Valve Specification
12.
2714-1 Valve cap, grooved for O-ring 1743-X 690 3
a 3458-X 691 3
2-031_ O-ring for valve cap
c
2716 Gasket (aluminum) for valve cap
13. c
2716-1 Gasket (copper) for valve cap O-ring Code
c
2716-2 Gasket (iron) for valve cap A Buna-N
B Neoprene®e
15. 7001-043 NC137A Bolt, 7/16-14 x 1-3/8" hex head
16. 1764 Valve cover plate b Not
a included in head assembly.
17. 2-235_ O-ring (cover plate) c Optional.
18. 2797 Valve cage d S/N NQ51455 and later. Earlier models use gasket #2177.
e Registered trademark of the DuPont company.
c
19. 2114-1 Valve gasket (copper)
c
2114-2 Valve gasket (iron)
20. 5000-77 Retainer ring
21. 3977 Suction valve relief housing (spec 3)
22. 1411 Spring
23. 1410 Relief ball
24. 3948 Valve seat (spec. 3)
25. 2534-1 Suction valve post (spec 3)
26. 3872 Inner valve plate
27. 3871 Outer valve plate
28. 3929 Inner valve spring
29. 3928 Outer valve spring
30. 3949 Valve bumper (spec. 3)
31. 3857 Valve bumper
32. 3920 Valve stud
33. 3856 Valve seat
77
Appendix J—691 and F691 Piston Assembly Details
Piston Assembly Number 1987-X1 Bill of Materials

Piston Diameter 4.5" (11.43 cm)
Ref
No.
4 1. 7002-025TP125A Screw, socket head 8
5
6
4. 1739 Piston ring 3
5. 1482 Locknut 1
7 6. 1483 Lock pin 1
7. 1735 Shim washer, thick As
8
8. 1986 Piston platform 1
690 0.000" (0.00 mm) 0.012" (0.30 mm)
691 0.015" (0.38 mm) 0.027" (0.68 mm)
Piston Rod a The distance from the bottom of the head to the top of the piston.
78
Appendix J—691 and F691 Packing Assembly Details
Ref
No.
1. 3457 Cylinder 1
Cartridge holddown
3. 1749 2
screw
1
6. 1728 Packing washer 2
7. 1724 Male packing ring 2
2 8. 1725 Packing ring 4
9. 1723 Female packing ring 2
10. 2407 Packing box cartridge 2
3 O-ring (packing
11. 2-233_a 2
cartridge)
4
12. 1748 Cartridge plate 2
5 14. 2405 Crosshead guide 1
7 6 17
16. 1761 Crankcase gasket 1
17. 1725-2X Packing set 2
7,8,9
8 Inspection plate gas-
18. 1760 1
ket
10 19. 1721 Inspection plate 1
7003-
9 20. Screw-1/4-20x3/8" 4
025NC037E
15 not Locking device for
1192 4
shown adj. screw
11 Locking device
not
2893 cartridge holddown
shown
screw
Other Assemblies
Assembly
14 Assembly Name
Number
1717-X1 Crosshead assembly “P” style
Crosshead guide assembly with
2405-X
1748 (2), 2405, 5000-350 (2)
12 3544-X4 Crosshead assembly “M” style
13
O-ring Code
A Buna-N
B Neoprene®b
Piston Rod 20
a _ denotes O-ring code. See O-ring chart
above for details.
b Registered trademark of the DuPont
company.
19
18 CAUTION: Always Relieve Pressure In The
16 Unit Before Attempting Any Repairs.
79
Appendix J—691 and F691 Connecting Rod Assembly Details
7 2

3 3
Part Number
Ref
Description
No. Spec. K,P Spec. M
Only Only
1. 1717-X1 3544-X4 Crosshead assy.
2. 1498 3590 Retainer ring
3. 1718 3540 Wrist pin
4. 1495-X a,b 3541-Xb,d Wrist pin bushing
5. 1726b 1726b Bolt
6. 1720-X 3785-X1 Conn. rod assy.
7. 1720 b 3785b Connecting rod
8. 1719b 3542b Conn. rod bearing
9. 1727 b,c 1727b,c Nut
9
d Must be rebored after replacing (1.1256/1.252 dia.)
Note
alignment Never attempt to separate the piston rod and crosshead. When
4,5 marks repair becomes necessary, the entire crosshead assembly must
be replaced.
CAUTION: Always Relieve Pressure In The Unit Before

Attempting Any Repairs.
6
80
Appendix J—691 and F691 Flywheel Assembly Details
Back Side

Flywheel assembly
three bolts)
Flywheel: 19.5"
1762
O.D., 4 groove
Hub with three
H E-2.125 bolts and
lockwashers
Front Side
81
Appendix J—691 and F691 Crankcase Assembly Details
15
14
16 20
5 19
13 18
17
12
11
28
9
8
4
10
7
26
25
24
5 23
4 22 27
3 21
2
1
6 31
29
30
37
38 51
39
40
32 36 41
35
34
33 28
Inside of
50 Bearing Carrier
49 57
48 56
47
46
45 54 55
44
43 53
42 60 Oil Passage Hole
55 52 Important! Line up hole in
gasket with oil passage hole.
33 58
59
50 Pump Cover Oil/Filter Adapter
55
42
60
61 Pumpside of adapter shown for

(Includes all parts shown proper orientation of cover and
except #52 and #53) location of pump cover pin.
82
Appendix J—691 and F691 Crankcase Assembly Details
Ref Ref
No. No.
1. 1737 Bearing cone 48. 2-112_d O-ring
d
2. 3638 Spacer 49. 2805-X_ Pump shaft bushing
3. 3635 Drive sprocket 50. 1629 Pipe plug, 1/16 NPT fl. seal
4. 1284 Crankshaft orifice 51. 1736 Bearing cup
5. 2135 Drive pin 52. 1302 Oil pressure gauge
6. 2933 Link pin 53. 1044 Bushing, 1/8 x 1/4 NPT
7. 3786 Crankshaft 54. 3220-2 Bearing carrier
8. 3503 Flywheel key 55. 3289 Pipe plug, 1/4 NPT fl. seal
9. 3580 Bearing cone 56. 2131 Bearing carrier gasket
10. 3786-X1 Crankshaft assembly 57. 2961-X Air release valve assembly
11. 7001-031NC075A Bolt, 5/16 - 18 x 3/4" hex head 58. 2590 Pipe plug, 1/8 NPT fl. Seal
12. 2122 Inspection cover 59. 4225 Filter
13. 2123 Gasket, inspection cover 60. 2798 Pump cover pin (included w/4222-X)
d
14. 2-210_ O-ring 61. 3220-2X Bearing carrier assembly M3 style
15. 3225-X1 Oil bayonet assembly (w/O-ring)
16. 2126 Breather ball Additional Assembly
17. 3579 Bearing cup Assembly Assembly Name
3589 Bearing adjustment shim (.005") Number
18. 3589-1 Bearing adjustment shim (.007") 3221-X1a Crankcase assembly (M3, 4, 8, 9) without lubrication
3589-2 Bearing adjustment shim (.020")
19. 3539 Bearing cover O-ring Code
20. 3526 Oil seal A Buna-N
21. 1280 Filter screw
B Neoprene®e
22. 1281 Gasket, filter
d a Not shown
23. 2-116_ O-ring
b Must be rebored and honed after replacing (0.876"/0.875" diameter)
24. 1276 Washer c Caution: To avoid damage during assembly, refer to installation
25. 1275 Oil filter screen Instruction Manual IE400.
d _denotes O-ring code. See O-ring chart above for details.
26. 3443 Pipe plug, 1/2" NPT steel
27. 3221 Crankcase
28. 7001-037NC100A Bolt, 3/8 - 16 x 1" hex head Gr. 5 CAUTION: Always Relieve Pressure In The Unit Before Attempting
29. 3875 Access cover Any Repairs.
30. 7003-025NC037E Screw, 1/4 - 20 x 3/8"

31. 3874 Gasket, access cover
32. 1515-X Closure cap assembly
33. 7001-025NC050A Bolt, 1/4 - 20 x 1/2" hex head
34. 1515 Closure cap
35. 1516 Closure body
d
36. 2-218_ O-ring
d
38. 2-011_ O-ring
c
42. 4222-X Oil filter adapter assembly (w/pin)
d
43. 2-228_ O-ring
c
44. 2849-1X Oil pump assembly
83
Appendix K—D891 Head and Valve Assembly Details
891 Head Valve Holddown Valve Holddown
Assembly (4-1/2") Assembly (4-1/2")
4 Suction Discharge
1
5 5
6 6
7 7
2 14 14
8 8
2
3
9 9
10
10
3
12
11
O-ring Code
A Buna-N
13 13
B Neoprene®d
Compressor Head and Valve Bill of Materials Valve Assemblies (4-1/2")

Ref Suction Discharge
Part No. Description Valve Valve
No.
1. 3923 Cylinder cap
15 20
2. 3924 Cylinder head (4-1/2")
3. 2-246__b O-ring
Bolt, 1/2 - 13 x 1-1/2" hex head
4. 7001-050 NC150A
Gr 5 (Torque to 65 ft•lbs)
16 16
5. 2714-1 Valve cap
6. 2-031__b O-ring
8. 1764 Valve cover plate 17 19
18
9. 2-235__b O-ring
21 21
10. 3570-1 Valve cage 17
11. 3732-X Suction valve assembly (4-1/2") 19 18
12. 3733-X Discharge valve assembly (4-1/2")
13. 2114a Valve gasket
Bolt, 7/16 - 14 x 1-1/2" hex head
14. 7001-043 NC150A 15
(Torque to 37 ft•lbs) 20
15. 3827 Valve seat (4-1/2")
16. 3828 Stud a Included with valve assembly
17. 3830c Valve plate, outer b_ denotes O-ring code. See O-ring chart above for details.
18. 3831c Valve plate, inner c Included with valve repair kit.
19. 3829c Spring
20. 3826 Valve bumper (4-1/2") CAUTION: Always relieve pressure in the unit before
21. 3805-X1c Valve repair kit (1st stage) attempting any repairs.
84
Appendix K—D891 Piston Assembly Details
1
Piston Assembly Bill of Materials

2 Part No.
Ref.
D891 Description Qty
No.
3925-X1 (4-1/2")
1. 7002-025-TP100A Screw, orlo gr. 8 (torque to 8 ft•lbs) 4
3 2. 3927 Piston cap 1
3.
2902-1 Shim washer, thin req.
1739 Piston rings
4 4. 1739-2 Alloy 50 rings—opt. 4
1739-3 Peek rings—opt.
5 5. 1740 Expander ring 4
4
6. 3604 Lock nut (torque to 150 ft•lbs) 1
5 3925
8. Piston 1
(4-1/2" diameter)
9.
4 3603-1 Shim washer, thin req.
10. 3812 (not shown) Loctite tube—620 1
5
Piston Clearance (Cold)

4 Model Top Min. a Top Max. a Bottom Min.b Bottom Max.b
D891 0.084" (2.13 mm) 0.104" (2.64 mm) 0.010" (0.25 mm) 0.020" (0.50 mm)
5
b The distance from the bottom of the piston to the top of the packing barrel.
6
Piston Piston
9
Piston Piston
Piston Piston bottom dead center

Piston top dead center
Rod
85
Appendix K—D891 Crosshead Guide Assembly Details
17
Packing barrels
17 and cartridges
(For parts details,
see D891 packing
on previous pages).
12
16
12
15
14
13
86
Appendix K—D891 Crosshead Guide Assembly Details
Crosshead Guide Bill of Materials

Ref
No.
1. 3922 Cylinder 1
Drain valve (lubricated
2. 1054 1
models)
3. 1071 Nipple, 1/4" x close 1
5. 3442 Pipe plug, 1/4" NPT 3
Bolt, 1/2" 13 x 1-3/4"
6. 7001-050NC175A 24
hex head gr 5
7. 3793-2S Flange (inlet/outlet) 2
8. 2-231_a O-ring for flange 2
9. 3253 Roll pin 1
10. 2405-1 Crosshead guide 1
11. 1064 Elbow, 1/4" NPT 1
12. 3974 Tag 1
13. 1761 Gasket, crankcase 1
Gasket, inspection
14. 1760 1
cover
15. 1721 Inspection cover 1
Bolt, 10 - 24 x 1/4"
16. 7012-010NC025B 10
Phillip hd.
O-ring Code
A Buna-N
B Neoprene®b
b Registered trademark of the DuPont company.

Any Repairs.
Note:
Packing barrel installation:
1. Use packing installation cone #905 on the piston rod.
2. Insert small barrel first, use finger holes to align slinger ring on to
the rod. Slip the packing barrel into place.
3. Align pin with slot in large packing barrel.
4. Slip large packing barrel in place.
87
Appendix K—D891 Packing Assembly Details
Specification “J” Specification “K”
1 1
2 2
3 3
4 4
5 5
6 Radial 6 Radial
Tangent Tangent
7 7
4 4
5 5
6 Radial 6 Radial
Tangent Tangent
7 7
18 18
4 4
Upper Upper 5
5
Segmented Segmented
Packing 6 Radial Packing 6 Radial
Set Tangent Set Tangent
7 7
4 4
5 5
6.1 Tangent 6.1 Tangent

Tangent Tangent
7 7
8 8
9 9
V-ring Packing Direction
10 10
11 Lower Packing Lower Packing 11
Specification Specification
12 “J” “K” 12
13 13
15 17
14 17
16 16
13 16
15 19
19 17
15 15 Lower
Lower 13
V-ring
V-ring 16
14 Packing
Packing
17 Set
Set To Crankcase To Crankcase
13
13
12
12
88
Appendix K—D891 Packing Assembly Details
Specification “R” Packing Assembly Bill of Materials
Ref
No.
1. 3926 Packing barrel (4-1/2")
a,c
2. 2-238_ O-ring
3. 3906 Crush gasket
1 Packing cup (Not included in 3810-X1
4. 3817
packing set)
2 5. 2-036_
a,d
Cup O-ring
Segmented packing
3 6. 3810
(radial—tangent) pair
4 Segmented packing
6.1. 3814
5 (tangent—tangent) pair
7. 3811 Back-up ring
6.1 Tangent
8. 7002-025OC100A Screw, 1/4-20 x 1" socket head
Tangent
9. 3885 Cartridge
7 10. 2-231_
a
O-ring
b
4 11. 1732 Oil deflector ring
5 12. 5000-175 Retainer ring
13. 1728 Washer
6.1 Tangent
14. 1731 Spring
Tangent
15. 1724 Male packing ring
7
16. 1725 V-ring packing
18 4 17. 1723 Female packing ring
Upper 5 e
18. 3810-X1 Segmented packing set
Segmented
Packing Tangent 19. 1725-2X V-ring packing set
6.1
Set Tangent
7 Identification of Packing Specification
4 Example: Model Number D891 J M4FBA
5 Packing Spec.
Tangent
6.1
Tangent Segmented Packing for Segmented packing for
7 Specification “J” & “K” Specification “J”, “K”, & “R”
Piston (Pressure) Side Piston (Pressure) Side
V-ring Radial Cut Tangent Cut

8 Packing (without pin) Align pin (without pin) Align pin
Direction with hole with hole
Tangent Cut Tangent Cut

Lower Packing (with pin) (with pin)
Specification
9 “R” Back-up Back-up
10 ring ring
11 15
12 16 To Crankcase To Crankcase
13
17 IMPORTANT: Identify and line up the rings before installing. Be sure
14 they face the way shown here and that the pin and hole are aligned
when assembled.
13
To Crankcase a _ denotes O-ring code. See O-ring chart for details.
19
15 b Deflector
Lower ring is loose within the packing cartridge until fitted on the
V-ring 16 piston rod. Must be put in from the bottom of the cartridge.
c Insert O-ring into the groove in the bottom of the barrel.
Packing O-ring Code
Set 17 d Starting with S.N. NN51397.
A Buna-N e Packing cup O-ring not included in packing set.
13 B Neoprene
®f f Registered trademark of the DuPont company.
®f
12 D Viton
E PTFE
®f
K Kalrez
89
Appendix K—D891 Connecting Rod Assembly Details
7 2

3 3
Ref
No.
1. 3544-X3 Crosshead assembly
3. 3540 Wrist pin
5. 1726b Bolt
6. 3785-Xa Connecting rod assembly
7. 3785a Connecting rod
8. 3542a Connecting rod bearing
9. 1727a,c Nut
a Included with connecting rod assembly
b Torque connecting rod nut to 40 ft. lbs.
c Must be rebored after replacing (1.1256/1.252 dia.)
9
Note becomes necessary, the entire crosshead assembly must be replaced.
alignment
4,5 marks CAUTION: Always Relieve Pressure In The Unit Before Attempting
Any Repairs.
90
Appendix K—D891 Flywheel Assembly Details
Back Side

Flywheel assembly
three bolts)
Flywheel: 21.2"
3852
O.D., 5 groove
Hub with three
H J-2.125 bolts and
lockwashers
Front Side
91
Appendix K—D891 Crankcase Assembly Details
15
14
16 20
5 19
13 18
17
12
11
28
9
8
4
10
7
26
25
24
5 23
4 22 27
3 21
2
1
6 31
29
30
37
38 51
39
40
32 36 41
35
34
33 28
Inside of
50 Bearing Carrier
49 57
48 56
47
46
45 54 55
44
43 53
42 60 Oil Passage Hole
55 52 Important! Line up hole in
gasket with oil passage hole.
33 58
59
50 Pump Cover Oil/Filter Adapter
55
42
60
61 Pumpside of adapter shown for

(Includes all parts shown proper orientation of cover and
except #52 and #53) location of pump cover pin.
92
Appendix K—D891 Crankcase Assembly Details
Ref Ref
No. No.
d
1. 1737 Bearing cone 48. 2-112_ O-ring
b
2. 3638 Spacer 49. 2805-X Pump shaft bushing
3. 3635 Drive sprocket 50. 1629 Pipe plug, 1/16 NPT fl. seal
4. 1284 Crankshaft orifice 51. 1736 Bearing cup
5. 2135 Drive pin 52. 1302 Oil pressure gauge
6. 2933 Link pin 53. 1044 Bushing, 1/8 x 1/4 NPT
7. 3786 Crankshaft 54. 3220-2 Bearing carrier
8. 3503 Flywheel key 55. 3289 Pipe plug, 1/4 NPT fl. seal
9. 3580 Bearing cone 56. 2131 Bearing carrier gasket
10. 3786-X1 Crankshaft assembly 57. 2961-X Air release valve assembly
11. 7001-031NC075A Bolt, 5/16 - 18 x 3/4" hex head 58. 2590 Pipe plug, 1/8 NPT fl. Seal
12. 2122 Inspection cover 59. 4225 Filter
13. 2123 Gasket, inspection cover 60. 2798 Pump cover pin (included w/4222-X)
d
14. 2-210_ O-ring 61. 3220-2X Bearing carrier assembly
15. 3225-X1 Oil bayonet assembly (w/O-ring)
16. 2126 Breather ball Additional Assembly
17. 3579 Bearing cup Assembly Assembly Name
3589 Bearing adjustment shim (.005") Number
a
18. 2589-1 Bearing adjustment shim (.007") 3221-X1 Crankcase assembly (M3, 4, 8, 9) without lubrication
2589-2 Bearing adjustment shim (.020")
19. 3539 Bearing cover O-ring Code
20. 3526 Oil seal A Buna-N
21. 1280 Filter screw
B Neoprene®e
22. 1281 Gasket, filter
d a Not shown
23. 2-116_ O-ring
b Must be rebored and honed after replacing (0.876"/0.875" diameter)
24. 1276 Washer c Caution: To avoid damage during assembly, refer to installation
25. 1275 Oil filter screen Instruction Manual IE400.
d _denotes O-ring code. See O-ring chart above for details.
26. 3443 Pipe plug, 1/2" NPT steel
27. 3221 Crankcase
28. 7001-037NC100A Bolt, 3/8 - 16 x 1" hex head Gr. 5 CAUTION: Always Relieve Pressure In The Unit Before Attempting
29. 3875 Access cover Any Repairs.
30. 7003-025NC037E Screw, 1/4 - 20 x 3/8"

31. 3874 Gasket, access cover
32. 1515-X Closure cap assembly
33. 7001-025NC050A Bolt, 1/4 - 20 x 1/2" hex head
34. 1515 Closure cap
35. 1516 Closure body
d
36. 2-218_ O-ring
d
38. 2-011_ O-ring
c
42. 4222-X Oil filter adapter assembly (w/pin)
d
43. 2-228_ O-ring
c
44. 2849-1X Oil pump assembly
93
94
95
Corken, Inc. • A Unit of IDEX Corporation
3805 N.W. 36th St., Oklahoma City, OK 73112
Phone (405) 946-5576 • Fax (405) 948-7343
Visit our website at http://www.corken.com
or e-mail us at [email protected]
Printed in the U.S.A.

July 2009

Installation, Operation & Maintenance Manual: Liquid Transfer-Vapor Recovery Compressors

Uploaded by

Document Informationclick to expand document information

Document Informationclick to expand document information

Copyright:

Available Formats

Installation, Operation & Maintenance Manual: Liquid Transfer-Vapor Recovery Compressors

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Installation, Operation & Maintenance Manual: Liquid Transfer-Vapor Recovery Compressors

Uploaded by

Copyright:

Available Formats

IE101H

Downloaded from www.Manualslib.com manuals search engine

Corken One Year Limited Warranty

All implied warranties, including any implied wa­rranty of merchantability or fitness

Contacting The Factory

Important Note to Customers!

O-ring head gaskets:

Ductile iron construction:

Self-lubricating PTFE piston rings:

Positively locked pistons:

Self-lubricating piston rod seals:

Nitride-coated piston rods:

Cast iron crossheads:

Pressure-lubricated crankcase with filter:

Construction Details—Model F291 Compressor

The process of compressing the gas also increases the

1.2 Residual Vapor Recovery

Pressure difference between

tanks causes liquid to flow out of

Four Way Valve Position 1 Liquid Line

Liquid line is valved closed

Removing vapor from Vapor is

Four Way Valve Position 2

Figure 1.2A: Residual Vapor Recovery

the point at which the inlet pressure is one-fourth the

Invariably, there is some liquid remaining in the tank

Corken’s automatically reversible oil pump design

Corken compressors use iron pistons that are locked

Piston rod packing is used to seal the gas in the

The typical Corken compressor valve consists of a seat, Suction Valve

Suction valve Valve plate

Valve gasket Valve gasket

Figure 1.3D: Suction and Discharge Valves

Figure 1.3B: Pressure Lubrication System

Corken compressors handling toxic or flammable gases such Note:

2.2 Foundation DO NOT SUPPORT PIPING WITH THE COMPRESSOR.

See ED410 (Compressor Foundation Concrete Ground level

Figure 2.3B: Five-Valve Manifold Piping System

On liquefied gas applications, a liquid trap must be used

Corken offers three types of liquid traps for removal of

It is of extreme importance to prevent the entry of

All piping must be in accordance with the laws and codes

For LP Gas – The National Fire Protection Association

For Ammonia – The American National Standards

Copies of these are available from NFPA, 60 Baterymarch

Corken’s most sophisticated trap provides the most

NOTE: The level switch MUST be removed from

For installation with engine drivers, thoroughly review

Depending on the truck design, the compressor may be

2.9 Shutdown/Alarm Devices

Low Oil Pressure Switch: Shuts down the unit if crankcase

High Temperature Switch: Shuts down the unit if the

Vibration Switch­: Shuts down the unit if vibration

Figure 2.8D: Top Transport Mounting

3.1 Inspection After

Drain the oil from the crankcase and remove the

Rotate unit manually to ensure running gear functions

All implied warranties, including any implied warranty of merchantability or fitness

Vibration Switch: Shuts down the unit if vibration