SERVICE MANUAL

STATIONARY STORAGE WATER HEATERS

CLASS-I

KGS15W6P-GDE,KGS15W6M-GDE,
KGS25W6P-GDE, KGS25W6M-GDE

CLASS-II

KGS15W5P , KGS15W5M
KGS25W5P, KGS25W5M

Please read this manual carefully to diagnose trouble correctly before offering service.
Record model name & serial number of the machine. Please quote this information when you require service.
 INDEX

SR. NO DESCRIPTION PAGE NO

01 PRODUCT SPECIFICATIONS 02-03

02 MAIN PARTS, THEIR FUNCTIONS & SPECIFICATIONS 04

03 TROUBLE SHOOTING 05

04 EXPLODED VIEW 06-07

05 SERVICE SPARE PARTS LIST 08-10

SERVICE MANUAL 01
 PRODUCT SPECIFICATIONS

* At Kenstar improvement is continuous process, specification may

change without any notice.
SERVICE MANUAL 02
 PRODUCT SPECIFICATIONS

* At Kenstar improvement is continuous process, specification may

change without any notice.
SERVICE MANUAL 03
 MAIN PARTS, THEIR FUNCTIONS & SPECIFICATIONS

CLASS-I &II
Outer body

OUTLET PIPE
INNER TANK
INLET PIPE
SG INSULATION/PUF
THERMOSTAT POCKET THERMAL CUT OUT POCKET
HEATING ELEMENT

FUSIBLE PLUG

INLET PIPE
VACCUUM RELEASE VALVE PRESSURE RELEASE VALVE(for Class-II only)
(for Class-II only)
NEON LAMP MULTI FUNCTION VALVE( for Class-I only)

SERVICE MANUAL 04
 TROUBLE SHOOTING

S. NO. DEFECTS POSSIBLE ACTION ACTION TAKEN

GREEN LAMP MAY BE DUE TO THE DEFFECT OF REPLACE THE DEFECTIVE

1 NOT GLOWING LAMP & THERMOSTAT CHECK BOTH. PARTS

ONLY RED LAMP THERMOSTAT NOT WORKING REPLACE THE THERMOSTAT

2 GLOWS

SPARKING INSIDE THIS HAPPEN DUE TO THE LOOSE ELECTRIC TIGHTEN THE ELECTRIC
3 THE WATER HEATER CONNECTION AT HEATING ELEMENT CONNECTIONS THEN START THE
WATER HEATER.

FIRST CHECK THE APPARATUS PLATE AT IF THERE IS LEAKAGE

4 HEATING ELEMENT, GASKET & MAIN GASKET
LEAKAGE THEN CHECK THE WATER TANK. CHANGE RESPECTIVE ONE

IF GREEN LIGHT GLOWS & NO HOT REPLACE THE HEATING

5 NO HOT WATER WATER IT MEANS ELEMENT PROBLEM. ELEMENT

SERVICE MANUAL 05
EXPLODED VIEW

SHOWCASE
PUF CLAMPING RING
FRONT COVER

ELEMENT
ELEMENT GASKET
ASSLY PLATE

POWER PLUG MAIN GASKET

SS TANK
METAL BODY
THERMOSTAT

THERMAL CUT-OUT
FRONT BEADING
INLET PIPE

OUTLET PIPE

UPPER PUF
BACK COVER
LOWER PUF PUF CLAMPING
RING

CLAMPING

CLAMPING PAD
CLAMPING REAR BEADING
NUT BOLT

SERVICE MANUAL : METAL BODY 06

 EXPLODED VIEW UPPER SHOWCASE

FRONT COVER

THERMOSTAT

THERMAL CUT-OUT INLET PIPE

HEATING ELEMENT UPPER PUF

L-GAURD

GASKET

LOWER SHOWCASE
ASSLY PLATE

POWER PLUG

SS TANK
REAR COVER ASSLY PLATE GASKET

CRCA CLAMP
CRCA CLAMP

TANK
CLAMP PAD CLAMPING NUT BOLT CLAMPING
RING

LOWER PUF

SERVICE MANUAL : PLASTICS BODY 07

Spare Part List
KGT03W1P WATER HEATER,3L INSTANT,KGT03W1P 1100046084 NEON LAMP,RED,KGT01W1P
1100046085 NEON LAMP,GREEN,KGT01W 1P
1100046036 MAIN BODY-3LTR,ABS,KGT03W1P 1100046086 ELEM EN T,HEATING,3 KW,KGT01W1P
1100046037 CLAMP,LEG,KGT03W1P 1100046087 SLEEVE,FIBRE GLASS,KGT01W1P
1100046038 TANK,SS 304,1 LTR,KGT03W1P 1100046088 THIMBLES,SMALL,KGT01W 1P
1100046089 THIMBLES,BIG,6MM,KGT01W1P
1100046039 INSTRUCTION MANUAL,KGT03W1P
1100046090 BOLT,6 x 25,M S,KGT01W1P
1300007383 BOX,PACKAGING,5PLY,INNER,PRINTD,KGT03W1P 1100046091 WASH ER ,M 6,KGT01W1P
1300007384 BUFFER THERMOCOL,KGT03W1P 1100046092 WASH ER ,SPRING,M 6,KGT 01W1P
1300007385 BOX,PACKAGING,5 PLY,OUTER,KGT03W1P 1100046093 NUT,6 M M,MS,KGT01W 1P
1100046094 SC REW ,6 X 16,SS,KGT01W1P
K GT 03W1P WATER HEATER,1L INSTAN T,K GT01W1P 1100046095 BOLT,H EX,M6 X8,SS,KGT01W 1P
1100046096 STU D,SS,M6 x 18,KGT01W1P
1100046066 MAIN BODY,ABS,KGT01W1P 1100046097 WASH ER ,SS,M 6,KGT01W1P
1100046067 CLAMP,LEG,KGT01W 1P 1100046098 NUT,HEX,M 6,SS,KGT01W1P
1100046068 TAN K,SS 304,1 LT R,KGT01W 1P 1100046099 WASH ER ,SPRING,,SS,KGT01W1P
1100046069 PLAT E,APPARAT US,BRASS,2.1MM,KGT 01W1P 1100046100 GASKET,127 M M,EPDM ,R UBBER,KGT01W 1P
1100046070 PIPE,THERM OSTAT 7",COPPER ,KGT01W 1P 1100046101 PIPE,PVC ,1/2",THREAD ,KGT01W 1P
1100046071 PIPE,CU T OUT 7",COPPER,KGT01W1P 1100046102 CAP,PVC,KGT01W1P
1100046072 PIPE,OUTER 4 ",IN+OUT,BRASS,KGT01W 1P 1100046103 CLIP,CORD,KGT01W1P
1100046073 PIPE,U & I,BRASS,23 ",KGT01W 1P 1100046104 GR OM MET,CORD,KGT01W1P
1100046105 ELEM EN T,EPDM,RU BBER,KGT01W 1P
1100046074 NOZZLE,BR ASS,KGT01W 1P
1100046106 GLASS,WOOL,KGT 01W1P
1100046075 PIPE,OUTSIDE,FU SABLE,PVC,KGT01W 1P
1100046107 STICKER,LOGO,KGT01W1P
1100046076 WASH ER ,FIBER ,R UBBER,KGT01W 1P
1100046108 STICKER,TRANSFER ANT ,JACUZ I,KGT 01W1P
1100046077 REDUCER,BRASS,KGT01W 1P 1100046109 STICKER,ISI,AL FOIL,KGT01W 1P
1100046078 VALVE,SAFETY,BRASS,KGT01W 1P 1100046110 STICKER,SPECIFIC ATION,AL FOIL,KGT01W1P
1100046079 ROD,WELD IN G,COPPER,KGT 01W1P 1100046111 STICKER,BU BBLES,KGT01W 1P
1100046080 THERMOSTAT, 11" / 7",KGT01W 1P 1100046112 IN STR UCTION MANUAL,KGT01W1P
1100046081 THERMAL CU T OU T 7",KGT01W1P 1300007398 CARTON,IN NER,PRINT D,5PLY,KGT01W 1P
1100046082 CABLE,PVC ,EXTER NAL,48/20,KGT01W 1P 1300007399 BU FFER TH ER MOCOL,KGT 01W1P
1100046083 WIRE,PVC,INTERNAL,48/20,KGT01W 1P 1300007400 CARTON,OU TER ,5 PLY,KGT01W1P

SERVICE MANUAL 08
Spare Part List
KGS15W4P WATER HEATER,15L,4*,JACUZZI,KGS15W4P KGS15W4M WATER HEATERE,15L,4*,HOT SPRING,KGS15W4

1100046139 MAIN BODY-15LTR,C.R.C.A.,KGS15W4M

1100046040 MAIN BODY-15LTR,ABS,KGS15W4P
1100046140 COVER END,CRC,12.5in,KGS15W4M
1100046121 CLAMP,LEG,KGS15W4P 1100046141 BRACKET,LEG CLAMP,CRC,KGS15W4M
1100046122 TANK,SS 304,15 LTR,KGS15W4P 1100046142 PUFF,INSULATION,KGS15W4M
1100046123 PLATE,APPARATUS,BRASS,2.3MM,KGS15W4P 1100046143 INSTRUCTION MANUAL,KGS15W4M
1100046124 PIPE,THERMOSTAT 11",COPPER,KGS15W4P
1100046125 PIPE,CUT OUT 11",COPPER,KGS15W4P KGS25W4P WATER HEATER,25L,4*,JACUZZI,KGS25W4P
1100046126 PIPE,U & I,BRASS,4 SOOT ",KGS15W4P
1100046144 MAIN BODY-25 LTR,ABS,KGS25W4P
1100046127 NOZZLE,BRASS, 2 SOOT, KGS15W4P 1100046145 CLAMP,LEG,KGS25W4P
1100046128 VALVE,VACUUM RELEASE, KGS15W4P 1100046146 TANK,SS 304,25 LTR,KGS25W4P
1100046129 THERMOSTAT,11", KGS15W4P 1100046147 PIPE,U & I,BRASS,4 SOOT ",KGS25W4P
1100046130 THERMAL CUT OUT ,11 INCH, KGS15W4P 1100046148 NOZZLE,BRASS, 2 SOOT, KGS25W4P
1100046131 MAINS CORD,PVC,3CORE,32/20,KGS15W4P 1100046149 PUFF,INSULATION,KGS25W4P
1100046132 WIRE,PVC, 1 CORE, 32/20,KGS15W4P 1100046150 INSTRUCTION MANUAL,KGS25W4P
1300007410 BOX,PACKAGING,5PLY,PRINTD,KGS25W4P
1100046133 ELEMENT,HEATING,2 KW,KGS15W4P
1300007411 BUFFER THERMOCOL,KGS25W4P
1100046134 SCREW 6x13 SS, KGS15W4P
1100046135 SCREW 6x95 SS, KGS15W4P KGS25W4M WATER HEATERE,25L,4*,HOT SPRING,KGS25W4M
1100046136 SCREW 4x12 SS, KGS15W4P
1100046137 PUFF,INSULATION, KGS15W4P 1100046151 MAIN BODY-25LTR,C.R.C.A.,KGS25W4M
1100046152 COVER END,WITH COV SH,12.5",KGS25W4M
1100046138 INSTRUCTION MANUAL,KGS15W4P
1100046153 BRACKET,LEG CLAMP,CRC,KGS25W4M
1300007386 BOX,PACKAGING,5PLY,PRINTED,KGS15W4P 1100046154 PUFF,INSULATION, KGS25W4M
1300007387 BUFFER THERMOCOL,KGS15W4P 1100046155 INSTRUCTION MANUAL,KGS25W4M
1300007388 BOX,PACKAGING,5PLY,PRINTD,KGS15W4M 1300007412 BOX,PACKAGING,5PLY,PRINTD,KGS25W4M
1300007389 BUFFER THERMOCOL,KGS15W4M 1300007413 BUFFER THERMOCOL,KGS25W4M

SERVICE MANUAL 09
Spare Part List : Only for Class-1 model.

M at eria l C od e D ESC R Pl an t
1 1 00 06 58 6 2 TA N K,SS,K GS 15 W 6 M - G DE /K GS 15 W 6 P -G D E S00 1
1 1 00 06 58 6 3 TA N K,SS,K GS 25 W 6 M - G DE /K GS 25 W 6 P -G D E S00 1
1 1 00 06 58 6 4 AP AR A TU S P L ATE , K GS 25 W 6 P -G D E,15 -2 5L -P /M S00 1
1 1 00 06 58 6 5 M FV , KG S2 5W 6 P- G DE , 1 5- 25 L- P/ M S00 1
1 1 00 06 58 6 6 K N O B SE T,EX TER N A ,KG S2 5W 6 P- G DE ,1 5 -25 L -P /M S00 1
1 1 00 06 58 6 7 ISI, KG S2 5W 6 P- G DE , AL L M O DE L S00 1
1 1 00 06 58 6 8 STIC K ER B E E,KG S1 5W 6 P- G DE S00 1
1 1 00 06 58 6 9 STIC K ER B E E,KG S1 5W 6 M -G D E S00 1
1 1 00 06 58 7 0 STIC K ER B E E,KG S2 5W 6 P- G DE S00 1
1 1 00 06 59 1 1 STIC K ER B E E,KG S2 5W 6 M -G D E S00 1
1 1 00 06 59 1 2 P LA TE R ATIN G , K G S25 W 6P -G D E S00 1
1 1 00 06 59 1 3 P LA TE R ATIN G , K G S15 W 6P -G D E S00 1
1 1 00 06 59 1 4 P LA TE R ATIN G , K G S25 W 6M -G D E S00 1
1 1 00 06 59 1 5 P LA TE R ATIN G ,KG S1 5W 6 M -G D E S00 1
1 1 00 06 59 1 6 M A N U AL , K GS1 5 W 6 P -G D E S00 1

11 0 00 65 91 7 STIC K ER C L ASS- 1, K G S15 W 6P -G D E S00 1

SERVICE MANUAL 10