Installation, Operation & Maintenance Manual - Acme Fluid Handling

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Disassembly1. Unscrew the valve cap and remove O-ring.2. With the special wrench supplied with your compressorat time of purchase, remove the holddown screw.3. After the holddown screw has been removed, thevalve assembly and valve gasket can be lifted out.4. Carefully inspect for dirt or broken/damaged parts.5. Inspect valves for breakage, corrosion, debris andscratches on the valve disc or plate. In many cases,valves may simply be cleaned and reinstalled. If thevalves show any damage, they should be repaired orreplaced. Replacement is usually preferable althoughrepair parts are available. If valve plates are replaced,seats should also be lapped until they are perfectlysmooth. If more than .005 in. must be removedto achieve a smooth surface, the valve should bediscarded. If plates are replaced without relapping theseat, rapid wear and leakage may occur.Assembly1. Insert metal valve gasket into the suction and/ordischarge opening of the head. The metal valvegasket should always be replaced when the valveis reinstalled.2. Insert cleaned or new valve assembly. Make surethe suction and discharge valves are in the propersuction and discharge opening in the head. NOTE:The spec 3 suction valves for a model 91 and 291compressor are pre-set so no adjustments to liquidrelief pressure are necessary.3. Replace the holddown screw and tighten to the valuelisted in Appendix B to ensure the valve gasket isproperly seated. NOTE: Gaskets and O-rings are notnormally reusable.4. Replace the O-ring (or gasket) and valve cap andtighten to the value listed in Appendix B. O-ringssealing the valve caps should be replaced.5. Check bolts and valve holddown screws after firstweek of operation. Re-torque if necessary. SeeAppendix B for torque values.Valve Inspection and/or Replacement for Models491, 691 and 891 CompressorsBefore removing and inspecting the valves, begin bydepressurizing and purging (if necessary) the unit.Disassembly1. Unscrew the valve cap/nut and remove the gasketfrom the coverplate.2. Remove the valve cover plate, O-ring and holddownscrew by removing each of the four bolts. NOTE:Since the holddown screw has been secured with animpact wrench at the factory, you will probably needto wait to remove the holddown screw until after thecover plate has been removed. At this point in time,the holddown screw can be easily removed from thecover plate. The holddown screw on model 691 and891 is most easily removed with the special wrenchsupplied with your compressor at time of purchasing.3. After the cover plate and O-ring have been removed,the valve spacer (model 491 only), valve cage, valveassembly and valve gasket can be lifted out.4. Inspect valves for breakage, corrosion, debris andscratches on the valve plate. In many cases, valvesmay simply be cleaned and reinstalled. If the valvesshow any damage, they should be repaired orreplaced. Replacement is usually preferable althoughrepair parts are available. If valve plates are replaced,seats should also be lapped until they are perfectlysmooth. If more than .005 in. must be removedto achieve a smooth surface, the valve should bediscarded. If plates are replaced without relappingthe seat, rapid wear and leakage may occur.Assembly1. Insert metal valve gasket into the suction and/ordischarge opening of the head. The metal valvegasket should always be replaced when the valve isreinstalled.2. Insert cleaned or new valve assembly. Make surethe suction and discharge valves are in the propersuction and discharge opening in the head.3. Insert the valve cage and valve spacer (NOTE: spacerapplies to model 491 compressor only).4. Replace the O-ring and valve cover plate. Torquebolts to the value listed in Appendix B. CAUTION: Besure the holddown screw has been removed.5. Insert the holddown screw and tighten to the valuelisted in Appendix B to ensure the valve gasket isproperly seated. NOTE: Gaskets and O-rings are notnormally reusable.6. Replace the O-ring (or gasket) and valve cap/nutand tighten to the value listed in Appendix B. O-rings sealing the valve cap should be replaced if theyshow signs of wear or damage. Valve caps sealedby flat metals gaskets should be reinstalled with newgaskets.7. NOTE: Spec 3 suction valves have an adjustingscrew to set the liquid relief pressure. To set theliquid relief pressure, tighten the adjusting screw untilit bottoms, then back out 3/4 turn.8. Check bolts and valve holddown screws after firstweek of operation. Re-torque if necessary. SeeAppendix B for torque values.18
5.2 HeadsA compressor head very seldom requires replacement ifthe compressor is properly maintained. The primary causeof damage to a head is corrosion and the entry of soliddebris or liquid into the compression chamber. Improperstorage can also result in corrosion damage to the head(for proper storage instructions see chapter 6).Many compressor repair operations require removalof the head. While the compressor is disassembled,special care should be taken to avoid damage orcorrosion to the head. If the compressor is to be leftopen for more than a few hours, bare metal surfacesshould be coated with rust preventative.When reassembling the compressor, make sure the boltsare retightened as shown in Appendix B.5.3 Piston Rings andPiston Ring ExpandersFigure 5.3A: Piston RemovalPiston ring life will vary considerably from application toapplication. Ring life will improve dramatically at lowerspeeds and temperatures.5.4 Pistons1. To replace the pistons, depressurize the compressorand purge if necessary.2. Remove the compressor cylinder and head (seesection 5.2).3. Remove the piston head by loosening and removingthe socket head bolts holding the piston head to thepiston platform (see figure 5.3A).4. Next, remove the roll pin with a pair of needle nosepliers. The castellated nut may then be removed andthe piston platform lifted off the end of the piston rod.5. Check the thrust washer and shims for damage andreplace if necessary.6. Before installing the new piston, measure thethickness of the existing shims. For Models 91through 491, the shims are placed between thethrust washer and piston platform. For model 691,the shims are placed between the platform andpiston head (see figures 5.4A and 5.4B).7. Reinstall the piston platform with the same thicknessof shims as before, BUT DO NOT REINSTALL THEROLL PIN.8. Replace the cylinder and install the piston heads withnew piston rings and expanders.9. Now measure dimension “X” shown in the illustration.If this measurement does not fall within the tolerancesshown in Appendix B, remove the piston, adjust theshims as necessary and remeasure the “X” dimension.10. When the piston is properly shimmed, tighten thecastellated nut as shown in Appendix B.11. Now install a new roll pin to lock the castellatedpiston nut in place.1. To replace the piston rings, depressurize thecompressor and purge if necessary.2. Remove the head to gain access to the compressorcylinder.3. Loosen the piston head bolts. Remove the pistonas shown in figure 5.3A by pinching two loosebolts together.4. Piston rings and expanders may then be easilyremoved and replaced. Corken recommendsreplacing expanders whenever rings are replaced.To determine if rings should be replaced, measurethe radial thickness and compare it to the chart inAppendix B.Figure 5.4A: Piston Cross SectionModel Sizes 91 Through 49119
Page 5 and 6: this by withdrawing vapors from the
Page 7 and 8: Corken’s automatically reversible
Page 10 and 11: 2.4 Liquid TrapsCompressors are des
Page 12 and 13: 2.5 Driver Installation / Flywheels
Page 14 and 15: Chapter 3—Starting Up Your Corken
Page 16 and 17: Chapter 4—Routine Maintenance Cha
Page 20 and 21: of damage to cylinders is corrosion
Page 22 and 23: 5. Push down on washer and insert r
Page 24 and 25: 5.9 Servicing the Four-Way ValveUnl
Page 26 and 27: Appendix AVertical Single-Acting Mo
Page 28 and 29: Appendix B—Vertical Single-Acting
Page 34 and 35: Appendix C—Compressor SelectionCo
Page 36 and 37: Appendix C—Compressor SelectionPr
Page 38 and 39: Appendix D—Outline DimensionsMode
Page 42 and 43: AUTOMATIC LIQUID TRAPLIQUID LEVEL S
Page 50 and 51: Appendix F—91 and F91 Head and Va
Page 52 and 53: Appendix F—91 and F91 Piston Asse
Page 54 and 55: Appendix F—91 and F91 Connecting
Page 56 and 57: Appendix F—91 and F91 Crankcase A
Page 58 and 59: Appendix G—291 and F291 Head and
Page 60 and 61: Appendix G—291 and F291 Piston As
Page 62 and 63: Appendix G—291 and F291 Connectin
Page 64 and 65: Appendix G—291 and F291 Crankcase
Page 66 and 67: Appendix H—490, 491, and F491 Hea
Page 68 and 69:
Appendix H—490, 491, and F491 Pis
Page 70 and 71:
Appendix H—490, 491, and F491 Con
Page 72 and 73:
Appendix H—490, 491, and F491 Cra
Page 74 and 75:
Appendix I—691 and F691 Head and
Page 76 and 77:
Appendix I—691 and F691 Piston As
Page 78 and 79:
Appendix I—691 and F691 Connectin
Page 80 and 81:
Appendix I—691 and F691 Crankcase
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Appendix J—D891 Head and Valve As
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Appendix J—D891 Crosshead Guide A
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Appendix J—D891 Connecting Rod As
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Appendix J—D891 Crankcase Assembl
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CORKEN, INC. • A Unit of IDEX Cor
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Installation, Operation & Maintenance Manual - Acme Fluid Handling

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