IJ110G LowRes

IJ110G
Installation, Operation
& Maintenance Manual
D and T-Style Double-Acting Gas Compressors
Models D791, T791, D891 and T891
Model D891
Compressor Package
Model T891
Compressor
Warning: (1) Periodic inspection and maintenance of Corken products is essential. (2) Inspection, maintenance and installation of Corken products must be made
only by experienced, trained and qualified personnel. (3) Maintenance, use and installation of Corken products must comply with Corken instructions, applicable laws
and safety standards (such as NFPA Pamphlet 58 for LP-Gas and ANSI K61.1-1972 for Anhydrous Ammonia). (4) Transfer of toxic, dangerous, flammable or explosive
substances using Corken products is at user’s risk and equipment should be operated only by qualified personnel according to applicable laws and safety standards.
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., 9201 North I-35 Service Road, Oklahoma City, OK. 73131.
Parts subject to wear or abuse, such as mechanical seals, blades, piston rings, valves, and packing, and other
parts showing signs of abuse are not covered by this limited warranty. Also, equipment, parts and accessories not
manufactured by Corken but furnished with Corken products are not covered by this limited warranty and purchaser
must look to the original manufacturer’s warranty, if any. This limited warranty is void if the Corken product has been
altered or repaired without the consent of Corken.
ALL IMPLIED WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS

FOR A PARTICULAR PURPOSE, ARE EXPRESSLY NEGATED TO THE EXTENT PERMITTED BY LAW AND
SHALL IN NO EVENT EXTEND BEYOND THE EXPRESSED WARRANTY PERIOD.
Corken disclaims any liability for consequential damages due to breach of any written or implied warranty on Corken
products. Transfer of toxic, dangerous, flammable or explosive substances using Corken products is at the user’s
risk. Such substances should be handled by experienced, trained personnel in compliance with governmental
and industrial safety standards.
Contacting The Factory

For your convenience, the model number and serial number are given on the compressor nameplate. Space is
provided below for you to keep a written record of this information.
Always include the model number and serial number when ordering parts.
Model No.
Serial No.
Date Purchased
Date Installed
Purchased From
Installed By
2
Table of Contents
FEATURES AND BENEFITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHAPTER 1—INSTALLING YOUR CORKEN COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Foundation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Liquid Trap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Driver Installation/Flywheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 Crankcase Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7 Purging, Padding, Venting and Draining of Distance Pieces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.8 Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.9 Shutdown/Alarm Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHAPTER 2—STARTING UP YOUR CORKEN COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Inspection After Extended Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Flywheel and V-belt Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Crankcase Oil Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Startup Check List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CHAPTER 3—ROUTINE MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CHAPTER 4—ROUTINE SERVICE AND REPAIR PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.1 Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Piston Rings and Piston Ring Expanders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.4 Piston Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5 Piston Rod Packing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.6 Cylinder and Packing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.7 Bearing Replacement for Crankcase and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.8 Oil Pump Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CHAPTER 5—EXTENDED STORAGE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
APPENDICES
A. Vertical Double-Acting Model Number Identification Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
B. Vertical Double-Acting Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
C. Outline Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
D. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
E. Assembly Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3
Features and Benefits
High-efficiency valves:
Corken valves offer quiet operation and high
durability in oil-free gas applications.
Ductile iron construction:

All cylinders and heads are ductile iron for maximum
thermal shock endurance.
Upper packing
(Segmented)
Self-lubricating PTFE piston rings:
Corken provides a variety of state-of-the-art piston
ring designs to provide the most cost-effective
operation of compressors for non-lube service. The
step-cut design provides higher efficiencies during
the entire life of the piston ring. Upper distance piece
Positively locked pistons:

Simple piston design allows end clearance to be Middle packing (V-ring)
precisely set to provide maximum efficiency and
long life.
Lower distance piece
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.
Oil deflector ring
Nitride-coated piston rods: Lower packing (V-ring)

Impregnated nitride coating provides superior
corrosion and wear resistance.
Adjustable packing screw:

Ensures maximum sealing capacity during the life of
the packing (T791 and T891 models only).
Cast iron crossheads:

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

Self-reversing oil pump ensures proper lubrication
regardless of directional rotation to main and
connecting rod bearings. Standard 10-micron filter
ensures long-lasting bearing life.
Construction details: Model T891 compressor
4
Chapter 1—Installing Your Corken Compressor
1.1 Location
Note: The depth of the concrete foundation will
vary based on local soil conditions.
NOTE: Compressor must be installed in a well Main beam (C-Beam)

ventilated area.
Concrete foundation Cross beam (H-Beam)
Corken compressors are designed and manufactured for
outdoor duty. For applications where the compressor will Hex nut
be subjected to extreme conditions for extended periods &
washer
such as corrosive environments, arctic conditions, etc.,
consult Corken. Check local safety regulations and building
codes to assure installation will meet local safety standards.
Corken compressors handling toxic or flammable

gases such as LPG/NH3 should be located outdoors in 3/4″ diameter “J” bolt
a well ventilated area. A minimum of 18 inches (45 cm)
clearance between the compressor and the nearest wall
is advised to make it accessible from all sides and to
provide unrestricted air flow for adequate cooling.
Figure 1.2: Recommended foundation details
for Corken compressors
Noise:
Corken vertical compressors should not exceed an 85 be at least the same diameter as the suction nozzle on
DBA noise level when properly installed. the compressor.
If a restrictive device such as a valve, pressure regulator,

1.2 Foundation or back-check valve is to be installed in the compressor’s
Proper foundations are essential for a smooth running suction line, care must be taken. The suction line volume
compression system. Corken recommends the between the restrictive device and the compressor
compressor be attached to a concrete slab at least 8 suction nozzle must be at least ten times the swept
inches thick with a 2 inch skirt around the circumference cylinder volume.
of the steel structural skid. The steel structural skid
should be securely anchored into the foundation by 3/4 On liquefied gas applications such as LPG/NH3, it is of
inch diameter “J” bolts that are 8 inches long. The total extreme importance to prevent the entry of liquid into the
mass of the foundation should be approximately twice compressor. Installing a liquid trap on the inlet side will
the weight of the compressor system (compressor, prevent liquid from entering the compressor (see section 1.4).
baseplate, motor, etc.). See figure 1.2 for details.
It is of equal importance to protect the discharge side
For a more detailed explanation of a proper foundation of the compressor from liquid entry. This may be done
design, please refer to ED410, Important Instructions by installing a check valve on the discharge side of the
for Compressor Foundation Design. compressor and using a piping design that does not
allow liquid to gravity drain into the compressor.
1.3 Piping
Proper piping design and installation is as important as a
Flexible connector Flexible connector
proper foundation is to a smooth operating compressor.
Improper piping installation will result in undesirable
transmission of compressor vibration to the piping.
Pipe support
Pipe support
DO NOT SUPPORT PIPING WITH THE COMPRESSOR.
Unsupported piping is the most frequent cause of vibration
Steel structural skid
of the pipe. The best method to minimize transmission of
vibration from the compressor to the piping is to use Concrete Ground level
flexible connectors (see figure 1.3 for details). foundation
Pipe must be adequately sized to prevent excessive

pressure drop between the suction source and the
compressor as well as between the compressor and
Figure 1.3: Flexible connectors should be used to minimize
the final discharge point. In most cases, piping should transmission of vibration to the piping.
5
For vapor recovery applications, be certain to install Corken’s liquid trap provides the most thorough liquid
a check valve on vapor lines discharging to the liquid separation (see figure 1.4) and is ASME code stamped.
space of the tank. It contains two level switches, one for alarm and one
for shutdown. In some cases the alarm switch is used
All piping must be in accordance with the laws and codes to activate a dump valve (not included with trap) or
governing the service. In the United States, the following sound an alarm for the trap to be manually drained by
codes apply: the operator. This trap also contains a mist pad. A mist
pad is a mesh of interwoven wire designed to remove
For LP Gas—The National Fire Protection Association fine liquid mists. The ASME code trap is standard in
Pamphlet No. 58, Standard for the Storage and Handling the 109B and 107B mounting configurations.
of Liquefied Petroleum Gases.
NOTE: The liquid level switch MUST be removed from
For Ammonia—The American National Standards the trap before grounding any welding devices to
Institute, Inc., K61.1-1989, Storage and Handling of the trap or associated piping! Failure to do so will
Anhydrous Ammonia. damage the switch contacts.
Copies of these are available from NFPA, 60 Baterymarch If your compressor is equipped with a liquid trap not
Street, Boston, Mass, 02110 and ANSI, 1430 Broadway, New manufactured by Corken, make sure it is adequately
York, N.Y., 10018. Install, use and maintain this equipment sized; otherwise it may not be able to remove the liquid
according to Corken instructions and all applicable federal, entrained in the suction stream.
state, and local laws and previously mentioned codes. Other
laws may apply in different industries and applications.
1.5 Driver Installation/Flywheels
1.4 Liquid Trap Corken vertical compressors may be driven by either
electric motors or combustion engines (gasoline, diesel,
Compressors are designed to pressurize gas—not to natural gas, etc.).
pump liquids. The entry of even a small amount of liquid
into the compressor will result in serious damage. Note: Never operate a reciprocating compressor without
a flywheel.
On liquefied gas applications, a liquid trap must be
used to prevent the entry of liquid into the compressor. Drivers should be selected so the compressor operates
between 400 and 900 RPM. The unit must not be
operated without the flywheel or severe torsional
imbalances will result that could cause vibration and
a high horsepower requirement. The flywheel should
never be replaced by another pulley unless it has a
higher wk2 value than the flywheel.
Humid climates can cause problems with explosion

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

instructions from the engine manufacturer to assure the
unit is properly installed.
1.6 Crankcase Lubrication

To ensure proper lubrication of the crankcase parts
before startup, the crankcase should be filled through the
Figure 1.4: ASME automatic liquid trap nameplate inspection opening.
6
Non-detergent oil is recommended for Corken vertical and from these tapped holes are essential for optimum
compressors. Detergent oils tend to keep wear particles compressor performance.
and debris suspended in the oil, whereas non-detergent
oils let them settle in the bottom of the crankcase. Corrosive gases should be prevented from entering the
When non-detergent oils are not available, detergent crankcase, since even small amounts of gas leakage into
oils may usually be successfully substituted, although the crankcase can seriously contaminate the crankcase
compressors handling ammonia, amine, or imine gases are oil. To prevent this contamination, the distance piece
notable exceptions. These gases react with the detergent may be purged, padded, or vented using a clean, non-
and cause the crankcase oil to become corrosive and corrosive gas like dry air or nitrogen.
contaminated. Figures 1.6A and 1.6B show recommended
oil viscosities and crankcase capacities. Ensure oil is Purging:
compatible with the product being compressed. Purging of the distance piece controls leakage of process
gas to the atmosphere. Process gas leakage into the
Synthetic lubricants are generally not necessary. Please distance piece is quickly diluted by the purge gas and
consult your lubricant supplier if you are considering the swept away. The purge gas should be vented to a safe
use of synthetic oil. release area, flare, compressor’s inlet, or treatment
facility, depending on the gas and local regulations.
1.7 Purging, Padding, Venting and When purging, it is critical to maintain the proper
Draining of Distance Pieces pressure loading across each set of packing. The higher
pressure should be on the open side of the “V”, which is
The key to leakage control and oil-free operation of also the side with the spring.
Corken compressors is the distance piece. The distance
piece is integral with the crosshead guide and forms Moisture, oil, or condensate can be removed from the
the upper portion of it. Distance pieces are equipped distance piece with the purge gas by using the lower
with tapped holes to allow purging, padding, venting, distance piece connection (drain location) as the purge
and draining (see Figure 1.7). Proper connections to gas outlet connection.
Acceptable Crankcase Oil Products for Corken

Compressors
Constant Weight - Non-Detergent - R&O Inhibited
Oil product ISO VI SAE Ambient Temp.
Exxon®
TERESSTIC 100 95 30 65° - 100° F
68 95 20+ 45° - 70° F
46 95 20 35° - 50° F
Mobil®
Upper
RARUS 427 Reciprocating 100 95 30 65° - 100° F
Distance
Compressor Oil Piece
DTE Oil Heavy Medium 64 95 20+ 45° - 100° F
Dectol R&O Oil 44 95 20 35° - 50° F
Conoco® Drain Plug
Dectol R&O Oil 100 98 30 35° - 50° F

68 97 20+ 45° - 70° F
46 99 20 35° - 50° F
Texaco®
Regal R&O Oil 100 92 30 65° - 100° F Lower
68 97 20+ 45° - 70° F Distance
46 102 20 35° - 50° F Piece
Sun®
SunVis 900 Oil 100 100 30 65° - 100° F
68 100 20+ 45° - 70° F
46 100 20 35° - 50° F
Drain Plug
Figure 1.6A: Oil selection chart
Compressor Approximate Capacity

Model Quarts Liters
791, 891 7.0 6.6
Figure 1.6B: Oil capacity chart Figure 1.7: Distance piece details
7
Corken offers Purge Kits which include the necessary devices should be selected to meet local code
regulator, valves, fittings, etc. Consult the factory or see requirements. Shutdown/alarm devices typically used on
Important Instruction, item number IE210, for details. Corken compressors are as follows:
Padding (Buffering): Low Oil Pressure Switch—shuts down the unit if

crankcase oil pressure falls below 12 psi due to oil pump
If purging is not practical, the distance piece can be
failure or low oil level in crankcase.
pressurized with a static pressure. This is called padding
or buffering. Padding is done at a pressure above the
High Temperature Switch—shuts down the unit if
compressor’s suction pressure using a clean non-
the normal discharge temperature is exceeded. This is
corrosive gas like dry air or nitrogen. The higher pressure
strongly recommended for all applications. Typically,
in the distance piece tends to reduce the process gas
the set point is about 30°F (-1°C) above the normal
leakage to the atmosphere. A small amount of purge gas
discharge temperature.
will likely get into the process gas. A pressure regulator
can be used to maintain proper distance piece pressure. Low Suction, High Discharge Pressure Switch—
shuts down the unit if inlet or outlet pressures are not
When padding, it is critical to maintain the proper
within preset limits.
pressure loading across each set of packing. The higher
pressure should be on the open side of the “V”, which is Vibration Switch —shuts down the unit if vibration
also the side with the spring. becomes excessive. Recommended for units mounted
on portable skids.
Venting:
The distance piece can also simply be vented to an
appropriate release area, flare, or treatment facility. This
is sometimes useful for indoor installations.
Draining:
Since some oil will pass the lower packing set, regular
draining of the distance piece is essential to maintain
oil-free operation (See Figure 1.7). Corken recommends
draining the distance piece once a week for units in
continuous-duty operation. Installing a drain cock to the
distance piece drain will help simplify draining of the
distance piece.
Highly Corrosive Gases:

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

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

For many applications, shutdown/alarm switches will
provide worthwhile protection that may prevent serious
damage to your compressor system. All electronic
8
Chapter 2—Starting Up Your Corken Compressor
NOTE: Read this entire chapter, then proceed with
the startup checklist.
2.1 Inspection After

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

nameplate and crankcase inspection plate. Inspect the
running gear for signs of rust and clean or replace parts Figure 2.2A: Flywheel installation
as necessary. Replace the crankcase inspection plate
and fill crankcase with the appropriate lubricant through
the nameplate inspection opening. Squirt oil on the
crossheads and rotate the crankshaft by hand to ensure
that all bearing surfaces are coated with oil.
Rotate unit manually to ensure running gear functions

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

Before working on the drive assembly, be sure that the
electric power is disconnected. When mounting new
belts, always make sure the driver and compressor are
close enough together to avoid forcing.
Figure 2.2B: Belt tension
Improper belt tension and sheave alignment can cause
vibration, excessive belt wear and premature bearing
failures. Before operating your compressor, check Tighten the belts so that they are taut, but not extremely
alignment of the V-grooves of the compressor flywheel tight. Consult your V-belt supplier for specific tension
and driver sheave. Visual inspection often will indicate if recommendations. Belts that are too tight may cause
the belts are properly aligned, but use of a square is the premature bearing failure. Refer to figure 2.2B.
best method.
The flywheel is mounted on the shaft via a split, tapered

2.3 Crankcase Oil
hub and three bolts (see figure 2.2A). These bolts should
be tightened in an even and progressive manner to the
Pressure Adjustment
specified torque values listed below. There must be a Your Corken compressor is equipped with an automatically
gap between the bushing flange and the flywheel when reversible gear type oil pump. It is essential to ensure
installation is complete. Always check the flywheel the pumping system is primed and the oil pressure is
runout before startup and readjust if it exceeds the value properly adjusted in order to assure smooth operation.
listed in Appendix B.
Before starting your compressor, check and fill the
crankcase with the proper amount of lubricating oil.
Set Screw
Hub Diameter Bolt Torque
Torque Ft-lb When the compressor is first started, observe the
Size in. (cm) Ft-lb (kg-meter)
(kg-meter) crankcase oil pressure gauge. If the gauge fails to
SF 4.625 (11.7) 12-18 (1.7–2.5) 22 (3.1) indicate pressure within 30 seconds, stop the machine.
E 6.0 (15.2) 30-36 (4.1–4.9) 22 (3.1) Loosen the oil filter and remove the pressure gauge.
Restart the compressor and run it until oil comes out of
J 7.25 (18.4) 75-81 (10.3–11.1) 109 (15.1)
the pressure gauge opening or around the filter. Tighten
the filter and reinstall the gauge.
9
The oil pressure should be about 20 psi (1.4 bars) minimum 10. Rotate unit by hand and make certain there is no
for normal service. If the compressor discharge pressure wobble or play.
is above 200 psi (14.8 bars), the oil pressure must be
maintained at a minimum of 25 psi (1.7 bars). A spring- 11. Check crankcase oil level.
loaded relief valve mounted on the bearing housing opposite
the flywheel regulates the oil pressure. As shown in figure 12. Drain all liquid traps, separators, etc.
2.3, turn the adjusting screw clockwise to increase the
oil pressure and counterclockwise to lower it. Be sure to 13. Verify proper electrical supply to motor and panel.
loosen the adjusting screw locknut before trying to turn the
screw and retighten it after making any adjustment. 14. Check all gauges and confirm a zero level reading.
15. Test piping system for leaks.
16. Purge unit of air before pressurizing with gas.

Oil pressure
relief valve and 17. Carefully check for any loose connections or bolts.
adjustment screw
18. Remove all stray objects (rags, tools, etc.) from vicinity
of the unit.
Oil filter 19. Confirm all valves are open or closed as required.
20. Double-check all of the above.
Breather cap After Starting Compressor

Oil pressure gauge
1. Verify and note proper oil pressure. Shut down and
Figure 2.3: Oil pressure adjustment correct any problems immediately.
2. Observe noise and vibration levels. Correct immediately

2.4 Startup Check List if excessive.
Please verify each item on this list below before
starting your compressor! Failure to do so may result 3. Verify proper compressor speed.
in a costly (or dangerous) mistake.
4. Examine entire system for gas or oil leaks.
Before Starting the Compressor
5. Note rotation direction.
1. Become familiar with the function of all piping
associated with the compressor. Know each line’s use! 6. Check start-up voltage drop, running amperage and
voltage at motor junction box (not at the starter).
2. Make certain actual operating conditions will match the
anticipated conditions. 7. Verify proper lubrication rate (lubed units only).
3. Ensure line pressures are within cylinder pressure 8. Test each shutdown device and record set points.
ratings.
9. Test or confirm set point on all relief valves.
4. Clean out all piping.
10. Check and record all temperatures, pressures and
5. Ensure all distance piece openings are tubed or volumes after 30 minutes and 1 hour.
plugged as desired.
11. After 1 hour running time, tighten all head bolts, valve
6. Check all mounting shims, cylinder and piping supports holddown bolts, and baseplate bolts. See Appendix B
to ensure that no undue twisting forces exist on the for torque values.
compressor.
7. Make certain strainer elements are in place and clean.
8. Make certain cylinder bore and valve areas are clean.
9. Check V-belt tension and alignment or drive alignment

on direct drive units.
10
Chapter 3—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)
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 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.
11
Chapter 4—Routine Service and Repair Procedures
CAUTION: Always relieve pressure in the unit before Valve Inspection and/or Replacement
attempting any repairs. After repair, the unit should
be pressure tested and checked for leaks at all joints Before removing and inspecting the valves, begin by
and gasket surfaces. depressurizing and purging (if necessary) the unit.
If routine maintenance is performed as listed in chapter Disassembly

3, repair service on your Corken gas compressor is
generally limited to replacing valves or piston rings. 1. Unscrew the valve cap and remove the O-ring.
When it comes time to order replacement parts, be sure
to consult the part details appendix in the back of this 2. Remove the valve cover plate, O-ring and holddown
Installation, Operation & Maintenance (IOM) manual for a screw by removing each of the four bolts. The holddown
complete list of part numbers and descriptions. screw is easily removed with the special wrench
supplied with your compressor.
4.1 Valves 3. After the cover plate and O-ring have been removed,
the valve cage, valve assembly and valve gasket can
Test the compressor valves by closing the inlet piping valves
be lifted out.
while the unit is running; however, do not allow the machine
to operate in this way very long. If the inlet pressure gauge
4. Inspect valves for breakage, corrosion, debris and
does not drop to zero almost immediately, one or more
scratches on the valve plate. In many cases, valves
of the valves is probably damaged or dirty. However, it is
may simply be cleaned and reinstalled. If the valves
possible for the pressure gauge itself to be faulty.
show any damage, they should be repaired or replaced.
Replacement is usually preferable although repair parts
In most cases, if a valve or gasket is leaking, it will create
are available. If valve plates are replaced, seats should
more heat. On a single-stage compressor, you may be
also be lapped until they are perfectly smooth. If more
able to compare the operating temperatures of the two
than .005 of an inch must be removed to achieve a
suction or discharge valves and cover plates to each
smooth surface, the valve should be discarded. If
other. If a valve or gasket is leaking, it will have a higher
plates are replaced without relapping the seat, rapid
operating temperature. NOTE: This method will not be
wear and leakage may occur.
suitable for two-stage compressors if each stage does
not have more than one valve.
Assembly
Each suction and/or discharge valve assembly is easily
1. Insert metal valve gasket into the suction and/or
removed as a unit for inspection. If any part of the
discharge opening of the head. The metal valve
valve assembly is broken, the valve assembly should be
gasket should always be replaced when the valve
replaced. See valve assembly parts details in the Appendix
is reinstalled.
E for a complete list of part numbers and descriptions.
2. Insert cleaned or new valve assembly. Make sure the
If a valve is leaking due to dirt or any other foreign
suction and discharge valves are in the proper suction
material that keeps the valve plate and seat from sealing,
and discharge opening in the head.
the valve may be cleaned and reused. New valve gaskets
and O-rings should be used to assure a good seal. 3. Insert the valve cage.
The valve holddown assemblies and valve assemblies 4. Replace the O-ring and valve cover plate. Torque the
on the following pages show the various specifications bolts to the value listed in Appendix B. CAUTION: Be
used on models 791 and 891 compressors. Since more sure the holddown screw has been removed.
than one suction valve arrangement is available for
each model of compressor, it is necessary to know your 5. To ensure the valve gasket is properly seated, insert
complete model number so you can identify the valve the holddown screw and tighten to the value listed
type specification number (see example listed below). in Appendix B. NOTE: Gaskets and O-rings are not
normally reusable.
Model number D891AM 4 FBANSNN 6. Replace the O-ring and valve cap and tighten to the
Valve type = spec 4 value listed in Appendix B.
7. Check bolts and valve holddown screws after first week

of operation. Re-torque if necessary. See Appendix B
for torque values.
12
4.2 Heads rings should be replaced, measure the radial thickness
and compare it to the chart in Appendix B.
A compressor cylinder cap and head very seldom requires
replacement if the compressor is properly maintained.
The primary cause of damage to a cylinder cap or head 4.4 Piston Replacement
is corrosion and the entry of solid debris or liquid into the 1. To replace the pistons, depressurize the compressor
compression chamber. Improper storage can also result and purge if necessary.
in corrosion damage to the cylinder cap and heads (for
proper storage instructions see chapter 5). 2. Remove the compressor cylinder cap, head and
cylinder (see section 4.2).
Many compressor repair operations require removal of
the cylinder cap and heads. While the compressor is 3. Remove the piston cap by loosening and removing the
disassembled, special care should be taken to avoid socket head bolts holding the piston cap to the piston
damage or corrosion. If the compressor is to be left open (see figure 4.3).
for more than a few hours, bare metal surfaces should be
coated with rust preventative. 4. Next, remove the lock nut and lift the piston off the end
of the piston rod.
When reassembling the compressor, make sure the
bolts are retightened per the torque values listed in 5. Check the thrust washer and shims for damage and
Appendix B. replace if necessary.
6. Before installing the new piston, measure the thickness

4.3 Piston Rings and Piston of the existing shims.
Ring Expanders 7. Replace the cylinder.
8. Install the piston with the same thickness of shims as

before, and with new piston rings and expanders.
9. Now remove a lower valve and measure dimension

“Y” at the bottom of the piston shown in Appendix E—
Piston Assembly Details. If this measurement does not
fall within the tolerances listed in the piston assembly
details (Appendix E), remove the piston, adjust the
shims as necessary and remeasure the “Y” dimension.
10. When the piston is properly shimmed, tighten the lock

nut as shown in Appendix B.
Figure 4.3: Piston cap removal
11. Replace the piston cap with the same thickness of
shims as before.
Piston ring life will vary considerably from application to
application. Ring life will improve dramatically at lower 12. Reinstall the piston cap and cylinder head.
speeds and temperatures.
13. Now remove an upper valve and measure dimension
1. To replace the piston rings, depressurize the “X” at the top of the piston shown in Appendix E—
compressor and purge if necessary. Piston Assembly Details. If this measurement does
not fall within the tolerances in Appendix E, remove
2. Remove the cylinder cap and heads to gain access to the cylinder head and piston cap and adjust the shims
the compressor cylinder. as necessary. Repeat the steps and measure the “X”
dimension again.
3. Loosen the piston cap bolts and remove the piston
cap as shown in figure 4.3 by pinching two loose 14. When the piston cap is properly shimmed, tighten the
bolts together. socket head bolts in an alternating sequence. Torque
socket head bolt to the values listed in Appendix B.
4. Remove the lock nut and lift the piston off the end of
the piston rod. 15. Replace the previously removed valves. Best results
will be obtained if new valve gaskets are used.
5. Piston rings and expanders may then be easily
removed and replaced. Corken recommends replacing 16. Follow standard startup procedures.
expanders whenever rings are replaced. To determine if
13
4.5 Piston Rod Packing Adjustment Packing Replacement Instructions
Piston rod packing should be adjusted or replaced For specific construction details and actual part numbers,
whenever leakage becomes noticeable. Adjust packing consult Appendix E in the back of this Installation,
by tightening packing nuts as shown in Figure 4.5. Operation & Maintenance (IOM) manual. Use instructions
below and on the following pages that apply to the
MODEL and SERIAL NUMBER of your compressor. Be
careful to arrange packing sets in the proper order.
CAUTION: Before installing the new piston rod

packing, bleed all pressure from the compressor and
piping and purge if necessary. After the new piston
rod packing has been installed, the unit should be
pressure tested and checked for leaks at all joints
and gasket surfaces. When the compressor is being
used with toxic, dangerous, flammable or explosive
gases, this pressure and leak testing should be done
with air or a dry, inert gas such as nitrogen.
Figure 4.5: Packing adjusting nuts (models T791 and T891 only) Cleanliness:
NOTE: Compressor models D791 and D891 do not Sealing a reciprocating piston rod is a very difficult
have adjustable packing nuts so the packing sets on task. Keep all parts, tools and your hands clean during
models D791 and D891 are not adjustable, the piston installation. Your new packing needs every chance it can
rod packing should be replaced whenever leakage get, so keep it clean.
becomes noticeable.
Workmanship:
Typically, it is a good idea to replace piston rod packing
and piston rings at the same time. For instructions on Your Corken compressor is a precision piece of equipment
replacing the piston rod packing, see section 4.6. with very close tolerances. Treat it as such. Never beat
on it to get parts in or out.
4.6 Cylinder and Packing Packing Configuration
Replacement The packing for these compressors includes segmented

packing in a packing barrel at the lower end of the
Cylinders very seldom require replacement if the cylinder and V-ring packing in a packing box cartridge
compressor is properly maintained. The primary cause below the segmented packing.
of damage to cylinders is corrosion and the entry of
solid debris or liquid into the compression chamber. Refer to Appendix E for packing assembly details. Note
Improper storage can also result in corrosion damage to the arrangement of the particular packing sets for the
cylinder (for proper storage instructions see chapter 5). model of machine that you have.
If the cylinder does become damaged or corroded, use 4.6.1 Model D791 and D891 Compressors (D-Style)
a hone to smooth the cylinder bore and then polish it
to the value shown in Appendix B. If more than .005 of On Models D791 and D891, there is one set of V-ring
an inch must be removed to smooth the bore, replace packing in a packing box cartridge attached to the
the cylinder. Cylinder liners and oversized rings are packing barrel. The packing box cartridge holds the
not available. OVERBORING THE CYLINDER WILL segmented packing inside the barrel.
RESULT IN GREATLY REDUCED RING LIFE.
Disassembly of Packing (D-Style)
Many compressor repair operations require removal of
1. Depressurize and open the compressor.
the cylinder. While the compressor is disassembled,
special care should be taken to avoid damage or
2. Remove the cylinder cap, heads, pistons and cylinder.
corrosion to the cylinder. If the compressor is to be left
open for more than a few hours, bare metal surfaces 3. Remove the packing barrels by prying upwardly under
should be coated with rust preventative. each one and lifting entire packing barrel/cartridge
assembly up from piston rod.
When reassembling the compressor, make sure the
bolts are retightened using the torque values listed in
Appendix B.
14
4. Remove the four socket head screws that hold the a. Clean the segmented packing cups and the area
packing box cartridge to the barrel. inside the packing barrel.
5. Remove segmented packing and cups from barrel. b. Insert the segmented packing cups, segmented
packing pairs and backup rings one at a time in
6. Remove lower retainer ring, washers, packing spring the order shown in Appendix E.
and old V-ring packing from packing box cartridge.
c. Reattach the packing box cartridge to the packing
Assembly of Packing (D-Style) barrel using the four socket head screws.
1. Replace packing as required. The segmented packing 4. Install three O-rings on the packing barrel and packing
and cups are located in the packing barrel while the box cartridge as shown in the D-Style Crosshead
V-ring packing is located in the packing box cartridge. Guide Assembly Details in Appendix E.
NOTE: Always use new O-rings when replacing
the packing. 5. Install packing installation cone part number 3905 over
the threaded end of the piston rod.
2. V-ring packing set:
6. Carefully install barrel/cartridge assemblies over the
NOTE: The instructions below are for packing piston rods, noting the alignment of the barrels as they sit
specification “J”. Depending on the packing on the crosshead guide. The valve scallops on the barrels
specification used in your compressor, the order must align properly with the valves in the cylinder.
of assembly for the packing rings, V-ring packing,
washers and packing spring will vary. Refer to 7. Remove packing installation cone.
Appendix E to view the V-ring packing arrangements
and follow the order of assembly and V-ring direction. 8. Replace pistons, cylinders, heads and cylinder cap. See
If you do not know the packing arrangement used details in Section 4.4 for proper assembly of pistons.
in your compressor, refer to the model number
identification codes listed in Appendix A. 9. Rotate unit by hand to ensure proper assembly.
a. Clean and lightly oil the packing area inside the 4.6.2 Model T791 and T891 Compressors (T-Style)
packing box cartridge. On Models T791 and T891 there are two sets of V-ring
packing in a separate packing box cartridge held in
b. Insert the oil deflector ring through the bottom the crosshead guide by a cartridge holddown screw. A
opening of the packing box cartridge. packing adapter holds the segmented packing inside the
packing barrel.
c. Insert the first retainer ring followed by a washer.
Disassembly of Packing (T-Style)
d. Insert the packing spring followed by another
washer. 1. Depressurize and open the compressor.
e. Insert a male packing ring followed by four V-rings 2. Remove the cylinder cap, heads, pistons and cylinder.
and one female packing ring. NOTE: Insert
packing rings and V-rings one at a time. Refer 3. Remove the packing barrels.
to Appendix E for the proper direction of the
male and female packing rings and V-rings. 4. Remove the four socket head screws that hold packing
adapter to the barrel.
f. Lastly, insert the final washer. Push in on the
washer and install the second retainer ring. 5. Remove segmented packing and cups from barrel.
3. Segmented packing: 6. Remove cartridge holddown screws with special

wrench supplied with the compressor, and remove
NOTE: The instructions below are for packing cages and packing box cartridges.
specification “J”. Depending on the packing
specification used in your compressor, the order of 7. On the lower V-ring packing set, remove adjusting
assembly for the segmented packing arrangement screw, washers, packing spring and old packing from
(radial or tangent) will vary. Refer to Appendix E each packing box cartridge.
to view the segmented packing arrangements. If
you do not know the packing arrangement used 8. On the middle V-ring packing set, remove upper
in your compressor, refer to the model number retainer ring, washers, packing spring and old packing
identification codes listed in Appendix A. from each packing box cartridge.
15
Assembly of Packing (T-Style) e. Lastly, push in on the washer and insert the third
retainer ring.
1. Replace packing as required. The segmented packing
and cups are located in the packing barrel while the f. Install two O-rings on the packing box cartridge as
V-ring packing is located in the packing box cartridge. shown in the T-Style Crosshead Guide Assembly
NOTE: Always use new O-rings when replacing Details in Appendix E.
the packing.
4. Segmented packing:
2. Lower V-ring packing set:
NOTE: The instructions below are for packing
NOTE: The instructions below are for packing specification “G”. Depending on the packing
specification “G”. Depending on the packing specification used in your compressor, the order of
specification used in your compressor, the assembly for the segmented packing arrangement
order of assembly for the packing rings, V-ring (radial or tangent) will vary. Refer to Appendix E
packing, washers and packing spring will vary. to view the segmented packing arrangements. If
Refer to Appendix E to view the V-ring packing you do not know the packing arrangement used
arrangements and follow the order of assembly in your compressor, refer to the model number
and V-ring direction. If you do not know the packing identification codes listed in Appendix A.
arrangement used in your compressor, refer to
the model number identification codes listed in a. Clean the segmented packing cups and the area
Appendix A. inside the packing barrel.
a. Clean and lightly oil the packing area inside the b. Insert the segmented packing cups, segmented
packing box cartridge. packing pairs and backup rings one at a time in
the order shown in Appendix E.
b. Insert the first retainer ring followed by a washer
through the bottom of the packing box cartridge. c. Reattach the packing adapter to the packing barrel
using the four socket head screws.
c. Insert the packing spring followed by another
washer. d. Install two O-rings on the packing barrel as shown
in the T-Style Crosshead Guide Assembly Details
d. Insert a male packing ring followed by four V-rings in Appendix E.
and one female packing ring. NOTE: Insert
packing rings and V-rings one at a time. Refer 5. Install packing installation cone part number 3905 over
to Appendix E for the proper direction of the the threaded end of the piston rod.
packing rings and V-rings.
6. Before installing the packing box cartridge over the
e. Lastly, install and tightened the adjusting screw packing cone and piston rod, you must insert the oil
until the PTFE locking device located on the side deflector ring through the side opening of the packing
of the adjusting screw is engaged with the first box cartridge. The oil deflector ring should rest on top
thread of the packing box cartridge. DO NOT OVER of the lower packing set. Make sure the oil deflector
TIGHTEN! The PTFE locking device should engage ring is centered over the piston rod opening before
(slightly bent) the first thread but not break off. sliding packing cartridge over the installation cone and
piston rod.
3. Middle V-ring packing set:
7. Install cages.
a. Clean and lightly oil the packing area inside the
packing box cartridge. 8. Install and tighten holddown screws with special
wrench.
b. Insert the second retainer ring followed by a washer
through the top of the packing box cartridge. 9. Install packing barrels, noting the alignment of the
barrels as they sit on the crosshead guide. The valve
c. Insert a female packing ring followed by four scallops on the barrels must align properly with the
V-rings and one male packing ring. NOTE: Insert valves in the cylinder.
packing rings and V-rings one at a time. Refer
to Appendix E for the proper direction of the 10. Remove packing installation cone.
male and female packing rings and V-rings.
11. Replace cylinder, pistons, heads and cylinder cap. See
d. Insert a washer and a packing spring followed by details in Section 4.4 for proper assembly of pistons.
another washer.
12. Rotate unit by hand to ensure proper assembly.
16
4.7 Bearing Replacement for 4. Make sure the lubrication hole in the bushing matches
the oil passage in the connecting rod. If the holes do
Crankcase and Connecting Rod not align, drill out the bushing through the connecting
rod lubricant passage with a long drill. Bore the wrist
1. To replace the crankcase roller bearings, wrist pin pin bushing I.D. as indicated. See Appendix E for
bushing and connecting rod bearings, begin by details. Over boring the bushing can lead to premature
removing the cylinder cap, heads, cylinder, pistons, failure of the wrist pin bushing.
crosshead guide and crosshead assemblies.
5. Inspect the oil passage for debris and clean thoroughly
2. Drain the crankcase and remove the inspection plates. before proceeding.
3. Before disassembly, choose and mark one connecting 6. Press the wrist pin back into the crosshead and wrist
rod and the corresponding connecting rod cap. DO pin bushing and reinstall retainer rings. NOTE: The
NOT MIX CONNECTING RODS AND CAPS. Loosen fit between the wrist pin and bushing is tighter than
and remove the connecting rod bolts in order to lubricated air compressors and combustion engines.
remove the crosshead and connecting rod assembly.
4.7.2 Replacing Connecting Rod Bearings
4.7.1 Wrist Pin Bushing Replacement
Connecting rod bearings are easily replaced by removing
1. To replace the wrist pin bushing, remove the retainer the semicircular bearings. Make sure the indentations
rings that position the wrist pin in the crosshead. in the connecting rod bearing and connecting rod line
up when installing the new bearings. MAKE SURE
2. Press out the wrist pin so the crosshead and connecting
THE ARROW AND/OR ALIGNMENT NOTCH ON
rod may be separated. Inspect the wrist pin for wear
CONNECTING ROD AND CAP ARE ALIGNED.
and damage and replace if necessary.
Before reinstalling the crosshead/connecting rod
3. Press out the old wrist pin bushing and press a new
assembly, make sure the crankshaft throw and bearing
bushing into the connecting rod. DO NOT MACHINE
surface are clean and lubricated. Tighten the connecting
THE O.D. OR I.D. OF THE BUSHING BEFORE
rod bolts to the torque values listed in Appendix B.
PRESSING INTO CONNECTING ROD.
Figure 4.7: Bearing carrier replacement
17
4.7.3 Replacing Crankcase Roller Bearings add more shims, but make sure not to over shim.
(Appendix B lists the proper crankshaft endplay). When
To inspect the roller bearings, remove the flywheel from
the crankshaft can be rotated freely by hand with
the crankshaft and then remove the bearing carrier and
proper endplay, the rest of the compressor may be
crankshaft from the crankcase. If corrosion or pitting is
reassembled. If the crankshaft roller bearings are too
present, the roller bearings should be replaced. When
tight or too loose, premature bearing failure will result.
replacing roller bearings, always replace the entire
bearing and not just the cup or the cone.
7. Reinstall the oil pump and flywheel and check the run
out as shown in Appendix B.
1. To replace the bearings, press the cups out of the
crankcase and bearing carrier and press the cones off
the crankshaft. 4.8 Oil Pump Inspection
2. Press the new bearings into position and reassemble If the compressor operates for a prolonged period
the crankshaft and bearing carrier to the crankcase. with dirty or contaminated crankcase oil, damage to
When reinstalling the bearing carrier, make sure the oil the oil pump and bearings may result.
pump shaft slot is aligned with the pin in the crankshaft.
Make sure to install the bearing carrier gasket so the oil 1. To check the oil pump, unbolt the pump cover and
passage hole is not blocked (see figure 4.7). remove the oil pump, spring guide, spring and oil
pump shaft adapter as shown in figure 4.8.
3. In order to check the crankshaft endplay, the oil pump
must first be removed (see section 4.8). 2. Inspect the gears in the oil pump for corrosion or
pitting and replace if necessary.
4. Press the end of crankshaft towards the crankcase; if a
clicking noise or motion is detected, the crankshaft has 3. Check the oil pump shaft bushing in the bearing
too much endplay. See Appendix B. carrier. If the bushing is corroded, pitted or worn,
the oil pump shaft bushing should be replaced.
5. To reduce endplay, remove the bearing cover and Inspect and replace other parts as necessary.
remove a thin shim. Recheck the endplay after replacing
the bearing cover. 4. Before reassembling the oil pump mechanism,
replace the O-rings in the oil pump cover and on
6. When there is no detectable endplay, the shaft must the oil pump adapter shaft (see figure 4.8).
still be able to rotate freely. If the crankshaft sticks
or becomes abnormally warm, then the crankshaft 5. Rotate the drive pin in the crankshaft to a vertical
bearings are too tight. If the crankshaft is too tight, position for easiest reassembly.
Figure 4.8: Oil pump inspection
18
6. Insert the shaft adapter so it engages the drive pin.
Chapter 5—Extended Storage
7. Next, insert the spring, spring guide and oil pump Procedures
assembly. The pin on the oil pump must align with
the slot in the shaft adapter. Following a few simple procedures will greatly minimize
the risk of the unit becoming corroded and damaged.
8. Install the pump cover so the pin on the case Corken recommends the following precautions to protect
is in the opening on the oil pump assembly as the compressor during storage:
shown in figure 4.8. When you are sure the pin is
properly aligned, install the cover bolts finger tight. 1. Drain the crankcase oil and refill with rust inhibiting oil.
If alignment is correct, the pump cover will mount
flush to the bearing carrier. If it does not, re-check 2. Operate for a few minutes while fogging oil into the
the pin alignment. compressor suction.
9. Tighten the bolts in an alternating sequence. See 3. Relieve V-belt tension.

section 2.3 for directions on oil pressure adjustment.
4. Plug all openings to prevent entry of insects and
10. Finally, rotate the crankshaft by hand to ensure moisture. (The cylinders may also be protected by the
smooth operation. Then rotate it in opposite use of a vapor phase inhibitor, silica gel, or dry nitrogen
directions, listening for a click, which indicates gas. If the silica gel is used, hang a tag on the unit
proper alignment of the oil pump’s pins and slots. indicating that it must be removed before start-up.)
5. Store in a dry area and off the ground if possible.
6. Rotate the flywheel every two weeks if possible.
19
Appendix A—Industrial Vertical Double Acting Model Number
Identification Code (D-Style)
MODEL NUMBER
BASE MODEL NUMBER D791 D891
Inlet 2" weld 2" weld BASE X X X X X X X X X X
Outlet 2" weld 2" weld
Intercooler connection 2" weld NA
Approximate shipping weight (lbs.) 930 900
SPECIFICATION FIELDS
Packing arranged for padding of distance piece Standard J
Packing
Packing arranged for venting of distance piece No charge option K
Arrangement
Atmospheric inlet or light vacuum service No charge option R
Pressure lubricated crankcase Standard M

Crankcase Std. crankcase with crankcase heater Charge option MH
Style Std. crankcase with cylinder lubricator Charge option Charge option L
Std. crankcase with cylinder lubricator and heater Charge option Charge option LH
Standard suction and discharge valves Standard 4

Standard suction & discharge valves w/ light springs No charge option No charge option 4L
Loadless start through suction valve unloaders and
Charge option Charge option 7(a)
hydraulic unloader
Constant speed unloading through suction valve
Charge option Charge option 8(b)
Valves unloaders and pilot valve
Combination control: loadless starting and constant
Charge option Charge option 78(a)(b)
speed unloading
Suction valve unloaders Charge option Charge option 9
Spec 4 valves w/MC1002 corrosion resistant coating NC NA 4C*
Spec 9 valves w/MC1002 corrosion resistant coating Charge option NA 9C*
PTFE piston ring and packing material Standard Standard F

Same as F with the addition of K-ring spacers Charge option Charge option FK
Piston Ring
Alloy 50 piston rings and packing material Charge option Charge option G
and Packing
Material Same as G with the addition of K-Ring spacers Charge option Charge option GK
PEEK piston ring and alloy 50 packing material Charge option Charge option H
Same as H with the addition of K-Ring spacers Charge option Charge option HK
Aluminum gasket material Standard B

Gasket Material Copper gasket material No charge option C
Iron-lead gasket material No charge option D
Buna-N Standard A
Neoprene® 1 No charge option B
O-ring Material
1
Viton® D
Charge option Charge option
1
PTFE and Kalrez® E
Weld flanges only, no intercooler Standard NA F

Intercooler
Connections Not applicable - single stage compressor, no
NA Standard N
intercooler
No flywheel supplied No charge option N

Flywheel
Standard flywheel Standard S
Coated cylinder only Charge option C

Protective
No coating Standard N
Coating
Coating on all necessary wetted parts Charge option W*
Piston Rod
Nitride Standard N
Coating
*Must select Protective Coating Option "W" when selecting valve option "4C", or "9C" for the D791
(a) 1 = up to 200 psi or 2 = above 200 psi (discharge pressure)
(b) 1 = 30 to 70 psi or 2 = 71 to 150 psi or 3 = 151 to 500 psi (discharge pressure)
NA = Not Available NC = No Charge Option 1
Registered trademarks of the DuPont company.
20
Appendix A—Industrial Vertical Double Acting Model Number
Identification Code (T-Style)
MODEL NUMBER
BASE MODEL NUMBER T791 T891
Inlet 2" weld 2" weld BASE X X X X X X X X X X
Outlet 2" weld 2" weld
Intercooler connection 2" weld NA
Approximate shipping weight (lbs.) 1,030 1,000
SPECIFICATION FIELDS
Packing arranged for padding of distance piece Standard G
Packing
Packing arranged for purging of distance piece No charge option H
Arrangement
Atmospheric inlet or light vacuum service No charge option F
Pressure lubricated crankcase Standard M

Crankcase Std. crankcase with crankcase heater Charge option MH
Style Std. crankcase with cylinder lubricator Charge option Charge option L
Std. crankcase with cylinder lubricator and heater Charge option Charge option LH
Standard suction and discharge valves Standard 4

Standard suction & discharge valves w/ light springs No charge option No charge option 4L
Loadless start through suction valve unloaders and
Charge option Charge option 7(a)
hydraulic unloader
Constant speed unloading through suction valve
Charge option Charge option 8(b)
Valves unloaders and pilot valve
Combination control: loadless starting and constant
Charge option Charge option 78(a)(b)
speed unloading
Suction valve unloaders Charge option Charge option 9
Spec 4 valves w/MC1002 corrosion resistant coating NC NA 4C*
Spec 9 valves w/MC1002 corrosion resistant coating Charge option NA 9C*
PTFE piston ring and packing material Standard Standard F

Same as F with the addition of K-ring spacers Charge option Charge option FK
Piston Ring
Alloy 50 piston rings and packing material Charge option Charge option G
and Packing
Material Same as G with the addition of K-Ring spacers Charge option Charge option GK
PEEK piston ring and alloy 50 packing material Charge option Charge option H
Same as H with the addition of K-Ring spacers Charge option Charge option HK
Aluminum gasket material Standard B

Gasket Material Copper gasket material No charge option C
Iron-lead gasket material No charge option D
Buna-N Standard A
Neoprene® 1 No charge option B
O-ring Material
1
Viton® D
Charge option Charge option
1
PTFE and Kalrez® E
Weld flanges only, no intercooler Standard NA F

Intercooler
Connections Not applicable - single stage compressor, no
NA Standard N
intercooler
No flywheel supplied No charge option N

Flywheel
Standard flywheel Standard S
Coated cylinder only Charge option C

Protective
No coating Standard N
Coating
Coating on all necessary wetted parts Charge option W*
Piston Rod
Nitride Standard N
Coating
*Must select Protective Coating Option "W" when selecting valve option "4C", or "9C" for the T791
(a) 1 = up to 200 psi or 2 = above 200 psi (discharge pressure)
(b) 1 = 30 to 70 psi or 2 = 71 to 150 psi or 3 = 151 to 500 psi (discharge pressure)
NA = Not Available NC = No Charge Option 1
Registered trademarks of the DuPont company.
21
Appendix B—Vertical Double-Acting Specifications
Equipment Type & Options
Double-acting, vertical, reciprocating piston type compressor
Two-stage configuration (model 791 only)
Double packed rod (models D791 & D891); triple packed rod (models T791 & T891)
Slip-on weld connections
Features & Benefits

Self-lubricating piston rings: Non-lubricated operation to minimize oil in gas
Multiple materials and configurations: Versatility for your application
Multiple mounting configurations: Versatility for your application
High efficiency valves: Quiet, reliable operation
Reversible oil pump: Allows operation in either direction
Simplified top down design: Routine maintenance is minimally invasive
Material Specifications
Part Standard Material Optional Material
Head, cylinder, cylinder cap Ductile iron ASTM A536
Crosshead guide
Crankcase, flywheel Gray iron ASTM A48, Class 30
Bearing carrier
Flange ASTM A36 carbon steel
Valve seat, bumper 17-7 PH stainless steel
Valve plate 410 stainless steel PEEK
Valve spring 17-7 PH stainless steel
Valve gaskets Soft aluminum Copper, iron-lead
Piston Ductile iron ASTM A536
Piston rod 1045 steel, Nitrotec
Crosshead Ductile iron ASTM A536
Piston rings PTFE, glass and moly filled Alloy 50, PEEK
Piston ring expanders 302 stainless steel
Packing cartridge and barrel
Ductile iron ASTM A536
Connecting rod
Segmented packing rings Carbon-filled PTFE
V-ring packing Filled reinforced PTFE
Crankshaft Ductile iron ASTM A536
Connecting rod bearing Bimetal SAE 12 babbit
Wrist pin C1018 steel or equivalent
Wrist pin bushing Bronze SAE J461
Main bearing Tapered roller
Inspection plate Aluminum
O-rings Buna-N PTFE, Viton®1, Neoprene®1
Retainer rings Steel
Miscellaneous gaskets Rubber compositions
1 Registered trademarks of the DuPont company.
22
Appendix B—Vertical Double-Acting Specifications
Specifications and Performance
Specification D791 D891 T791 T891
Bore of cylinder, inches (mm)
first stage 6 (152.4) 4.5 (113) 6 (152.4) 4.5 (113)
second stage 3.25 (82.5) — 3.25 (82.5) —
Stroke, inches (mm) 4.0 (101.6) 4.0 (101.6) 4.0 (101.6) 4.0 (101.6)
Piston displacement, cfm (m3/hr)
minimum @ 400 RPM 51.2 (87.0) 56.6 (96.2) 51.2 (87.0) 56.6 (96.2)
maximum @ 900 RPM 115.3 (196.0) 127.6 (216.8) 115.3 (196.0) 127.6 (216.8)
Maximum working pressure, psig (bar g)
first stage 350 (24.1) 465 (32.1) 350 (24.1) 465 (32.1)
second stage 600 (41.3) — 600 (41.3) —
Maximum brake horsepower, kW 45 (34) 45 (34) 45 (34) 45 (34)
Maximum rod load, lb (kg) 7,000 (3,175.2) 7,000 (3,175.2) 7,000 (3,175.2) 7,000 (3,175.2)
Maximum outlet temperature °F (°C) 350 (177) 350 (177) 350 (177) 350 (177)
Bare unit weight, lb (kg) 900 (408.2) 855 (387.8) 1,060 (480.8) 1,015 (460.4)
791 & 891 Bolt Torque Values 791 & 891 Clearances and Dimensions
Specification ft•lb Specification Inches
Connecting rod bolt 40 Piston clearance (see Appendix E)
Bearing carrier 40 Clearance: connecting rod bearing to 0.0013
Bearing cover 40 crankshaft journal 0.0033
Crankcase inspection plate 9 Clearance: wrist pin to wrist pin
0.001
Crosshead guide 65 bushing (maximum)3
Cylinder to head1,2 65 Cylinder bore diameter (maximum)—
4.515
Single stage 891
Valve cover plate bolt 37
Cylinder bore diameter (maximum)—
Valve holddown screw2 40
First stage 791 6.018
Piston lock nut torque 150 Second stage 791 3.260
Piston screw torque (in•lb) 100 Cylinder finish 16–32 RMS
Valve cap torque 25 Piston ring radial thickness (minimum)
1 Preliminary tightening—snug all head bolts in the sequence shown. Single stage 891 0.082
Final torqueing—torque all head bolts in the sequence shown to the
First stage 791 0.155
listed value.
2 Retorque to the listed value after 2–5 hours running time. Second stage 791 0.082
3 Dimensions for honing are included with new bushings (which must
Clearance: oil pump adapter shaft to
be installed, then honed). 0.0036
bushing (maximum)3
0.002
Crankshaft end play (cold)
0.003
Flywheel runout at O.D. (maximum) 0.020
Clearance: crosshead to crosshead
0.008
guide bore (maximum)
32 RMS
(limited
number of
Crosshead guide bore finish
small pits and
scratches are
acceptable)
23
Appendix C—Outline Dimensions
Model D791 (Two Stage) Bare Compressor with Flywheel
Adjustable head
4 (10.2) 2-9/16 (6.5)
Suction valve
unloaders
1st stage (optional)
2nd stage outlet inlet
(2" weld flange) (2" weld 1st stage inlet 1st stage
flange) (2" weld flange) outlet
(2" weld
flange)
46
(116.8)
5-5/8
(14.3) 42-7/8
(108.9) 1/4” NPT
drain
35-5/8
(90.5) 31-3/8
(79.7)
21-3/16
(53.8)
20
(50.8)
8-1/4
(21)
1 (2.5)
Crankcase
2-1/8 5-1/2 oil heater
(5.4) (14.1) (optional) Four 9/16 (1.4) 5-3/8
diameter (13.7)
holes 5-3/8
4-3/4 13-7/16 (13.7)
(12.1) (34.1)
15 (38.1) 14-1/2 (36.8)
Inches (Centimeters)
24
Model D891 (Single Stage) Bare with Flywheel
Suction 5-1/2" 5-1/2"

valve unloaders (13.9) (13.9)
(optional)
Inlet
Inlet
(2" weld Outlet
(2" weld
flange) pressure
flange)
gauge
Inlet
pressure Outlet
guage (2" weld
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)
25
Inlet
Inlet (2 ″ weld flange)
(2 ″ weld flange)
Outlet
(2 ″ weld flange)
26
Model D891 (Single Stage) with 103 Mounting
Model D891 (Single Stage) with 107B Mounting
27
12-1/2
(31.75)
Relief valve
2" NPT pipe away
FLOW
CORKEN
Suction valve
unloaders (optional)
79-13/32 5-1/2
Inlet (13.92)
(201.69) 2" 300# RF
weld neck flange
Outlet pressure gauge
6-1/2
(16.49) 68
(172.72)
CORKEN CORKEN
High liquid level 9/16
shutdown switch (1.43) Outlet 2" weld flange
1/2" NPT
Belt guard Inlet Electric motor driver
40-15/16 pressure
High liquid level (103.99) gauge
alarm switch
1/2" NPT 9/16
34-15/16 (1.43) 41-21/32
28
(88.75) Drain valve (105.81)
1" NPT
28-15/16
3-23/32 (73.51)
Model D891 (Single Stage) with 109B Mounting
(9.45)
Crankcase
oil drain 10-11/16
(27.15)
7-1/16 3-21/32 5-15/16
3/4 (17.96) (9.31) (15.09) Low oil Crankcase Adjustable driver Use
(1.91) pressure switch heater slide base eight 3/4"
22-1/2 (optional) (optional) anchor
(57.15) bolts
24 9-3/32
(60.96) (23.07)
27
(68.58)
30-5/64
(76.41)
45
(114.30)
63
(160.02)
72
(182.88)
Model T791 (Two Stage) Bare Compressor with Flywheel
4 (10) 2-9/16 (7)
Adjustable
head
Suction valve
unloaders
(optional)
2nd stage 1st stage
outlet (2″ inlet (2″
weld flange) weld flange) 1st stage 1st stage
inlet (2″ outlet (2″
weld flange) weld flange)
1/4″ NPT
54 upper 1/4″ NPT
(137) distance lower
piece distance
50-7/8 piece
(129)
5-5/8
(14) 43-5/8
(111)
39-3/8
(100)
21-3/16
(54)
20 (51)
8-1/4
(21)
Crankcase 1 (3)
oil heater
4-3/4 5-1/2 (14) (optional)
(12) Four 9/16″ (1.4)
diameter holes 5-3/8 5-3/8
2-1/8 (5) 13-3/4 (35) (14) (14)
15 (38) 14-1/2 (37)
29
Model T891 (Single Stage) Bare Compressor with Flywheel
Suction valve 5-7/16 5-7/16

unloaders (13.9) (13.9)
(optional)
Inlet
(2″ weld flange) Inlet Outlet (2″
(2″ weld flange) weld flange)
1/4″ upper
distance
piece
1/4″ NPT
51-1/4 lower
(130.1) distance
piece
5-5/8
(14.3) 43-5/8
(110.8)
21-3/16
(53.8)
20
(50.8)
8-1/4
(21)
1 (2.5)
2-1/8 (5.4) 5-1/2 (14.1) Crankcase
oil heater 5-3/8 5-3/8
(optional) (13.6) (13.6)
4-3/4 (12.1) 13-5/8 (34.5)
Four 9/16″ (1.4)
15 (38.2) 14-1/2 (36.9)
diameter holes
30
Suction valve unloaders
(optional) Suction valve unloaders 5-1/2 5-1/2
(optional) (13.92) (13.92)
Inlet
Inlet Pressure gauge
(2″ weld flange) (2″ weld flange) (outlet)
Pressure gauge Outlet
(Inlet) (2″ weld flange)
2
Purge (5.08)
connections
(1/4″) Purge connections
(1/4″)
1-1/2
5-3/4 (3.81)
(14.61) Crankcase heater
Beltguard (optional) Electric motor driver
57-1/4
(145.34)
31
49-5/8
126.10
Model T891 (Single Stage) with 103 Mounting
31
Crankcase (78.74)
oil drain
6 Use six 3/4″
(15.24) anchor bolts
4
3/4 7 (10.21) Low oil pressure switch Adjustable driver slide base
(1.91) (17.78) (optional)
22-1/2 (57.15) 18 (45.72)
3-9/16
7 24 (60.96) (9.13) 10 (25.40) 36 (91.44)
(17.78)
56 (142.24)
Appendix D—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, 8, 15, 17
Overheating 1, 2, 3, 5, 6, 11, 16
Knocks, rattles and noise 1, 7, 9, 10, 11, 15
Oil in cylinder 8, 12, 15
Abnormal piston-ring wear 1, 3, 5, 6, 11, 15, 16
Product leaking through crankcase breather 8, 15
Product leakage 4, 8, 15, 17
Oil leakage around compressor base 17, 18, 19, 20
No oil pressure 19, 20
Excessive vibration 1, 7, 9, 10, 11, 13, 14, 28
Motor overheating or starter tripping out 21, 22, 23, 24, 25, 26, 27, 28
Ref. Possible Causes What To Do

1. Valves broken, stuck or leaking Inspect and clean or repair
2. Piston ring worn Inspect and replace as necessary
3. Inlet strainer clogged Clean or replace screen as 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. Oil in distance piece Tighten packing nut — drain weekly
13. Inadequate compressor base Strengthen, replace or grout
14. Improper foundation or mounting Tighten mounting or rebuild foundation
15. Loose valve, piston or packing Tighten or replace as necessary
16. Dirty cooling fins Clean weekly
17. 4-way control valve not lubricated Inspect and lubricate
18. Leaking gas blowing oil from crankcase Tighten packing
19. Bad oil seal Replace
20. No oil in crankcase Add oil
21. Oil-pump malfunction See oil pressure adjustment
22. Low voltage Check line voltage with motor nameplate. Consult power company
23. Motor wired wrong Check wiring diagram
24. Wire size too small for length of run Replace with correct size
25. Wrong power characteristics Voltage, phase and frequency must coincide with motor nameplate.
Consult with power company.
26. Wrong size of heaters in starter Check and replace according to manufacturer’s instructions
27. Compressor overloading Reduce speed
28. Motor shorted out See driver installation
29. Bad motor bearing Lubricate according to manufacturer’s instructions
Two-Stage Compressor Troubleshooting

Two-stage compressors can have problems that never Another cause for high interstage pressure is a low
occur with single-stage machines. Interstage pressure compression ratio. Two-stage machines should not be
is an important indicator of the condition of a two- used in applications where the compression ratio is
stage compressor. below 5. To use two-stage compressors in this kind of
If interstage pressure is too high: situation results in rapid ring wear, machine imbalance
1. Second stage valves may be broken or leaking. and excessive horsepower. If you think you have a
2. Second stage piston rings may be worn. problem in this area, consult factory.
If interstage pressure is too low:
1. First stage valves may be broken or leaking.
2. First stage piston rings may be worn.
32
33
Appendix E—D791 and T791 Head and Valve Holddown Assembly Details
Head First Stage Holddown Assembly (6") First Stage Holddown
1 Suction with Unloader Suction (Standard) Assembly (6")
9 12 Discharge
25 25
2
13
13 13
See
figure A 15 15
3
15 16
16
4 16
5 17 17
17
6
22 18
18 18
19
10
19
20 29
7
21
11
23 26
8
23
24 24 24
CAUTION: Always relieve pressure in the

unit before attempting any repairs.
Unloader Piston Assembly Details Second Stage Holddown Assembly (3-1/4") Second Stage Holddown
Suction with Unloader Suction (Standard) Assembly (3-1/4")
Apply Loctite #290 12 25
12 Discharge 25
when assembling 52
53 13 13
13
15 15
54 See
figure A
55 15
16 16
53
16
Important: 14 (6")
14-1 (3-1/4") 27 27
Note seal direction
27
32 28 28 28
Figure A
29 29 29
30
31 33 35
33
34 34
34
34
First Stage Valve Assembly (6") Second Stage Valve Assembly (3-1/4")
Suction Discharge Suction Discharge
36 43 43
42
44 50
45
37 37
46
48
47
38 40 46
39 48 47
41 41
38
39 45
40
42 36 49 51
Ref Ref
Part No. Description Part No. Description
No. No.
1. 3665 Adjusting screw nut 31. 3690c Spring
2. 2-127 a O-ring 32. 3689-X 37 Unloader assembly (3-1/4")
3. 3867 Cylinder cap 33. 2438-X Suction valve assembly (3-1/4")
4. 2-250 a O-ring 34. 1418-2b Valve gasket
5. 3663 Adjusting cup 35. 2439-X Discharge valve assembly (3-1/4")
6. 2-248 a O-ring 36. 3827 Valve seat (6")
7. 3876 Cylinder head (6") 37. 3828 Stud
8. 2-258 O-ring 38. 3830d Outer valve plate
Bolt (1/2–13x1-1/2" hex hd gr 5)(Torque 39. 3831d Inner valve plate
9. 7001-050-NC150A
to 65 ft•lbs) 40. 3829d Spring
10. 3877 Cylinder head (3-1/4") 41. 3805-X1 Valve repair kit
11. 2-236 a O-ring 42. 3826 Valve bumper (6")
12. 2598-1c Unloader cap 43. 2446 Bolt
13. 2-031 a O-ring 44. 2438 Suction valve seat (3-1/4")
14. 3696c Unloader piston (6") 45. 2442 Valve plate
14-1. 2618c Unloader piston (3-1/4") 46. 2445e Spacer (two per valve)
15. 2715 Holddown screw 47. 3355 Washer
Bolt (7/16–14x1-1/2" hex hd)(Torque to 48. 1407 Spring
16. 7001-043-NC150A
37 ft•lbs)
49. 2440 Suction valve bumper (3-1/4")
17. 1764 Valve cover plate
50. 2441 Discharge valve bumper (3-1/4")
18. 2-235 a O-ring
51. 2439 Discharge valve seat (3-1/4")
19. 3570-1 Valve cage
52. 1910c Bolt
20. 3694c Actuator
53. 2619-Xc Unloader piston seal assembly
21. 3695c Spring
54. 2857c Unloader piston cap
22. 3694-X Unloader assembly (6")
55. 2858c Gasket
23. 3732-X Suction valve assembly (6")
24. 2114b Valve gasket a _ denotes O-ring code. See O-ring chart O-ring Code
25. 2714-1 Valve cap for details.
bIncluded with valve assembly. A Buna-N
26. 3733-X Discharge valve assembly (6") B Neoprene ®f
c Included with unloader assembly.
27. 2205 Valve cover plate dIncluded with valve repair kit. D Viton®f
28. 2-143 a O-ring e Install spacers back to back.
E PTFE
29. 3569 Valve cage f Registered trademark of the DuPont
K Kalrez®f
30. 3689c Actuator company.
35
Head Holddown Assembly (4-1/2") Holddown Assembly (4-1/2")
Suction with Unloader Suction (Standard) Discharge
4 5
1 18 18
6
6 6
See
figure A 8 8
8
2 9 9
9
10 10
2 10
3 11
15
11 11
12
12
3 13 19
14
20
CAUTION: Always relieve pressure in the 16
unit before attempting any repairs.
16
17 17 17
Unloader Assembly Part Details Valve Assemblies (4-1/2")

Suction Valve Discharge Valve
Apply Loctite #290 12
when assembling 28
21 26
29
30
31
22 22
29
Important: 7
Note seal direction 23 25
24
27 27
Figure A 23
25 24
26 21
36
Compressor Head and Valve Bill of Materials
Ref Ref
No. No.
1. 3923 Cylinder cap 18. 2714-1 Valve cap
2. 3924 Cylinder head (4-1/2") 19. 3569 Valve cage
a
3. 2-246 O-ring 20. 3733-X Discharge valve assembly (4-1/2")
Bolt (1/2 - 13 x 1-1/2" hex head Gr 5) 21. 3827 Valve seat (4-1/2")
4. 7001-050 NC150A
(Torque to 65 ft•lbs) 22. 3828 Stud
5. 2598-1c Unloader cap 23. 3830d Valve plate (outer)
6. 2-031 a O-ring 24. 3831d Valve plate (inner)
7. 3696 c Unloader piston 25. 3829d Spring
8. 2715 Holddown screw 26. 3826 Valve bumper (4-1/2")
Bolt (7/16 - 14 x 1-1/2" hex head)(Torque 27. 3805-X1 Valve repair kit
9. 7001-043 NC150A
to 37 ft•lbs) 28. 1910c Bolt
10. 1764 Valve cover plate 29. 2619-Xc Unloader piston seal assembly
11. 2-235 a O-ring 30. 2857c Unloader piston cap
12. 3570-1 Valve cage 31. 2858c Gasket
13. 3694c Actuator
14. 3695c Spring
a _ denotes O-ring code. See O-ring chart below for details.
b Included with valve assembly
15. 3694-X Unloader assembly (4-1/2") c Included with unloader assembly
16. 3732-X Suction valve assembly (4-1/2") dIncluded with valve repair kit.
17. 2114b Valve gasket e Registered trademark of the DuPont company.
O-ring Code
A Buna-N
B Neoprene ®e
D Viton®e
E PTFE
K Kalrez®e
37
Appendix E—D791, T791, D891 and T891 Piston Assembly Details
1
3
Piston Assembly Bill of Materials
Part No.
Ref. D/T791 2nd Description Qty
No. D/T791 1st Stage Stage
D/T891
3879-X1 (6") 3925-X1 (4-1/2")
3884-X1 (3-1/4")
4 Screw, orlo gr. 8
1. 7002-025-TP100A 7002-010-TP100A 7002-025-TP100A 4
(torque to 100 in•lbs)
5 2. 3562a 3561a 3927a Piston cap 1
3625 3731 2902 Shim washer (thick) As
4 3.
3625-1 3731-1 2902-1 Shim washer (thin) req.
5 1752 1756 1739 Piston rings

4. 1752-2 1756-4 1739-2 Alloy 50 rings (opt.) 4
1752-3 1756-3 1739-3 Peek rings (opt.)
4 5. 1753 1757 1740 Expander ring 4
Lock nut (torque to
5 6. 3604 1
150 ft•lbs)
7. 3730 Thrust washer 2
3879a 3884a 3925a
4 8. Piston 1
(6" diameter) (3-1/4" diameter) (4-1/2" diameter)
5 3603 Shim washer (thick) As

9.
3603-1 Shim washer (thin) req.
10. 3812 (not shown) Loctite tube (620) 1
6 a MC1002 coated piston and cap available. Add “C” to end of a standard part number (e.g. 3562C)
7 Piston Clearance (Cold)

Model (Y) Bottom Min.c (Y) Bottom Max.c (X) Top Min.b (X) Top Max.b
D791/D891 0.010" (0.25 mm) 0.020" (0.50 mm) 0.084" (2.13 mm) 0.104" (2.64 mm)
8 T791/T891 0.005" (0.13 mm) 0.015" (0.38 mm) 0.089" (2.26 mm) 0.109" (2.77 mm)
b The distance from the bottom of the head to the top of the piston.
c The distance from the bottom of the piston to the top of the packing barrel.
CAUTION: Always relieve pressure in the unit before attempting any repairs.
(X) (X )
9
Piston Piston
(Y) (Y)
Piston Piston
Piston
Rod
Piston bottom dead center Piston top dead center
38
Appendix E—D791, T791, D891 and T891 Connecting Rod and
Crosshead Assembly Details
6 2
7
Connecting Rod and Crosshead Assembly
3
Bill of Materials
3
Ref
Part No. Description
No.
3544-X3 Crosshead assembly (D791, D891)
3544-X9 Crosshead assembly (T791, T891)
1.
Crosshead assembly—coated piston rod
3544-X10
(T791, T891)
2. 3590 Retainer ring
3. 1726b Bolt
3785-X1 Connecting rod assembly
4.
3785a,d Connecting rod
5. 1727 a,b Nut
6. 3540 Wrist pin
7. 3541a,c Wrist pin bushing
8. 3542a Connecting rod bearing
4
a Included with connecting rod assembly
b Torque connecting rod nut to 40 ft. lbs.
c Must be rebored after replacing (1.1258/1.1254 dia.)
8
Note dNot sold separately
alignment
marks Never attempt to separate the piston rod and crosshead. When
repair becomes necessary, the entire crosshead assembly must
be replaced.
CAUTION: Always relieve pressure in the unit before attempting

5 any repairs.
39
Appendix E—D791 and D891 Packing Assembly Details
Specification “J” Specification “K”
1 1
2 2
3 3
4 4
5 Radial 5 Radial
Tangent Tangent
6 6
3 3
4 4
5 Radial 5 Radial
Tangent Tangent
6 6
16 16
3 3
Upper Upper 4
4
Segmented Segmented
Packing 5 Radial Packing 5 Radial
Set Tangent Set Tangent
6 6
3 3
4 4
5.1 Tangent 5.1 Tangent

Tangent Tangent
6 6
7 7
8 8
V-ring Packing Direction
9 Lower Packing Lower Packing 9

Specification Specification
10 “J” “K” 10
11 11
13 15
12 15
14 14
11 14
13 17
17 15
13 13 Lower
Lower 11
V-ring
V-ring 14
12 Packing
Packing
15 Set
Set To Crankcase To Crankcase
11
11
10
10
40
Appendix E—D791 and D891 Packing Assembly Details
Specification “R” Packing Assembly Bill of Materials
Ref
No.
3886 Packing barrel (3-1/4")(791 second stage)
1. 3887 Packing barrel (6")(791 first stage)
3926 Packing barrel (4-1/2")(891 only)
1
2. 3906 Crush gasket
Packing cup (Not included in 3810-X1
3. 3817
packing set)
4. 2-036_a,c,d Cup O-ring
2
Segmented packing
5. 3810
3 (radial—tangent) pair
4 Segmented packing
5.1. 3814
(tangent—tangent) pair
5.1 Tangent
6. 3811 Back-up ring
Tangent
7. 7002-025OC100A Screw (1/4-20 x 1" socket head)
6
8. 3885 Cartridge
3 9. 1732b Oil deflector ring
4 10. 5000-175 Retainer ring
Tangent 11. 1728 Washer
5.1
Tangent 12. 1731 Spring
13. 1724 Male packing ring
6
14. 1725 V-ring packing
16 3
15. 1723 Female packing ring
Upper 4
Segmented 16. 3810-X1d Segmented packing set
Packing 5.1 Tangent 17. 1725-2X V-ring packing set
Set Tangent
6 Identification of Packing Specification
3 Example: Model Number D891 K M4FBA
4 Packing Spec.
Tangent
5.1
Tangent
Segmented Packing for Segmented packing for
6 Specification “J” & “K” Specification “J”, “K”, & “R”
Piston (Pressure) Side Piston (Pressure) Side
V-ring Radial Cut Tangent Cut

7 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
8 “R” Back-up Back-up
ring ring
9 13
10 14
To Crankcase To Crankcase
11
15 IMPORTANT: Identify and line up the rings before installing. Be sure
12 they face the way shown here and that the pin and hole are aligned
when assembled.
11
17 To Crankcase a _ denotes O-ring code. See O-ring chart for details.
13
Lower b Deflector ring is loose within the packing cartridge until fitted on the
V-ring 14 piston rod. Must be put in from the bottom of the cartridge.
Packing c Starting with S.N. NN51397.
15 O-ring Code
Set dPacking cup O-ring not included in packing set.
A Buna-N e Registered trademark of the DuPont company.
11
B Neoprene ®e
10 D Viton®e
E PTFE
K Kalrez®e
41
Appendix E—T791 and T891 Packing Assembly Details
Specification “G” Specification “H”
1 1
2 2
3 3
4 4
Radial Radial
5 5
Tangent Tangent
6 6
3 3
4 4
Radial Radial
5 5
Tangent Tangent
6 6
18 3 18 3
Upper 4 Upper 4
Radial Radial
Segmented 5 Segmented 5
Tangent Tangent
Packing 6 Packing 6
Set 3 Set 3
4 Tangent 4 Tangent
7 Tangent 7
Tangent
6 6
8 8
9 9
10 10
11 11
12 V-ring Packing Direction 15
14
11 Middle Packing Middle Packing 13
19 13 Specification Specification 19
11 Middle
Middle 14 “G” “H”
V-ring 12 V-ring
15 13 Packing
Packing 15
11 11 Set
Set
14 10
10
14
15
13
16 To Crankcase To Crankcase 16
20 20
Lower Packing Lower Packing
Specification Specification
“G” “H”
10 10
13 13
11 11
14 14 12
12
11 15 11
15
19 13 13 19
Lower 14 Lower
14 V-ring
V-ring 15
Packing 15 To Crankcase To Crankcase Packing
Set Set
17
17
PTFE Locking Device PTFE Locking Device
42
Appendix E—T791 and T891 Packing Assembly Details
Specification “F” Packing Assembly Bill of Materials
Ref
No.
3886 Packing barrel (3-1/4")(791 second stage)
1. 3887 Packing barrel (6")(791 first stage)
1
3926 Packing barrel (4-1/2")(891 only)
2. 3906 Crush gasket
2 Packing cup (Not included in 3810-X1
3 3. 3817
packing set)
4
7 Tangent 4. 2-036_a,c,d Cup O-ring
6 Tangent Segmented packing
5. 3810
3 (radial—tangent) pair
4 6. 3811 Back-up ring
7 Tangent Segmented packing
7. 3814
6 Tangent (tangent—tangent) pair
18 3 8. 4748 Packing adapter
Upper 4 9. 7002-025OC100A Screw (1/4-20 x 1" socket head)
Segmented 7 Tangent 10. 5000-175 Retainer ring
Packing Tangent 11. 1728 Washer
6
Set 3 12. 1731 Spring
4 13. 1724 Male packing ring
7 Tangent
14. 1725 V-ring packing
Tangent
6 15. 1723 Female packing ring
8 16. 4746 Cartridge
17. 1722-X Adjusting screw
V-ring
9 18. 3810-X1d Segmented packing set
Packing
19. 1725-2X V-ring packing set
Direction
10 20. 1732 Oil deflector ring
11 Middle Packing
Specification
12 “F”
Identification of Packing Specification
11 13
19 13 Example: Model Number T891 G L4FBDNSNC
Middle 14
14 Packing Spec.
V-ring
15
Packing 15
11 Segmented Packing for Segmented packing for
Set
Specification “F” & “G” Specification “F”, “G”, & “H”
10
Piston (Pressure) Side Piston (Pressure) Side
To Crankcase
Radial Cut Tangent Cut
(without pin) Align pin (without pin) Align pin
Lower Packing with hole with hole
Specification
Tangent Cut Tangent Cut
16 “F”
20 (with pin) (with pin)
13 Back-up Back-up
ring ring
14
10
15
11 To Crankcase To Crankcase
12
IMPORTANT: Identify and line up the rings before installing. Be sure
11 To Crankcase they face the way shown here and that the pin and hole are aligned
19 13 when assembled.
Lower
14
V-ring a _ denotes O-ring code. See O-ring chart for details.
15 O-ring Code Deflector ring is loose within the packing cartridge until fitted on the
Packing b
Set A Buna-N piston rod. Must be put in from the bottom of the cartridge.
17 B Neoprene ®e c Starting with S.N. NN51397.
dPacking cup O-ring not included in packing set.
D Viton®e
PTFE Locking Device e Registered trademark of the DuPont company.
E PTFE
K Kalrez®e
43
Appendix E—D791 Crosshead Guide Assembly Details
Crosshead Guide Bill of Materials

Ref
Part No. Description Qty
No.
1. 3866 Cylinder 1
2. 3442 Pipe plug (1/4" NPT) 10
3. 1054 Drain valve (lubricated models) 1
4. 1071 Nipple (1/4" x close) 1
5. 2-258_a O-ring for cylinder (1st stage) 1
5-1. 2-236_a O-ring for cylinder (2nd stage) 1
Bolt (1/2" - 13 x 1-3/4" hex head
6. 7001-050NC175A 16
gr 5)
7. 3793-2S Flange (inlet/outlet) 4
17 8. 2-231_a O-ring for flange 4

9. 3253 Roll pin 1
Packing barrels 10. 2405-1 Crosshead guide 1
and cartridges
(For parts details, 11. 1064 Elbow (1/4" NPT) 1
see D791 packing 12. 7005-050175A Bolt (1/2" 13 x 1-3/4" ferry head) 16
17 on previous pages). 13. 1761 Gasket (crankcase) 1
14. 1760 Gasket (inspection cover) 1
15. 1721 Inspection cover 1
16. 7012-010NC025B Bolt (10 - 24 x 1/4" Phillips hd.) 10
17. 2-231_a O-ring 2
12
O-ring Code
A Buna-N
16
12 B Neoprene ®b
15
D Viton®b
14
E PTFE
K Kalrez®b
a _ denotes O-ring code. See O-ring chart above for details.
b Registered trademark of the DuPont company.

any repairs.
13 NOTE:
Packing barrel installation:
1. Use packing installation cone #3905 on the piston rod.
2. Insert small barrel first, use finger holes to align slinger ring on to
the rod. Slip the packing barrel into place.
3. Align pin with slot in large packing barrel.
4. Slip large packing barrel in place.
44
Appendix E—D891 Crosshead Guide Assembly Details

Ref
No.
1. 3922 Cylinder 1
2. 3442 Pipe plug (1/4" NPT) 6
4. 1071 Nipple (1/4" x close) 1
5. 2-246_a O-ring for cylinder 2
Bolt (1/2"- 13 x 1-3/4" hex head
6. 7001-050NC175A 8
gr 5)
8. 2-231_a O-ring for flange 2
17
9. 3253 Roll pin 1
10. 2405-1 Crosshead guide 1
Packing barrels 11. 1064 Elbow (1/4" NPT) 1
17 and cartridges
12. 7005-050175A Bolt (1/2" 13 x 1-3/4" ferry head) 16
(For parts details,
see D891 packing 13. 1761 Gasket (crankcase) 1
on previous pages). 14. 1760 Gasket (inspection cover) 1
15. 1721 Inspection cover 1
16. 7012-010NC025B Screw (10 - 24 x 1/4" Phillips hd.) 10
17. 2-231_a O-ring 2
12
O-ring Code
A Buna-N
B Neoprene ®b
16
12 D Viton®b
15
E PTFE
14
K Kalrez®b

any repairs.
NOTE:
13 Packing barrel installation:
1. Use packing installation cone #3905 on the piston rod.
2. Insert small barrel first, use finger holes to align slinger ring on to
45
Appendix E—T791 Crosshead Guide Assembly Details

Ref
No.
1. 3866 Cylinder 1
2. 3442 Pipe plug (1/4" NPT) 16
5-1
4. 1071 Nipple (1/4" x close) 1
5. 2-258_a O-ring for cylinder (1st stage) 1
5-1. 2-236_a O-ring for cylinder (2nd stage) 1
18 Bolt (1/2" 13 x 1-3/4" hex head

6. 7001-050NC175A 16
gr 5)
18 19 Packing barrels 8. 2-231_a O-ring for flange 4
19 and cartridges 9. 3253 Roll pin 1
20 (For parts details,
20 10. 1716-4 Crosshead guide 1
see T791 packing
21 on previous pages). 11. 7005-050175A Bolt (1/2" 13 x 1-3/4" ferry head) 16
21 12. 1748 Cartridge plate 2
13. 5000-350 Retainer ring 2
14. 1761 Gasket (crankcase) 1
15. 1760 Gasket (inspection cover) 1
22 16. 1721 Inspection cover 1
22 17. 7012-010NC025B Bolt (10 - 24 x 1/4" Phillips hd.) 10
18. 2-238_a O-ring 2
21 21 19. 1749 Cartridge holddown screw 2
20. 4747 Cage 2
21. 2-233_a O-ring 2
22. 1732 Oil deflector ring 2
11
O-ring Code
A Buna-N
B Neoprene ®b
D Viton®b
E PTFE
K Kalrez®b
17
16 CAUTION: Always relieve pressure in the unit before attempting
15
any repairs.
11
NOTE:
Packing barrel installation:
12 1. Use packing installation cone #3905 on the piston rod.
12 2. Insert small barrel first, use finger holes to align slinger ring on to
13
13 the rod. Slip the packing barrel into place.
14 4. Slip large packing barrel in place.
46
Appendix E—T891 Crosshead Guide Assembly Details

Ref
No.
1. 3922 Cylinder 1
2. 3442 Pipe plug (1/4" NPT) 12
4. 1071 Nipple (1/4" x close) 1
18 5. 2-246_a O-ring for cylinder 2

Bolt (1/2" 13 x 1-3/4" hex head
6. 7001-050NC175A 6
gr 5)
18 19 7. 3793-2S Flange (inlet/outlet) 2
Packing barrels 2-231_a
19 8. O-ring for flange 2
and cartridges
20 9. 3253 Roll pin 1
20 (For parts details,
see T891 packing 10. 1716-4 Crosshead guide 1
21 on previous pages). 11. 7005-050175A Bolt (1/2" 13 x 1-3/4" ferry head) 16
21
12. 1748 Cartridge plate 2
13. 5000-350 Retainer ring 2
14. 1761 Gasket (crankcase) 1
22 15. 1760 Gasket (inspection cover) 1
22 16. 1721 Inspection cover 1
17. 7012-010NC025B Bolt (10 - 24 x 1/4" Phillips hd.) 10
21 18. 2-238_a O-ring 2

21
19. 1749 Cartridge holddown screw 2
20. 4747 Cage 2
21. 2-233_a O-ring 2
11 22. 1732 Oil deflector ring 2
2 O-ring Code
A Buna-N
B Neoprene ®b
D Viton®b
E PTFE
K Kalrez®b

17 b Registered trademark of the DuPont company.
16
15
11 CAUTION: Always relieve pressure in the unit before attempting
any repairs.
NOTE:
12 Packing barrel installation:
12
13 1. Use packing installation cone #3905 on the piston rod.
13 2. Insert small barrel first, use finger holes to align slinger ring on to
14
47
Appendix E—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
63 (Pipe plug on under side of
6 crankcase is not shown)
31
29
30
37
38 51
39
40
32 36 41
35
34
33 28
Inside of
50 Bearing Carrier
49 57
54
48 56
47
46
45 54 55
44
43 53
42 60 Oil Passage Hole
62 52 Important! Line up hole in
55
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.
48
Appendix E—Crankcase Assembly Details
Crankcase Assembly Bill of Materials
Ref Ref
No. No.
1. 1737 Bearing cone 47. 3219 Pump shaft adapter
2. 3638 Spacer 48. 2-112_c O-ring
3. 3635 Drive sprocket 49. 2805-Xa Pump shaft bushing
4. 1284 Crankshaft orifice 50. 1629 Pipe plug (1/16 NPT fl. seal)
5. 2135 Drive pin 51. 1736 Bearing cup
6. 2933 Link pin 52. 1302 Oil pressure gauge
7. 3786 Crankshaft 53. 1044 Bushing (1/8 x 1/4 NPT)
8. 3503 Flywheel key 54. 3220-2 Bearing carrier
9. 3580 Bearing cone 55. 3289 Pipe plug (1/4 NPT fl. seal)
10. 3786-X1 Crankshaft assembly 56. 2131 Bearing carrier gasket
11. 7001-031NC075A Bolt (5/16 - 18 x 3/4" hex head) 57. 2961-X Air release valve assembly
12. 2122 Inspection cover 58. 2590 Pipe plug (1/8 NPT fl. seal)
13. 2123 Gasket, inspection cover 59. 4225 Filter
14. 2-112_c O-ring 60. 2798 Pump cover pin (included w/4222-X)
15. 3225-X1 Oil bayonet assembly (w/O-ring) 61. 3220-2X Bearing carrier assembly
16. 2126 Breather ball 62. 4222 Oil filter adapter
17. 3579 Bearing cup 63. 3289 Pipe plug (1/4" x 18 NPTF x 7/8")
3589 Bearing adjustment shim (.005")
18. 3589-1 Bearing adjustment shim (.007") Assembly
Assembly Name
3589-2 Bearing adjustment shim (.020") Number
19. 3539 Bearing cover 3221-X1 Crankcase assembly (M, 4, 8, 9) without lubricator
20. 3526 Oil seal 3221-X2 Crankcase assembly (M7, 78) without lubricator
21. 1280 Filter screw 3221-X3 Crankcase assembly (L, 4, 8, 9) with lubricator
22. 1281 Gasket, filter 3221-X4 Crankcase assembly (L7, 78) with lubricator
23. 2-116_c O-ring

24. 1276 Washer O-ring Code
25. 1275 Oil filter screen A Buna-N
26. 3443 Pipe plug (1/2" NPT steel) B Neoprene ®b
27. 3221 Crankcase D Viton®b
28. 7001-037NC100A Bolt (3/8 - 16 x 1" hex head Gr. 5) E PTFE
29. 3875 Access cover K Kalrez®b
30. 7003-025NC037E Screw (1/4 - 20 x 3/8") a Must be rebored and honed after replacing (0.876"/0.875" diameter)
31. 3874 Gasket (access cover) b Caution: To avoid damage during assembly, refer to installation
32. 1515-X Closure cap assembly Instruction Manual IE400.
c _ denotes O-ring code. See O-ring chart above for details.
33. 7001-025NC050A Bolt (1/4 - 20 x 1/2" hex head) dRegistered trademark of the DuPont company.
34. 1515 Closure cap
35. 1516 Closure body CAUTION: Always relieve pressure in the unit before attempting
any repairs.
36. 2-118_c O-ring
37. 1290 Relief valve adjusting screw
38. 2-011_c O-ring
39. 1291 Adjusting screw locknut
40. 1292 Relief valve spring
41. 1293 Relief valve ball
42. 4222-Xb Oil filter adapter assembly (w/pin)
43. 2-228_c O-ring
44. 2849-1Xb Oil pump assembly
45. 2851 Spring guide
46. 2852 Oil pump spring
49
Appendix E—Flywheel Assembly Details
Back Side Front Side
Flywheel Assembly Bill of Materials

Assembly
Assembly Name
Number
Flywheel assembly (flywheel, hub,
3852-X
and three bolts)
3852 Flywheel: 21.2" O.D., 5 groove
Hub with three bolts and
H J-2.125
lockwashers
50
51
Solutions beyond products...
CORKEN, INC. • A Unit of IDEX Corporation
9201 North I-35 Service Road, Oklahoma City, OK. 73131
Phone (405) 946-5576 • Fax (405) 948-7343
Visit our website at www.corken.com
or e-mail us at cocsalesdept@idexcorp.com
@CorkenInc
Printed in the U.S.A.

March 2021

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Corken One Year Limited Warranty

ALL IMPLIED WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS

Contacting The Factory

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

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

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

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

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

Ductile iron construction:

Positively locked pistons:

Nitride-coated piston rods: Lower packing (V-ring)

Adjustable packing screw:

Cast iron crossheads:

Pressure-lubricated crankcase with filter:

Construction details: Model T891 compressor

NOTE: Compressor must be installed in a well Main beam (C-Beam)

Corken compressors handling toxic or flammable

If a restrictive device such as a valve, pressure regulator,

Pipe must be adequately sized to prevent excessive

Humid climates can cause problems with explosion

For installation with engine drivers, thoroughly review

1.6 Crankcase Lubrication

Acceptable Crankcase Oil Products for Corken

Oil product ISO VI SAE Ambient Temp.

Dectol R&O Oil 100 98 30 35° - 50° F

Compressor Approximate Capacity

Padding (Buffering): Low Oil Pressure Switch—shuts down the unit if

Highly Corrosive Gases:

1.8 Relief Valves

1.9 Shutdown/Alarm Devices

2.1 Inspection After

Drain the oil from the crankcase and remove the

Rotate unit manually to ensure running gear functions

2.2 Flywheel and V-belt Alignment

The flywheel is mounted on the shaft via a split, tapered

15. Test piping system for leaks.

16. Purge unit of air before pressurizing with gas.

20. Double-check all of the above.

Breather cap After Starting Compressor

2. Observe noise and vibration levels. Correct immediately

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

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

9. Check V-belt tension and alignment or drive alignment

Drain liquid from accumulation points 3

Drain distance pieces

If routine maintenance is performed as listed in chapter Disassembly

7. Check bolts and valve holddown screws after first week

6. Before installing the new piston, measure the thickness

8. Install the piston with the same thickness of shims as

9. Now remove a lower valve and measure dimension

10. When the piston is properly shimmed, tighten the lock

CAUTION: Before installing the new piston rod

4.6 Cylinder and Packing Packing Configuration

Replacement The packing for these compressors includes segmented

3. Segmented packing: 6. Remove cartridge holddown screws with special

Figure 4.7: Bearing carrier replacement

Figure 4.8: Oil pump inspection

9. Tighten the bolts in an alternating sequence. See 3. Relieve V-belt tension.