Corken Z-Series Installation, Operation & Maintenance Manual
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Corken Z-Series Installation, Operation & Maintenance Manual

Truck and stationary pumps
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ID105J
Installation, Operation
& Maintenance Manual
Z-Series Truck and Stationary Pumps
Model Z2000 Truck Pump
Model Z3200 Truck Pump
Model Z3500 Truck and
Stationary Pump
Model Z4200 Truck Pump
Model Z4500 Stationary Pump
Warning: (1) Periodic inspection and maintenance of Corken products is essential. (2) Inspection, maintenance and installation of Corken prod-
ucts must be made only by experienced, trained and qualifi ed 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, fl ammable or explosive substances using Corken products is at user's risk and equipment should
be operated only by qualifi ed personnel according to applicable laws and safety standards.

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Summary of Contents for Corken Z-Series

  • Page 1 Warning: (1) Periodic inspection and maintenance of Corken products is essential. (2) Inspection, maintenance and installation of Corken prod- ucts must be made only by experienced, trained and qualifi ed 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...
  • Page 2 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,...

  • Page 3: Table Of Contents

    Pump Assembly Instructions For Z-Series Truck Pumps ........

  • Page 4: Applicable Notice Of Atex Conformity

    Applicable Notices for Training Instructions: Instructions for the safe application and use of this ATEX 94/9/EC Conformity product are provided in this manual. Read this manual completely prior to installation and use of this product. Product Type: Only qualified and properly trained personnel should be Coro-Vane ®...

  • Page 5: Principles Of The Z-Series Coro-Vane ® Pump

    Coro-Vane Pump Z-Series Coro-Vane Truck Pump The Corken Z-Series truck pump is a special type of rotary Before installing of your pump, remove all temporary positive displacement pump, known as a sliding vane pump. plastic plugs. The sliding vane pump has many of the positive displacement The installation of the Z-Series CORO-VANE ®...

  • Page 6: Outlet Piping Should Include The Following

    All Z-Series pumps (except ZX2000, which is set abnormal wear. at 175 psid) are set near 150 psid.

  • Page 7: Hydraulic Drive Systems

    For proper installation of pump drives, follow the rules 4. If your system has a Corken T-166 bypass valve, adjust listed below: the valve by turning the adjusting screw counter clockwise until the pump discharge pressure gauge shows nearly 1.

  • Page 8: Installation Of Your Corken Z-Series Coro-Vane Stationary Pump

    NOTE: EVEN WITH THIS INTERNAL SAFETY VALVE, AN EXTERNAL BYPASS VALVE MUST BE INSTALLED. • Specific safety measures to be applied (e.g. gas detection, automatic shut-off valves, personal protective Installation of Your Corken Z-Series equipment, etc.). ® Coro-Vane Stationary Pump The following table shows the weight of the bare pump for each model.

  • Page 9: The Bypass System Must Include The Following

    3. Always install an external bypass relief valve (such as guarantee an explosion-proof or totally enclosed motor the Corken ZV200 or B177) in the pump discharge line. against damage from moisture. The bypass valve may discharge into the tank at any convenient opening, either liquid or vapor;...

  • Page 10: Operation Of Your Z-Series Stationary Coro-Vane

    Maintenance (IOM) Manual (IH106) for more details emergency procedures in event of a malfunction. on the use of the Corken bypass valves. 6. Close all hose valves. 12. Your pump has an internal relief valve, it must be set higher than the external bypass setting.

  • Page 11: Maintenance Of Your Z-Series Coro-Vane

    ® Coro-Vane Pump System grease seals, are offered in the Corken “repair kit” listed in this manual directly after the Seal Replacement Instruction on page nine. Use only genuine Corken replacement parts All repairs to the pump must be performed by when repairing your Corken Z-Series pump.

  • Page 12: Preventive Maintenance Program

    Preventative Maintenance Program for Z-Series LPG Pumps 5. Lubricate Motor Bearing: Purpose By following an effective preventive maintenance Follow the recommendations of the electric motor program, unscheduled downtime can be eliminated. This manufacturer for the type of grease to use and the program should be used by the Operation Manager to lubrication frequency.

  • Page 13: Z-Series Coro-Vane ® Seal Replacement Instructions

    PUMP AND PIPING BEFORE STARTING TO Workmanship INSTALL YOUR SEAL ASSEMBLY. Your Corken pump is a precision piece of equipment with very close clearances. Treat it as such. Never use force during assembly or disassembly (see steps 1 through 10).
  • Page 14 ® Z-Series Coro-Vane Seal Replacement Instructions Step 5 Step 7 Seal retainer and carbon installation Completing installation Clean the pump and apply a generous amount of light oil. Torque the head bolts in a crossing pattern. There is no need to disassemble or re-shim the bearing caps.

  • Page 15: Repair/Re-Build Kits

    Repair/Re-build Kits Z4200, ZH4200, Z4500 Repair Kit 3197-X1 Z2000, ZH2000, ZX2000, ZXH2000 Repair Kit 3193-X1 2-224A O-ring, Buna-N 2-231A O-ring, Buna-N 2-231A O-ring, Buna-N 2-234A O-ring, Buna-N 2754-X Roller bearing 4460-X Roller bearing 4262-X Vane driver 4449-X Vane driver 4428 Vane 4448 Vane...

  • Page 16: Pump Assembly Instructions For Z-Series Truck Pumps

    Pump Assembly Instructions For Z-Series Truck Pumps 1. Place the pump head on a clean work surface with the 14. Carefully install the head over the pump shaft and seal bolting flange down. assembly and torque the bolts in accordance with the appropriate bolt torque pattern drawing.

  • Page 17: Model Number And Identification Code

    Appendix A—Z-Series Truck Pumps Model Number and Identification Code Base Model Z2000/ZH2000 ZX2000/ZXH2000 Z/ZH3200 Z/ZH4200 Model Number Inlet 2" NPT 2" NPT 3" ANSI 4" ANSI Base X X X X X X Outlet 2" NPT 2" NPT 2" ell Dual 2"...
  • Page 18 Appendix A—Z-Series Stationary Pump Model Number and Identification Code Base Model Z3500 Z4500 Model Number Inlet 3" NPT (Standard) 4" 300# ANSI Base X X X X X Outlet 3" NPT Elongated (Standard) 3" 300# ANSI Weight—bare pump lb (kg)

  • Page 19: Features, Benefits, And Operations And Material Specifications

    Appendix B—Specifications Equipment Type & Options Applications Truck sliding vane pump Propane bulk transfer Auto-fuel pumping Multiple connection options nurse tanks Carousel cylinder filling Optional auxiliary inlet LPG cylinders Features & Benefits Sliding vane type: Positive displacement pump Heavy duty bearings: Long bearing life Single mechanical seal: Very easy seal replacement and maintenance...

  • Page 20: Performance Curves And Charts

    3. Temperatures below 70°F (21°C) This loss of delivery is not caused by the pump but is a result of the natural thermodynamic properties of liquefied petroleum gases. See the “GUIDE TO CORKEN LIQUEFIED GAS TRANSFER EQUIPMENT” (CP226) for additional information.
  • Page 21 3. Temperatures below 70°F (21°C) This loss of delivery is not caused by the pump but is a result of the natural thermodynamic properties of liquefied petroleum gases. See the “GUIDE TO CORKEN LIQUEFIED GAS TRANSFER EQUIPMENT” (CP226) for additional information.
  • Page 22 3. Temperatures below 70°F (21°C) This loss of delivery is not caused by the pump but is a result of the natural thermodynamic properties of liquefied petroleum gases. See the “GUIDE TO CORKEN LIQUEFIED GAS TRANSFER EQUIPMENT” (CP226) for additional information.
  • Page 23 Appendix C—Performance Charts Z2000, ZH2000, ZX2000, and ZXH2000 Coro-Vane ® Truck Pumps Pump Differential Approximate Delivery of Brake hp Pump Torque Speed Pressure Propane Required Required psid (kPa) gpm (L/min) bhp (kW) ft•lb (N•M) 50 (345) 82 (309) 2.9 (2.2) 20.4 (27.7) 100 (689) 77 (291)
  • Page 24 Appendix C—Performance Curves Z3500...
  • Page 25 Appendix C—Performance Curves Z4500...

  • Page 26: Outline Dimensions

    (40.61) 1/4" x 1-9/16" square key INTERNAL RELIEF VALVE SET AT 150 P.S.I. NOT FOR RECIRCULATING INSTALLER TO PROVIDE SEPARATE BY-PASS VALVE SET AT 125 P.S.I. MAXIMUM CORKEN, INC. 2-1/8 2-1/8 A Unit Of IDEX Corp. (5.40) (5.40) 1-1/8 (2.85) 3-1/4 (8.25)
  • Page 27 (37.94) INTERNAL RELIEF VALVE (12.70) SET AT 150 P.S.I. NOT FOR RECIRCULATING INSTALLER TO PROVIDE SEPARATE BY-PASS VALVE SET AT 125 P.S.I. MAXIMUM CORKEN, INC. A Unit Of IDEX Corp. 1/4" NPT Internal 1-5/8 (4.13) relief 2" NPT valve discharge...
  • Page 28 Appendix D—Outline Dimensions for Model Z3500 3.25 (8.18) 7.688 (19.5) 1.125 (2.9) 3" NPT outlet 6.813 6.046 (17.3) (15.4) 7.188 1/4" (18.3) keyway 1.758 5.500 (4.5) (14.0) 3" NPT inlet 3.000 3.000 1.250 1.250 (7.6) (7.6) (3.2) (3.2) 1.750 1.750 4.125 4.125 (4.4)
  • Page 29 Appendix D—Outline Dimensions for Model Z4200 1-3/16 (3.01) Internal relief valve INLET 1/4" NPT 2" NPT auxillary inlet (20.32) 2-5/8 (6.67) 13-13/16 (35.08) OUTLET 3-1/4 (8.26) 1/4" NPT 7-3/4 (17.78) (19.69) 16-31/32 (43.08) 19-1/2 (49.53) 7-7/8 BC 10-1/8 D (20.00) (25.72) Inlet: 2-1/8...
  • Page 30 Appendix D—Outline Dimensions for Model Z4500 8-Ø .875 (2.2) on a 6-5/8" B.C. Outlet 3" R.F. 300# ANSI flange 8.469 1.875 (21.5) (4.8) Inlet 4" R.F. 300# 10.75 ANSI flange (27.3) 5/16" square key (2.5) (16.5) 8-Ø .875 (2.2) 2.875 2.875 4.688 4.688...
  • Page 31 Hydraulic drive adapter assembly 2-1/8 INTERNAL RELIEF VALVE SET AT 150 P.S.I. NOT FOR RECIRCULATING INSTALLER TO PROVIDE SEPARATE BY-PASS VALVE (5.40) SET AT 125 P.S.I. MAXIMUM CORKEN, INC. A Unit Of IDEX Corp. 4248 1-1/8 D (2.85) Hydraulic motor 3-1/4 (8.25) 13/16 (2.06)
  • Page 32 10-15/16 (27.75) INTERNAL RELIEF VALVE SET AT 150 P.S.I. NOT FOR RECIRCULATING INSTALLER TO PROVIDE SEPARATE BY-PASS VALVE SET AT 125 P.S.I. MAXIMUM CORKEN, INC. A Unit Of IDEX Corp. Hydraulic motor Hydraulic drive adapter assembly 6-5/8 D B.C. 3-7/8 (16.83)
  • Page 33 (24.77) 12-3/8 (31.43) MODEL SERIAL CORO-VANE CORKEN,INC. A Unit Of IDEX Corp. OKLAHOMA CITY,OKLAHOMA MADE IN U.S.A. POWER OPERATED PUMP FOR LPG OR ANHYDROUS NH READ CORKEN INSTRUCTION MANUAL BEFORE OPERATING LISTED 656L PAT. NOS. 3,072,066 AND 3,392,677 Hydraulic motor...
  • Page 34 Appendix D—Outline Dimensions for Z3500–103 Mounting All dimensions are in inches (centimeters).
  • Page 35 Appendix D—Outline Dimensions for Z4500–103 Mounting All dimensions are in inches (centimeters).

  • Page 36: Parts Details

    Appendix E—Parts Details for Models Z/ZH/ZX/ZXH2000 37 (45 ft•lb) 36 (25 ft•lb) 36 (25 ft•lb) 35 (15 ft•lb) 37 (45 ft•lb) 36 (25 ft•lb) Inlet O-ring Code A Buna-N Note: Hydraulic motor is not shown. B Neoprene ®1 ®1 D Viton See page 15 for repair/re-build kits.
  • Page 37 Appendix E—Parts Details for Models Z/ZH3200 28 (60 ft•lb) 25 (25 ft•lb) Inlet 29 (15 ft•lb) 28 (60 ft•lb) Outlet O-ring Code (25 ft•lb) A Buna-N Note: Hydraulic motor is not shown. B Neoprene ®1 See page 15 for repair/re-build kits. ®1 D Viton CAUTION: Always relieve pressure in the unit before attempting...
  • Page 38 Appendix E—Parts Details for Models Z3500 35 (45 ft•lb) 34 (25 ft•lb) 34 (25 ft•lb) 33 (25 ft•lb) O-ring Code 34 (25 ft•lb) A Buna-N B Neoprene ®1 Note: Hydraulic motor is not shown. D Viton ®1 See page 15 for repair/re-build kits. Teflon ®1 CAUTION: Always relieve pressure in the unit before attempting any repairs.
  • Page 39 Appendix E—Parts Details for Models Z/ZH4200 O-ring Code A Buna-N ®1 B Neoprene D Viton ®1 ®1 Teflon Note: Hydraulic motor is not shown. See page 15 for repair/re-build kits. CAUTION: Always relieve pressure in the unit before attempting any repairs. Ref.
  • Page 40 Appendix E—Parts Details for Model Z4500 O-ring Code A Buna-N ®1 B Neoprene D Viton ®1 ®1 Teflon Note: Hydraulic motor is not shown. See page 15 for repair/re-build kits. CAUTION: Always relieve pressure in the unit before attempting any repairs. Ref.

  • Page 41: V-Belt Selection For Stationary Coro-Vane

    ® Appendix F—V-Belt Selection for Stationary Coro-Vane Pumps 1,450 RPM Motor 1,750 RPM Motor Motor Nominal Belt Sheave Pitch Diameter Sheave Pitch Diameter Belt Pump RPM Number Number Pump Motor Pump Motor B15.4 B7.4 1-3V14.0 1-3V3.35 3V600 B13.6 B4.2 1-3V10.6 1-3V2.80 3V530 B12.4...

  • Page 42: Troubleshooting Guide

    Appendix F—V-Belt Selection for the Z-4500 1,450 RPM Motor 1,750 RPM Motor Motor Nominal Belt Sheave Pitch Diameter Sheave Pitch Diameter Belt Pump RPM Number Number Pump Motor Pump Motor 3VX690 QD3/3V14.00 QD3/3V4.12 QD3/3V19.00 QD3/3V4.75 3/3V800 3VX710 QD3/3V14.00 QD3/3V4.50 QD2/3V19.00 QD2/3V5.30 3VX800 3VX710...
  • Page 43 Appendix G—Troubleshooting Guide (continued) Problem Cause Solution Low capacity Suction pipe too small or Indicated by pump inlet pressure dropping several pounds (continued) restricted when pump is started. Remove restriction or modify piping. Worn vanes Replace. Pump without vapor return Without vapor equalization, a pump can remove only about 3% of the truck tank capacity per minute without severe cavitation and capacity loss.

  • Page 44: Storage Of The Z-Series Coro-Vane

    Appendix I—Hydraulic Motor ® Z-Series Coro-Vane Truck Pumps Specifications If your Corken Z-Series pump is to be removed from Operating Specifications for Char-Lynn Hydraulic Motor service for some time, the pump must be protected Mounting flange 2 bolt SAE A as propane, butane and anhydrous ammonia all leave 1 in.

This manual is also suitable for:

Zh2000Zx2000Z3200Zxh2000Zh3200Z3500 ... Show all

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