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KIRLOSKAR KC12 - User Manual

KIRLOSKAR KC12
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Kirloskar KC Series Refrigeration Compressors
Instruction and
Operation Manual
Versions:
Single Stage : KC2, KC3, KC4, KC6, KC9, KC12
Two Stage : KC21, KC31, KC42, KC51, KC63, KC72, KC84,
KC93 & KC102
KIRLOSKAR
KIRLOSKAR PNEUMATIC CO. LTD.
Kirloskar Refrigeration
INDIAN REGISTER
©
OF SHIPPING 1993
MGMT. SYS.
RvA C 071
ISO 9001 : 2000

Table of Contents

Questions and Answers

  • J
    Jaime LopezAug 17, 2025
    Why is the delivery pressure too high in my KIRLOSKAR Air Compressor?
    • M
      michaelmclaughlinAug 17, 2025
      The delivery pressure might be too high due to several reasons: * The delivery stop valve is not open wide enough. Open it fully. * There is less or too warm cooling water. Increase the water supply. * The gas suction pressure is too high (during starting-up period only). Partially close the suction stop valve. * The suction pressure is higher than normal. Refer to fault No. 9.3. * There is too much refrigerant in the condenser. Open the liquid control valve further or release some liquid from the system. * The condenser tubes are blocked or dirty. Clean the condenser. * There is air in the system. Purge the system. * The delivery pressure gauge is defective. Repair it.
  • A
    amanda37Aug 20, 2025
    What causes leakage of shaft seal in KIRLOSKAR KC12 Air Compressor and how to fix it?
    • J
      Jeffery Mckay DDSAug 20, 2025
      Leakage of the shaft seal can occur due to several reasons: * Worn out 'O' rings: Replace them. * Scratch marks on sealing faces: Lap the faces up to 2 light bands or replace sealing faces. * Dirty oil: Change the oil, and also clean the seal assembly and seal chamber. * Excessive axial thrust: Adjust axial thrust. * Scratch marks on shaft seal areas of the crankshaft: Lap shaft on seal area. * Losing of spring effect: Replace springs. * Oil flow inadequate to shaft seal cooling: Check the oil pump and its piping for blocking the oil passage. Adjust recommended oil pressure on the pressure regulator.
  • L
    Lee HarrisonAug 23, 2025
    What to do if delivery pressure is too low in KIRLOSKAR Air Compressor?
    • D
      Derek CarsonAug 23, 2025
      If the delivery pressure is too low, consider the following possible causes: * The H.P. safety valve is leaking: Repair or renew it. * The suction stop valve is not open wide enough: Open it fully. * The suction pressure is lower than normal: Refer to fault No. 9.4. * The delivery pressure gauge is faulty: Repair or renew it. * The delivery valve is defective: Replace it.
  • M
    melissapattersonAug 26, 2025
    Why is the suction pressure too high in my KIRLOSKAR KC12 Air Compressor?
    • M
      Michele StarkAug 26, 2025
      A high suction pressure can be caused by: * The liquid control valve being open too wide: Readjust the setting. * A leaking H.P. safety valve: Repair or replace it. * A defective pressure gauge: Repair or replace it. * The capacity control being out of order (if fitted): Inspect and repair it. * Defective suction or delivery valves: Renew them. * Excessive leakage past the piston: Replace the piston rings.
  • T
    Tara JonesAug 28, 2025
    What causes malfunctioning of loading/unloading operation of compressors KIRLOSKAR?
    • H
      harrisivanAug 28, 2025
      Malfunctioning of loading/unloading operation of compressors could happen because: * Solenoid valve not functional well due to: 1. Chattering of valve coil, 2. Valve top and bottom seat damaged or blocked. 3. Plunger neoprene seat swelled excessively: Check continuity of coil and wiring to solenoid valve. * No sufficient actuating pressure to unloader assembly: Repair or place valves seat part. * Capacity control piston 'O' ring and piston ring worn out: Replace or cut excessive swelled portion of neoprene seat. * Blockage of control lines: Check oil control lines for blockage and repair/replace.
  • C
    Christine MorganAug 30, 2025
    How to fix low suction pressure in KIRLOSKAR KC12 Air Compressor?
    • J
      John JonesAug 30, 2025
      Low suction pressure can occur due to: * The suction stop valve not being open wide enough: Open it fully. * The liquid control valve not being open wide enough: Open it further. * The refrigerant suction strainer being chocked: Clean it. * There being less refrigerant in the system: Top up with refrigerant.
  • R
    Rhonda McdanielSep 3, 2025
    What causes high oil consumption in KIRLOSKAR Air Compressor?
    • H
      hartangelaSep 3, 2025
      Excessive oil consumption in your air compressor can stem from: * A defective or chocked automatic oil return valve from the oil separator: Repair or replace/clear it. * Worn piston rings: Fit new piston rings. * Defective oil return valve(s) in cylinder jackets: Replace them.
  • K
    kaufmanchristopherSep 5, 2025
    What is liquid stroke in KIRLOSKAR Air Compressor and how to prevent it?
    • J
      Janet JonesSep 5, 2025
      Liquid stroke can be caused by: * The liquid control valve being open too wide: Readjust the setting. * The capacity control being out of order (if fitted): Inspect and repair it. * A defective evaporator float (if fitted): Inspect and repair or replace it.
  • D
    Daniel LevineSep 8, 2025
    Why is oil pressure too low in my KIRLOSKAR KC12?
    • D
      drogersSep 8, 2025
      Low oil pressure can be attributed to: * The oil pressure differential pressostat probably operates: Repair/Readjust it. * The oil pressure regulator is defective: Top up with oil. * Insufficient oil in the crankcase: See fault No. 9.4. * Suction pressure too low: Clean it. * The oil suction and/or delivery strainer is blocked: Clean out or repair it. * The oil return pipe between the crankcase and oil suction strainer is blocked: Refit it. * Slack bearings: Clean-out.
  • K
    kennethschneiderSep 12, 2025
    What causes high oil pressure during running in KIRLOSKAR Air Compressor?
    • P
      pdaySep 12, 2025
      High oil pressure during running can be caused by: * The oil pressure regulator being defective or maladjusted: Repair or readjust it. * A defective pressure gauge: Repair or renew it.

Summary

SAFETY

Dos & Do Nots

PRESERVATION OF REFRIGERATION COMPRESSOR

TECHNICAL DATA & OVERALL DIMENSIONS

GENERAL TECHNICAL DATA (Single Stage Compressor)

Detailed specifications for single-stage KC compressors, including dimensions and connections.

General Technical Data: (Two Stage Compressor)

Detailed specifications for two-stage KC compressors, including dimensions and connections.

CONSTRUCTIONAL DETAILS

GENERAL OPERATING INSTRUCTIONS

OPERATION OF COMPRESSOR

Step-by-step guide for compressor operation, including start-up and loading.

LIQUID STROKE

Explanation of liquid stroke, its causes, and potential damage to the compressor.

SAFETY RULES: AMMONIA:

Safety precautions and handling guidelines for ammonia refrigerant.

CAPACITY CONTROL SYSTEM - SINGLE STAGE COMPRESSOR

LIMITS OF PART LOAD OPERATION - SINGLE STAGE COMPRESSOR

OPERATING INSTRUCTION AND CAPACITY CONTROL SYSTEM TWO STAGE COMPRESSOR

STARTING OF TWO STAGE COMPRESSOR

LIMITS OF OPERATIONS

DETERMINATION OF LIMITS OF OPERATION

PARALLEL OPERATION OF COMPRESSOR

INSTALLATIONS PRECAUTIONS

PERIODICAL MAINTENANCE AND ITS SCHEDULE

PERIODICAL INSPECTION

VALVES

Procedure for inspecting, repairing, or replacing compressor valves.

SAFETY VALVES

Inspection and maintenance procedures for safety valves to ensure proper function.

PISTON RINGS

Inspection and replacement guidelines for piston and scraper rings.

BEARINGS

Inspection procedures for main bearings and connecting rod bolts.

SHAFT SEAL

OIL PUMP

Maintenance and dismantling procedures for the oil pump.

OIL STRAINER

REFRIGERANT SUCTION STRAINER

LUBRICATION INSTRUCTIONS

Importance of lubrication records and procedures for oil renewal and topping up.

MAINTENANCE SCHEDULE

Summary of maintenance actions required at different operating hours.

ACCESSORIES

PRESSURE SWITCHES

Function and importance of pressure switches (pressostats) for compressor safety.

HIGH PRESSURE PRESSOSTAT

Protection against excessive delivery pressure using HP pressostat.

LOW PRESSURE PRESSOSTAT

Protection against low suction pressure using LP pressostat.

OIL PRESSURE DIFFERENTIAL PRESSOSTAT

Protection against low oil pressure using differential pressostat.

COMBINED HP;LP PRESSOSTAT

CRANKCASE HEATER

TROUBLE SHOOTING CHART

FAULT ANALYSIS

Troubleshooting chart for common compressor faults and their causes and remedies.

RECOMMENDED SPARES

ORDERING OF SPARE PARTS

ILLUSTRATED SPARES PARTS LIST

OIL PUMP ASSEMBLY (Figure No. 39)

OIL FILTER ASSEMBLY (Figure No. 40)

PRECAUTIONS TO PREVENT FAILURES ON COMPRESSORS

SOURCE OF ENTRY

Identification of common sources of system dirt that can damage compressors.

PREVENTION

Measures to prevent system dirt entry, including flushing and using cloth bags.

PREVENTION FOR COMPRESSOR

Initial checks, oil changes, and strainer cleaning procedures for compressor longevity.

RESTART

KEEP YOU SAFE

Critical safety warnings and instructions for operating the compressor safely.

IMPORTANT INSTALLATION CHECKS

CRANKSHAFT RUSTING OCCURRING IN THE FIELD

Steps to prevent crankshaft rusting during installation and fitment.

COUPLING;FLYWHEEL;MOTOR PULLEY FITMENT

Guidelines for fitting flywheel, motor pulley, and checking alignment.

BASE FRAME

Instructions for foundation, base frame installation, and compressor mounting.

LIQUID FLOODBACK DURING OFF CYCLE

KIRLOSKAR KC12 Specifications

General IconGeneral
ModelKC12
TypeReciprocating
Power SourceElectric
Free Air Delivery120 L/min
Maximum Pressure8 bar (116 psi)

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