KIRLOSKAR KC6 - User Manual

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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

M
Marcus DavisAug 16, 2025
Why is the delivery pressure too high in my KIRLOSKAR KC6 Air Compressor?
- T
  Tom DanielAug 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.
S
Sara PatelAug 19, 2025
What causes leakage of shaft seal in KIRLOSKAR KC6 and how to fix it?
- R
  Rachael SolisAug 19, 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.
E
Eric WoodsAug 22, 2025
What to do if delivery pressure is too low in KIRLOSKAR Air Compressor?
- C
  Cody JonesAug 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.
Y
Yolanda BarrAug 25, 2025
Why is the suction pressure too high in my KIRLOSKAR KC6 Air Compressor?
- S
  Stephanie PerezAug 25, 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.
M
Matthew ChambersAug 27, 2025
What causes malfunctioning of loading/unloading operation of compressors KIRLOSKAR?
- P
  Philip FlemingAug 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
Danielle RossAug 30, 2025
How to fix low suction pressure in KIRLOSKAR KC6 Air Compressor?
- B
  Brandon StephensAug 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.
J
Jose AdamsSep 2, 2025
What causes high oil consumption in KIRLOSKAR Air Compressor?
- M
  Michael LyonsSep 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
Monica DonaldsonSep 4, 2025
What is liquid stroke in KIRLOSKAR KC6 and how to prevent it?
- K
  Krystal PettySep 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.
V
vwebbSep 7, 2025
Why is oil pressure too low in my KIRLOSKAR Air Compressor?
- S
  spencetammySep 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 Watts MDSep 10, 2025
What causes high oil pressure during running in KIRLOSKAR KC6?
- S
  Stephanie BaxterSep 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

Constructional Details

SAFETY VALVE

Details on safety valve inspection and function.

General Operating Instructions

OPERATION OF COMPRESSOR

Procedure for compressor start-up and normal running.

LIQUID STROKE

Risks and consequences of liquid refrigerant entry.

SAFETY RULES: AMMONIA

Safety precautions when using ammonia.

SAFETY RULES: FREON

Safety precautions when using Freon refrigerant.

PREPARATION FOR COMPRESSOR OPERATION

Steps before initial compressor run.

OIL CHARGING

Procedure for filling the compressor with oil.

OIL PRESSURE ADJUSTMENT

How to adjust the oil pressure regulator.

EVACUATION OF SYSTEM WITH COMPRESSOR AND VACUUM PUMP FOR FREON PLANTS

Procedure for evacuating Freon systems.

EVACUATION OF THE SYSTEM WITH COMPRESSOR ALONE FOR AMMONIA PLANT

Procedure for evacuating Ammonia systems.

REFRIGERANT CHARGING

Process for charging refrigerant into the system.

PURGING REFRIGERATING PLANT

Procedure for removing air and moisture from the plant.

PRESSOSTATS

Function and settings of pressure switches.

STARTING

Detailed procedure for starting the compressor.

SUPERVISION DURING OPERATION

Checks to perform while compressor is running.

STOPPING

Procedure for stopping the compressor.

Operating Instruction and Capacity Control System Two Stage Compressor

STARTING OF TWO STAGE COMPRESSOR

Procedure for starting and loading two-stage compressors.

STEPS OF OPERATION

Detailed steps for two-stage compressor operation.

Parallel Operation of Compressor

INSTALLATIONS PRECAUTIONS

Safety measures for installing parallel compressors.

Periodical Maintenance and its Schedule

VALVES

Maintenance procedures for compressor valves.

SAFETY VALVES

Inspection and maintenance of safety valves.

PISTON RINGS

Inspection and replacement of piston rings.

BEARINGS

Inspection and maintenance of compressor bearings.

SHAFT SEAL

Maintenance and inspection of the shaft seal.

OIL PUMP

Maintenance and overhaul of the oil pump.

OIL STRAINER

Cleaning and replacement of oil strainers.

REFRIGERANT SUCTION STRAINER

Maintenance procedures for suction strainers.

LUBRICATION INSTRUCTIONS

Guidelines for compressor lubrication and oil checks.

MAINTENANCE SCHEDULE

Summary table of maintenance tasks by hours.

Trouble Shooting Chart

Delivery pressure too high

Delivery pressure too low

Suction pressure too high

Suction pressure too low

Liquid stroke

Troubleshooting issues related to liquid refrigerant.

Oil pressure too high during running

Oil pressure too low

Pressure difference between suction and delivery pressures too small

Oil consumption too high

Leakage of shaft seal

Malfunctioning of loading;unloading operation of compressors

Recommended Spares

10.3 ORDERING OF SPARE PARTS

Illustrated Spares Parts List

Precautions to Prevent Failures on Compressors

12.1 SOURCE OF ENTRY

12.2 PREVENTION

12.3 PREVENTION FOR COMPRESSOR

12.4 RESTART

IMPORTANT INSTALLATION CHECKS

Key checks to perform during compressor installation.

KIRLOSKAR KC6 Specifications

General

Brand	KIRLOSKAR
Model	KC6
Category	Air Compressor
Language	English

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