Rix 4v4b-6.1-p1 A, B, C, D Manual (C)

OPERATING INSTRUCTIONS
and PARTS LIST for
RIX INDUSTRIES'
OXYGEN COMPRESSOR
MODEL NO. 4V4B-6.1-P1
A, B, C & D
MODEL # VOLTS/PH/HZ
4V4B-6.1-P1A 208-230/3/60
4V4B-6.1-P1B 460/3/60
4V4B-6.1-P1C 380-415/3/50
4V4B-6.1-P1D 230/3/50
MANUAL P/N: MAN-4V4B-6.1-P1 REV (C),
4900 Industrial Way Benicia, CA 94510 Phone 707-747-5900 FAX 707-747-9200

P/N: MAN-4V4B-6.1-P1
REVISION PAGE
Pages
Revision Date By Revised Brief Description
A 1/16/17 KA i-ii Table of Contents
iii Drawing Index
4 Table 3-1
5 Table 4-1
6 Deleted 4.2 – Electric Motor Lubrication
8 4.6 – Piston Ring Replacement
17-34 Corrective Maintenance
35 O2 Cleaning – CGA G-4.1
36-50 Parts Lists
Dwg’s Updated Drawing Revisions, add 23081 and
23078, remove B4900
B 2/10/17 KA 44 Accessory Parts List
C 5/16/17 KA ALL General update to drawing and parts list

format
Rev (C)
TABLE OF CONTENTS
4V4B-6.1-P1A, B, C & D
Title Page
Table of Contents ..................................................................................................................... i-ii
Drawing Index.... ....................................................................................................................... iii
Compressor Registration... ......................................................................................................... iv
Important Operating Considerations ........................................................................................... v
Warranty .................................................................................................................................... vi
1. OPERATING INSTRUCTIONS ............................................................................................. 1

1.1 SCOPE .......................................................................................................................... 1
1.2 CAPABILITY .............................................................................................................. 1
1.3 GENERAL DESCRIPTION ......................................................................................... 1
2. INSTALLATION ...................................................................................................................... 2
2.1 GENERAL.................................................................................................................... 2
2.2 PLUMBING ................................................................................................................. 2
2.3 LUBRICATION ........................................................................................................... 2
2.4 ELECTRICAL CONNECTIONS ................................................................................. 2
2.5 STORAGE .................................................................................................................... 2
3. START-UP AND OPERATING PROCEDURES.................................................................. 3

3.1 CRANKCASE .............................................................................................................. 3
3.2 COOLING SYSTEM.......... .......................................................................................... 3
3.3 SYSTEM CHECKOUT.......... ...................................................................................... 3
3.4 START-UP ................................................................................................................... 3
3.5 CONTROL SYSTEM ................................................................................................... 3
3.6 SWITCH/RELIEF VALVE SETTINGS ...................................................................... 4
4. SCHEDULED MAINTENANCE ............................................................................................ 5

4.1 INTRODUCTION ........................................................................................................ 5
4.2 OIL LEVEL AND CHANGE INTERVAL .................................................................. 6
4.3 OIL FILTER REPLACEMENT ................................................................................... 7
4.4 GAS SYSTEM PIPING ................................................................................................ 7
4.5 COMPRESSOR VALVES INSPECTION AND RECONDITIONING ...................... 8
4.6 PISTON RING REPLACEMENT................................................................................ 8
4.7 PRESSURE RELIEF VALVES ................................................................................... 9
5. COMPRESSOR TROUBLESHOOTING ............................................................................ 10

5.1 TROUBLESHOOTING.............................................................................................. 10
5.2 LUBE OIL SYSTEM ................................................................................................. 11
5.3 HIGH PRESSURE READINGS ................................................................................ 11
5.4 LOW PRESSURE READINGS ................................................................................. 12
5.5 HIGH TEMPERATURE PROBLEMS ...................................................................... 12
5.6 REDUCED CAPACITY............................................................................................. 13
5.7 UNUSUAL NOISE .................................................................................................... 13
5.8 UNUSUAL VIBRATION .......................................................................................... 14
5.9 INABILITY TO START COMPRESSOR ................................................................. 14
5.10 INABILITY TO RESTART COMPRESSOR ............................................................ 15
5.11 INABILITY TO STOP COMPRESSOR .................................................................... 15
5.12 OIL LEAKAGE .......................................................................................................... 16
6. CORRECTIVE MAINTENANCE ........................................................................................ 17

6.1 INTRODUCTION ...................................................................................................... 17
6.2 V-BELTS AND PULLEYS ........................................................................................ 17
6.3 CYLINDER HEADS .................................................................................................. 18
6.4 PISTON AND ROD ASSEMBLY ............................................................................. 18
i
TABLE OF CONTENTS
4V4B-6.1-P1A, B, C & D
6.5 PISTON RINGS ......................................................................................................... 20

6.6 CYLINDERS .............................................................................................................. 21
6.7 OIL WIPERS .............................................................................................................. 22
6.8 GUIDE CYLINDERS ................................................................................................ 22
6.9 CONNECTING ROD ................................................................................................. 23
6.10 OIL PUMP. ................................................................................................................. 24
6.11 MAIN BEARINGS ..................................................................................................... 25
6.12 V-BELTS .................................................................................................................... 26
6.13 HEAT EXCHANGER ................................................................................................ 27
6.14 THERMOWELL ......................................................................................................... 27
6.15 SHAFT SEAL............................................................................................................. 27
6.16 PRESSURE RELIEF VALVES ................................................................................. 28
6.17 COMPRESSOR VALVES ......................................................................................... 29
7. COMPRESSOR ASSEMBLY PARTS LIST ....................................................................... 35

7.1 INTRODUCTION..................................................................................................... 35
COMPRESSOR PARTS LIST ............................................................................................. 36

CRANKCASE PARTS LIST ................................................................................................ 41
ACCESSORY PARTS LIST ................................................................................................. 44
PLUMBING PARTS LIST .................................................................................................... 47
ELECTRICAL PARTS LIST ................................................................................................ 49
TABLES:
3-1 SHUTDOWN SWITCH SETTINGS ........................................................................... 4
3-2 RELIEF VALVE SETPOINTS .................................................................................... 4
4-1 LUBRICATION & PREVENTATIVE MAINTENANCE .......................................... 5
5-1 COMPRESSOR TROUBLESHOOTING GUIDE ..................................................... 10
6-1 HYDROSTATIC TEST PRESSURES OF COMPONENTS ..................................... 32
6-2 WRENCH TORQUES............................................................................................... .32
6-3 CLEARANCES AND TOLERANCES ...................................................................... 33
7-1 COMPRESSOR PARTS LISTS ................................................................................. 35
ii
DRAWING INDEX
4V4B-6.1-P1A, B, C & D
Title Pages
INSTALLATION ARRANGEMENT .......................................................................... 51

COMPRESSOR CROSS SECTION ............................................................................ 53
VALVE ASSEMBLIES:
1ST STAGE ..................................................................................................... 57
2ND STAGE .................................................................................................... 58
3RD STAGE ..................................................................................................... 59
4TH STAGE ..................................................................................................... 60
PISTON ASSEMBLIES:
1ST STAGE ..................................................................................................... 61
2ND STAGE .................................................................................................... 62
3RD STAGE ..................................................................................................... 63
4TH STAGE ..................................................................................................... 64
PISTON ROD OIL PACKING ..................................................................................... 65
CRANKCASE ASSEMBLY ........................................................................................ 66
FLOW SCHEMATIC ................................................................................................... 69
ACCESSORIES ............................................................................................................ 70
PLUMBING SCHEMATIC.......................................................................................... 72
ELECTRICAL BOX ..................................................................................................... 73
APPENDIX
Title Pages
CONNECTING ROD ASSEMBLY ............................................................................ A1

O-RING INFORMATION........................................................................................... A2
INSTRUCTIONS FOR INSTALLING SPIRAL
PISTON RINGS ON FIXED PISTONS .......................................................... A3
PISTON ADJUSTMENT TOOL ................................................................................. A4
PRESSURE SWITCHES ............................................................................................. A5
V-BELT DRIVE, INSTALLING A CONVENTIONAL ........................................... A6
iii
COMPRESSOR REGISTRATION
The following information should be used when ordering replacement parts and when
requesting service information.
Compressor Model 4V4B-6.1-P1A, B, C & D Size 2-5/8” & 1-3/8” & 3/4” & 1/2” x 3 1/4”
Cross Section D3886, B11165
Application for which designed Oxygen
Compressor Rotation Counterclockwise from Flywheel Side
Normal Oil Pressure 3-10 Psi
The compressor has been test operated with the following results. Operating pressures should
be approximately as follows:
OPERATING PRESSURES (PSIG)
First Second Third Fourth Compressor

Suction Stage Stage Stage Stage RPM SCFM
40-50 psig 180-230 600-720 1400-1700 2200-3000 600-630 17-20

RELIEF
VALVES 55 275 800 1800 3300
NOTE: The flow rate will vary according to the temperature of the gas being compressed,
the suction pressure and the final discharge pressure.
Electric Motor: 15 HP, 208/230/380/415/460/3/50/60, 1500/1800 RPM,

1.15 SF
Motor Frame: 254T
4900 Industrial Way Benicia, CA 94510 USA Phone 707-747-5900 FAX 707-747-9200
iv
WARNING
OPERATION OF THIS EQUIPMENT WITH PROTECTIVE

DEVICES INOPERATIVE, DISCONNECTED, ALTERED OR
IMPROPERLY ADJUSTED MAY RESULT IN SERIOUS
PERSONNEL AND/OR EQUIPMENT DAMAGE.
Some of the control devices which could be included on this machine are the following:
EXAMPLES OF ACTIONS WHICH COULD

SAFETY DEVICES RESULT IN REDUCED SAFETY INTEGRITY
Pressure Relief Valves Removal/Valved out of circuit

Bypassed
Replaced with improper rating
Sensing Switches Improper setting

Removal
Electrical Overload System Removal/Bypassed
Protective Guards Removal/Damage/Modification
MAINTENANCE OR ADJUSTMENTS TO THE EQUIP-MENT,

WHEN ENERGIZED OR PRESSURIZED, REQUIRES
APPROPRIATE SAFETY PRECAUTIONS. CONTROLS MAY
ALLOW THE COMPRESSOR TO START AT ANY TIME.
This equipment is designed only for a specific application. Our Engineering Department
welcomes your consultation if alternate service is considered.
v
____________________________________________________________
RIX INDUSTRIES'
4V4 COMPRESSOR WARRANTY
RIX Industries warrants all 4V4 compressors as follows:
Every RIX compressor is carefully inspected, assembled and thoroughly tested before
shipment is made from the factory and each new 4V4 compressor sold by RIX Industries is
warranted to be free from defect in material and workmanship for a period of twelve (12) months
from the date of first operation, or eighteen (18) months from shipment, whichever comes first.
RIX certifies that all 4V4 oxygen compressors have been test run on pure oxygen gas at
maximum pressures and flow rate and that the compressors are oxygen clean at shipment. Purchaser
takes full responsibility for all components added to the compressor package that could contaminate
the gas stream causing a failure.
The obligation under this warranty, statutory or otherwise, is limited to the replacement or
repair at the Manufacturer's factory, or at a point designated by the Manufacturer, of such parts as
shall appear to the manufacturer, upon inspection at such point, to have been defective in material or
workmanship.
This warranty shall not apply to any compressor which has been subject to misuse, neglect,
or accident, nor shall it apply to any machine upon which repairs or alterations have been made
unless authorized by the Manufacturer.
RIX Industries makes no warranty in respect to accessories such as electric motors and/or
gasoline engines powering the compressor, or to controls such as pressure switches, solenoid valves
and motor starters, such being subject to the warranties of their respective manufacturers.
The Manufacturer shall in no event be liable for consequential damages or contingent

liabilities arising out of the failure of any compressor or parts to operate properly.
No express, implied or statutory warranty other than herein set forth is made, or authorized to
be made, by the Manufacturer.
vi
____________________________________________________________
RIX INDUSTRIES'
4V4 COMPRESSOR WARRANTY
WARNING
The gas produced with the compressor described in this manual is subject to strict quality standards.
Ignoring the operating and maintenance instructions can lead to severe injury or death.
This compressor has been built in conformance to the following standards:
EN 61000-6-4: 2006 including: EN55022: 2009 + A1 Class A,

EN61000-6-2: 2005 including: EN 61000-4-2: 2008, EN 61000-4-3: 2010
EN61000-4-4: 2010, EN 61000-4-5: 2005, EN61000-4-6: 2008,
EN61000-4-8: 2009, EN61000-4-11: 2004, EN 61010-1: 2010 & EN60204: 2009
vii
48
49
50
51
CHAPTER 1 - OPERATING INSTRUCTIONS
1.1 SCOPE
This technical manual has been prepared to enable the service technician to mechanically maintain
the RIX Model 4V4B-6.1 Compressor. It includes component identification, describes component
systems and presents troubleshooting and detailed maintenance procedures necessary to insure
proper operation of the equipment. Drawings necessary to fully define all parts of the compressor
are included.
1.2 CAPABILITY
The RIX Model 4V4B-6.1 Compressor will compress oxygen to the pressure indicated on the
registration page of this manual.
1.3 GENERAL DESCRIPTION
1.3.1 COMPRESSOR: The RIX Model 4V4B-6.1 is a crosshead type, oil-free compressor,
incorporating materials of construction suitable for the compression of the subject gas. Conservative
design is embodied in the construction of all components. Bearing loads are moderate and the use of
crosshead guide pistons eliminates the side load normally present on reciprocating type pistons,
resulting in long lived piston rings and minimum cylinder wear. When operated with reasonable
care, the user may expect the compressor to operate continuously for long periods of time.
1.3.2 GAS FLOW: Gas entering at the suction of the first stage is successively compressed
through all stages to provide the final discharge pressure. After each stage of compression the gas is
cooled in a heat exchanger. A flow schematic shows the gas flow in more detail. (Refer to the
Drawing Index at the beginning of this manual for the Flow Schematic drawing number).
1.3.3 COOLING: Due to the high temperature created within the cylinders by compression and
piston ring friction, it is necessary to cool the cylinders and keep the temperature uniform. This is
accomplished by blowing air through the heat exchanger and across the cylinders. It is important
that there is enough cool ambient air in the compressor location to facilitate this.
1.3.4 LUBRICATION: Oil is drawn from the crankcase through a screen, which removes
foreign matter, to the oil pump. From this point, lubrication is pumped through a replaceable filter
to an oil gallery from where all internal components are splash lubricated.
All compression stages are self-lubricating via TFE piston rings. No oil is used in the compression
process; therefore, there is no oil or vaporous contamination of the pumped gas. A small amount of
inert piston ring dust will pass into the gas stream; this can be filtered out if desired.
4V4B-6.1 1
CHAPTER 2 - INSTALLATION
2.1 GENERAL: The compressor must be firmly bolted down on a rigid foundation.
Since the compressor is air cooled, it is important to maintain adequate ventilation at the compressor
installation. Extremely low ambient temperatures may require the addition of an oil sump heater.
2.2 PLUMBING: Before piping to the gas inlet, be sure that all pipes are absolutely free from
contamination. A particulate filter or strainer is to be installed at the compressor gas inlet.
2.3 LUBRICATION: Verify that the crankcase is full with oil to the FULL mark on the oil
dipstick. The oil is Chevron AWS 150.
2.4 ELECTRICAL CONNECTIONS: All electrical components are wired to a PLC based
controller. When main power is connected to the controller, jog the unit to ensure rotation of
compressor is correct. Oil pump will not work in the reverse direction. See Registration Page of
manual for proper rotation. Check cooling fan rotation to ensure that cooling air is pulled through
the heat exchanger and directed over the heads and cylinders.
2.5 STORAGE: If the compressor is taken out of service for an extended period of time,
provision should be made to protect the machinery and electrical equipment. At minimum, gas
suction and discharge lines should be capped and belt tension should be relieved. The compressor
should be rotated at least once every two months.
4V4B-6.1 2
CHAPTER 3 - START-UP AND OPERATING PROCEDURES
3.1 CRANKCASE: Check the crankcase oil level (via dipstick) and inspect for contamination
from water or other foreign material. Oil should be free of grit or discoloration.
3.2 COOLING SYSTEM: Ambient cooling air should be as cool as possible. If the
compressor is installed in a closed area the surrounding area must be ventilated to prevent
overheating.
3.3 SYSTEM CHECKOUT: Check that fan rotates freely without touching shroud, and that
the fan & compressor rotation is correct. Correct if necessary. After checking cooling and oil
system, insure that a free flow of gas is available to the compressor inlet and that the high pressure
discharge line is unobstructed. It is essential that an approved safety relief valve and pressure gauge
are installed between the compressor aftercooler and the discharge check valve or the first valve in
your system. Do not start the compressor until these items are properly installed. A reliable high
pressure gauge should be visible from the start station.
Test the high/low suction pressure and high discharge pressure safety switches to ensure that the
compressor will not operate without design pressure at the inlet. Also check the high gas temp
shutdown (RTD4) is operating. Operating the compressor with lower than designed suction pressure
may overheat the final stage compression cylinder and/or cause banging of floating pistons creating
the potential for severe damage.
3.4 START-UP: Start the compressor and observe the pressure gauges and verify oil pressure.
The interstage pressures should approach rated pressure as the final stage comes up to the rated
discharge pressure.
When starting the compressor for the first time, stop the unit after a short time and check for leaks in
the gas piping. A soapy water solution is one way to do this. Also monitor the cylinder and gas
discharge temperatures. The cylinder walls and the lines returning from the heat exchanger to the
next stage cylinders should be slightly warm to the touch.
WARNING
A painful burn can be caused by touching any of the heads or

discharge lines from the cylinders to the inter/aftercooler.
After checking and correcting any leaks in the new system, bring it up to rated pressure. If the
system does not shut off or unload when the set pressure is reached, manually shut down
immediately and check the pressure switch and related wiring. If required, adjust the switch
according to the directions. When the pressure switch controls the system properly, recheck for
leaks.
Observe the oil and cylinder pressures, which should be as indicated on the Registration Page of this
manual. It is recommended that a log be kept, noting operating pressures and maintenance done
versus hours of compressor operation.
3.5 CONTROL SYSTEM: The control system is designed for manual and automatic modes of
operation. In manual mode, the unit is started by pressing the START button. It will run until
4V4B-6.1 3
the discharge pressure switch (PSS) opens at which time it will stop. If any of the safety
switches actuates to cause a shutdown, the corresponding red fault light will come on to indicate
the cause. The STOP button must be pressed to clear the fault or to reset the cylinder full light.
The STOP button may be pressed at any time to stop the compressor. In automatic mode the
suction and discharge pressure switches will allow the compressor to start and stop when the
proper pressure conditions have been met. The Hand-Off-Auto switch is used to select between
the two mode.
3.6 SWITCH / RELIEF VALVE SETTINGS:
Table 3-1 Shutdown Switch Settings
SWITCHES Symbol Set Point Function
Low Inlet Pressure PSIL 40 psig decr. Shutdown

High Inlet Pressure PSIH 50 psig incr. Shutdown
High Discharge Pressure PSS 3000 psig Shutdown
High Gas Temperature, 4th Stage RTD4 275˚F* Shutdown
___________
*These temperatures are estimated from available data. They may need to be adjusted in the field,
they should be approx. 50ºF above max operating temperatures, but less than 450ºF.
Table 3-2 Relief Valve Setpoints
RELIEF VALVES Symbol Set Point (psig)
Relief Valve, Suction RVS 55

Relief Valve, 1st Stage RV1 275
Relief Valve, 2nd Stage RV2 800
Relief Valve, 3rd Stage RV3 1800
Relief Valve, 4th Stage RV4 3300
4V4B-6.1 4
CHAPTER 4 - SCHEDULED MAINTENANCE
4.1 INTRODUCTION
The purpose of this chapter is to provide the operator with the scheduled maintenance required to
insure a long service life of the RIX Compressor, Model 4V4B-6.1. This chapter covers the
procedures for performing examinations, tests, replacements, preventive maintenance tasks, and
overhauls. Material and test equipment requirements are covered in the following paragraphs for
each specific task. The chart is arranged with the most frequently performed tasks covered first, the
less frequent tasks later. Where maintenance tasks require significant disassembly, they are
referenced here for scheduling in Chapter 6 - Corrective Maintenance. Also, any corrective
maintenance required as a result of any preventive maintenance inspections is covered in Chapter 6.
On a daily basis, visually inspect the operating compressor. Check gas pressures, gas and water
temperatures, and any leaks or unusual noises.
WARNING
Before attempting any repairs or adjustments, de-energize the machine

by pushing the STOP button, disconnect power to the system (to avoid
shock hazard), vent pressure by opening hand valves and give the
discharge piping time to cool down (discharge air lines are hot and can
cause burns).
Table 4-1 Lubrication & Preventive Maintenance
Para. Operation Time Intervals in Hours

4.2 Crankcase Lubricating Oil ............................................................6000
4.3 Oil Filter Replacement ..................................................................6000
4.4 Gas System Piping .......................................................................4000
4.5 Compressor Valves Inspection and Reconditioning .....................4000
4.6 Piston Ring Replacement: 1st Stage ...........................................3000
2nd Stage..........................................3000
3rd Stage ..........................................3000
4th Stage ..........................................2000
4.7 Pressure Relief Valves ..................................................................8000
WARNING
Before performing any of the scheduled maintenance tasks in Chapter

4, the compressor should be shut off and tagged “Out of Service.”
This is to prevent an inadvertent start which could cause injury to
personnel or damage to the equipment. After completing the
maintenance action, the compressor should be restored to full
operation and the tags removed.
4V4B-6.1 5
4.2 OIL LEVEL AND CHANGE INTERVAL
4.2.1 Under normal operation, the oil and filter need only be changed when there is evidence of
contamination or degradation of the oil. Prior to 6000 hours of operation there should be little or no
change in the color (clear) of the oil.
There is no set limit to the number of hours of service before changing the oil.
The oil has a viscosity near that of Chevron AWS 150 motor oil. Loss of viscosity would be cause
for an oil change. Given the nature of the oil this is considered unlikely inside of 10,000 hours of
normal operation.
As the compressor does not consume oil by design, a drop in oil level indicates leakage. The oil
level should be maintained to assure adequate lubrication.
As a guide the oil level should be checked frequently and examined for discoloration. If the oil is
found to be discolored as a minimum the filter should be replaced. If this does not correct the
problem in the subsequent 10 to 20 hours of operation an oil sample should be sent to a qualified lab
for analysis. Alternately the oil can be replaced although the expense often warrants otherwise.
4.2.2 FREQUENCY Every 6000 hours of running time (or annually) the crankcase oil should be
renewed. Extended life testing by the Navy has shown that more frequent oil changes are not
needed under normal conditions. If oil analysis procedures are available, every 1000 hours or when
there is a suspicion of contamination, a sample of oil should be taken for analysis. A particulate
contamination level of 10 mg per 100 ml at 5 micron filtration is sufficient to require an oil change.
Failing to change the oil as scheduled may result in premature or accelerated wear to the running
gear (crankshaft, main and connecting rod bearings, and the cross head).
The oil filter should be changed whenever the oil is renewed. See Para. 4.3 for oil filter change
instructions.
4.2.3 MATERIALS The crankcase requires 7 quarts of oil.
4.2.4 PROCEDURE
a. Remove the oil drain cap from the drain tube (Ref. 22, Pg 67).
b. Collect used crankcase oil in a shallow pan.
c. Reinstall the drain cap.
d. Refill the crankcase with new oil through the filler tube after removing the
breather (Ref. 65, Pg 67).
e. Inspect the breather for cleanliness, clean if required, and reinstall.
4V4B-6.1 6
4.3 OIL FILTER REPLACEMENT.
4.3.1 FREQUENCY The oil filter should be replaced whenever the oil is changed.
4.3.2 MATERIALS Have on hand a replacement filter and a supply of rags. A strap-type oil filter
wrench may aid in filter removal.
4.3.3 PROCEDURE
a. Remove the oil filter. Since the filter is mounted at an angle, it is impossible to
prevent oil from running down onto the oil filter.
b. Clean all excess oil by wiping up with rags.
c. Apply a film of clean compressor oil to the new filter gasket.
d. Install the new oil filter. Screw on until gasket contacts the mounting surface.
Hand tighten an additional 3/4 turn.
e. Start the compressor and check for oil leakage. If necessary, increase filter
tightness until all leakage stops.
4.4 GAS SYSTEM PIPING
4.4.1 FREQUENCY Every 4000 hours of running time or any time the piping system is disturbed,
such as during a corrective maintenance action, the piping should be examined for leaks. Any
obvious leaks should be dealt with as they are detected. Leak testing the piping requires that the
compressor is pressurized, and therefore running.
NOTE
The test is simplified if the compressor is allowed to cool, then

restarted, immediately prior to running the leak test, since the hot
discharge pipes can boil away the leak test soap solution, making
detection of leaks difficult or impossible.
WARNING
Hot discharge lines can produce painful burns. Be careful to avoid

making contact with hot pipes while performing tests and repairs.
If a leak is detected, it should be noted or conspicuously marked so that it can be repaired at the next
convenient shutdown period.
4.4.2 MATERIALS A soapy solution in a squirt bottle works best for locating leaks in an air
system. The gaskets and O-rings needed for the specific repair should be on hand prior to
attempting to fix a leak.
4V4B-6.1 7
4.4.3 PROCEDURE
a. Restart compressor after it has been allowed to cool down.
b. Systematically move from joint to joint and fitting to fitting in the gas system
piping, spraying the leak test solution.
c. Observe for the formation of bubbles. Mark the location of any detected leaks.
Large leaks may blow the soap solution away as quickly as it is applied. These may
be detected by feel, again being careful of hot discharge lines.
d. Test relief valves and drain valves by forming a bubble across the outlet opening
and observing if the bubble grows.
e. Leaks in other plumbing such as oil and water plumbing will be evidenced by a
local collection of water, oil, or a staining of the joint at the leak point.
f. Leaks in gasketed joints may, in some cases, be corrected by retightening the

joint.
CAUTION
Avoid over-tightening as this can produce distortion and make the problem
more severe. If the joint is tight and still leaks, the gasket must be replaced.
g. O-ring joints cannot be corrected by additional tightening. In most every case,

the leaking O-ring must be discarded and a new one installed. Always inspect the
surfaces that seal against the O-ring for defects and correct them as required.
4.5 COMPRESSOR VALVES INSPECTION AND RECONDITIONING
4.5.1 FREQUENCY Every 4000 hours the compressor valves should be removed and
reconditioned. Step by step procedures for removing and servicing the valves are given in 6.17. As
a minimum during the 4000 hour maintenance action, the O-rings should be replaced with new parts
and the valve seat resurfaced to remove any and all defects.
It is recommended to maintain a stock of spare valves so that servicing can be as simple as possible.
This allows the service technician to change out the valves and reduce the down time during this
maintenance action. The used valves may then be reconditioned as time permits so that they are
ready for the next change out.
4.6 PISTON RING REPLACEMENT
4.6.1 FREQUENCY The 3rd and 4th stage compression and rider rings should be replaced every
3000 and 2000 hours respectively. The 1st and 2nd stage piston rings should be checked every 2000-
3000 hours and replaced as necessary. Piston ring replacement procedures are given in Paragraph
6.5. If the piston rings are allowed to wear beyond their recommended service limit per Table 6.3,
the compressor output will be reduced, causing more frequent compressor operation and unnecessary
4V4B-6.1 8
wear on other components. There is also the risk of damaging the cylinder walls if either the
compression or rider rings wear out completely.
4.7 PRESSURE RELIEF VALVES
4.7.1 FREQUENCY The pressure relief valves should be removed from the compressor and tested
to confirm the correct set-point every 8000 hours. If a valve fails to lift at its rated pressure, it must
be readjusted and if necessary, serviced per Paragraph 6.16.
4V4B-6.1 9
CHAPTER 5 - COMPRESSOR TROUBLESHOOTING
5.1 TROUBLESHOOTING
5.1.1 INTRODUCTION This chapter contains information to allow the technician to locate a
malfunction or identify a potential fault with the compressor. The troubleshooting guide is prepared
with the most likely and easily diagnosed probable causes listed first. The chart is prepared so that
all troubleshooting procedures and diagnostics can be performed on the organizational level.
Subsequent repair actions may involve higher levels of maintenance.
Diagrams included elsewhere in this manual may help in diagnosing troubles. For convenience, they
are listed here and referenced in the troubleshooting charts.
Table 5-1 Compressor Troubleshooting Guide
TYPE OF PROBLEM SECTION PAGE
Lube Oil System Problems 5.2 11
High Pressure Readings 5.3 11
Low Pressure Readings 5.4 12
High Temperature Problems 5.5 12
Reduced Capacity 5.6 13
Unusual Noise 5.7 13
Unusual Vibration 5.8 14
Inability to Start Compressor 5.9 14
Inability to Restart Compressor 5.10 15
Inability to Stop Compressor 5.11 15
Oil Leakage 5.12 16
4V4B-6.1 10
5.2 LUBE OIL SYSTEM PROBLEMS
SYMPTOMS IMMEDIATE PROBABLE CAUSE REMEDY

ACTION
1. Low oil level on 1. Stop the 1. Gasket or thread 1. Repair leak and fill to
dipstick. compressor. sealant leak. full mark. (ref. 4.2)
2. Leaking oil filter or 2. Repair any leakage.

external fitting. (ref. 4.3)
3. Leaking oil wiper 3. Replace oil wiper

seal seal. (ref. 6.7)
5.3 HIGH PRESSURE READINGS
SYMPTOMS IMMEDIATE PROBABLE REMEDY

ACTION CAUSE
1. High pressure on 1. Continue run- 1. Defective suc- 1. Remove, clean,

first, second, third or ning and monitor tion or discharge repair or replace
fourth stage. pressures. valve in the next suspect valves as
higher stage. necessary. (ref. 6.17)
2. First, second or 2. Shut down the 2. Defective relief 2. Reset or replace the
third stage relief is compressor. valve. relief valve. (ref. 6.16)
"popping".
3. High pressure on 3. Continue run- 3. Pressure switch 3. Reset or replace

fourth stage. ning and monitor improperly set or switch.
pressure. inoperative.
4. Fourth stage relief 4. Shut down the 4. Discharge lines 4. Clean valve and/or
valve is "popping". compressor. or back pressure lines.
valve is restricted.
5. Defective relief 5. Reset or replace the

valve. relief valve. (ref. 6.16)
4V4B-6.1 11
5.4 LOW PRESSURE READINGS

ACTION CAUSE
1. Low pressure 1. Continue running 1. Worn or broken 1. Replace piston rings and
on any stage. and monitor pressures rings in the stage inspect cylinder for wear or
until a convenient time with the most scoring. (ref. 6.5, 6.6)
to shut the compressor pronounced low
down. pressure.
Blown head gasket or Replace gasket or O-ring. (ref.

valve O-ring in that 6.3, 6.6, 6.17)
stage.
2. Low pressure 2. Suction or discharge 2. Clean, repair, or

on first stage. valve on first stage is replace suspect valve
leaking. as necessary.
(ref. 6.17)
5.5 HIGH TEMPERATURE PROBLEMS

ACTION CAUSE
1. Compressor 1. Shut down the 1. Insufficient 1. Ensure adequate ambient air

overheats. compressor. cooling. flow to the compressor.
2. High temperature 2. Restriction in 2. Inspect piping for kinks

switch shuts piping caused by and other physical damage
down the damage. and repair.
compressor.
3. Faulty compressor 3. Repair or replace. (ref. 6.17)
valves.
4. Dirty or clogged 4. Clean heat exchangers and/or

heat exchangers or water jackets.
water jackets.
4V4B-6.1 12
5.6 REDUCED CAPACITY

ACTION CAUSE
1. Output of 1. Continue running; 1. Low inlet pressure. 1. Restore to normal pressure.

compressor is monitor pressures; service
reduced. unit at first opportunity.
2. Longer than 2. First stage valves 2. Check and repair as

normal time leaking. necessary. (ref. 6.17)
required to fill
receiver.
3. Leaks in piping, 3. Locate and repair. (ref. 4.4)
heads, heat
exchangers, packing
or gaskets.
4. Loose V-belts. 4. Tighten to correct tension.
(ref. 6.2)
5. Worn compression 5. Replace rings. (ref. 6.5)

rings
5.7 UNUSUAL NOISE

ACTION CAUSE
1. Clacking noises 1. Check pressure 1. Worn or broken 1. Remove suspect

from cylinder head(s). gauges. Shut valves. valves and repair or
compressor down replace them. (ref. 6.17)
if pressures vary
from normal.
2. Flat, slapping 2. Try to isolate 2. Worn piston 2. Remove suspect

sound when compres- location of noise. and/or cylinder. pistons and cylinders
sor starts and stops. Worn rider rings. and check for wear.
Repair as necessary.
Replace rider rings.
(ref. 6.5)
3. Metallic knock. 3. Check oil level. 3. Worn 3. Replace connecting

connecting rod rod bearings. (ref. 6.9)
bearings.
4V4B-6.1 13
5.8 UNUSUAL VIBRATION

ACTION CAUSE
1. Entire compressor 1. Stop compres- 1. Bedplate not 1. Check vibration

vibrates sor and correct properly secured. isolation assembly for
trouble before proper stack-up.
restarting. Tighten mounting bolts.
2. Compressor 2. Tighten mounting

bolts at crankcase bolts.
mounting loose.
3. Sheaves or 3. Adjust belts and

V-belts loose. secure sheaves. (ref.
6.2)
5.9 INABILITY TO START COMPRESSOR

ACTION CAUSE
1. Compressor fails to 1. No immediate 1. Pressure switch 1. Re-adjust pressure

start. action. senses high pres- switch if setting is too
sure in receiver. low. Otherwise wait
until there is a drop in
receiver pressure that
signals a restart.
2. Fault shutdown 2. Clear fault, 2. Loss of main or 2. Restore power and

circuit energized. press stop/reset control power. full voltage to the
button on the compressor. Reset
motor controller, circuit breakers.
then attempt Replace fuses as
restart. necessary.
4V4B-6.1 14
5.10 INABILITY TO RESTART COMPRESSOR

ACTION CAUSE
1. Compressor fails to 1. No immediate 1. Shutdown was 1. Allow the

start after recent action. initiated by the compressor to cool,
shutdown. temperature press stop/reset button
switch. on motor controller
then restart. See Chart
5.5 "High Temperature
Troubles."
2. No immediate 2. Shutdown was 2. Allow pressure at

action. initiated by high switch to drop, reset
pressure switch. motor controller and
restart.
3. No immediate 3. Shutdown was 3. Determine and

action. initiated by low or resolve cause of low or
high inlet pressure high inlet pressure.
switch. Press "Stop" button on
motor controller and
restart.
5.11 INABILITY TO STOP COMPRESSOR

ACTION CAUSE
1. Compressor does 1. Push "Stop" 1. Improperly set 1. Readjust, repair, or

not stop when high pushbutton on or inoperative replace pressure switch
pressure set point is controller. pressure switch. as necessary.
reached.
2. Compressor does 2. Cut power to 2. Improperly 2. Trace circuit wiring

not stop when "Stop" compressor at wired or faulty in motor controller
pushbutton is pressed. main disconnect. "Stop" pushbutton against wiring diagram.
on controller.
3. Repair or replace
faulty "Stop"
pushbutton as
necessary.
4V4B-6.1 15
5.12 OIL LEAKAGE

ACTION CAUSE
1. Oil leaking past oil 1. Shut down 1. Oil wipers 1. Replace oil wipers.
wiper boxes. compressor to worn or damaged. (ref. 6.7)
prevent oil from
leaking further. Scored piston rod. Repair or replace piston
rod. (ref. 6.4)
2. Oil seeping through 2. Shutdown 2. Gasket or 2. Isolate and repair or

gaskets or threaded compressor and thread sealant replace defective part,
connections. assess volume of failure. or remove and reinstall
leakage. with new thread sealant.
4V4B-6.1 16
CHAPTER 6 CORRECTING MAINTENANCE
6.1 INTRODUCTION This chapter presents instructions for all adjustments and repairs to the
compressor and its accessory items. All repairable parts and assemblies are covered in this chapter.
Scheduled maintenance items are covered in Chapter 4. Where special tools are required, they are
called out in the applicable paragraph. This chapter is divided into two sections: Section I,
Adjustments, and Section II, Repair.
WARNING
Before attempting any repairs or adjustments: de-energize the machine by

pushing the STOP button, disconnect power to the system (to avoid shock
hazard), vent pressure by opening hand valves down stream and give the
discharge piping time to cool down Discharge gas lines are hot and can
cause burns.
If servicing any parts that begin with an “X” per chapter 7 of this manual
or performing maintenance which has the possibility of exposing any “X”
part to contamination, those parts must be oxygen cleaned before
reassembly and reintroducing oxygen to the system. See “CGA G-4.1:
Cleaning Equipment for Oxygen Service” for acceptable oxygen cleaning
practices.
SECTION I ADJUSTMENTS AND ALIGNMENTS
6.2 V-BELTS AND PULLEYS
6.2.1 ALIGNMENT OF DRIVE PULLEYS Following any repair to the motor or pulleys (i.e.
motor sheave or compressor flywheel), it may become necessary to realign the pulleys. The pulleys
are keyed to the shafts and locked in place with tapered hubs. First remove the beltguard. The hub
and pulley can be separated by removing the three bolts that hold them together. The bolts can then
be used as jacking devices by inserting them in the threaded holes in the hub and tightening
sequentially until the pulley breaks loose from the hub. When this happens, the pulley and hub can
be slid back and forth on the shaft to achieve alignment. Alignment is measured by laying a straight
edge across the outside faces of the pulleys.
To tighten the pulleys after aligning them, use the three bolts inserted into the assembly holes (a
clearance hole in the hub and a tapped hole in the pulley). Tighten sequentially to 30 Ft-lbs torque.
Check alignment and repeat procedure if necessary. Reinstall beltguard.
6.2.2 TIGHTENING DRIVE V-BELTS (Ref. Pg A6) To obtain the proper tension on the V-belts
use the following procedure:
a. Remove the beltguard.
b. Loosen the motor tie-down bolts at least three turns.
c. Turn the adjustable bedplate screw located beneath the motor clockwise until the
desired belt tension is achieved.
4V4B-6.1 17
d. Correct belt tension allows a 5/16 – 3/8” deflection with 5-8 lb. force applied across
each belt section at mid-span. See Appendix Pg A6 for instructions when installing
and tensioning a new belt.
e. Reinstall belt guard.
SECTION II REPAIR
6.3 CYLINDER HEADS
6.3.1 GENERAL There is no scheduled maintenance requirement on the cylinder heads. However,
removal is necessary to perform other required maintenance. The procedures for removing the 1st,
2nd, 3rd and 4th stage heads are similar and may be accomplished by disconnecting the piping and
removing the retaining bolts.
6.3.2 REMOVE HEAD (Dwg. Pgs 53-56)
a. Relieve pressure and allow heads to cool.
b. Disconnect the gas system piping from the head being removed.
c. Remove the retaining bolts; carefully lift the head from the cylinder. Discard the
used O-rings.
6.3.3 INSTALL HEAD
a. Install new O-rings in their respective heads.
b. Carefully position and orient the head on the cylinder and install the nuts or bolts.
Tighten nuts using a cross sequence and 2 or more torque-steps, to 20 Ft-lbs with
standard nuts or 25 Ft-lbs with prevailing torque style locknuts.
6.4 PISTON AND ROD ASSEMBLY
6.4.1 GENERAL There is no scheduled maintenance requirement for the piston and rod assemblies.
However, removal and installation is necessary to perform other required maintenance. The 1st and
2nd compression pistons and rods are furnished by the factory as assemblies only. The 3rd and 4th
stage rods and pistons are separate with floating pistons. The guide cylinder pistons are considered
individual items, furnished with or without connecting rods. The removal and installation procedure
for the compression piston and rod assemblies is similar for all stages.
4V4B-6.1 18
6.4.2 REMOVE PISTON AND ROD ASSEMBLY
a. Remove the upper cylinder head in accordance with paragraph 6.3.2. Remove
distance piece covers.
b. Turn the flywheel by hand to position the piston at top dead center.
c. For the 3rd and 4th stage free floating pistons, use a #10-32 screw as a puller and lift
out piston separately.
d. Remove the two cap screws and washers (Ref. 17, 18 Pg 54) and slide the oil wiper
box upward on the rod until the guide piston jam nut is exposed.
e. Use the special piston adjustment tool (88-B4277) to clamp the piston down,
preventing twisting. Loosen the jam nut and screw the piston and rod assembly out
of the guide piston. Then remove the jam nut from the rod. (Ref. 23, Pg 56)
f. Push the piston rod up enough to remove the wiper box, slinger and o-ring (Ref. 9-14
& 24. Pg 55) and clean oil film from lower portion of the rod.
NOTE: Surfaces on the rods must not exceed a finish of 20 rms.
g. For all stages, push the piston and rod assemblies straight up and out of the cylinder
carefully to prevent damage to the oil wipers and shaft seals.
NOTE: To remove the 3rd or 4th stage piston rod, the cylinder must first be
removed. See Section 6.6.
6.4.3 INSTALL PISTON AND ROD ASSEMBLY
a. Clean the piston and rod assembly per accepted Oxygen cleaning procedure.
b. The 1st and 2nd stage piston/rod assemblies are installed through the cylinders. The 3rd
and 4th stage rods must be installed before the cylinders are installed.
c. Install the 1st and 2nd stage piston/rod assemblies into the cylinder until the bottom
piston ring reaches the top of the cylinder. Use sleeve tool (63-C1148-11-2) to
compress the 2nd stage piston rings before installation.
d. For all stages, with the bottom of the rod in the distance piece, install the slinger with
o-ring loose on the rod followed by the oil wiper box, then screw the jam nut onto the
rod. Inspect and replace the oil wiper box o-ring if necessary. Push the 1st and 2nd
stage pistons into the cylinders (1st stage rings must be compressed by hand) until the
rod reaches the top of the guide pistons. Screw the rods all the way into the guide
pistons.
NOTE: The 3rd and 4th stage rods will be loose in the distance piece and care
must be taken to protect the rod surface finish until the cylinder is
4V4B-6.1 19
installed. The slingers may be installed loose on these rods prior to
inserting the rod into the distance piece.
e. Install the 3rd and 4th stage cylinders per 6.6.2 and install the pistons using the sleeve
tools (63-C1148-6 and 63-A5549 respectively).
f. Reinstall the cylinder head in accordance with paragraph 6.3.3.
CAUTION
The piston to cylinder head clearance adjustment is critical. Insufficient

clearance will result in the piston hitting the head.
g. Turn the flywheel by hand to position the piston at top dead center.
h. Screw the rod out of the guide piston until the piston touches the cylinder head.
i. Be certain the piston is still at top dead center, then screw the piston down three
quarters of one turn.
j. Hold the guide piston with the adjustment tool (88-B4277) to prevent twisting and
tighten the jam nut to 50 Ft-lbs torque. (Ref. Appendix A4)
k. The piston-to-cylinder head clearance will be approximately .040 inch.
l. Slide the oil wiper box into position and secure with the cap screws. Tighten the cap
screws to 5 Ft-lbs torque.
m. Turn the flywheel until the piston is at bottom dead center. Position and tighten the
slinger in place with ¼ - ½” clearance from the bottom of the slinger to the oil wiper
box.
n. Turn the flywheel by hand a few revolutions to be certain that everything is clear
before starting the compressor.
6.5 PISTON RINGS
6.5.1 GENERAL The compressor is single acting, meaning that in a single crankshaft revolution,
suction and compression occur once in each cylinder. In order to accomplish sealing and to deliver
gas free of oil, high pressure, glass filled Teflon non-lubed rings are used. A Viton expander is used
under most of the compression rings. In addition to the compression rings, glass filled Teflon rider
rings are used on each piston to keep the piston centered in the cylinder, preventing metal to metal
contact with the cylinder wall. Each piston has compression rings and at least one rider ring. The
rings should be inspected for wear and replaced as necessary. See Section 4.7. Rings not meeting
the tolerances specified in Table 6-3 should be replaced.
4V4B-6.1 20
6.5.2 REPLACE PISTON RINGS (Dwg. Pgs 53-56, 61-64)
a. Remove the cylinder head per paragraph 6.3.2.
b. Turn the flywheel by hand to position the piston at bottom dead center.
c. Remove the pistons per paragraph 6.4.2.
d. Remove and discard the used rings and expander o-rings.
e. Clean the ring grooves, install a new expander o-ring, and carefully spread a new ring
and install in the ring groove. Repeat for each ring, being certain the ends of the
spiral fit completely into the groove to insure proper sealing.
f. Discard the used O-rings from the cylinder head.
g. Install new O-rings in their respective heads.
h. Clean and inspect the cylinder for wear or damage. Wear must be within the
tolerance specified in Table 6-3.
i. Reinstall the pistons per paragraph 6.4.3.
j. Reinstall the cylinder head in accordance with paragraph 6.3.3.
k. Rotate the flywheel by hand several times to be certain that the parts are free. Then
operate the compressor with the discharge pressure at 1500 psig for a minimum of
two hours to permit the rings to seat properly.
NOTE: 1500 psig is the set flowing pressure for the back pressure regulator.
6.6 CYLINDERS
6.6.1 GENERAL The compression cylinders must be removed to service the rings, pistons and
guide cylinders. Each port should be marked prior to removal to enable proper orientation upon
reinstallation. There is no scheduled maintenance required on the cylinders. The removal and
installation procedure is similar for all cylinders.
6.6.2 REMOVE AND INSTALL COMPRESSION CYLINDER (Dwg. Pgs 53-56)
a. Remove the cylinder head in accordance with paragraph 6.3.2.

b. Turn the flywheel by hand to position the piston at bottom dead center.
c. Being careful to prevent side stress on the piston and rod assembly, lift the cylinder
off the piston. Remove and discard the used O-rings.
4V4B-6.1 21
NOTE: Take care when handling the 3rd and 4th stage cylinders to prevent the
floating pistons from falling out of the cylinder. Removing the pistons
per 6.4.2 prior to cylinder removal is recommended.
d. Reinstall the compression cylinders in the reverse sequence of removal, using new O-
rings.
6.7 OIL WIPERS
6.7.1 GENERAL A rubber oil wiper ring arrangement consisting of a wiper box, oil packing, baffle
plate and wiper cap is installed in each guide cylinder above the guide piston to prevent crankcase
oil from being expelled from the guide cylinder by the guide piston movement. The oil packings
also wipe oil from the rod, ensuring separation of oil from the gas. There is no scheduled
maintenance for the oil packings. The packings should be replaced at such time that oil leakage is
evident.
6.7.2 REPLACE OIL WIPERS (Dwg. 53-56, 65)
a. Remove the piston and rod assembly in accordance with paragraph 6.4.2.
b. Remove the wiper box from the crankcase. Discard the used O-rings.
c. Remove the capscrews, wiper cap, and oil packing from the wiper box. Discard the
used oil packings.
d. Clean the remaining parts and dry them.
e. Install new oil packing in the wiper box with the groove facing the guide piston.
f. Apply a light film of Silicone, Krytox grease or crankcase oil to the wiper box O-ring
(use new O-ring) and a film of crankcase oil to the oil wiper ring. Reassemble the
wiper box assembly in the reverse procedure.
g. Reinstall the piston and rod assembly in accordance with paragraph 6.4.3.
6.8 GUIDE CYLINDERS
6.8.1 GENERAL The guide cylinders each have two bores and a distance piece. They support the
compression cylinders.
6.8.2 REMOVE AND INSTALL GUIDE CYLINDERS
a. Remove heads, pistons, compression cylinders and oil wipers per paragraphs 6.3.2,
6.4.2, 6.6.2 and 6.7.2.
b. Remove nuts holding down the guide cylinder and carefully lift the guide cylinder off
of its two guide pistons.
c. Reinstall in reverse order with new guide cylinder gasket.
4V4B-6.1 22
6.9 CONNECTING ROD
6.9.1 GENERAL The connecting rod is cast iron, cast to an "I" section with a closed eye at the
upper end and a cap at the lower end. The closed eye has a needle bearing around the wrist pin. The
connecting rod assemblies include the lower bearing caps, replaceable precision type connecting rod
bearing sets, bolts, nuts, and wrist pin needle bearing pressed into place. There is no scheduled
maintenance required for the connecting rod assembly. However, wear will occur on the rod bearing
shell and wrist pin surfaces. If the clearances are not within the tolerances specified in Table 6-3,
the bearing shell or wrist pin should be replaced.
6.9.2 REPLACE CONNECTING ROD BEARING SETS
a. Drain oil, disconnect all tube lines from compressor pump, and remove the
compressor and crankcase assembly from the bed plate.
b. With the crankcase elevated for proper access, remove the drain pan from the
underside of the crankcase.
c. Rotate the crankshaft to position the throw at bottom dead center.
d. Remove the two nuts (Ref. Appendix A1) and separate the connecting rod. Discard
the connecting rod bearing set.
e. Using a micrometer, inspect the crankshaft journal for proper size, out of roundness
or taper. If the measurements are not within the tolerance specified in Table 6-3,
repair or replace the crankshaft as required.
f. Clean the rod and journal with a lint-free cloth and install new bearing shells in each
half of the connecting rod.
g. Apply a coating of clean crankcase oil (see paragraph 4.3.1 for oil type) to the
bearing shell surface and to the crankshaft journal. Then pull the rod down into
position on the journal and assemble the connecting rod. Tighten the nuts to 25 Ft-lbs
torque.
h. Reinstall the pan and gasket (Ref. 21, 23, Pg 68).
i. Reinstall the compressor assembly on the bed plate and reconnect all tube lines. Any
tube lines, fittings or other gas passage components which may have been
contaminated require Oxygen Cleaning (see paragraph 6.1).
6.9.3 REPLACE CONNECTING ROD
a. Remove the compression cylinders in accordance with paragraph 6.6.2. Remove the
pistons, and the guide cylinders.
b. Drain oil and remove the pan from the crankcase. Crankcase must be removed from
bed plate to access the drain pan.
c. Rotate the crankshaft by hand to position the throw at bottom dead center.
d. Remove the two nuts and separate the connecting rod.
4V4B-6.1 23
e. Lift the rod and guide piston from the crankcase.
f. Remove a snap ring and push the wrist pin out to separate the guide piston from the
rod.
g. Inspect the wrist pin and needle bearing for wear or damage; replace if necessary.
(See Table 6-3.)
h. Install the guide piston on a new rod in the reverse sequence of removal.
i. Apply a coating of crankcase oil (see paragraph 4.3.1 for type of oil) on the bearing
shell and crankshaft journal surface. Position the guide piston and rod on the
crankshaft and install the cap, using the two nuts. Tighten the nuts to 25 Ft-lbs
torque.
j. Install the pan and gasket (Ref. 21, 23, Pg 68). Tighten the cap screws to 10 Ft-lbs
torque.
k. Reinstall the compression cylinders in accordance with paragraph 6.6.2.
6.10 OIL PUMP
6.10.1 GENERAL The compressor oil pump is a rotary gear type, which is driven by the
compressor crankshaft through an idler gear. The crankcase has to be removed from the bed plate for
proper access. Service instructions for the oil pump are as follows:
6.10.2 DISASSEMBLY
a. Drain oil and remove pan, gear cover, crankcase support, and oil pump drive gear.
b. Remove the lock screw and capscrew holding the oil pump in place.
c. Withdraw pump. Note: Crankshaft must be rotated so as not to obstruct pump.
d. Unbolt and remove the oil pump housing (Ref. 24, Pg 68).
e. Inspect all wearing parts and seals for evidence of damage or excessive wear.
Replace as necessary.
6.10.3 REASSEMBLY
a. Assemble the oil pump into the crankcase. Tighten the capscrew to 1 ft-lb. and
replace the lock screw.
b. Insert the key into the slot in the shaft.
c. Replace the drive gear and nut. Torque to 10 Ft-lbs.
4V4B-6.1 24
d. Install the gear cover, being careful not to damage the gasket. Torque the 12
capscrews to 10 Ft-lbs.
e. Install the gasket and pan and torque the capscrews to 10 Ft-lbs.
6.11 MAIN BEARINGS
6.11.1 GENERAL The crankshaft is supported in the crankcase by two main bearings. They are
tapered roller design, consisting of an inner race, outer race and rollers. Lubrication to the bearings
is supplied by the crankcase oil. There is no scheduled maintenance for the main bearings. With the
bearings properly installed and lubrication free of contamination, the main bearings will function
indefinitely.
6.11.2 REMOVE MAIN BEARINGS (Dwg. Pgs 65-68)
a. Drain the crankcase oil (refer to section 4.3)
b. The compressor must be completely disassembled. Paragraphs 6.3.2, 6.4.2, 6.6.2,

6.7.2, 6.8.2 and 6.9.3 detail the disassembly of the compressor.
c. Remove the beltguard.
d. Remove the drive V-belt per paragraph 6.12.2.
e. Remove the flywheel and bushing by removing the three capscrews that secure the
flywheel and bushing to the crankshaft. Use these screws in the bushing tapped holes
to jack the flywheel and bushing apart. This will "unlock" the bushing from the
crankshaft.
f. Remove the crankcase from the bedplate to remove the pan and connecting rods.
g. Remove the bearing plate, seal, and gaskets (Ref. 9-14, Pg 68).
h. Pull the crankshaft forward and remove it from the crankcase.
CAUTION
Do not let the crankshaft drop as the bearings are pulled out of their housings.
Support the weight of the crankshaft at all times to avoid damaging machined
surfaces.
i. With a suitable puller, remove the bearings from each end of the crankshaft and the
outer races from the bearing plate and crankcase.
6.11.3 INSTALL MAIN BEARINGS
4V4B-6.1 25
a. Thoroughly clean the crankcase, oil screen assembly, oil pump, adapter plate, and
crankcase covers. Dry the parts with clean compressed nitrogen.
b. Press a new bearing on each end of the crankshaft main bearing journals. Preheating
the bearings to 250˚F will facilitate installation.
c. Install new outer races in bearing plate and crankcase. Preheating the crankcase and
bearing plate to 250˚F, using an oven or a heating torch, will facilitate installation.
Make sure the main bearing is fully seated before continuing.
d. Install the crankshaft with bearings into the crankcase. If the case can be blocked up
on the oil pump end, the crankshaft can be lowered into place from above.
e. Install a new seal in the flywheel end bearing plate. Place a new gasket over the
crankshaft for the bearing plate.
f. Install the bearing plate; tighten the bearing plate capscrews to 25-30 Ft-lbs torque.
The shaft end play should be .002-.004 inches. Shims are provided for this
adjustment.
g. Install the flywheel, hub and key, drive V-belts and beltguard in the reverse
procedure of removal. Insure that the flywheel and driver sheave are lined up. Align
V-belts and pulleys per paragraph 6.2.
h. Replace the piston assemblies and their respective guide and compression cylinders,
being careful that the connecting rods seat properly on the crankshaft. Replace the
cylinder heads.
i. Ensure that the crankcase is clean and free of foreign particles, and then install the
crankcase pan and gasket. Tighten the capscrews to 10 Ft-lbs torque.
j. Connect the gas and coolant piping to their respective ports on the cylinders and
heads. Use Pg 72 to aid in replacing the compressor plumbing.
k. Fill the crankcase to the proper level with oil as specified in paragraph 4.3.
l. Turn the flywheel by hand a few revolutions to be certain everything is clear before
starting the compressor.
m. Start the compressor and check for gas, oil or coolant leaks. If leakage is present,
repair as required. See Chapter 2, Operation.
6.12 V-BELTS
6.12.1 GENERAL There is no scheduled replacement of the V-belts. Replacement is on an as-

required basis when they become frayed or broken. V-belts are used to drive the compressor.
6.12.2 COMPRESSOR DRIVE BELTS
4V4B-6.1 26
6.12.2.1 BELT REMOVAL
a. Loosen the four motor tie-down bolts on the sliding base at least three turns.
b. Slide the motor toward the compressor by turning the sliding base screw counter-
clockwise for one and one-half (1-1/2) inches of travel.
c. Roll the belt off the flywheel and driver sheave sequentially, one groove at a time.
6.12.2.2 BELT REPLACEMENT
a. To replace the belt, reverse order of above procedure.
b. Tension the belt per replacement procedure in Appendix Pg A6.
6.13 HEAT EXCHANGER
6.13.1 GENERAL There is no scheduled maintenance on the heat exchanger.
6.14 THERMOWELL
6.14.1 GENERAL A Thermowell is provided for measurement of 4th stage discharge gas
temperatures. Normal operating ranges are given in 3.6.
There is no maintenance on the thermowell. The compressor may be run with no leakage of gas
without a thermometer or thermocouple installed.
6.15 SHAFT SEAL
6.15.1 GENERAL The shaft seal is located at the flywheel end of the crankshaft. If significant oil
leakage develops, it should be replaced. The procedure for replacing the seal is given here.
6.15.2 REMOVAL (Dwg. Pgs 65-68)
a. Remove the beltguard.
b. Remove the main drive belt per paragraph 6.12.2.
c. Remove the flywheel and bushing by removing the three capscrews that secure the
flywheel and hub to the crankshaft. Use these screws in the hub tapped holes to jack
the flywheel from the bushing.
d. Remove the bearing plate, seal, and gasket. Discard the seal.
e. Inspect the crankshaft surface where the oil seal makes contact. Remove any burrs or
scratches that might inhibit a tight seal. Be careful to avoid getting any foreign
material on the exposed bearing.
6.15.3 REASSEMBLY
4V4B-6.1 27
a. Reassemble in the reverse order, using a new oil seal. Check shaft end play -- .002-
.004 inches.
b. Be sure that the flywheel and driver sheave are lined up. This can be accomplished
by laying a straight edge across the sheave face. See paragraph 6.2.1.
c. Install and adjust the belt per paragraph 6.12.2.
d. Replace beltguard.
6.16 PRESSURE RELIEF VALVES
6.16.1 GENERAL Five relief valves are plumbed into the compressor piping to protect the
components from excessive pressure. They are located in the suction line and after each stage, as
shown on the flow and plumbing schematic (Ref. Pg 69, 72). Their set pressures are given on pg. 4.
Follow the procedure detailed here for corrective maintenance.
6.16.2 REMOVAL Unscrew and remove the safety valve from the compressor. Disassemble the
safety valve as follows.
6.16.3 DISASSEMBLY
a. Unscrew the lock nut and remove the adjustment cap, exposing the spring. Remove
the spring and unscrew the bonnet. Remove poppet and seals from lower body.
b. Replace spring if broken or if compressed length prohibits adjustment to the proper

pressure range.
c. Inspect all parts for flaws and examine the seat for deficiencies that may cause
leakage. Replace all seals and any defective parts.
6.16.4 REASSEMBLY
a. Insert poppet seal O-ring, insert, clamp disc, clamp nut, poppet, upper seal ring
retainer, upper seal ring, bonnet seal O-ring, bonnet, spring, locknut and adjustment
cap. The bonnet is torqued to 50 Ft-lbs. Connect the assembly to a distilled water
source with a pump or other method to build pressure and an accurate pressure gauge.
b. Set the crack pressure to 55 psig, 275 psig, 800 psig, 1800 psig or 3300 psig for the
inlet, 1st, 2nd, 3rd, and 4th stage valves respectively. The relief valves are set by turning
the adjustment cap. Always test the crack pressure with the lock nut tight against the
adjustment cap. Always relieve the pressure prior to adjusting the cap. Once the
cracking pressure is correct, tighten the lock nut to 100 In-lbs.
6.16.5 INSTALLATION Screw the safety valve into the proper location on the compressor, using
Teflon tape on the threads. Run the compressor and check for leaks, using a soap bubble solution.
4V4B-6.1 28
6.17 COMPRESSOR VALVES
6.17.1 GENERAL Each stage has a valve assembly whose main components are a suction reed,
discharge reed and a valve seat. A bad valve, either suction or discharge, in one stage will usually
be indicated by higher pressures than normal on the preceding stage. Severe usage over long periods
of time may result in worn or broken valves which may be destructive if the unit is allowed to
operate with them in this condition. Worn or broken valves are evidenced by clacking noises in the
cylinder head. Remove, disassemble, inspect, and service the valves every 4,000 hours of operation.
This may readily be accomplished by removing the cylinder heads.
CAUTION
When reinstalling valves with O-ring seals, care must be taken to avoid
damaging the O-rings. Lubricate the O-ring with Krytox. Avoid tilting the
valve when installing into the head and apply even finger pressure about the
circumference until the valve is completely installed.
6.17.2 REMOVAL AND INSTALLATION OF 1ST STAGE VALVE ASSEMBLY

(Dwg. Pgs 53-57)
6.17.2.1 REMOVAL OF SUCTION AND DISCHARGE VALVES
a. Remove inlet and discharge piping from the head.
b. Remove the bolts which hold down the 1st stage head and lift the head off.
c. Remove the suction reeds and inspect. Remove the screw that attaches the valve seat
to the head.
d. Remove the seat. Remove the screws which attach the discharge reed and stop to the
seat.
e. Inspect and repair as necessary.
6.17.2.2 INSTALLATION OF SUCTION AND DISCHARGE VALVES
a. Once the valve reeds have been examined or replaced and the seat has been
examined, lapped or replaced, reassemble in reverse order of disassembly.
b. Attach discharge reed and both stops to valve seat using screws. Torque to 1 ft-lb.
maximum.
c. Install the valve seat assembly, using new o-rings, into the head with the valve
retaining screw and tighten evenly to 30 in-lbs. torque.
d. Set the suction reed and o-ring on the valve seat and reinstall the head per section
6.3.3. Reconnect the inlet and discharge lines.
4V4B-6.1 29
6.17.3 REMOVAL AND INSTALLATION OF 2ND STAGE VALVE ASSEMBLY
(Dwg. Pgs 53-56, 58)
6.17.3.1 REMOVAL OF THE 2ND STAGE VALVE
a. Remove the inlet and discharge lines on the 2nd stage head. Remove the four nuts.
b. Lift off head. Remove o-ring and discard. Remove suction guard and suction reed.
c. Remove the O-ring and discard. Remove the valve seat from the cylinder head.
d. Remove the second O-ring and discard. Remove the discharge reed.
6.17.3.2 INSTALLATION OF 2ND STAGE VALVES
a. Apply a light film of Krytox to the new O-rings.
b. Set the discharge valve over the pin and place the first O-ring in the valve pocket.
Place the seat in over the pin. Place the second O-ring into position. Put the suction
valve in position over the pin followed by the suction guard. Finally place the third
O-ring into position over the guard.
c. Reinstall the head per section 6.3.3. Reconnect the inlet and discharge lines.
6.17.4 REMOVAL AND INSTALLATION OF 3RD STAGE VALVE ASSEMBLY

(Dwg. Pgs 53-56, 59)
6.17.4.1 REMOVAL OF THE 3RD STAGE VALVE
a. Remove the inlet and discharge lines on the 3rd stage head. Remove the four nuts.
6.17.4.2 INSTALLATION OF 3RD STAGE VALVES
6.17.5 REMOVAL AND INSTALLATION OF 4TH STAGE VALVE ASSEMBLY
4V4B-6.1 30
(Dwg. Pgs 53-56, 60)
6.17.5.1 REMOVAL OF THE 4TH STAGE VALVE
a. Remove the inlet and discharge lines on the 4th stage head. Remove the four nuts.
6.17.5.2 INSTALLATION OF 4TH STAGE VALVES
6.17.6 VALVE INSPECTION AND REPAIR The valve disassembly, inspection and repair
instructions here cover all the compressor valve assemblies. The respective valve drawings should
be used as guides for assembly.
a. Inspect the reed valves for cracking or pitting. Remove any deposits from the reeds.
A thin impression of a circle should be evident where the reed seals over the valve
seat ports. Any radial lines or streaks extending outward from these circles indicate
valve leakage.
b. Examine the valve seat carefully for cracks or pits and for leakage past the seat.
Streaked marks on the seat also indicate leakage. Replace parts as required.
c. Lap the valve seat on a lapping plate or regrind the valve seat using a very fine valve
grinding compound. When lapping or grinding, remove a minimum of material to
just clean up the surface. When the trepans or grooves between sealing surfaces on
the valve are reduced to less than .005 inches deep, the seat should be replaced (1st
and 2nd stages only).
e. Carefully clean the valve parts to remove the compression residue and valve grinding
compound from the seat.
f. Reassemble the valve in the reverse order of disassembly.
4V4B-6.1 31
Table 6-1 Hydrostatic Test Pressures of Components
Test
Components Pressures
1st Stage Gas Passage ...................................................... 300 psi
2nd Stage Gas Passage ................................................... 1100 psi
3rd Stage Gas Passage ................................................... 2500 psi
4th Stage Gas Passage.................................................... 5000 psi
Heat Exchangers ............................................................ 5000 psi
Table 6-2 Wrench Torques (Oiled Threads)
Foot Pounds
Cylinder heads with standard nuts .........................................20*

Cylinder heads with self-locking nuts ...................................25*
Connecting Rod Nuts ...............................................................35
Compression Piston Jam Nuts .................................................50
Crankcase Bearing Retainer Bolts ...........................................30
Oil Wiper Box ........................................................................... 6
Flywheel Hub Bolts .................................................................30
Crankcase Pan Bolts ..................................................................8
Gear Cover Bolts .......................................................................8
Guide Cylinder Nuts ................................................................35
*Over tightening head nuts will damage valves
4V4B-6.1 32
Table 6-3 Clearances and Tolerances
Refer to Dwgs. D3886 & B11165
Nominal
Indicator Dimensions Wear Limit
Crankshaft Bearings By inspection for pits, scratches,

knocking or rough running.
Crankshaft Journals 1.875 Diameter Diameter -.002 in. Maximum wear.
Connecting Rod Bearing 1.878 Diameter Diameter +.002 in. Maximum wear.
Journal and Bearing .003 .0055 in. Maximum.
Clearance
Wrist Pins .625 Diameter Diameter -.0015 in. Maximum wear.
Wrist Pin Bearing .625 Diameter Diameter +.002 in. Maximum wear.
Wrist Pin and Bearing .001 .004 in. Maximum wear.
Clearance
Guide Piston 3.172 Diameter -.003 in. Maximum wear.
Guide Cylinder Liner 3.175 Diameter +.002 in. Maximum wear.
Guide Piston and .004 .008 in. Maximum.
Cylinder Clearance
Piston Rods .750 Diameter .002 in. Diametral Wear.
Pistons: 1st Stage 2.625 Diameter 2.620 Diameter Minimum
2nd Stage 1.375 " 1.370 " "
3rd Stage 0.750 " .745 " "
4th Stage 0.500 " .495 " "
(Pistons do not wear under normal
conditions. Rider rings are used to prevent
the piston from contacting the cylinders.)
Rider Rings:
1st - 2.625 in. Diameter .187 Thick .020 in. Radial wear
2nd - 1.375 in. Diameter .187 Thick .020 in. Radial wear
3rd - 0.750 in. Diameter .090 Thick .005 in. Radial Wear
4th - 0.500 in. Diameter .056 Thick .003 in. Radial Wear
Piston Rings: 1st - .250 Radial Thick When average radial wear is
2nd - .150 " " 2/3 of ring or blow-by occurs.
3rd - .080 " "
4th - .068 " "
1st - .120 Axial Thick .015 in. Maximum.
2nd - .105 " "
3rd - .075 " "
4th - .075 " "
4V4B-6.1 33
Table 6-3. Clearances and Tolerances (Continued)
Refer to Figures 7-1 & 7-2
Nominal
Indicator Dimensions Wear Limit
Seals: includes
Oil Wipers
Segmented Packings Visual Any leakage should be corrected
Shaft Seal
Cylinders and Liners 1st - 2.626 Diameter .004 in. Diametral Wear.
2nd - 1.376 " .003 " "
3rd - 0.751 " .002 " "
4th - 0.501 " .001 " "
Valve Plates, (see 1st - .012" .002 in. wear or when pitted
Figs. 7-4 thru 7-7) 2nd - .015" enough to cause insufficient
3rd - .012" seating
4th - .010"
Valve Seats, (see Pitted or Streaked .010 in. wear or when pitted
Figs. 7-5 thru 7-8) enough to cause insufficient
seating.
4V4B-6.1 34
CHAPTER 7 COMPRESSOR ASSEMBLY PARTS LISTS
7.1 INTRODUCTION The parts listed here cover the RIX Model 4V4B-6.1 Compressor
identified by the Serial Number(s) recorded on the Registration Page. The parts listed cover all parts
of the compressor assembly furnished by RIX Industries as follows:
Table 7-1 Compressor Parts Lists

Drawing
Item Description Pages Ref. Page
1 Compressor Parts List 53-65 36

2 Crankcase Assembly Parts List 66-68 41
3 Accessory Parts List 69-71 44
4 Plumbing Parts List 72 47
5 Electrical Parts List 73-76 49
Each item is identified by a RIX P/N, description, quantity, and, where applicable, a reference
number to a corresponding drawing. Recommended spare part quantities are listed in the right most
(*) column.
For common items such as screws, nuts, etc., if a part number is not given, the item description is
meant to give enough of a description to allow for local procurement.
All parts can be obtained from RIX Industries: Spare Part Sales – (707) 745-7177
Main Office – (707) 747-5900
FAX – (707) 747-9200
IMPORTANT
All parts in contact with Oxygen MUST be Oxygen Cleaned
An “X” at the beginning of a part number signifies O2 clean. Parts with this
designation are specially cleaned and supplied in sealed plastic bags.
Note: Some parts may be purchased without oxygen cleaning if specified and
cleaned by user prior to installation. Cleaning by the user must comply with:
CGA G-4.1: Cleaning Equipment for Oxygen Service
Caution: Drawings include parts that require O2 cleaning but do not have “X”
prefixes. User to order parts with X prefix or take responsibility for cleaning
part.
4V4B-6.1 35
COMPRESSOR PARTS LIST
MODEL 4V4B-6.1-P1 A, B, C & D
REF. CROSS SECTION/ASSEMBLIES (PG 53-65)
REF PART QTY

NO NO. DESCRIPTION UNIT *
Note: The compression cylinder assemblies and crankcase are detailed on separate
drawings and parts lists, on pages following.
1 A100-D2267 Crankcase Assy 1

(See separate Parts List)
2 16-54 Gasket 2 2
3 301-D3882 Distance Piece 2
4 20-4629 Washer, flat, 7/16 12
5 53-4753 Nut, 7/16-20 12
6 8-C1877 Guide Piston 4
7 17-A5555 Wrist Pin 4
8 31-24 Snap Ring 8
9 123-234-5 O-Ring 4 4
10 119-C1878 Wiper Box 4
11 215-405 Gland 4
12 125-A7637 Oil Wiper 8 8
13 A119-A5629 Baffle (Inc. 1-2) 4
119-A5629 1. Baffle Plate 1
119-A5629-1 2. Spacer 1
14 32-8429 Bolt, SHCS 10-32 8
15 32-1156 Bolt, Hex Head 8
16 20-12877 Washer, Flat, 1/4 AN 8
17 32-4638 Bolt, Hex Head, 1/4-20 8
18 20-1003 Washer 24
19 16-B5716 Gasket 4 4
20 38-B4148-2 Cover Plate 2
21 38-B4148-3 Cover Plate 2
22 32-4136 Bolt, Hex Head, 1/4-20 16
*Recommended Spares
P/N: MAN-4V4B-6.1-P1A, B, C, D 36
REF PART QTY

23 53-402 Nut, Special, 5/8-18 4
24 222-1001 Slinger 4
25 X119-C3606 Spacer, 1st stage 1
26 XA1-B8296 Cylinder (Inc. 1-2) 1
X1-D3298 1. Cylinder 1
X63-B8285 2. Liner 1
27 X123-152-5 O-Ring 1 1
28 X2-C3024 Head 1
29 XA15-A7998 Valve Assy, 1st stage (See Pg 57, Inc. 1-10) 1 1
X17-410 1. Roll Pin 1
X123-021-5 2. O-Ring 1 1
X123-042-5-90 3. O-Ring 2 2
X34-607 4. Screw, #6-32 2
X15-A3946 5. Valve Backing Plate 1
X15-A3720 6. Discharge Reed 2
X15-B5287 7. Valve Seat 1
X15-A7960 8. Suction Reed 2
X123-012-5 9. O-Ring 1 1
X34-807 10. Screw, 1/4-20 1
30 XA8-B12763 Piston Assy (Inc. 1-6) 1
X3-B12762 1. Piston Rod 1
X8-B12635 2. Piston 1
X53-B11608 3. SuperNut 1
X20-A10608 4. Spacer 1
X32-11313 5. Set Screw 4
X123-110-5 6. O-Ring 1
31 X18H-C755-40G Compression Ring 8 8
32 X18-C758-40G Rider Ring 1 1
33 X119-C3609 Spacer, 2nd stage 1
34 XA1-B8461-42 Cylinder, 2nd stage (Inc. 1-3) 1
X1-D3333-1 1. Cylinder 1
*Recommended Spares
P/N: MAN-4V4B-6.1-P1A, B, C, D 37
REF PART QTY

X123-031-5 2. O-Ring 1
X63-B8474-42 3. Liner 1
35 X2-D3340 Head 1
36 XA15-A9281 Valve Assy, 2nd stage (See Pg 58, Inc. 1-5) 1 1
X123-031-5-90 1. O-Ring 3 3
X15-A9762 2. Valve Stop 1
X15-B8510 3. Valve Reed 2
X17-7943 4. Pin 2
38 XA8-A3484-11-9 Piston Assy, 2nd stage (See Pg 62, Inc. 1-7) 1
X32-1143 1. Set Screw 1
X8-D1195-11-7AB 2. Piston 1
X18-C1791-11-1G 3. Compression Ring 7 7
X123-120-5-90 4. O-Ring 7 7
X18-C1147-11G 5. Rider Ring 2 2
X123-011-5 6. O-ring 1 1
X3-B12766 7. Piston Rod, 2nd stage 1
X63-C1148-11-2 8. Sleeve Tool 1 3/8" 1
39 XA1-B12799-1 Cylinder Assy, 3rd stage (Inc 1-2) 1
X63-B9073-2 2. Liner 1
40 X2-D3883 Head 2
41 XA15-A9280 Valve Assy, 3rd stage (See Pg 59, Inc. 1-5) 1 1
X123-028-5-90 1. O-Ring 3 3
X17-7943 3. Pin 2
42 XA8-B8873 Floating Piston, 3rd stage (See Pg 63, Inc. 1-6) 1
X8-B8873 1. Floating Piston, 3rd stage 1 1
*Recommended Spares
P/N: MAN-4V4B-6.1-P1A, B, C, D 38
REF PART QTY

X18-C1603-6G 2. Breaker ring 2 2
X18-C1791-6-1G 3. Compression Ring 5 5
X18-C1147-6G 4. Rider Ring 2 2
X123-014-5-90 5. O-Ring 5 5
X63-C1148-6 6. Sleeve Tool 3/4" 1
47 XA3-B12765 Piston Rod Assy, 3rd stage (Inc. 1-3) 1
X18-C1147-6B 1. Rider Ring 1 1
X3-A9608-2 2. Adapter 1
X3-B12764 3. Piston Rod 1
48 XA1-B12799-2 Cylinder Assy, 4th stage (Inc. 1-2) 1
X63-B9073-6 2. Liner 1
49 XA15-A9279-1 Valve Assy, 4th stage (See Pg 60, Inc. 1-6) 1 1
X123-028-5-90 1. O-Ring 3 3
X17-7943 4. Spring Pin 1
X17-10208 6. Spring pin
50 X3-B12747 Piston Rod 1
51 XA508-A5554 Floating Piston, 4th Stage (See Pg 64, Inc. 1-5) 1 1
X18-A2750-3G 1. Rider Ring 2 2
X63-A5549 2. Sleeve Tool 1
X18-C1791-4G 3. Compression Ring 8 8
X123-011-5-90 4. O-Ring 8 8
X508-B4152 5. Piston 1
X34-633 6. Pan Head Bolt 1
52 X18-A2750-5G Rider Ring 1
53 105-C1993-133 Threaded Stud 16
54 20-703 Washer, Flat 16
55 53-1000 Nut, Hex 16
*Recommended Spares
P/N: MAN-4V4B-6.1-P1A, B, C, D 39
REF PART QTY

56 X123-032-5 O-Ring 12
57 X54P-6HP5ONSS Hollow Hex Plug, 9/16-18 2 2
58 X54P-10HP5ONSS Hollow Hex Plug, 7/8-14 1
59 X123-910-5 O-Ring 1
60 X123-906-5 O-Ring 2 2
*Recommended Spares
P/N: MAN-4V4B-6.1-P1A, B, C, D 40
CRANKCASE ASSEMBLY PARTS LIST
RIX ASSEMBLY A100-D2267
REF. CRANKCASE (PG 66-68)
REF PART QTY

1 66-18 Spacer, Gear Cover 1

3 A5-B4900 Crankshaft Assembly (Incls. 1-5) 1
M5-B4222 1. Crankshaft (Modified) 1
181-720 2. Bearing, Oil Pump End 1
181-721 3. Bearing, Flywheel End 1
46-404 4. Gear 1
91-306 5. Key, #8 Woodruff 1
4 A7-B4172 Connecting Rod Assembly (Incls. 1-4) 4
7-B4154 1. Connecting Rod 1
181-722 2. Needle Bearing 1
21-403-3 3. Bearing Shell 1
35-403-1 4. Bolt & Nut 2
9 22-154 Shim 1
10 16-56 Gasket, Bearing Plate, Flywheel End 3 3
11 16-57 Gasket, Bearing Plate, Flywheel End 3
13 125-37 Shaft Seal Spool Type 1
14 A38-168 Main Bearing Plate Assembly 1
15 954-11 Nozzle, Oil Spray 4
16 PA100-D2267 Crankcase 1
17 32-4549 Bolt, Hex Head, 1/2-13 x 1 1/2, Stl. Gr. 5 4
18 20-4043 Lockwasher, 1/2" Spring Lock, Stl. Gr. 5 4
19 32-4672 Bolt, Hex Head, 5/16-18 x 5/8" Stl. Gr. 5 19
20 20-1016 Lockwasher, Spring Lock, 5/16" 30
21 16-53 Gasket, Oil Pan 1 1
22 54-915 Pipe, Oil Drain 1
*Recommended Spares
P/N: MAN-4V4B-6.1-P1A, B, C, D 41
REF PART QTY

23 38-170 Plate Cover, Bottom 1
24 81-191 Oil Pump 1
25 54P-1/8HHPS Plug, Crankcase 5
25.1 100-302-3 Plug, Crankcase (Slotted) 1
26 16-52 Gasket, Spacer, Crankcase 1 1
27 16-881 Gasket, Gear Cover 1 1
28 17-414 Dowel Pin, Gear Cover 2
29 106-512 Lockscrew, Oil Pump 1
30 32-4684 Bolt, Flat Soc. Hd., 5/16-18 x 3/4", Stl. Gr. 5 4
31 20-4685 Lockwasher, Countersuck, 5/16 Stl. 4
35 38-169 Plate, Bearing Retainer 1
36 A38-B4220-1 Cover Assembly, Gear (Incls. 1-3) 1
19-10 1. Freeze Plug, 2 1/8" 1
19-10454 2. Freeze Plug, 7/8" 1
35-7644 3. Copper Coat Gasket Compound 1
38-B4220-1 Gear Cover 1
37 32-4529 Bolt, Hex Hd. 5/16-18 x 3/4, Stl. Gr. 5 4
38 38-171 Cover Plate, Top Crankcase 1
38.1 38-B4174 Cover Plate, Gear Plate 1
38.2 16-B4175 Gasket, Cover Plate 1 1
39 100-302-6 Plug 5/8 Expansion 2
40 20-646 Washer, Idler Gear & Spacer Plate, 5/16 Copper 2
41 106-17 Stud, Idler Gear 1
42 106-510 Screw, Allen Head, 5/16-18 x 3/8 1
43 32-1162 Bolt, Hex. Head, 5/16-18 x 1-1/4, Stl Gr. 5 12
45 46-405 Idler Gear 1
*Recommended Spares
P/N: MAN-4V4B-6.1-P1A, B, C, D 42
REF PART QTY

46 16-59 Gasket, Top Plate, Crankcase 1 1
47 105-1009 Stud, 1/4-28, Stl. 2
47.1 20-1017 Lockwasher, Springlock, 1/4" Stl 2
47.2 53-4101 Nut, 1/4-28, Stl 2
48 16-54 Gasket, Guide Cylinder 2 2
49 100-302-2 Stud, Cylinder Block to Crankcase 12
52 39-606 Support, Engine 2
53 100-302-8 Screw, Oil Filter 2
54 560-3 Tube Dipstick 1
55 560-A8157 Dipstick 1
56 100-302-7 Plug, Camshaft 1
57 34-B3204-36 Stud 6
57.1 53-4103 Nut, 3/8-24, Stl. 12
57.2 20-4564 Flatwasher, 3/8" 6
58 20-402 Lockwasher, 3/8" Spring Lock 12
59 100-302-4 Plug, Face of Crankshaft, 7/16-14 NPT 4
60 16-55 Gasket, Oil Filter 1 1
61 40-102 Bracket, Oil Filter 1 1
62 49-412 Oil Filter Cartridge 1
63 100-302-5 Screen, Oil Filler (Part of Item 64) 1
64 100-302-1 Tube, Oil Filler 1
65 49-7 Breather Cap 1
66 35-7644 Copper Coat Gasket Compound 1
*Recommended Spares
P/N: MAN-4V4B-6.1-P1A, B, C, D 43
ACCESSORY PARTS LIST
MODEL 4V4B-6.1-P1A, B, C & D
REF. FLOW SCHEMATIC (PG 69)
REF REF. PART PER

NO SYM. NO. DESCRIPTION UNIT
202 RVI X515-12979 Relief Valve Suction @ 55 PSIG 1

203 RV1 X515-12980 Relief Valve 1st Stage @ 275 PSIG 1
204 RV2 X515-12981 Relief Valve 2nd Stage @ 800 PSIG 1
205 RV3 X515-12982 Relief Valve 3rd Stage @ 1800 PSIG 1
206 RV4 X515-12983 Relief Valve 4th Stage @ 3300 PSIG 1
207 HX X71-13042 Heat Exchanger 1
214 BPR X116-464 Back Pressure Regulator 1
219 FO 49-412 Oil Filter 1
220 B 49-7 Breather Cap 1
221 DS 560-A8157 Dip Stick 1
222 PO 81-191 Oil Pump 1
REF TIS4 REF (PG 49) Temperature Controler 1
224 PSS X76-714-3000 Pressure Switch, 3000 PSIG 1
225 PSIL/H X76-16458-50 Pressure Switch, 50 PSIG 1
226 PGI X60-9274-060 Pressure Gauge 0-60 PSIG 1
227 PG1 X60-9274-400 Pressure Gauge 0-400 PSIG 1
239 CV X615-53 Check Valve 1
241 SNS X74-401 Snubber, Inlet Pressure Switch 1
242 SN X715-19385 Gauge Snubber, Hand Valve 3
243 SN4 XA715-1004 Gauge Snubber, Hand Valve 1
247 PGO 60-405 Pressure Gauge 0-30 PSIG 1
249 RTD4 X138-5531 RTD 4th Stage 1
P/N: MAN-4V4B-6.1-P1A, B, C, D 44
ACCESSORY PARTS LIST
REF. FLOW SCHEMATIC (PG 69)
REF REF. PART PER

NO SYM. NO. DESCRIPTION UNIT
N/A 88-B4277 Piston Adjusting Tool (Shipped Loose, 1

used for piston and rod installation)
N/A 62-403 Label, RIX Logo 1
N/A 62-A7278-3 Label, O2 Clean 1
N/A 62-A7278 Caution Label, Piston Adjustment 1
N/A 62-A7514 Label, RIX Info 1
N/A 62-A7507 Label, O2 Nameplate 1
N/A 62-416 Caution Label, Controls 1
N/A 62-A8471 Label, Rotation 1
N/A 62-422 Caution Label, Auto Equip. 1
N/A 62-A7353 Caution Label, Oil Level 1
N/A 62-18792 Label, CE 1
N/A 62-21031 Label, Made in America Flag 1
P/N: MAN-4V4B-6.1-P1A, B, C, D 45
ACCESSORY PARTS LIST (CONT'D)
REF. ACCESSORIES DRAWING (PG 70-71)
REF PART PER

NO NO. DESCRIPTION UNIT
201 142-254T Slide Base 1
208 91-A4992-1 Key 1
209 107-456 Motor 15 HP, 1500 RPM 230/380-415/50, 1
1800 RPM 208-230/460/60
210 11-144-SF Bushing 1
212 36-C2828-1 Flywheel 1
213 40-15451 Bracket 2
215 70-D3888 Bedplate 1
216 X10-B12817 Manifold 1
217 A156-D3892 Beltguard 1
218 148-D3893 Shroud 1
244 40-C3621 Mounting Stand 1
245 40-C3640 Bracket 1
246 455-B12860 Oil Fill Tube 1
250 148-B9775 Fan Shroud 1
251 40-B6240-1 Discharge Support Bracket 1
P1A/P1B (60 Hz) Specific Parts

211 11-162-SDS Bushing 1
231 36-2B068 Pulley, Motor 1
232 41-B88-1 Belt 1
248 42-17356 Fan 1
P1C/P1D (50 Hz) Specific Parts

211 11-162-SK Bushing 1
231 36-2B080 Pulley, Motor 1
232 41-B90-1 Belt 1
248 42-16734 Fan 1
P/N: MAN-4V4B-6.1-P1A, B, C, D 46
PLUMBING PARTS LIST
REF. PLUMBING SCHEMATIC (PG 72)
IMPORTANT: When ordering replacements, specify "Oxygen Cleaned"
REF PART PER

301 X54D-13033 Female Connector 3/4" 1

302 X54D-12103TTFSS Female Branch Tee 3/4" 1
303 X54P-3/41/4PTRSS Pipe Thread Reducer 1
304 X54D-1210116STSS Male Connector 3/4" 1
306 X54D-10109SS Union Elbow 5/8" 1
307 X54D-13034 Female Run Tee 5/8" 1
308 X54P-1/4GGSS Pipe Coupling 1
310 X54D-8109SS Union Elbow 1/2" 1
311 X54D-8103TFTSS Female Run Tee 3/8" 1
313 X54D-13035 Union Elbow 3/8" 1
314 X54D-6003TFTSS Female Run Tee 3/8" 3
315 X54D-40014SS Male Connector 1/4 8
319 X54D-60014SS Male Connector 3/8" 3
321 X54P-1/4CRSS Male Pipe Elbow 1
322 X54P-1/41/8PTRB Pipe Thread Reducer 1/4 2
323 X54P-1/4FFSS Pipe Nipple 6
324 X54P-1/4CDSS Street Elbow 1
325 X54P-1/4MROSS Male Run Pipe Tee 1
328 X123‐916‐5 O‐Ring 1
P/N: MAN-4V4B-6.1-P1A, B, C, D 47
PLUMBING PARTS LIST
REF. PLUMBING SCHEMATIC (PG 72)
IMPORTANT: When ordering replacements, specify "Oxygen Cleaned"
REF PART PER

329 X123‐910‐5 O‐Ring 2

330 X123‐906‐5 O‐Ring 5
331 X455‐15954‐1 Tubeline Inlet 1
332 X455‐15954‐2 Tubeline 1st Stage Inlet 1
333 X455‐15954‐3 Tubeline 1st Stage Discharge 1
334 X455‐15954‐4 Tubeline 2nd Stage Inlet 1
335 X455‐15954‐5 Tubeline 2nd Stage Discharge 1
336 X455‐15954‐6 Tubeline 3rd Stage Inlet 1
337 X455‐15954‐7 Tubeline 3rd Stage Discharge 1
338 X455‐15954‐8 Tubeline 4th Stage Inlet 1
339 X455‐15954‐9 Tubeline 4th Stage Discharge 1
340 X455‐15954‐10 Tubeline Final Discharge 1
342 X455‐15954‐12 Tubeline Inlet Gauge 1
343 X455‐15954‐13 Tubeline 1st Stage Guage 1
344 X455‐15954‐14 Tubeline 2nd Stage Guage 1
345 X455‐15954‐15 Tubeline 3rd Stage Gauge 1
346 X455‐15954‐16 Tubeline 4th Stage Gauge 1
P/N: MAN-4V4B-6.1-P1A, B, C, D 48
ELECTRICAL PARTS LIST
REF. ELECTRICAL BOX (PG 73-76)
REF REF PART PER

NO SYM NO. DESCRIPTION UNIT
2.1.1 138-15330 Terminal Strip 1

2.2.1 138-15331 Terminal Strip 1
2.3 KA 676-12592 Relay 1
2.5 QF2 76-12896 Circuit Breaker, 1 Pole, 5A 1
2.6 QF1 76-12897 Circuit Breaker, 2 Pole, 4A 1
2.7 KM 76-13746 Coil Contactor 1
2.8 138-15332 Terminal Strip 2
2.9 KMOVLD 76-13748 Overload 1
5 HM 113-10156 Hour Meter 1
6 TIS4 76-12579 Temperature Switch Set @ 275F 1
7 SB1 76-12606 Push-Pull Button Emergency Stop 1
8 SA 76-12604 Selector Switch, HOA 1
9 SB2 76-12605 Push button, Start 1
10 HL1 76-12627 LED Indicating Light, Green (Start) 1
11 HL2 76-12698 LED Indicating Light, Red (Stop) 1
12 REF Groung Lug 1
13 C1 976-12908 Fan/Motor Capacitor 1
16 Q1 76-13747 Disconnect Fusible 1
17 REF Stop Label 1
18 REF Run Label 1
19 REF Hand-Off-Auto Label 1
20 REF Estop Label 1
21 REF Start label 1
24 TC1 185-12892 Transformer, 500VA 1
FM REF (PG 46) Fan/Motor 1
P/N: MAN-4V4B-6.1-P1A, B, C, D 49
ELECTRICAL PARTS LIST
REF. ELECTRICAL BOX (PG 73-76)
REF REF PART PER

NO SYM NO. DESCRIPTION UNIT
M REF (PG 46) Electric Motor 1
PSS REF (PG 44) Pressure Switch Set @ 3000 PSIG 1
PSIH/L REF (PG 44) Pressure Switch Set @ 1
40 PSIG Falling / 50 PSIG Rising
RTD4 REF (PG 44) Resistive Temperature Device 1
P1A (208-230V/3PH/60Hz) Fuses
FU 163-13751 Fuse, 80 A Time Delay 3
P1B (460V/3PH/60Hz) Fuses
FUR 163-13755 Fuse Reducer 3
P1C (380-415V/3PH/50Hz) Fuses
FUR 163-13755 Fuse Reducer 3
P1D (208-230V/3PH/60Hz) Fuses
Electrical Plumbing Components

401 138-9021 Elbow 1”, Nonmet, 45 Deg 2
402 138-8256 Elbow ½”, Nonmet, 90 Deg 4
403 138-8254 Fitting ½”, Nonmet, St 2
404 138-449 .25-.38” Cord Connector 1
405 54-5195 Coupling, ½” Npt, Galv. 1
406 138-10475 .125-.187” Strain Relief 1
407 138-606 Nut, ½” Npt 1
408 61-9020 Conduit, 1” Nonmet A/R
409 61-8251 Conduit, ½” Nonmet A/R
P/N: MAN-4V4B-6.1-P1A, B, C, D 50
Installation Arrangement
P/N: MAN-4V4B-6.1-P1A, B, C, D 51
Installation Arrangement (Cont’d)
P/N: MAN-4V4B-6.1-P1A, B, C, D 52
Cross Section
P/N: MAN-4V4B-6.1-P1A, B, C, D 53
Cross Section (Cont’d)
P/N: MAN-4V4B-6.1-P1A, B, C, D 54
P/N: MAN-4V4B-6.1-P1A, B, C, D 55
P/N: MAN-4V4B-6.1-P1A, B, C, D 56
1st Stage Valve
P/N: MAN-4V4B-6.1-P1A, B, C, D 57
2nd Stage Valve
P/N: MAN-4V4B-6.1-P1A, B, C, D 58
3rd Stage Valve
P/N: MAN-4V4B-6.1-P1A, B, C, D 59
4th Stage Valve
P/N: MAN-4V4B-6.1-P1A, B, C, D 60
1st Stage Piston Assembly
P/N: MAN-4V4B-6.1-P1A, B, C, D 61
2nd Stage Piston Assembly
P/N: MAN-4V4B-6.1-P1A, B, C, D 62
3rd Stage Piston Assembly
P/N: MAN-4V4B-6.1-P1A, B, C, D 63
4th Stage Piston Assembly
P/N: MAN-4V4B-6.1-P1A, B, C, D 64
Oil Packing Arrangement
P/N: MAN-4V4B-6.1-P1A, B, C, D 65
Crankcase
P/N: MAN-4V4B-6.1-P1A, B, C, D 66
Crankcase (Cont’d)
P/N: MAN-4V4B-6.1-P1A, B, C, D 67
Crankcase (Cont’d)
Section A-A
P/N: MAN-4V4B-6.1-P1A, B, C, D 68
Flow Schematic
P/N: MAN-4V4B-6.1-P1A, B, C, D 69
Accessories
P/N: MAN-4V4B-6.1-P1A, B, C, D 70
Accessories (Cont’d)
P/N: MAN-4V4B-6.1-P1A, B, C, D 71
Plumbing Schematic
P/N: MAN-4V4B-6.1-P1A, B, C, D 72
Electrical Box – Wiring Diagram
P/N: MAN-4V4B-6.1-P1A, B, C, D 73
Electrical Box (Cont’d) – Schematic
P/N: MAN-4V4B-6.1-P1A, B, C, D 74
Electrical Box (Cont’d) – Layout
P/N: MAN-4V4B-6.1-P1A, B, C, D 75
Electrical Box (Cont’d) – Plumbing
P/N: MAN-4V4B-6.1-P1A, B, C, D 76
Appendix – Connecting Rod
P/N: MAN-4V4B-6.1-P1A, B, C, D A1
Appendix – O-Ring Information
P/N: MAN-4V4B-6.1-P1A, B, C, D A2
Appendix – Piston Ring Installation
P/N: MAN-4V4B-6.1-P1A, B, C, D A3
Appendix – Piston Adjustment Tool
P/N 88-B4277
P/N: MAN-4V4B-6.1-P1A, B, C, D A4
Appendix – Pressure Switches
Spectra 10 Series
Each 4V4B-6.1-P1 compressor is supplied from the factory with an inlet and discharge pressure
switch set to the following:
 Inlet – 40 PSIG Falling / 50 PSIG Rising

 Discharge – 3000 PSI Rising
These switches are set to maintain the compressor at normal design operating conditions, but
other operating pressures may be suitable. Please contact RIX for application support and
evaluation of desired alternative operating pressures. RIX will provide instructions for adjusting
the pressure switch settings following approval of alternative operating pressures by RIX
engineering.
RIX Technical Support: Sales Engineer – (707) 745-7176

Technical Support – (707) 745-7143
[email protected]
Warning: Modifying the pressure switch settings can lead to unsafe operating
conditions! Any modification to these settings without prior approval from RIX
will void the compressor warranty!
P/N: MAN-4V4B-6.1-P1A, B, C, D A5
Appendix – V-Belt Installation
The 4V4B-6.1-P1 compressor is driven by 2 V-Belts. These belts should be replaced periodically
when they display signs of cracking, fraying or other visible signs of wear, or when it becomes
necessary to re-tension the belt more frequently. The procedure for installing a V-Belt, new or
re-used, is detailed below.
Belt Removal:
1. Relieve tension on the belt using the slide base adjustment screw.
2. Remove the belt.
Note: Do not roll or pry the belt off of the sheaves as it may damage the belt and/or sheaves.
Belt Installation:
1. Check the alignment of the sheaves. One method is shown in the figure below:
2. Install the belts into the rear and front grooves. If it is difficult, the motor should be
adjusted closer to the compressor rather than trying to roll or pry the belt onto the
sheaves.
3. Adjust the slide base to tension the belts. The belts are properly tensioned when they
deflect 5/16 – 3/8” as shown in the figure below using the following deflection forces:
(force and deflection measured perpendicular to the relaxed belt as shown)
Re-Used New
Belt Belt
One Belt 5-8 Lbs 10 Lbs
Both Belts 10-15 Lbs 20 Lbs
4. For newly installed belts, the tension should be checked and re-tensioned as necessary
after 24-48 hours of run time.
P/N: MAN-4V4B-6.1-P1A, B, C, D A6

Rix 4v4b-6.1-p1 A, B, C, D Manual (C)

Uploaded by

Copyright:

Available Formats

Rix 4v4b-6.1-p1 A, B, C, D Manual (C)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Rix 4v4b-6.1-p1 A, B, C, D Manual (C)

Uploaded by

Copyright:

Available Formats

OPERATING INSTRUCTIONS

and PARTS LIST for

MANUAL P/N: MAN-4V4B-6.1-P1 REV (C),

4900 Industrial Way Benicia, CA 94510 Phone 707-747-5900 FAX 707-747-9200

B 2/10/17 KA 44 Accessory Parts List

C 5/16/17 KA ALL General update to drawing and parts list

1. OPERATING INSTRUCTIONS ............................................................................................. 1

3. START-UP AND OPERATING PROCEDURES.................................................................. 3

4. SCHEDULED MAINTENANCE ............................................................................................ 5

5. COMPRESSOR TROUBLESHOOTING ............................................................................ 10

6. CORRECTIVE MAINTENANCE ........................................................................................ 17

6.5 PISTON RINGS ......................................................................................................... 20

7. COMPRESSOR ASSEMBLY PARTS LIST ....................................................................... 35

COMPRESSOR PARTS LIST ............................................................................................. 36

INSTALLATION ARRANGEMENT .......................................................................... 51

CONNECTING ROD ASSEMBLY ............................................................................ A1

Cross Section D3886, B11165

Application for which designed Oxygen

Compressor Rotation Counterclockwise from Flywheel Side

Normal Oil Pressure 3-10 Psi

OPERATING PRESSURES (PSIG)

First Second Third Fourth Compressor

40-50 psig 180-230 600-720 1400-1700 2200-3000 600-630 17-20

Electric Motor: 15 HP, 208/230/380/415/460/3/50/60, 1500/1800 RPM,

OPERATION OF THIS EQUIPMENT WITH PROTECTIVE

EXAMPLES OF ACTIONS WHICH COULD

Pressure Relief Valves Removal/Valved out of circuit

Sensing Switches Improper setting

Electrical Overload System Removal/Bypassed

Protective Guards Removal/Damage/Modification

MAINTENANCE OR ADJUSTMENTS TO THE EQUIP-MENT,

RIX Industries warrants all 4V4 compressors as follows:

The Manufacturer shall in no event be liable for consequential damages or contingent

This compressor has been built in conformance to the following standards:

EN 61000-6-4: 2006 including: EN55022: 2009 + A1 Class A,

1.3 GENERAL DESCRIPTION

A painful burn can be caused by touching any of the heads or

3.6 SWITCH / RELIEF VALVE SETTINGS:

Table 3-1 Shutdown Switch Settings

SWITCHES Symbol Set Point Function

Low Inlet Pressure PSIL 40 psig decr. Shutdown

Table 3-2 Relief Valve Setpoints

RELIEF VALVES Symbol Set Point (psig)

Relief Valve, Suction RVS 55

Before attempting any repairs or adjustments, de-energize the machine

Table 4-1 Lubrication & Preventive Maintenance

Para. Operation Time Intervals in Hours

Before performing any of the scheduled maintenance tasks in Chapter

4.2.3 MATERIALS The crankcase requires 7 quarts of oil.

4.4 GAS SYSTEM PIPING

The test is simplified if the compressor is allowed to cool, then

Hot discharge lines can produce painful burns. Be careful to avoid

f. Leaks in gasketed joints may, in some cases, be corrected by retightening the

g. O-ring joints cannot be corrected by additional tightening. In most every case,

4.5 COMPRESSOR VALVES INSPECTION AND RECONDITIONING

4.6 PISTON RING REPLACEMENT

4.7 PRESSURE RELIEF VALVES

Table 5-1 Compressor Troubleshooting Guide

TYPE OF PROBLEM SECTION PAGE