EasyManua.ls Logo

KIRLOSKAR KC4 - User Manual

KIRLOSKAR KC4
58 pages
Save Page as PDF
Print Icon
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Loading...
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

  • T
    Terry HintonAug 17, 2025
    Why is the delivery pressure too high in my KIRLOSKAR KC4?
    • A
      Ashley RodriguezAug 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.
  • B
    Brandon RichardAug 20, 2025
    What causes leakage of shaft seal in KIRLOSKAR Air Compressor and how to fix it?
    • S
      Susan Fisher MDAug 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.
  • A
    Andrew DeckerAug 22, 2025
    What to do if delivery pressure is too low in KIRLOSKAR KC4?
    • N
      Nathan LittleAug 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.
  • D
    Denise AdamsAug 25, 2025
    Why is the suction pressure too high in my KIRLOSKAR KC4?
    • R
      Richard RoblesAug 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.
  • N
    Nancy MartinAug 27, 2025
    What causes malfunctioning of loading/unloading operation of compressors KIRLOSKAR?
    • M
      Michael RyanAug 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.
  • D
    Douglas HuntAug 30, 2025
    How to fix low suction pressure in KIRLOSKAR KC4 Air Compressor?
    • C
      cgoodmanAug 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.
  • I
    ismithSep 2, 2025
    What causes high oil consumption in KIRLOSKAR KC4 Air Compressor?
    • C
      Claudia HallSep 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
    Melissa PerrySep 5, 2025
    What is liquid stroke in KIRLOSKAR KC4 Air Compressor and how to prevent it?
    • C
      Christopher BeltranSep 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
    Denise BaileySep 8, 2025
    Why is oil pressure too low in my KIRLOSKAR KC4 Air Compressor?
    • J
      Jacqueline KellySep 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.
  • N
    Nathaniel ArcherSep 10, 2025
    What causes high oil pressure during running in KIRLOSKAR KC4?
    • D
      Douglas SmithSep 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 Guidelines

Dos and Do Nots

Essential guidelines for safe operation, maintenance, and handling of the compressor.

Handling and Storage

Lifting and Handling Guidelines

Proper planning and precautions for lifting and handling the compressor to avoid damage.

Lifting Slings and Shackles Selection Guideline

Guideline for selecting appropriate lifting slings and shackles for material handling.

Compressor Preservation

Pre-Operation Checks and Procedures

Startup Checks and Priming

Checks and priming procedures before starting the compressor and during initial runs.

Compressor Operation and Loading

Guidelines for compressor operation and cylinder loading for single and two-stage units.

Mandatory Maintenance Schedule

Schedule for oil, filter, and strainer checks after initial run and subsequent periods.

Technical Data and Overall Dimensions

Constructional Details

Compressor Component Details

Safety Valve Function

Details on the safety valve, its function, and the importance of its proper operation.

General Operating Instructions

Compressor Operation

Detailed steps for operating the compressor, including no-load starting and bringing cylinders on load.

Liquid Stroke Hazards

Explanation of liquid stroke, its potential for damage, and protective devices.

Safety Rules: Ammonia

Precautions related to ammonia handling, storage, and potential health hazards.

Operation Procedures and Safety

Safety Rules: Freon

Safety precautions for Freon, including its characteristics and leak detection.

Preparation for Compressor Operation

Oil Charging Procedure

Oil Pressure Adjustment

Plant Operation Procedures

Leak Test Procedure

Method for testing the plant's soundness using gas pressure, typically air or nitrogen.

Evacuation for Freon Plants

Detailed steps for evacuating Freon systems using a compressor and vacuum pump.

Evacuation for Ammonia Plants

Procedure for evacuating ammonia plants using only the compressor.

System Charging and Purging

Refrigerant Charging

Steps for charging the system with refrigerant after leak testing and evacuation.

Refrigerating Plant Purging

Compressor Starting Procedure

Step-by-step guide for starting the compressor, including initial oil pickup and operation.

Supervision During Operation

Compressor Stopping Procedure

Capacity Control System: Single Stage

Part Load Operation Limits: Single Stage

Advisories on operating single-stage compressors at minimum capacity steps and discharge temperature limits.

Operating Instructions and Capacity Control: Two Stage

Starting Two Stage Compressors

Careful procedure for starting and loading two-stage compressors to avoid temperature/pressure issues.

Two Stage Operation Steps

Sequence of operations for starting and increasing capacity, considering evaporation and condensing temperatures.

Capacity Control Limits and Examples

Limits of Operation

Guidelines on using capacity control steps for pull-down and minimum load requirements.

Determining Capacity Control Limits

Methodology for determining minimum capacity steps for reduced heat loads and avoiding operational issues.

Parallel Operation of Compressors

Parallel Operation Installation Precautions

Periodical Maintenance and Schedule

Periodic Inspection and Component Maintenance

Guidelines for periodic inspection and maintenance of valves, piston rings, and bearings.

Safety Valve Inspection

Piston Ring Inspection

Compressor Maintenance Procedures

Lubrication Instructions

Importance of lubrication records, oil renewal, topping up procedures, and oil pressure checks.

Maintenance Schedule

Accessories and Controls

Pressure Switches (Pressostats)

Function and importance of pressure switches for safety and operational control.

High Pressure Pressostat

Low Pressure Pressostat

Oil Pressure Differential Pressostat

Protection provided by the oil pressure differential pressostat against low oil pressure.

Trouble Shooting Chart

Pressure Issues (Suction;Discharge)

Troubleshooting high/low suction and discharge pressure issues.

Oil System Issues

Troubleshooting high/low oil pressure and high oil consumption.

Operational and Mechanical Issues

Troubleshooting liquid stroke, pressure difference, loading/unloading malfunctions.

Safety Valve and Shaft Seal Issues

Troubleshooting warm HP safety valve side and shaft seal leakage.

Recommended Spares

Ordering Spare Parts

Illustrated Spare Parts List

Stop Valve Assembly and Pressure Components

Pressure Cut-Outs

Pressure Gauges

Precautions to Prevent Failures

Source of Entry for Failures

Identification of common sources of system dirt that cause compressor failures.

Prevention of System Dirt Entry

Methods to avoid dirt entry, including flushing systems and using cloth bags in strainers.

Compressor Prevention Measures

Steps to take before first start and during initial runs to prevent compressor damage.

Restart Procedures and Precautions

Guidelines for restarting the compressor, using new oil, and checking pressure settings.

Important Installation Checks

Shaft, Flywheel, and Pulley Fitment

Base Frame and Piping Installation

KIRLOSKAR KC4 Specifications

General IconGeneral
BrandKIRLOSKAR
ModelKC4
CategoryAir Compressor
LanguageEnglish

Related product manuals