Rix 4v4b-6.1-p1 A, B, C, D Manual (C)
Rix 4v4b-6.1-p1 A, B, C, D Manual (C)
Rix 4v4b-6.1-p1 A, B, C, D Manual (C)
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
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
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
2. INSTALLATION ...................................................................................................................... 2
2.1 GENERAL.................................................................................................................... 2
2.2 PLUMBING ................................................................................................................. 2
2.3 LUBRICATION ........................................................................................................... 2
2.4 ELECTRICAL CONNECTIONS ................................................................................. 2
2.5 STORAGE .................................................................................................................... 2
i
TABLE OF CONTENTS
4V4B-6.1-P1A, B, C & D
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
APPENDIX
Title Pages
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”
The compressor has been test operated with the following results. Operating pressures should
be approximately as follows:
NOTE: The flow rate will vary according to the temperature of the gas being compressed,
the suction pressure and the final discharge pressure.
4900 Industrial Way Benicia, CA 94510 USA Phone 707-747-5900 FAX 707-747-9200
iv
WARNING
Some of the control devices which could be included on this machine are the following:
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
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.
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.
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.
1.3.1 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
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.
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
WARNING
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.
4.2.4 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.
4.4.1 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
WARNING
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.
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.
4.6.1 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.
4.7.1 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.
4V4B-6.1 10
5.2 LUBE OIL SYSTEM PROBLEMS
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. 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".
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.
4V4B-6.1 11
5.4 LOW PRESSURE READINGS
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.
4V4B-6.1 12
5.6 REDUCED CAPACITY
4V4B-6.1 13
5.8 UNUSUAL VIBRATION
4V4B-6.1 14
5.10 INABILITY TO RESTART COMPRESSOR
4V4B-6.1 15
5.12 OIL LEAKAGE
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)
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
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.
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:
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.
SECTION II REPAIR
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.
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.
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.
6.4.1 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.
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.
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).
CAUTION
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)
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.
6.5.1 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)
b. Turn the flywheel by hand to position the piston at bottom dead center.
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.
h. Clean and inspect the cylinder for wear or damage. Wear must be within the
tolerance specified in Table 6-3.
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.
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.
6.7.1 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.
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.
6.8.1 GENERAL The guide cylinders each have two bores and a distance piece. They support the
compression 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.
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.
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).
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.
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.
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.
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.
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.
6.11.1 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.
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).
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.
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
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.
6.14 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.
6.15.1 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.
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.
d. Replace beltguard.
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.
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.
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.
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)
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.
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.
a. Remove the inlet and discharge lines on the 3rd 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.
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.
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.
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.
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.
6.17.6 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
Foot Pounds
4V4B-6.1 32
Table 6-3 Clearances and Tolerances
Refer to Dwgs. D3886 & B11165
Nominal
Indicator Dimensions Wear Limit
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:
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)
Note: The compression cylinder assemblies and crankcase are detailed on separate
drawings and parts lists, on pages following.
*Recommended Spares
P/N: MAN-4V4B-6.1-P1A, B, C, D 36
COMPRESSOR PARTS LIST
MODEL 4V4B-6.1-P1 A, B, C & D
REF. CROSS SECTION/ASSEMBLIES (PG 53-65)
*Recommended Spares
P/N: MAN-4V4B-6.1-P1A, B, C, D 37
COMPRESSOR PARTS LIST
MODEL 4V4B-6.1-P1 A, B, C & D
REF. CROSS SECTION/ASSEMBLIES (PG 53-65)
*Recommended Spares
P/N: MAN-4V4B-6.1-P1A, B, C, D 38
COMPRESSOR PARTS LIST
MODEL 4V4B-6.1-P1 A, B, C & D
REF. CROSS SECTION/ASSEMBLIES (PG 53-65)
*Recommended Spares
P/N: MAN-4V4B-6.1-P1A, B, C, D 39
COMPRESSOR PARTS LIST
MODEL 4V4B-6.1-P1 A, B, C & D
REF. CROSS SECTION/ASSEMBLIES (PG 53-65)
*Recommended Spares
P/N: MAN-4V4B-6.1-P1A, B, C, D 40
CRANKCASE ASSEMBLY PARTS LIST
MODEL 4V4B-6.1-P1 A, B, C & D
RIX ASSEMBLY A100-D2267
REF. CRANKCASE (PG 66-68)
*Recommended Spares
P/N: MAN-4V4B-6.1-P1A, B, C, D 41
CRANKCASE ASSEMBLY PARTS LIST
MODEL 4V4B-6.1-P1 A, B, C & D
RIX ASSEMBLY A100-D2267
REF. CRANKCASE (PG 66-68)
*Recommended Spares
P/N: MAN-4V4B-6.1-P1A, B, C, D 42
CRANKCASE ASSEMBLY PARTS LIST
MODEL 4V4B-6.1-P1 A, B, C & D
RIX ASSEMBLY A100-D2267
REF. CRANKCASE (PG 66-68)
*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)
P/N: MAN-4V4B-6.1-P1A, B, C, D 44
ACCESSORY PARTS LIST
MODEL 4V4B-6.1-P1A, B, C & D
REF. FLOW SCHEMATIC (PG 69)
P/N: MAN-4V4B-6.1-P1A, B, C, D 45
ACCESSORY PARTS LIST (CONT'D)
MODEL 4V4B-6.1-P1A, B, C & D
REF. ACCESSORIES DRAWING (PG 70-71)
P/N: MAN-4V4B-6.1-P1A, B, C, D 46
PLUMBING PARTS LIST
MODEL 4V4B-6.1-P1A, B, C & D
REF. PLUMBING SCHEMATIC (PG 72)
IMPORTANT: When ordering replacements, specify "Oxygen Cleaned"
P/N: MAN-4V4B-6.1-P1A, B, C, D 47
PLUMBING PARTS LIST
MODEL 4V4B-6.1-P1A, B, C & D
REF. PLUMBING SCHEMATIC (PG 72)
IMPORTANT: When ordering replacements, specify "Oxygen Cleaned"
P/N: MAN-4V4B-6.1-P1A, B, C, D 48
ELECTRICAL PARTS LIST
MODEL 4V4B-6.1-P1A, B, C & D
REF. ELECTRICAL BOX (PG 73-76)
P/N: MAN-4V4B-6.1-P1A, B, C, D 49
ELECTRICAL PARTS LIST
MODEL 4V4B-6.1-P1A, B, C & D
REF. ELECTRICAL BOX (PG 73-76)
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
Cross Section (Cont’d)
P/N: MAN-4V4B-6.1-P1A, B, C, D 55
Cross Section (Cont’d)
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:
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.
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