Kirloskar Pneumatic Co. Ltd.

, Pune

Operation and Maintenance Manual

For KES 7 & KES 11

KIRLOSKAR PNEUMATIC COMPANY LTD.,

PUNE – 411 013 INDIA
Kirloskar Pneumatic Co. Ltd., Pune

Operation and Maintenance Manual

For KES 7 & KES 11

KIRLOSKAR PNEUMATIC COMPANY LTD.,

PUNE – 411 013 INDIA
Kirloskar Pneumatic Co. Ltd., Pune

Document Number : S271.068.D98

Publication Number : N27.21.000.033.00

Revision Status: R03

Date: MAY 2011

Contact Information:

Head of Servicing Department

KIRLOSKAR PNEUMATIC COMPANY LTD.,
HADAPSAR INDUSTRIAL ESTATE
PUNE – 411 013 INDIA

Phone : 91 – 20 26870133/26870341

Fax : 91 – 20 26870297 / 26870634

e-mail : [email protected] and [email protected]

Contact your nearest dealer for any assistance or dial

Toll free number 1800 301 00009

Kirloskar Pneumatic Co. Ltd., Pune

MACHINE IDENTIFICATION AND SALE RECORD

Owner’s name: ___________________________________

Address:___________________________________

Compressor Model:___________________________________

Compressor Serial Number:____________________________________

Year of Manufacture:____________________________________

Main motor make:____________________________________

Main motor Serial Number:____________________________________

Motor Rating: ___________kW @ ____________ Rev/min

Compressor Capacity:____________m3/min @ ___________ bar g

Date of delivery:_____________________________________

Date of Commissioning:_____________________________________

Dealer Name / Code:_____________________________________

Dealer signature / stamp:

NOTE: Always indicate Compressor Serial Number given above while communicating with KPCL
dealer / Service Centre/ Branch office regarding your compressor. The warranty on this compressor is
valid only if the dealer signs and stamps on the warranty card supplied along with the compressor.
Message from the Managing Director
Kirloskar Pneumatic Co. Ltd., Pune

Dear Customer,

We welcome you to the family of users of Electric Screw

Air Compressors from KPCL, one of the largest
manufacturers of AIR and GAS compressors in India.
Kirloskar Pneumatic products would always give you Value
for money for years to come! We are sure that you will be
proud of its performance.

At Kirloskar, listening to the user & customer and meeting

his/her needs is a tradition as old as the group itself. For it
is they who drive us further, make us reach higher, and
engineer better solutions.

KPCL has designed your compressor to be safe, best in

performance, reliable, user friendly and easy to maintain.
To ensure a long and trouble free life of your machine, give
it proper care and maintenance as described in this
manual.

KPCL is honored to be the choice for all your compressed

air needs. We look forward to your continued satisfaction
as KPCL compressor user.
Kirloskar Pneumatic Co. Ltd., Pune

About Kirloskar Pneumatic Company

Kirloskar Pneumatic Company Ltd, a flagship company in Kirloskar
group is an ISO 9001 company. KPCL has grown over the past 50 years
by serving the customers with all types of air and gas compressors. The
multi-product company has transformed with innovative products and
processes to meet the innovative demands and applications as well as
the challenges of globalization. KPCL is Asia’s largest air compressor
manufacturing company with products ranging from 3 HP to 2MW power
capacity. The company has a strong presence in the global market with
customers in more than 40 countries and partners from more than 10
countries.

KPCL operates from Pune factory with state of the art facilities for
Research & Development, Manufacturing, Metrology and other Business
processes. KPCL’s dedication in serving the customers through its
network of branch offices, dealers, distributors, service providers and
web based customer care system has earned excellent reputation to the
company and valuable customers and partners.

Driven by the Kirloskar Group philosophy of “Enriching Lives”,

KPCL believes service to customers & society through partnership with
its customers and partners worldwide guided by values, innovation,
technology and consistency in business processes.
Kirloskar Pneumatic Co. Ltd., Pune

TABLE OF CONTENTS
Section 1 USER INFORMATION Page No.

1.1 General 1

1.2 Warranty 2
1.3 ISO Symbols 3-4
1.4 Receiving the Compressor 5

1.5 Lifting the Compressor 6-8

1.6 General Installation Guidelines 9
1.7 Installation requirements 10-15
Section 2 SAFETY 16
Section 3 DOs and DON’Ts 17
Section 4 COMMISSIONING

4.1 General 18

4.2 Points to be observed before Initial Start 18

4.3 Commissioning the compressor 19-20
Section 5 TECHNICAL SPECIFICATIONS AND SALIENT FEATURES

5.1 Technical Specifications 21-22

5.2 Salient Features 23-26
Section 6 SYSTEM OPERATION 27-28
Section 7 MAINTENANCE
7.1 General 29
7.2 Maintenance Schedule 29
7.3 List of Consumables and Spare parts 30-31
Section 8 DETAILS OF SUB-ASSEMBLIES
8.1 Air Intake System 32
8.2 Drive System 33-34
8.3 Discharge System 35-36
8.4 Cooling System 37
8.5 Lubrication System 38
8.6 Capacity Control System 39

8.7 Electrical System 40-41

8.8 Structure assembly 42-43

8.9 Maintenance instructions for Intake Valve Assembly 44-45

8.10 Maintenance instructions for V Belt 46-48
Section 9 TROUBLE SHOOTING 49-51
`Kirloskar Pneumatic Co. Ltd., Pune

1. USER INFORMATION

1.1 GENERAL
The contents in this Manual are proprietary and confidential to Kirloskar
Pneumatic Company Ltd and should not be reproduced without prior written
permission of Kirloskar Pneumatic Company Ltd.

The abbreviation KPCL used in this Manual means Kirloskar Pneumatic

Company Ltd, Hadapsar Industrial Estate, Pune - 411013.

This Manual contains instructions and technical data to cover all routine
operation and Scheduled maintenance tasks by operation and maintenance
staff. Major overhauls are outside the scope of this manual and should be
referred to an authorized KPCL Service department.

All components, accessories, pipes and connectors added to the compressed

air system should be:

• Of good quality, procured from a reputable manufacturer and, wherever

possible, be of a type approved by KPCL.
• Clearly rated for a pressure at least equal to the machine maximum
allowable working pressure.
• Compatible with the compressor lubricant/coolant.
• Accompanied with instructions for safe installation, operation and
maintenance.

The use of repair parts / lubricants / fluids other than those included within the
KPCL approved parts list may create hazardous conditions over which KPCL
has no control. Therefore KPCL cannot be held responsible for equipment in
which non–approved repair parts are installed.

KPCL reserves the right to make changes and improvements to products

without notice and without incurring any obligation to make such changes or
add such improvements to products sold previously.

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`Kirloskar Pneumatic Co. Ltd., Pune

1.2 WARRANTY
The warranty applicable for the compressor purchased by you is given in
the Warranty Certificate sent along with the Compressor. Preserve it to get
warranty service from KPCL dealer/KPCL.

KPCL does not accept any liability for damages in transit and during handling in
transport. Inspect the physical conditions of the compressor on receipt and get the
transporter’s confirmation regarding the damages on receipt on the transporter
invoice to claim the insurance.

Any other complaint should be informed to the authorized dealer of KPCL or KPCL
branch or KPCL registered office, Pune in writing within 6 days from the receipt of
complaint. Preserve the Warranty Certificate sent along with the compressor.

KPCL will not accept the warranty for any problems/damages arising out of failures
to observe the conditions given in this Manual, alterations done on the compressor
without getting written permission from KPCL, improper repairs, insufficient
maintenance and use of spare parts other than KPCL make and supplies.

KPCL reserves the right for modifications without notice in the interest of
technology progress.

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1.3 ISO SYMBOLS

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`Kirloskar Pneumatic Co. Ltd., Pune

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`Kirloskar Pneumatic Co. Ltd., Pune

1.4 RECEIVING THE COMPRESSOR

On receipt of the compressor with packing case, the condition of the packing case
has to be checked immediately for any damages. In case of damages, the proof of
condition has to be obtained from the transporter on the transporter invoice and
then the details are to be reported to insurance authorities (if transit insurance is
done) and also to KPCL dealer / KPCL.

The condition of the compressor inside the packing case also has to be verified by
unpacking the case (except the base of the packing case). In case of damages,
follow the instructions given above.

The contents are to be verified with the packing list received with the invoice /
delivery note. Written complaint to be given to KPCL dealer / KPCL immediately, if
any item is found missing w.r.to packing list. Following items are sent with
Standard Compressor without spares /accessories:
1) One No. Key for the canopy doors
2) One no. Operation and Maintenance manual

The condition of compressor parts also to be checked by opening the canopy

doors. If any parts are missing, contact KPCL dealer / KPCL immediately.
Now the compressor has to be kept in covered condition till the site is ready for
installing the compressor. Even during this temporary storage, ensure the
compressor is kept on a raised place and covered to protect it from rain / water
logging.

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`Kirloskar Pneumatic Co. Ltd., Pune

1.5 LIFTING THE COMPRESSOR

KPCL air compressors are shipped in wooden packing cases. Refer the
figures given below to lift the compressor with overhead crane or forklift. Wooden
frame shall to be used to keep the ropes away from the canopy while lifting the
compressor with overhead crane. Soft pad / wooden panel shall be used between
canopy and forklift arm to avoid damages to canopy while lifting the compressor
using forklift.

Prior to lifting inspect the bails, ropes and support frame for their capacity
and condition to suit the weight of the compressor.

Ensure lifting hook is with functional safety latch or equivalent and is fully
engaged.

Use guide ropes or an equivalent supports to avoid the lifted unit is swinging
in air.

Do not lift the compressor in open area with high wind speed.

Ensure all the personnel are out under the compressor when suspended.

Ensure the lift operator is kept under constant observation when
compressor is suspended.

Ensure the compressor is not lifted beyond the requirement of clearance
from floor.

Check the unit is firmly sitting on the forks when forklift is used for lifting.

Ensure the compressor is slightly tilted towards forklift by tilting the forks to
avoid slipping during movement.

Ensure the compressor is resting on forklift vertical beams with pad kept
between.

Ensure the speed of the forklift / crane does not cross 5-km/hr speed.

In case of shifting the compressor to site without forklift / overhead crane,
use pipes or cylindrical rods under the compressor with wooden base of
packing case.

Use tripods with adequate capacity chain & pulley blocks to lift the
compressor from the wooden base.

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`Kirloskar Pneumatic Co. Ltd., Pune

A LWAYS USE WOODEN

PADS HERE

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`Kirloskar Pneumatic Co. Ltd., Pune

1.6 GENERAL INSTALLATION GUIDELINES

Observe the following conditions while installing the compressor:

Adhere Accident Prevention Regulations

Adequate accessibility around the compressor as in fig below

Area around the compressor/ compressor room is dry and clean

Temperature around the compressor is with +5 to +45 degC

Adequate opening for air intake and hot air exhaust

10 m radius from compressors is free from combustible materials

Fire extinguisher kept in reachable position near the compressor

Quantity of hot air to be ventilated for KES 7 to KES11 models is 2118 cfm (60 m3/min). The open area
around the compressor has to be kept free for operating & maintenance personnel movement for
performing the routine checks and maintenance activities.

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`Kirloskar Pneumatic Co. Ltd., Pune

1.7 INSTALLATION REQUIREMENTS

Site preparation: The compressor does not need any special foundation or
grouting. Normal shop floor suitable for installing metal cutting machines is
sufficient. The surface of installation area should be with minimum variation to
avoid non-uniform seating of the compressor foot. Use shims to ensure the base
frame seating on floor at all corners to avoid vibrations during running. The
compressor suction side has to be positioned towards the open area or opening on
the wall to ensure fresh atmospheric air entry to the compressor. Exhaust fan /
ducting has to be installed to avoid the hot air recirculation and increase in
temperature in the compressor. Refer the figures given on the previous page and
the following page for general guidance. The exhaust fan sizing has to be done
such that the air velocity does not exceed 10 m/sec. Installation of higher capacity
fan may result in capacity problem in the compressor. The compressor positioning
also to be such that the hot air from other compressors or equipments is not
diverted to the compressor to be installed.
Failure to observe the instructions regarding installation and ventilation will
result in increase in discharge temperature which in-turn result in frequent
tripping and pre-matured failure of parts.

Mechanical connections: The compressor is provided with 2 outlet points on

air receiver for Compressed air outlet, drain line from receiver. The moisture
draining from the compressor will have the traces of oil. Ensure the moisture
drainpipe line is connected to the central drain line with ball valves and conditions
as per the local statutory regulations for wastewater disposal. The compressor air
outlet line has to be connected to network air pipeline after installing Non-Return
Valve after the ball valve on compressor air outlet point. Ensure the air pipeline is
with adequate size to avoid pressure drops and with adequate water traps.

Electrical connections: The compressor is provided with 4Pin industrial

socket with plug on the canopy for power supply. The incoming power supply line
must be through a switchboard with fuses. Fuse ratings applicable for 415 V, 50Hz,
3 Phase power supply and recommended cable size are given in the table on next
page:

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`Kirloskar Pneumatic Co. Ltd., Pune

Recommended cable size

Model Type of Motor Backup fuse Recommended cable size

Starting rating
Copper cable Aluminium cable

KES 7 DOL 50 Amps 3.5 core, 4 sq.mm 3.5 core, 6 sq.mm

KES 11 Star-Delta 32 Amps 3.5 core, 4 sq.mm 3.5 core, 10 sq.mm

Connect the earth line to the bolt below to the cable entry socket.

Follow the electrical safety norms as per local statutory regulations and electrical
standards for the safety of operating personnel and the compressor.

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`Kirloskar Pneumatic Co. Ltd., Pune

Refer the illustrations and drawings on the following pages for installation.

A-Room ventilation through opening in the wall. B- Room ventilation with exhaust system

C -- Room ventilation with exhaust system D -- Hot air duct from compressor

E -- Ducting for room heating

Refer the illustrations given above for installing the air-cooled compressor.
Best installation is with hot air exhaust duct from compressor to atmosphere and
air inlet side is kept directly inline with the air intake opening from the atmosphere.

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Electric Circuit Diagram KES-7

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`Kirloskar Pneumatic Co. Ltd., Pune

Electric Circuit Diagram KES-11

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`Kirloskar Pneumatic Co. Ltd., Pune

General Arrangement Drawing for KES 7- KES 11 Models

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2.0 SAFETY
The compressors designed and manufactured by KPCL are for safe operation at
the designated conditions. The safe operation of the compressor lies with the
personnel operating and maintaining it. Hence, those who are trained and
understood this OPERATION AND MAINTENANCE MANUAL only shall operate
the compressor.

Never start the compressor when it is not safe to do so. Never operate the
compressor with known unsafe conditions. When the compressor is unsafe, tag
the unit to indicate to other and disconnect the power supply either by removing
decontactor plug to avoid accidents.

This air compressor is not explosion proof and hence it has to be installed away
from the explosion area. Do not use the air from this compressor for direct contact
with food & medicine substances and do not use for breathing purpose.

Do not modify the compressor without getting the written permission from KPCL.

Pressure release: The compressor is provided with pressure relief valve to

release the pressure from the air-oil separator tank incase of pressure exceeds the
set values and electrical interlocks fail. Do not open the valves / air lines / air-oil
separator tank connections or plugs without releasing the pressure by using the
pressure relief valve (safety valve).

Fire or Explosion: Install fire extinguishers near the compressor. Do not store
inflammable materials near the compressor. Keep the compressor clean from oil
spills to ensure safety to operating personnel and equipment.

Hot Surfaces: Do not handle/touch the hot surfaces on the compressor without
using proper protection & handling devices. Avoid body contact with hot surfaces,
oil and air.

Electrical safety: Ensure electrical safety standards are adhered for the safe
operation of the compressor and personnel. Do not store materials inside the
electrical panel even though free space is available. Attempt repairs after removing
the fuses in the incoming power supply lines and keep notice near the fuse box to
avoid accidental connections.

Waste disposal: Follow the local safety standards for disposing the used oil, filters
and other used parts of the compressor to protect the environment.

DANGER

Death or serious injury may result from inhaling compressed air without using proper
safety equipment.

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`Kirloskar Pneumatic Co. Ltd., Pune

3.0 DOs and DON’Ts

DOs

Operating personnel read this manual thoroughly and follow instructions.

Clean the Compressor regularly.

Check the air filter condition regularly and replace in time.

Maintain correct oil level.

Maintain lowest belt tension at which belt will not slip under peak load
(correct tension-28 to 38 N) and check from time to time.

Use genuine parts from KPCL only.

Use proper tools for operation and maintenance.

Attend immediately to anything unusual in the compressor.

DON’Ts

Neglect the routine maintenance

Allow the leakages in the system

Clean the air filter with pressurized air

Change the settings on compressor parts

Use cleaning agents while changing the oil other than recommended

Keep tools & other material on compressor

Leave loose the free end of air line hoses

Use the air for breathing

Use the air for direct contact with food products without recommended filters

Pry or roll belts into the pulley grooves.

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`Kirloskar Pneumatic Co. Ltd., Pune

4.0 COMMISSIONING
4.1 GENERAL
The instructions given in this Manual is for a Standard Air Compressor without
additional equipment. Check for the visual damages after completing the
installation has to be done. Each compressor is supplied with electrical circuit
diagram -pasted inside the electrical panel. Check the condition of the parts and
connections. Each compressor is subjected to test run before dispatch. There are
chances of settings get disturbed during transport or installation Verification of
firmness of all connections has to be done after installing compressor at site. The
commissioning of the compressor has to be done by the KPCL dealer only after
the installation and connections are done.

4.2 POINTS TO BE OBSERVED BEFORE INITIAL START

Remove all supports used for support during transit.

Ensure the airline connections from compressor to air network are done without
gaps or loose bolts.

Ensure the electrical connections are firm and correct as per recommendations.

Ensure the moisture drain lines are connected and drain line ball valve is kept
close.

Ensure the oil drain ball valve on Air-oil separator tank is closed and fitted with a
threaded plug at open end of the valve.

Ensure the pulleys are properly tightened.

Check belt tension with the help of belt tension tester.

Remove the rubber bend and pour 250 ml of recommended oil inside the intake
valve by pressing the tappet plate. This is to ensure the lubrication oil is present
inside the airend at the time of starting.

Check and ensure the oil level in the Air-oil Separator tank of the compressor is
filled to middle level of the sight glass fitted on tank. Use the Servo system
HLP68 only. Though oil fill capacity is 4.5 litres, actual fill may be low since other
points in the oil line are may not be filled. Further oil fill-up to be done during the
commissioning process. Fix threaded plug at pour point and tighten it fully.

Ensure the air filter is firmly fitted on the intake valve with the clamp.

Ensure the electrical connections are done as per circuit.

Ensure the power supply line is with adequate capacity for the KES-11
compressor with Star –delta & for KES-7 compressor with DOL starting system
for the main motor.

Ensure the ball valve on air outlet line is kept open.

If the compressor was stored for more than 3 months from the date of
manufacturing, the KPCL dealer has to be informed to do additional checks to
confirm all the moving parts like motors, airend, valves etc and critical parts are
in good conditions.

Ensure the motors are with stickers on fan cover or body to indicate direction of
rotation.

Ensure earthing connection is done.

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`Kirloskar Pneumatic Co. Ltd., Pune

4.3 COMMISIONING THE COMPRESSOR

Drain the moisture with manual drain valve on air receiver.

Check the belt tension.

Switch ON the main power supply.

Remove the canopy front door to view the motor.

Check the correct direction of rotation at first start up.

Press Start button (green color) on the panel to make the main motor ON. If motor
is energized, switch off the compressor by pressing Emergency stop button on
panel. Check and confirm the direction of the rotation is in line with the direction
arrow mark sticker pasted on the air end. If the direction of rotation is wrong, check
the main power supply lines and correct them. If the direction of rotation is correct,
fit the canopy door in position.

Close the ball valve at the compressor air outlet line.

Run the compressor for ONE minute and switch OFF to make the oil in the oil lines
to flow back to the tank.

Check the oil level on the sight glass after 5 mins. Add oil till the level reaches to
middle level of the sight glass.

Ensure the threaded plug provided on oil pour point is tightened fully.

The compressor will go to “Unload” mode once the pressure reaches maximum
pressure/unload pressure. This is when 7.5Kg/mm sq. in pressure gauge is
unloading pressure value of the model.

Open the canopy doors and confirm no leakage of air and oil at the joints/fittings.

Open the ball valve slowly till the pressure in pressure gauge is the working
pressure of the model.

Refer the specifications given in Section 5 of this Manual for each model to confirm
the compressor performance is within the limits.

Ensure the temperature inside the compressor room is not more than 5 degC
above the temperature outside the room during the continuous run.

Refer Trouble –shooting guide given in this manual for any abnormalities found.

Report to KPCL, if problem persists after applying remedial actions given in the
trouble-shooting guide.

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`Kirloskar Pneumatic Co. Ltd., Pune

Front View of Control Panel

4 Pin industrial socket with plug for incoming power supply

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5.0 SPECIFICATIONS & SALIENT FEATURES

5.1 TECHNICAL SPECIFICATIONS - KES-7

Sl.No. Description Unit Data

1 Models KES 7-7.5 KES 7 -10 KES 7-13
2 cfm 41 36 31
Free Air Delivery (FAD)
m3/min 1.16 1.02 0.88
3 Operating Pressure kg/cm 2
7.0 9.5 12.5
4 Maximum / Unloading Pressure kg/cm 2
7.5 10 13
5 Cut-in / Reloading pressure kg/cm 2
6.5 9.0 12
6 MPVL opening pressure kg/cm 2
4.0 4.0 4.0
7 Power supply conditions 415V +/- 10%, 50Hz +/- 5%, 3 Phase
8 Capacity Control system LOAD - UNLOAD
9 Main motor rating kW 7.5 kW with SF 1.15
10 degC &
Operating conditions - ambient & altitude + 5 to + 45 degC & 1000 metre Altitude
metres
11 Fan motor rating kW 0.55
12 Type of motors (Main & Fan drive) Squirrel Cage Induction
13 Insulation & protection of motors Class F & TEFC (IP55)
14 Rated speed of Main motor RPM 2900
15 Rated speed of Fan motor RPM 2820
16 132 Frame, Flange cum foot mounted
Frame size, Mounting type & Make of Main motor
Make- CGL
17 Frame size & mounting type of Fan motor GD71S & Flange mounted
18 Efficiency of Main motor at full load power 90%
19 Efficiency of Fan motor at full load power 74.0%
20 Over Load Relay setting for Main Motor Amps 21
21 Over Load Relay setting for Fan Motor Amps 1.4
22 Type of starting for Main motor DOL
23 Type of starting for Fan motor DOL
24 Type of coupling & size/model Belt drive
25 Oil fill capacity litres 4.5
26 Discharge Temperature (at airend outlet) degC 85 to 100
27 Air temperature at compressor outlet degC Ambient + 10
28 Air outlet port size & Qty. Inch& Nos. 3/4 inch BSP x 1 No
29 Sound Pressure Level of the Compressor
dB(A) 70 +/-3
@ 1 metre distance
30 Overall dimensions of the unit, L x B x H mm 1235 x 600 x 1715
31 Weight of the unit without oil kg 417
32 Reference standard for FAD and SPC ISO 1217 : 1996 Annexure C
33 Reference standard for Sound Pressure Level Cagi Pnuerop PN8NTC2.2

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TECHNICAL SPECIFICATIONS - KES-11

Sl.No. Description Unit Data

1 Models KES11-7.5 KES11-10 KES11-13
2 cfm 58 50 38
Free Air Delivery (FAD)
m3/min 1.64 1.42 1.08
3 Operating pressure kg/cm2 7.0 9.5 12.5
4 Maximum / Unloading Pressure kg/cm 2
7.5 10.0 13.0
5 Cut-in / Reloading pressure kg/cm2 6.5 9.0 12
6 MPVL opening pressure kg/cm 2
4.0 4.0 4.0
7 Power supply conditions 415V +/- 10%, 50Hz +/- 5%, 3 Phase
8 Capacity Control system LOAD - UNLOAD
9 Main motor rating kW 11 kW with SF 1.15
10 Operating conditions - ambient & altitude DegC & metres + 5 to +45 degC & 1000 metre Altitude
11 Fan motor rating kW 0.55
12 Type of motors (Main & Fan drive) Squirrel Cage Induction
13 Insulation & protection of motors Class F & TEFC (IP55)
14 Rated speed of Main motor RPM 2920
15 Rated speed of Fan motor RPM 2820
16 132 Frame, Flange cum foot mounted
Frame size, Mounting type & Make of Main motor
MAKE - CGL
17 Frame size & mounting type of Fan motor GD71S & Flange mounted
18 Efficiency of Main motor at full load power 90.0%
19 Efficiency of Fan motor at full load power 74.0%
20 Over Load Relay setting for Main Motor Amps 14
21 Over Load Relay setting for Fan Motor Amps 1.4
22 Type of starting for Main motor Star - Delta
23 Type of starting for Fan motor DOL
24 Type of coupling & size/model Belt drive
25 Oil fill capacity litres 4.5
26 Discharge Temperature (at airend outlet) degC 85 to 100
27 Air temperature at compressor outlet degC Ambient + 10
28 Air outlet port size & Qty. Inch& Nos. 3/4 inch BSP x 1 No
29 Sound Pressure Level of the Compressor
dB(A) 70 +/-3
@ 1 metre distance
30 Overall dimensions of the unit, L x B x H mm 1235 x 600 x 1714
31 Weight of the unit without oil kg 417
32 Reference standard for FAD and SPC ISO 1217: 1996 Annexure C
33 Reference standard for Sound Pressure Level Cagi Pnuerop PN8NTC2.2

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5.2 SALIENT FEATURES

Best Performance: The combination of energy efficient airend driven by efficient

motor along with control system and optimally designed accessories makes the
whole system to perform at the best possible efficiency to deliver most economical
compressor air.

Air Quality: The cyclone separation system optimized over the years of research
and tests along with the best quality coalescent type oil mist separation filter
element ensure efficient separation of oil particles from the compressed air with
minimum pressure drop. This optimally designed system ensures consistent
quality of air is delivered during all modes operating cycles.

Safety systems: The compressor is provided with multiple safety systems and
elements to protect the equipment and operating personnel. Temperature switch,
overload relay, single-phase preventor, Reverse phase protection, and safety
valve provided ensure the unit runs with adequate protections.

Pulsation – free airflow: The helical fluted rotors in the airend with optimum
Length to Diameter ratio of rotors ensures pulsation free flow of compressed air.
This gives a great advantage of getting continuous flow of air.

High Reliability: The airend with only rotating parts mounted on oil lubricated
rolling bearings and minimum number of best quality moving parts is air
compression system ensures the system operates trouble-free for longer period of
time.

Low operating costs: With rotating parts of the airend and all moving parts well
lubricated, amply sized consumables of the compressor, best suitable oil and low
operating temperature of the entire system ensures the operating costs are much
lower than conventional compressors.

Airend: This is the main component of the compressor package called as Airend.
Free atmospheric air is being compressed during the rotation of optimally designed
twin helical screws in the airend. The air end is driven by electric motor through a
pair of V belt. Both air-end & motor is mounted on base frame, which is mounted
on anti vibration pads placed on the air receiver. With this arrangement we ensure
less vibrations and longer life of the compressor. High efficiency air-end and
reliable arrangement for transmission of power makes the compressor energy
efficient and reliable performance machine.

Electric Motor: This is flange mounting, 2 Pole, TEFC, IP 55 protection, Class F

insulation motor designed with necessary starting torque and operational load
variations. Motor is suitable for above-mentioned voltage and frequency variations.
Make of the motor is as per KPC standard.

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Air Intake: Trouble free operation of this close tolerance, screw type compressor
is achieved by suction air filtration system. It is with Dry, Paper type filter element
in cartridge form for easy replacement. Complete filter assembly is within canopy
of the compressor, which avoids entry of heavy particles in the compressor.

Lubrication: Lubrication of the air-end gives duel advantage. It removes heat of

compression & lubricates screw, bearings & gears. ISO VG68 grade oil is used for
this purpose. Pressurized, cool & filtered oil is injected in the air-end and comes
out of the compressor from discharge of the air end along with compressed air.
Positive oil pressure is ensured in air/oil separator tank. Hence we do not require
any separate oil pump.

Lube oil Filtration: Spin-on type oil filter is used to filter Lube oil before injecting
to the airend. This enhances long life of the compressor and reliable operation.

Air/Oil Separation: Spin-on type Air oil separator is used to separate Compressed
air and lube oil. High efficient air/oil separator element, limits oil carryover to
desired level in the delivered air from compressor package.

Lube oil Cooling: Temperature of the compressor system is maintained within

limits by cooling oil in radiator type air-cooled oil cooler. Temperature of the oil is
monitored through the temperature switch fitted at discharge port of airend in the
oil line for high temperature tripping of compressor so as to ensure uniform oil
temperature irrespective of the ambient temperature.

After Cooling: High-pressure discharge air is cooled in radiator type air-cooled

after-cooler. The condensation happens due to cooling of air & separates out in
the air receiver. We provide ball valve to remove water form the system.

Canopy & Base Frame: All components of the compressor package are mounted
on a single base frame & air receiver. It does not require any foundation. The
complete package can be shifted with forklift or hydraulic lift trolleys by using the
provision given in the air receiver. Powder Coated Metallic Canopy of the
compressor is of modular design. It is acoustically designed to limit sound pressure
level of the package to 70 dB (A) at a distance of one meter. The noise
measurement is as per Pneurop / Cagi PN8NTC2 standard. Easily removable
doors with locks are provided for easy accessibility to internal components. Air
outlet line is terminated on the air receiver for easy connection to the air network.
4 Pin industrial socket is provided on canopy for electrical power supply line from
Main supply panel without making any cutouts in the canopy or base frame.

Capacity Control: Load/Unload capacity control is provided which functions as

per demand conditions. Power saving and optimum utilization of compressor
package is achieved due to this type of capacity control.

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`Kirloskar Pneumatic Co. Ltd., Pune

Safety Devices: Following mechanical safety devices are provided to ensure safe
operation of the compressor

Minimum Pressure Valve - Maintains minimum air pressure in oil tank

so that positive oil flow is ensured.

Safety Relief Valve - De-pressurize compressor system if pressure exceeds

beyond limits of the system

Oil Level indicator - This is mounted on air/oil separator tank. It gives visual
indication of minimum & maximum level of oil present
in compressor system

Control Panel: In KES-11 model auto star-delta starter cum control panel while in
KES-7 model direct online starter cum control panel packaged on the same
canopy of the compressor.

Panel is wired and hooked up with main motor and all instruments with in the
package. Electrical circuit diagram sticker is pasted inside the canopy for ready
reference during wiring or trouble-shooting.

Safety & Control: Following Trip signals are provided to protect the machine from
abnormal operating conditions:

High air-oil mixture temperature

Main motor over load

Fan motor overload

SPP/RPP fault (Single phase /Reverse rotation)

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`Kirloskar Pneumatic Co. Ltd., Pune

Schematic Flow Diagram of the Air Compressor

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`Kirloskar Pneumatic Co. Ltd., Pune

6.0 SYSTEM OPERATION

The Air Intake Valve provided is normally open type. As the supply to the motor is
on due to the vacuum created in the compressor, air enters in the bare compressor
from suction filter. The compressed air is delivered to Air/oil separator. The
pressure in Air/Oil separator starts rising. This air pressure signal passes through
the open type solenoid Valve & is given to the inside piston of Air Intake Valve.
This closes the air intake valve & supply of air to the compressor is cut off. Thus
compressor is immediately unloaded. This ensures that the starting torque
required is less thereby limiting the starting current of the motor. In KES-7 the
motor is started with DOL where as in KES-11 the motor is started in star
connection & after a preset delay the motor runs in delta connection & compressor
runs smoothly in unloaded condition. At same time, the Solenoid Valve is
energized & the signal line to air intake valve is cut off & connected to exhaust.
With this the Air Intake Valve is immediately open & compressor comes on load.
As soon as the pressure rises in the Oil tank, the oil flow to compressor is started,
irrespective of whether the compressor is in loaded or unloaded condition.

Integrated Air / oil separator separates the oil from air/oil mixture down to 1 to 3
PPM by mechanical as well as with the help of air-oil separator element as
described earlier. The minimum pressure valve starts opening at a pressure of 3.5
kg/cm² (full open at 4.0 kg/cm2). The compressed air from oil tank then passes
through the after-cooler part of the combi-cooler where it is cooled with air of fan
driven by motor. Because of Centrifugal Force moisture gets separated from the
compressed & cooled air. The condensed moisture is drained by mechanical drain
valve of the Air Receiver. Pressurized air is now available at the air delivery valve
for user’s network.

When the demand for air decreased or when there is no demand, pressure builds
up in the system. The pressure switch connected to the air receiver senses this
pressure. When the system pressure in the system increases beyond a set value,
an electric signal is given to the Solenoid Valve & it is de-energized. The pressure
signal line from oil tank is connected to the Air Intake Valve & the compressor is
immediately unloaded. Air intake valve has in-built spring resistance which helps to
maintain a minimum pressure of 2.0 kg/cm^2g during unloading. This not only
ensures that the power consumption during unloading is minimum & but also
sufficient oil flow is maintained during unloading.

Whenever the compressor is stopped, the Solenoid Valve de-energizes. Air Intake
Valve closes, which ensures that there is no oil back flow from compressor to air
filter. Also the air receiver gets connected to the atmospheric pressure & pressure
in the oil tank is relived totally. This ensures that when the compressor is started
again, there is no pressure in the receiver.

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`Kirloskar Pneumatic Co. Ltd., Pune

The heat of compression is absorbed by oil besides sealing the rotor gaps and
lubricating the moving parts including bearings. The oil that is separated in Air/Oil
separator is collected in oil tank portion in Air/Oil separator. Due to the pressure
differential the oil starts flowing from oil tank and is passed through oil cooler part
of the compact combi-cooler, where it is cooled by air of Fan & Motor. Further it is
filtered in oil filter and supplied to compressor. Thermostatic valve is provided to
ensure that oil temperature should not below 60 deg.

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`Kirloskar Pneumatic Co. Ltd., Pune

7.0 MAINTENANCE

7.1 GENERAL
Before carrying-out any maintenance activity, stop the compressor and wait for 5
minute for all the rotating parts to stop and air from the oil tank separator tank is
relieved by Air intake valve. Use proper tools during maintenance to avoid
damage to compressor parts. Ensure this Manual is read and understood. KPCL
dealer / KPCL servicing department shall be contacted to clarify the doubts and
assist.

7.2 MAINTENANCE SCHEDULE

Period Activity Part / Part Number

Daily – Check oil level in Oil tank Sight glass
before Drain the moisture with manual drain valve Ball valve below air receiver
starting
Daily – after Check Pressure is building in air receiver Pressure gauge
starting
After first Change oil Servo system HLP68
100 hrs of Change Oil Filter Element 271.01.418.50
running
After every Change oil Servo system HLP68
1000 hrs of Clean the cooler assembly core area
running Change Air Filter Element 271.01.609.50
Change Oil Filter Element 271.01.418.50
After every Additional activities apart from changing the parts
2000 hrs of given above are:
running 1) Check the oil and air line fittings for leakage Refer Recommended Spares
2) Check the electrical wiring connections list for fittings and O-rings for
3) Check the condition of contacts on contactors fittings.
4) Check the condition of rubber hoses Hose Kit - 271.01.425.50

After every Additional activities apart from changing the parts

4000 hrs of given above are:
running 1) Replace Air-oil Separator element 271.01.598.50
2) Check the condition of all valves for leakages Refer Recommended Spares
or sluggish action. list for kits.

After every Additional activities apart from changing the parts 271.01.599.50
8000 hrs of given above are: Refer the list of recommended
running or 1) Check the condition of rubber hoses and spare parts.
ONE year replace the defective “V” Belt-Select according to
(which ever 2) Change the kit of spares for Integrated Air oil model from chart given on
is earlier) separator & Intake Valve with solenoid valve. page no.34
3) Change the V belts

The above recommendation is valid for General Engineering industry only.

Life of consumables will vary depending on the operating environment.

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7.3 LIST OF CONSUMABLES AND SPARE PARTS KITS

A. Kit of Consumables for every 4000 hrs of running -- 271.01.598.50

consists of
1) 271.01.418.50 – Oil Filter Element ----------------------------- 5 Nos
2) 271.01.609.50 – Air Filter Element ------------------------------ 4 Nos
3) 271.01.612.50 – Air-oil Separator element -------------------- 1 No

The kit consists of 1 No oil filter element to be replaced along with the oil after first
100 hrs of running.

B. 1.Kit of Consumables for every 8000 hrs of running -- 271.01.599.50

consists of
1) 271.01.418.50 – Oil Filter Element ----------------------------- 9 Nos
2) 271.01.609.50 – Air Filter Element ------------------------------- 8 Nos
3) 271.01.612.50 – Air-oil Separator element ---------------------- 2 Nos

2. “V” Belt-Select according to model from chart given on page no.34-----

---- 2 Nos

The kit consists of 1 No oil filter element to be replaced along with the oil after first
100 hrs of running.

The Compressor oil Servo System HLP68 is not given in the consumable list
since it can be procured directly from the oil manufacturer by the
customer/user.

The rubber & non-metallic parts like O-rings, gaskets, hoses are not considered in
the list of consumables since the life depends on the operating temperature which
in-turn depends on the operating environment, operation & maintenance
conditions. Apart from this, the gaskets and O-rings are to be replaced when the
part is damaged during the maintenance/repair of compressor parts during
operation. Hence KPCL recommends user to maintain one set of gaskets and O-
rings as stand-by stock

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`Kirloskar Pneumatic Co. Ltd., Pune

i. Kit of Spares after 8000 hrs run or ONE year

For KES 7 & 11 Models- 271.10.218.50 consists of

Sl.
PART No. PART DESCRIPTION QTY.
No.
1 271.01.644.50. GASKET BETWEEN AIR END & ADAPTOR PLATE 1
2 271.01.675.50 GASKET AIR END DELIVERY 2
3 271.01.669.50 ‘O’ RING AIR END DELIVERY HOSE 1
4 271.00.530.50 ‘O’ RING 1/8” 1
5 271.00.532.50 ‘O’ RING 1/4” 1
6 271.00.536.50 ‘O’ RING 1/2” 1
7 271.00.538.50 ‘O’ RING 3/4” 5
8 271.00.540.50 ‘O’ RING 1” 6
9 271.00.544.50 ‘O’ RING 1-1/2” 1
10 271.01.836.50 COMBINATION BLOCK 1
11 271.10.220.50 SERVICE KIT FOR AIR INTAKE VALVE 1
12 271.01.425.50. HOSE KIT 1

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`Kirloskar Pneumatic Co. Ltd., Pune

8 DETAILS OF SUB-ASSEMBLIES OF THE COMPRESSOR

8.1 AIR INTAKE SYSTEM

SR.NO. ITEM NO. DESCRIPTION QTY. REMARK

1 271.01.608.50 AIR FILTER 1
2 999.30.534.50 HOSE CLIP 2
3 271.01.684.50 RUBBER BEND 1
4 271.01.627.50 ADAPTOR FOR AIR FILTER 1
5 271.01.610.50 SUCTION CONTROL VALVE 1
6 999.01.621.50 SCREW HEX. STD. M8X1.25X20L 4
7 999.11.262.50 SPRING WASHER ID 8.2 X 2 THK 8
8 999.01.623.50 SCREW HEX. STD. M8X1.25X25L 4

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`Kirloskar Pneumatic Co. Ltd., Pune

8.2 DRIVE SYSTEM

SR.NO. ITEM NO. DESCRIPTION QTY. REMARK

1 271.01.616.50 ELECTRIC MOTOR 11 Kw 1
2 999.50.220.25 SCREW HEX. STD. M10X1.5X25L 4
3 999.11.268.50 SPRING WASHER ID 10.2 X 2.2 THK 4
4 999.18.730.50 PLAIN WASHER ID 11 X 2 THK 4
5 271.10.062.50 AIR END 1
6 999.01.623.50 SCREW HEX. STD. M8X1.25X25L 3
7 999.11.262.50 SPRING WASHER ID 8.2 X 2 THK 3
8 REF.CHART ON PAGE 34 V BELT 2
9 271.01.624.50 V PULLEY WITH TAPER LOCK BUSH 1
10 REF.CHART ON PAGE 34 MOTOR PULLEY 1

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`Kirloskar Pneumatic Co. Ltd., Pune

8.2 DRIVE SYSTEM

CHART FOR MOTOR PULLEY AND ‘V’ BELT

MODEL MOTOR PULLEY PART NO. ‘V’ BELT PART NO.

KES 7-7.5 271.10.099.50 271.01.694.50

KES 7-10 271.10.098.50 271.01.625.50

KES 7-13 271.01.801.50 271.01.799.50

KES 11-7.5 271.01.623.50 271.01.626.50

KES-11-10 271.10.217.50 271.01.696.50

KES 11-13 271.10.099.50 271.01.694.50

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`Kirloskar Pneumatic Co. Ltd., Pune

8.3 DISCHARGE SYSTEM

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`Kirloskar Pneumatic Co. Ltd., Pune

8.3 DISCHARGE SYSTEM

SR.NO. ITEM NO. DESCRIPTION QTY. REMARK

1 271.01.612.50 AIR OIL SEPERATOR ELEMENT 1
2 271.01.634.50 HOSE ASSEMBLY 1"X 1360MM L(90 X ST) 1
3 271.01.676.50 UNION 1"BSP X 1"BSP 5
4 271.01.824.50 GASKET 1
5 999.02.643.50 SCREW HEX SOCKET HEAD M10X1.5 x 35L 8
6 271.01.618.50 OIL TANK 1
7 999.30.857.50 PLUG TAPER SQ. HD.R-3/8 1
8 270.02.691.50 BALL VALVE 3/8"BSP 1
9 271.01.658.50 PIPE NIPPLE 3/8"BSPX160L 1
10 271.00.320.50 OIL LEVEL INDICATOR 1
11 999.01.621.50 SCREW HEX. STD. M8X1.25X20L 4
12 999.11.262.50 SPRING WASHER ID 8.2 X 2 THK 8
13 271.01.621.50 AIR RECEIVER 270 LITERS 1
14 999.30.689.00 NIPPLE HEX G 3/4 A TR 1
15 270.02.681.50 BALL VALVE 20NB 3/4"BSP 1
16 272.01.299.50 OIL DRAIN PIPE 1/2"BSP X 150L 1
17 270.02.618.50 BALL VALVE 1/2"BSP 1
18 030.48.091.00 SAFETY VALVE 3/4" BSP (SET 7 TO 17 Kg/CM^2) 1
19 271.01.635.50 HOSE ASSEMBLY 1"X 1000MM L(90 X ST) 1
20 999.01.631.50 SCREW HEX. STD. M8X1.25X40L 2
21 271.01.669.50 O' RING 1
22 999.01.623.50 SCREW HEX. STD. M8X1.25X25L 2
23 271.01.645.50 ADAPTOR FOR AIR END HOSE 1
24 271.01.675.50 GASKET FOR AIR END DELIVERY 1
25 271.00.368.50 PLUG 1"BSP 1
26 271.01.633.50 HOSE ASSEMBLY 1"X 750MM L(90 X 90FLANGE OPP.) 1
27 271.01.420.50 ANTI VIBRATION MOUNT 4
030.46.071.00 SAFETY VALVE 1/2" BSP (SET PR. 8.1 BAR) 1
28 030.46.072.00 SAFETY VALVE 1/2" BSP (SET PR. 11 BAR ) 1
030.46.073.00 SAFETY VALVE 1/2" BSP (SET SET PR. 14.1 BAR ) 1
29 271.01.883.50 TOP COVER 1
30 271.01.836.50 COMBINATION BLOCK 1
31 99.02.628.50 BOLT HEX. SOCKET HD. M8 x 1.25 x 40 L 4
32 271.01.882.50 FUNNEL 1
33 271.01.825.50 PIPE 1/2" 1
34 999.01.606.50 SCREW HEX. STD. M6 x 1 x 12 L 3

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`Kirloskar Pneumatic Co. Ltd., Pune

8.4 COOLING SYSTEM

SR.NO. ITEM NO. DESCRIPTION QTY. REMARK

1 211.09.321.50 ELECTRIC MOTOR, 0.55kW 1
2 271.01.643.50 FAN COWL WITH MOTOR MOUNTING BRACKET 1
3 999.01.621.50 SCREW HEX. STD. M8X1.25X20L 16
4 999.06.623.50 NUT HEX. M8X 1.25 10
5 999.11.262.50 SPRING WASHER ID 8.2 X 2 THK 16
6 271.01.660.50 FAN 1
7 999.50.201.15 SCREW HEX. STD. M6X1X15L 4
8 271.01.617.50 COMBI COOLER 1
9 271.01.642.50 FAN MOUNTING ADAPTOR 1
10 999.11.268.50 SPRING WASHER ID 10.2 X 2.2 THK 4
11 999.01.638.50 SCREW HEX. STD. M10X1.5X25L 4

8.5 LUBRICATION SYSTEM

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`Kirloskar Pneumatic Co. Ltd., Pune

SR.NO. ITEM NO. DESCRIPTION QTY. REMARK

1 271.00.548.50 SPECIAL UNION ASSEMBLY 3/4" BSP X 3/4" BSP 2
2 271.01.677.50 SPECIAL UNION ASSEMBLY 3/4" BSP X 1/2" BSP 1
3 271.01.630.50 HOSE ASSEMBLY 3/4"X 1000MM L (90 X ST) 1
4 271.01.631.50 HOSE ASSEMBLY 3/4"X 1100MM L (90 X ST) 1
5 271.01.632.50 HOSE ASSEMBLY 1/2"X 22 L (90 X ST) 1
6 271.00.583.50 UNION 1/2"BSP X 1/2" BSP 2
7 273.03.916.00 SPECIAL UNION ASSEMBLY 1/4" BSP X 3/8" BSP 2
8 275.00.779.50 TEE 3/8” 1
9 271.01.661.50 HOSE ASSEMBLY 1/4"X 550MM L(90 X 90) 1
10 271.01.664.50 SPECIAL UNION ASSEMBLY 1/4" BSP X 1/8" BSP 2
11 271.01.819.50 OIL RECOVERY (RP 1/8) 1
12 271.01.418.50 OIL FILTER ELEMENT 1

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`Kirloskar Pneumatic Co. Ltd., Pune

8.6 CAPACITY CONTROL SYSTEM

SR.NO. ITEM NO. DESCRIPTION QTY. REMARK

1 998.16.123.50 ASSEMBLY OF STUD TAPER MALE R1/4 LIGHT 1

2 998.16.541.50 ASSEMBLY OF T CONNECTING SOCKET OD 6 1
3 999.37.103.00.01 TUBE STEEL OD 6 X 1THK SEAMLESS 2.2MTR
4 998.16.121.50 ASSEMBLY OF STUD TAPER MALE R1/8 LIGHT 2
5 996.00.110.02 PRESSURE GAUGE 0-16Kg/CM2, 1
6 998.16.181.50 ASSEMBLY OF STUD UNION FEMALE GR1/8"BSP 1
7 211.09.003.50 TEMP. SWITCH 1/4"BSP 1
8 275.00.787.50 ADAPTOR M12 X G1/4 1
9 999.16.001.50 FERRULE, ID6, STEEL 1
10 999.16.061.50 UNION NUT ID 6 LIGHT STEEL 1
11 211.09.004.50 PRESSURE SWITCH RANGE 2-14 BAR 1

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`Kirloskar Pneumatic Co. Ltd., Pune

8.7 ELECTRICAL SYSTEM FOR KES-11

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`Kirloskar Pneumatic Co. Ltd., Pune

8.7 ELECTRICAL SYSTEM FOR KES-11

SR.NO. ITEM NO. DESCRIPTION QTY. REMARK

271.14.09 ELECTRICAL SYSTEM

1 CONTROL PANEL PLATE 1
2 CABLE GUARD 1
3 211.08.242.50 FAN MOTOR CONTACTOR 1
4 211.09.338.50 MAIN CONTACTOR 1
5 211.09.338.50 DELTA CONTACTOR 1
6 211.09.337.50 STAR CONTACTOR 1
7 211.09.110.50 STAR/DELTA TIMER 1
8 211.09.105.50 REVERSE PHASE PROTECTOR 1
9 999.01.623.50 SCREW HEX. STD. M8X1.25X25L 4
10 999.11.262.50 SPRING WASHER ID 8.2 X 2 THK 4
11 999.18.720.50 PLAIN WASHER ID 8.2 X 2 THK 4
12 211.09.340.50 MCB-2(CONTROL CIRCUIT) 1
13 211.08.470.50 MCB-1(FAN MOTOR) 1
14 INCOMING POWER TERMINALS 1
15 MAIN MOTOR POWER TERMINALS 1
16 FAN MOTOR POWER TERMINALS 1
17 CONTROL POWER TREMINALS 1
18 AUXILLARY CONTACT 7
19 211.09.113.50 MAIN MOTOR OVER LOAD RELAY 1
20 211.09.339.50 FAN MOTOR OVAR LOAD RELAY 1
21 211.09.343.50 HOUR COUNTER 1
22 211.09.344.50 INDICATION LAMP RED COLOR 1
23 211.09.341.50 START PUSH BUTTON 1
24 211.09.103.50 MUSHROOM TYPE STOP PUSH BUTTON 1
25 211.09.342.50 4 PIN INDUSTRIAL SOCKET WITH PLUG 1

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`Kirloskar Pneumatic Co. Ltd., Pune

8.8 STRUCTURE ASSEMEBLY (BASE FRAME AND CANOPY)

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`Kirloskar Pneumatic Co. Ltd., Pune

8.8 STRUCTURE ASSEMEBLY (BASE FRAME AND CANOPY)

SR.NO. ITEM NO. DESCRIPTION QTY. REMARK

271.07.12 STRUCTURE ASSEMBLY

1 271.01.638.50 CANOPY ASSEMBLY TOP COVER 1
2 271.01.504.50 CONTROL PANEL BOX 1
3 --- KNOB HANDLE 1
4 271.01.637.50 BELT TENSIONING BRACKET 1
5 271.01.620.50 AIR END MOUNTING BRACKET 1
6 999.11.274.50 SPRING WASHER ID 12.2 X 2.5 THK 4
7 999.01.664.50 SCREW HEX. STD. M12X1.75X25L 4
8 271.01.639.50 COOLER SUPPORT ASSEMBLY 1
9 271.01.638.50 CANOPY ASSEMBLY DOOR 2
10 271.01.638.50 CANOPY ASSEMBLY SIDE COVER 2
11 271.01.638.50 CANOPY ASSEMBLY FIXED PANEL RIGHT SIDE 1
12 271.01.628.50 BASE FRAME 1
13 271.01.652.50 BELT GUARD 1
14 271.01.638.50 CANOPY ASSEMBLY FIXED PANEL LEFT SIDE 1
15 999.01.619.50 SCREW HEX. STD. M8X1.25X16L 41
16 999.11.262.50 SPRING WASHER ID 8.2 X 2 THK 41
17 999.18.720.50 PLAIN WASHER ID 8.2 X 2 THK 41
18 999.02.620.50 SCREW SOCKET HD. STD. M8X1.25X20L 4
19 --- PRESSURE SWITCH MOUNTING BRACKET 1
20 --- AIR FILTER CLAMP 1

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`Kirloskar Pneumatic Co. Ltd., Pune

8.9. Maintenance instructions for Air intake valve

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`Kirloskar Pneumatic Co. Ltd., Pune

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`Kirloskar Pneumatic Co. Ltd., Pune

8.10. Maintenance instructions for V Belt

• V-belts run longer and perform better if given proper care and attention during
installation, and in particular, during the subsequent 48-hour running-in period.
• The run-in period is a critical time for V-belts, especially if they are to last for a
few years. During this time span, the initial stretch is removed from the belt.
Also, the soft rubber surface of the belt’s outer envelope abrades away, and the
belt settles deeper in the groove of the sheave. This causes the belt to run
slack.
• At this point, take up the slack on the new belts to avoid considerable slippage,
frictional burning and other irreparable damage.
• It’s important to check the belts often during the first days of operation and
adjust to the correct tension until no signs of stretching are present. This
eliminates early damage and promotes longer belt life.
• Follow the standard procedure for correctly installing a V-belt and the
sheaves in which they operate. This, in turn, improves mechanical efficiency of
the motor and driven mechanical equipment by reducing wear on rotating
mechanical components.

Standard procedure for correctly installing a V-belt

Step 1
• Clean the sheaves of all foreign matter with a stiff brush that includes bristles
softer than the sheave surface material. Heavy-duty wire brushes can scratch
the surface of the groove walls.
• These scratches can, in turn, tear the V-belt’s outer skin and systematically
destroy the belt.

Step 2
• Using “go/no go” slip gauges obtained from a belt manufacturer, determine the
condition of the V-groove in the sheave.
• If the sheaves don’t meet these criteria or are damaged in other ways (chipped
or cracked sidewalls), discard these defective parts and install new ones.

Step 3
• Verify that the new belts are the correct size. Check with the “go/no go” gauge
to ensure the cross section of the V-belt is compatible with the V section in the
groove. The belt must ride in the groove with its top flat surface level with the
outer periphery of the sheave.

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`Kirloskar Pneumatic Co. Ltd., Pune

Step 4
• Before installing new belts, the following checks must be made:
• Check the total indicated run-out (TIR) of both the driver and driven shafts.
These should be within plus or minus 0.003 inches. If the run-out reading
exceeds this value, the shaft(s) must be straightened. Also carry out this check
on the outer rim of each sheave, as it is common to find the shaft hole in the
hub-drilled off-center, causing damaging eccentricity. Eccentricity causes the
belts to slacken off at the 3 o’clock position and snap into tension at the 9
o’clock position during shaft rotation. This continual snapping action creates
rapid belt and bearing deterioration.
• Check all of the hold-down bolts around the bedplate to determine if any soft
foot conditions exist. This reading should not be greater than 0.002 inches.
• Check sheave alignment by placing a straightedge or a tightly drawn cord
across the sheave faces so it touches all four points of contact. This method of
alignment is only effective when the sheaves are a matched pair.
• If the sheaves are mismatched, there may be differences in the sidewalls’
thickness, which aggravates the misalignment. When this is the case, align the
Vs with each other. Misalignment causes uneven wear on one side of the belt,
which causes it to roll over in the sheave, or it can throw the entire load on one
side of the belt, stretching or breaking the cords.
• Therefore, parallel the position of the sheave shafts and correctly align the
grooves in the sheave.

Step 5
• Install the new belts on the sheaves so the slack sides of all belts are on the
same side (top or bottom) of the drive.
• Never install the belts by prying them onto the sheaves with a screwdriver or
any other forcible method. This damages the internal cords of the belts and
could break off the rim of the sheave’s sidewalls. This would cause unbalance
of the rotating components. The motor must be dimensioned enough to allow
the belts to be removed or installed without forcing them.

Step 6

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`Kirloskar Pneumatic Co. Ltd., Pune

• Adjust the tensioning screws to pull the motor away from the driven unit until
the belts are correctly in tension. The following formula is used for determining
the correct tension of the belts:
Tension load = The distance in inches between the axes of the driver and
driven shafts x 1/64 inches.
• For example, if the distance between the centers of the driver shaft and the
driven shaft is 64 inches, the belt deflection load is:
64 inches x 1/64 inch = 1 inch of deflection

Step 7
• When the belts are correctly in tension, paint a thin, narrow line across the
belts’ top surfaces at 90 degrees to the length. After the unit is started, a
strobe light flashing on the belts at the operating frequency of the belts will
show the painted line appearing as if it was stopped.
• Should there be any slippage, the slipping belts will move away from the line at
various speeds according to their degree of looseness. This can be expected
during the initial run-in period, but the belts must again be retensioned to allow
the correct deflection. Repeat until all slack is taken out of the belts.

Step 8
• Replace the safety guard before removing all lockout and tag-outs. The guard
should be constructed from open mesh steel. This permits free passage of air
across the belt area, thus cooling the belts and allowing heat to escape.
Start the unit and allow the belts to seat themselves in the grooves of the
sheaves

Step 9
• Stop the unit after a few hours to check the tension of all belts (refer to Step 7).
Before checking the belt tension, ensure all lockout procedures are in place.

Step 10
• Restart the unit. This is probably the most ignored task in belt installation, but it
is very important. As such, it is worth repeating the following: After the machine
has run for 48 hours, check the tension on the new belts and retighten to the
correct mid-span deflection set point. Repeat this process until there is no
stretch.
• Belts that squeal during acceleration or when operating at full load usually have
slippage. Never add a lubricant to the belts. Squealing indicates belts need to
tightening. This extends the life of the belts and bearings immensely.
• Avoid leaving old V-belts and other maintenance debris lying around after
completing maintenance activities. Collect waste products in an approved
container and dispose of them according to established procedures.

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`Kirloskar Pneumatic Co. Ltd., Pune

9. TROUBLE SHOOTING
Problem Probable Reason or Parts Remedy
Involved

Insufficient air flow Air intake filter clogged. Replace filter

Safety valve Leakage. Replace Safety valve

Solenoid Valve Leakage Check & Repair

High air temperature a) Insufficient or no oil flow due to

- Low oil level in tank Top-up oil

- Oil filter clogged Replace oil filter element

b) Inadequate cooling of oil due to

- Fan motor not ON Check motor & circuit

- Thermostatic valve failure Check and replace

- Fan failure/damaged Check and replace/correct

- Air passage in the cooler Clean the cooler with vacuum

blocked cleaner after removing the fan
cowl.

Check all joints, gearbox for

c) Oil loss due to leakages
leakages

Excessive oil in air Scavenge line blocked Remove the scavenge

line pipe/hose, fittings and clean the
passage.

Check and correct.

Excessive oil in the tank.
Check and replace
Air-oil separator element damaged

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`Kirloskar Pneumatic Co. Ltd., Pune

Problem Probable Reason or Parts Involved Remedy

Oil throw through air Leakage across Air Intake Valve. Check for damages on tappet
filter during stopping plate and the sealing ring.
Replace the defective part.
Intake valve is not closing when
compressor stops due to the absence
of Air flow to intake valve piston is not Check the parts and repair /
given due to solenoid valve failure or replace.
line blockage

Compressor loading -Intake valve is stuck Check and repair/replace the

not happening parts.

- Solenoid Valve not functioning Check the spool and repair

- Solenoid valve is not getting Check electrical connections

energized Check the Intake valve, clean
- Intake valve is not opening or stuck and replace damaged parts
at closed position due to seal/piston
jam in the piston or dust.
Safety valve opening Pressure switch setting is disturbed or Check the pressure switch &
during operation pressure switch damaged setting, check and
repair/replace the

Safety valve is defective Check the valve & replace

Motor not starting Contactor is defective Check and replace.

Motor stalls after - Supply voltage is low Check and correct the power
starting - Inadequate cable for power Check the cable size
line Check the power supply to
- Intake valve not closed at Solenoid Valve, circuit and
starting due to solenoid valve Intake Valve. Replace
failure or no air supply or defective parts.
electrical signal failure to
solenoid valve or leakage in
the air line from solenoid valve
to Intake Valve.

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`Kirloskar Pneumatic Co. Ltd., Pune

Problem Probable Reason or Parts Involved Remedy

Motor tripping during - Air pressure in the air-oil separator Release the air from the tank
Starting. tank due to failure of air intake valve to by opening the safety valve
exhaust the air when compressor was manually. Then check the
switched off. functioning of solenoid valve
- Motor damage/failure & its circuit and air intake
valve with air connection.
- Airend damage
Check motor, airend & belt
- Loose connection in motor power tension
line
Motor tripping after Intake valve opens before the Star- Check the timer settings for
running few seconds delta changeover is completed. Star- Delta changeover
from start
Motor tripping after High starting current due to loose Check the connections and
few start /stops and connections or Intake Valve in open Intake Valve piston.
contactors jammed position during starting.

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`Kirloskar Pneumatic Co. Ltd., Pune

DETAILS OF KPCL BRANCH OFFICES

PLACE ADDRESS PHONE NO FAX NO E MAIL ADDRESS Person concerned

PUNE HADAPSAR 020 26870341, 020 26870634 [email protected] Mr. V.V. Raghavan
INDUSTRIAL ESTATE, 26870133, 26874590 26870297/
PUNE 411 013 26874217

MUMBAI G-401-408 KAILASH 022 25181081, 022 25181313 [email protected] Mr. P.V. Rajeev
INDUSTRIAL 25181082,
COMPLEX, PARK SITE, 25181083 [email protected]
BEHIND GODREJ
RESIDENTIALCOLONY,
VIKHROLI(W), MUMBAI
400 079

DELHI 208 MEGHDOOT 011 30981341,42 011 26429685 [email protected] Mr. Rajesh kumar
BUILDING 94 NEHRU 26417549 [email protected]
PLACE, NEW DELHI
110 019

BANGALORE NO 102, 1ST FLOOR, 080 22270029, 080 22270045 [email protected] Mr G Ramesh
ANDREE CAPITOL, 22270079
8/1 KH ROAD, [email protected]
BANGALORE 560 027

CHENNAI 1ST FLOOR, ELCANSO 044 28193066, 044 28194937 [email protected] Mr G Ramesh
COMPLEX NO.10, 28190436, 28192092
COSA MAJOR ROAD, [email protected]
EGMORE, CHENNAI
600 008

HYDERABAD 3-5-907,403-404, 040 23260743, 040 23260171 [email protected] Mr S Anand Kishore

MAHAVIR LOK, 23260746 [email protected]
HIMAYATNAGAR,
HYDERABAD 500 029

KOLKATA 15 GANESH CHANDRA 033 22119080, 033 [email protected] Mr Biswajit Datta

AVENUE, 9TH FLOOR, 22119081, 22111905 22365586, [email protected]
KOLKATTA 700 013 22116948
[email protected]

VADODARA CHI CHI TOWER "A" 0265 2284604, 0265 2280095 [email protected] P.V. Rajeev
KOLLOL CHILDREN 2284605, 2284606
HOSPITAL LANE,TANA [email protected]
APPT, ELLORA PARK,
SUBHANPURA,
VADODARA 390 007

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`Kirloskar Pneumatic Co. Ltd., Pune

INSPECTION AND SERVICING RECORD SHEET

Sl. Date of Brief description of Inspection/Servicing/Parts Name and

Inspection/Servicing changed Signature
No
/Overhaul

53
`Kirloskar Pneumatic Co. Ltd., Pune

Sl. Date of Brief description of Inspection/Servicing/Parts Name and

Inspection/Servicing changed Signature
No
/Overhaul

54
`Kirloskar Pneumatic Co. Ltd., Pune

Notes

55
`Kirloskar Pneumatic Co. Ltd., Pune

Notes

56
 `Kirloskar Pneumatic Co. Ltd., Pune

Contact your nearest dealer for any assistance or dial Toll free number 1800 301 00009

Document Number: S271.068.D98 Publication Number : N27.21.000.033.00

Revision Status: R03

57