L&W Compressors LW 200 B MC Operating Instructions Manual Download Page 32

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LW 200 B MC / 250 B MC
Version: 01.05.2020

R E M E D Y I N G F A U L T S

Compressor overheated

Cause of fault

Remedy

Inlet filter cartridge contaminated

Replace

Ambient temperature too high

Improve room ventilation /
Reduce operation times

Cooling air Inlet- / Outlet insufficient

Observe minimum distances (see Installation
Instructions)

Air intake hose too long

Reduce length of the air intake hose

Air intake hose diameter too small

Use a larger diameter

Wrong compressor rotation direction

Ensure correct phase rotation,
observe rotation direction arrow!

Inlet- / Outlet valves contaminated / defective

Clean, replace if necessary

Safety valve leaks

Cause of fault

Remedy

Inlet- / Outlet valves of the following pressure

stage defective

Clean, replace if necessary

Sinter filter of the following water separator

blocked

Replace

Safety valve leaky

Replace,

turn out vent screw if necessary

Oil taste in the air

Cause of fault

Remedy

Mole carbon filter cartridge saturated

Replace

Compressor oil unsuitable

Use prescribed oil quality

Filter cartridge unsuitable

Use prescribed filter type

Cylinder(s), piston(s) or piston ring(s) defective

Replace

Summary of Contents for LW 200 B MC

Page 1: ...sts Options if equipped Attachment A B C D E Manufacturer in terms of 97 23 EC The full name and address of the manufacturer is Lenhardt Wagner GmbH An der Tuchbleiche 39 68623 Hüttenfeld Germany Phone 49 0 62 56 85 88 0 0 Fax 49 0 62 56 85 88 0 14 E Mail service lw compressors com Internet www lw compressors com ...

Page 2: ... original invoice Should verifiably defective parts have been delivered we will decide to either replace the parts or repair them The resulting transport and assembly costs will be invoiced No reduction of the purchase price or changes to the contract can be made The parts for which a claim is being made should be kept safe by the purchaser and when requested sent to us at their cost Replaced part...

Page 3: ...A Operating Instructions Breathing Air Compressor LW 200 B MC LW 250 B MC Version 01 05 2020 ...

Page 4: ... Safety Precautions Intended Use Operators 11 Safety Instructions on the Unit 12 General Safety Precautions 13 Unit customised Safety Notices 14 Maintenance Instructions 15 Transportation Instructions Safety Regulations 16 Installation Outdoor Installation 18 Dimensions 19 Minimum Distances 20 Operation Important Operation Instructions 22 First Commissioning 23 24 Daily Commissioning 25 Filling Pr...

Page 5: ...ng Filter Cartridge 44 Filter Cartridge Change 45 Maintenance Filter Housing 46 Inlet Filter 47 Maintenance Inlet Filter Housing 48 Valve Heads and Valves 49 Replace Inlet Outlet Valve 1st Stage 50 51 Replace Inlet Outlet Valves 2nd 3rd Stage 52 53 Safety Valves 54 Pressure Maintaining Non Return Valve 55 Adjust Pressure Maintaining Valve 56 O rings Filling Valve and Filling Hose 57 Test of Pressu...

Page 6: ...rom these instructions is excluded from warranty and liability for this product Carry out other commissioning steps only if you have fully understood the following contents Before commissioning and using the unit carry out all the essential preliminary work and measures concerning legal regulations and safety These are described on the following pages of this operati on manual G E N E R A L I N F ...

Page 7: ...s are highly predestined for mobile breathing air applications Versions Filling pressure versions PN 225 bar PN 330 bar PN 225 330 bar Specifications Options Automatic stop at final pressure Additional filling hose c w filling valve Oil pump Oil pressure gauge Intermediate pressure gauges Switch over device 200 300 bar Hour counter Additional high pressure outlet Wheelset Honda drive engine 4 stro...

Page 8: ...der Bore 3rd Stage mm Ø 14 Ø 14 Medium Compressed Air Breathing Air Intake Pressure atmospheric Oil Capacity l 0 8 0 8 Intake Temperature C 0 45 0 45 Ambient Temperature C 5 45 5 45 Engine Drive Power kW HP 6 7 9 0 6 7 9 0 RPM Motor min 1 3600 3600 Start Starter Cord Handle Noise level dB A 89 90 Dimensions L x W x H mm 1060 x 500 x 590 1060 x 500 x 590 Dimensions with telescope intake pipe B x T ...

Page 9: ...20 Unit Assembly D E S C R I P T I O N No Designation 1 Drive Engine 2 Final Filter Housing with Safety Valve 3 Condensate Drain Hoses 4 Filling Hose with Filling Valve and Filling Pressure Gauge 5 Compressor Block 6 Telescope Intake Pipe 3 1 2 6 5 4 ...

Page 10: ...Page A 8 A LW 200 B MC 250 B MC Version 01 05 2020 D E S C R I P T I O N Drive Engine No Designation 1 Throttle Control 2 Choke 3 Fuel Shut off 4 Starter Cord handle 5 Stop Switch 5 1 2 3 4 ...

Page 11: ...e 9 Condensate Release Valve 10 Condensate Release Hose 11 3rd Pressure Stage 12 Cooling Pipe Final Stage 13 Oil Water Separator 14 Final Pressure Safety Valve 15 Condensate Release Valve 16 Condensate Release Hose 17 Pressure Maintaining Valve 18 Non Return Valve 19 Filling Hose 20 Filling Connector 21 Filling Valve 22 Pressure Gauge Filling Pressure 23 Vent Valve 24 Unit Filling Valve Cross Desi...

Page 12: ...A S A F E T Y P R E C A U T I O N S ...

Page 13: ...the instruction manual is complied with and inspection and maintenance requirements are en forced No change and modification to the unit can be made without the written agreement of the manu facturer The manufacturer is not liable for damage to persons or property resulting from unauthori sed modifications Operators Target groups in these instructions Operators Operators are persons who are author...

Page 14: ...nstructions on the Unit Importance of notes and warning signs that are affixed to the compressor according to the applica tion or its equipment S A F E T Y P R E C A U T I O N S Warning High voltage Note Ensure correct direction of rotation Warning Hot surfaces ...

Page 15: ...se this product Comply with all local and national rules and regulations associated with this product Only trained and competent personnel are permitted to inspect repair and service the product Only authentic L W parts and accessories may be used for maintenance work Otherwise the proper functioning of the product may be impaired Do not use faulty or incomplete products Do not modify the product ...

Page 16: ...nsure that the machine is only taken into operation under safe and functional conditions Only operate the compressor if all protective and safety equipment e g detachable protective equipment are provided and in good working order Check the compressor at least once per day for obvious damage and defects Inform the respon sible department person immediately if anything is not as is should be includ...

Page 17: ...splay a warning sign on the main switch The machine and especially the connections and fittings should be cleaned from oil fuel and maintenance products at the beginning of the maintenance repair Do not use aggressive cleaning agents Use fibre free cleaning cloths Switch off compressor and clean with a slightly damp cloth Remove dirt from cooling pipes by using a brush After cleaning examine all p...

Page 18: ...ower Do not stand or work under suspended loads Also separate from minor relocation machinery system of any external energy supply Before recommissioning reconnect the machine to the mains according to regulations When recommissioning proceed according to the operating instructions Safety Regulations Inspections according to legal and local obligatory regulations regarding accident prevention are ...

Page 19: ...A I N S TA L L AT I O N ...

Page 20: ...osion Outdoor Installation For outside installation observe the following Install the unit horizontally and level The floor must be vibration free and capable of taking the load of the system weight On units employing petrol or diesel motors it is most important that only clean air is used Position compressor in direction of wind so that exhaust fumes are blown away from the unit Intake air must b...

Page 21: ...Page A 19 A LW 200 B MC 250 B MC Version 01 05 2020 Dimensions Fig Dimensions I N S T A L L A T I O N ...

Page 22: ...mpressor always has a sufficient amount of fresh air available To prevent serious damage ensure that the cooling air flow can flow freely The following minimum distances must be adhered Front side min 1500 mm sides min 500 mm rear side min 500 mm Avoid anything in this area which can restrict the cooling air flow Fig Minimum distances 500 500 500 500 1500 ...

Page 23: ...A O P E R AT I O N ...

Page 24: ...ersons handling the compressor are familiar with function and operation of the unit i Wear hearing protection When working on a running machine always wear hearing protection Danger Compressors with petrol or diesel motors must only be located outdoors never indoors not even in partially closed rooms however large they may be ...

Page 25: ...flow freely Take protection measures to avoid damages or injury by exhaust gases exhaust pipe Check fuel capacity Check drive engine oil level Check compressor oil level see Service and Maintenance Check all connections and retighten if necessary Check if the filter cartridge is in place see Service and Maintenance Check the V belt tension see Service and Maintenance Read carefully the handbook of...

Page 26: ...ve carefully 12 Run the compressor up to maximum pressure and check the function of the final pressure safety valve If the compressor is equipped with an automatic stop system please check the au tomatic shut down at final pressure If the final pressure switch does not shut off switch off the compressor with the stop switch see chapter Remedying faults 13 Stop the compressor with the stop swith 14...

Page 27: ...irection of wind so that exhaust fumes are blown away from the unit Ensure cooling air can flow freely Take protection measures to avoid damages or injury by exhaust gases exhaust pipe Check fuel capacity Check drive engine oil level Check compressor oil level Check if filter cartridge is in place observe filter cartridge life Ensure toxic free pure intake air ...

Page 28: ...ed pressure close slowly the valve of the cylinder 8 Switch off the compressor 9 Close and vent the filling valve 10 Disconnect compressed air cylinder from filling valve 11 Open condensate drain valves manually Caution Fill only cylinders which are marked with the test mark and the test stamp of the expert have been hydrostatic tested check last test date are rated for the final pressure are free...

Page 29: ... equipped as standard with an auto shut down The unit must always be stopped manually when final pressure is reached During filling process the system can be shut down at any time by switching the stop switch in off 0 position Note After switching off the compressor open condensate drain valves manually to vent the unit i ...

Page 30: ...A R E M E D Y I N G FA U LT S ...

Page 31: ...cessary Final pressure switch stop unit Verify settings replace if necessary Piston of automatic condensate valve sticks Only valid with the option Automatic Conden sate Drain Clean automatic condensate valve and restore function check replace o rings replace valve completely if necessary Air supply too low Cause of fault Remedy Inlet Outlet valves contaminated defective Clean replace if necessary...

Page 32: ...compressor rotation direction Ensure correct phase rotation observe rotation direction arrow Inlet Outlet valves contaminated defective Clean replace if necessary Safety valve leaks Cause of fault Remedy Inlet Outlet valves of the following pressure stage defective Clean replace if necessary Sinter filter of the following water separator blocked Replace Safety valve leaky Replace turn out vent scr...

Page 33: ...l pressure Only valid with the option Automatic Condensate Drain Cause of fault Remedy Pressure stages are not as prescribed control pressure of automatic condensate valve too low Check corresponding Inlet Outlet valve re place if necessary Piston sealing of automatic condensate valve contaminated used up Clean replace if necessary Timer relais defective Replace Timer relais settings not correct A...

Page 34: ...artridge already partly saturated before change Store filter cartridges properly dispose defective cartridges Cylinder s piston s or piston ring s defective Replace Operating temperature too high Ensure sufficient ventilation Oil consumption too high Cause of fault Remedy Cylinder s piston s or piston ring s defective Replace Compressor oil unsuitable Use prescribed oil quality Operating temperatu...

Page 35: ...A M A I N T E N A N C E A N D S E R V I C E ...

Page 36: ...n not be explained exactly and detailed in this manual Only use authentic spare parts for service work Danger Components under pressure such as hose ends can quickly come loose when manipula ted and can cause potentially fatal injuries due to the pressure surge Any work on system parts may only be performed in a pressure compensated state Warning The use of accessories that have not been tested ca...

Page 37: ...d condition LW 200 B MC 1 000111 Check automatic condensate drain open manual condensate taps Check Retorque all connections and bolts LW 250 B MC 1 011154 Maintenance work Type Quantity Order No Oil change if less than 1000 operating hours 0 8 ltr 000001 Check opening pressure of final safety valve Clean coolers Clean all oil water separators if less than 500 operating hours Service intake filter...

Page 38: ...leaks Clean oil water separators Check V belt tension and condition LW 200 B MC 1 000111 LW 250 B MC 1 011154 Every 1000 Operating Hours Maintenance work Type Quantity Order No Replace o ring of the DIN filling connector 1 001237 Replace o ring of the revolvable filling hose 1 001224 Replace sintered metal filter of oil separator 1 002123 Replace o ring of the water separator 1 001255 Replace o ri...

Page 39: ...ing Hours Maintenance work Type Quantity Order No Replace o rings and gaskets of 1st 2nd and 3rd stage O Ring 1st stage 1 011104 O Ring 2nd 3rd stage 2 011105 Replace all Inlet Outlet valves incl Gaskets 1st stage 1 003652 2nd stage 1 000551 3rd stage 1 011123 Upper gasket 1st 1 003651 Lower gasket 1st 1 011103 ...

Page 40: ...sures that all required parts are ordered and replaced and gives assurance that all parts are included in the order Depending on the model and interval the service kits include parts such as O Rings Sinter Filter Inlet Filter Silencers In Outlet Valve Valve Seals and Compressor oil Compressor Operating Hours Order No LW 200 B MC LW 250 B MC 1000 h 011169 LW 200 B MC LW 250 B MC 2000 h 011170 Servi...

Page 41: ... clockwise increase V belt tension Rotation direction anti clockwise reduce V belt tension Attention make sure V belt pulley groove and flywheel wheel groove are align Tighten mounting screws of the motor flange Check V belt tension and adjust if necessary Correct V Belt Tension Do not tension V belts too tight This damages bearings of compressor and motor The V belt should only be tensioned until...

Page 42: ...ation of the system The oil level should be between the middle and upper end of the oil sight glass Never start the compressor with a too low oil level Refill new compressor oil at least when the oil level reached the middle of the indicated area Fig Oil Sight Glass Attention Check oil level daily Never start the compressor with a too low oil level Risk of accidental loss destruction or deteriorat...

Page 43: ...er neck by a funnel Check oil level The oil level should be between the middle and upper end of the oil sight glass The oil change is now completed Maintenance Intervals First oil change at 25 operating hours total hours Second oil change at 1000 operating hours total hours All further changes after each 1000 operating hours Oil and Oil Capacity Approx 800 ml synthetic compressor oil is necessary ...

Page 44: ...e max 1 5 turns anti clockwise The condensate will be drained Then close valve spindle clockwise Maintenance Intervals We recommend to clean oil and water separators every 500 operating hours or at least once a year to check for corrosion damage and to replace o rings if necessary The oil water separator has an integrated sinter filter which has to be replaced every 1000 operating hours Note The c...

Page 45: ... ring previously grease new o ring Fig 3 Change sinter filter Fig 4 screw in new sinter filter by using a suitable tool Place sinter filter holder into the water separator and tighten Connect pipe connections and tighten The oil water separator maintenance is now completed M A I N T E N A N C E A N D S E R V I C E Note Clean all parts thoroughly before assembly i Fig 1 Loosen Pipe Connection Fig 2...

Page 46: ...m Air is compressed up to 350 bar dried and odour and tasteless purified Oil residues are bounded The breathing air filter cartridge consists of a molecular sieve and activated carbon filter All breathing air filter cartridges are factory vacuum sealed We recommend unpacking the filter cartridges just before installation Filter cartridges which are exposed too long could be saturated with moisture...

Page 47: ...ove the filter cartridge by using the filter key Fig 3 Remove adapter from used cartridge Open the vacuum sealed packet of the new filter cartridge Put on filter adapter Fig 5 on new cartridge Use spanner to make sure adapter is sealing to cartridge bottom Insert filter cartridge incl Installed filler adapter Fully turn filter housing cover by using the filter key and turn it back turn This avoids...

Page 48: ... by using the filter key Fig 1 Change o ring previously grease new o ring Fig 2 Screw the filter housing cover in by using the filter key Fig 1 The filter housing maintenance is now completed Note Clean all parts thoroughly before assembly i M A I N T E N A N C E A N D S E R V I C E Fig 1 Remove screw in Filter Housing Cover Fig 2 Change O ring ...

Page 49: ... degree of contamination the filter inlet can be cleaned by compressed air Defective air inlet filters should be immedia tely replaced with a corresponding filter Maintenance intervals We recommend that the filter cartridge should be replaced every 500 working hours depending on pollution grade Fig Inlet Filter Note Dirty filters make air intake difficult and reduce delivery capacity Risk of compr...

Page 50: ...ive fissures Place o ring into the housing Fig 4 Insert the new cartridge and assemble the housing Place o ring into the groove Place and align the filter housing carefully inlet port up hose connector 90 turned to the right Fig 2 Tighten mounting screw and connect the crankcase breather hose Fig 3 Fig 1 The filter inlet change is now completed Note Clean all parts thoroughly before assembly i Fig...

Page 51: ...ons Dismount valve heads to change valves The three valves are combined Inlet Outlet valves The first stage is a plate valve The stages two and three are made of a spring operated piston which acts inside a bronze cylinder Maintenance Intervals All valves should be replaced after 2000 working hours due to normal wear and tear To replace valves the cylinder heads have to be removed There are no spe...

Page 52: ...ove the fan guard Disconnect the crankcase breather hose Fig 2 Loosen pipe connection Fig 3 Loosen valve head screws Fig 4 Remove valve head and check if defective Fig 5 Continued on next page Note The figures of the parts can differ due to the different stages i Fig 1 Loosen Mounting Screws of the Fan Guard Fig 2 Disconnect the Crankcase Breather Hose Fig 3 Loosen Pipe Connection Fig 4 Loosen Val...

Page 53: ...d valve head locating pin Fig 7 Place valve head carefully on top of the cylinder take care to keep valve in place Tighten valve head screws crosswise Fig 8 Tighten pipe connection and fix crankcase breather hose to air intake housing Don t forget to fix spring wire clamp Mount fan guard Fig 9 Inlet Outlet valve change 1st stage is now completed Note The figures can differ from the delivered parts...

Page 54: ...mounting screws of the fan guard Fig 1 and remove the fan guard Loosen pipe connection Fig 2 Loosen valve head screws Fig 3 Remove valve head Observe that the lower valve gasket is also pulled out It can still stick inside the cylinder head Remove inlet outlet valve Fig 4 Check valve head if defective check locating pin Continued on next page Fig 1 Loosen Mounting Screws of the Fan Guard Fig 2 Loo...

Page 55: ...ring must face to the inlet outlet valve Change lower valve gasket aluminium gasket Insert new inlet outlet valve into the valve head Fig 5 Caution Observe correct position between valve centre hole and valve head locating pin Place the valve head with the new inlet outlet valve Tighten valve head screws crosswise Fig 6 Tighten pipe connections Mount fan guard Fig 7 Inlet Outlet valves change 2nd ...

Page 56: ...avoid manipulation of the limit value settings Safety valves with removed seals have to be immediately checked for the prescribed settings and replaced if necessary The safety valve of the final stage is furthermore equipped with a knurled screw to be activated once Turning the knurled screw clockwise could vent the valve completely and therefore the final filter housing During normal operation co...

Page 57: ...e compressed air from blowing off final pressure gauge 0 bar When the adjusted opening pressure is reached 150 and 180 bar the purified compressed air flows via pressure maintaining and non return valve to the filling valve The value of the opening pressure of the pressure maintaining valve can be read at the final pres sure gauge When opening pressure is reached the pressure gauge value increases...

Page 58: ...a suitable slotted screwdriver Start compressor and check opening pressure adjust if necessary Tighten clamp screw on the side Check opening pressure again Reduce opening pressure Vent filling valve filling pressure 0 bar Loosen clamp screw on the side Turn adjusting screw anti clockwise by using a suitable slotted screwdriver Start compressor and check opening pressure adjust if necessary Tighten...

Page 59: ...y and change if necessary O ring at the Filling Valve Change o ring previously grease new o ring Fig 1 O ring at the Filling Hose Remove filling hose from the filling valve Fig 2 Change o ring previously grease new o ring Connect filling hose to the filling valve and tighten Fig 1 O ring at the Filling Valve Fig 2 O ring at the Filling Hose Note Clean all parts thoroughly before assembly i ...

Page 60: ...licensed expert is required 1 Examination after 5 years by a qualified person or authorized organisations Visual inspection inside and outside 2 Examination after 10 years by a qualified person or authorized organisations Visual inspection inside and outside In addition a water pressure test is carried out at 1 5 times of the permissible vessel operating pres sure The test methods described in poi...

Page 61: ...A M A I N T E N A N C E R E C O R D S ...

Page 62: ...urname Name Date Place Signature Instructor By adding themselves to this list the person that signs it confirms having been given a yearly introduction instruction about the function and operation of the compressor unit Furthermore they have be informed about the relevant safety rules and regualtions TRG DGRL BetrSichV GSG GSGV ...

Page 63: ...Page A 61 A LW 200 B MC 250 B MC Version 01 05 2020 M A I N T E N A N C E R E C O R D S Top up oil oil change Date Operating hours Oil quantity l Name ...

Page 64: ...Page A 62 A LW 200 B MC 250 B MC Version 01 05 2020 M A I N T E N A N C E R E C O R D S Cartridge change Date Operating hours Difference Name ...

Page 65: ...Page A 63 A LW 200 B MC 250 B MC Version 01 05 2020 M A I N T E N A N C E R E C O R D S Maintenance work Description Date signature ...

Page 66: ...Page A 64 A LW 200 B MC 250 B MC Version 01 05 2020 M A I N T E N A N C E R E C O R D S Replaced Parts Designation Part number Date signature ...

Page 67: ... cap of final filter housing clean threat grease o ring and threat with a food grade grease or silicone grease Close filter housing Remove intake filter cartridge and undo intake pipes on all valve heads Start compressor unit Spray a few drops of compressor oil into intake connectors Stop compressor unit and insert intake filter cartridge Bring intake pipes back in position and fix connections and...

Page 68: ... for foreign objects Check condition and tension of V belts replace if necessary Check condition of filling hoses replace if necessary Secure hoses against whipping and open filling valves and run compressor for approximately 10 minutes Check condition of final filter cartridge replace if necessary Close filling valves and run compressor up to final pressure Check safety valve relief pressure of f...

Page 69: ...en recommissioning proceed according to the operating instructions Disposal The product must be disposed in accordance with national waste disposal regulations and by an appropriate waste disposal company Electric and Electronic Components EU wide regulations for the disposal of electric and electronic appliances which have been defined in the EU Directive 2002 96 EC and in national laws are effec...

Page 70: ...C ERSATZTEILLISTEN SPARE PARTS LISTS DETAILANSICHTEN DETAILED VIEWS ...

Page 71: ... Kompressorblock Compressor Block 17 Ansaugfilter Intake Filter 20 Öl Wasserabscheider Oil Water Separator 22 Kolben 1 Stufe Piston 1st Stage 24 Kompressionskolben 2 Stufe Compression Piston 2nd Stage 25 Kompressionskolben 3 Stufe Compression Piston 3rd Stage 26 Saug Druckventil 2 Stufe In Outlet Valve 2nd Stage 27 Saug Druckventil 3 Stufe In Outlet Valve 3rd Stage 28 Kurbeltrieb Crank Drive 29 La...

Page 72: ...C Version 01 05 2020 D E T A I L A N S I C H T D E T A I L E D V I E W Gesamtansicht Kompressor Overall View Compressor C 1 LW 200 250 B MC ...

Page 73: ...A8 001713 Standfuß Gummipuffer Rubber Stand 001859 Befestigungsschraube Ø5 5x19 Fixing Bolt V Belt Cover 008397 Aufsteckstutzen Lüfterabdeckung Plug on Fan Cover 008419 Linsenflanschschraube M8x25 Buttonhead Screw M8x25 mm 011002 Grundkonsole Main Console LW 200 011003 Tragegriff ohne Stütze Carrying Handle LW 200 011130 Gummigriffe mit Endkappen 1 Paar Rubber grips with end caps 011364 Linsenschr...

Page 74: ...C Version 01 05 2020 D E T A I L A N S I C H T D E T A I L E D V I E W Baugruppe Grundgestell Assembly Main Frame C 3 LW 200 250 B MC ...

Page 75: ...4 Stoppmutter M10 Lock Nut M10 001186 U Scheibe A10 Washer A10 001195 U Scheibe A13 Washer A13 001828 U Scheibe A10 5 Washer 008968 Spannbuchse für Riemenscheibe Taper Lock bush 011135 Spannschraube M10 Fixing Block Tensioning Bolt 011154 Keilriemen XPA 1382 V Belt 011373 Keilriemenscheibe SPA 106 1 V Belt Pulley 011528 Antriebsmotor Briggs Stratton Engine 011529 Keilriemenscheibe SPA 132 1 V Belt...

Page 76: ...C Version 01 05 2020 D E T A I L A N S I C H T D E T A I L E D V I E W Baugruppe Motor Assembly Engine C 5 LW 200 250 B MC ...

Page 77: ...chschraube M6x25mm Flange Button Head Screw 008015 Aufkleber Rotation Sticker Rotation 008396 Gummitülle Rubber Grommet 011152 Aufkleber LW MC Series Sticker LW MC Series w b 011358 Gummitülle Ø18x24x7mm Rubber Grommet Ø18x24x7mm 011527 Ventilatorschutz mit Wellengitter Fan Guard 011533 Aufkleber LW 200 B MC Sticker LW 200 B MC white 011534 Aufkleber LW 250 B MC Sticker LW 250 B MC white C 6 LW 20...

Page 78: ...C Version 01 05 2020 E R S A T Z T E I L L I S T E S P A R E P A R T L I S T Baugruppe Lüfterabdeckung Assembly Fan Guard C 7 LW 200 250 B MC ...

Page 79: ... DIN Filling connector 000498 U Scheibe A6 Washer A6 000797 Verschraubung EW10L Elbow Connection 002811 Hochdruckschlauch 1000mm HP Hose 006257 6 kant Schraube M6x14mm Hexagon Bolt 011157 Rohrleitung Ø12mm komplett mit M S PipeØ12mm c w Nuts and Olives 011535 Rohrleitung Ø8mm komplett mit M S Pipe Ø8mm c w Nuts and Olives Rohrleitungssystem Pipework C 8 LW 200 250 B MC ...

Page 80: ...C Version 01 05 2020 D E T A I L A N S I C H T D E T A I L E D V I E W Rohrleitungssystem Pipework C 9 LW 200 250 B MC ...

Page 81: ...anschluss O Ring DIN filling connector 001391 O Ring O Ring 001392 Füllhandrad Kreuzventil Hand Wheel Filling Valve cross 001393 Entlüftungsspindel Vent Spindle 001394 Entlüftungshandrad Vent Hand Wheel 001395 Gleitscheibe schwarz Kreuzventil Slide Washer plastic black 001397 Kupferdichtung Copper Seal Ring 001398 Madenschraube Worm Screw 001399 Oberspindel Adapter Shaft 001400 Dichtspindel Kreuzv...

Page 82: ... E W Baugruppe Kreuzventil Assembly Cross Design Valve Andere verfügbare Füllanschlüsse Other available filling connectors Benennung Description Best Nr Order No CGA 346 200bar 008394 CGA 347 300bar 006842 INT Yoke 200 232 bar 002307 004977 000665 C 11 LW 200 250 B MC ...

Page 83: ...enschraube Worm Screw 001039 Zylinderschraube Allen Bolt 001181 U Scheibe A8 Washer A8 001718 Innenrohr Filtergehäuse Inner Tube Filter Housing 001742 Druckstift DHRV Pressure Pin 001743 Einlassverschraubung DHRV Inlet Connection 001744 Einstellschraube DHRV Adjusting Bolt 001745 Düsenrohr HD Filter Inlet Jet 001753 Patronenstift Zylinder Cartridge Pin 001769 O Ring Filtergehäuse O Ring Filter Hou...

Page 84: ...er 008348 Düsenrohr Hochdruckfilter Nozzle Tube 009657 Filterschlüssel Filter key 010572 Drallscheibe Swirl Disk 010573 Umlenkung Einlassluftstrom Deflection Inlet Airflow 010576 O Ring O ring 63 5 x 2 010759 Zylinderschrauben M4x12mm Allen Bolt M4x12mm 011174 Atemluft Filterpatrone 0 44 Liter Filter Cartridge 0 44 ltr 011189 Filterpatrone 0 44 Liter Filter Cartridge 0 44 ltr 011281 Filtergehäuse ...

Page 85: ...C Version 01 02 2020 D E T A I L A N S I C H T D E T A I L E D V I E W Baugruppe Endfiltergehäuse Volumen 0 37 Ltr Assembly Final Filter Tower Volume 0 37 ltr C 14 LW 200 250 B MC ...

Page 86: ...C Version 01 02 2020 D E T A I L A N S I C H T D E T A I L E D V I E W Baugruppe Endfiltergehäuse Volumen 0 44 Ltr Assembly Final Filter Tower Volume 0 44 ltr C 15 LW 200 250 B MC ...

Page 87: ...C Version 01 05 2020 D E T A I L A N S I C H T D E T A I L E D V I E W Gesamtansicht Verdichtereinheit Overall View Compressor Assembly C 16 LW 200 250 B MC ...

Page 88: ...Screw 001063 Zylinderschraube M8x95mm Allen Screw 001081 6 kant Schraube M8x20mm Hexagon Screw 001082 6 kant Schraube M8x25mm Hexagon Screw 001159 Stoppmutter M8 Lock Nut 001164 Stoppmutter M10 Lock Nut 001181 U Scheibe A8 Washer 001186 U Scheibe A10 Washer 002124 Ventilkopf 3 Stufe Valve Head 3rd Stage 003651 Obere Dichtung Ventil 1 Stufe Gasket Valve 1st Stage up 003652 Saug Druckventil 1 Stufe ...

Page 89: ...c w gasket 011103 O Ring Ø81x2mm O ring 011104 O Ring Ø84x2mm O ring 011105 O Ring Ø50x2mm O ring 011106 Anschlussadapter Kurbelgehäuseentlüftung Adapter Crankcase Vent 011107 Distanzstück 15mm Spacer 15mm 011109 Verschlussschraube GN 740 G3 8 Plug 011110 Verschlussschraube GN 441 G3 4 Plug 011111 Luftleitblech mit Gewindenieten Air Deflector 011112 Halteblech Wasserabscheider Holder Oil Water Sep...

Page 90: ...C Version 01 07 2020 D E T A I L A N S I C H T D E T A I L E D V I E W Baugruppe Kompressorblock Assembly Compressor Block C 19 LW 200 250 B MC ...

Page 91: ...ion 001707 Ansaugfiltergehäuse Air Intake Filter Housing 001708 Ansaugfilterpatrone Air Intake Filter Cartridge 001772 Flügelmutter PVC schwarz Winged Nut PVC black 001778 O Ring Ø22x2mm O Ring 001782 O Ring Ø80x2mm O Ring 001829 Deckel Ansaugfiltergehäuse Cover Air Intake Housing 004064 Teleskop Ansaugrohr 3 teilig Telescope intake pipe C 20 LW 200 250 B MC ...

Page 92: ...C Version 01 05 2020 E R S A T Z T E I L L I S T E S P A R E P A R T L I S T Baugruppe Ansaugfilter Assembly Intake Filter C 21 LW 200 250 B MC ...

Page 93: ... 000837 Verschlussstopfen G1 8 Plug 000863 Winkelverschraubung WE 18L R1 2 Elbow Connection 001255 O Ring Ø26x2mm O Ring 002123 Sinterfilter G3 8 AG Sinter Filter 002128 Wasserabscheider 1 und 2 Stufe Water separa 1st 2nd Stage 002130 Halter für Sinterfilter G3 8 Holder for Sinterfilter G3 8 003077 Entwässerungsventil R1 4 AG konisch Drain Valve R1 4 male 003766 Aludichtring für G3 8 Gewinde Alloy...

Page 94: ...C Version 01 02 2020 D E T A I L A N S I C H T D E T A I L E D V I E W Baugruppe Öl Wasserabscheider Assembly Oil Water Separator C 23 LW 200 250 B MC ...

Page 95: ...nge Ø75 5mm 1 Stufe Set Piston Rings 1st Stage 000050 Kolben 1 Stufe Ø72mm komplett Piston 1st Stage complete 000051 Satz Kolbenringe Ø72mm 1 Stufe Set Piston Rings 1st Stage 010814 Kolben 1 Stufe Ø75 5mm komplett Piston 1st Stage complete 010815 Kolben 1 Stufe Ø80mm komplett Piston 1st Stage complete 011116 Satz Kolbenringe Ø80mm 1 Stufe Set Piston Rings 1st Stage C 24 LW 200 250 B MC ...

Page 96: ... I S T Baugruppe Kompressionskolben 2 Stufe Assembly Compression Piston 2nd Stage Best Nr Order No Benennung Description 010816 Kolben 2 Stufe Ø32mm komplett Piston 2nd Stage complete 011117 Satz Kolbenringe 2 Stufe 7Stk Set of Piston Rings 2nd Stage C 25 LW 200 250 B MC ...

Page 97: ...R T L I S T Baugruppe Kompressionskolben 3 Stufe Assembly Compression Piston 3rd Stage Best Nr Order No Benennung Description 010817 Kolben 3 Stufe Ø14mm komplett Piston 3rd Stage 011118 Satz Kolbenringe 3 Stufe 7Stk Set of Piston Rings 3rd Stage C 26 LW 200 250 B MC ...

Page 98: ...uppe Saug Druckventil 2 Stufe Assembly In Outlet Valve 2nd Stage Best Nr Order No Benennung Description 000532 Ventildichtung Saug Druckventil unten Lower Valve Gasket 000541 Dichtring Dichtung Ventil Upper Alloy Seal Ring 000551 Saug Druckventil In Outlet Valve C 27 LW 200 250 B MC ...

Page 99: ...ppe Saug Druckventil 3 Stufe Assembly In Outlet Valve 3rd Stage Best Nr Order No Benennung Description 000534 Ventildichtung Saug Druckventil Lower Valve Gasket 000541 Dichtring Dichtung Ventil Upper Alloy Seal Ring 011123 Saug Druckventil komplett In Outlet Valve C 28 LW 200 250 B MC ...

Page 100: ...ungsring Circlip A30 001365 Sicherungsring Circlip I35 010112 Passfeder Woodruff Key 010809 Kurbelgehäuse Crankcase 010818 Pleuel 1 Stufe Con Rod 010823 Kurbelwelle Crankshaft 010824 Gegengewicht Unterteil Counterweight lower Part 010829 Kreuzkopf Crosshead 010830 Kreuzkopfbolzen Crosshead Pin 011099 Flachkopfzylinderschraube Pan Head Bolt 011100 Passfeder Woodruff Key 011121 Zylinderrollenlager 1...

Page 101: ...C Version 01 02 2020 D E T A I L A N S I C H T D E T A I L E D V I E W Baugruppe Kurbeltrieb Assembly Crank Drive C 30 LW 200 250 B MC ...

Page 102: ...el Side Best Nr Order No Benennung Description 001361 Sicherungsring I70 Circlip 010279 Sicherungsring I62 Circlip 010785 O Ring Ø128x2mm O Ring 010821 Lagerdeckel Bearing Cover Flywheel Side 010831 Wellendichtring 30x72x10RST Shaft Seal 011119 Rillenkugellager 30x72x19mm Bearing 011120 Zylinderrollenlager 30x62x16mm Bearing C 31 LW 200 250 B MC ...

Page 103: ...01030 Zylinderschraube M6x16mm Allen Bolt 001047 Zylinderschraube M6x12mm Allen Bolt 001848 Rohrschelle Ø15 18mm Pipe Clamp 8mm Finned Pipe 009564 Rohrschelle Ø21 12 breit Pipe Clamp 010396 Kühler 1 Stufe mit Muttern Schneidr Cooler 1st Stage LW 200 010397 Kühler 2 Stufe mit Muttern Schneidr Cooler 2nd Stage LW 200 010425 Kühler 3 Stufe Cooler 3rd Stage LW 200 011113 Halteblech Kühler Holder Coole...

Page 104: ...C Version 01 05 2020 D E T A I L A N S I C H T D E T A I L E D V I E W Baugruppe Kühler Assembly Cooler C 33 LW 200 250 B MC ...

Page 105: ...terrad Assembly Flywheel Assembly Best Nr Order No Benennung Description 001043 Zylinderschraube M8x35 Allen Bolt 001184 Schnorr Scheibe S8 Clamp Washer 003983 Scheibe Schwungrad Washer Flywheel 010898 Lüfterrad Ø460mm Fan Wheel Ø460mm 011328 Anlegescheibe 3mm Washer 3mm C 34 LW 200 250 B MC ...

Page 106: ...D O P T I O N S ...

Page 107: ...haltsverzeichnis Additional Filling Hose 1 Auto Shut Down 4 Hour Counter 7 Oil Pump 9 Oil Pressure Gauge 13 Interstage Pressure Gauge 16 Switch Over Device 200 300bar 20 Wheel Set 24 Honda Drive Engine 27 ...

Page 108: ...D A D D I T I O N A L F I L L I N G H O S E D 1 LW 200 250 B MC ...

Page 109: ...ng process Spare Part List Best Nr Order No Benennung Description 000102 Einschraubstutzen DIN Füllanschluss G5 8 Holder DIN Filling connector 000126 Y Verteiler schwarz eloxiert Y connector 000498 U Scheibe A6 Washer A6 000783 Gerade Verschraubung GE10L Straight Connection 000797 Verschraubung EVW10L Elbow Connection 000799 Verschraubung EGE10L Connection with fixed nut 002811 Hochdruckschlauch 1...

Page 110: ...Version 01 05 2020 D A D D I T I O N A L F I L L I N G H O S E Detailed View D 3 LW 200 250 B MC ...

Page 111: ...D A U T O S H U T D O W N D 4 LW 200 250 B MC ...

Page 112: ...ws Increasing cut out pressure Turn the adjusting screw clockwise Reducing cut out pressure Turn the adjusting screw anti clockwise Adjust the pressure switch in steps of a quarter turn Restart the compressor after every adjustment step to verify the actual cut out pressure Example settings Note Do not adjust the final pressure switch to the safety valve pressure The final pressure switch has to b...

Page 113: ...Order No Benennung Description 000203 Druckschalter G1 4 IG PV 50 350 bar Pressure Switch 50 350 bar 009682 Verschraubung EL08L T Connection 009683 Verschraubung EGE08L Connection with fixed nut 011541 Rohrleitung Ø8mm komplett mit M S Pipe Ø8mm c w Nuts and Olives D 6 LW 200 250 B MC ...

Page 114: ...D H O U R C O U N T E R D 7 LW 200 250 B MC ...

Page 115: ...C O U N T E R Spare Part List Best Nr Order No Benennung Description 007324 Betriebsstundenzähler Hour Counter c w battery 011168 Flachkopfschraube mit Kreuzschlitz M2 5x12 Screw with cross recess Detailed View D 8 LW 200 250 B MC ...

Page 116: ...D O I L P U M P D 9 LW 200 250 B MC ...

Page 117: ...e gaskets with oil before placing respect mounting direction Be sure to position the arrow from the new oil sieve opposite to inlet and return ports of the pump see Fig 2 Remount the cover with the 4 cover screws Tightening torque 4 5 8 N The oil sieve change is now completed Maintenance intervals We recommend cleaning or replacing the oil sieve every 1 000 working hours Service Kit oil pump 00256...

Page 118: ...Copper Seal Ring 002340 O Ring Ölpumpenflansch O Ring oil pump flange 005272 Hohlschraube G1 4 AG Banjo Bolt G1 4 male 010785 O Ring O Ring 010820 Lagerdeckel Bearing Cover Oil Pump Side 010822 Ölpumpen Mitnehmer Oil Pump Driver 011106 Anschlussadapter Adapter Crankcase Vent 011110 Verschlussschraube GN 441 3 4 Plug G3 4 011121 Zylinderrollenlager 17x40x16 mm Bearing 011227 Spezialschraube M10 Spe...

Page 119: ...D Version 01 05 2020 Detailed View O I L P U M P D 12 LW 200 250 B MC ...

Page 120: ...D O I L P R E S S U R E G A U G E D 13 LW 200 250 B MC ...

Page 121: ...direction see rotation direction arrow Oil level too low not enough oil in the compressor Oil pump filter contaminated Oil intake pipe damaged defective Oil temperature below 5 C lubrication not possible Oil temperature higher than 120 C oil viscosity too low Oil pump defective If oil pressure value stays above the maximum value Low oil temperature between 5 C and 10 C Should stay within the range...

Page 122: ...er 0 6 bar Ø63mm Press Gauge glycerine brass 000721 Verschraubung WE06L Connection 001156 Stoppmutter M6 Lock Nut M6 zinc plated 002281 Verschraubung EW06L Connection with fixed nut 004739 Manometerschlauch 400mm Pressure gauge hose 005842 Linsenflanschschraube M6x16mm Flange Button Head Screw 011543 Halter Öldruckmanometer Bracket Oil Pressure Gauge D 15 LW 200 250 B MC ...

Page 123: ...D I N T E R S TA G E P R E S S U R E G A U G E D 16 LW 200 250 B MC ...

Page 124: ...le pressure gauge This is serviceable for trou bleshooting and allows detecting faults at an early stage Indicated interstage pressures depend on final pressure settings The pressure gauges should show the following values at a final pressure of 300 bar 1st stage approx 5 bar 2nd stage approx 60 bar 3rd stage approx 300 bar D 17 LW 200 250 B MC ...

Page 125: ...g GE06L Connection w o nut olive seal 001446 Manometerschlauch 700mm Pressure Gauge Hose 002281 Verschraubung EW06L Connection with fixed nut 002507 Einbaumanometer 0 10bar Pressure Gauge 0 10bar 005539 Einbaumanometer 0 100bar Pressure Gauge 0 100bar 011258 Halteblech Zwischendruckmanometer Holder 1st 2nd Pressure Gauge D 18 LW 200 250 B MC ...

Page 126: ...D Version 01 05 2020 I N T E R S T A G E P R E S S U R E G A U G E Detailed View D 19 LW 200 250 B MC ...

Page 127: ...D S W I T C H O V E R D E V I C E 2 0 0 3 0 0 B A R D 20 LW 200 250 B MC ...

Page 128: ...essure selector spindle 1 should be screwed fully out anti clockwise S W I T C H O V E R D E V I C E 2 0 0 3 0 0 B A R Switch over Device Drain Valve at Final Filter Tower ATTENTION Operate 200 300bar pressure selector spindle 1 only if filterhousing has been vented by u sing the drainage valve 2 i 1 2 D 21 LW 200 250 B MC ...

Page 129: ...nderschraube M8x70mm Allen Bolt 001156 Stoppmutter M6 Lock Nut M6 001244 O Ring Ø16x2mm O Ring flange safety valve 001770 O Ring Düsenschraube O Ring Inlet Jet 002354 O Ring Ø8x1 5mm O Ring 002811 Hochdruckschlauch 1000mm HP Hose 005173 Spindel Druckumschaltung Spindle switch over device 005174 Dichtkegel Druckumschaltung 200 300 bar Conical nipple switch o device 006257 6 kant Schraube M6x14mm He...

Page 130: ...D Version 01 05 2020 S W I T C H O V E R D E V I C E 2 0 0 3 0 0 B A R Detailed View D 23 LW 200 250 B MC ...

Page 131: ...D W H E E L S E T D 24 LW 200 250 B MC ...

Page 132: ...be A8 Washer 001186 U Scheibe A10 Washer 001713 Standfuß Gummipuffer Rubber Stand 001828 U Scheibe A10 5 Washer 005842 Linsenflanschschraube Flange Button Head Screw 008419 Linsenflanschschraube M8x25 Flange Button Head Screw 008655 Linsenflanschschraube Flange Button Head Screw 011366 Lenkrolle Ø100x32 mm Swivel Castor Wheel Ø100x32 mm 011384 Distanzstück für Gummifuß Radsatz Spacer Ø50mm anodize...

Page 133: ...Version 01 05 2020 D W H E E L S E T Detailed View D 26 LW 200 250 B MC ...

Page 134: ...D H O N D A D R I V E E N G I N E D 27 LW 200 250 B MC ...

Page 135: ... Nut M10 001186 U Scheibe A10 Washer A10 001195 U Scheibe A13 Washer A13 001828 U Scheibe A10 5 Washer 008968 Spannbuchse für Riemenscheibe Taper Lock bush 011135 Spannschraube M10 Fixing Block Tensioning Bolt 011154 Keilriemen XPA 1382 V Belt 011373 Keilriemenscheibe SPA 106 1 V Belt Pulley 011529 Keilriemenscheibe SPA 132 1 V Belt Pulley 011530 Sechskantschraube UNF7 16x1 Hexagonal Bolt 011532 P...

Page 136: ...Version 01 05 2020 D H O N D A D R I V E E N G I N E Detailed View D 29 LW 200 250 B MC ...

Page 137: ...E A T T A C H M E N T Version 11 12 E ...

Page 138: ...essure 160 350 bar 1 100 l min Suitable media Media resistant non corrosive gases The safety valve is used for protection of pressurized components eg pipelines pressure vessels or the compressor itself The hand wheel on the top of the safety valve is marked with the adjusted set pressure 1 Identification of set pressure 2 Seal 3 Fixing screws1 4 Venting srew hand wheel 5 Identification serial num...

Page 139: ...he problem is on the system A constant blowing of the safety valve is not permitted the sealing seat of the valve can be damaged The error on the system must be detected and repaired before further filling operations The safety valve may only be used if it is ensured that the maximum flowrate of the system does not exceed the blow off rate of the safety valve The safety valve may only be used with...

Page 140: ...iately Notes The safety valve must be installed directly on the protected pressure vessel and or the plant The safety valve must be installed in an upright position The flow area of the port must be greater than the valve opening Protect valve against splashes Maintenance In accordance with current Pressure Equipment Directives the safety valve must be periodically checked for operation and reliab...

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L&W Compressors LW 200 B MC, Operating Instructions Manual

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