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KIRLOSKAR KC3 - User Manual

KIRLOSKAR KC3
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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
    Jennifer BrownAug 16, 2025
    Why is the delivery pressure too high in my KIRLOSKAR Air Compressor?
    • K
      Kevin BrownAug 16, 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.
  • J
    Jacqueline SmithAug 22, 2025
    What to do if delivery pressure is too low in KIRLOSKAR Air Compressor?
    • R
      Ryan HarrisAug 22, 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.
  • K
    Keith LeonAug 25, 2025
    Why is the suction pressure too high in my KIRLOSKAR KC3?
    • Z
      Zachary RobinsonAug 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.
  • C
    Chad StoneAug 27, 2025
    What causes malfunctioning of loading/unloading operation of compressors KIRLOSKAR?
    • C
      Charlotte HolderAug 27, 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.
  • J
    Julia MirandaAug 30, 2025
    How to fix low suction pressure in KIRLOSKAR KC3 Air Compressor?
    • B
      Brandon SchmidtAug 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.
  • G
    gilbertbarrySep 2, 2025
    What causes high oil consumption in KIRLOSKAR Air Compressor?
    • S
      Sarah MaynardSep 2, 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.
  • M
    Maria ElliottSep 4, 2025
    What is liquid stroke in KIRLOSKAR KC3 and how to prevent it?
    • N
      Natalie BlackSep 4, 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.
  • B
    bthomasSep 7, 2025
    Why is oil pressure too low in my KIRLOSKAR KC3 Air Compressor?
    • V
      vwhiteSep 7, 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.
  • D
    Deborah MillerSep 10, 2025
    What causes high oil pressure during running in KIRLOSKAR Air Compressor?
    • R
      richard94Sep 10, 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.
  • M
    Matthew Vega DDSSep 10, 2025
    What causes leakage of shaft seal in KIRLOSKAR KC3 and how to fix it?
    • G
      George RasmussenSep 12, 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.

Summary

Safety Guidelines

General Safety Considerations

Discusses review of safety programs, hazards, protective guards, shutdown devices, and overpressure protection.

Operational Dos and Do Nots

Lifting and Hauling Procedures

Compressor Preservation

Pre-Operation Checks and Procedures

Pre-Starting Compressor Checks

List of essential checks before starting the compressor.

Priming Procedures

Steps for priming the compressor with oil before starting.

Post-Commissioning Maintenance

Compulsory maintenance tasks and log book keeping.

Constructional Details

Lubrication Diagram

Lubricating Chart

Recommended Lubricants for KC Series

Table listing recommended oils for different refrigerants and temperatures.

Safety Valve Function

General Operating Instructions

Compressor Operation Procedure

Step-by-step guide for starting and operating the compressor.

Liquid Stroke Precautions

Information on liquid stroke, its causes, and potential damage.

Safety Rules for Ammonia

Precautions related to ammonia handling, storage, and leakage.

Preparation for Compressor Operation

System Evacuation for Freon Plants

Drying and Evacuation Procedure

Detailed steps for drying and evacuating Freon systems.

Ammonia Plant Evacuation

Evacuation Using Compressor

Procedure for evacuating ammonia systems with the compressor.

Refrigerant Charging Procedure

Purging the Refrigerating Plant

Compressor Starting Procedure

Initial Startup Steps

Detailed steps for initial compressor startup.

Compressor Stopping Procedure

Capacity Control: Single Stage Compressors

Part Load Operation Limits: Single Stage

Single Stage Capacity Control Diagrams

More Single Stage Capacity Control Diagrams

Two Stage Capacity Control Diagrams

More Two Stage Capacity Control Diagrams

Final Two Stage Capacity Control Diagrams

Two Stage Compressor Operation and Control

Two Stage Compressor Starting Procedure

Steps for starting and loading two-stage compressors carefully.

Steps of Operation for Two Stage Compressors

Detailed operational steps for two-stage compressors.

Two Stage Compressor Operational Limits

Field Application Diagram

Parallel Compressor Operation

Periodical Maintenance and Schedule

General Maintenance Recommendations

Importance of regular maintenance for performance and cost.

Periodical Inspection Guidelines

Schedule and importance of periodic inspections.

Valve Maintenance and Inspection

Procedures for inspecting, repairing, and replacing valves.

Safety Valve Inspection

Guidelines for inspecting safety valves.

Piston Ring Inspection

Procedure for checking piston ring gap clearance.

Bearing Inspection

Recommendations for inspecting compressor bearings.

Lubrication Instructions

Oil Change and Topping Up Frequency

Log Sheet

Maintenance Schedule

Compressor Accessories

Pressure Switches (Pressostats)

Function and installation of pressure switches for safety.

Trouble Shooting Chart

High Delivery Pressure Troubleshooting

Common causes and remedies for high delivery pressure.

Low Delivery Pressure Troubleshooting

Common causes and remedies for low delivery pressure.

High Suction Pressure Troubleshooting

Common causes and remedies for high suction pressure.

Low Suction Pressure Troubleshooting

Common causes and remedies for low suction pressure.

Liquid Stroke Troubleshooting

Causes and remedies for liquid stroke issues.

High Oil Pressure During Running Troubleshooting

Causes and remedies for high oil pressure during operation.

Low Oil Pressure Troubleshooting

Causes and remedies for low oil pressure.

Small Pressure Difference Troubleshooting

Causes and remedies for small pressure difference between suction and delivery.

Trouble Shooting Chart (Continued)

Warm HP Safety Valve Suction Side Troubleshooting

Causes and remedies for warm HP safety valve suction side.

High Oil Consumption Troubleshooting

Causes and remedies for excessive oil consumption.

Shaft Seal Leakage Troubleshooting

Causes and remedies for shaft seal leakage.

Loading;Unloading Operation Malfunction Troubleshooting

Causes and remedies for issues with capacity control.

Recommended Spare Parts

List of Recommended Spare Parts

Spare Parts Ordering Procedure

Illustrated Spare Parts List

Crankcase Assembly with Safety Valve (Figures-31)

Bearing Covers and Intermediate Bearing (Figures-32)

Crankshaft Assembly Parts

Piston and Connecting Rod (Figure-34)

Connecting Rod Assembly with Needle Roller Bearing (Two Stage HP Side)

Cylinder Liner and Valve Lifting Mechanism (Figure No. 36)

Suction & Discharge Valve Assembly (Figure No. 37)

Shaft Seal Assembly (Figure No.38)

Oil Pump Assembly (Figure No. 39)

Oil Filter Assembly (Figure No. 40)

Lubricating Oil Lines (Figure No. 41)

Suction Gas Strainer Assembly (Figure No. 42)

Pressure Gauges and Cut-Outs

Pressure Cut-Outs Specifications

Pressure Gauges Specifications

Precautions to Prevent Compressor Failures

Source of System Dirt Entry

Identifying sources of contaminants entering the compressor system.

Prevention of System Dirt Entry

Measures to prevent dirt from entering the compressor.

Compressor Prevention Measures

Specific steps to take before and after initial compressor runs.

Restart Procedure After Maintenance

Steps for restarting the compressor after work is done.

Important Installation Checks

Crankshaft Rusting Prevention During Installation

Precautions against crankshaft rusting during installation.

Coupling, Flywheel, Motor Pulley Fitment

Guidelines for fitting coupling, flywheel, and motor pulley.

Base Frame Installation

Instructions for installing and leveling the base frame.

Stop Valves Installation and Preparation

Piping Connection Guidelines

Liquid Floodback During Off Cycle

Preventing liquid floodback on R12/R22 systems.

KIRLOSKAR KC3 Specifications

General IconGeneral
BrandKIRLOSKAR
ModelKC3
CategoryAir Compressor
LanguageEnglish

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