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Corken D Series User Manual

Corken D Series
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Model FT891
Compressor
Model FD891
Compressor
Model D791
Compressor
Installation, Operation
& Maintenance Manual
D and T-Style Double-Acting Gas Compressors
All Models 791 and 891
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. (4) Transfer of toxic, dangerous, flammable or explosive substances using Corken products is at users risk and equipment should be operated only
by qualified personnel according to applicable laws and safety standards.
ORIGINAL INSTRUCTIONS IJ110H
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Corken D Series Specifications

General IconGeneral
BrandCorken
ModelD Series
CategoryAir Compressor
LanguageEnglish

Summary

Chapter 1: Features and Benefits

High-efficiency PEEK Valves

Offers quiet operation and increased durability in process gas applications.

Ductile Iron Construction

Provides maximum thermal shock endurance for cylinder and head.

Self-lubricating PTFE Piston Rings

Step-cut design maximizes performance and life for non-lube service.

Positively Locked Pistons

Simple design allows precise setting of end clearance for efficiency.

Self-lubricating Piston Rod Seals

Spring-loaded PTFE seals self-adjust for normal wear.

Nitride-Coated Piston Rods

Impregnated nitride coating provides superior corrosion and wear resistance.

Adjustable Packing Screw

Ensures maximum sealing capacity during packing life (T791/T891 models).

Cast Iron Crossheads

Durable cast iron provides superior resistance to corrosion and galling.

Pressure-Lubricated Crankcase with Filter

Self-reversing oil pump ensures proper lubrication; 10-micron filter.

Chapter 2: Installation

2.1 Location

Ensures proper ventilation, access, and compliance with safety and building codes.

2.2 Foundation

Essential for smooth operation; requires structural steel skid attached to concrete slab.

2.3 Piping

Proper design minimizes vibration transmission; use flexible connectors.

2.4 Liquid Trap

Prevents liquid entry into compressor; ASME code stamped with level switches.

2.5 Driver Installation and Flywheels

Proper driver selection and installation is crucial; never operate without a flywheel.

2.6 Crankcase Lubrication

Fill crankcase to full mark with appropriate industrial oil.

2.7 Purging, Padding, Venting, and Draining of Distance Pieces

Key for leakage control and oil-free compression; use clean gas.

2.8 Relief Valves

Must be installed on discharge side; material compatible with gas.

2.9 Shutdown and Alarm Devices

Provide protection against damage; includes low oil pressure, high temp switches.

Chapter 3: Start Up

3.1 Inspection After Extended Storage

Check cylinder bore and valve areas for rust or debris.

3.2 Flywheel and V-belt Alignment

Ensure proper belt tension, sheave alignment, and flywheel runout.

3.3 Crankcase Oil Pressure Adjustment

Adjust oil pressure to approximately 20 psi minimum for normal service.

3.4 Startup Check List

Comprehensive list of pre-start and post-start checks.

Chapter 5: Service Procedures

5.1 Valves

Test valves by closing inlet; inspect for damage, corrosion, or debris.

5.2 Heads/Cylinder Cap

Seldom require replacement; damage due to corrosion or debris entry.

5.3 Piston Rings and Piston Ring Expanders

Replace rings and expanders; measure radial thickness for wear.

5.4 Piston Replacement

Depressurize, remove head, piston cap; adjust shims for clearance.

5.5 Piston Rod Packing Adjustment

Adjust or replace packing when leakage is prevalent by tightening nuts.

5.6 Cylinder and Packing Replacement

Cylinders seldom require replacement; avoid damage from corrosion or debris.

5.7 Bearing Replacement for Crankcase and Connecting Rod

Replace bearings by removing components; ensure proper alignment and lubrication.

5.8 Oil Pump Inspection

Inspect gears, shaft bushing for corrosion or wear; replace O-rings.

5.9 Gasket Sets

List of available repair kits for various compressor models.

Appendix A: Model Number Identification Code and Available Options

Base Model Identification

Defines base model codes for D791, T791, FD891, FT891.

Specification Fields Overview

Details for packing, crankcase, valves, materials, and coatings.

Model Number Construction

Explains how to build a model number from specification choices.

Appendix B: Specifications

Operating Specifications

Key operating parameters like bore, stroke, displacement, and pressure.

Clearances and Dimensions

Lists critical clearances and dimensions for assembly and maintenance.

Bolt Torque Values

Provides specific torque values for various bolts and fasteners.

Appendix C: Outline Dimensions

Model D791 Outline Dimensions

Dimensional drawings and measurements for the D791 model.

Model D891 Outline Dimensions

Dimensional drawings and measurements for the D891 model.

Model T791 Outline Dimensions

Dimensional drawings and measurements for the T791 model.

Model FT891 Outline Dimensions

Dimensional drawings and measurements for the FT891 model.

Appendix D: Parts and Assembly Details

Head and Valve Assemblies

Parts breakdown for heads, valve holddowns, and valve assemblies.

Piston Assembly Details

Parts list and clearance data for piston assemblies.

Packing Assembly Details

Parts breakdown and assembly for various packing specifications.

Crosshead Guide Parts Details

Parts list for crosshead guide assemblies.

Connecting Rod and Crosshead Assemblies Parts

Parts list for connecting rod and crosshead assemblies.

Flywheel Assembly Parts Details

Parts list for flywheel assembly components.

Crankcase Assembly Parts Details

Parts list for crankcase assembly components.

Appendix E: Troubleshooting

Compressor Problems and Causes

Lists common issues and their potential causes.

Troubleshooting Actions

Provides recommended steps to resolve compressor problems.

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