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Corken HG601 Series Installation, Operation & Maintenance Manual

Plain & t-style double acting gas compressors
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ORIGINAL INSTRUCTIONS
IJ100D
Installation, Operation
& Maintenance Manual
Plain & T-Style Double-Acting Gas Compressors
Models HG601, HG602, THG601 & THG602 Series
Model THG602BE
(T-style)
Model HG601EE
(Plain style)
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.

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Summary of Contents for Corken HG601 Series

  • Page 1 (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.
  • 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 one year from date of installation, provided that the warranty shall not extend beyond twenty-four (24) months from the date of shipment from Corken.

  • Page 3: Table Of Contents

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

  • Page 4: Features And Benefits

    While piston rings seal the piston tightly or elevated suction pressures are required. With a large selection of design options available, Corken offers the enough for it to do compression work, they do not provide enough sealing to isolate the compression chamber from...
  • Page 5 Your new Corken horizontal compressor is a double-acting reciprocating compressor; however, when an optional blank valve is used, the compressor is single acting. Corken horizontal compressors have a large number of configurations to fit your individual requirements. They are manufactured as single stage- or two-stage units.

  • Page 6: Chapter 1-Installation Of Your Compressor

    Noise: DO NOT SUPPORT PIPING WITH THE COMPRESSOR. Corken horizontal compressors should not exceed an 85 Unsupported piping is the most frequent cause of vibration DBA noise level when properly installed. of the pipe. The best method to minimize transmission of vibration from the compressor to the piping is to use flexible connectors (see figure 1.3 for details).

  • Page 7: Liquid Trap

    If your compressor is equipped with a liquid trap not All piping must be in accordance with the laws and codes manufactured by Corken, make sure it is adequately governing the service. In the United States, the following sized; otherwise, it may not be able to remove the liquid codes apply: entrained in the suction stream.

  • Page 8: Driver Installation And Flywheels

    1.5 Driver Installation and Flywheels NOTE: No motor manufacturer will guarantee their explosion proof or totally enclosed (TEFC) motor against Corken compressors may be driven by either electric damage from moisture. motors or internal combustion engines (e.g. gasoline, diesel, natural gas, etc.). The wiring of an electric...

  • Page 9: Crankcase Lubrication

    1.6 Crankcase Lubrication Non-detergent oil is recommended for Corken horizontal compressors. Detergent oils tend to keep wear particles and debris suspended in the oil, whereas non-detergent The crankcase of your compressor was drained before oils let them settle in the bottom of the crankcase. When shipment.

  • Page 10: Relief Valves

    Recommended for units mounted An appropriate relief valve must be installed on to a portable skid. the discharge side of the compressor. On Corken 107C-style mounted units, a relief valve should be fitted in the piping between the compressor discharge and the four-way valve.

  • Page 11: Chapter 2-Starting Up Your Corken Compressor

    Chapter 2—Starting Up Your Corken Compressor The initial operation of your compressor is the most critical Rotate unit manually to ensure running gear functions time it will ever face. READ ALL OF CHAPTER TWO BEFORE properly. Replace the crankcase inspection plate and YOU PROCEED WITH THE STARTUP CHECKLIST.

  • Page 12: Compressor Speed And Rotation Direction

    The lubrication system of the Corken horizontal the crankcase (see lubricator assembly details in compressor is designed to operate at a minimum of 400 Appendix D).

  • Page 13: Variable Clearance Heads (Vch)

    NOTE: 1) Since Corken uses more than one vendor when purchasing lubricators, the lubricator shown below and respective operational instructions may vary from the one used on your compressor. 2) Operational instructions can be found on the side of the lubricator reservoir.

  • Page 14: Startup Check List

    3) Turning the end of the adjusting cup inward (clockwise) 17. Carefully check for any loose connections or bolts. reduces cylinder head end clearance. 18. Remove all stray objects (rags, tools, etc.) from 4) Turning the end of the adjusting cup outward vicinity of the unit.

  • Page 15: Chapter 3-Routine Maintenance Chart

    If routine maintenance is performed as listed in chapter Each suction and/or discharge valve assembly is easily 3, repair service on your Corken gas compressor is removed as a unit for inspection. If any part of the generally limited to replacing valves or piston rings.

  • Page 16: Heads

    Valve Inspection and/or Replacement replaced. Replacement is usually preferable although repair parts are available. If valve plates are replaced, Before removing and inspecting the valves, begin by seats should also be lapped until they are perfectly depressurizing and purging (if necessary) the unit and smooth.

  • Page 17: Piston Rings And Piston Ring Expander Replacement

    Appendix B. particularly under high temperature conditions. 4.4 Pistons CORKEN uses one of the best PTFE ring formulations available. The normal life expectancy is approximately As you read the following instructions, refer to 2,200 hours of continuous service within recommended Appendix D for parts details.

  • Page 18: Cylinder Replacement

    “X” at the outboard end of the piston as (Corken #3905) over piston rod threads. This shown in the Appendix B. If this measurement does will aid and protect packing during installation.
  • Page 19 Workmanship: outward to remove the packing cartridge cap from Your Corken compressor is a precision piece of equipment the rest of the packing cartridge assembly, adapter with very close tolerances. Treat it as such. Never beat and over the piston rod.
  • Page 20 b. Install the oil wiper ring set, packing washer and d. Install a purge packing cup with O-ring and biased inner retainer ring into the crankcase side of the packing set (tangent-tangent with springs toward packing cartridge body. crankcase [sTT]) into cylinder side of packing cartridge body.
  • Page 21 If the packing components are not easily removable, it may be necessary to use Corken Packing Removal 3. Refer to Appendix D for your particular model of Tool 4789-X. Referring to Figure 4.6A, orient the...
  • Page 22 Step 1 Step 2 Packing removal tool (4789-X) Packing removal tool (4789-X) Lever Push lever in to actuate Engagement end of tool Engagement end of lever Packing cartride body Purge packing cup Purge packing cup Figure 4.6A: Packing disassembly Figure 4.6B: Packing disassembly 10.
  • Page 23 Step 2 Step 3 Packing assembly tool (4974-X) Packing assembly Slotted clamp tool (4974-X) Packing cartridge adapter Slotted clamp Inner packing set Wiper ring cup and inner oil wiper ring set End plate Packing cartridge Purge packing cup and adapter inner packing set End plate Figure 4.6D : Packing assembly...

  • Page 24: Bearing Replacement For Crankcase And Connecting Rod

    5. Middle Packing f. Install a new O-ring on the outside of the packing cartridge adapter and inside the adapter a. For compressors set up for pad packing (Specification Code G), install a purge packing g. Install a packing installation cone (Part no. 3905) cup with O-ring and a biased packing set (tangent- on the threaded end of the piston rod.
  • Page 25 Oil seal Bearing cover Shim Bearing cup Crankcase Bearing cone Drive pin Crankshaft Bearing cone Flywheel key Bearing cup Bearing carrier gasket Bearing carrier Spacer Drive sprocket Link pin Make sure this hole is aligned with the oil-passage hole on the bearing carrier. Backside of bearing carrier Align slot with the pin located...
  • Page 26 Crankcase inspection plate: Backside of Fill crankcase with oil through oil filter adapter this opening. Pump shaft bushing Oil suction Align pin with slot on pump shaft adapter. Oil filter O-ring Spring Pump shaft adapter Align slot with Spring guide the pin at the end of Oil filter adapter the crankshaft.

  • Page 27: Oil Pump Inspection

    If the compressor operates for a prolonged period with the risk of the unit becoming corroded and damaged. dirty or contaminated crankcase oil, damage to the oil Corken recommends the following precautions to protect pump and bearings may result. the compressor during storage: 1.

  • Page 28: Compressor Troubleshooting

    General If interstage pressure is too high: In most cases problems with your CORKEN gas compressor can be solved quite simply. The table below • Second stage valves may be broken or leaking. lists some of the more frequent problems that occur with reciprocating compressors along with a list of possible •...

  • Page 29: Gasket Sets And Repair Kits

    Gasket Sets and Repair Kits Care must be exercised when selecting the cylinder kit required for a specific application. The proper head type and piston material must be chosen. To maintain proper Gasket Set Part Type Head Type balance, the following piston combinations are required 3582-X Crankcase for two-stage compressors.

  • Page 30: Model Number Identification Code

    Appendix A—Model Number Identification Code INDUSTRIAL HORIZONTAL SINGLE CYLINDER COMPRESSORS MODEL NUMBER HG601AX HG601BX HG601CX HG601DX HG601EX HG601FX BASE MODEL NUMBER BASE X X X X X X X X X X X " " Plain Style Cylinder size 8" 6"...
  • Page 31 Appendix A—Model Number Identification Code INDUSTRIAL HORIZONTAL TWO CYLINDER, SINGLE-STAGE COMPRESSORS MODEL NUMBER BASE MODEL NUMBER HG601AA HG601BB HG601CC HG601DD HG601EE HG601FF BASE X X X X X X X X X X X Plain Style Cylinder size 8" x 8" 6"...
  • Page 32 Appendix A—Model Number Identification Code INDUSTRIAL HORIZONTAL TWO CYLINDER, TWO-STAGE COMPRESSORS MODEL NUMBER BASE X X X X X X X X X X X BASE MODEL NUMBER HG602AB HG602AC HG602AD HG602BC HG602BD Plain Style Cylinder size 8" x 6" 8"...
  • Page 33 Appendix A—Model Number Identification Code INDUSTRIAL HORIZONTAL TWO CYLINDER, TWO-STAGE COMPRESSORS (cont'd.) MODEL NUMBER BASE X X X X X X X X X X X BASE MODEL NUMBER HG602BE HG602BF HG602DE HG602DF HG602EF Plain Style Cylinder size 6" x 3¼" 6"...
  • Page 34 Appendix A—Model Number Identification Code LPG HORIZONTAL TWO CYLINDER, SINGLE-STAGE COMPRESSORS MODEL NUMBER BASE X X X X X X X X X X X HG601AA HG601BB HG601CC HG601DD HG601EE HG601FF BASE MODEL NUMBER Plain Style Cylinders 8" x 8" 6"...

  • Page 36: Operating Specifications

    Appendix B—Operating Specifications Single-Stage Horizontal Compressors Single Cylinder HG601AX HG601BX HG601CX HG601DX HG601EX HG601FX Models THG601AX THG601BX THG601CX THG601DX THG601EX THG601FX Size 8" 6" 5" 4" 3.25" 2.75" Displacement cfm (m /hr) 400 rpm 68.8 (116.9) 38.4 (65.2) 26.4 (44.9) 16.8 (28.5) 10.8 (18.3) 7.6 (12.9)
  • Page 37 Appendix B—Operating Specifications Cylinder Data Cylinder Code Description Cylinder Bore in. (mm) 8.0 (203.2) 6.0 (152.4) 5.0 (127) 4.0 (101.6) 3.25 (82.6) 2.75 (69.9) Maximum working pressure 1,650.0 300.0 (20.7) 350 (24.1) 750 (51.7) 1,000.0 (69.0) 1,200.0 (82.8) psia (bar g) (113.8) Piston ring radial thickness 0.215 (5.46)
  • Page 38 Appendix B—Material Specifications (HG600/THG600 Series) Part Model No. Standard Material Optional Material Crankcase Ductile iron ASTM A536, Grade 65-45-12 Adapters Ductile iron ASTM A536, Grade 65-45-12 Cylinders Ductile iron ASTM A536, Grade 65-45-12 Cylinder heads (adjustable & standard) Ductile iron ASTM A536, Grade 65-45-12 Valve caps Ductile iron ASTM A536, Grade 65-45-12 Crankcase bearing carrier...
  • Page 39 Appendix B—Bolt Torque Values Horizontal Compressor Bolt Torque Values Cylinder Size 2.75" 3.25" 4" 5" 6" 8" Connection rod bolt ft•lb Bearing carrier ft•lb Bearing cover ft•lb Crankcase inspection plate ft•lb Adapter to crankcase or distance piece Distance piece to crankcase Cylinder to adapter ft•lb Valve cover plate bolt ft•lb Valve holddown screw ft•lb...
  • Page 40 Appendix B—Piston Clearance Details Piston Clearance—Bottom Dead Center (3.25" cylinder shown) Top of packing Adapter box cartridge Bottom of piston Cylinder Piston Clearance—Top Dead Center (3.25" cylinder shown) Adapter Cylinder Top of piston cap Bottom of head Shim washer Piston body X and Y Dimension–Inches (mm) Piston Size 2.75"...

  • Page 41: Outline Dimensions

    Appendix C—Outline Dimensions HG601 Series—Plain Style Single Cylinder 2.125" Diameter shaft 2.124" 0.5" Square keyway Adjustable head 0.78 5.53 10.09 (14.0) (1.9) (25.6) 3.88 (9.8) 7.25 (18.4) 9.81 (24.9) 3.38 (8.5) 23.53 (59.7) 4.88" Diameter holes C1 (Adjustable head) 22.19 C (Standard head) (56.1)
  • Page 42 Appendix C—Outline Dimensions HG601/HG602 Series— Plain Style Double Cylinder 2.125" Diameter shaft 2.124" 0.5" Square keyway Adjustable head 4.88" Diameter holes 5.53 (14.0) 0.78 10.09 (1.9) (25.6) 3.88 9.81 (9.8) 7.25 (24.9) (18.4) 3.38 (8.5) 23.53 (59.7) C1 (Adjustable head) C1 (Adjustable head) C (Standard head) C (Standard head)
  • Page 43 Appendix C—Outline Dimensions THG601 Series—T-Style Single Cylinder 2.125" Diameter shaft 2.124" 0.5" square keyway 4.88" Diameter holes Adjustable 5.53 head 0.78 3.88 10.09 (14.0) (1.9) (25.6) (9.8) 9.81 7.25 (24.9) (18.4) 3.38 (8.5) 23.53 (59.7) C1 (Adjustable head) 22.19 C (Standard head) (56.1) 6.69 (16.9)
  • Page 44 Appendix C—Outline Dimensions THG601/THG602 Series—T-Style Double Cylinder 2.125" Diameter shaft 2.124" 0.5" Square keyway 4.88" Diameter holes Adjustable head 5.53 3.88 10.09 0.78 (14.0) (9.8) (25.6) (1.9) 7.25 3.38 (18.4) (8.5) 23.53 (59.7) 9.813 (24.9) C1 (Adjustable head) C1 (Adjustable head) C (Standard head) C (Standard head) 6.69...

  • Page 45: Assembly Details

    Appendix D—Cylinder Head Assembly Details (HG600/THG600 Series) 2.75" Cylinder Head Adapter (see packing assembly for details) Cylinder Head Assembly Bill of Materials for 2.75" Ref. Qty. per O-ring Code Description Part number cylinder Torque to 65 ft.-lbs. Buna-N O-ring 2-232_ ®e Neoprene Cylinder...
  • Page 46 Appendix D—Cylinder Head Assembly Details (HG600/THG600 Series) 3.25", 4", and 5" Cylinder Head Adapter (see packing assembly for details) Torque to 65 ft.-lbs. Torque to 65 ft.-lbs. Cylinder Head Assembly Bill of Materials for 3.25", 4", and 5" O-ring Code Part number Ref.
  • Page 47 Appendix D—Cylinder Head Assembly Details (HG600/THG600 Series) 6" and 8" Cylinder Head Adapter (see packing assembly for details) Torque to 65 ft.-lbs. Torque to 65 ft.-lbs. Cylinder Head Assembly Bill of Materials for 6" and 8" Part number O-ring Code Ref.
  • Page 48 Appendix D—Valve Holddown Assembly Details (HG600/THG600 Series) Valve Holddown Assembly (2.75" only) Valve Holddown Assembly (3.25", 4", 5", 6", & 8" only) Suction Discharge Suction Discharge Cylinder Diameter Ref. Quantity Quantity Quantity Description 2.75" 3.25" 4" cylinder cylinder cylinder Hex head bolt 7001-050NC150A 7001-043NC150A 7001-043NC150A...
  • Page 49 Appendix D—Valve Holddown Assembly Details (HG600/THG600 Series) Suction Valve with Unloader Unloader Piston Assembly Details (3.25", 4", 5", 6", & 8" only) Apply Loctite #290 when assembling See gure A Important: Note seal direction Figure A CAUTION: Always Relieve Pressure In O-ring Code The Unit Before Attempting Any Repairs.
  • Page 50 Appendix D—Valve Assembly Details (HG600/THG600 Series) 2.75" Valve 3.25" Valve Suction Discharge Suction Discharge Cylinder Diameter Ref. Quantity Quantity Quantity Quantity Description 2.75" 3.25" 4" 5" cylinder cylinder cylinder cylinder 3900-X 4029-X2 (iron) 3807-X (iron) 3856-4X (aluminum) (iron) Suction valve 3807-X1 assembly —...
  • Page 51 Appendix D—Valve Assembly Details (HG600/THG600 Series) 4", 5", 6" Valve 8" Valve Suction Discharge Suction Discharge 6" Only 6" Only Cylinder Diameter Quantity Quantity Quantity Quantity Ref. Description 6" 6" 8" 8" cylinder cylinder cylinder cylinder (15+ psi suction pressure) (0 to 15 psi suction pressure) (15+ psi suction pressure) (0 to 15 psi suction pressure) 3856-X...
  • Page 52 Appendix D—Piston Assembly Details (HG600/THG600 Series) 2.75", 3.25", 4", 5" and 6" Piston Sizes Piston rod (see connecting rod assembly details for more information) NOTE: See Appendix B for piston clearance specifications. 8" Piston Size Piston rod (see connecting rod assembly for more information) NOTE: See Appendix B for piston clearance specifications.
  • Page 53 Appendix D—Piston Assembly Details (HG600/THG600 Series) Piston Assembly Bill of Materials for the 2.75", 3.25", and 4" Piston Sizes Cylinder Diameter Ref. Description 2.75" 3.25" 4" Part No. Qty. Part No. Qty. Part No. Qty. Piston assembly 3889-X1 3525-X1 4292-X1 - Iron Thrust washer 3730...
  • Page 54 Appendix D—Packing Assembly Details for HG600 Series (Plain Style) 2.75" Standard Packing Specification NOTE: Cover the end of the piston rod with packing O-ring locations for adapter cone (part # 3905) before installing packing. For 65 ft. lb. lubricated compressors, the lubricating quill located on the adapter must be removed before packing cartridge can be removed.
  • Page 55 Appendix D—Packing Assembly Details for HG600 Series (Plain Style) 2.75" Purge Packing Specification NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing. 65 ft. lb. For lubricated compressors, the lubricating quill located on the adapter must be removed before packing cartridge can be removed.
  • Page 56 Appendix D—Packing Assembly Details for HG600 Series (Plain Style) 3.25" and 4" Standard Packing Specification NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing. For lubricated compressors, the lubricating quill located on the adapter must be removed before packing cartridge can be removed. O-ring locations 65 ft.
  • Page 57 Appendix D—Packing Assembly Details for HG600 Series (Plain Style) 3.25" and 4" Purge Packing Specification NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing O-ring locations packing. For lubricated compressors, the lubricating quill located on the adapter must be removed before packing cartridge can be removed.
  • Page 58 Appendix D—Packing Assembly Details Appendix D—Packing Assembly Details for HG600 Series (Plain Style) 5" Standard Packing Specification NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing. O-ring locations For lubricated compressors, the lubricating quill located on the adapter must be removed before packing cartridge can be removed.
  • Page 59 Appendix D—Packing Assembly Details Appendix D—Packing Assembly Details for HG600 Series (Plain Style) 5" Purge Packing Specification NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing. O-ring locations For lubricated compressors, the lubricating quill located on the adapter must be removed before packing cartridge can be removed.
  • Page 60 Appendix D—Packing Assembly Details for HG600 Series (Plain Style) 6" and 8" Standard Packing Specification NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing. O-ring locations For lubricated compressors, the lubricating quill located on the adapter must be removed before packing cartridge can be removed.
  • Page 61 Appendix D—Packing Assembly Details for HG600 Series (Plain Style) 6" and 8" Purge Packing Specification NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing. O-ring locations For lubricated compressors, the lubricating quill located on the adapter must be removed before packing cartridge can be removed.
  • Page 62 Appendix D—Packing Assembly Details for HG601/HG602 Series (Plain Style) Inner Oil Wiper Ring Sets 1. Standard Specification Part number 3816 Oil wiper ring set (Radial, Radial) Crankcase Cylinder Side Side Radial Cut Align pin with Radial Cut (with pin) hole on backside. (without pin) 2.
  • Page 63 Appendix D—Packing Assembly Details for HG601/HG602 Series (Plain Style) Outer Packing Details for Standard and Purge Packing Specifications 1. Purge Specification Part number 4273 Biased Segmented Packing Set (Tangent, Tangent with springs toward crankcase—sTT) Crankcase Cylinder Side Side Purge Packing Cup Backup Ring Tangent Cut Align pin with...
  • Page 64 Appendix D—Packing Assembly Details for THG600 Series (T-Style) 2.75" Pad Packing Specification NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing. For lubricated compressors, the lubricating quill located on the adapter must be removed before 65 ft.
  • Page 65 Appendix D—Packing Assembly Details for THG600 Series (T-Style) 2.75" Purge Packing Specification NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing. For lubricated compressors, the lubricating quill located on the adapter must be removed before packing cartridge can be removed.
  • Page 66 Appendix D—Packing Assembly Details for THG600 Series (T-Style) 3.25" and 4" Pad Packing Specification NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing. For lubricated compressors, the lubricating quill located on the adapter must be removed before 65 ft.
  • Page 67 Appendix D—Packing Assembly Details for THG600 Series (T-Style) 3.25" and 4" Purge Packing Specification NOTE: Cover the end of the piston rod with packing cone (part # 3905) before installing packing. For lubricated compressors, the lubricating quill located on the adapter must be removed before 65 ft.
  • Page 68 Appendix D—Packing Assembly Details for THG600 Series (T-Style) 5" Pad Packing Specification NOTE: Cover the end of the piston rod with packing cone O-ring locations (part # 3905) before installing packing. For lubricated compressors, the lubricating quill located on the adapter must be removed before packing cartridge can be removed.
  • Page 69 Appendix D—Packing Assembly Details for THG600 Series (T-Style) 5" Purge Packing Specification NOTE: Cover the end of the piston rod with packing cone O-ring locations (part # 3905) before installing packing. For lubricated compressors, the lubricating quill located on the adapter 65 ft.
  • Page 70 Appendix D—Packing Assembly Details for THG600 Series (T-Style) 6" and 8" Pad Packing Specification NOTE: Cover the end of the piston rod with packing cone O-ring locations (part # 3905) before installing packing. For lubricated compressors, the lubricating quill located on the adapter 65 ft.
  • Page 71 Appendix D—Packing Assembly Details for THG600 Series (T-Style) 6" and 8" Purge Packing Specification NOTE: Cover the end of the piston rod with packing cone O-ring locations (part # 3905) before installing packing. For lubricated compressors, the lubricating quill located on the adapter 65 ft.
  • Page 72 Appendix D—Packing Assembly Details for THG600 Series (T-Style) Inner Oil Wiper Ring Set Pad or Purge Specification Part number 3816 Inner Oil Wiper Ring Set (Radial, Radial) Crankcase Cylinder Side Side Radial Cut Align pin with Radial Cut Wiper Ring Cup (with pin) hole on backside.
  • Page 73 Appendix D—Packing Assembly Details for THG600 Series (T-Style) Middle Packing Details 1. Pad Specification Part number 3814 Segmented Packing Set (Tangent, Tangent) Crankcase Cylinder Side Side Packing Cup Back-up Ring Tangent Cut Align pin with Tangent Cut (not included) (not included) (with pin) hole on backside.
  • Page 74 Appendix D—Packing Assembly Details for THG600 Series (T-Style) Outer Packing Details 1. Purge Specification Part number 4273 Biased Segmented Packing Set (Tangent, Tangent with springs toward crankcase—sTT) Crankcase Cylinder Side Side Purge Packing Cup Backup Ring O-ring Purge Packing Spacer Tangent Cut Align pin with Tangent Cut...
  • Page 76 Appendix D—Connecting Rod Assembly Details for HG600/THG600 Series Connecting Rod Assembly Bill of Materials Part No. Description Qty. 3536-X Connecting rod assembly 1727 Connecting rod nut 3542 Connecting rod bearing (pair) 1726 Connecting rod bolt 3541 Wrist pin bushing 3590 Wrist pin retainer ring 3544-X1 Crosshead assembly...
  • Page 77 Appendix D—Single Cylinder Assembly Details for HG600/THG600 Series Crankcase CAUTION: Always Relieve Pressure In The Unit Before Attempting Any Repairs. Cylinder Diameter 2.75" 3.25" 4" 5" 6" 6" 8" 8" Ref. Part Number Description Piston Material Steel Steel Steel Aluminum Iron Aluminum Iron...
  • Page 78 Appendix D—Crankcase Assembly Details for HG600/THG600 Series Breather cap and ball details Cross section of bearing carrier shows lubrication tubing used to lubricate the crossheads. Note: Oil transfer tubing mounts inside the crankcase. Optional lubricator available (see lubricator assembly details for more information) CAUTION: Always Relieve Pressure In The Unit Before Attempting Any Repairs.
  • Page 79 Appendix D—Crankcase Assembly Details for HG600/THG600 Series Crankcase Assembly Bill of Materials Part No. Description Qty. Part No. Description Qty. 3289 Pipe plug (1/4 NPT flush seal) 3538 Crankcase 3823 Pipe plug (3/8" NPT flush seal) Crankcase assembly - HG600M 3538-X1 (without external lubricator) 3443...
  • Page 80 Appendix D—Bearing Carrier Assembly Details for HG600/THG600 Series Align pin with slot on pump shaft adapter. Align slot with the pin at the end of the crankshaft. Backside of bearing carrier Cross section of bearing carrier shows lubrication tubing used to lubricate Make sure oil-passage the crossheads.
  • Page 81 Appendix D—Bearing Carrier Assembly Details for HG600/THG600 Series Crankcase Assembly Bill of Materials Part No. Description Qty. Part No. Description Qty. 1515-X Closure cap assembly 1629 Pipe plug (1/16" NPT flush seal) 7001-025NC050A Hex head bolt (1/4" - 20 x 1/2") 2805 Pump shaft bushing 1515...
  • Page 82 Appendix D—Crankshaft Assembly Details for HG600/THG600 Series Crankcase (see crankcase assembly for more information) Crankshaft Assembly Bill of Materials Part No. Description Qty. 3537-X1 Crankshaft assembly 2135 Rotor drive pin 1737 Bearing cone 1736 Bearing cup 3638 Spacer 3635 Drive sprocket 1287 Crankshaft orifice 2933...
  • Page 83 Appendix D—Lubricator Assembly Details for HG600/THG600 Series Single cylinder divider Lubricator Assembly Bill of Materials Part No. Description Qty. Part No. Description Qty. 3639-X Lubricator assembly 2609 Tee (1/8" NPT steel) 3634 Spring clip connecting link 7101-037NC01A Hex nut (3/8" - 16) 3633 Chain 7206-037A...
  • Page 84 Appendix D—3870-X1 External Oil Cooler Assembly Details for HG600/THG600 Series (Inlet) 4 (Outlet) Oil lter Oil lter adapter Oil pressure guage 3870-X1 External Oil Cooler Assembly Bill of Materials Part No. Description Qty. Part No. Description Qty. 3870 External oil cooler 2021 Nipple - 1/4 X 2-1/2", SCH 80 7001-037NC075A Hex HD 3/8-16 X 3/4", GR 5...
  • Page 85 Appendix D—Flywheel Assembly Details for HG600/THG600 Series Rear view Flywheel Assembly Bill of Materials Assembly Assembly Name Number Flywheel assembly 3852-X (flywheel, hub, and three bolts and washers) Flywheel: 21.2" O.D., 5 3852 groove Hub with three bolts and H J-2.125 lockwashers Front view...
  • Page 88 Corken, Inc. • A Unit of IDEX Corporation 3805 N.W. 36th St., Oklahoma City, OK 73112 Phone (405) 946-5576 • Fax (405) 948-7343 Visit our website at http://www.corken.com or e-mail us at info.corken@idexcorp.com Printed in the U.S.A. February 2012...

This manual is also suitable for:

Thg601 seriesHg602 seriesThg602 series

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