L&W LW 225 E Operating Instructions Manual Download Page 5

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LW 225 E / LW 245 B
Version: 19.11.2015

Maintenance and Service

Service, Repair and Maintenance ..................................................................................................... 43

Maintenance Lists / Maintenance Intervals ................................................................................ 44 - 46

Service Kits LW 225 E ....................................................................................................................... 47

Service Kits LW 245 B ....................................................................................................................... 48

Check V-belt tension / Tension V-belt / Settings ............................................................................... 49

Compressor lubrication / Check oil level ........................................................................................... 50

Oil change ....................................................................................................................................... 51

Manual condensation dump system ................................................................................................ 52

Oil / water separators 2nd stage - maintenance ............................................................................... 53

Filter housing / Filter cartridge ......................................................................................................... 54

Filter cartridge change ..................................................................................................................... 55

Filter housing - maintenance ........................................................................................................... 56

Inlet Filter ........................................................................................................................................ 57

Check or change filter inlet .............................................................................................................. 58

Valve heads and valves .................................................................................................................... 59

Fan protection cover dismantling / Mounting the fan protection cover ........................................... 60

Replace inlet and outlet valve 1st stage .................................................................................... 61 - 62

Replace inlet and outlet valves 2nd .................................................................................................. 63

Replace inlet and outlet valves 3rd .................................................................................................. 64

Safety valves .................................................................................................................................... 65

Pressure maintaining / non return valve ........................................................................................... 66

Adjust pressure maintaining valve ................................................................................................... 67

O-rings - filling valve and filling hose ............................................................................................... 68

Motor change .................................................................................................................................. 69

Pressure gas vessel test .................................................................................................................... 70

Maintenance records ................................................................................................................ 72 - 76

Storage

Conservation / storage of the compressor ....................................................................................... 77

De-conservation, commissioning ..................................................................................................... 78

Transportation instructions / Disposal / Electric and electronic components .................................... 79

T A B L E O F C O N T E N T S

Summary of Contents for LW 225 E

Page 1: ...ment A B C D 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 Version 11 12 E ...

Page 2: ...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 parts become t...

Page 3: ...A Operating Instructions Breathing Air Compressor LW 225 E LW 245 B Version 02 14 E ...

Page 4: ...on the unit 15 General Safety Precautions 16 Unit customised safety notices 17 Maintenance instructions 18 Transportation instructions Safety regulations 19 Installation Installation LW 225 E 21 Installation LW 245 B 22 Dimensions LW 225 E 23 Dimensions LW 245 B 24 Minimum distances 25 Ventilation LW 225 E 26 Electrical Installation LW 245 E 27 28 Operation Important operation instructions 30 Firs...

Page 5: ...nance 56 Inlet Filter 57 Check or change filter inlet 58 Valve heads and valves 59 Fan protection cover dismantling Mounting the fan protection cover 60 Replace inlet and outlet valve 1st stage 61 62 Replace inlet and outlet valves 2nd 63 Replace inlet and outlet valves 3rd 64 Safety valves 65 Pressure maintaining non return valve 66 Adjust pressure maintaining valve 67 O rings filling valve and f...

Page 6: ...om 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 operation manual G E N E R A L I N F O ...

Page 7: ...245 B High performance 4 gear motor 6 kW with integrated fuel tank Pull start auto cut off at low oil level LW 225 E 5 5 kW E Motor 400V 3 Phase 50 Hz or 60 Hz Start Stop switch phase selector switch ready to connect c w cable and 16A CEE plug D E S C R I P T I O N ...

Page 8: ...or 200 and 300 bar Hour counter Special voltages frequencies on request Conversion set Petrol electro version Electro motor Standard 400V 3 phase 50Hz Power cable with plug and phase selector Start Stop Switch Steel frame c w carrying handles Manual condensate drain Pressure maintaining and non return valve 1x Filling hose c w filling valve and pressure gauge Intermediate coolers Stainless steel p...

Page 9: ...ure Switch over device for 200 or 300 bar Motor protection switch Conversion set Petrol electro version High performance 4 gear motor 6 kW with integrated fuel tank Pull start auto cut off at low oil level Stainless steel frame Manual condensate drain Pressure maintaining and non return valve 1x Filling hose c w filling valve and pressure gauge Intermediate coolers Stainless steel pipes Oil Water ...

Page 10: ...der Bore 3rd Stage mm Ø 14 Ø 14 Medium Industrial Air Breathing Air Intake Pressure atmosphaeric Oil Capacity l 0 8 0 8 Intake Temperature C 0 45 0 45 Ambient Temperature C 5 45 5 45 Cooling Air Volume m h 1650 1800 Voltage 400V 3 Phase 50 Hz Protection Class Drive Motor IP 54 Drive Power kW 5 5 6 RPM Motor min 1 2 890 3 600 Start Start Stop Switch Hand start Noise level dB A 87 93 Dimensions L x ...

Page 11: ...e A 9 A LW 225 E LW 245 B Version 19 11 2015 Unit Assembly LW 225 E No Designation 1 Pressure gauge 2 Filling hose with filling valve 3 Filter housing 4 Phasen selector switch 3 2 1 4 D E S C R I P T I O N ...

Page 12: ... 10 A LW 225 E LW 245 B Version 19 11 2015 Phase selector switch LW 225 E No Designation 1 Switch position 0 OFF 2 Switch position 1 ON Rotation 1 3 Switch position 2 ON Rotation 2 2 3 1 D E S C R I P T I O N ...

Page 13: ...Page A 11 A LW 225 E LW 245 B Version 19 11 2015 D E S C R I P T I O N Unit Assembly LW 245 B No Designation 1 Pressure gauge 2 Filling hose with filling valve 3 Filter housing 4 Hand start 1 4 3 1 ...

Page 14: ...nsate Release Valve 10 Oil Water Separator 11 3rd Pressure Stage 12 Final pressure Safety Valve 13 Cooling Pipe Final Stage 14 Condensate Release Hose 15 Condensate Release Valve 16 Oil Water Separator 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 Design D E S C R ...

Page 15: ...A S A F E T Y P R E C A U T I O N S ...

Page 16: ...he instruction manual is complied with and inspection and maintenance requirements are enforced No change and modification to the unit can be made without the written agreement of the manufacturer The manufacturer is not liable for damage to persons or property resulting from unauthorised modifications Operators Target groups in these instructions Operators Operators are persons who are authorized...

Page 17: ...5 Safety instructions on the unit Importance of notes and warning signs that are affixed to the compressor according to the application 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 ...

Page 18: ...ed and competent personnel are permitted to use 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 i...

Page 19: ...n 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 responsible department person immediately if anything is not as is should be including operation performance Shut down the machine imm...

Page 20: ...d 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 pipes for leaks loose connections chafing and damage Im...

Page 21: ...o not stand or work under suspended loads Even minor relocation please disconnect the machine system from 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 ar...

Page 22: ...A I N S TA L L AT I O N ...

Page 23: ... the compressor fan can intake fresh air from outside Ensure adequate ventilation and exhaust air opening When locating the compressor in rooms of less than 30 m space where natural ventilation is not ensured or other systems having high radiation are operating in the same room measures must be taken to provide artificial ventilation Intake air must be free from noxious gas e g smoke solvent vapou...

Page 24: ...Position compressor in direction of wind so that exhaust fumes are blown away from the unit Intake air must be free from noxious gas e g smoke solvent vapours exhaust fumes etc Observe the specified operating temperature see Technical Data 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 Wind Wi...

Page 25: ...Page A 23 A LW 225 E LW 245 B Version 19 11 2015 390 560 780 450 Dimensions LW 225 E Fig Dimensions I N S T A L L A T I O N ...

Page 26: ...Page A 24 A LW 225 E LW 245 B Version 19 11 2015 390 570 920 450 Dimensions LW 245 B Fig Dimensions I N S T A L L A T I O N ...

Page 27: ...ling air flow can flow freely The following minimum distances must be adhered Front side min 300 mm rear side min 300 mm Avoid anything in this area which can restrict the cooling air flow No minimum distances are required at the side panels Fig Minimum distances LW 160 E 300 mm 300 mm Hinweis Do not use LW 245 B in closed rooms i I N S T A L L A T I O N Note Minimum distances must be adhered i ...

Page 28: ...ng air flow can flow freely The necessary cooling air flow can be calculated by using the following formula 300 x drive power kW required cooling air flow m h Example 11kW motor 300 x 11kW 3300 m h required cooling air flow The fan capacity for fresh air and warm air must meet at least the required cooling air flow The fans must have the same capacity Fig Ventilation via ventilation stack I N S T ...

Page 29: ...on and frequency with those of the electric network see name plate on the compressor The fusing should be done in accordance with the valid regulations of the responsible electricity supply company When connecting the unit to the electrical supply check the compressor direction of rotation see chapter Operation First commisioning LW 225 E E1 Fuse the motor correctly see table use slow blow fuses I...

Page 30: ...tor 4 8 5 20 16 2 5 1 5 5 5 11 3 25 20 2 5 1 5 Electrical Installation LW 225 E The compressor comes fully wired with cable and plug An installation is not necessary Recommended fuses for 220 240 V operating voltage Nominal motor power Fusing start A Connection in mm kw A Direct Star Delta Contactor supply S D to Motor 4 14 8 25 20 2 5 1 5 5 5 19 6 35 25 4 2 5 S D Star Delta I N S T A L L A T I O ...

Page 31: ...A O P E R AT I O N ...

Page 32: ...l engines operation unit must only be located outdoors never indoors not even in partially closed rooms however large they may be Note Ensure that all persons 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 ...

Page 33: ... open filling valve carefully 5 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 automatic shut down at final pressure If the final pressure switch does not shut off switch off the compressor by placing the switch at position 0 see chapter Remedying faults 6 Check the com...

Page 34: ...direction Immediately after switching the compressor on check rotation direction Depending on the place of installation the phase sequence can influence the rotation direction Rotation direction change LW 225 E In case of a wrong rotation direction there is the possibility to change the switching position of the phase selector switch In case of wrong rotation direction in switching position 1 star...

Page 35: ...itch in position 1 3 Pull start Fig 2 4 Close condensate valves 5 Run the compressor for about 2 minutes 6 Close the open filling valve carefully 7 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 automatic shut down at final pressure If the final pressure switch does not...

Page 36: ... LW 245 B Ensure cooling air can flow freely Position compressor in direction of wind so that exhaust fumes are blown away from the unit see Installation Installation LW 245 B Take protection measures to avoid damages or injury by exhaust gases exhaust pipe Check the compressor oil level Check if filter cartridge is in place observe filter cartridge life Check fuel capacity Check drive motor oil l...

Page 37: ... Switch off the compressor 8 Close and vent all filling valves 9 Disconnect all compressed air cylinders from filling valves 10 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 from humidity i Note The unit must be stopped...

Page 38: ...re is reached During filling process the system can be shut down at any time by switching the phase selector switch in position 0 Switch off the compressor unit LW 225 E Stop compressor by switching the phase selector switch in position 0 Switch off the compressor unit LW 245 B Stop compressor by the toggle switch Close fuel shut off valve Note After switching off open condensate drain valves manu...

Page 39: ...A R E M E D Y I N G FA U LT S ...

Page 40: ...ve leaky Replace Pipes heat exchanger broken Replace Condensate drain valves leaky Unscrew valves check sealing surfaces clean replace if necessary Final pressure switch stop unit Verify settings replace if necessary Piston of pneumatic condensate valve sticks Clean pneumatic condensate valve and restore function check replace o rings replace valve completely if necessary Air supply too low Cause ...

Page 41: ...ameter Wrong compressor rotation direction Ensure correct phase rotation observe rotation direction arrow Inlet and outlet valves contaminated defective Clean replace if necessary Safety valve leaks Cause of fault Remedy Inlet and outlet valves of the following pressure stage defective Clean replace if necessary Sinter filter of the following water separator blocked Replace Safety valve leaky Repl...

Page 42: ...ssure Only valid with the option Automatic Condensate Drain Cause of fault Remedy Pressure stages are not as prescribed control pressure of pneumatic condensate valve too low Check corresponding inlet and outlet valve replace if necessary Piston sealing of pneumatic condensate valve contaminated used up Clean replace if necessary Timer relais defective Replace Timer relais settings not correct Adj...

Page 43: ...rtridge 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 temperatur...

Page 44: ...A M A I N T E N A N C E A N D S E R V I C E ...

Page 45: ... is necessary because all maintenance work can not be explained exactly and detailed in this manual Only use authentic spare parts for service work Any work on the petrol engine should be done in accordance with ist specific handbook Danger Components under pressure such as hose ends can quickly come loose when manipulated and can cause potentially fatal injuries due to the pressure surge Any work...

Page 46: ...ly or as needed Maintenance work Type Quantity Order No Check V belt tension and condition Check automatic condensate drain open manual condensate taps Check Retorque all connections and bolts Annually Maintenance work Type Quantity Order No Oil change if less than 250 operating hours 0 8 000001 Check opening pressure of final safety valve Clean coolers Clean all oil water separators if less than ...

Page 47: ...237 Replace o ring of the revolvable filling hose 1 001224 Change intake filter 1 001708 Replace o ring of the water separator O Ring 2 000016 Replace o ring of the condensate drain vlave 2 000043 Replace o ring of the final filter housing 2 000016 Check pressure maintaining non return valve Check all connections for leaks O Ring 2 003099 Change o ring of intake filter housing 1 001778 1 001782 M ...

Page 48: ...2nd stage 1 000035 o ring valve 3rd stage 1 000034 Replace all inlet and outlet valves incl Gaskets 1st stage 1 003652 2nd stage incl gasket 1 000031 3rd stage incl gasket 1 000032 Spacer copper 1 000038 Every 1000 operating hours M A I N T E N A N C E A N D S E R V I C E Note All stated quantities are parts of our 1000h service kit You can find an overview on page Service Kits i ...

Page 49: ...uch as O Rings Sinter Filter Inlet Filter V Belts Silencers In Outlet Valve Valve Seals and Compressor oil Compressor Frequency Operating Hours Order No LW 225 E 50 Hz 500 h 006771 LW 225 E 50 Hz 1000 h 006629 LW 225 E 60 Hz 500 h 006772 LW 225 E 60 Hz 1000 h 006773 Service Kits LW 225 E Versions from 2008 Compressor Frequency Operating Hours Order No LW 225 E 50 Hz 500 h 006770 LW 225 E 50 Hz 100...

Page 50: ...ding on the model and interval the service kits include parts such as O Rings Sinter Filter Inlet Filter V Belts Silencers In Outlet Valve Valve Seals and Compressor oil Compressor Frequency Operating Hours Order No LW 245 B 50 Hz 500 h 006771 LW 245 B 50 Hz 1000 h 006629 Service Kits LW 245 B Versions from 2008 Compressor Frequency Operating Hours Order No LW 245 B 500 h 006770 LW 245 B 1000 h 00...

Page 51: ...otation direction clockwise increase V belt tension Rotation direction anti clockwise reduce V belt tension 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 belts should only be tensioned until there is no noise caused by slipping during start Motor Ty...

Page 52: ...ick as far as it will go back into its tube and screw in Screw out oil dipstick again The oil level should reach the upper maximum marking but minimum the lower edge of the oil dipstick Refill new compressor oil at least when the recommended oil level wasn t reached Screw in the oil dipstick as far as it will go back into its tube Warning Check oil level daily Never start the compressor with a too...

Page 53: ...nd insert the oil cover The oil change is now completed Maintenance intervals First oil change after 25 operating hours total hours All further changes after each 250 operating hours Oil and oil capacity Approx 800 ml synthetic compressor oil is necessary for one oil change Only use synthetic compressor oil which is recommended as suitable from L W P N 000001 Only LW 245 B Drive motor oil change i...

Page 54: ...ing Fig 2 Open valve spindle 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 inside every 250 operating hours or at least once a year to check for corrosion damage and to replace o rings if necessary not the o ring of the valve spindle All oil water separators have integrated o rings...

Page 55: ...cooler and screw pipe connections slightly Tighten mounting screws of the cooler bracket Fig 1 and pipe connections Fig 2 3 Tighten lock ring with the filter key Fig 5 Turn off condensate drain valve change o ring and turn in condensate drain valve completely Fig 6 The oil water separator maintenance is now completed Abb 4 Remove lock ring and change o ring Abb 6 O ring condensate drain valve Abb ...

Page 56: ... 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 The cartridges of petrol driven versions are equipped with additional CO CO2 filters All breathing air filter cartridges are factory vacuum sealed We recommend unpacking the filter cartridges just before installation Filter cartridges whi...

Page 57: ...r opening the housing pull out spring and filter cartridge Fig 3 Check the condition of the o ring and replace if necessary Open the packaging of the new filter cartridge and place it into the filter housing press slightly Put on the spring Fig 3 Screw in the filter cover with help of the filter tool The filter cartridge change is now completed Note Ensure that the old filter cartridge is disposed...

Page 58: ...er key Insert filter cartridge place spring and tighten filter cover with the filter tool Turn off condensate drain valve completely change o ring and turn in condensate drain valve completely Fig 6 The oil water separator maintenance is now completed Hinweis Alle O Ringe vorher einfetten sowie alle Einzelteile vor dem Einbau gründlich reinigen i Abb 4 Remove lock ring Abb 6 Change o ring Abb 5 Re...

Page 59: ... can be cleaned by compressed air Defective air inlet filters should be immediately replaced with a corresponding filter Maintenance intervals We recommend that the filter cartridge should be replaced every 500 working hours depending on pollution grade Intake filter Note Dirty filters make air intake difficult and reduce delivery capacity Risk of compressor overheating i M A I N T E N A N C E A N...

Page 60: ...the housing Fig 3 Insert the new cartridge and assemble the housing Place o ring into the groove Fig 4 Place and align the filter housing carefully inlet port up hose connector 90 turned to the left Fig 5 Tighten mounting screw and connect the crankcase housing ventilation hose to the oil fill port Fig 6 The filter inlet change is now completed Note Clean all parts thoroughly before assembly i Fig...

Page 61: ...re subject to normal wear and tear and have to be replaced at specified intervals depending on specific operating conditions Dismount valve heads to change valves All valves are combined valves inlet and outlet valves are a single unit To change the inlet and outlet valves it is necessary to remove the fan protection cover Fig 2 In and outlet valve c w gaskets 2nd stage top und 3 Stufe below Fig 1...

Page 62: ...antling is now completed Mounting the fan protection cover Mount the fan protection cover as follows Tilt the compressor aside Place the fan protection cover Tighten both bottom mounting screws Position the compressor upright Adjust the protection plate between cylinder head and cover Tighten top mounting screw Fig 1 The fan protection cover mounting is now completed Fig 1 Remove top mounting scre...

Page 63: ...e valve head screws Fig 3 Check valve head if defective check centre pin Remove lower valve gasket Fig 4 Remove in and outlet valve Fig 5 Remove upper valve gasket Install inlet outlet valve see following page Note The figures can differ from the delivered parts i Fig 5 Remove in and outlet valve Fig 2 Pipe connection Fig 4 Lower valve gasket Fig 3 Valve head screws Fig 1 Spring wire clamp M A I N...

Page 64: ... take care to keep valve in place Fig 4 Tighten valve head screws crosswise Fig 5 Set tight connecting nut and fix vent hose to air intake housing Don t forget to fix spring wire clamp Fig 7 Inlet and outlet valves change 1st stage is now completed Note The figures can differ from the delivered parts i Fig 2 Correct position of in and outlet valve Fig 4 Take care to kkeep valve in place Fig 3 Corr...

Page 65: ...Change upper valve gasket o ring Change lower valve gasket aluminium gasket Insert new inlet and outlet valve into the valve head Fig 4 CAUTION Observe correct position between valve centre hole and valve head locating pin Place the valve head with the new inlet and outlet valve Place pipe connections Tighten valve head screws crosswise Fig 2 Tighten pipe connections Fig 1 Inlet and outlet valves ...

Page 66: ...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 and outlet valve Tighten pipe connections Tighten valve head screws crosswise Fig 2 Tighten mounting screws of the cooling pipe bracket Fig 3 Tighten pipe connections Fig 1 2 Inlet and outlet valves change 3rd stage is now completed Hinweis Before...

Page 67: ...mit 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 conditions the knurled screw h...

Page 68: ... 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 pressure gauge When opening pressure is reached the pressure gauge value increases within a few seconds Adjust press...

Page 69: ... a suitable slotted screwdriver Start compressor and check opening pressure adjust if necessary Tighten clamp nut Check opening pressure again Reduce opening pressure Vent filling valve filling pressure 0 bar Loosen clamp nut Turn adjusting screw anti clockwise by using a suitable slotted screwdriver Start compressor and check opening pressure adjust if necessary Tighten clamp nut Check opening pr...

Page 70: ... 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 71: ...screws of the motor flange Remove motor tensioner bolt Remove V belt Remove motor v belt pulley Remove motor carefully Place new motor Mount motor v belt pulley Mount flange mounting screws and tighten nuts slightly Insert motor tensioner bolt Check Ensure the alignment of both key slots motor compressor Tension V belt Tighten flange mounting screws Place V belt cover and tighten mounting screws E...

Page 72: ...ple Filter housing 0 5 l Maximum operating pressure 350 bar Content volume 0 5 litres 350 bar x 0 5 litres 175 175 is smaller than the minimum of 200 result Test is not applicable Pressure equipment from 200 up to 1000 have to be tested as follows 1 Examination after 5 years by a qualified person or authorized organisations Visual inspection inside and outside 2 Examination after 10 years by a qua...

Page 73: ...A M A I N T E N A N C E R E C O R D S ...

Page 74: ...name 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 75: ...Page A 73 A LW 225 E LW 245 B Version 19 11 2015 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 76: ...Page A 74 A LW 225 E LW 245 B Version 19 11 2015 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 77: ...Page A 75 A LW 225 E LW 245 B Version 19 11 2015 M A I N T E N A N C E R E C O R D S Maintenance work Description Date signature ...

Page 78: ...Page A 76 A LW 225 E LW 245 B Version 19 11 2015 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 79: ...s depending on the compressor type this may happens automatically Remove top 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 ...

Page 80: ...lace intake filter cartridge and check oil level Clean compressor unit check 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...

Page 81: ...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 82: ...B ERSATZTEILLISTEN SPARE PARTS LISTS DETAILANSICHTEN DETAILED VIEWS ...

Page 83: ...hmen Carrying Handles 8 Kühlrohre Cooling Pipes 10 Lüfterrad Cooling Fan Wheel 12 E Motor 14 Benzin Motor Bencine Motor pub 16 Öl Wasserabscheider 2 Stufe Oil Water Separator 2nd Stage 18 Filtergehäuse Filter Housing 20 Sicherheitsventil Safety Valve 22 Ansaugfilter Intake Filter 24 Füllschlauch Filling Hose 26 Kreuzventil Cross Design Valve 27 ...

Page 84: ... crankcase ventilation 11 000060 Kugellager Ball Bearing 12 000059 Kugellager Ball Bearing 13 000018 Radial Wellendichtung Shaft Seal 14 000017 O Ring 52 x 3 NBR70 O Ring 52 x 3 NBR70 15 000013 O Ring 130 x 3 NBR70 O Ring 130 x 3 NBR70 16 002523 O Ring 30 x 2 NBR70 O Ring 30 x 2 NBR70 17 000014 O Ring 85 x 2 O Ring 85 x 2 18 001042 Zylinderschraube Allen Screw 19 001131 Sechskantschraube Hexagon S...

Page 85: ...B Version 11 02 2014 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 Kurbelgehäuse Crankcase B 3 LW 225 E LW 245 B ...

Page 86: ...ton Rings 3rd Stage Complete Set 49 003983 Anlaufscheibe Schwungrad Washer Flywheel 50 000049 Unterer Pleuelbolzen 1 Stufe Lower Gudgeon Pin 1st stage 51 008165 Sicherungsring I40 Circlip I40 53 000048 Kolbenbolzen 1 Stufe Piston Pin 1st Stage 54 001355 Sicherungsring I20 Circlip I20 55 000053 Kolbenringe 2 Stufe Kompletter Satz Piston Rings 2nd Stage Complete Set 56 000047 Kolbenringe 1 Stufe Kom...

Page 87: ...B Version 11 02 2014 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 47 35 38 Kurbeltrieb Crank Drive B 5 LW 225 E LW 245 B ...

Page 88: ... 3rd Stage 83 000041 Sicherheitsventil 2 Stufe Safety Valve 2nd Stage 84 000039 Sicherheitsventil 1 Stufe Safety Valve 1st Stage 85 000091 Verschraubung Connection 86 000787 Verschraubung Auslass 1 Stufe Connection Outlet 1st Stage 88 003652 Saug Druckventil 1 Stufe In Outlet Valve 1st Stage 91 003063 Ventildichtung unten 3 Stufe Alu Lower Valve Gasket 3rd stage Alloy 98 003062 Ventildichtung unte...

Page 89: ...B Version 18 11 2015 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 Zylinder Ventilköpfe Cylinders Valve Heads 98 91 111 110 B B 7 LW 225 E LW 245 B ...

Page 90: ...0103 Verschlussstopfen Eckig mit Bohrung Square Plastic Caps Frame 10 004090 Verschlussstopfen Eckig Plug angular 11 004091 Massekabel Earth cable 12 004092 Spannschraube für Keilriehmen Clamp screw for v belt 15 004093 Blechschraube Sheet metal screw 16 004094 Inbusschraube Allen screw 17 001163 Mutter M10 Nut M10 18 004089 Mutter M8 Nut M8 19 004096 Unterlegscheibe für M8 Washer for M8 4 000121 ...

Page 91: ...B Version 07 02 2014 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 Tragrahmen Carrying Frame B 9 LW 225 E LW 245 B ...

Page 92: ...to 3rd stage 7 006677 Alu Kühlrohrhalteklammern 1 Paar Alloy clamp for cooling pipe 1 Pair 8 006726 Alu Kühlrohrhalteklammern 1 Paar Alloy clamp for cooling pipe 1 Pair 9 005111 Alu Kühlrohrhalteklammern 1 Paar Alloy clamp for cooling pipe 1 Pair 11 004248 Halteklammer Holding clamp 12 004248 Halteklammer Holding clamp 14 001006 Zylinderschraube Allen Screw 15 001151 Mutter M5 Nut M5 19 000780 Ver...

Page 93: ...B Version 14 02 2014 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 Kühlrohre Cooling Pipes 20 B 11 LW 225 E LW 245 B ...

Page 94: ...T E I L L I S T E S P A R E P A R T L I S T Pos Best Nr P N Benennung Description 115 000025 Lüfterrad Cooling Fan Wheel 116 002801 Keilriemenscheibe V belt pulley 117 001082 Sechskantschraube Hexagon screw 118 004096 Unterlegscheibe Washer B 12 LW 225 E LW 245 B ...

Page 95: ...B Version 07 02 2014 Lüfterrad Cooling Fan Wheel 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 B 13 LW 225 E LW 245 B ...

Page 96: ...ibe 50Hz 3 Pulley 50Hz 3 006668 Riemenscheibe 60Hz 3 Pulley 60Hz 3 006668 Riemenscheibe 50Hz 1 Pulley 50Hz 1 5 000123 Keilriemen 50Hz 3 V belt 50Hz 3 000125 Keilriemen 60Hz 3 V belt 60Hz 3 000125 Keilriemen 50Hz 1 V belt 50Hz 1 6 001164 Stoppmutter M10 Lock Nut M10 7 001186 U Scheibe A10 Washer A10 8 001104 Sechskantschraube Hexagon Screw 9 008160 Distanzscheibe E Motor standard Version Spacer Mot...

Page 97: ...B Version 08 08 2014 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 E Motor B 15 LW 225 E LW 245 B ...

Page 98: ...799 Keilriemen LW 245 B V belt LW 245 B 4 008161 Unterlegscheibe Motorriemenscheibe Washer Engine Pulley 6 001103 Sechskantschraube Hexagon Screw 7 001082 Sechskantschraube Hexagon Screw 8 001164 Stoppmutter M10 Lock Nut M10 9 001186 U Scheibe A10 Washer A10 10 001184 Schnorr Scheibe Clamp Washer 12 006674 Auspuffhalterung Krümmer Block Exhaust bracket 13 001081 Sechskantschraube Hexagon Screw 14 ...

Page 99: ...B Version 08 06 2015 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 Benzin Motor Bencine Motor B 17 LW 225 E LW 245 B ...

Page 100: ... 6 000040 Entwässerungsspindel Condensate Drain Spindle 7 003000 Kondensatschläuche 2Stk Condensate Hoses 2pcs 8 000042 Feder Entwässerungsspindel Spring Condensate Drain Spindle 9 004398 Kondensatablaßstutzen Condensate Outlet Sleeve 11 001321 Kupferring Copper ring 12 000043 O Ring Entwässerungsspindel O Ring Condensate Drain Spindle 13 000016 O Ring Gehäuse O Ring Housing 14 001039 Zylinderschr...

Page 101: ...n 07 02 2014 Öl Wasserabscheider 2 Stufe Oil Water Separator 2nd stage 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 Öl Wasserabscheider komplett Complete Oil Water Separator 000288 1 B 19 LW 225 E LW 245 B ...

Page 102: ... Connection Pressure Maintaining Valve 11 000090 Verschraubung Connection 12 000070 Verbindungsstutzen Wasserabscheider Coupler Water Separator 13 004398 Kondensatablaßstutzen Condensate Outlet Sleeve 14 003000 Kondensatschläuche 2Stk Condensate Hoses 2pcs 24 000042 Feder Entwässerungsspindel Spring Drain Spindle 25 000094 Feder Filterpatrone Spring Filter Cartridge 26 002809 CU Ring Kupfer CU Rin...

Page 103: ...B Version 27 05 2014 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 Filtergehäuse Filter Housing Öl Wasserabscheider komplett Complete Oil Water Separator 000162 1 37 B 21 LW 225 E LW 245 B ...

Page 104: ...ety Valve TÜV 300 bar 000556 Sicherheitsventil Bauteilgeprüft Safety Valve TÜV 330 bar 000557 Sicherheitsventil Bauteilgeprüft Safety Valve TÜV 350 bar 000838 Verschlussstopfen 1 4 Plug 1 4 000893 Doppelnippel 3 8X1 4FF33MS Double Nipple 3 8X1 4FF33MS 001058 Zylinderschraube Allen Bolt 001244 O Ring O Ring flange safety valve 001814 Sicherheitsventil Bauteilgeprüft Safety Valve 001815 Sicherheitsv...

Page 105: ...C Version 13 02 2014 Sicherheitsventil Safety Valve 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 B 23 LW 225 E LW 245 B ...

Page 106: ...augfilterpatrone Air Intake Filter Cartridge 001772 Flügelmutter PVC schwarz m Messingein Winged Nut PVC black 001778 O Ring Oeleinfüllrohr O Ring oil filler pipe 001782 O Ring Ansaugfiltergehäuse O Ring 001807 Schlauch Kurbelgehäuse Entlüftung Hose Crankcase Vent 001829 Deckel Ansaugfiltergehäuse Cover air intake housing 003650 Stehbolzen Messing Threaded Stud brass 006846 Schlauchschelle Hose cl...

Page 107: ...B Version 05 07 2013 Baugruppe Ansaugfilter Assembly Intake Filter 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 B 25 LW 225 E LW 245 B ...

Page 108: ...sion 06 11 2014 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 Best Nr Order No Benennung Description 002811 Hochdruckschlauch 10L HP Hose 10L Füllschlauch Filling Hose 002811 B 26 LW 225 E LW 245 B ...

Page 109: ...001237 O Ring DIN Flaschenanschluss 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 ...

Page 110: ... I 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 000665 B 28 LW 225 E LW 245 B ...

Page 111: ...C O P T I O N S Version 11 12 D ...

Page 112: ...Table of Contents Auto Shut Down 2 Automatic Condensation Drain 5 Switch Over Device 200 300bar 7 Additional Filling Hose LW100 10 ...

Page 113: ...C A U T O S H U T D O W N D 2 LW 225 E 245 B ...

Page 114: ...is already adjusted to the corresponding cut out pressure The pressure can be adjusted with the upper adjusting screw as follows 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...

Page 115: ...U T D O W N Best Nr Order No Benennung Description 000203 Druckschalter 50 350 bar Pressure Switch 50 350 bar 000712 Verschraubung Connection 000722 Winkelverschraubung Elbow Connection Druckschalter Pressure Switch D 4 LW 225 E 245 B ...

Page 116: ...C A U T O M A T I C C O N D E N S AT I O N D R A I N D 5 LW 225 E 245 B ...

Page 117: ...ys at a small condensate valeblock and activates the dump valves about every 20 minutes To release the complete condensate through the black plastic hoses we recommend using an 20 l container at least The drain noise can be kept to a minimum by using a silencer Maintenance intervals We recommend to clean oil and water separators every 250 operating hours or at least once a year to check for corros...

Page 118: ...C 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 7 LW 225 E 245 B ...

Page 119: ... and a second filling pressure gauge When opening the ball valve the second final stage safety valve is then approached which directly lowers the pressure to 200 bar So the system pressure will be reduced to 200 bar and so the 300 bar filling outlet does also only provide 200 bar The handwheels are colour coded to allow an optical differentiation 200 bar black 300 bar red DIN handwheels 200 bar an...

Page 120: ...ve should be completely opened to reduce the pressure to 200 bar The opened ball valve ensures an air flow to the 200 bar fill connector 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 ATTENTION Operate ball valve only if filterhousing has been vented by using the drainage valve i Switch over device system Drainage valve D 9 LW 225 E 245 B ...

Page 121: ...C A D D I T I O N A L F I L L I N G H O S E D 10 LW 225 E 245 B ...

Page 122: ...ubung Connection 000799 Verschraubung mit fester Mutter Connection with fixed nut 000783 000799 000783 000126 The additional hose with filling valve allows to fill two bottles simultaneously The hose with filling valve is available in 200 and 300 bar version Please refer to Chapter A for all information about the filling process D 11 LW 225 E 245 B ...

Page 123: ...D A T T A C H M E N T Version 11 12 E ...

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L&W LW 225 E, Operating Instructions Manual

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