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 KC3
Summarization of Contents
Preface
Symbols Used in Manual
Explains symbols like CAUTION and IMPORTANT for manual comprehension.
Handling
Unpacking
Instructions for checking and handling unpacked equipment.
Lifting and Handling
Guidance on planning and executing lifting operations safely.
Storage
Recommendations for storing compressors to prevent damage.
Pre-Operation Checks and Procedures
Compressor Start-Up Checks
Essential checks before initial compressor start-up.
Priming Procedure
Procedure for filling oil into critical components before operation.
Air Run Trial
Steps for conducting a trial run of the compressor on air.
Mandatory Maintenance
Required maintenance schedule and actions after commissioning.
Commissioning Notification
Instructions to contact the service department with specific details.
Technical Data and Dimensions
General Data
Overview of KC series compressors, refrigerants, and capacity control.
Single Stage Compressor Data
Table detailing specifications for single-stage KC models.
Two Stage Compressor Data
Table detailing specifications for two-stage KC models.
Salient Features of Construction
Cylinder Liner and Suction Valve
Features of cylinder liners and the suction valve mechanism.
Lubrication System & Filter
Details of the forced lubrication system and filtering components.
Discharge Valve Assembly
Description of the discharge valve assembly design and features.
Piston/Connecting Rod Assembly
Features of the piston and connecting rod assembly.
Crankshaft and Main Bearings
Details on the crankshaft and its main bearing construction.
Welded Steel Crankcase
Features of the welded steel crankcase.
Constructional Details
General Construction Overview
General information about KC series compressors, bore, pressure, and speed.
Crankcase and Cylinder Jackets
Details on the fabricated crankcase and cylinder jackets.
Cylinder Liner Details
Information on renewable cylinder liners and their features.
Valve Assembly Details
Description of suction and delivery valve design and operation.
Piston Construction
Details on the construction and features of the pistons.
Oil Pump
Schematic Diagram of Oil Circuit
Illustrates the compressor's oil circuit and components.
Lubrication Diagram
Oil Pressure Regulator Diagram
Diagram of the oil pressure regulator.
Lubrication System Diagram
Diagram of the compressor's lubrication system.
Recommended Oil
Details on recommended oil types for Kirloskar compressors.
Valve Lifting Mechanism
Valve Lifting Mechanism Diagram
Diagram showing the valve lifting mechanism.
Oil Control Piping Diagrams
Diagrams of oil control piping for cylinder loading/unloading.
General Operating Instructions
Compressor Operation
Step-by-step guide for compressor operation, including starting and loading.
Liquid Stroke Hazards
Explanation of liquid stroke, its causes, and potential damage.
Ammonia Safety Rules
Safety precautions for handling ammonia refrigerant.
Pre-Operation and System Preparation
Freon Safety Rules
Safety precautions for handling Freon refrigerant.
Compressor Room Guidelines
Guidelines for compressor room design, ventilation, safety, and noise control.
Preparation for Compressor Operation
Steps for preparing a new compressor for initial operation.
Oil Charging and Pressure Adjustment
Procedures for filling oil and adjusting oil pressure.
Refrigeration Plant Preparation and Leak Testing
Steps before plant operation and leak testing.
Compressor Operation Procedures
Refrigerant Plant Purging and Settings
Procedure for purging air and system settings.
Pressostats and Operating Procedure
Information on pressostats and general operating guidance.
Starting, Supervision, and Stopping
Step-by-step instructions for starting, monitoring, and stopping.
Two Stage Compressor Operation & Control
General Overview
Overview of the nine types of two-stage KC compressors manufactured.
Intercoolers
Explanation of intercoolers and their types used in two-stage compressors.
Starting Two Stage Compressors
Guidance on starting and loading two-stage compressors carefully.
Two Stage Operation Steps
Steps for operating two-stage compressors, including parameter notes.
Parallel Compressor Operation
General Parallel Operation
Explanation of parallel compressor operation and oil distribution issues.
Installation Precautions
Precautions for installing compressors in parallel.
Optional Parallel Operation Instructions
Optional steps for starting and stopping parallel compressors.
Periodical Maintenance Schedule
Periodical Inspection
Guidelines for periodic inspections of the compressor.
Valve Maintenance
Instructions for inspection, repair, and replacement of valves.
Safety Valve Maintenance
Procedures for inspecting and maintaining safety valves.
Piston Ring Maintenance
Instructions for inspecting and replacing piston rings.
Bearing Maintenance
Guidelines for inspecting and replacing compressor bearings.
Component Maintenance
Shaft Seal and Oil Pump Maintenance
Instructions for maintaining shaft seals and oil pumps.
Strainer and Lubrication Maintenance
Cleaning strainers and lubrication procedures.
General Maintenance Instructions
General precautions and procedures for maintenance.
Accessories and Components
Pressure Switches and Pressostats
Function and importance of various pressure switches and pressostats.
Combined HP/LP Pressostat and Gauge Panel
Overview of combined pressostats and gauge panel installation.
Spare Parts Information
Recommended Spares Introduction and Ordering
Intro to spares, list, ordering, and storage guidance.
Standard Spare Parts Kits and Illustrated List
Lists of kits and illustrated spare parts for identification.
Precautions to Prevent Failures
Source of Entry
Identifies primary causes of compressor failures due to dirt ingress.
Prevention Measures
Measures to prevent dirt entry and system contamination.
Compressor Prevention
Specific preventative actions for the compressor itself.
Restart Procedures
Procedures and precautions for safely restarting the compressor.
Important Installation Checks
Crankshaft Rusting and Component Fitment
Checks for crankshaft rust prevention and fitment of coupling/flywheel.
Base Frame and Piping Installation
Procedures for base frame installation and piping connection.
Stop Valves, Liquid Floodback, and General Precautions
Details on stop valves, liquid floodback, and general installation precautions.
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