Kirloskar Pneumatic Company Limited

A Kirloskar Group Company

KCX SERIES COMPRESSOR

HP suction from evaporator Discharge pressure

HP discharge Capacity control
safety valve
LP discharge solenoid valves
Discharge gas
pipe/manifold LP suction gas inlet
K5 Valves – to
from evaporator
isolate pressure
Suction gas pipe/ gauge tubing
connected to
manifold
process

Cylinder head
cover

Oil Pump
(Internal Gear
Air cooled cylinder Type)
blocks Discharge oil filter
housing - paper filter

Inspection doors
TAH8 service valve
to drain/charge the
Suction gas strainer oil
Suction to crankcase Suction oil filter housing
housing cover
pressure equalizing pipe - wire gauze Filter

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

PREFACE

This manual intended as a guide for the attendant of the Kirloskar Refrigeration Compressors type KCX,
contains a description of the compressor as well as service and maintenance instructions.

It is necessary to go through the text carefully before installing and starting the compressor.

Symbols used in this manual and their meanings:

WARNING - Read it carefully

SPECIAL ATTENTION - Important note/procedure

Periodic reading of the instructions will provide a better knowledge of compressor construction and operation to
prevent the breakdown. If abnormal operating conditions occur, the trouble shooting chart will be of great help in
tracing and rectifying the problem. Repairs should be carried out as soon as possible by Kirloskar Pneumatic
Company certified refrigeration/mechanical engineer, technician and mechanic only, otherwise irreparable
damage may occur.

Kirloskar Pneumatic has been always aspired to improve the products and processes. We therefore reserve all
rights to change or improve the KCX compressor series design while maintaining key features without being
obliged to immediately update this product instruction and operation manual accordingly.

Please put a warning sign at the entrance of the plant room as “ONLY COMPANY CERTIFIED EXPERT
SERVICE ENGINEERS / TECHNICIANS ARE AUTHORIZED FOR SERVICE AND MAINTENANCE OF
KIRLOSKAR COMPRESSORS”

COPYRIGHT
Any draft of this manual may not be copied or published by means of printing, photocopying or otherwise without
prior written consent of KPCL.

LEGAL NOTICE
KPCL reserves the right to modify the information given in the manual for correction. Although every effort is
made to provide correct information, KPCL cannot be held responsible for any error therein nor for the
consequences of the formation.

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

SAFETY

It is assumed that your safety department has established a program of safety based on a thorough analysis of
industrial hazards. Before installing and operating or maintaining the equipment described in this manual, it is
recommended that you review the safety program to ensure that it covers hazards arising from high speed
rotating machinery.

It is also important that due attention is given to hazards arising from electrical power, hot oil, high pressure, high
temperature, presence of toxic, flammable liquids and gases etc. Proper installation and care of protective guards,
shutdown devices and over-pressure protection should be considered for essential parts of safety program.

In addition special precautionary measures are also necessary to prevent the possibility of powering the machine
at any time when maintenance work is in progress. The prevention of rotation due to reverse flow in moving
machinery should not be ignored.

Refrigeration system and plant design should comply with applicable directive principles, standards, ordinances,
regulatory rules and laws established by state/local authorities. This is in view of the safety and efficiency of plant
operation as well as the health and environmental protection essential to mankind of the society.

In general, you should be guided by all basic safety rules associated with the equipment and the process for
human safety.

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

Do's & Do Not's

DO

1) DO study this manual in detail.

2) DO ascertain what tools and equipment are required to carry out the job.

3) DO use proper tools to suit the job. Avoid unnecessary dismantling.

4) DO ensure that all nuts, screws, pipe connections, electrical cable Connections and covers are properly
tightened.

5) DO ensure that suction filter elements are clean.

6) DO ensure sufficient & recommended refrigeration grade of lube oil is used for Compressor.

7) DO drain condensates from all manual drain points.

8) DO check oil level in crankcase. Oil should be visible and should be well above minimum level marked on
oil level indicator during working of compressor.

9) DO ensure proper direction of rotation before starting.

10) DO watch for unusual / abnormal noise and remove the fault without delay.

11) DO ensure that the compressor room is properly ventilated and there is sufficient circulation of fresh air.

12) DO display the Maintenance Chart supplied along with Compressor duly put on a frame or support.

DO NOT

1) DO NOT attend the unit when it is in operation.

2) DO NOT use cotton waste for cleaning purpose.

3) DO NOT attempt to start the unit unless fault is rectified.

4) DO NOT change the settings of any of the instruments.

5) DO NOT attempt to carry out maintenance / service operation on the equipment unless the system is
depressurised. (Wherever applicable).

6) DO NOT tighten and loosen any of the nuts and bolts of compressors unnecessarily as they are factory
fitted torque tightened.

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

HANDLING

UNPACKING:
Remove the crating and boxes and check for all the items shown on the shipping / packing list. Make sure that
there are no missing or damaged parts. Handle all the parts carefully. If the equipment is damaged during
transportation/ shipment, contact immediately the transporter and also nearest Kirloskar Pneumatic Company
Limited office.

LIFTING AND HANDLING:

Lifting and handling of compressor must be planned considering weight & overall dimensions mentioned in
technical data. Refer overleaf guide for selecting appropriate sling & shackles. Caution must be exercised such
that no compressor parts come in contact with lifting ropes.

STORAGE/PRESERVATION OF COMPRESSOR:
Indoor storage in a clean and dry place at ambient temperature is recommended for the compressor. Rust
prevention is applied to the parts of the compressor before shipment. The protective effectiveness of this
corrosion prevention is significantly affected by the conditions during external storage. Care must be taken in the
case of outdoor storage so that the equipment is not subjected to extreme conditions of temperature, humidity or
corrosive environment.

If the compressor is to be stored for a long time after receipt at site, please refer instructions on
‘Preservation of Refrigeration Compressor’ in this manual.

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

LIFTING AND HAULING OF COMPRESSOR

Refer to the manual/brochure for product information and weight before starting lifting and hauling activity.

Select the correct size/lifting tackle such as slings, wire ropes, shackles, rings etc. (see selection guidelines
provided by such equipment manufacturers).

Take care of all the necessary safety aspects during lifting and hauling. Use lifting hooks provided on the
compressor to fasten the lifting shackle. Balance the weight of the compressor in its CG and natural position (do
not lift in an inclined position). Maintain the proper position as shown in the sketch with the lifting tackle; raise the
compressor at suitable height above ground level before moving it to another location.

In short, take all necessary precautions to avoid any sort of accident or damage at work place.

It is mandatory to follow directive principles, ordinance, statutory and regulatory laws established by state/local
authorities, in view of safety and functionality of work environment.

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

SELECTION GUIDELINE OF LIFTING SLINGS AND

SHACKLES FOR MATERIAL HANDLING

MAXIMUM SAFE WORKING LOAD IN MAXIMUM SAFE WORKING LOAD IN

KG FOR SINGLE PART SLINGS KG FOR DOUBLE PART SLINGS
Min. Vertical Basket Choker Min. Vertical Basket Choker
Rope Rope
Size Size
(mm) (mm)
12 1200 2400 900 12 2400 4800 1800
14 1750 3500 1300 14 3500 7000 2600
18 2500 5000 1875 18 5000 10000 3750
20 3300 6500 2475 20 6600 13200 4950
22 4000 8000 3000 22 8000 16000 6000
24 4600 9200 3450 24 9200 18400 6900
25 5000 10000 3750 25 10000 20000 7500
28 6500 13000 4875 29 13000 26000 9750
32 8000 16000 6000 32 16000 32000 12000
35 9200 18400 6900 35 18400 35800 13800
36 10400 20800 7800 36 20800 41800 15600
38 12000 24000 9000 38 24000 48000 18000
40 12700 25400 9625 40 25400 50800 19050

Note: The capacity indicated in the above table for basket hitch and choker hitch is for guidance only. Vertical
column is the actual load and safe working load is applicable for vertical fall only.

Jaw Body Eye

Inside Pin
Inside Material Outside Safe Working Loads Tonnes
Length Dia
Width Dia Dia
Grade Grade Grade
W S d D min e min Grade
30 40 63
18 40 10 12 24 - - 1.0 -
20 44 12 14 28 - 1.0 1.25 -
22 49 14 16 32 1.0 1.25 1.6 2.0
25 55 16 19 36 1.25 1.6 2.0 3.25
28 62 17 20 40 1.6 2.0 2.5 -
32 70 19 22 44 2.0 2.5 3.2 4.75
34 79 22 26 52 2.5 3.2 4.0 6.5
48 80 24 28 56 3.2 4.0 5.0 8.5
45 99 27 31 62 4.0 5.0 6.3 9.5
50 110 30 35 70 5.0 6.3 8.0 12
56 124 34 39 78 6.3 8.0 10 13.5
63 139 38 44 88 8 10 12.5 17
70 154 43 50 100 10 12.5 16 25
80 176 48 55 110 12.5 16 20 35
90 198 54 62 124 16 20 25 40
100 220 60 69 138 20 25 32 55
Note: Shackles of grade 30, 40,
107 236 65 75 152 25 32 40 -
63 conform to ISI specification
117 258 71 82 164 32 40 50 -
6132. Grade 80 shackles are
130 206 79 91 182 40 50 63 - made of carbon manganese
140 308 84 97 194 50 63 80 - forged steel shackles with alloy
153 337 93 110 220 63 80 - - steel pins heat treated for
optimum strength.

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

PRESERVATION OF REFRIGERATION COMPRESSOR

If the compressor is not to be commissioned immediately after receipt at site, then in order to avoid rusting/
damages to internal & external parts of the compressor, following preservation action should be taken by the end
user/ contractor/erector.

• SEAL COVER & SEAL:

Open ¼" BSP plug on seal cover. Pour new refrigeration oil in sufficient quantity & rotate crankshaft. This will
protect seal assembly & also crankshaft main bearings & connecting rod big end bearings. Refit the above
plug after oil application.

• PUMP END :
Remove pressure gauge union ¼" BSP size fitted on top of pump housing. Pour new refrigeration oil in
sufficient quantity & rotate crankshaft. This will protect pump gears, bearings & also main bearings &
intermediate bearings. Refit the above union after oil application.

• INTERNAL PARTS OF THE COMPRESSOR :

At the time of dispatch of compressor from factory (after shop testing & painting of the same) each
2
compressor is evacuated & filled with Nitrogen gas at pressure of about 2 Kg/cm (g). However during
transit/storage at site Nitrogen gas may leak out. So, after application of oil in seal cover & pump end as
described above, evacuate the compressor & charge it with dry Nitrogen gas.

• CRANKSHAFT PROTECTION :
Apply heavy-duty grease (Servogem 3 of IOCL) on entire taper portion of crankshaft to prevent rusting.

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

IMPORTANT
1) READ THE MANUAL CAREFULLY
2) DISPLAYS THE MAINTENANCE CHART PROVIDED WITH THE COMPRESSOR IN THE PLANT
ROOM AND STRICTLY FOLLOW MAINTENANCE SCHEDULE
3) INFORM NEAREST KPCL BRANCH OFFICE/DEALER FOR COMPRESSOR COMMISSIONING,
REFER TO LAST PAGES OF THIS MANUAL FOR DEALER ADDRESS AND CONTACT DETAILS

CHECKS:

BEFORE STARTING THE COMPRESSOR

1. Make sure the key is properly fitted into the crankshaft and flywheel hub keyway.
2. Check flywheel tightness for correct fitment & ensure the safety lock plate is fitted properly.
3. Check the alignment of flywheel & motor pulley in case belt drive.
4. Check alignment of compressor and motor shaft with coupling hub in case of direct drive.
5. Maintain the lubricating oil level to the maximum level marked on the sight glass.
6. Verify electrical connection of HP, IP LP, OP safety pressure switch and confirm that compressor-motor trip at
safety cut-out set pressure
7. Fill oil in shaft seal cover, in suction & discharge oil filter housings.

AIR RUN TRIAL: Keep suction and discharge port open to atmosphere and conduct air run test for 5 minutes to
2
check oil pressure, (Minimum 1.5 Kg/cm (g). Check loading & unloading of compressor by operating capacity
control solenoid valve (CCSV) one at a time.
SINGLE STAGE COMPRESSOR (KCX1, KCX2, KCX3, KCX4, KCX6, KCX9, and KCX12): Do not start the
compressor at 100% load. Load the compressor electrically from gauge board panel based on evaporating
temperature/load requirement. Unload the CCSV (compressor capacity control solenoid) and then shut down the
compressor. Keep minimum of 120 seconds time delay for each loading or unloading step, avoid rapid
loading/unloading.
TWO STAGE COMPRESSORS (KCX21, KCX31, KCX42, KCX51, KCX63, KCX72, KCX84, KCX93, and
KCX102): Run the compressor on direct cylinder to achieve temperature minus 10°C & then load CCSV.
WARNING: Intermediate pressure should not exceed above operating limit as high pressure & high discharge
temp may cause damage at HP connecting rod big end bearing & crankshaft.
MAINTENANCE (COMPULSORY) : During the first 50 operating hours the compressor should be checked
regularly for all the points mentioned in maintenance schedule (refer to chapter 7.14) and more frequently in
cases where irregularities are found. Refer chapter 7 for further details. Always maintain a log book & note down
operating hours from hour meter.

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

CONTENTS

PAGE
SR. NO. CHAPTER
NO.
1. TECHNICAL DATA & OVERALL DIMENSIONS 13

2. CONSTRUCTIONAL DETAILS 17

3. GENERAL OPERATING INSTRUCTIONS 22

4. CAPACITY CONTROL SYSTEM 27

OPERATING INSTRUCTION AND CAPACITY CONTROL

5. 35
SYSTEM TWO STAGE COMPRESSOR

6. PARALLEL OPERATION OF COMPRESSOR 39

7. PERIODICAL MAINTENANCE AND ITS SCHEDULE 41

8. ACCESSORIES 46

8.1 PRESSURE SWITCHES 46

8.2 HIGH PRESSURE PRESSOSTAT 46

8.3 LOW PRESSURE PRESSOSTAT 46

8.4 INTERMEDIATE PRESSURE PRESSOSTAT 46

8.5 OIL PRESSURE DIFFERENTIAL PRESSOSTAT 46

8.6 PRESSURE GAUGE PANEL 46

8.7 DRIVE ARRANGEMENT FOR COMPRESSOR 49

8.8 OIL SEPARATOR 49

8.9 CRANKCASE HEATER 51

8.10 INTERSTAGE COOLER 51

9. TROUBLE SHOOTING CHART 53

10. SPARE PARTS 55

10.1 INTRODUCTION 55

10.2 ORDERING OF SPARE PARTS 55

10.3 STORAGE OF SPARE PARTS 55

10.4 KITS FOR STANDARD SPARE PARTS 55

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

PAGE
SR. NO. CHAPTER
NO.
OVERHAULING GASKET SET, O RING SET AND PACKING
10.4.1 56
SET
10.5.0 ILLUSTRATED SPARE PARTS LIST 56

10.5.1 CRANKCASE ASSEMBLY 57

10.5.2 SAFETY VALVE ASSEMBLY 58

10.5.3 BEARING COVER ASSEMBLY WITH DISC HOLDING 59

10.5.4 CRANKSHAFT ASSEMBLY WITH RETAINER PLATE 60

10.5.5 PISTON AND CONNECTING ROD ASSEMBLY 61

CONNECTING ROD ASSEMBLY WITH NEEDLE ROLLER
10.5.6 BEARING (FOR TWO STAGE COMPRESSOR ON H.P. SIDE 63
ONLY)
CYLINDER LINER ASSEMBLY AND VALVE LIFTING
10.5.7 63
MECHANISM
10.5.8 SUCTION AND DELIVERY VALVE ASSEMBLY 64

10.5.9 SHAFT SEAL ASSEMBLY 65

10.5.10 OIL PUMP ASSEMBLY 66

10.5.11 OIL FILTER ASSEMBLY 67

10.5.12 SUCTION GAS STRAINER ASSEMBLY 68

10.5.13 SPECIAL TOOL KIT ASSEMBLY 69

10.5.14 CAPACITY CONTROL OIL PIPING 70

10.5.15 PRESSURE GAUGES AND PRESSURE CUTOUTS 70

10.5.16 STOP VALVES 71

11. TABLE OF TIGHTENING TORQUE VALVES 73

PRECAUTIONS TO PREVENT FAILURES OF
12. 74
COMPRESSORS
13. INSTALLATION CHECKS 76

14. DISPOSAL GUIDELINES FOR PRODUCTS 77

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

SALIENT FEATURES OF CONSTRUCTION

Discharge Valve Assembly
• Three concentric discharge valve rings ensure
ample gas passage at low lifting height.
• The use of sinusoidal springs together with precision
machined and lapped surface results in a trouble-
free operation for a remarkably long time.
• Minimum inventory for spares since most parts are
identical throughout the KCX-series compressors.

Piston/Connecting Rod Assembly

• Perfect sealing and low oil consumption due to 3
compression and 2-oil scrapper rings on each
aluminium piston
• The nodular iron connecting rod is drilled through for
pressure lubrication of the piston pin.
• Steel backed white metal shells on big end and bronze
bearing on small end of connecting rod.
• The complete assembly can be removed from the top
for servicing without withdrawing the cylinder liner
Cylinder Liner and Suction Value
• Interchangeable cylinder liners are made of fine-
grained, centrifugally cast, and alloy iron.
• Fine boring and honing results in a mirror smooth
running surface.
• A hydraulic mechanical solution value lifting
mechanism on each individual cylinder achieves
loading and unloading
• For unloading, the suction valve ring is lifted from
its seat in the cylinder collar by spring tension.
Welded Steel Crankcase
Admitting controlled oil pressure to the control • Low in weight
piston, allowing the suction valve ring to descend • Rapid heat dissipation
on its seat effects loading or cylinder. • Gas tight and impact proof
• Smooth internal surfaces guarantee
good oil condition

Lubrication System and Oil Filter

• Forced Lubrication by an Internal Gear pump directly
driven by the Crankshaft
• The Pump incorporates two differential pressure
regulators to provide separate pressures for two oil Crankshaft and Main Bearings
systems: Lubrication system and control oil system for • Bearing surfaces of the high quality nodular cast
operating Cylinder loading unloading mechanism. iron crankshaft are ground to fine tolerances.
• Automatically operating solenoid valve ensures • Main bearings are white metal lined steel backed
complete unloaded start of compressor. bushes, pressed into the cast iron bearing covers.
• A Metal gauze suction filter element and a throwaway Intermediate bearing blocks are provided with
discharge paper filter cartridges are provided for split type bearing shell of the same type.
excellent filtering capacity of the lubricating oil. • Each crankshaft is dynamically balanced together
with the counter weights.

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

1. TECHNICAL DATA AND OVERALL DIMENSIONS

1.1 GENERAL DATA:
These KCX series heavy duty open type industrial refrigeration reciprocating compressors are designed for use
with R717 (Ammonia), R404a, R507, Rl34a, R22 refrigerants. There are two variants of compressors with
following models.
a. Single stage compressors: KCX1, KCX2, KCX3, KCX4, KCX6, KCX9, & KCX12.
b. Two stage compressors: KCX21, KCX31, KCX42, KCX51, KCX63, KCX72, KCX84, KCX93, & KCX102
These single stage compressors can also be used as booster compressor. The refrigeration capacity of each
compressor is controllable in various steps by means of oil pressure control piping and solenoid valves. The
solenoid valves can be operated manually or by remote control electrical signals.

1.2 GENERAL TECHNICAL DATA (Single Stage Compressor)

Sr.
Description Compressor Type
No.
KCX1 KCX2 KCX3 KCX4 KCX6 KCX9 KCX12
1 No of cylinders 1 2 3 4 6 9 12
2 Cylinder Bore (mm) 160 160 160 160 160 160 160
3 Piston Stroke (mm) 110 110 110 110 110 110 110
4 Cylinder arrangement In-line 1xV 1xW 2xV 2xW 3xW 4xW
Swept volume at 1000 rpm,
5 132.7 265.4 398.1 530.8 796.2 1194.3 1592.4
(m3/hr)
6 Direction of rotation Anticlockwise looking from flywheel end
Standard compressor speeds
7 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950 & 1000 rpm
(Motor rpm 1450/1000}

8 Capacity control steps Refer chapter No 4

Crankcase 7 10 10 14.5 18.5 27 36
Max. Oil charge Oil filters and 1 litre oil in suction and discharge oil filter housing each & 0.5 litre in
9
capacity shaft seal shaft seal cover
Compressor 9.5 12.5 12.5 17 21 29.5 38.6
10 Bare compressor weight (kg) 333 490 565 702 940 1255 1590

Overall dimension and space

11 Refer Figure 1
requirement
12 Suction connection size (NB) 50 65 80 80 100 125 150
Suction connection hole
diameter in (upper part of) Ø61 Ø77 Ø91 Ø91 Ø116 Ø116 Ø116
counter flange (mm)

Stop valve Type for suction 50 70 80 80 100 125 150

13 Discharge connection size (NB) 32 50 50 80 80 100 100

Discharge connection hole

diameter in (upper part of) Ø44 Ø61 Ø61 Ø77 Ø91 Ø116 Ø116
counter flange (mm)

Stop valve Type for discharge 32 50 50 70/80 80 100 100

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

Figure 1: Overall Dimensions of Single Stage Compressor

Compressor Type KCX1 KCX2 KCX3 KCX4 KCX6 KCX9 KCX12

A - 984 955 984 960 960 960

B 728 1047 1194 1047 1194 1194 1194

C 925.5 950 890 950 950 950 950

D - 325 80 325 643 643 643

Main Dimensions E - 445 589 395 639 641.5 1033

F 310 387 387 403 404.5 426.5 426.5

G 247 215 215 380 570 960 1350

H - 326 324 345 389.5 393.5 393.5

J 807 1022 1022 1224 1494 1909 2302

Minimum required free space for removal of components

Flywheel U 920 920 920 920 920 950 950

Crankshaft (V or W) V/W 1000 1000 1000 1000 1050 1450 1840

X 1200 1200 1200 1200 1200 1200 1200

Piston and cylinder liners
Y 420 420 545 420 545 545 545

Gas suction strainer

Z - 900 900 900 1100 1100 1100
element

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

1.3 GENERAL TECHNICAL DATA (Two Stage Compressor)

Compressor
Sr. Type
Description
No.
KCX21 KCX31 KCX42 KCX51 KCX63 KCX72 KCX93 KCX84 KCX102

1 No of cylinders 3 4 6 6 9 9 12 12 12

2 Cylinder Bore (mm) 160 160 160 160 160 160 160 160 160

3 Piston Stroke (mm) 110 110 110 110 110 110 110 110 110

4 Cylinder arrangement 1xW 2xV 2xW 2xW 3xW 3xW 4xW 4xW 4xW
Swept volume at 1000 rpm,
5 3
(m /hr} 265.4 398.1 530.8 663.5 796.2 928.9 1194.3 1061.6 1327

6 Direction of rotation Anticlockwise looking from flywheel end

Standard compressor speeds
7 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950 & 1000 rpm
(Motor rpm 1450/1000)

8 Capacity control steps Ref. Chapter No. 4

Crankcase 10 14.5 18.5 18.5 27 27 36 36 36
1 liter oil in suction and discharge oil filter housing each & 0.5 liter in shaft seal
Max. Oil Oil filters and
cover
9 charge shaft seal
capacity (lts)
Compressor 17 21 21 29.5 29.5 38.5 38.5 38.5
12.5
10 Bare compressor weight (kg) 613 753 940 980 1255 1255 1590 1590 1590
Overall dimension and
11 Ref. Figure No.2
space requirement
LP Suction connection size
80 80 100 100 125 125 125 125 125
(NB)
LP Suction connection hole
12 diameter in (upper part of) Ø77 Ø91 Ø91 Ø91 Ø116 Ø116 Ø116 Ø116 Ø116
counter flange(mm)

Stop valve size at LP

70/80 80 80/100 125
Suction (NB)

LP discharge/HP Suction
65 65 65 65 80 65 80 80 80
connection size (NB)
LP discharge /HP Suction
connection hole diameter in
13 Ø77 Ø77 Ø77 Ø77 Ø91 Ø77 Ø91 Ø91 Ø91
(upper part of) counter flange
(mm)
Stop valve size at LP dis-
70 70 70 70 80 70 80 80 80
charge/HP Suction (NB)
HP Discharge connection size
65 65 65 65 65 65 65 65 65
(NB)

HP discharge connection hole

14 diameter in (upper part of) Ø61 Ø61 Ø77 Ø77 Ø77 Ø77 Ø77 Ø77 Ø77
counter flange (mm)

Stop valve size at HP

50 I 70 50 I 70 70 70 70 70 70 70 70
discharge (NB)
Recommended liquid
injection valve
15 For standard type A
TEA TEA TEA TEA
intercooler & ammonia
20-2 20-3 20-5 20-8
refrigerant

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

Figure 2: Overall Dimensions of Two Stage Compressor

Compressor Type KCX21 KCX31 KCX42 KCX51 KCX63 KCX72 KCX84 KCX93 KCX102

A 955 984 960 960 960 960 960 960 960

B 1194 1047 1194 1194 1194 1194 1194 1194 1194
C 890 950 950 950 950 950 950 950 950
D 350 325 375 375 375 375 375 375 375
E (-)270 0 270 270 270 270 270 270 270
F (-)280 145 296.5 296.5 270 270 290 290 290
Main Dimensions G (-)191.5 (-)236 191.5 191.5 191.5 191.5 191.5 191.5 191.5

H 1024 1224 1498 1498 1910 1910 2301 2301 2301

J 394 659 1038 1038 1103 1103 1491 1491 1491
K 579 389/797 680 680 676 676 1084 1084 1084
L 387 403 404.5 404.5 426.5 426.5 426.5 426.5 426.5

M 215 380 570 570 960 960 1350 1350 1350

N 326 345 393.5 393.5 393.5 393.5 391.5 391.5 391.5
Minimum required free space for removal of
components
Flywheel U 920 920 920 920 920 920 920 920 920
Crankshaft (V or W) V/W 1000 1000 1050 1050 1450 1450 1850 1850 1850

Piston & Cylinder X 1200 1200 1200 1200 1200 1200 1200 1200 1200
liners Y 545 420 545 545 545 545 545 545 545

Gas suction
Z 900 900 1100 1100 1100 1100 1100 1100 1100
strainer element

For KCX21 & KCX31 E & G dimensions are in opposite direction of reference line

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

2. CONSTRUCTIONAL DETAILS
2.1 GENERAL:
KCX series comprises 1, 2, 3, 4, 6, 9, 12 cylinder compressors, which are manufactured as single stage and two
stage machines. These compressors are mainly designed for Ammonia, R22, R134a, R404a, R507c refrigerants
but can also be used for new refrigerants. The direction of rotation is anticlockwise, looking from the flywheel end.
2
The maximum safe delivery pressure for continuous operation is 18 kg/cm (g). The minimum speed is 450 rpm
and the maximum 1000 rpm.

2.2 CRANKCASE AND CYLINDER JACKETS:

Crankcase is a welded steel structure comprises of cylinder blocks, suction manifold and discharge pipe. After
welding, the complete unit is stress relieved and cleaned. The suction gas strainer is fitted at the inlet which is
removable for cleaning thus the filtered gas enters into cylinder. Oil separated from the refrigerant gas into the
suction chamber can flow back into the crankcase through a non return valve in the lower ring of the cylinder
block. Blind plugs fitted in HP-cylinders of two stage compressors to separate intermediate pressure gas from low
suction pressure in crankcase. Two or more inspection covers are provided on both sides of the crankcase to
allow access to the internal parts of the compressors for maintenance. A minimum oil level is always required in
the crankcase for lubrication. Sight glass are provided to check crankcase oil level on both sides of the crankcase.

2.3 CYLINDER LINER:

Cylinder liners made from cast iron are centrifugally cast are pressed into the cylinder jacket and can be easily
replaced. Surface finish is achieved by precise boring and honing for effective lubrication. The collar at the top of
the cylinder liner is provided with holes and serves as the valve seat for the suction valve ring. Cylinder numbering
starts from right to left from the flywheel end. In KCX4 compressor, for example, has cylinders 1 and 2 in the first
row and cylinder 3 and 4 in the next row. (Capacity control diagram shows the cylinder number for each
compressor model).

2.4 VALVES:
The suction and delivery valves are of ring type and of special steel. Valve springs apply preload to keep valve
ring in closed condition. The valve lift is limited by the stroke limitor, however the design ensures that a sufficient
flow area is provided for the gas to flow through the valve lift. The suction valve consists of valve ring & two
sinusoidal springs mounted between the cylinder liner collar and the suction stroke limitor. This stroke limiter is
centered in the cylinder liner collar which also serves as the valve seat. The three concentric delivery valve rings
with the pair of valve springs and the delivery valve stroke limiter are assembled to the valve seat by means of a
center bolt and lock nut. This valve assembly is held against liner collar by a heavy buffer spring. This
construction enables delivery valve assembly to lift in case of liquid stroke to avoid undue material stresses (Ref.
Fig.3).

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Discharge

1. Spring Cup
Suction 2. Buffer Spring
3. Discharge Valve Ring with Wavy
Spring
4. Discharge Valve Stroke Limitor
5. Suction Valve Stroke Limitor, also
Discharge Valve Seat
6. Suction Valve Ring with Wavy Spring
7. Cylinder liner, also suction valve seat
8. Plug/NRV

Figure 3: Schematic Construction and operation of suction and discharge valve

2.5 PISTONS:
The light alloy pistons are die cast and provided with three piston rings and two oil scraper rings, one of the latter
being positioned below the case hardened gudgeon pin. Due to this an extremely good piston seal is obtained,
none the less providing adequate lubrication together with minimum oil consumption.

2.6 CONNECTING RODS:

The connecting rod is made of nodular cast Iron, fitted with split, white metal lined, precision steel backed big end
bearing and a push-fit, bronze, small end bearing bush. Internal oil ways permit oil to flow from the big end
bearing to the gudgeon pin bush, which is adequately grooved for lubrication in between gudgeon pin and bronze
bush. In case of two stage compressor HP connecting rods are fitted with needle roller bearing in place of small
end bush.

2.7 CRANKSHAFT:
The dynamically balanced crankshaft is made of nodular cast iron with good running characteristics and high wear
resistance. The crankshaft is supported at both ends by precision thin-walled white metal bearing bushes in
bearing covers. The bearing housing on the flywheel end also includes a gastight shaft seal, which prevents oil or
refrigerant from leaking out of the crankcase. Additionally, in cases where intermediate main bearings are fitted,
they are of similar construction to connecting rod big end split bearings. Internal oil passages supply oil to the
main and big end bearings.

2.8 OILPUMP:
The compressor is fitted with a internal gear pump provided with lubricating oil pressure regulator & control oil
pressure regulators. In this way a low-pressure oil supply is made available for lubrication purposes and high-
pressure oil supply for valve lifting mechanism i.e. capacity control through time delay solenoid valve.
The regulator consists of a valve housing in which a ball valve is held against oil inlet by spring. The compression
of this spring is adjusted by turning a set pin, which is sealed by a nipple and washer. A cap, which has to be
removed before the oil pressure can be adjusted. After removing the cap. The set pin can be turned with a
screwdriver. To achieve higher pressure, the set pin should be turned in clockwise direction.
1) Control oil pressure regulator is to be set between 6 to 8 kg/cm2
2
2) Lubricating oil pressure regulator is to be set between 1.5 to 3.0 kg/cm above crankcase pressure.
Note: Above pressure setting should be done when oil temp. is about 50°C.

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2.9 LUBRICATION SYSTEM:

The lubrication of compressor is of forced feed type and effected by a internal gear pump driven by the
crankshaft. The oil circuit is shown in Fig. No. 4.

Figure 4: Schematic of Lubrication System

2.10 PRESSURE EQUALIZING LINE:

A pressure equalising line is fitted between the suction pipe and crankcase. This line provides an open connection
between the crankcase and the suction line, in order to prevent the crankcase pressure from rising due to piston
leakage. Consequently, the crankcase pressure is equal to suction pressure for single-stage as well as for two-
stage compressors. LP/HP suction and discharge connections have welding nipples for connecting tubing to
pressure gauges and pressure safety switches. In case of KRMS, a thermowell is provided at the compressor
connection for the temperature sensor elements and provision has been made for mounting the pressure
transducer on the K5 valve mounted on the suction strainer housing.

2.11 TIMEDELAY:
It is important that compressor should start at 100 % unloaded condition to reduce starting current. In this
compressor time delay function is operated by electrically operated solenoid valve.
This solenoid valve is the same solenoid valve used for capacity control function. But the oil connections are
made such that it functions as normally open (NO) type valve. (See oil piping circuit diagram provided Fig.5)
This time delay solenoid valve requires energizing first before staring the compressor. The delay period requires
is approx. 20 seconds thereafter it is to be de-energized. (After starting the compressor).
This can be done by following three methods:
1) Manually - press upright and turn manual reset knob provided on valve by hand.
2) By providing separate electrical on/ off timer switch.
3) By means of star/ delta circuit of electric motor. Connect this valve in such a way that during star
operation of motor time delay valve remains on, it is off after change over from star-to-delta.
(Refer piping circuit diagram carefully). Maximum 6 starts per hour and at least 10 minutes between stopping and
starting is recommended.

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Figure 5 : Capacity Control Schematic Arrangement

2.12 RECOMMENDED LUBRICATION OIL:

Recommended lubricant for Single Stage, Two Stage & Booster Compressors (ISO VG 68 Grade).

Recommended Oil

KIRLOSKAR ADVANTAGE AC & REFRIGERATION COMPRESSOR OIL

• Part No. - 085.00.001.50 • No need to invest on 200 ltr drum
• 20 ltr smart pack • Grade ISOVG68
• Easy to buy, stock and use • Suitable for refrigerants NH3 and R22
0
• No risk of loose purchased adulterated • Evaporating temp. range: +10 C to (-
0
and reconditioned oil )30 C

Notes:
1. Never mix different brands of oil.
2. Whenever you need to change brand of oil from earlier one, whole refrigeration system to be flushed with
Nitrogen so that no traces of earlier oil exist in refrigeration system.
3. For other grades of refrigeration oil please check whether it complies to ISO VG 68 grade.
2.13 SAEFTY VALVE:
The compressor is fitted with one safety valves on compressor. The safety valve is spring loaded relief valve fitted
between the delivery and suction manifolds. At the time of excessive pressure in the delivery manifold it by-
passes gas back into the suction line. The device can be easily removed for inspection or renewal.
The compressor should not be kept running with an open or leaking safety valve as the machine would then
become too hot and the possibility of damage to, or even seizure of, the piston and cylinder would arise. The line
on the suction side of the safety valve should be cold when the compressor is operating. When it is found warm,
the safety valve is leaking, causing loss of capacity. In this case safety valve must be repaired or replaced.

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2.14 VALVE LIFTING MECHANISM:

This mechanism can be subdivided into hydraulic and mechanical components. The hydraulic assembly consists
of a piston housing with a "O" ring sealed piston controlled by oil pressure. The mechanical assembly consists of
pressure ring to which are attached two actuating rods on its underside. Eight valve lifting pins are located around
the upper face of the pressure ring and the whole assembly is free to move in vertical direction. The actuating
rods pass through a support ring which is rigidly held in a groove around the outside of cylinder liner. pressure
springs are fitted around each actuating rod, tending to force the operating ring in an upward direction. To the
lower end of the actuating rods is attached a semicircular lever. The fulcrum of which is fixed to the supporting
ring. The movement of this lever is controlled by the piston stem of the hydraulic assembly bearing its upper end.
In the "No-load" position the pressure ring is in the upper position, thus lifting the suction valve ring. When the
hydraulic piston is moved in towards the cylinder liner by the high-pressure oil it bears against the lever, causing
the actuating rods to be drawn down against the spring load. This causes the lifting pins to be retracted thus
enabling the suction valve ring to descend on to its seat, thereby putting the cylinder on load. (Ref. Fig. 6).

Figure 6 : Valve - Lifting Mechanism

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3. GENERAL OPERATING INSTRUCTIONS

While design, construction and installation of plant user must consider Environment Health and Safety
requirements.
Refer following standards:
1] EN ISO 12100: 2010
2] EN 12693: 2008
2] EN378: 2016
Also refer other statutory requirements of state/local authority.

3.1 OPERATION OF COMPRESSOR:

When the compressor is not turned on, the suction valves are held away from their seats by the valve lifting
mechanism. As soon as rotation begins, the oil pump comes into operation, supplying a low pressure lubricating
oil to the moving parts and under a time delay control, also providing high pressure oil supply that activates the
valve lifting mechanism. The time delay ensures that normal running speed is first attained before allowing the
compressor cylinders to be progressively brought on load. Rest cylinders can be loaded /unloaded by capacity
control solenoid valves. When starting, if the suction valve is held clear off its seats, as the piston descends on its
suction stroke, gas is drawn into the stroke, the gas is merely recalculated back into the suction manifold through
the open suction valve. Thus, the only energy required to drive the compressor is that necessary to overcome its
inertia, friction and pumping losses. This condition of start-up referred to as 'no-load' starting, and is effective in
reducing peak starting electrical requirements and heavy wear of the starter & motor.
In normal operation, the piston travels down the cylinder, reducing the pressure and the gas in the suction
manifold at a higher pressure, lifts the suction valve from its seat against the pressure of the valve springs, and
flows into the cylinder. As soon as the gas pressure in the cylinder and the suction manifold is equal, the suction
valve springs force the valve ring back onto its seat. As the piston rise on its compression stroke the gas pressure
is raised equal to discharge pressure and delivery valves rings are lifted from suction valve stroke limitor and the
gas is allowed to flow through into the delivery manifold. (See Fig No. 3). In case of low evaporating temperature
installations, the suction pressure is also too low, and it is not practical to compress the gas to the condensing
pressure in one stage. For this reason, two-stage compressors are used. In the first stage the gas is compressed
to an intermediate pressure and then in the second stage de-superheated gas at intermediate pressure is
compressed to condensing pressure.

3.2 LIQUID STROKE:

The term liquid stroke refers to the situation where some amount of wet saturated or even liquid refrigerant is
carried into the cylinder and forced by the piston; the valve mechanism audibly rises from its seat. This constitutes
an overload of valve mechanism as liquid is not compressible. Generally the compressors without a liquid stroke
protection will suffer damages when liquid carryover and compression occurs. They are designed for superheated
or dry suction gas entry i.e. for 3 °C to 5 °C suction superheat. While designing refrigerating plant, it must be
ensured that the suction gas reaches the compressor in perfectly dry or in superheated condition. KPCL does
not take any responsibility for any damage arising due to liquid stroke, but in order to safeguard against a minor
liquid stroke, a protection device called ‘‘buffer spring” is fitted to all KCX compressors. However, this
arrangement allows the valve seat to be lifted up to allow a small amount of wet refrigerant to pass through
without serious damage to compressor. But when large amount of liquid enters into the cylinder, the delivery valve
assembly is lifted to such an extent that it cannot return to its normal position, thus keeping the valve permanently
displaced from position cause irreparable damage to the compressor. Even if small amount of wet refrigerant gas
is continuously drawn in cylinder, it can have a detrimental effect on the lubrication. The operating temperature of
gas passing through the delivery valves drop abruptly, thus imposing an additional thermal load on the valve
assemblies, over and above the existing mechanical load. If this happens frequently, it leads to early failure of the
valve ring/spring. Subsequently valve leakage cause cylinder overheating & seize the piston in cylinder liner.
Similarly, liquid refrigerant that enters the crankcase and mixes with the lubricating oil and consequently degrades
the oil characteristics, which can damage the bearings, crankshaft and cylinder liner or even cause complete
seizure of the piston. Therefore, wet refrigerant gas entry into the compressor cylinder is as damaging as liquid
stroke. The compressor must be inspected for damage immediately after liquid stroke occurs.

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3.3 INSTRUCTION FOR SAFE HANDLING OF AMMONIA REFRIGERANT (Characteristics, Storage,

Leakage):

Ammonia (NH3) causes watering eyes, coughing and very painful skin inflammation, especially of the mucous
membranes and eyelids, inhalation may cause inflammation of the respiratory organs, choking, cramp and even
death in severe exposure.
The liquid ammonia stock should be stored in a properly designed store, outside the engine rooms where no other
gas bottles are stored. Full and empty ammonia bottles should be kept in a horizontal position in order to avoid
their falling over. It is permissible however to store the bottles in a vertical position, provided that each bottle can
be separately fastened in such a way that the possibility of its falling over is absolutely excluded. Ammonia bottles
should not be exposed to direct sunlight or to temperature exceeding 59°C or lower then about (-) 10°C. They
should be carefully handled. Before use, the content should be tested to be, sure that it is ammonia and not some
other liquid or gas. Even when bottle carries label indicating its contents, this check should not be omitted. The
ammonia should be obtained from reliable firms in order to be sure that the refrigerant does not contain water
and/ or alcohol.

As it is possible that leak might suddenly develop, at least one gas mask must be placed in a conspicuous and
accessible spot, the mask must completely cover the eyes, nose and mouth. It should be occasionally checked for
correct functioning and the filter should be renewed periodically for its effective long life. The mask should be a
good fit. A gas mask and a pair of leather or rubber gloves are essential, while working on the refrigeration plant,
the possibility of ammonia leak exists. The gloves and the mask should be kept at the same place. Small leak can
be traced with the aid blue litmus paper, which will fade to violet on coming into contact with ammonia.

3.4 INSTRUCTIONS FOR SAFE HANDLING OF FREON REFRIGERANTS:

Freon is a colourless and non-poisonous gas. When it comes into the contact with hot surfaces, however, harmful
chemical reaction takes place. For this reason leaks should never be traced whilst the operator is smoking, as the
possibility exist that Freon gas may be inhaled over the burning tobacco thus introducing poisonous gas into the
body.
The instructions given for the storage of ammonia are also applicable to the storage of Freon.
Freon is heavier than air and it escapes through even the smallest aperture. As the gas is odourless there is no
immediate indication of possible leaks, which may result in a serious loss of this very expensive refrigerant. It is
therefore desirable to check the plant regularly for signs of any leakage by means of leak detection lamp or an
electronic leak detector, while trying to detect possible leak, the engine room should be thoroughly ventilated. It is
mandatory to follow safety rules and regulations established by local authority.

3.5 COMPRESSOR ROOM:

The compressor room, where compressor and other machinery of the refrigerating plant are installed should have
two exits (if possible situated opposite each other) leading to open air. Doors, shutters and hatch cover should be
tight when shut, and open outside. The compressor and other machinery should be easily accessible to the
attendants, who should also be able to reach the open air without difficulty, if necessary. The walls and the
sealing of the compressor room should be fireproof. Ventilation for the space should be fitted at level (Ammonia
and Freon gases are heavier than air) and to be so arranged that any leak in gas cannot penetrate into adjacent
compartment, the local labour safety regulations must also be observed as well as the additional requirements of
the insurance company. Naked lights and fires are dangerous in spaces where ammonia is used and therefore
forbidden.

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The dimension of the compressor room shall allow the installation of equipment in favourable condition, leaving
sufficient free space for operation, maintenance, service and disassembly. Refer fig 1 and fig.2 in which mini-mum
free space required around the compressor are given.
Compressor room must have adequate illumination (light) to allow safe operation of controls. Also emergency
lighting system shall be provided in case of normal lighting fails as well as evacuation of personnel in emergency.
Ensure that noise level outside the compressor room should not be more than 70 db (A) sound pressure level. If
required compressor room must be provided with acoustic insulation. Use personal safety equipment (PPE) while
attending compressor room such as helmet, ear plug/cap, safety goggles, glows, breathing respirators, etc.

3.6 PREPARATION FOR REFRIGERATION PLANT OPERATION:

After completion of erection of new refrigeration plant, the following procedure should be carried out before it can
be put into full operation.
Ensure that time delay solenoid valve is properly connected in electrical circuit

3.7 LEAKTEST:
This pneumatic pressure test should be carried out to ensure the soundness of all weld joints and bolted joints.
Refer test pressure from refrigeration system P & ID or manual. Use of dry nitrogen gas is recommended to carry
out pressure test.
2
WARNING: Suction, oil and intermediate pressure gauges and pressure switches have a range of upto 16 kg/cm
2
(g). Check the tubing connected to the gauge and pressure switch at 10 to 12 kg/cm (g) test pressure. Close the
K5 valve to isolate the instruments and then carry out pressure of other joints at the required test pressure.
2
Pressure testing above 16 kg/cm (g) causes mechanical damage to the gauge and switches.

3.8 EVACUATION OF SYSTEM WITH VACUUM PUMP FOR REFRIGERATION PLANT:

Before charging the refrigerant into the system, air and water must be removed from the compressor and plant.
Plant must be thoroughly dried before charging it with refrigerant, As the presence of water may lead to acid
formation which can react with system components and cause corrosion from inside and impair the performance
and reliability of the plant.
In addition water may cause blockage through freezing, particularly in a low temperature plants.
Water at a temperature of 20°C boils at a vacuum of 743 mm mercury (equal to an absolute of 17 mm mercury or
0.0228 atm.) The water vapour contained in the air in a system decreases proportionally with an increase in
vacuum. A high vacuum pump should be used to evacuate the plant. It is recommended that the evaporator,
condenser etc. should be warmed during evacuation. The time required for this cannot be laid down strictly, and
depends on the capacity of the vacuum pump and the volume of the plant. The reading of most vacuum gauges is
not sufficiently accurate to determine whether the plant has been evacuated adequately. The pump outlet should
be provided with the tube or hose discharging into a vessel filled with oil. The evacuation should be stopped only
when there are no longer any bubbles visible in the oil. Evacuating the plant after first filling it with Nitrogen, will
ensure that it is thoroughly dried. Any moisture still present in the system is absorbed by Nitrogen and exhausted
with it.
This operation should be carried out as follows:
a. Connect a vacuum Pump to the system and open compressor and system valves to ensure entire system is
open for evacuation.
b. Start Vacuum pump to pull down 40 mm Hg vacuum. It may take several hours to bring 40 mm Hg Vacuum.
c. Stop vacuum pump and fill system with nitrogen for dry purging.
d. Release nitrogen via a hose leading into the open air until an atmospheric pressure remains in the system
and close the valve to disconnect the hose.
e. Again start vacuum pump to remove air, nitrogen and water from the system & to pull down require vacuum
of 20mmHg.
f. Hold the vacuum for 8 Hours.
g. If the vacuum breaks repeat steps from b to f.
h. Ensure moisture content is less than 20 PPM before charging refrigerant into the system.

3.9 REFRIGERANT CHARGING:

Prior to gas charging into the refrigeration system ensure that all initial startup and installation requirement have
been met.
Make sure required vacuum exists in the system.
Ensure refrigerant charging line is properly connected to the suction line and slowly crack open charging valve.
Charge required quantity of refrigerant in system to maintain designed operating pressure.

3.10 PURGING REFRIGERATING PLANT:

As the presence of air can cause a lot of trouble, the refrigerant plant should be purged if necessary. Purging is
carried out while the compressor is at standstill and cooling water left open to the condenser where air mainly
collects. The air vent valves, which may be fitted on the gas delivery line and/ or on the condenser, as well as the

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liquid receiver, should be fitted with a hose, capable of discharging into water. During purging, the vent valves
should be opened at½ or¼ turn only.
On Ammonia plants, the hose is kept under water subsequent to opening the air vent valve. Once any bubbles
stop rising, only pure Ammonia gas then escapes and is immediately dissolved into water. The plant is then
purged and the air vent valve should be shut and the hose removed. On Freon plants the air vent valves should
be cracked open and held, this until the system pressure corresponds to the gas saturation pressure at the
existing cooling water temperature. The connecting hose must lead to the open air so that the Freon discharged
can escape without dangerous effects.
Normally it will be necessary to repeat the purging operation. Every time, between each purge, the compressor
should be operated for some time so that any residual air may be returned to and trapped in the condenser.

3.11 PRESSOSTATS (SAFETY PRESSURE SWITCHES):

The pressostat protects the compressor from breakdown if the operating pressure exceeds the set value
parameter. Follow OCP to set trip pressure based on operating parameters of single or two stage compressors.

3.12 OPERATING PROCEDURE:

Starting and stopping the compressor should be carried out as per standard operating procedure (SOP) to
prevent mistake and accidents. Each refrigerant plant has its own sequence of operations for starting and
stopping. As only the compressor is discussed here, the operating manual for the plant concerned should be
consulted.

3.13 PREPARATION FOR COMPRESSOR OPERATION:

When a new compressor has been installed the necessary arrangements for its initial run must first be made. It
must be filled with oil, using the correct brand (refer to lubrication chart.) for renewal and topping up of oil refer to
the same chart.

3.14 OIL CHARGING:

Follow the procedure as below to charge oil in compressor crankcase using oil charging pump i.e. compressor
shutdown is not required.
a. Observe standing pressure when compressor is not in operation. Generally it will be 10 to 12 kg/cm2(g).
b. Ensure suction & discharge stop valves provided on compressor connection are accessible and stop valves
are in closed condition.
c. TAH8 valve provided for oil charging or oil drain is in closed condition.
d. Connect oil charging pump outlet hose connection to TAH8 valve ½”BSP(M) connection. Confirm the hose
connection is leakage proof.
e. Open discharge stop valve & start the compressor within minute or so suction pressure will reduce to 2
2 2
kg/cm (g). Now partially open suction stop valve to maintain suction pressure about 2 kg/cm (g).
f. Open TAH8 valve & start oil charging into crankcase.
g. Check crankcase oil level though sight glass until level slightly exceeds the max level marked on oil level
glass.
h. Close TAH8 valve and disconnect the hose.
i. Use necessary PPE as prescribed for safety in the plant room to attend the ammonia compressors.
j. KPCL offers oil charging pump (part no. - 085.31.380.50.)

3.15 OIL PRESSURE ADJUSTMENT:

2
a. The lubricating oil pressure is set to 1-1.5 kg/cm (g) during the factory air run test, use pressure regulators
provided on the oil pump to set lubricating oil pressure & control oil pressure at site.
b. Start compressor and observe suction & oil pressures.
c. Remove cap from oil pressure regulator.
d. With the aid of screwdriver, turn slotted set pin anticlockwise or clockwise, to obtain lower or higher oil
pressure respectively.
2
e. Maintain oil pressure 1.5 kg/cm (g) above suction pressure.
f. Regulate oil pressure until desired suction pressure & temperature is achieved and it is steady.
g. Screw cap back on oil pressure regulator

3.16 STARTING:
When putting the machine into operation for very first time or after complete dismantling, it may happen that the
gears of oil pump are dry and the pump has difficulty in picking up the oil. In this case the union nut on the upper
line between the suction oil strainer and the oil pump should be loosened and the pump casing filled with oil. The
union nut should then be tightened. On starting following procedure should be adopted.
a. Make sure that suction stop valve on compressor & liquid stop valve of liquid receiver are shut. Check position
of manually operated expansion valve. (If fitted).
b. Open delivery stop valve on compressor and all other stop valves in refrigerant circuit, except those
mentioned in step 'a' (see also operating manual of the refrigerant plant concerned for cooling water etc.)

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c. Start compressor. After about 1 minute it should become operative.

d. Open compressor suction stop valve slowly.
e. Open liquid stop valve completely.
f. Adjust pressure gauge service valve (K5) in such a way that the pointers do not vibrate. On compressors
fitted with automatic capacity control nothing further is required to be done. On compressor with manually
operated capacity control, however, the necessary number of cylinders should be switched in manually.
g. During the first quarter of an hour after putting the compressor into operation, its functioning should be
checked carefully and during this time, the attendant should not leave the compressor room.
h. Refer operating instructions for the refrigerating plant for further action required.

3.17 SUPERVISION DURING OPERATION:

While the compressor is operating the following should be checked regularly:
a. Lubrication (oil pressure and oil level)
b. H.P. safety valve (leakage)
c. Pressure gauges (correct pressure reading and Gauge pointers stationary)

3.18 STOPPING:
a. Shut liquid stop valve on condenser and then compressor suction stop valve.
b. Stop compressor.
c. Refer operating instruction for the refrigerating plant concerned for further action required.

d. The refrigeration system provider should provide one or more emergency stop devices at appropriate
locations to avert actual or impeding danger.

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4. CAPACITY CONTROL SYSTEM - SINGLE STAGE

COMPRESSOR
Capacity control system is used to balance the compressor cooling capacity to the refrigeration load. This is
achieved by operating unloaded piston valve assembly by means of high pressure hydraulic oil circuit through 3
way solenoid valves. This loading- unloading of cylinder is explained in chapter no. 2 under heading “VALVE
LIFTING MECHANISM”.
The capacity control can be exercised by either manual or automatic operation of3-way solenoid valve.
In case of manual capacity control, the solenoid valves are either manually actuated through toggle switch or
through mechanical manual over-ride provided to solenoid valve.
In case of automatic control, the solenoid valves are actuated by electrical remote control source. This electrical
remote source may be a temperature sensing device installed in the space to be cooled or may be LP pressostat
fitted to suction pipe of compressor.

LIMITS OF PART LOAD OPERATION -

SINGLE STAGE COMPRESSOR
1. As a general rule, irrespective of refrigerant and conditions of operation, it is advisable not to run the
compressor at minimum part condition for a prolonged period of time.
2. In case of continuous part load operation of ammonia refrigerant system, all existing standard capacity
control steps given in the tables can not be used. There is a limitation, with respect to minimum capacity,
which depending on the amount of suction superheat, is determined by maximum discharge temperature.
This part load condition cannot be eliminated by applying cylinder head water cooling system.
3. In case of R22 there are least possibilities of very high discharge gas temperature. Therefore, all capacity
control steps can be used for these refrigerants. Only under very extreme conditions like, ambient
temperature more than 40°C and suction gas superheat may exceed very high, this situation may occur
that during part load operation and discharge temperature may reach to 170°C and/or oil temperature
reaches to 70°C. In this case, it is not permitted to switch off the cylinder down to standard minimum
capacity step. (Ref. Fig. 7 to 12 for Single Stage and Fig. 14 to 22 for Two Stage Compressors).

CAPACITY CONTROL DIAGRAMS (SINGLE STAGE)

* TDV – Time delay valve

* SOV – Solenoid operated
valve

Cylinder Block
Compressor No. Capacity
Model KCX1 %
1

SOV No. 1 ON  100

Figure 7

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Cylinder Block No.

Compressor Model Capacity
KCX2 %
1 2
TDV OFF (Direct
-  50
Connection)
SOV No. 1 ON   100
Figure 8

Cylinder Block No.

Compressor Capacity
Model KCX3 %
1 2 3
TDV OFF (Direct
- -  33
Connection)
SOV No. 1 ON  -  67

SOV No. 2 ON    100

Figure 9

Cylinder Block No.

Compressor Model Capacity
KCX4 %
1 2 3 4
TDV OFF (Direct
  - - 50
Connection)
SOV No. 1 ON   -  75

SOV No. 2 ON     100

Figure 10

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Cylinder Block No.

Compressor Capacity
Model KCX6 %
1 2 3 4 5 6
TDV OFF (Direct
 -  - - - 33
Connection)
SOV No. 1 ON    -  - 67

SOV No. 2 ON       100

Figure 11

Figure 12

Cylinder Block No. Capacity %

Compressor
Model KCX9
1 2 3 4 5 6 7 8 9
TDV OFF (Direct
 -  - - - - - - 22
Connection)
SOV No. 1 ON    - -  - - - 44

SOV No. 2 ON     -   -  78

SOV No. 3 ON          100

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Figure 13

Compressor Cylinder Block No.

Capacity
Model KCX12 %
1 2 3 4 5 6 7 8 9 10 11 12
TDV OFF (Direct
   - - - - - - - - - 25
Connection)
SOV No. 1 ON    - - - - - -  -  42

SOV No. 2 ON    -  -   -  -  67

SOV No. 3 ON         -  -  83

SOV No. 4 ON             100

CAPACITY CONTROL DIAGRAMS (TWO STAGE)

LP HP Capacity
Compressor Cylinder Block No. Ø
Cyl Cyl %
Model KCX21
1 2 3 -
TDV OFF
(Direct - -  0 1 - -
Connection)
SOV No. 1 ON    2 1 100 2

Figure 14

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Cylinder Block No. Ø

Compressor LP HP Capacity
Model KCX31 Cyl Cyl %
1 2 3 4 -
TDV OFF
(Direct -  - - 0 1 - -
Connection)
SOV No. 1 ON   -  2 1 67 2

SOV No. 2 ON     3 1 100 3

Figure 15

Figure 16

Compressor Model Cylinder Block No. Capacity Ø

LP Cyl HP Cyl
KCX42 1 2 3 4 5 6 % -
TDV OFF (Direct
- - -  - - 0 1 - -
Connection)
SOV No. 1 ON - -    - 2 1 50 2

SOV No. 2 ON -     - 3 1 75 3

SOV No. 3 ON       4 2 100 2

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Figure 17

Compressor Model Cylinder Block No. LP HP Capacity Ø

KCX51 1 2 3 4 5 6 Cyl Cyl % -
TDV OFF (Direct
 - - - - - 0 1 - -
Connection)
SOV No. 1 ON  -   - - 2 1 40 2
SOV No. 2 ON  -    - 3 1 60 3
SOV No. 3 ON      - 4 1 80 4
SOV No. 4 ON       5 1 100 5

Figure 18

Compressor Cylinder Block No. LP HP Capacity Ø

Model KCX63 1 2 3 4 5 6 7 8 9 Cyl Cyl % -
TDV OFF (Direct
- - -  - - - - - 0 1 - -
Connection)
SOV No. 1 ON - -   - -  - - 2 1 33 2

SOV No. 2 ON  -    -   - 4 2 67 2

SOV No. 3 ON          6 3 100 2

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Figure 19

Compressor Cylinder Block No. LP HP Capacity Ø

Model KCX72 1 2 3 4 5 6 7 8 9 Cyl Cyl % -
TDV OFF (Direct
- - -  - - - - - 0 1 - -
Connection)
SOV No. 1 ON -  -  - -  - - 2 1 29 2
SOV No. 2 ON -  -  - -   - 3 1 43 3
SOV No. 3 ON      -   - 5 2 72 2.5
SOV No. 4 ON          7 2 100 3.5

Figure 20

Compressor Cylinder Block No. LP HP Capacity Ø

Model KCX84 1 2 3 4 5 6 7 8 9 10 11 12 Cyl Cyl % -
TDV OFF (Direct
- - -  - - - - - - - - 0 1 - -
Connection)
SOV No. 1 ON - -   - -  - - - - - 2 1 25 2
SOV No. 2 ON  -   -   - -  - - 4 2 50 2
SOV No. 3 ON     -    -  -  6 3 75 2
SOV No. 4 ON             8 4 100 2

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Figure 21

Compressor Cylinder Block No. LP HP Capacity Ø

Model KCX93 1 2 3 4 5 6 7 8 9 10 11 12 Cyl Cyl % -
TDV OFF (Direct
- - -  - - - - - - - - 0 1 - -
Connection)
SOV No. 1 ON - - -   - -  -  - - 3 1 33 3
SOV No. 2 ON  - -   - -  -   - 4 2 45 2
SOV No. 3 ON  -       -   - 7 2 78 3.5
SOV No. 4 ON             9 3 100 3

Figure 22

Compressor Cylinder Block No. LP HP Capacity Ø

Model KCX102 1 2 3 4 5 6 7 8 9 10 11 12 Cyl Cyl % -
TDV OFF (Direct
 - -  - - - - - - - - 0 2 - -
Connection)
SOV No. 1 ON  -   -   - - - - - 3 2 30 1.5
SOV No. 2 ON         - - - - 6 2 60 3
SOV No. 3 ON         -  -  8 2 80 4
SOV No. 4 ON             10 2 100 5

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5. OPERATING INSTRUCTION & CAPACITY

CONTROL SYSTEM TWO STAGE COMPRESSOR

5.1 GENERAL

We are manufacturing Two Stage Compressors in KCX versions.

a. KCX21 Ref Fig. No. 14
b. KCX31 Ref Fig. No. 15
c. KCX42 Ref Fig. No. 16
d. KCX51 Ref Fig. No. 17
e. KCX63 Ref Fig. No. 18
f. KCX72 Ref Fig. No. 19
g. KCX84 Ref Fig. No. 20
h. KCX93 Ref Fig. No. 21
i. KCX102 Ref Fig. No. 22

Last single digit of nomenclature indicates no. of HP cylinders and remaining one or two digit indicate no. of LP
cylinders in the compressor e.g, KCX31, 1 = no. of HP cylinders and 3 = no. of LP Cylinders.
All these compressors are equipped with Electrically operated Solenoid Valves for capacity control operation of
compressor. The details of no. of Solenoid Valves and % capacity achieved with these valves is shown in figure 7
to 22. Against each
Capacity control step, ratio Ø is indicated. This Ø is defined as ratio.

NO. OF LP CYLINDERS IN OPERATION

Ø = TOTAL NO. OF HP CYLINDERS IN
OPERATION

This Ø ratio plays an important role in selecting steps to move for higher capacity control operation.

5.2 INTERCOOLERS:
Two stage refrigeration systems with either booster-highstage or compound compressor require Interstage Gas
Cooler to cool down the compressed gas of the LP stage to a level acceptable for the HP stage. Basically two-
stage compression becomes necessary when condensing temp tc - evaporating temp to exceed 50 K with
Ammonia or 70 K with Freon, at full load conditions. Compressor selection program SPARC assists to select
compressors for evaporating temperature below (-)15 deg C with different interstage gas cooler arrangements.
There are four different types of intercoolers widely used in vapour compression refrigeration systems namely
1. System A : Liquid Injection interstage gas cooling
2. System B : Dish. gas cooling & liquid subcooling
3. System C : Open flash type intercooler
4. System D : Closed flash interstage cooling (shell & coil type intercooler)

5.3 STARTING OF STANDSTILL TWO-STAGE COMPRESSORS

In case of two-stage compressors refer capacity control diagram of respective compressor model. Ensure Time
Delay SOY (TDSOV) is energised to enable unloaded starting of compressor. After 20 seconds time period de-
energise TDSOV electrically to connect control oil pressure line from oil pump to one or more H.P. cylinders to
become operative through VLD mechanism. During first start-up of compressor suction pressure & temperature
will be relatively high as refrigeration plant is not in operation. Initially one or more
0
H.P. cylinders will be in operation till evaporating temperature reach to (-)10 C. That means during starting none
of CCSV is allowed to be energized and all L.P. cylinders are out of operation.

5.4 PROCEDURE FOR STARTING TWO-STAGE OPERATION

1. Refer capacity control diagram of respective compressor model and note down part load capacity control
steps and volume ratio (Ø).
2. Refer "FIELD APPLICATION DIAGRAM" Draw horizontal lines for designed condensing temperature for
each volume ratio (Ø). These horizontal lines will intersect to bold lines of field application diagram, select

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right side intersecting points and draw vertical lines from these intersecting point. These vertical lines will
indicate minimum evaporation temperature required to shift to this capacity control step.
3. Note down each switch over evaporation temperature for every corresponding capacity step say
For Ø evaporation temp is t1 - (minimum capacity step)
For Ø evaporation temp is t2 - (Second capacity step)
For Ø evaporation temp is t3 - (Third capacity step)
For Ø evaporation temp is t4 - (Fourth capacity step and so on)
4. There are two situations wherein two-stage operation is required:
A) The compressor is started at a relatively high evaporating temperature
When compressor is started after a long period of time or when the compressor operates on a batch
operation
e.g. warm product is loaded in freezing tunnel.
In this situation it is not permitted to switch over to two-stage operation with minimum capacity until the H.P.
cylinders already in operation have lowered (in single stage) the evaporating temperature and lies inside
the field of application of the two stage minimum part-load step concerned. After this first step has been
energized, ensure intermediate pressure is within operating limit. Limiting pressure ratio, Intermediate
pressure/ Suction pressure is 10.
For example:
2 2
If Intermediate pressure (Pm)= 6 kg/cm (g) & Suction pressure (Ps) = 0.5 kg/cm (g), pressure ratio
Pm/Ps= 6/0.5= 12; which is beyond operating limit.
2 2
Whereas, if Pm= 5 kg/cm (g) &Ps= 0.5 kg/cm (g), pressure ratio Pm/Ps= 5/0.5 = 10. Therefore
intermediate cut-off pressure depends on minimum suction pressure.
B) The compressor started at relatively low evaporation temperature:
This situation occurs after the compressor has been stopped for certain period of time because of low
capacity requirements of the installations. In this condition, start the compressor, observe evaporation
temperature. If it is less than t1 go to next capacity steps and so on. In the case of ammonia, it is necessary
to ensure compressor is not working with direct connected H.P. cylinders; otherwise the compressor would
be running in single-stage under two-stage evaporating temperature, resulting in too high a discharge
temperature.

5.5 LIMITS OF OPERATIONS:

All capacity steps of compressor can be used for “PULL DOWN TEMPERATURE” of system.
Once on 100% compressor load, the desired temperature of product to cool, is attained, the thermostat may cut
off compressor capacity wise, as per the system load is demanded for. For maintaining minimum load
requirements, compressor may shift to minimum capacity requirement. For this minimum capacity step you have
to be very careful.
For determining minimum capacity control step:
Draw vertical line on “FIELD APPLICATION DIAGRAM” (Fig. No 23) from design evaporation temperature point
and horizontal lines corresponding to designed condensing temperature for every Ø value. Note intersecting point
of both these lines. For certain value of Ø some points will be out of bounded area of diagram. Capacity control
steps corresponding to these valves are not at all allowed for this application.
ALL THESE STEPS WILL BE WELL UNDER-STOOD FROM EXAMPLE GIVEN BELOW EXAMPLE NO. 1:
Compressor KCX51 with Ammonia Gas, design evaporation temperature (-)40°C & condensing temperature
40°C. Saturation temperature on gauge +30°C. (i.e. prolonged standstill condition of compressors).

STEPS:
1. NOTE DOWN PARAMETERS OF REFRIGERATION SYSTEMS:
A. Compressor Model KCX51
B. Gas Used in System Ammonia
0
C. Designed Condensing Saturation Temperature of System = 40 C
0
D. Designed Evaporation Saturation Temperature of System = (-)40 C

2. NOTE DOWN CAPACITY CONTROL STEPS AND Ø VALUES FROM CAPACITY CONTROL DIAGRAM
(FIG. 17).
CAPACITY STEP Ø VALUE
40% 2.0
60% 3.0
80% 4.0
100% 5.0

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3. Draw horizontal line for 40°C condensing temperature and Ammonia Gas for Ø = 2, 3, 4, 5. Intersecting
points, to right side of field application bold lines, will be a1, a2, a3, a4. Corresponding to these points
read vertically down, to find minimum evaporation temperature for every capacity step.

4.
Point Evaporation mini. Temperature Capacity Step
0
a1 t1 = (-)12 C 40%
0
a2 t2 = (-)22 C 60%
0
a3 t3 = (-)27 C 80%
0
a4 t4 = (-)32 C 100%

5.
a. Start condenser water pump/Brine pump/cooling tower fans pump etc.
b. Put all capacity control solenoid valve to OFF position.
c. Start compressor. Observed evaporation temperature is say 15°C. Run compressor on HP Cylinder only
till you get evaporation temperature t1 = (- )12°C.
d. Once you attain t1 = (-)12°C load compressor to 40% capacity by operating solenoid valve 1 manually or
electrically. Let compressor run to 40% capacity till evaporation temperature comes down to t2 = (-)22°C.
e. Once you got evaporation temperature t2 = (-)22°C, load compressor to next capacity step i.e. 60%
capacity. Run this compressor to this capacity till you get next temperature t3 = (-)27°C.
f. Follow this sequence till compressor is loaded to 100%.

5.6 DETERMINATION OF LIMITS OF OPERATION:

Determine minimum capacity control step to operate compressor in two stages for taking care of reduced
installation heat load.
As described in limits of operating, draw a vertical line on field application diagram corresponding to designed
evaporation temperature (-)40°C, and horizontal line corresponding to designed condensing temp. 40°C for Ø 2,
3, 4, 5. Intersecting points will be point’s b1, b2, b3, & b4 as shown. Since point b1 and b2 are falling outside the
bounded area, we cannot use capacity steps Ø2, and 3, i.e. capacity control steps 40% and 60% (Ø = 2 and 3)
cannot be used for maintaining designed evaporation temp. (-)40°C. Minimum capacity steps to be used is 80%
(Ø = 4) only. (These 40% and 60% capacity steps can be used for heat load pull down situation only.)
Since in this example, you are not permitted capacity steps of 40% and 60% for taking care of minimum external
heat load, you may be tempted to run the compressor on single stage i.e. (On HP Cylinders) all solenoid valves
are in off position. But do not do this. Below 80% capacity operation, you stop running of compressor till you get
higher permitted evaporation temperature for 60% loading of compressor.

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FIELD APPLICATION DIAGRAM

Figure 23

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6. PARALLEL OPERATION OF COMPRESSOR

GENERAL
Whenever two or more compressors are installed with common suction header piping and these compressors are
operating simultaneously, the operation is called as parallel operation of the compressor. In this case, discharge
line of individual compressor may be either connected to common discharge header or separately to individual
condensers.
During operation, the oil return from evaporator(s) will not be uniform to the crankcases of different compressors.
This may cause shortage of oil in some compressors and excess in other, leading to failure of compressor. To
overcome this situation following precautions are necessary to be taken during installations:

INSTALLATIONS PRECAUTIONS
1. See that all compressors are installed in same horizontal level.
2. Connect all compressors by oil equalizing line with isolating valve in between each pair of compressor. Oil
equalizing line must run in level with oil equalizing tapping or below the oil level of the compressor. Under no
circumstances this line should run at level higher than compressor oil level.
3. Connect all compressors by crankcase gas equalizing line with isolating valve in between each pair of
compressor. Under no circumstances this line should run below than that of crank case gas equalizing
tapping provided on crankcase.
4. For multiple condensing units interconnect all condensers to equalize condensing pressure with proper
isolating valves.
A construction whereby just one horizontal line with ample diameter, fitted between two adjacent compressors
onto their sight glass connections, serves both purposes, viz to maintain equal oil levels as well as equal
crankcase pressure. See figure 24 for reference.
No extra gas equalizing lines are necessary because the vertical location of the oil equalizing line is such, that the
prescribed oil level in the crankcase is approx., half way this line thus leaving ample passage to equalize the
crankcase pressures as well.
A stop valve in the equalizing line should be mounted with the spindle in a horizontal position in order to avoid the
interruption of the oil level, when the valve is open.
We can supply a set of oil and gas equalizing line consisting of
a) TAL valve type 40.
b) Tee connection left
c) Tee connection right
d) Joining 40 NB steel pipe
The number of parallel compressors to be interconnected in this way should be restricted to three, whereby the
length of the equalizing line between the sight glasses of two adjacent compressors should preferably not exceed
2 mtrs.
Moreover, it is recommended always to provide each compressor with an individual oil separator and
corresponding oil return line to its crankcase.
OPTIONAL INSTRUCTIONS:
1. Before starting all these parallel connected compressors, OPEN fully. isolating valves installed in gas and oil
equalizing line and then follow other instructions for starting the plant.
2. If one of the compressor needs to be cut off from the operation CLOSE fully isolating valve related to the
compressor to be cut off and then follow other instructions for stopping the concern compressor.

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A Kirloskar Group Company

Figure 24

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A Kirloskar Group Company

7. PERIODICAL MAINTENANCE AND ITS SCHEDULE

7.1 GENERAL
The compressor, like any other machine, requires regular maintenance, If it is maintained well, the cost of this
work is recovered for the most part through improved performance. It is, therefore, recommended to follow the
instruction as strictly as possible. There is, however no objection in carrying out the following at times other than
indicated, provided the periods between do not exceed the stated number of hours. It is necessary to inspect the
compressor completely every year, irrespective of number of hours it has run.
When it is necessary to work on the compressor, the machine must always be evacuated beforehand.

7.2 PERIODIC INSPECTION

In order to prevent unexpected failures, it is recommended to inspect the compressor periodically after
commissioning at a certain number of operating hours. In many cases a slight deviation from the normal situation
can be observed during inspection and that enables to take action in time.

7.2.1 Kirloskar Remote Management System (KRMS)

Therefore, KRMS may be installed in compressor for ‘Proactive Maintenance’ of the Compressor.
Kirloskar Remote Management System (KRMS) brings the vigilance of Compressor under the fingertips of user.
As the name suggests, the remote management system i.e. KRMS will increase the accessibility of information of
the operating conditions, by not only allowing the users to access the information through wired connections but
also through our web portal. This web portal can be accessed by our customers, vide remote access. The user
will not only be able to observe but also record the available information for further analysis and troubleshooting.

KRMS can be further subdivided into two units:

1. Kirloskar Compressor Controller
2. RMS (Remote Monitoring System)

RMS
The RMS unit receives data from the compressor controller unit which it then transmits into the KPCL KRMS web
portal through a cellular network. The users are provided with individual username and password, through which
his/her account, can be accessed.

The RMS unit when connected to the network can perform the following functions:
• Transmitting information of real time parameters onto the KPCL Springboard.
• Auto alerts of Alarms and safety trips.
• Set/Reset Alarm, Safety trip & operating parameters.
• Auto mail of log data every week/month.
• Auto alert messages & email for periodical maintenance.

The Company will also have access to the data received from the compressor for ‘Proactive Maintenance’.

The Company strongly recommends to the Customer/End User to buy and use KRMS which facilitates
‘Proactive Maintenance’ in turn getting effective after sales service.

7.2.2 Maintenance
During the first 50 operating hours the compressor should be checked regularly for all the points mentioned in
maintenance schedule (refer to chapter 7.14), and more frequently in cases where irregularities are found.
The frequency stated in maintenance schedule is to be taken as a recommendations based on the experience
gained in practice.

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7.3 EVACUATION OF COMPRESSOR PRIOR TO OPEN FOR INSPECTION OR MAINTENANCE

a) Close the suction stop valve and ensure discharge stop valve is open.
b) Close the stop valve in the oil return line of the oil separator.
c) In the case of two-stage compressors with liquid injection inter stage gas cooler: shut off the liquid lines of
the inter stage cooler.
d) Bypass the electric contacts of the suction pressure safety switch / pressure transducer.
e) Start compressor and wait until the suction pressure is below the atmospheric pressure. Caution: Stop the
2
compressor immediately as soon as the lubricating oil pressure becomes lower than 1.5 kg/cm
f) Stop compressor and close discharge stop valve.
g) Fix a hose to K5 connection and put its open end in water bucket
h) Slowly open the K5 pressure gauge stop valve so that the discharge gas still present in the compressor
can escape via the hose.
i) Remove the hose.
j) Follow step (a) to (i) except step (e) wherein compressor starting is not possible.

7.4 OILPUMP
The oil pump should be completely dismantled after every 9,000 hours running. Various parts of the pump will
have become dirty during that period, impairing its efficient operation, and producing unnecessary wear if not
rectified. Ensure that the oil pump is reassembled correctly. Incorrect operation of the oil pump will cause faulty
lubrication and manufactured of the compressor controls. This may result in additional wear, or even damage to
the compressor.
NOTE: On dismantling, the gears should be marked so that, while reassembling, it is possible to refit them in
exactly the same way. This is necessary as the gears are meshed to each other.

7.5 LUBRICATION OIL

It is very important to pay full attention to the lubrication of compressor. The lubrication record chart will be of
great assistance provided the records are accurately filled. With the aid of this record, time of oil renewal, as well
as the consumption, can be checked. During initial 50 hrs. check oil quality regularly and replace after 50 hrs. if
any sign of discoloration is observed. The dust, dirt, rust and weld slag from refrigeration system which is not
retained by suction gas strainer eventually finds their way in the lubricating oil. Therefore, check or replace oil
replace after 100, 500, 1500 & 3000 operating hours if any sign of discoloration is observed. Afterwards, replace
oil after every 3000 hr. if discoloration is observed or else replace oil once in year.
Therefore, in the case of a new installation (or after expansion or modification of an existing installation) the oil
should be renewed twice during the first 100 operating hours of the compressor (Refer to the maintenance
schedule overleaf). In the case of a possible rapid discoloration of the oil, it should be drained and renewed
sooner than at the times mentioned in maintenance schedule. Oil change must take place as soon as the oil is
dirty. Dirty oil has a dark colour and is hardly transparent. In order to find out if it is necessary to change oil, a
slight quantity of oil should be drained via the oil charging valve (TAH8) and compared with fresh oil.
Never mix different brands of oil. In case brand of oil is changed from earlier one, first remove all the stale oil from
filters, oil pump, crankcase, shaft seal, oil separator and refrigeration system and flushed with nitrogen to remove
traces of earlier oil.
Oil top up can be carried out without affecting the operation of the compressor, the oil may be topped up by
means of a separate oil charging pump. This pump enables the oil to be forced into the crankcase via the oil
charging valve (TAH8), against suction pressure.

Renewal of the oil should be carried out when the compressor is stopped at working temperature. Evacuate the
compressor (refer to chapter 7.3) and fill the crankcase with fresh oil as far as possible via the service opening
using oil charging pump.

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7.6 OIL Filters

When the compressor is put into operation in most of the cases, oil filters have to be cleaned / replaced during
first 50 operating hours. Dirty oil may cause clogging of suction wire gauze filter; this will be indicated on pressure
gauge as drop in oil pressure. In this case it is necessary to clean the suction wire gauze filter therefore it is
recommended to check oil pressure regularly during initial 50 operating hours. Besides thorough cleaning of
suction wire gauze filter element, the discharge paper filter should be replaced. Thereafter clean suction wire
gauze after 100, 500, 1500 operating hours & replace after 3000 operating hours and replace discharge paper
after 100, 500, 1500 & 3000 operating hours.
Afterwards clean suction wire gauze filter after every 1500 operating hours and replace after every 3000 operating
hours. Replace discharge paper filter after every 1500 operating hours the compressor. Refer maintenance chart
for periodicity to clean or replace oil filter.
Note: Discharge paper filter element 03 nos. are supplied along with compressor.

7.7 REFRIGERANT SUCTION GAS STRAINER

After the initial start of the compressor, clean suction gas strainer regularly during first 50 operating hours. Then
after, 100 operating hours, until no dirt and scale is trapped in suction gas strainer and finally after 500 operating
hours. Afterwards, clean suction gas strainer after every 1500 operating hours.

7.8 VALVES
Suction and discharge valves are very important parts of the compressor. Hence periodic maintenance is very
important.
Even for the slight damage to the valve rings it is advisable to renew them. Damaged valve seats must also be
repaired or renewal. If the seat face lips are only slightly damaged, they can be repaired by grinding with a very
fine abrasive compound, using a completely smooth glass plate. Heavily damaged seats must be turned off on a
lathe and lapped. In order to maintain the correct valve lift, the chamber of the delivery valve, in which the stroke
limitor centres, must be turned out. As this work is specialised, it is recommended that the supplier should do it.
Before reassembling the valve, all the parts should be cleaned and dried carefully. Then these should be lightly
oiled, with the same oil as used in the compressor. After reassembling, check that the valve rings can be pushed
up flat against the stroke limitor. Only in this way the correct assembly of the valve rings and spring is ensured.
It is recommended to have as many complete valve assemblies in stock as there are cylinders. This will
considerably reduce the shutdown periods of the compressor during routine inspection of the valves, since
complete new valve assemblies can be fitted directly to the compressor in place of the original valves. Those
removed can be inspected at leisure and repaired as necessary, once the compressor has put back into operation
with the new valves. Spare parts should also be available in order to completely renovate damaged valves. All
valve rings and spring must be renewed after about 9,000 hours running.
It is empathetically pointed out that assembly of the valves should be carried very carefully. Incorrectly assembled
valve will immediately give rise to trouble.
When valve components are replaced, it is important to make a note of the date in the compressor logbook so
that ready check is available to indicate when valve rings and springs required renewal.

7.9 SAFETY VALVES

The safety valves should be inspected only if they are leaking. They should then be disconnected and cleaned.
Upon reassembly they should be light oiled with the same oil as used in compressor.
The compressor must on no account be kept running with an open-or-leaking safety valve as the machine would
then become too hot and the possibility of damage or to even seizure of the piston and cylinder liner would arise.
The line on the suction side of the safety valve should be cold when the compressor is operating. When it is found
warm the safety valve is leaking thus causing loss of capacity, in this case the safety valve must be repaired or
renewed.

7.10 PISTON RINGS

The piston and scraper rings should be inspected after 5,000 hours running. In the stretched and cold condition
they should have a gap clearance of 1.0-1.1mm. These rings must never be removed from the piston if not strictly
necessary. Only when it is essential they should be removed, and then only with the correct ring removal tool.
When used, but undamaged, rings are fitted to the piston, it is essential that each ring should be replaced in its
original ring groove. This operation must always be carried with the aid of correct ring fitting tool. When fitting a
complete new set of piston rings, the chromium plated one must always be fitted in the topmost groove of the
piston. Measuring the rung clearance can be carried out by pulling up the piston so that the ring to be checked is
visible in the top of the cylinder but still remain in it. The gap clearance can then be measured with a feeler gauge.

7.11 BEARINGS
When a main bearing bush located in either of the end covers requires renewal, particular attention should be
paid to ensure that it is inserted absolutely true to the centre line of the housing bore. If it is introduce even slightly
out of centre, it will become distorted and will remain so even if forced for full length into the housing. It is

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therefore essential that bush should be pressed into end cover, with both the bearing cover and the bush itself
held true between the parallel faces of a press.
A locating pins is fitted in the end face of both end cover bearing bushes, thus preventing it from rotating, the main
bearing bushes are provided with an oil distributor well and when the end covers are fitted to the compressor it
must be ensured that this well lies in a position 45 from vertically upwards position measured in the direction
opposite to the rotation of the shaft.
While assembling the connecting rods on the crankshaft, full attention should be paid to tightening of the
connecting rod bolts. These bolts should be so tightened that both the connecting rod halves touch each other.

7.12 SHAFT SEAL

The shaft seal should be inspected after about 4,500 hours running. In most cases only the rubber ‘O’ rings will
have to be renewed, to ensure that a reliable seal is maintained.

7.13 LOG SHEET

OPERATION LOGSHEET
Compressor Model:
Compressor Sr. No. :
Discharge Temperature in ( C)
Discharge Pressure (kg/cm g)

Chiller/Evaporator
0
Suction Temperature in ( C)

2
Suction Pressure (kg/cm g)

Condensation

Oil Level (Min/Mean/Max)

0
2

Temp (Refr)

Temp (Refr)

Operator Remarks/Sign
Intermediate Pressure

Oil Pressure (kg/cm )

2
Working hours
% of Loading

Current (A)
(kg/cm g)

Out ( C)

Out ( C)
2

Volt (V)
In ( C)

In ( C)
0

0
Time

7.14 MAINTENANCE SCHEDULE:

Besides the periodical inspection of compressor after commissioning described in chapter 7.2, the maintenance
schedule below indicates after how many operating hours maintenance operations have to be carried out. This
schedule can be regarded as a directive, based on the experience gained with a large number of compressors.
For most of the maintenance operations the compressor must be put out of action and should be made during the
normal shutdown periods as much as possible, so that the compressor is always available for operation. The
schedule has been drawn up in such a way that several operations can be carried out simultaneously, which
results in reduced maintenance costs. Moreover, it is recommended to have the compressor inspected annually
by the installation engineer, irrespective of the number of operating hours.

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HOURS OF OPERATION
COMPONENT
ACTION 150 750 1050 1200 1300
OF SYSTEM 0-50 100 500 3000 4500 6000 9000
0 0 0 0 0
OIL LEVEL CHECK
OIL
PRESSURE
(DIFF.),
DISCHARGE
PRESSURE
AND
SUCTION
CHECK & CHECK DAILY
PRESSURE
RECORD
INTERMEDIA
TE
PRESSURE
FOR TWO
STAGE
COMPRESSO
R
CHECK
FOR
PRESSURE
PROPER            
SWITCHES
FUNCTIO
NING
REPLACE
LUBRICATIN (R) /
        
G OIL CHECK
(1)
(CH)
CLEAN (C)
SUCTION OIL
/
WIRE GAUZE C C C C R C R C R C R C
REPLACE
FILTER
(R)
DISCH. OIL
PAPER REPLACE            
FILTER
SUCTION
GAS CLEAN            
STRAINER
CHECK &
ADJUST
        
BELT
TENSION
CHECK
TIGHTNE
SS OF
DRIVE FLYWHEE CHECK EVERY 1500 HOURS
SYSTEM L
RETAININ
G PLATE
CHECK
ALIGNME
NT OF       
COUPLIN
G
COMPRESSO
CHECK
R AND
TIGHTNE      
FOUNDATION
SS
BOLTS

Note:
1) In the case of a possible rapid discoloration of the oil, it would be drained and renewed sooner than at the
times given above. This time is dependent on pollution.
2) The periodicity to clean/ renew oil, oil filters and suction gas strainer is highly depends on the cleanliness of
compressor installation.
3) We recommend complete overhaul of the compressor after three years or 26,000 hours of operation
whichever is earlier.

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8. ACCESSORIES

The user / System provider should ensure that accessories like Stop valves, Pressure Switches, Pressure
gauges, Oil Separator and Crankcase heater should be CE mark/ approved.

8.1 PRESSURE SWITCHES

In the delivery and suction lines and the lubrication system, pressostats may be fitted to protect both the
compressor and the refrigerant plant. These pressostats are connected into the electrical control circuit of the
compressor driving motor and they interrupt this circuit when abnormal working conditions occur.
Following wiring diagrams of pressostat circuit (Fig. No.26 & 26A), are given for reference.
[While using diesel engine as a prime mover ensure that engine is provided with engine stop solenoid valve also
called as fuel solenoid valve, having engine safety controls like low lub. oil pr./over speed control/high water
temperature etc.]

8.2 HIGH PRESSURE PRESSOSTAT

This pressostat serves as protection against excessive discharge pressure and is connected to the gas delivery
line. The compressor is automatically switched off when the delivery pressure exceeds the pre-set maximum
value. The pressostat can also be arranged to operate, via an auxiliary contact, an alarm or a hooter. A lock
device provides protection against automatic reclosing of the broken contact when the pressure fails below the
pre-set maximum value. Moreover, to restart the compressor, the lock device has to be first reset manually.
NOTE: Before restarting the compressor the reason for high pressure tripping should be traced and
rectified.

8.3 LOW PRESSURE PRESSOSTAT

This pressostat is connected in the gas suction line and is adjusted at a minimum suction pressure. A fall in the
suction pressure below the pre-set minimum pressure causes the electric motor to be switched off.

8.4 INTERMEDIATE PRESSURE PRESSOSTAT

This pressostat is connected in the HP gas suction line and is adjusted at a maximum intermediate pressure; its
operating and locking off are similar to those of the HP pressostat. A rise in the intermediate Pressure above the
pre-set maximum pressure causes the electric motor to be switched off.

8.5 OIL PRESSURE DIFFERENTIAL PRESSOSTAT

This pressostat serves as a protection against too low oil pressure and is installed between the oil pressure gauge
stop valve and the suction pressure gauge stop valve. Thus the device is acted on by the actual pressure
differential across the pump, as indicated by these gauges. The minimum safe differential oil pressure is pre-set
on the pressostat. When the true oil pressure drops below the pre-set value, the electric motor is switched off by
the interruption of the control circuit. This circuit is automatically remade when the pressure exceeds the pre-set
value. Pressostat to be manually pre-set. The oil pressure switch incorporates an automatic time delay to bridge
the main contacts during start up to enable the compressor to start initially before any oil pressure has been built
up. If an alternative type of oil pressure switch without automatic time delay is to be used then external time switch
is necessary during start-up.

8.6 PRESSURE GAUGE PANEL

The no. of pressure gauges in panel depends upon type of compressor, i.e. 3 nos for single stage compressor
and 4 nos for two stage compressor. It is advisable to install the gauge panel at readable height and about 1
meter away from the compressor. This will protect the gauges and the piping from vibration of the compressor.
Refer Figure 25 that illustrates mounting of the gauge cutout panels.

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Figure 25 : Cut Out & Gauge Panel Mounting

Figure 26 : Wiring Diagram for Pressostats (for Electric Motor Drive)

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Figure 26A : Wiring diagram for pressostats (for diesel engine drive)

Figure 27 : Schematic wiring diagram for slip ring motors with stator rotor starters

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Figure 27A : Schematic wiring diagram for star delta starter for squirrel cage induction motor

8.7 DRIVE ARRANGEMENT FOR COMPRESSOR

Belt Drive: This drive system consists of standard flywheel, V-belt and motor pulley. The drive set is designed
keeping in mind the standard 4 pole electric motors, select the motor pulley from the drive chart to operate the
compressor at the required speed.
Direct Drive: The compressor shaft is coupled to the motor shaft using specially designed metal flexible couplings.
The maximum operating speed of the compressor is 1000 rpm so a 6 pole electric motor is required.

8.8 OIL SEPARATOR

The refrigeration compressor is lubricated by an oil charge that resides in its crankcase. Unfortunately, due to the
compression process, oil in fine mist or vapour form can be carried by refrigerant out into the system and as a
result not provide the required lubrication for the compressors components. The actual quantity of oil "carried
over" into a refrigeration system lead to a shortage of the lubricant in the compressors crankcase. The challenge
for refrigeration system engineers is to keep this vital lubricant where it is required and to facilitate the return of
any oil that have been released into the system. When the compression process takes place, the discharged high
pressure refrigerant exit the compressor it carries lubricating oil in the discharge line. This "carried over" oil enters
into condenser & evaporator which cause Oil fouling of the heat transfer surface and a loss of efficiency of a
refrigeration system. Oil entering in to refrigeration system reduces the overall rate of heat transfer; this increases
both operating head pressures and the saturated condensing temperature which effectively reducing the capacity
of the condenser. Particularly at very low temperatures, this might also lead to blockage of the system owing to
freezing of the oil in the evaporator. As a rule of thumb, for every 1K rise in condensing temperature above the
design condensing temperatures, the overall refrigeration capacity drops by approximately 1%. As a result, you
are getting far less efficiency out of the condenser. The purpose of this document is to highlight how to ensure
that any oil that leaves the compressor during the compression process returns as quickly as possible to the
crankcase. The best answer is to this challenge is to employ an oil separator.
The separator is fitted between the compressor and the condenser. In two stage compressors an additional
separator may be installed between the L.P. and H.P. cylinders, before the intercooler. The oil separator consists
of a closed cylinder fitted with a refrigerant inlet and outlet, oil drain stop valve, automatic oil return valve with float
and a demister pad.
The high pressure gas enters the separator and during separation the droplets enter in the wire mesh and collide
with the wire surface. The collected oil mist in wire mesh falls back as larger droplets in to the vessel. The
separated oil is collected at the bottom of the separator where a float controlled return valve is fitted. When the oil
level exceeds a preset level, the valve opens and the oil is returned under pressure to the crankcase, the valve
automatically shuts off when the oil level has fallen sufficiently. The hand operated oil drain is also fitted in order
to be able to drain the oil during the running in period as the oil is heavily polluted and therefore must not be
returned to the crankcase.

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Figure 28A

High efficiency: Demister Type Oil Separator (Fig. 28A)

Originally oil separator was designed to separate oil from discharge gas & 'just' maintain the correct oil level in the
compressor. Subsequently oil separator is well recognised for its critical role in preventing the circulation of oil
throughout the system. In order to have the refrigeration system operating at its highest levels of efficiency the
use of high efficiency demister type oil separator will further reduce the oil carry-over to an absolute minimum. A
wire mesh oil droplet separator is called demister is fitted in vessel. By installing efficient oil separator, it keeps the
heat exchangers on both the low and high sides of the system free to do what they are designed for, without being
penalised by insulating oil films. Higher efficiencies over the life of the plant will result in lower running costs.

Installation of an Oil Separator (Fig. 28A)

When installing an oil separator to a system it must first be pre-charged with oil. This quantity of oil is held in the
sump of the oil separator and is vital. If the oil separator is not pre-charged with the amount specified, (using oil of
the same type as that of the compressor), damage can result to the oil return float mechanism. Further to this, if
not pre-charged, the actual oil level in the compressor and its lubricating ability could be significantly affected due
to any pumped-out oil getting 'stuck' in the oil separators sump and not being able to return until such time as the
float mechanism is activated. The oil separator should be installed close to the compressor, in the discharge line
between compressor and condenser. It is recommended trade practice to install a check valve between the oil
separator's outlet and the condenser in order to prevent refrigerant from 'migrating' to the oil separator and
condensing there during the systems off cycle. As the internal float mechanism cannot differentiate between liquid
refrigerant and 'liquid' oil there is the risk that the float could lift off its seat and return liquid refrigerant to the
compressors crankcase. Any liquid refrigerant that enters the crankcase can produce a 'cooling effect' on the
sump oil, chilling it in temperature, raising its viscosity and consequently reducing the lubricating ability of the oil.
Liquid refrigerant may also wash out bearings leading to damage.

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8.9 CRANKCASE HEATER

The crankcase may be fitted with a built-in heater to maintain the oil at working temperature while the compressor
is stopped. Generally these crankcase heaters are only required for R-22 plants. This is because, while the
compressor is stopped, the crankcase oil may become saturated with liquid refrigerant, the extent depending on
the pressure and temperature. If the compressor starts under these conditions a sudden decrease in crankcase
pressure will cause dissolved liquid refrigerant to evaporate. This will cause foaming of the oil, thus impeding the
proper functioning of the oil pump, and also producing the possibility of an oil stroke. Heating of the oil while the
compressor is stopped, will, ensure that the above conditions do not arise.

Recommended Crankcase Heaters for Various Compressors

Sr. Compressors Type Heater Rating Qty. per Part No. Heater Part No. Heater
No. Watts. Compressor Assy. Cartridge
1 KCX1, KCX2, KCX3, KCX4, 325 1 082.26.181.50 082.26.181.51
KCX6, KCX21, KCX31,
KCX42, KCX51
2 KCX9, KCX12, KCX63, 525 1 082.26.182.50 082.26.182.51
KCX72, KCX84, KCX93,
KCX102

8.10 INTERSTAGE COOLER

Most two-stage compressors are fitted with an intercooler between the L.P. delivery and the H.P. suction. While
being compressed the gas temperature rises to such a level that, without intercooling, further compression in the
second stage raises the temperature to a dangerous degree. The Intercooler reduces the temperature of the gas
from the L.P. cylinder, thus bringing the operating temperature within reasonable limits. There are many types of
intercoolers, from simple units to complex systems, set up adjacent to, the compressor. In one type of inter stage
gas cooler high pressure, liquid refrigerant is injected in the hot L.P. discharge gas by means of an adjustable
injection valve. This adjustable injection valve may be of either thermostatic or manual type, having automatic or
non-automatic settings respectively. From the L P. cylinder the hot compressed gas enters the L P. side of
intercooler. As the pressure in the liquid receiver in which the refrigerant collects after condensation, exceeds the
delivery pressure of the LP. Cylinder, a certain amount of liquid will be injected into the L.P. delivery compartment.
This amount depends on the degree of opening of the injection valve. The injected liquid evaporates, thus
lowering the temperature of L.P. delivery gas. Since the liquid injection valve is situated on the L.P. side of
intercooler, the passage of gas from L.P. to H.P. ensures complete evaporation of liquid. The H.P. suction is thus
operating with compressed gas of reasonably low

Figure 29

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KPCL offers standard intercoolers except system B. As the customer has the option to select the intercooler type
at the time of order booking, System A intercooler is supplied fitted on two stage compressors and System C /
System D intercoolers are supplied in loose, being large pressure vessels.

There are seven standard Interstage Gas Cooler models of System C & System D each.
System C models - C1, C2, C3, C4, C5, C6 & C7 characterized by their inlet nozzle connection size 50 NB, 65
NB, 80 NB, 100 NB, 125 NB, 150 NB, 200 NB respectively.
Similarly, System D models are D1, D2, D3, D4, D5, D6 & D7.

Interstage Gas Coolers are KPCL’s proprietary design however best engineering practices are followed in design
& manufacturing of the vessel. Refer to the selection chart overleaf to select the appropriate intercooler type for
the compressor or number of compressors in parallel. This product data sheet also provides GA drawing and
installation guide for information and further requirements.

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9. TROUBLE SHOOTING CHART

Fault Cause Remedy

9.1 Delivery pressure too high  Delivery stop valve not open  Open fully
(probably H.P. pressostat becomes wide enough
operative) (On water cooled  Less or too warm cooling water  Increase water supply
condensers the temperature  Gas suction pressure too high  Partially close suction stop
indicated by delivery pressure (during starting-up period only) valve
gauge rises more than 6°C above  Suction pressure higher than
that of cooling water outlet. On air normal  Refer fault No. 9.3
cooled condensers the  Too much refrigerant in
temp­erature indicated by delivery condenser  Open liquid control valve
pressure gauge rises more than further or release some liquid
10°C above that of air temperature from system
at condenser outlet).  Condenser tubes blocked or
dirty  Clean condenser
 Air in the system
 Defective delivery pressure  Purge system
gauge  Repair
9.2 Delivery pressure too low  Leaking H.P. safety valve  Repair/Renew
 Suction stop valve not open  Open fully
wide enough
 Suction pressure lower than  Refer fault No. 9.4
normal
 Faulty delivery pressure gauge  Repair/Renew
 Defective delivery valve  Replace
9.3 Suction pressure too high  Liquid control valve open too  Readjust setting
wide
 Leaking H.P. safety valve  Repair/Replace
 Defective pressure gauge  Repair/Replace
 Capacity control out of order (if  Inspect and repair
fitted)
 Suction or delivery valves  Renew
defective
 Excessive leakage past piston  Replace piston rings
9.4 Suction pressure too low  Suction stop valve not open  Open fully
(probably L.P. pressostat operates) wide enough
 Liquid control valve not open  Open further
wide enough
 Refrigerant suction strainer  Clean
chocked
 Less refrigerant in system  Top up with refrigerant
9.5 Liquid stroke  Liquid control valve open too  Readjust setting
wide.
 Capacity control out of order (if  Inspect and repair
fitted)
 Defective evaporator float (if  Inspect and repair or replace
fitted)
9.6 Oil pressure too high during  Oil pressure regulator defective  Repair/Readjust
running (during running-up period or maladjusted
oil pressure is always higher than  Defective pressure gauge  Repair/Renew
normal until operating temperature
reached)
9.7 Oil pressure too low (oil  Oil pressure regulator defective  Repair/Readjust
pressure differential pressostat or
probably operates)  Insufficient oil in crankcase  Top up with oil
 Suction pressure too low  See fault No. 9.4
 Oil suction and/or delivery  Clean

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strainer blocked
 Oil return pipe between  Clean out or repair
crankcase and oil suction
strainer blocked
 Slack bearings  Refit
 Blocking of oil ways in  Clean-out
crankshaft
9.8 Pressure difference between  Suction pressure too high  See fault No. 9.3
suction and delivery pressures too  Delivery pressure too low  See fault No. 9.2
small
9.9 Warm suction side of H.P.  Leaking safety valve  Repair/Renew
safety
9.10 Oil consumption too high  Automatic oil return valve from  Repair or renew/clean
oil separator defective/chocked
worn piston rings
 Oil return valve(s) in cylinder  Fit new piston rings
jackets defective  Replace
9.11 Leakage of shaft seal  Worn out 'O' rings  Replace
 Scratch marks on sealing faces  Lap the faces up to 2 light
bands or replace sealing faces
 Dirty oil  Change oil, also clean seal
assembly and seal chamber
 Excessive axial thrust  Adjust axial thrust
 Scratch marks on shaft seal  Lap shaft on seal area
areas of crank shaft
 Losing of spring effect  Replace springs
 Oil flow inadequate to shaft  Check oil pump and its piping
seal cooling for blocking the oil passage.
Adjust recom­mended oil
pressure on pressure regulator
9.12 Malfunctioning of loading/ a. Solenoid valve not functional
unloading operation of well due to:
compressors 1. Chattering of valve coil  Check continuity of coil and
wiring to solenoid valve
2. Valve top and bottom seat  Repair or place valves seat
damaged or blocked. part
3. Plunger neoprene seat
swelled excessively  Replace or cut excessive
b. No sufficient actuating swelled portion of neoprene
pressure to unloader assembly seat
 Check oil control lines for
blockage & repair/replace. Also
c. Capacity control piston 'O' ring check hydraulic time delay
and piston ring worn out system and set right
d. Blockage of control lines  Replace 'O' ring and piston
rings

 Repair/clean or replace

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10. SPARE PARTS

10.1 INTRODUCTION
This chapter deals with list of recommended spares parts, illustrations showing spare part details and part
numbers.
How to order spare parts is explained below. Recommendations for storage of spare parts, information for field
assistance and customer training are outlined in this chapter.
Stocking of recommended spare parts enable prompt compressor maintenance, otherwise that could cause
lengthy and unwarranted shutdown.

10.2 ORDERING OF SPARE PARTS

When ordering spares, always communicate following information:

1. Equipment Model number and serial number
2. Equipment Order Acceptance (O.A.) number
3. Catalogue number from the spare part list or drawing number
4. Part name/description and quantity required
5. Name and address of the purchaser
6. Complete shipping address and shipping instructions
7. Details of service required (viz., for preventive maintenance, parts replacement failure, any others.)
8. Date and schedule by which these parts are required

10.3 STORAGE OF SPARE PARTS

Spare parts usually represent a substantial investment. To protect this investment following must be observed:
1. Inspect all the parts and coat all the unprotected surfaces with a rust preventive.
2. Tag or mark the parts so that they can be easily located and identified.
3. Store all the parts in cool and dry place.
4. Store the parts in bins or neatly on shelves to prevent damage.
5. Inspect the parts frequently. Clean and recoat the parts if necessary.

10.4 KITS FOR STANDARD SPARE PARTS

Sr. No. Description Spec. No.

1. Kit-Oil Filters 085.29.03.

2. Kit-Shaft Seal 'O' Ring 085.28.04.

3. Kit-Oil pump Gear 085.29.05.

4. Kit-Cylinder Maintenance 085.29.06.

5. Kit-Crank Shaft Bearings 085.29.07.

6. Kit-Delivery Valve Ring/ spring 085.28.08.

7. Kit HP Conn. Rod & Piston Assembly 085.28.09.

8. Kit Liner Parts 085.29.10.

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10.4.1 OVERHAULING GASKET SET, O RING SET AND PACKING SET

Sr. No. Model Gasket Set O Ring Set Packing Set

1. KCX1 335.51.901.50. 335.51.902.50.
2. KCX2 336.51.901.50. 336.51.902.50.
3. KCX3 337.51.901.50. 337.51.902.50.
4. KCX4 338.51.901.50. 338.51.902.50.
5. KCX6 339.51.901.50. 339.51.902.50.
6. KCX9 340.51.901.50. 340.51.902.50.
7. KCX12 341.51.901.50. 341.51.902.50.
8. KCX21 342.51.901.50. 337.51.902.50.
338.41.903.50.
9. KCX31 343.51.901.50. 338.51.902.50.
10. KCX42 344.51.901.50. 339.51.902.50.
11. KCX51 344.51.901.50. 339.51.902.50.
12. KCX63 346.51.901.50. 340.51.902.50.
13. KCX72 347.51.901.50. 340.51.902.50.
14. KCX84 330.51.901.50. 341.51.902.50.
15. KCX93 330.51.901.50. 341.51.902.50.
16. KCX102 330.51.901.50. 341.51.902.50.

10.5 ILLUSTRATED SPARE PARTS LIST

These lists are meant for identification and accurate specifications of spare parts.
In order to facilitate quick reference to the required parts, the list and corresponding figures are divided into
following groups of parts. :

Sr. No. Description Page No. Fig. No.

10.5.1 Crankcase Assembly 57 30
10.5.2 Safety Valve Assembly 58 31
10.5.3 Bearing Cover Assembly with Disc Holding 59 32
10.5.4 Crankshaft Assembly & Retainer Plate 60 33
10.5.5 Piston and Connecting Rod Assembly 61 34
Connecting Rod Assembly with Needle Roller Bearing
10.5.6 63 35
(For Two Stage Compressor on H.P. Side Only)
10.5.7 Cyl. Liner Assembly and Valve Lifting Mechanism 63 36
10.5.8 Suction and Delivery Valve Assy 64 37
10.5.9 Shaft Seal Assembly 65 38
10.5.10 Oil Pump assembly 66 39
10.5.11 Oil Filter Assembly 67 40
10.5.12 Suction Gas Strainer Assembly 68 41
10.5.13 Special Tools Kit Assembly 69 42
10.5.14 Capacity Control Oil Piping 70 -
10.5.15 Pressure Gauges & Pressure Cut-outs 70 -
10.5.16 Stop Valve Assembly 71 43

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10.5.1 CRANKCASE ASSEMBLY

Sr. No. Name of the part Part No. Qty. Remarks

1A Crank case assly. 335.40.100.50 1 For KCX1
1B Crank case assly. 336.50.100.50 1 For KCX2
1C Crank case assly. 337.50.100.50 1 For KCX3
1D Crank case assly. 338.50.100.50 1 For KCX4
1E Crank case assly. 339.50.100.50 1 For KCX6
1F Crank case assly. 340.50.100.50 1 For KCX9
1G Crank case assly. 341.50.100.50 1 For KCX12
1H Crank case assly. 342.50.100.50 1 For KCX21
1I Crank case assly. 343.50.100.50 1 For KCX31
1J Crank case assly. 344.50.100.50 1 For KCX42
1K Crank case assly. 345.50.100.50 1 For KCX51
1L Crank case assly. 346.50.100.50 1 For KCX63
1M Crank case assly. 347.50.100.50 1 For KCX72
1N Crank case assly. 330.50.100.50 1 For KCX84
1O Crank case assly. 348.50.100.50 1 For KCX93
1P Crank case assly. 349.50.100.50 1 For KCX102
2 Stud STD TYPE A M16X2X60L 999.03.702.50 10 As per cyl.
3 Stud STD TYPE A M16X2X81L 999.03.710.50 2 As per cyl.
4 Gasket 082.28.650.50 1 As per cyl.
4A Gasket 084.28.740.50 2 For KCX4/ KCX31
5 Cylinder cover complete E 082.28.100.50 1 As per cyl.
6 Nut hex M16X2 999.06.687.50 12 As per cyl.
7 Stud STD TYPE A M16X2X60L 999.03.702.50 21
8 Stud STD TYPE A M16X2X76L 999.03.709.50 3
Gasket round flange 40NB
9 993.00.305.00 4
K51*TB E
10 Oil level glass E 082.28.170.50 2
11 Oil level glass cover 082.28.180.50 2
12 Screw Hex STD M8X1.25X30L 999.01.624.50 8
13 Al. washer 1/2" BSP 999.18.537.50 3
14 Plug 1/2" BSP 082.28.920.50 1
15 Adaptor 1/2" MLx1/2"FL' 335.41.301.50 1
16 TAH8 Valve 351.09.003.50 1
17 Gasket 993.00.311.00 1 Per side connection
18 Side cover 082.28.110.52 1 Per side connection
19 Screw head M12 x 30 L 999.01.690.50 8 Per side connection
20A Pipe 336.41.402.50 1 For KCX2/KCX3
20B Pipe 338.41.402.50 1 For KCX4
20C Pipe 339.41.402.50 1 For KCX6
20D Pipe 340.41.402.50 1 For KCX9
20E Pipe 341.41.402.50 1 For KCX12
Per cylinder/per LP
21 NRV Valve 082.06.000.50 1 cylinder for two
stage compressor
Per HP cylinder for
21A Plug 1/4" BSP 082.07.230.50 1 two stage
compressor

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

Figure 30
10.5.2 SAFETY VALVE ASSEMBLY

Sr. No. Name of the part Part No. Qty. Remarks

1 Pipe For Seat 1 Refer Sr. No. 2
2 Bottom Housing Assl Crankcase 336.13.015.50 1 Welded to
Single stage & two
3A Set of safety valve parts - -
stage HP side
3B Set of safety valve parts - - Two stage LP side
3.1 Hex. Nut M8 999.06.623.50 6
3.2 Valve Guide 336.13.001.50 1
3.3 Ring Teflon 336.13.002.50 1
3.4 Cup Spring 336.13.003.50 1
3.5 Safety Plate 351.03.105.50 1
3.6 Hex. Hd. Screw M8x35 999.01.625.50 1
3.7 Spring 336.13.005.50 1
3.8A Gasket 993.00.306.00 1 For Item 3A only
3.8B Gasket 993.00.306.00 2 For Item 3B only
3.9A Distance Ring Not required -
3.9B Distance Ring 342.15.003.50 1 For Item 3B only
3.10 Ring Adjusting Adjustment 336.13.008.50 - Qty. as per press
3.11 Top Housing Assly. 336.13.009.50 1
3.12A Hex. Hd. Screw 999.01.624.50 4 For Item 3A only
3.12B Hex. Hd. Screw M8x30 Not required -
3.13A Hex. Hd. Screw M8x50 999.01.628.50 2 For Item 3B only
3.13B Hex. Hd. Screw M8x50 999.01.628.50 6 For Item 3B only

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

Figure 31

10.5.3 BEARING COVER ASSEMBLY WITH DISC HOLDING

Qty. 1/2/3/4 cyl Qty. 6/9/12 cyl

Sr. No. Name of the part Part No.
models models
1 Nut Hex. M16 999.06.687.50 24 24
2 Spring Washer M16 999.11.286.50 24 24
3 Cover Assembly (Flywheel Eng) 335.50.210.50 1 1
3.1 Cover Bearing (Flywheel Eng) 400.05.919.50 1 1
Brg. Brush PI Single (Flywheel 336.40.212.50
3.2 1 1
Eng)
3.3 Washer AI. 1/2" BSP 999.18.537.50 1 1
3.4 Plug Blind AI. 1/2" BSP 336.40.792.50 1 1
4 'O' Ring 999.12.926.50 2 2
5 Cover Assly. Pump End 335.20.220.50 1 -
5.1 Cover Brg. Pump End 400.05.920.50 1 -
5.2 Brg. Bush FI Single (Pump End) 336.40.222.50 1 1
5.3 Pin Cylindrical 4Øx8L 999.09.572.50 1 1
5.4 Restriction Plate 400.05.898.50 1 -
5.5 Spring Washer M6 999.11.250.50 2 -
5.6 Bolt Hex. Skt. Hd. M6x10L 999.02.601.50 2 -
5.7 AI. Washer 1/2' BSP 999.18.537.50 2 3
5.8 Plug Blind 1/2' BSP 336.40.792.50 2 3
5.9 Pin Cylindrical Ø6x12L 999.09.642.50 1 1
5.10 Stud M12x110L 999.03.687.50 7 7
5.11 AI. Washer 1/4' BSP 999.18.525.50 1 1
5.12 Plug Blind 1/4' BSP 082.07.230.50 1 1
6 Thrust Ring (Bearing) 336.40.303.50 1 1
7 Disc Holding Assly. 336.40.304.50 1 1
7.1 Disc Holding 336.40.305.50 1 1
7.2 Pin Cylindrical Ø8x25L 999.09.686.50 2 2
8 Soc. Hd. Cap Screw M10x40L 999.02.647.50 4 4
9 Intermediate Brg Assly. 086.15.040.50 - 1
9.1 Bottom Housing - - 1
9.2 Bearing Cap - - 1
9.3 Connecting Rod Bolt 082.04.040.51 - 4
9.4 Safety Plate 082.04.050.50 - 4
9.5 Hex. Nut M16x1.5 082.04.100.50 - 4
9.6 Brg. Intermediate Half (std) 086.15.030.50 - 1
10 Hex. Hd. Screw M20x2.5x45 999.01.746.50 - 3
11 Spring Washer. M20 999.11.298.50 - 3

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

Figure 32

DETAILS OF UNDERSIZED BEARINGS:

Sr. No. Description Drg. No.

3.2a Bearing Bush Flywheel end First undersized (0.125mm) 336.40.213.50
3.2b Bearing Bush Flywheel end Second undersized (0.25mm) 336.40.214.50
3.2c Bearing Bush Flywheel end third undersized (0.50mm) 336.40.215.50
3.2d Bearing Bush Flywheel end fourth undersized (0.75mm) 336.40.216.50
5.2a Bearing bush pump end first undersized (0.125mm) 336.40.223.50
5.2b Bearing Bush pump end Second undersized (0.25 mm) 336.40.224.50
5.2c Bearing Bush Pump end third undersized (0.50mm) 336.40.225.50
5.2d Bearing Bush Pump end fourth undersized (0.75mm) 336.40.227.50
9.6a Bearing Intermediate half first undersized (0.1 25mm) 086.15.031.50
9.6b Bearing Intermediate half Second undersized (0.25) 086.15.032.50
9.6c Bearing Intermediate half third undersized (0.50mm) 086.15.033.50
9.6d Bearing Intermediate half fourth undersized (0.75mm) 086.15.034.50

10.5.4 CRANKSHAFT ASSEMBLY WITH RETAINER PLATE

Sr. No. Name of the part Part No. Qty. Remark

1A Crankshaft Assly. Complete 336.40.300.50 1 For KCX2
1B Crankshaft Assly. Complete 337.40.300.50 1 For KCX3/KCX21
1C Crankshaft Assly. Complete 338.40.300.50 1 For KCX4/KCX31
1D Crankshaft Assly. Complete 339.40.300.50 1 For KCX6/KCX42/KCX51
1E Crankshaft Assly. Complete 340.40.300.50 1 For KCX9/KCX63/KCX72
Crankshaft Assly. Complete 341.50.300.50 For
1F 1 KCX12/KCX84/KCX93,
KCX102
1.1 Crankshaft Bare - 1 Included in sr. no. 1
1.2 Weight Counter - 1 Included in sr. no. 1
1.3 Weight Counter - 1 Included in sr. no. 1
1.4 Bolt Hex. M16x80L 999.01.699.50 4 Included in sr. no. 1
1.5 Plate Safety 082.28.240.50 2 Included in sr. no. 1
1.6 Screw Grube M12x16L 999.02.950.50 1 Included in sr. no. 1
1.7 Ring Spacer Assly. 082.05.000.50 1 For KCX2
1.7.1 Adjusting Bolt M8 082.05.020.50 2 For KCX2
1.7.2 Ring Distance Half 082.05.010.50 2 For KCX2
1.7.3 Plate Safety 082.05.030.50 2 For KCX2
1.7.4 Nut Hex. M8 999.06.623.50 2 For KCX2
2 Key 082.28.191.50 1
3 Retainer Plate Assly. 336.14.114.50 1
4 Locking Plate 336.14.103.50 1
5 Washer Plain 999.18.740.50 1
6 Bolt Hex. M12x40L 999.01.670.50 4

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

Figure 33

10.5.5 PISTON AND CONNECTING ROD ASSEMBLY

Sr. No. Name of the part Part No. Qty. Remark

1 Piston Assembly 082.03.000.50 - As Required
1.1 Piston 082.03.110.50 1
1.2 Gudgeon Pin 082.03.020.50 1
1.3 Safety Plate 082.03.040.50 1
1.4 Bolt Safety 082.03.030.50 1
1.5 Set of Piston Ring 082.03.150.50 1
1.5.1 Ring Oil Scraper - 2
1.5.2 Ring Piston - 1
1.5.3 Ring Piston - 1
1.5.4 Ring Piston - 1
2 Conn. Rod Assly. 082.04.000.50 1 As Required
2.1 Conn. Rod With Bolt 082.04.070.50 1
2.1.1 Connecting Rod 082.04.010.50 1
2.1.2 Bolt Connecting Rod 082.04.040.51 2
2.1.3 Nut Hex. M16 082.04.100.51 2
2.1.4 Plate Safety 082.04.050.50 2
2.2 Big End Brg. Half STD 082.04.030.50 1
2.3 Bush Con. Rd. 082.04.020.50 1

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

Sr. No. Name of the part Part No. Remark

2.2.0 Big End Bearing Half First undersized (0.25mm) 082.04.031.50
2.2.b Big End Bearing Half Second undersized (0.50mm) 082.04.032.50
2.2.c Big End Bearing Half third undersized (0.75mm) 082.04.033.50

Figure 34

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

10.5.6 CONNECTING ROD ASSEMBLY WITH NEEDLE ROLLER BEARING (FOR TWO STAGE
COMPRESSOR ON H.P. SIDE ONLY)

Item No. Drawing No. Description Qty.

1 082.04.001.50 Connecting Rod Assly. 1
1.1 082.04.002.50 Needle Roller Bearing 2
1.2 082.04.003.50 Spacer For NRB 1
1.3 082.04.030.50 Big End Bearing Set 1
1.4 082.04.071.50 Conn. Rod With Bolt 1
1.4.1 082.04.040.51 Bolt Conn. Rod 2
1.4.2 082.04.100.51 Hex. Nut M 16x1.5 P 2
1.4.3 082.04.050.50 Safety Plate 2

Figure 35

10.5.7 CYLINDER LINER ASSEMBLY AND VALVE LIFTING MECHANISM

Sr. No. Name of the part Part No. Qty. Remark

1A Gasket Thk. 1.5mm 082.28.670.50 1 To be selected
2 Cylinder Liner Assly. 336.40.400.50 1 Qty. As Per Compr.
2.1 Cylinder Liner 336.40.401.50 1
2.2 Nut Hex. M6 x 1P 999.06.616.50 4
2.3 Ring Pressing Assy. 336.40.402.50 1
2.4 Spring 336.40.407.50 2
2.5 Ring with Hinged Point 082.10.030.50 1
2.6 Sprint Curtain 082.10.080.50 1
2.7 Tap Bolt M6x132L 336.40.408.50 2
2.8 Lever For Valve Lifting Device 082.10.040.51 1
2.9 Pin Fulcrum 336.40.406.50 1
2.10 Washer Plane M6 999.18.700.50 1
2.11 Split Pin 999.30.252.50 1
3 Washer Alu. 3/4" BSP 999.18.548.50 1 Per Cylinder
4 Guide Bush 336.40.504.50 1 Per Cylinder
5 Actuating Plunger 336.40.505.50 1 Per Cylinder
6 Piston Assly For VLD 336.40.502.50 1 Per Cylinder
6.1 Piston 336.40.503.50 1 Per Cylinder

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

6.2 'O' Ring 336.40.506.50 1 Per Cylinder

7 'O' Ring 999.12.708.50 1 Per Cylinder
8 KIT Piston Housing 400.05.794.51 1 Per Cylinder
8.1 Housing Piston (VLD) 400.05.794.50 1 Per Cylinder
8.2 Soc. Hd. Screw M10x25L 999.02.643.50 4 Per Cylinder
9 Packing 999.18.525.50 1 Per Cylinder
10 Male Connector 1/4' 400.05.827.50 1 Per Cylinder

Figure 36

10.5.8 SUCTION AND DELIVERY VALVE ASSEMBLY

Sr. No. Name of the part Part No. Qty. Remark

1 Suction Valve Ring 082.28.130.50 1
2 Suction Valve Spring 336.12.001.50 2
3V Valve Assly. Discharge 336.41.101.50 1
3.1 Self Locknut 400.01.084.50 1
3.2 Limitor Stroke 336.12.005.50 1
3.3 Wavy Spring 088.06.150.50 2
3.4 Wavy Spring 082.11.110.50 2
3.5 Wavy Spring 082.11.120.50 2
3.6 Ring Valve Discharge 088.06.040.50 1
3.7 Ring Valve Discharge 082.11.030.50 1
3.8 Ring Valve Discharge 082.11.040.50 1
3.9 Limitor Stroke Suction Valve 336.41.102.50 1
3.10 Centre Bolt 336.12.006.50 1
4 Cup Spring 336.41.103.50 1
5 Spring Buffer 082.28.090.50 1

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

Figure 37

10.5.9 SHAFT SEAL ASSEMBLY

Sr. No. Name of the part Part No. Qty. Remark

1 Cover Shaft Seal 336.40.801.50 1
2 Shaft Seal Assy Complete 082.08.000.50 1
2.1 Pressing Ring 082.08.050.50 1
2.2 Rotary Sealing Ring 082.08.010.50 1
2.3 Set Screw M4 x 8L 082.08.030.50 5
2.4 Stationary Sealing Ring 082.08.020.50 1
2.5 'O' Ring 082.08.060.50 1
2.6 'O' Ring 082.08.070.50 1
2.7 Spring 082.08.040.50 12
3 'O' Ring 082.28.280.50 1
4 Washer Spring M12 999.11.274.50 8
5 Hex. Nut. M12 999.06.650.50 8
6 Packing Alu. 1/4" BSP 999.18.525.50 1
7 Plug Blind 1/4" BSP 082.07.230.50 1
8 Packing Alu. 1/8" BSP 999.18.520.50 1
9 Union Socket Screw Assy. 1/8" BSP 998.16.241.50 1

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

Figure 38

10.5.10 OIL PUMP ASSEMBLY

Sr. No. Name of the part Part No. Qty. Remark

1 Oil Pump Assly. 336.40.700.50 1
1.1 Oil Pump Housing 336.40.712.50 1
1.2 Dowel Pin Ø 6 x 12L 999.09.642.50 1
1.3 Gasket For Oil Pump Cover 336.40.744.50 1
1.4 Washer Al. 1/2" BSP 999.18.537.50 4
1.5 Pump Blind 1/2" BSP 336.40.792.50 5
1.6 Pump Element Assly. 336.40.720.50 1
1.7 Washer Spring M6 999.11.250.50 8
1.8 Hex. Hd. Screw M6x25L 999.01.610.50 8
1.9 Lub. Oil Pre. Regulator Assly. 336.40.750.50 1
1.10 'O' Ring Ø 3 999.12.212.00 1
1.11 Washer Alu. 1" BSP 999.18.561.50 1
1.12 Control Oil Pre. Regulator Assly. 336.40.760.50 1
1.13 'O' Ring 3.53 x 21.8 999.12.212.00 1
1.14 Washer Alu. 1" BSP 999.18.561.50 1
1.15 Washer Alu. 1/2" SSP 999.18.537.50 1
1.16 Reducer 1/2" SSP (Ext) x 1/4" BSP (Int.) 336.40.790.50 1
1.17 Male Run Tee (Positionable) 400.05.831.50 1
2 'O' Ring 3.53 x 21.8 999.12.212.00 2
3 'O' Ring 082.28.280.50 1
4 Plate Driving 336.40.306.50 1
5 Washer Spring M12 999.11.274.50 7
6 Nut Hex. M12 336.03.001.50 7

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

Figure 39

10.5.11 OIL FILTER ASSEMBLY

Sr. No. Name of the part Part No. Qty. Remark

1 Suction Filter Assly. 336.41.001.50 1
1.1 Filter Housing 336.41.004.50 1
1.2 Spring 336.10.006.50 1
1.3 Spacer Ring 336.10.007.50 1
1.4 Filter Wire 336.10.009.50 1
1.5 'O' Ring 999.12.723.50 1
1.6 Housing Manifold 336.41.003.50 1
1.7 Plain Washer M10 999.18.018.50 4
1.8 Bolt Hex. Soc. Hd. M10x40L 999.02.647.50 2
1.9 Bolt Hex. Soc. Hd. M10x65L 999.02.655.50 2
1.10 Packing Alu. 1/2" BSP 999.18.537.50 1
1.11 Plug 1/2" BSP 082.28.920.50 1
1.12 Packing Alu. 1/4" BSP 999.18.525.50 1
1.13 Plug 1/4" BSP 082.07.230.50 1
2 Discharge Filter Assly. 336.41.002.50 1
2.1 Filter Housing 336.41.004.50 1
2.2 Spring 336.10.006.50 1
2.3 Spacer Ring 336.10.007.50 1
2.4 Filter Paper 351.09.014.50 1
2.5 'O' Ring 999.12.723.50 1
2.6 Housing Manifold 336.41.003.50 1
2.7 Plain Washer M10 999.18.018.50 4
2.8 Bolt Hex. Soc. Hd. M10x40L 999.02.647.50 2
2.9 Bolt Hex. Soc. Hd. M10x65L 999.02.655.50 2
2.10 Packing Alu. 1/2" BSP 999.18.537.50 1
2.11 Plug 1/2" BSP 082.28.920.50 1
2.12 Packing Alu. 1/4" BSP 999.18.525.50 1
2.13 Plug 1/4" BSP 082.07.230.50 1
3 Gasket 336.41.008.50 2
4 Plain Washer M10 999.18.018.50 4
5 Bolt Hex. Soc. Hd. M10x120L 999.02.662.50 4

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

Figure 40

10.5.12 SUCTION GAS STRAINER ASSEMBLY

Sr. No. Name of the part Part No. Qty. Remark

1a Housing Suction Strainer 336.50.601.50 1 For KCX2
1b Housing Suction Strainer 337.50.601.50 1 For KCX3/21
1c Housing Suction Strainer 338.50.601.50 1 For KCX4/31
1d Housing Suction Strainer 339.50.601.50 1 For KCX6/42/51
1e Housing Suction Strainer 340.50.601.50 1 For KCX9/12/63/72
1f Housing Suction Strainer 341.50.601.50 1 For KCX84/93
*1.1 Ferrule 400.05.825.50 1 For KCX2/3/4/31
*1.2 Union Nut 400.05.826.50 1 For KCX6/9
*1.3 Cylindrical Pin Ø6 999.09.650.50 1 For KCX2/3/4/31
2 Gasket 082.28.630.51 2 For KCX6/9
2 Gasket 993.00.311.00 2 For KCX2/3/4/31
3 Cover 082.12.031.51 1 For KCX6/9
3 Cover 082.28.110.52 1 For KCX2/3/4/31
4 Hex. Hd. Screw M12x30L 999.01.666.50 16 For KCX6/9
4 Hex. Hd. Screw M12x35L 999.01.690.50 16 For KCX2/3/4/31
5 'O' Ring 999.12.898.50 1 For KCX6/31
5 'O' Ring 999.12.909.50 1 For KCX2/3/4/31
6 Suction Strainer Element Assembly 082.12.020.50 1 For KCX6/9
6 Suction Strainer Element Assembly 086.12.020.50 1 For KCX2/3/4/31
7 Spring 082.12.040.50 1 For KCX6/9
8 Cover Assembly Suction Strainer 082.12.030.50 1 For KCX2/3/4/31
8 Cover Assembly Suction Strainer 086.12.030.50 1 For KCX6/9
9 Gasket 993.00.308.00 2 For KCX2/4/31
9 Gasket 993.00.309.00 2 For KCX3/6/9/12
10 Bolt Hex. Hd. M16x65L 999.01.696.50 8 For KCX2/4/31
11 Nut Hex. M16 999.06.687.50 8 For KCX2/4/31
10 Bolt Hex. Hd. M20x80L 999.01.755.50 8 For KCX3/6/9/12
11 Nut Hex. M20 999.06.742.50 8 For KCX3/6/9/12
12 Suction Cloth Bag Filter 082.12.061.50 1 For KCX2/3/4/31
12 Suction Cloth Bag Filter 086.12.056.50 1 For KCX6/9

*Include in Sr. No. 1

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

Figure 41

10.5.13 SPECIAL TOOL KIT ASSEMBLY

Sr. No. Name of the part Part No. Qty. Remark

1 Bottom plate 082.24.042.50 1
2 Stud 082.24.043.50 1
3 Hex Nut M16 999.06.687.50 1
4 Top plate assly. 082.24.020.50 1
5 Screw liner push M20X150L 082.24.020.50 1
6 Bush for piston insertion 082.24.020.50 1
7 Key for piston removal 082.24.030.50 1
8 Top Plate 082.24.051.50 1
9 Bottom Plate 082.24.052.50 1
10 Bolt Hx Head M10X45L 082.24.053.50 2
11 Spl. Torque Spanner 082.24.054.50 1
12 Socket torque wrench 082.24.047.50 1
13 Bush for piston insertion 082.24.020.50 1

Figure 42

10.5.14 CAPACITY CONTROL OIL PIPING

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

Sr. No. Name of the part Part No. Remark

1 Male Connector 1/4" 400.05.926.50 For 6 mm tubing
2 Union Nut 400.05.925.50
3 Ferrule 400.05.924.50
4 Tee connecting socket assly. 400.05.923.50 For 6 mm tubing
5 Packing 999.18.525.50
6 Solenoid Valve Assly. (NC) 336.41.610.50 For 230 V.A.C.
6A Solenoid Valve Assly. (NO) 336.41.620.50 For 230 V.A.C.
7 Coil for Solenoid Valve (NC & NO) 336.41.612.50 For 230 V.A.C.
8 K-5 Valve Assly. 082.16.00150 For 6 mm tubing
9 'O' Ring 999.12.626.50
10 Stainless Steel Tube 6 dia 999.37.711.00.01
11 Adaptor (Top) Solenoid Valves 400.05.928.50 For 6 mm tubing
12 Ext. Adaptor Solenoid Valve 400.05.929.50
13 Male Run Tee (Positionable) 400.05.927.50
(Above mentioned parts are normally required to fabricate the capacity control piping at site. Quantity will depend upon type of
compressor.)

10.5.15 PRESSURE GAUGES & PRESSURE CUT-OUTS

Sr. No. Name of the part Part No. Remark

A Pressure Cut-Outs :
1 LP Pressure cut-outs KP 1 999.52.069.01 For R134A, R22
2 LP Pressure cut-outs KP 1A 999.52.069.02 For Ammonia
3 HP Pressure cut-outs KP 5 999.52.069.03 For R134A, R22
4 HP Pressure cut-outs KP 5A 999.52.069.04 For Ammonia
5 HP/LP Pressure cut-outs KP 15 999.52.069.05 For R134A, R22
6 HP/LP Pressure cut-outs KP 15A 999.52.069.06 For Ammonia
7 LP/OP Pressure cut-outs MP 55 999.52.069.07 For R134A, R22
8 LP/OP Pressure cut-outs MP 55A 999.52.069.08 For Ammonia

Sr. No. Name of the part Part No. Remark

B Pressure Gauges :
1 Ammonia Pressure Gauge with Bottom entry, Range (-) 996.00.220.01 For Ammonia
760 mm of Hg to 16 kg/cm2, 100 mm Dial, Glycerin Filled
2 Ammonia Pressure Gauge with Bottom entry, Range (-) 996.00.220.02 For Ammonia
760 mm of Hg to 25 kg/cm2, 100 mm Dial, Glycerin Filled
3 Ammonia Pressure Gauge with Back entry, Range (-) 760 082.18.525.50 For Ammonia
mm of Hg to 16 Kg/cm2, 100 mm Dial, Glycerin Filled
4 Ammonia Pressure Gauge with Back entry, Range (-) 760 082.18.526.50 For Ammonia
mm of Hg to 25 Kg/cm2, 100 mm Dial, Glycerin Filled
5 R22, Pressure Gauge with Bottom entry, Range (-) 760 996.00.220.04 For R22
mm of Hg to 16 Kg/cm2, 100 mm Dial, Glycerin Filled
6 R22 Pressure Gauge with Bottom entry, Range (-) 760 996.00.220.05 For R22
mm of Hg to 16 Kg/cm2, 100 mm Dial, Glycerin Filled
7 R22 Pressure Gauge with Back entry, Range (-) 760 mm 082.18.530.50 For R22
of Hg to 25 Kg/cm2, 100 mm Dial, Glycerin Filled
8 R22 Pressure Gauge with Back entry, Range (-) 760 mm 082.18.531.50 For R22
of Hg to 16kg/cm2, 100 mm Dial, Glycerin Filled
9 R134A Pressure Gauge with Bottom entry, Range (-) 760 082.18.539.50 For R134
mm
of Hg to 25 Kg/cm2, 100 mm Dial, Glycerin Filled
10 R134A Pressure Gauge with Bottom entry, Range (-) 760 082.18.540.50 For R134
mm of Hg to 16Kg/cm2, 100 mm Dial, Glycerin Filled

10.5.16 STOP VALVE ASSEMBLY FOR KCX SERIES

Sr. Description TYPE 32 TYPE 50 TYPE 50/70 TYPE 70 TYPE 70/80

No. IN
Stop Valve 085.04.001.50 085.06.001.50 085.89.001.50 085.07.001.50 085.91.001.50

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Kirloskar Pneumatic Company Limited
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Assly. w/flg.
1 Hand Wheel 085.20.023.50 085.20.023.50 085.20.023.50 085.20.024.50 085.20.024.50
2 Cap Nut 085.06.022.50 085.06.022.50 085.06.022.50 085.07.022.50 085.07.022.50
3 Top Hsg. Assly. 085.06.382.50 085.06.382.50 085.06.382.50 085.07.382.50 085.07.382.50
4 Gasket 085.06.410.50 085.06.410.50 085.06.410.50 993.00.310.50 993.00.310.50
5 Spindle Assly. 085.04.416.50 085.06.416.50 085.06.416.50 085.07.415.50 085.07.415.50
5.1 Teflon Ring Top 085.04.490.50 085.04.490.50 085.04.490.50 085.07.490.50 085.07.490.50
5.2 Teflon Seat 085.04.500.50 085.06.500.50 085.06.500.50 085.07.500.50 085.07.500.50
Bottom
5.3 Supporting Disk 085.04.037.50 085.06.037.50 085.06.037.50 085.07.037.50 085.07.037.50
5.4 Hex. Screw 999.01.617.50 999.01.617.50 999.01.617.50 999.01.660.50 999.01.660.50
6 Gland Bush 085.06.023.50 085.06.023.50 085.06.023.50 085.07.025.50 085.07.025.50
7 PTFE Packing 085.06.026.50 085.06.035.50 085.06.035.50 085.07.035.50 085.07.035.50
8 Packing Seat 085.06.036.50 085.06.036.50 085.06.036.50 085.07.036.50 085.07.036.50
9 Gasket for Sq. 993.00.304.00 993.00.306.00 993.00.306.00 993.00.307.50 993.00.307.00
flg. inlet
10 Bottom Hsg. 085.04.310.50 085.06.310.50 085.89.310.50 085.07.310.50 085.91.310.50
11 Gasket for Sq. fl. 993.00.304.00 993.00.306.00 993.00.307.00 993.00.307.50 993.00.308.00
outlet
12 Nut 999.06.632.50 999.06.623.50 999.06.623.50 999.06.650.50 999.06.650.50
13 Washer 999.18.520.50 999.18.520.50 999.18.520.50 999.18.525.50 999.18.525.50

Sr. Description TYPE 80 TYPE 80/100 TYPE 100 TYPE TYPE

No. 100/125 SPL 100/125 SPL
Stop Valve 085.08.001.50 085.92.001.50 085.90.001.50 085.97.000.50 085.98.001.50
Assly. w/flg.
1 Hand Wheel 085.20.024.50 085.20.024.50 085.20.024.50 085.20.024.50 085.20.024.50
2 Cap Nut 085.07.022.50 085.07.022.50 085.07.022.50 085.07.022.50 085.07.022.50
3 Top Hsg. Assly. 085.07.382.50 085.07.382.50 085.09.382.50 085.09.382.50 085.09.382.50
4 Gasket 993.00.310.50 993.00.310.50 085.09.410.50 085.09.410.50 085.09.410.50
5 Spindle Assly. 085.08.415.50 085.08.415.50 085.09.415.50 085.09.415.50 085.09.415.50
5.1 Teflon Ring Top 085.07.490.50 085.07.490.50 085.07.490.50 085.07.490.50 085.07.490.50
5.2 Teflon Seat 085.08.500.50 085.08.500.50 085.09.500.50 085.09.500.50 085.09.500.50
Bottom
5.3 Supporting Disk 085.08.037.50 085.08.037.50 085.09.037.50 085.09.037.50 085.09.037.50
5.4 Hex. Screw 999.01.660.50 999.01.660.50 999.01.660.50 999.01.660.50 999.01.660.50
6 Gland Bush 085.07.025.50 085.07.025.50 085.07.025.50 085.07.025.50 085.07.025.50
7 PTFE Packing 085.07.035.50 085.07.035.50 085.07.035.50 085.07.035.50 085.07.035.50
8 Packing Seat 085.07.036.50 085.07.036.50 085.07.036.50 085.07.036.50 085.07.036.50
9 Gasket for Sq. 993.00.308.00 993.00.308.00 993.00.309.00 993.00.310.00 993.00.311.00
flg. inlet
10 Bottom Hsg. 085.08.310.50 085.92.310.50 085.09.310.50 085.09.710.50 085.09.810.50
11 Gasket for Sq. fl. 993.00.308.00 993.00.309.00 993.00.309.00 993.00.310.00 993.00.311.00
outlet
12 Nut 999.06.650.50 999.06.650.50 999.06.650.50 999.06.650.50 999.06.650.50
13 Washer 999.18.525.50 999.18.525.50 999.18.525.50 999.18.525.50 999.18.525.50

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

Figure 43

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

11. TABLE OF TIGHTENING TORQUE VALVES

Sr. No. Location Size Tightening Torque kg-m

1 Cylinder Cover to Crankcase Stud M16x2Px35L 13

2 Cylinder Cover to Crankcase Stud M16x2Px65L 13

3 Cylinder Cover to Crankcase Hex Nut M16x2P 18

4 Side Cover to Crankcase Hex Head Screw 16.5

M16x2Px35L
5 Sight Glass to Crankcase Hex Head Screw 2.5
M8x1.25Px30L
6 Safety Valve Top and Bottom Housing Hex Head Screw 2.5
Assembly M8x1.25Px50L
7 Safety Valve Top and Bottom Housing Hex Head Screw 2.5
Assembly M8x1.25Px40L
8 Safety Valve Top and Bottom Housing Hex Nut M8x1.25P 2.5
Assembly
9 Safety Valve Spring Cap to Seat Hex Head Screw 2.5
M8x1.25Px22L
10 Bearing Covers to Crankcase Stud M16x2Px25L 13

11 Bearing Covers to Crankcase Hex NutM16x2P 18

12 Shaft Seal Cap to Bearing Housing Stud M12x1.75Px100L 6.5

13 Shaft Seal Cap to Bearing Housing Hex Nut M12x1.75P 8.0

14 Oil Pump Housing to Bearing Cover Stud M12x1.75Px125L 6.5

15 Oil Pump Housing to Bearing Cover Hex Nut M12x1.75P 8.0

16 Intermediate Bearing Housing to Crankcase Hex Head Screw 30

M20x2.5Px30L
17 Connecting Rod/Intermediate Bearing Bolt & Nut M16x1.6P 7 to 9
Housing Cap Bolt and Nut
18 Discharge Valve Assembly Stud M12x1.75P 14

19 Discharge Valve Assembly Self lock Nut M12x1.75P 14

20 VLD Piston Housing to Crankcase Hex. Head Bolt 5

M10x1.5Px75L

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Kirloskar Pneumatic Company Limited
A Kirloskar Group Company

12. PRECAUTIONS TO PREVENT FAILURES OF

COMPRESSORS

Our analysis of 'Field Failures' has shown that 98% of failures on KCX compressors have occurred due to
'SYSTEM DIRT' entering the compressor and thereby damaging the bearings, connecting rods, pistons,
crankshaft, valves etc.

12.1 SOURCE OF ENTRY:

i. The dirt enters from the inter connecting pipe lines, various joints, condensers, chillers coils etc. and
consists of metallic sand in fine and coarse condition, welding slag, copper powder etc.
ii. The contractor/erection staff need thoroughly clean the various pipes before welding, complete draining of
water from condenser, chiller after these are pressure tested, flanged joint are kept open during other
masonry work or digging of trenches for cable laying etc., in the vicinity of refrigeration plant.

12.2 PREVENTION:
i. Source of entry has to be avoided.
ii. The system has to be thoroughly flushed off before connecting pipes to compressor suction and
discharge line.
iii. In addition it is preferable to put a cloth bag inside the gas strainer (The cloth bag should be slightly
oversize than the strainer ID) to catch very fine dirt particles coming from the system. This bag should fit
tight at the place where 'O' ring of strainer fits.

Note: This cloth should not be fitted on external OD of gas-strainer, as fine threads of cotton may enter in to
compressor suction zone.

12.3 PREVENTION FOR COMPRESSOR:

i. Before the very first start of compressor do not forget to fill oil in shaft seal through the plug provided on
shaft seal cover and suction and discharge oil filter chambers.
ii. During the first 50 operating hours, compressor should be checked regularly as per the points mentioned
in maintenance schedule checklist (refer to chapter 7.14), and more frequently in cases where
irregularities are found. During initial maintenance, pump down the system and stop the compressor
iii. Drain oil from compressor.
iv. Open side covers/inspection covers.
v. Open liquid line strainer, clean and refit.
vi. Open additional suction line gas strainer, check, clean and refit.
vii. Open compressor suction gas strainer, check, clean and refit
viii. Open compressor suction oil filter, check, clean/replace by new.
ix. Open compressor delivery oil filters, check, clean/replace by new.
x. Check oil strainer housing/chamber for metallic sand, paste, etc.

Depending on the oil discoloration and dirt found in the oil during inspection, operator/technicians at site shall use
their 'own discretion' to replace lubrication oil. Ensure lubrication system is thoroughly cleaned before charging
fresh oil in crankcase. Lubrication oil will have to be changed sooner than the given interval in case dirty oil is
seen in the crankcase through sight glass.

WHILE COMPRESSOR IN OPERATION

• Do not touch hot surfaces of compressor (cylinder heads, discharge header/piping).
• Do not remove belt/coupling, safety guards.
• Don not insert fingers/body parts/tools in safety guards.
• Only authorised trained staff should handle compressor.
• Do respect the safety of self, society, environment and nation.

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13. INSTALLATION CHECKS

A. CRANKSHAFT RUSTING
i. If soap solution is used to check for leakage in the shaft seal cover area make sure it is thoroughly
cleaned otherwise the crankshaft may rust in that area. To prevent this clean the surface and apply
antirust oil.
ii. Rust preventive oil applied on Crank shaft taper during dispatch of compressor, should be removed during
Coupling/flywheel fitment only.

B. COUPLING/FLYWHEEL/MOTOR PULLEY FITMENT

Use oil on mating surfaces of key & keyway, do not fit dry. Make sure the key is fitted properly on the shaft
keyway and the hub keyway. Key will have push-fit and it will rest on keyway bottom face. It is very important to
ensure key is properly fitted for flywheel, motor pulley, compressor and motor side coupling hub. Refer to the
checkpoints mentioned in the maintenance schedule and inspect key fixed in hub from an expert technician each
time.

For fitment on taper diameters:

i. Fit flywheel/coupling hub on compressor shaft without key check fitment depth from face of crankshaft
and flywheel or coupling hub face.
ii. Refit flywheel/coupling with the key, confirm that the key depth is the same as that checked in (i) above.
After the flywheel/coupling is fitted, fix the retainer plate and ensure that the bolt/screw on the crankshaft
is fully tightened, oil the threads of the bolt/screw for smooth fitment and rust prevention. Verify that the
safety lock plate is properly fixed. During tightening, the crankshaft/flywheel/coupling will rotate. So lock it
mechanically and ensure complete tightness of bolt/screw. Remove this mechanical lock and check the
free rotation of the compressor crankshaft. Failure to do so will damage the crankshaft/coupling or
flywheel bore/keyway and result in crankshaft breakage.

For fitment on parallel shaft:

Fit retainer plate and centre bolt to lock the motor pulley/coupling hub axially on motor shaft.

C. BASE FRAME:
i. Only Kirloskar Pneumatic Company Limited supplied base frame should be used. Ensure correct base
frame is received at site (as per motor frame size informed while placing your order.) Foundation should
be done as per Kirloskar Pneumatic Company Limited recommendations / foundation layout drawings
provided.
ii. Levelling of base frame should be done correctly.
iii. Foundation studs for base frame fitment and for compressor mounting on base frame should be separate
i.e., Do not use the same stud for foundation, base frame and compressor.
For compressor fitment on base frame use separate bolts, nuts, plain and spring washers, Ensure
sufficient bolt length so that all thread of nuts are utilized after fitment of plain and spring washers.
iv. Foundation grouted bolts /studs should be cast vertically/right angle to floor face as slant bolts/studs will
result in little or no face-contact of nuts on base frame channel.
Slant bolt/studs will have to be corrected as the bolt/studs will break-off in the foundation during nut
tightening or excessive vibrations on compressor assembly will occur during running.
To take care of above, the foundation studs/bolts should be set accurately. In concrete footing, pipe
sleeves of at least one pipe size larger than the bolt/stud diameter should be slipped over the bolts/studs
and cast in place. This will facilitate adjustment of bolts/studs centres after the foundation has set thus
simplifying installation.
v. Ensure full tightness of base frame to foundation after allowing sufficient curing time of concrete.
vi. Mount compressor on base frame, level it correctly and fix compressor by nuts, bolts, plain and spring
washers. Ensure full tightness of all bolts and nuts. Wherever channel base frames are used, use taper
washers.
vii. Align motor and compressor axis accurately within 0.1 to 0.20 mm by dial indicator. During alignment
work ensure suction and discharge pipe line of compressor are not strained, so that further connection
should not be forced. Generally compressor should be kept in position, and motor should be moved
axially, transversely or vertically.
viii. For self-driven compressor align flywheel and motor pulley & ensure no-axial-pull exists on compressor
crank-shaft after mounting belts and checking their tension.
If axial pull exists, then wear of main bearing of crankshaft will be faster excessive and can cause
premature failure / breakage of the crankshaft.

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ix. After alignment and fitment of coupling/belts/solenoid valves, gauges etc. fill compressor with clean
specified refrigeration oil up to required level and conduct air-run test for 10 minutes, observe oil pressure,
abnormal noise, local overheating, oil return, loading/unloading of direct cylinder, vibration etc.

D. STOP VALVES
Stop Valves are necessarily required on each connection of compressor to isolate from connected system piping.
KPCL supplies a range of stop valves designed for refrigeration systems. These are straight line valves provided
with a set of flanges to suit for suction, intermediate & discharge flange. The design and construction ensures long
working life and at the same time ease of maintenance.

E. PIPING:
i. While connecting piping from compressor to other equipment, please ensure that there are no
undesirable stresses. All the bolts between connecting flanges should be inserted smoothly without
pulling or pushing the pipes: abnormal stresses on compressor would lead to severe vibration and
consequent compressor damage.
ii. Ensure that all pipes are thoroughly cleaned from inside before installation: this will avoid dirt entering in
to compressor and resulting in costly damage to equipment.

F. LIQUID FLOODBACK DURING OFF CYCLE:

On Freon installation, insist upon crankcase heater to avoid foaming at start up leading to lubrication failure.

G. GENERAL PRECAUTIONS:
i. Avoid hydraulic testing of heat exchangers and pressure vessels; because it invariably leaves water in the
vessels, and on starting the plant, water frequently enters the compressor, expansion valves and chokes
driers.
ii. It is preferable to install an hour meter to know exact running hour of equipment and to ensure timely
preventive maintenance.

It is mandatory to follow directive principles, standards, rules, ordinance and regulatory laws established
by state/local authorities, in view of safety and functionality of the plant operation, environment and
society mankind.

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14. DISPOSAL GUIDELINES FOR PRODUCTS

1.0 PURPOSE:
These guidelines are reference document for handling of product at the end of product life.

2.0 SCOPE:
These are intended to provide guidance and broad outline, however, the specific methods of treatment and
disposal for specific wastes needs to be worked out according to the hazard/risk potential of the waste under
question. These Guidelines provide the minimum practice required to be followed.
The State Department of Environment or State Pollution Control Board or Local authority in prevailing area of
operations, may prescribe more stringent norms as deemed necessary.

These are required to be complied.

3.0 OPERATING INSTRUCTIONS:

a) WASTE DISPOSAL METHODS:

Advantages Disadvantages/Environmental Impact
i) Ocean Dumping
 Convenient  Ocean overburdened
 Inexpensive  Destruction of food sources
 Source of nutrients, shelter and breeding  Killing of plankton
 Desalination
ii) Sanitary Landfill
 Volume can increase with little addition of people/  Completed landfill areas can settle and requires
 Filled land can be reused for other community maintenance Equipment
 Requires proper planning, design and operation
purposes
iii) Incineration
 Requires minimum land  Air Pollution
 Can be operated in any weather  Expensive to build &operate
 Produces stable odor-free residue  High energy requirement
 Refuse volume is reduced by half  Requires skilled personnel and continuous
maintenance
 Unsightly- smell, waste, vermin
iv) Open Dumping
 Inexpensive  Health-hazard-insects, rodents, etc.
 Damage due to air pollution
 Ground water and run-off pollution
v) Recycling
 Key to providing a liveable environment for the  Expensive
future  Some wastes cannot be recycled
 Technological push needed
 Separation of useful material from waste

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A Kirloskar Group Company

b) CLASSIFICATION OF RECOMMENDED WAYS OF DISPOSAL:

Category Definition Code
Recycled Recycling returns a product to raw material form, which can be used as A
raw material for a future manufacturing process without any impact on
environment.
Repair Repair makes a broken product operational again. B
Re-used/Used This term is generally applied to a product that has been used previously. C
The product will retain the problems it acquired during its previous life as it
will not have been repaired.
Recondition/Refurbish/ Reconditioning restores a product functionally to as-new or almost as-new D
Restore condition but may not come with a warranty that matches a new product.
Reconditioning may return a product to like-new quality but the process
may not disassemble and clean all of a product's components; this means
it is not 'remanufacture'.
De-manufacture De manufacturing' describes a disassembly process and is often E
associated with recycling. Automobiles for example need to be
disassembled to ensure segregation of materials such as steel, aluminium,
various plastics, etc. De manufacturing is a step of that could in theory be
applied to any ‘re’ but is not a process in its own right.
Re-manufacture Remanufacture returns a used product to like-new condition; it is a F
process of recapturing the value added to the material when a product was
first manufactured. Remanufacture results in reduced energy and material
use, and production cost reductions.
Dispose Use and dispose (i.e. hand over to authorized recycler) G

c) CATEGORIZED LIST OF ITEMS AND DISPOSAL RECOMMENDATIONS:

Type Sub- Disposal Typical Component
classification category
Castings Ferrous A, D Gear housing, crankcase, connecting rod, pistons,
crankcase covers, flywheel, motor pulleys, piston
rings.
Non-ferrous A Gear housing, connecting rod, pistons.
Forgings Ferrous A, D Crankshaft, connecting rod, gears, pinions, shafts.
Non-ferrous A Connecting rod.
Machined components Ferrous A, D Crankcase, gudgeon pin, covers, shafts, springs,
(bar, plates) keys, gears, pinions, shafts.
Non-ferrous A Piston, bearing bushes, unloader piston.
Fabricated components Ferrous A Compressor crankcase, heat exchangers
(intercooler, after cooler, oil cooler), receivers,
pulsation vessels, piping, oil separator, gas cooler
vessels, stop valve.
Non-ferrous A Heat exchangers (intercooler, after cooler, oil cooler),
receivers, pulsation vessels,
piping, oil separator
O-Rings Rubber G Packings
Seals Rubber G Shaft seals
Metal A Mechanical seals
Hardware Metal A Nuts/Bolts/Washers
Name Plates Metal A Aluminium /Stainless Steel/Steel
Non-metallic G Plastic/Polymide
Adhesive G For name plates
Sealants G Loctite
Oil Lubricating Mineral A, G Crankcase oil, gear oil
Synthetic A, G Crankcase oil, gear oil
Grease Lubricating G Bearing grease
Instruments Indicating G, B Pressure gauge, temp. gauge, temp. switch,
pressure switch.
Plastic G Caps (covering for opening), pouches for spare parts
Glass Covers A Crankcase oil level, instruments
Acrylic covers Covers G Crankcase, distance piece
Steel wool Steel/Ferrous G Oil separator

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Tubing Ferrous A, C Instrument, gauge tubing

Stainless
Steel
Plastic G Instrument, gauge tubing
Non-ferrous A, C Instrument, gauge tubing
Copper
Electrical items Motors B, G Main motor, oil pump motor
Control G, B Starter
Panels
Wiring G, C Power cables, Instrument cables
Heater G Crankcase
Conduits C, G Plastic/Metallic
Batteries G Lead Acid
Refrigerant Gases C HFC, Ammonia
Insulating Material Foams/Wool G PUF, Neoprene based rubber sheet
Packing Material Non-metallic A Wood, plywood
G Thermocole, plastic bags, bubble sheet
A Tarpaulin sheets
Paints/Thinner Belts Chemical G Product paints (surface)
Vee/Flat G Drive belts
Balata packing (anti vibration mount)
Coupling element Rubber G Flexible (elastomer) couplings
Filled PTFE Carbon/ G Seals, piston rings , guide / wear rings, valve seat,
bushes
Filter elements Air G Suction filters
Lube Oil - G Lube oil filters
paper
Bearings Lube Oil- G Strainers, lube oil filters
wiremesh
Anti-friction G Ball Bearings, cyl. roller, taper roller
Bi-metal G
Sintered Material Bronze G Clutch plates, bushes, vent silencers
Moisture adsorption G Molecular sieve, water resistant pearl, born-silicate
material glass fiber

d) RECOMMENDATIONS TO END USER:

Contact authorised local landfill agency / manager, scrap metal recycling center or hazardous waste facility and
ask what the proper procedures are for disposing of refrigeration compressor in your area. Since each
country/state/local authority has different regulations as to how this should be handled, they will know the
proper steps for your country.

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