Intermech BBR-6015-2 User manual

Compressor Service Manual
Customer :
Company Origin Energy
Address 1 King William Street
City/State Adelaide, South Australia
ZIP Code 5000
Phone +61 8 8217 5211 (reception)
Fax +61 8 8217 5768 (reception)
Site Location East Perth Bus Depot, Kensington Street,
East Perth, Western Australia, 6004
Product Compressor BBR- 6015-2 Vol. 2 (J1563)
Model No CO-BBR-6015-2
Serial No R4837; R5081
INTERMECH LTD.
88 Leonard Road, Penrose
PO Box 12284, Penrose
Auckland, New Zealand
Ph 64 (9) 525 2220
Fax 64 (9) 579 3900
Email [email protected]

REVISIONS RECORD
Revision Date Changes / Additions Issued
1 March,2006 New edition

Table of Contents
1GENERAL.....................................................................................................................................6
1.1 INTRODUCTION.......................................................................................................................6
1.1.1 Compressor General Arrangement -(BBR-6015-2)..........................................................7
1.1.2 Compressor GA – X-Section (BBR-6015-2) .....................................................................8
1.1.3 Compressor Parts List - (BBR-6015-2) ............................................................................9
2SAFETY.......................................................................................................................................10
2.1 GENERAL SAFETY ................................................................................................................10
2.2 MAINTENANCE SAFETY........................................................................................................11
3COMPRESSOR SPECIFICATION..........................................................................................13
3.1 MODEL.................................................................................................................................13
3.2 DESIGN SPECIFICATION........................................................................................................13
3.3 MANUFACTURER’S PLATE & LABEL INFORMATION.............................................................13
3.3.1 Specification Plate..........................................................................................................13
3.3.2 Cylinder Identification Plate ..........................................................................................14
3.3.3 Suction Identification Plate ............................................................................................14
3.3.4 Discharge Identification Plate........................................................................................14
3.3.5 Warning Plate.................................................................................................................15
3.3.6 Rotation Plate.................................................................................................................15
3.4 CLEARANCES .......................................................................................................................15
3.4.1 Original Running Clearances.........................................................................................15
3.4.2 Piston Ring Side Clearances / End Gaps........................................................................16
3.4.3 Piston to Cylinder Clearances........................................................................................18
3.4.4 Torque Settings...............................................................................................................18
3.4.5 Rhino Compressor Tools ................................................................................................20
3.5 OPERATING PROCEDURES ....................................................................................................21
3.5.1 Start Up Check List Contents .........................................................................................21
3.5.2 Package Details..............................................................................................................21
3.5.3 Prior to Starting..............................................................................................................22
3.5.3 Prior to Starting..............................................................................................................22
3.5.4 After Starting ..................................................................................................................23
3.5.5 Maximum Allowable Working Pressure .........................................................................23
3.6 LUBRICATION.......................................................................................................................24
3.6.1 General Description.......................................................................................................25
3.6.2 Oil Specification.............................................................................................................25
3.6.3 Before Starting................................................................................................................26
3.6.4 Top Up With Oil .............................................................................................................26
3.6.5 Primary Starting.............................................................................................................26
3.6.5.1 Priming the lubrication system using priming pump...........................................................27
3.6.6 Oil Filter.........................................................................................................................28
3.6.7 Lube Oil Pressure Adjustment........................................................................................28
3.6.8 Oil Relief Valve Setting...................................................................................................28
3.6.9 Compression Cylinder Injection Lubrication System .....................................................29
4MAINTENANCE........................................................................................................................30
4.1 GENERAL .............................................................................................................................30
4.2 OIL PUMP (CRA-357) & OIL PUMP HOUSING (CRA-352-1)................................................31
4.2.1 Oil Pump Housing Drawing (CRA-352-1) .....................................................................31
4.2.2 Oil Pump Housing (CRA-352-1) Parts List....................................................................32
4.2.3 Oil Pump Assembly Drawing (CRA-357).......................................................................33
4.2.4 Oil Pump Assembly (CRA-357) Parts List......................................................................34
4.2.5 Oil Pump Relief Valve Drawing (CRA-333)...................................................................35
4.2.6 Oil Pump Relief Valve (CRA-333) Parts List .................................................................36
4.2.7 Disassembly – Oil Pump Housing..................................................................................37
4.2.8 Disassembly – Oil Pump Relief Valve ............................................................................37

4.2.9 Disassembly – Oil Pump.................................................................................................37
4.2.10 Assembly – Oil Pump.................................................................................................38
4.2.11 Oil Pump Relief Valve................................................................................................38
4.2.12 Assembly – Oil Pump Housing (CRA-352)................................................................39
4.3 RHINO CRANKCASE (CRA-3603).........................................................................................40
4.3.1 Rhino Crankcase Drawing (CRA-3603).........................................................................40
4.3.2 Rhino Crankcase Drawing (CRA-3602).........................................................................41
4.3.3 Rhino Crankcase (CRA-3603) Parts List........................................................................42
4.3.4 Rhino Crankcase (CRA-3602) Parts List........................................................................42
4.3.5 Taper Lock Bearing Housing Assembly Drawing (CRA-3640)......................................43
4.3.6 Taper Lock Bearing Housing Assembly Parts List (CRA-3640).....................................44
4.3.7 Rhino Crankcase Filler Bowl Drawing (CRA-820)........................................................45
4.3.8 Rhino Crankcase Filler Bowl (CRA-820) Parts List ......................................................46
4.3.9 Disassembly – Crankshaft (CR-3253) ............................................................................47
4.3.10 Assembly – Crankcase (CRA-3603)...........................................................................48
4.4 DRIVE END BEARING HOUSING / MECHANICAL SEAL ASSEMBLY (CRA-356)....................51
4.4.1 Drive End Bearing Housing / Mechanical Seal Drawing (CRA-356 RevB)...................51
4.4.2 Mechanical Seal Housing (CRA-356) Parts List............................................................52
4.4.3 Disassembly / Assembly - Mechanical Seal....................................................................53
4.5 CONNECTING ROD ASSEMBLY .............................................................................................55
4.5.1 Connecting Rod Assembly Drawing (ROA-8525)...........................................................55
4.5.2 Connecting Rod Assembly Parts List (ROA-8525).........................................................56
4.6 CROSS HEAD CYLINDER/PISTON (CYXA-6003)..................................................................57
4.6.1 X-Head Cylinder Assembly – (CYXA-6003)...................................................................57
4.6.2 X-Head Cylinder Parts List– (CYXA-6003)....................................................................58
4.7 CROSS HEAD CYLINDER/PISTON (CYXA-6004)..................................................................59
4.7.1 X-Head Cylinder Assembly – (CYXA-6004)...................................................................59
4.7.2 X-Head Cylinder Parts List– (CYXA-6004)....................................................................60
4.7.3 Disassembly - Cross-Head Cylinder/Piston ...................................................................61
4.7.4 Assembly - Cross-Head Cylinder/Piston ........................................................................61
4.8 1ST/2ND STAGE CYLINDER/PISTON / PISTON ROD ASSEMBLY .................................................63
4.8.1 Cylinder Assembly – X-Section (CYA-6046-3)...............................................................63
4.8.2 Cylinder Assembly – Exploded View (CYA-6046-3).......................................................64
4.8.3 Cylinder Assembly (CYA-6046-3) Parts List..................................................................65
4.8.4 Cylinder Head Assembly Drawing - (HEA-6000)...........................................................67
4.8.5 Cylinder Head Parts List – (HEA-6000) ........................................................................68
4.8.6 Disassembly – 1st / 2nd Stage Piston...............................................................................69
4.8.7 Reassembly 1st / 2nd Stage Cylinder................................................................................69
4.9 3RD / 4TH STAGE CYLINDER/PISTON/PISTON ROD ASSEMBLY...............................................71
4.9.1 Cylinder Assembly – X-Section (CYA-3015-1)...............................................................71
4.9.2 Cylinder Assembly – Exploded View (CYA-3015-1).......................................................72
4.9.3 Cylinder Assembly (CYA-3015-1) Parts List..................................................................73
4.9.4 Piston Rod Assembly Drawing (ROPA-3280) ................................................................75
4.9.5 Piston Rod Assembly (ROPA-3280) ...............................................................................76
4.9.6 Piston 3.0” x 1.5” Assembly Drawing (PIA-3015-2) .....................................................77
4.9.7 Piston Assembly 3.0” x 1.5” Parts List (PIA –3015-2)..................................................78
4.9.8 Disassembly – Final Stage Cylinder / Piston .................................................................79
4.9.9 Disassembly – 3rd Stage Cylinder / Piston......................................................................79
4.9.10 Assembly- 3rd / 4th Stage Cylinder / Piston.................................................................80
4.10 ROD SEAL HOUSING ASSEMBLY SEA-3503.........................................................................82
4.10.1 Rod Seal Housing Assembly 3.00”– (SEA-3060).......................................................82
4.10.2 Rod Seal Assembly 3.00”– (SEA-3060) Parts List.....................................................83
4.10.3 Disassembly...............................................................................................................83
4.10.4 Assembly....................................................................................................................83
4.11 COMPRESSOR VALVES .........................................................................................................85
4.11.1 Removal .....................................................................................................................85
4.11.2 Installation.................................................................................................................85

Table of Figures
Figure 1 Plan and Elevation of Four-Stage Compressor ____________________________________7
Figure 2 X-Sectional Plan `A-A’_______________________________________________________8
Figure 3 Specification Plate _________________________________________________________13
Figure 4 Cylinder Specification Plate__________________________________________________14
Figure 5 Suction Identification Plate __________________________________________________14
Figure 6 Discharge Identification Plate ________________________________________________14
Figure 7 Warning Plate_____________________________________________________________15
Figure 8 Rotation Plate_____________________________________________________________15
Figure 9 Compressor Tools__________________________________________________________20
Figure 10 Oil Circulation Schematic __________________________________________________24
Table of Tables
Table 1 Specification Chart__________________________________________________________13
Table 2 Original Running Clearance __________________________________________________15
Table 3 Piston Ring End Gaps _______________________________________________________16
Table 4 Piston Ring Side Clearances __________________________________________________17
Table 5 Piston to Cylinder Clearances _________________________________________________18
Table 6 Torque Settings_____________________________________________________________19
Table 7 The Maximum Allowable Working Pressure ______________________________________23

Page 6 of 85
1 General
1.1 Introduction
The Rhino compressor has been developed specifically for CNG/NGV with
the following features :
Gas tight pressurised crankcase, up to 40 bar (600 psig).
Hoerbiger valves for specific performance and reliability.
Double row spherical roller main bearings.
Heavy duty crankcase.
High strength crankshaft, 100-80-3 ductile iron, 89mm (3.5" journals).
Full flow, filtered, pressurised lubrication.
Generous integral cross-head piston bearing surface.
Standardized design, 22 - 200 kW (30 - 270 hp), 0.5-30 bar, (8 - 435psig)
inlet pressure.
High quality oil flooded mechanical crankcase seals.
Double acting two, three or four stage design.
Exclusive low friction cylinder treatment.
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1.1.1 Compressor General Arrangement -(BBR-6015-2)
Figure 1 Plan and Elevation of Four-Stage Compressor
Intermech Ltd. BBR-6015-2 Compressor Service Manual

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1.1.2 Compressor GA – X-Section (BBR-6015-2)
Figure 2 X-Sectional Plan `A-A’
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1.1.3 Compressor Parts List - (BBR-6015-2)
Item
Number Part Number Description Quantity
1 CRA-3603 Crankcase Assy. 1
2 LUB-BBR-SB-6015 RHINO Compressor Lubricator Assembly 1
3 CYA-6046-3 6" x 4.5" Cylinder Assembly 1
4 CYA-3015-1 Cylinder Assy. 3.25" x 1.5" (MT Valve Plates) 1
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2 Safety
2.1 General Safety !!! WARNING !!!
COMPRESSED GAS IS A HIGHLY DANGEROUS
SUBSTANCE
READ AND UNDERSTAND THIS SECTION OF
MANUALS
IT IS ESSENTIAL FOR THE SAFE OPERATION
OF EQUIPMENT
2.1.1. Systems must be entirely vented before repair or maintenance is carried
out.
2.1.2. The installation, operation, maintenance and repair shall be carried out
only by qualified personnel and in accordance with the corresponding
regulations for operation and safety.
2.1.3. No smoking or naked lights within 10m of any gas installation.
2.1.4. Do not adjust, remove or bypass any protective device.
2.1.5. Rotating machine parts represent a special danger. Covers and guards
must not be removed whilst the machine is operating.
2.1.6. Persons operating the compressor should use hearing protection.
2.1.7. Do not store flammable materials e.g. oily rags near the compressor
unit or engine drive.
2.1.8. Supply pipework and other components, which may not be included in
scope of supply, must be suitable for the respective working pressure.
2.1.9. If necessary they have to be tested and protected by a pressure-
unloading device.
2.1.10.Electrical cable must be Flameproof and must not be linked, or allowed
to contact rotating parts.
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2.2 Maintenance Safety
!!! WARNING !!!
COMPRESSED GAS IS A HIGHLY
DANGEROUS SUBSTANCE.
BEFORE DISMANTING ANY PART OF
THE COMPRESSOR, ENSURE THAT THE
UNIT IS COMPLETELY DEPRESSURED
2.2.1. Maintenance and repair may be carried out only on the shutdown and
entirely vented compressor unit. If necessary isolate all storage
systems and blow-down all condensate traps and heat exchanger
collectors. Open all manual drain valves.
2.2.2. Isolate the equipment electrically by pad-locking the main switch in the
"OFF" position and fixing a corresponding warning sign.
2.2.3. Only use original spare parts and recommended products for
maintenance and repair works on the compressor unit.
2.2.4. Never do work that will produce heat, like welding near oil or gas
systems. Before working on oil or gas tanks empty them and clean
them carefully eg. by a steam jet or purge with nitrogen.
2.2.5. During maintenance and repair work observe strict cleanliness. Keep
impurities away, by covering dismounted parts and free openings with
a clean rag, paper or adhesive tape.
2.2.6. After having finished the works be sure that no tools, loose parts or
cleaning rags have been left on or in the compressor unit, or near the
engine air cleaner.
2.2.7. Do not use easily flammable solving agents for cleaning of parts, until
the unit has cooled thoroughly. After the use of solving agents
carefully rinse the parts and clean them with compressed air.
2.2.8. Be very careful, use eye protection, when working with compressed air
for cleaning equipment.
2.2.9. After modification or repair work on pressure vessels and safety
equipment, such as relief valves, all work must be tested and accepted
by the inspection authority concerned.
2.2.10.The switchboard may be opened only by qualified and authorized
persons. Even if the main switch is set to the "OFF" position, the poles
of the switch and feed cables of the terminal strip are alive. Therefore
do not touch anything on the switchboard, and do not carry out work,
with the mains current supply is not disconnected. Before starting
work check if the system is entirely free of power.
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2.2.11.Do not touch bare wires and live (current-carrying) parts, when the
electrical system is energized.
2.2.12.After modification or repair work to compressor, and before power is
supplied to machine, always manually turn compressor over by hand to
ensure compressor is running free.
2.2.13.Intermech takes no responsibility for personal injury or damage on the
unit, caused by the non-observance of the safety precautions during
handling, operation, maintenance or repair of compressor units or other
equipment.
Intermech Ltd. BBR-6015-2 Compressor Service Manual

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3 Compressor Specification
3.1 Model
This package utilises the BBR-6015-2 compressor.
First/Second Stage 6”x 4-1/2” Tandem Acting cylinder
Third Stage 3” Tandem Acting cylinder
Final Stage 1-1/2” Tandem Acting cylinder
3.2 Design Specification
DESCRIPTION IMPERIAL UNITS
STROKE 3.25 inches
ROD LOAD, COMPRESSION 10,000 lbs
ROD LOAD, TENSION 10,000 lbs
FRAME HORSEPOWER to 270 hp
MAX. INTERNAL PRESSURE 600 psi
WEIGHT, APPROXIMATE 1900 lb
RPM to 1800 rpm
OIL PUMP CAPACITY 6 gpm @ 1600rpm
SUMP CAPACITY 4.5 gallons
Table 1 Specification Chart
3.3 Manufacturer’s Plate & Label Information
3.3.1 Specification Plate
Figure 3 Specification Plate
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3.3.2 Cylinder Identification Plate
Figure 4 Cylinder Specification Plate
3.3.3 Suction Identification Plate
Figure 5 Suction Identification Plate
3.3.4 Discharge Identification Plate
Figure 6 Discharge Identification Plate
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3.3.5 Warning Plate
Figure 7 Warning Plate
3.3.6 Rotation Plate
Figure 8 Rotation Plate
Note : Rotation direction is anti-clockwise looking at the compressor from the oil
sight glass side.
3.4 Clearances
3.4.1 Original Running Clearances
Original Running Clearances Minimum Maximum
Connecting rod thrust (side clearance) 0.010” 0.015”
Crankpin bearing (con-rod big end) 0.002” 0.004”
Connecting rod bushing to wrist pin 0.0015” 0.0035”
Crosshead to wrist pin 0.0015” 0.002”
Oil pump impellor assembly end clearance 0.003" 0.005"
Crosshead to guide 0.007” 0.010”
Drive end metering plate to crankshaft 0.002” 0.004”
Table 2 Original Running Clearance
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3.4.2 Piston Ring Side Clearances / End Gaps
Min Max Min Max Min Max
Straight Cut 0.004 0.014 0.042 0.052 0.011 0.021
45º Cut 0.003 0.013 0.030 0.040 0.008 0.018
Straight Cut 0.004 0.014 0.046 0.056 0.012 0.022
45º Cut 0.003 0.013 0.032 0.042 0.008 0.018
Straight Cut 0.004 0.014 0.049 0.059 0.013 0.023
45º Cut 0.003 0.013 0.035 0.045 0.009 0.019
Straight Cut 0.006 0.016 0.082 0.092 0.020 0.030
45º Cut 0.004 0.014 0.058 0.068 0.014 0.024
Straight Cut 0.006 0.016 0.089 0.099 0.022 0.032
45º Cut 0.004 0.014 0.063 0.073 0.015 0.025
Straight Cut 0.006 0.016 0.096 0.106 0.023 0.033
45º Cut 0.004 0.014 0.068 0.078 0.016 0.026
Straight Cut 0.006 0.016 0.103 0.113 0.025 0.035
45º Cut 0.005 0.015 0.072 0.082 0.017 0.027
Straight Cut 0.007 0.017 0.116 0.126 0.028 0.038
45º Cut 0.005 0.015 0.082 0.092 0.019 0.029
Straight Cut 0.007 0.017 0.123 0.133 0.029 0.039
45º Cut 0.005 0.015 0.087 0.097 0.021 0.031
Straight Cut 0.008 0.018 0.129 0.139 0.031 0.041
45º Cut 0.005 0.015 0.091 0.101 0.022 0.032
Straight Cut 0.009 0.019 0.163 0.173 0.038 0.048
45º Cut 0.006 0.016 0.115 0.125 0.027 0.037
Straight Cut 0.010 0.020 0.176 0.186 0.041 0.051
45º Cut 0.007 0.017 0.125 0.135 0.029 0.039
Straight Cut 0.011 0.021 0.216 0.226 0.050 0.060
45º Cut 0.008 0.018 0.153 0.163 0.035 0.045
Straight Cut 0.012 0.022 0.223 0.233 0.052 0.062
45º Cut 0.008 0.018 0.158 0.168 0.036 0.046
Straight Cut 0.012 0.022 0.230 0.240 0.053 0.063
45º Cut 0.008 0.018 0.163 0.173 0.038 0.048
Straight Cut 0.014 0.024 0.270 0.280 0.062 0.072
45º Cut 0.010 0.020 0.191 0.201 0.044 0.054
Ring Gaps
Peek
Ring Material
3.5
Cast Iron
1.5
1.75
Clylinder Size
8.5
3.75
10
6.5
6
4.5
4.75
8
8.25
4.25
1.625
Carbon Teflon *
3.25
3
Table 3 Piston Ring End Gaps
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Side Clearance
Table 4 Piston Ring Side Clearances
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3.4.3 Piston to Cylinder Clearances
Clearances Minimum Maximum
Crosshead piston to guide 0.008" 0.010"
8.0" - 10.0" Dia cylinder 0.035" 0.040"
7.0” – 8.0” Dia cylinder 0.032” 0.037”
6.0" - 7.0" Dia cylinder 0.030" 0.035"
5.0" - 5.25" Dia cylinder 0.025" 0.030"
4.125" – 4.75" Dia cylinder 0.020" 0.025"
3.5" - 4.0" Dia cylinder 0.018" 0.022"
2.75" – 3.25" Dia cylinder 0.015" 0.020"
2.0" – 2.5" Dia cylinder 0.013" 0.018"
1.25" – 1.75" Dia cylinder 0.016" 0.025"
Table 5 Piston to Cylinder Clearances
3.4.4 Torque Settings
Torque Settings Size Type Torque ft-lb
Piston Nut (8” to 8-1/2” Piston) 1-1/8” - UNF 150
3" - 3-1/2" Piston 1" – UNF - 200
Piston Rod to Crosshead Lock Nut 1" – UNF Rod 300
Piston Rod to Crosshead 1" – UNF - 300
Final Stage Cylinder to C.E.Cylinder ¾" – UNC Stud 125
Final Stage Cylinder to C.E.Cylinder ¾" – UNF Stud 106
Final Stage Head ¾" – UNF Stud 140
Cylinder Head. 10" ¾" – UNF Stud 96
Cylinder Head. 6" Thru 8" ¾" – UNF Stud 96
Crosshead Cylinder To Crankcase ¾" – UNF Stud 105
Compression Cylinder To Crosshead
Guide ¾" – UNF Stud 112
Crankcase Inspection Cover 5/8" – UNC Cap Screw 92
Valve Lantern Jacking Screw 5/8" - UNF Socket Set Screw 80
Crankcase Mounting Bolts 5/8" - UNC Hex Bolts 80
Cylinder Head. 4-½" thru’ 3-1/2” 5/8" - UNC Cap Screw 51
Final Stage Discharge Valve Cover ½" – UNF Cap Screw 50
Cylinder Head. 3-1/4" thru’ 3” ½" – UNC Cap Screw 51
Valve Covers ½" – UNC Cap Screw 45
Oil Filter Housing ½" – UNC Cap Screw 53
Split Flange Clamps ½" – UNC Bolt 45
Conrod Bearing Cap ½ " - UNF Cap Screw 62
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Torque Settings Size Type Torque ft-lb
Drive Bearing Housing ½" – UNC Cap Screw 45
Oil Pump Housing to Crankcase ½" – UNC Cap Screw 45
Final Stage Piston Retaining Nut ½" – UNF - 30
Rod Seal Housing to Cylinder ½" – UNF Cap Screw 45
Rod Seal Housing to Cylinder 7/16" - UNF Cap Screw 40
Tandem Piston (5-1/4") to Crosshead 3/8" – UNC Cap Screw 25
Tandem Piston (3" to 3-1/2") to Piston
Rod Lock Bolt 3/8" - UNF Cap Screw 27
Split Flange Clamps 3/8" - UNF Cap Screw 20
Gudgeon Pin End-CapRetaining Bolt
Nut 3/8" UNF Bolt / Nut 30
Mechanical Seal Retainer 5/16 " -UNC Cap Screw 15
Bearing Cover Plate 5/16" - UNC Cap Screw 15
Oil Pump Housing Seal Cover 5/16" -UNC Cap Screw 15
Oil Pump Retainer 5/16" –UNC Cap Screw 17
Final Stage Piston Retaining Plate 5/16" – UNC Cap Screw 22
Piston “Power Nut” Locking Screw
(10” Piston) 5/16” – UNF Grub Screw 12
Rod Wiper Retainer Plate 5/16” – UNF Cap Screw 18
Piston Rod Balance Nut Lock Screw
(Power Nut type) 5/16" UNF Grub Screw 12
Piston Rod Balance Nut Lock Screw
(Standard Balance Nut) ¼" UNF Grub Screw 6
Piston Rod Locking Screw ¼" UNF Grub Screw 6
Table 6 Torque Settings
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3.4.5 Rhino Compressor Tools
Figure 9 Compressor Tools
Intermech Ltd. BBR-6015-2 Compressor Service Manual
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