KIRLOSKAR KC9 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:

E
Eddie ReyesAug 17, 2025
Why is the delivery pressure too high in my KIRLOSKAR KC9 Air Compressor?
- A
  Amber WalkerAug 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.
S
Steven MartinAug 20, 2025
What causes leakage of shaft seal in KIRLOSKAR KC9 Air Compressor and how to fix it?
- S
  swansonmatthewAug 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.
R
Robert WelchAug 22, 2025
What to do if delivery pressure is too low in KIRLOSKAR KC9?
- P
  Pamela RobertsAug 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.
E
elizabeth46Aug 26, 2025
Why is the suction pressure too high in my KIRLOSKAR KC9 Air Compressor?
- J
  Jessica FloresAug 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.
R
Ronald NorrisAug 28, 2025
What causes malfunctioning of loading/unloading operation of compressors KIRLOSKAR?
- M
  Michelle DanielAug 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
danny32Aug 30, 2025
How to fix low suction pressure in KIRLOSKAR KC9?
- P
  Paul GarnerAug 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
richardsonmelissaSep 2, 2025
What causes high oil consumption in KIRLOSKAR Air Compressor?
- J
  James BrownSep 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.
S
Stephanie BairdSep 5, 2025
What is liquid stroke in KIRLOSKAR KC9 and how to prevent it?
- K
  Katrina WilliamsSep 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.
R
Rebecca GoldenSep 8, 2025
Why is oil pressure too low in my KIRLOSKAR KC9?
- K
  Kelly PopeSep 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.
J
Jamie QuinnSep 12, 2025
What causes high oil pressure during running in KIRLOSKAR KC9?
- M
  murrayjohnSep 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.

KIRLOSKAR KC9 Specifications

General

Brand	KIRLOSKAR
Model	KC9
Category	Air Compressor
Language	English

Summary

Kirloskar KC Series Refrigeration Compressors

Safety

Guidelines and precautions for safe operation and maintenance.

Handling

Procedures for unpacking, lifting, and storing the compressor safely.

Maintenance

Procedures for routine inspection, servicing, and schedule.

Before Starting the Compressor

Checks and preparation steps before initial compressor operation.

Salient Features of Construction

Lubrication System & Filter

Details on the compressor's forced lubrication system.

Constructional Details

In-depth breakdown of compressor parts and their construction.

Crankcase and Cylinder Jackets

General Operating Instructions

Fundamental guidelines for operating the compressor.

Operation of Compressor

Step-by-step guide for compressor startup and running.

Liquid Stroke

Information on preventing damage from liquid refrigerant.

Safety Rules: Ammonia

Safety precautions specific to ammonia refrigerant.

Compressor Room

Preparation for Compressor Operation

Steps before initial operation, including oiling and pressure checks.

Oil Charging

Oil Pressure Adjustment

Evacuation of System

Procedures for removing air and moisture from the refrigeration system.

Refrigerant Charging

Procedures for safely charging the system with refrigerant.

Purging Refrigerating Plant

Starting

Detailed procedure for starting the compressor correctly.

Capacity Control System - Single Stage Compressor

How to adjust cooling capacity for single-stage models.

Limits of Part Load Operation

Standard Capacity Control Steps

Operating Instruction and Capacity Control System Two Stage Compressor

Guidelines for operating and controlling two-stage compressors.

Intercoolers

Starting of Two Stage Compressor

Procedure for starting and loading two-stage compressors.

Steps of Operation

Limits of Operations

Parallel Operation of Compressor

Guidelines for installing and operating multiple compressors in parallel.

Installations Precautions

Periodical Maintenance and Its Schedule

Recommended maintenance tasks and their frequency.

Periodical Inspection

Regular checks to ensure compressor health and performance.

Valves

Maintenance procedures for suction and discharge valves.

Safety Valves

Inspection and maintenance of safety valves.

Piston Rings

Bearings

Lubrication Instructions

Critical guidance for compressor lubrication and oil management.

Accessories

Pressure Switches

Function and importance of pressure switches (pressostats).

High Pressure Pressostat

Low Pressure Pressostat

Oil Pressure Differential Pressostat

Trouble Shooting Chart

Identification and resolution of common compressor faults.

Recommended Spares

List of essential spare parts and how to order them.

Ordering of Spare Parts

Pressure Gauges and Pressure Cut-Outs

Precautions to Prevent Failures on Compressors

Measures to avoid compressor failures caused by system dirt.

Source of Entry

Identifying sources of contamination entering the compressor.

Prevention

Methods to prevent system dirt from entering the compressor.

Prevention for Compressor

Specific steps to protect the compressor from contamination.

Restart

Important Installation Checks

Critical checks required during compressor installation.

Crankshaft Rusting Occurring in the Field

Coupling/Flywheel/Motor Pulley Fitment

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