Table of Contents
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Instruction and
Operation Manual
Kirloskar KC Series Refrigeration Compressors
Versions:
Single Stage : KC2, KC3, KC4, KC6, KC9, KC12
Two Stage
: KC21, KC31, KC42, KC51, KC63, KC72, KC84,
KC93 & KC102
Kirloskar Refrigeration
KIRLOSKAR PNEUMATIC CO. LTD.
MGMT. SYS.
©
R vA C 071
INDIAN REGISTER
OF SHIPPING 1993
ISO 9001 : 2000
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Table of Contents
Related Manuals for KIRLOSKAR KC2
Summarization of Contents
HANDLING
UNPACKING
Procedure for unpacking compressors and checking for missing or damaged parts.
LIFTING AND HANDLING
Guidance on planning and executing safe lifting and handling operations for compressors.
STORAGE
Recommendations for storing compressors indoors or outdoors to maintain condition.
PRESERVATION OF REFRIGERATION COMPRESSOR
WATER JACKET RUSTING
Method to prevent water jacket rusting by filling with oil and draining after a specified period.
SEAL COVER & SEAL
Procedure to lubricate seal assembly and crankshaft bearings with oil.
PUMP END
Method to lubricate pump gears and bearings by filling the pump housing with oil.
INTERNAL PARTS OF THE COMPRESSOR
Instructions for evacuating and charging compressors with Nitrogen gas after preservation.
CRANKSHAFT PROTECTION
Guidance on applying grease to the crankshaft taper to prevent rusting.
INITIAL OPERATION AND CHECKS
CHECKS: BEFORE STARTING THE COMPRESSOR
Critical checks for compressor start-up, including tightness, alignment, and oil levels.
PRIMING
Procedure for filling oil into the shaft seal cover and oil filter housings.
BEFORE OPERATING / MOUNTING TAL STOP VALVES
Instructions to apply oil and grease in glands to prevent leakage before valve operation.
AIR RUN TRIAL
Procedure for a five-minute air run trial to check oil pressure and loading functions.
TECHNICAL DATA & OVERALL DIMENSIONS
GENERAL DATA
Overview of KC series compressors, their design, refrigerant compatibility, and control systems.
GENERAL TECHNICAL DATA (single Stage Compressor)
Detailed specifications for single-stage KC compressors, including dimensions and connection sizes.
General Technical Data : (Two Stage Compressor)
Detailed specifications for two-stage KC compressors, including dimensions and connection sizes.
Salient Features of Construction
Cylinder Liner and Suction Valve
Details on cylinder liners, their material, finish, and the hydraulic suction valve lifting mechanism.
Lubrication System & Filter
Explanation of the forced lubrication system, gear pump, and oil filter components.
Discharge Valve Assembly
Description of the discharge valve assembly design, ensuring ample gas passage and long-term operation.
Piston/Connecting Rod Assembly
Details on piston and connecting rod assemblies, including rings and lubrication for pistons.
Crankshaft and Main Bearings
Information on crankshaft construction, dynamic balancing, and main bearing types.
Welded Steel Crankcase
Features of the welded steel crankcase, emphasizing low weight, heat dissipation, and gas tightness.
CONSTRUCTIONAL DETAILS
GENERAL
Overview of KC series compressors, design, operating pressure, and speed limits.
CRANKCASE AND CYLINDER JACKETS
Details on the fabricated steel structure of the crankcase and cylinder jackets, including cooling.
CYLINDER LINER
Description of renewable cylinder liners, their material, finish, and numbering.
VALVES
Explanation of suction and delivery valve design, assembly, and material.
PISTONS
Details on light-alloy pistons, piston rings, scraper rings, and gudgeon pins.
LUBRICATION DIAGRAM
Recommended Oil
Lists recommended oils for Kirloskar ACR compressors, including brand, type, and refrigerant suitability.
GENERAL OPERATING INSTRUCTIONS
OPERATION OF COMPRESSOR
Describes the compressor's operation, including start-up, valve lifting mechanism, and normal running sequence.
LIQUID STROKE
Explains the phenomenon of liquid stroke, its causes, potential damage, and protective measures.
SAFETY RULES: AMMONIA
Safety precautions related to ammonia handling, storage, and potential health hazards.
PREPARATION FOR COMPRESSOR OPERATION
OIL CHARGING
Step-by-step instructions for charging the compressor with the correct type and amount of oil.
PREPARATION FOR REFRIGERATING PLANT OPERATION
LEAK TEST
Procedure for testing the entire system for leaks using gas under pressure, typically air or Nitrogen.
ACCESSORIES
PRESSURE SWITCHES
Explanation of pressure switches (pressostats) for safety, their connection, function, and maintenance.
RECOMMENDED SPARES
INTRODUCTION
Overview of the chapter content, including spare parts, illustrations, ordering, and field assistance.
SPARE PARTS
List of recommended spares to ensure prompt maintenance and minimize unwarranted shutdowns.
ORDERING OF SPARE PARTS
Essential information to include when ordering spare parts for prompt and speedy dispatch.
STORAGE OF SPARE PARTS
Guidelines for storing spare parts to protect investment, including inspection and proper conditions.
KITS FOR STANDARD SPARE PARTS
List of available spare parts kits for common maintenance and repair needs.
PRECAUTIONS TO PREVENT FAILURES ON COMPRESSORS
SOURCE OF ENTRY
Identifies common sources of 'SYSTEM DIRT' entering the compressor, such as pipe lines and joints.
PREVENTION
Measures to prevent dirt entry, including flushing the system and using cloth bags in gas strainers.
PREVENTION FOR COMPRESSOR
Specific preventive actions for the compressor, including initial oil filling and pump-down.
IMPORTANT INSTALLATION CHECKS
Crankshaft Rusting Prevention
Precautions to prevent crankshaft rusting during installation, involving oil application and compressed air.
Coupling/Flywheel/Motor Pulley Fitment
Guidelines for fitting couplings and flywheels, ensuring correct key size, fitment, and locking.
Fitment on Taper Diameters
Instructions for fitting components on taper diameters, including checking depth and securing with retainer plates.
Fitment on Parallel Shaft
Guidelines for fitting motor pulleys or couplings on parallel shafts, ensuring correct alignment and axial security.
Base Frame Installation
Instructions for using KPCL base frames, ensuring correct foundation, levelling, and securing the compressor.
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