LW Compressors LW 170 D Nautic / AL, Operating Instructions Manual

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: ...Page A 1 A LW 170 E LW 170 D Nautic Version 15 10 2019 Operating Instructions Breathing Air Compressor LW 170 E Nautic AL LW 170 D Nautic AL ...

Page 4: ...eneral Safety Precautions 16 Unit customised safety notices 17 Maintenance instructions 18 Transportation instructions Safety regulations 19 Installation Installation LW 170 E Nautic AL 21 Installation LW 170 D Nautic AL 22 Dimensions LW 170 E Nautic AL 23 Dimensions LW 170 D Nautic AL 24 Minimum distances 25 Ventilation LW 170 E Nautic AL 26 Electrical Installation LW 170 E Nautic AL 27 28 Operat...

Page 5: ...tenance 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 66 Pressure maintaining non return valve 67 Adjust pressure maintaining valve 68 Lever filling valve 69...

Page 6: ... from 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 ...

Page 7: ...Drive motors LW 170 D Nautic AL Air cooled diesel engine 4 8 kW separate stainless steel fuel tank pull start and 12V electric start LW 170 E Nautic AL 4 0 kW E motor 400V 3 phase 50 Hz or 60 Hz fully wired with cable and 16A CEE plug D E S C R I P T I O N ...

Page 8: ...evice for 200 or 300 bar Motor protection switch Special voltages frequencies on request Additional HP Outlet Aluminium Frame Electro Motor Standard 400V 3 phase 50Hz Power cable with plug and phase selector Start Stop Switch Operating hour counter Steel frame Manual condensate drain Pressure maintaining and non return valve 2x Filling hose c w filling valve and pressure gauge Intermediate coolers...

Page 9: ... drain Automatic stop at final pressure Switch over device for 200 or 300 bar Motor protection switch Aluminium Frame Air cooled diesel engine 4 8 kW with separate stainless steel fuel tank Pull start and 12V electro start Steel frame Manual condensate drain Operating hour counter Pressure maintaining and non return valve 1x Filling hose c w filling valve and pressure gauge Intermediate coolers St...

Page 10: ...um 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 1200 1650 Voltage 400V 3 phase 50 Hz Protection Class Drive Motor IP 54 Drive Power kW 4 0 4 8 RPM Motor min 1 2 890 2 890 Start Start Stop switch Electric Hand start Noise level dB A 85 92 Dimensions W x D x H mm 1030 x 500 x 730...

Page 11: ...c Version 15 10 2019 Unit Assembly LW 170 E Nautic AL No Designation 1 Pressure gauge 2 Lever filling valve with hose and filling connection 3 Start Stop button with operating lamp 4 Phasen selector switch 3 2 1 4 D E S C R I P T I O N ...

Page 12: ...170 E LW 170 D Nautic Version 15 10 2019 Phase selector switch LW 170 E Nautic AL D E S C R I P T I O N No Designation 1 Switch position 0 OFF 2 Switch position 1 ON Rotation 1 3 Switch position 2 ON Rotation 2 2 3 1 ...

Page 13: ... D Nautic Version 15 10 2019 D E S C R I P T I O N Unit Assembly LW 170 D Nautic AL No Designation 1 Pressure gauge 2 Lever filling valve with hose and filling connection 3 Electrical start Start Stop key 4 Diesel engine 3 2 1 4 ...

Page 14: ...Page A 12 A LW 170 E LW 170 D Nautic Version 15 10 2019 D E S C R I P T I O N Flow chart ...

Page 15: ...Page A 13 A LW 170 E LW 170 D Nautic Version 15 10 2019 S A F E T Y P R E C A U T I O N S ...

Page 16: ...t 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 auth...

Page 17: ...2019 Safety instructions 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 ...

Page 18: ...ained 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 o...

Page 19: ... under safe and functional conditions Only operate the compressor if all protective and safety equipment e g detachable protective equipment is 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 it should be including operation per formance Shut down the machine imm...

Page 20: ...e 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 pipes for leaks loose connections chafing and damag...

Page 21: ...Do not stand or work under suspended loads Even for minor relocation please disconnect the machine system from any external energy supp ly 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 prevent...

Page 22: ...Page A 20 A LW 170 E LW 170 D Nautic Version 15 10 2019 I N S TA L L AT I O N ...

Page 23: ...nner that 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 solv...

Page 24: ...rs it is most important that only clean air is used Posi tion 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 par...

Page 25: ...Page A 23 A LW 170 E LW 170 D Nautic Version 15 10 2019 Dimensions LW 170 E Nautic AL Fig Dimensions I N S T A L L A T I O N ...

Page 26: ...Page A 24 A LW 170 E LW 170 D Nautic Version 15 10 2019 Dimensions LW 170 D Nautic AL Fig Dimensions I N S T A L L A T I O N ...

Page 27: ...ng air flow can flow freely The following minimum distances must be adhered Front side min 500 mm rear side min 500 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 170 E Nautic 500 mm 500 mm Note Do not use LW 170 D Nautic in closed rooms i I N S T A L L A T I O N Note Minimum distances must be adh...

Page 28: ...e cooling 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...

Page 29: ... tension 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 170 E Nautic Fuse the motor correctly see table use slow bl...

Page 30: ...D to Motor 2 2 5 10 1 5 1 5 4 8 5 20 2 5 1 5 Electrical Installation LW 170 E Nautic 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 2 2 8 7 20 1 5 1 5 4 14 8 25 2 5 1 5 S D Star Delta I N S T A L L A T I O ...

Page 31: ...Page A 29 A LW 170 E LW 170 D Nautic Version 15 10 2019 O P E R AT I O N ...

Page 32: ...iesel 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: ...ion 2 3 Run the compressor for about 2 minutes 4 Close the open filling valve carefully 5 Run the compressor up to maximum pressure and check the function of the final pressure sa fety valve If the compressor is equipped with an automatic stop system please check the auto matic shut down at final pressure If the final pressure switch does not shut off switch off the compressor by placing the switc...

Page 34: ...ssor on check rotation direction Depending on the place of installation the phase sequence can influence the rotation direction Rotation direction change LW 170 E Nautic AL 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 start the compres sor in switching positio...

Page 35: ...nd slowly open the associated filling valve Start the compressor 1 Fix the filling connectors in the aluminium holder 2 Open the lever filling valves 3 Open the manual condensate valves 4 Turn the start stop key clockwise to start the motor Fig 2 5 Close the manual condensate valves 6 Run the compressor for about 2 minutes 7 Close the lever filling valves 8 Run the compressor up to maximum pressur...

Page 36: ... LW 170 D Nautic 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 170 D Nautic Take protection measures to avoid damage 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 driv...

Page 37: ...rs 7 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 sto...

Page 38: ...s 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 170 E Nautic Stop compressor by switching the phase selector switch in position 0 Switch off the compressor unit LW 170 D Nautic Stop compressor by the start stop key Close fuel shut off valve Note After switching off open condensate drain ...

Page 39: ...Page A 37 A LW 170 E LW 170 D Nautic Version 15 10 2019 R E M E D Y I N G FA U LT S ...

Page 40: ...ty valve 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 ...

Page 41: ...a larger diameter Wrong compressor rotation direction Ensure correct rotation 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 Replace Oil taste in the air Cau...

Page 42: ...l pressure 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 re place if necessary Piston sealing of pneumatic condensate valve contaminated worn Clean replace if necessary Timer relay defective Replace Timer relay settings not correct Ad...

Page 43: ... cartridge 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 tempera...

Page 44: ...Page A 42 A LW 170 E LW 170 D Nautic Version 15 10 2019 M A I N T E N A N C E A N D S E R V I C E ...

Page 45: ...el This 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 diesel engine should be done in accordance with its specific handbook 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 ...

Page 46: ...nal pressure switch Check filter cartridge lifetime Maintenance work Type Quantity Order No Check V belt tension and condition LW 170 E Nautic 50Hz 2 000148 Check automatic condensate drain open manual condensate taps Check Retorque all connections and bolts Check condition of the Battery Check condition of fuel hose LW 170 E Nautic 2 LW 170 D Nautic 2 000148 Weekly or as needed Daily before takin...

Page 47: ... operating hours Maintenance work Type Quantity Order No Oil change 0 8 ltr 000001 Maintenance work Type Quantity Order No Oil change if less than 250 operating hours 0 8 ltr 000001 Check safety valve function refill oil 1 008500 Clean the coolers Clean all oil water separators if less than 250 operating hours Service intake filter depends on condition if less than 500 operating hours Check lever ...

Page 48: ...ring of the final filter housing O Ring 2 000016 O Ring 2 003099 O Ring 1 003692 Replace o ring of the condensate drain vlave 2 000043 Check pressure maintaining non return valve Check all connections for leaks M A I N T E N A N C E A N D S E R V I C E Every 500 operating hours Every 250 operating hours Maintenance work Type Quantity Order No Clean oil water separators Note All stated quantities a...

Page 49: ...n gasket 1st stage 2 000033 Replace all inlet and outlet valves incl Gaskets 1st stage inlet valve 1 000026 1st stage outlet valve 1 000029 2nd stage 1 000031 3rd stage 1 000032 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 kits You can find an overview on page Service Kits i ...

Page 50: ...contain parts for maintenance according to the factory requirements The use of the service kits ensures 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 Com pressor oil Service Kits Servi...

Page 51: ...tion 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 com pressor and motor The V belts should only be tensioned until there is no noise caused by slipping during start We recommend using a...

Page 52: ... Oil level check as follows Remove oil cover The oil level should reach the upper edge of the threaded hole To assist checking use a tool Install the oil cover In case the oil level does not reach the upper maximum top up with new compressor oil Oil cover Oil level M A I N T E N A N C E A N D S E R V I C E Warning Check oil level daily Never start the compressor with a too low oil level Risk of ac...

Page 53: ...omplete Maintenance intervals First oil change at 10 operating hours total hours Second oil change at 30 operating hours total hours Third oil change at 100 operating hours total hours All further changes after each 100 operating hours Oil and oil capacity Approx 800 ml synthetic compressor oil is necessary for one oil change Only use synthetic com pressor oil which is recommended as suitable from...

Page 54: ...housing 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 r...

Page 55: ... ring afterwards Put on lock ring loosely place cooler and attach pipe connections loosely Tighten mounting screws of the cooler bracket Fig 1 and pipe connections Fig 2 3 Tighten lock ring with the filter key Fig 5 Unscrew condensate drain valve change o ring install and tighten condensate drain valve Fig 6 The oil water separator maintenance is now complete Fig 4 Remove lock ring and change o ri...

Page 56: ...ar 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 diesel 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 which...

Page 57: ...ischarges from the condensate release ho ses the pressure vessels are depressurized Remove the end filter cover Fig 1 Fig 2 Remove the filter cover by using the filter tool The housing must not be opened when it is still under pressure After 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...

Page 58: ... filter housing and tighten with the filter key Insert filter cartridge install spring and install and tighten filter cover with the filter tool Unscrew condensate drain valve change o ring and install and tighten condensate drain valve Fig 6 The oil water separator maintenance is now complete Hinweis Alle O Ringe vorher einfetten sowie alle Einzelteile vor dem Einbau gründlich reinigen i Fig 4 Re...

Page 59: ...ke filter can be cleaned by compressed air An defective air intake filter should be im mediately replaced with a new filter Maintenance intervals We recommend that the filter cartridge be replaced every 500 working hours depending on grade of pollution Intake filter M A I N T E N A N C E A N D S E R V I C E Note Dirty filters make air intake difficult and reduce delivery capacity Risk of compresso...

Page 60: ...intake filter housing cover Fig 2 Change O Ring Change intake filter Fig 3 Install the intake filter housing cover Fig 2 Tighten mounting screws Fig 1 The filter inlet change is now complete Fig 1 Iloosen mounting screw Fig 2 Remove intake filter housing cover Fig 3 Change intake filter 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 ...

Page 61: ...have to be replaced at specified intervals depending on specific opera ting conditions Dismount valve heads to change valves In 1st stage there is an inlet valve and an outlet valve in use The valves of 2nd and 3rd stage are combined valves inlet and outlet valves are a single unit To change the inlet and outlet valves it is necessary to remo ve the fan protection cover Fig 2 In and outlet valve c...

Page 62: ...The fan protection cover removal is now complete Installing the fan protection cover Install the fan protection cover as follows Tilt the compressor aside Place the fan protection cover Install and tighten both bottom mounting screws Position the compressor upright Adjust the protection plate between cylinder head and cover Install and tighten top mounting screw Fig 1 The fan protection cover inst...

Page 63: ... and washers Fig 3 4 Remove valve head and check if defective Fig 5 Spring plate Fig 5 remove inlet and outlet valve bracket Fig 6 Remove inlet and outlet valve Install inlet outlet valve see following page Note The figures can differ from the delivered parts i Fig 5 Spring plate inside the valve head Fig 7 Inlet and outlet valve inside the valve head Fig 6 Inlet valve braket Fig 2 Pipe connection...

Page 64: ...e Fig 3 Change valve gaskets Fig 4 and spring plate Ensure the correct position of the spring plate Fig 5 Position valve head Install valve head bolts washers and valve cover bolts nuts and washers Tighten valve head and cover bolts and nuts crosswise torque settings 25 Nm Fig 6 Attach pipes and tighten connections Fig 7 Attach hose and spring wire clamp The inlet and outlet valve change is now co...

Page 65: ...lve 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 centre pin Position the valve head with the new inlet and outlet valve Install valve head bolts and washers Attach pipes Tighten valve head bolts crosswise torque settings 25 Nm Fig 2 Tighten pipe connecti...

Page 66: ...ket o ring Change lower valve gasket aluminium gasket Insert new inlet and outlet valve into the valve head Fig 5 CAU TION Observe correct position between valve centre hole and valve head locating pin Position the valve head with the new inlet and outlet valve on to cylinder Install valvehead bolts and washers Attach pipe connections Tighten valve head bolts crosswise torque settings 25 Nm Fig 2 ...

Page 67: ...ion of the limit value settings Safety valves with removed seals have to be immediately checked for the prescribed settings and replaced if necessa ry In addition the safety valve of the final stage has a lifting device knurled screw Turning the knurled screw clockwise could vent the valve completely and therefore the final filter housing During normal operation conditions the knurled screw has to...

Page 68: ...y valid Pressure Equipment Directives be checked for operation and reliability Refill annually lubricating oil Oil filling position Hole on the spacer see arrow Figure 1 Oil level Fill the lubrication oil into the hole until oil runs out M A I N T E N A N C E A N D S E R V I C E Note Lubricating oil for the safety valve L W Article N 008500 content 30 ml i Figure 1 Position for oil refill ...

Page 69: ...intaining the valve prevents the compressed air from blowing off final pressure gauge 0 bar When the adjusted opening pressure is reached between 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 reac...

Page 70: ...sing 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 openin...

Page 71: ...included all wear parts and O rings as used Lubricant grease MOLYKOTE 111 Compound Available are furthermore all parts according to parts list on page 12 Except the parts which are included in the maintenance and gasket kit NOTE Before dismantling carefully clean the valve external especially the inlet and outlet threads Clean all single parts after dismantling Use normal mild fat dissolving clean...

Page 72: ...0 mm 3 Valve Dismantling NOTE Numbers stated behind the parts designation are related to the Parts List at page 12 3 1 Moulded bellows 1 removal First remove moulded bellow 1 from valve body upper part 7 than pull it from the toggle lever 2 Check moulded bellows 1 for damages as cracks or holes If such existing replace moulded bellows 1 NOTE Valve may be kept by hand for the above 3 2 Toggle lever...

Page 73: ...lve body upper part 7 and Valve body lower part 15 separate CAUTION For this fix the valve in a vice with smooth vice jaws or a firm cloth Unscrew the 3 pcs hexagon screws 21 with an open ended or ring spanner jaw size 10 mm CAUTION Press valve body upper part 7 and valve body lower part 15 together by hand at removal from the vice to avoid the pop out of internal valve parts 3 3 continued place v...

Page 74: ...move valve pin 8 and plunger 15 by W1 centering pin Ø 3 mm as shown CAUTION Act carefully to avoid damage on the seal seat of the valve pin 8 Remove O ring 5 Ø 7 x Ø 1 5 mm from plunger 6 3 5 O ring 11 removal Remove O ring 11 Ø 9 x Ø 1 5 mm with W4 safety pin CAUTION Throw away O ring 11 Ø 9 x Ø 1 5 mm It is impaired by the above described procedure 3 6 Valve seat 10 removal Put valve pin 8 with ...

Page 75: ...Valve spring 13 and O ring 14 removal Remove sealing cone 12 valve spring 13 O ring 14 Ø 10 82 x Ø 1 78 mm from valve body lower part 15 3 8 Retaining screw 19 O rings 18 and 17 Filter 16 removal CAUTION For this fix valve body lower part 15 with its narrow sides in a vice with smooth vice jaws or a firm cloth Remove retaining screw 19 by a hexagon key L wrench hexagon 5 mm Remove O ring 18 Ø 8 x ...

Page 76: ...rt 15 on a clean surface until the filter 16 falls out 4 Valve Assembly NOTE Numbers stated behind the parts designation are related to the Parts List at page 12 NOTE Check all single parts for wear Replace all worn or faulty parts Always replace sealing cone 12 Always replace all O rings Use gasket kit HBV 117 A Use maintenance kit HBV 118 A Lightly lubricate threads and O rings with MOLYKOTE 111...

Page 77: ...er 16 thereby do not tilt it Move filter 16 down against block Check mounting depth 15 5 mm Y Put O ring 17 Ø 4 47 x Ø1 78 mm not lubricated onto filter 16 Screw in retaining screw 19 with a hexagon key L wrench hexagon 5 mm CAUTION Fasten retaining screw 19 by a torque wrench with 8 5 Nm 0 85 kpm 4 3 Valve spring 13 Sealing cone 12 assembly Insert valve spring 13 and sealing cone 12 in valve body...

Page 78: ... 1 78 Press O Ring 9 with W3 plunger in valve seat 10 Remove W2 retainer X Lubricate projecting part of the valve pin 8 and face of the valve seat 10 CAUTION In this connection do not move valve pin 10 to avoid that O Ring 9 will be pushed out of valve seat 10 4 6 Valve seat 10 with Valve pin 8 and O ring 9 assembly Insert valve seat with mentioned parts into valve body upper part 7 X Lubricate O ...

Page 79: ...s fix only valve body upper part 7 in a vice with smooth vice jaws or a firm cloth Valve body lower part 15 should be still moveable 4 7 continued Align the sides of valve body upper part 7 with the sides of valve body lower part 15 Screw in by hand or with a open ended or ring span ner jaw size 10 mm the remaining 2 pcs hexagon screws 21 with curved spring washers 20 CAUTION Tighten hexagon screw...

Page 80: ...le lever 2 Place toggle lever 2 in the valve that it points back ward related to the valve outlet The bore in the valve body upper part 7 and in the toggle lever 2 should align Insert pin 3 to the middle of the valve and insert the disc spring 4 as shown If pin 3 cannot be moved by hand push it in with a pin punch Ø 5mm and a light hammer 4 9 continued Centre disc spring 4 with W1 drift Ø 5mm CAUT...

Page 81: ...ows 1 over toggle lever 2 and fix it at valve body upper part 7 Ensure that the beaded rim of moulded bellows 1 fits the groove on the valve body upper part 7 and check that the moulded bellows 1 is not twisted in itself Move the toggle lever 2 several times for perfect function Correct the installation of moulded bellows 1 if necessary The assembly of the toggle filling valve is thereby completed...

Page 82: ... Valve body upper part 8 1 HBV 115 P Valve pin 9 1 ORI 042 P O ring Ø 3 68 x Ø 1 78 10 1 HBV 114 P Valve seat 11 1 HBV 004 P O ring Ø 9 x Ø 1 5 12 1 HBV 116 P Sealing cone 13 1 FDR 001 P Valve spring Ø 5 x 11 14 1 ORI 044 P O ring Ø 10 82 x Ø 1 78 15 1 HBV 120 P Valve body lower part 16 1 HBV 148 P Filter conical 17 1 ORI 009 P O ring Ø 4 47 x Ø 1 78 18 1 ORI 043 P O ring Ø 8 x Ø 1 5 19 1 HBV 149 ...

Page 83: ...rly 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 84: ...ove mounting 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 moun...

Page 85: ...ure 330 bar Content volume 0 5 litres 330 bar x 0 5 litres 165 165 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 qualified person or authorized organisations Visual...

Page 86: ...Page A 84 A LW 170 E LW 170 D Nautic Version 15 10 2019 M A I N T E N A N C E R E C O R D S ...

Page 87: ... Surname 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 88: ...Page A 86 A LW 170 E LW 170 D Nautic Version 15 10 2019 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 89: ...Page A 87 A LW 170 E LW 170 D Nautic Version 15 10 2019 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 90: ...Page A 88 A LW 170 E LW 170 D Nautic Version 15 10 2019 M A I N T E N A N C E R E C O R D S Maintenance work Description Date signature ...

Page 91: ...Page A 89 A LW 170 E LW 170 D Nautic Version 15 10 2019 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 92: ... valves depending on the compressor type this may happen automatically Remove top cap of final filter housing clean thread grease o ring and thread with a food grade grease or silicone grease Close filter housing Remove intake filter cartridge and detach intake pipes on all valve heads Start compressor unit Spray a few drops of compressor oil into intake connectors Stop compressor unit and insert ...

Page 93: ...use Replace 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 val...

Page 94: ...When 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 eff...

Page 95: ...B ERSATZTEILLISTEN SPARE PARTS LISTS DETAILANSICHTEN DETAILED VIEWS ...

Page 96: ... LW 170 D Nautic Compressor Frame LW 170 D Nautic 9 Kühlrohre Cooling Pipes 11 E Motor LW 170 E Nautic 13 Diesel Motor LW 170 D Nautic 15 Öl Wasserabscheider 2 Stufe Oil Water Separator 2nd Stage 17 Filtergehäuse Filter Housing 19 Lüfterrad Cooling Fan Wheel 21 Sicherheitsventil Safety Valve 23 Druckminderer Pressure Reducer 25 Ansaugfilter Intake Filter 27 Kipphebelventil mit Füllschlauch Lever V...

Page 97: ...dial Wellendichtung Shaft Seal 15 000013 O Ring 130 x 3 NBR70 O Ring 130 x 3 NBR70 15A 005297 Papierdichtung Kurbelgehäuse Paper Gasket Crankcase Cover 16A 003692 O Ring O Ring 17 000014 O Ring 85 x 2 O Ring 85 x 2 18 001042 Zylinderschraube Allen Screw 19A 001131 Sechskantschraube Hexagon Screw 20 000960 Stiftschraube Threaded Stud 21 001101 Sechskantschraube Hexagon Screw 22 001158 Mutter M8 Nut...

Page 98: ...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 2 LW 170 E Nautic LW 170 D Nautic ...

Page 99: ...gs 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 001429 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 000051 Kolbenringe 1 Stufe Kompletter...

Page 100: ...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 4 LW 170 E Nautic LW 170 D Nautic ...

Page 101: ...Stufe Safety Valve 1st Stage 85 000091 Verschraubung Einlass 2 Stufe Connection Inlet 2nd Stage 86 000093 Verschraubung Auslass 1 Stufe Connection Outlet 1st Stage 87A 000036 Einlassventilhalter Alloy Valve Holder 88A 000026 Einlassventil 1 Stufe Inlet Valve 1st Stage 89 000037 Auslassventilhalter Alloy Valve Holder 91 003063 Ventildichtung unten 3 Stufe Alu Lower Valve Gasket 3rd stage Alloy 98 0...

Page 102: ...B Version 27 07 2018 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 89 B 6 LW 170 E Nautic LW 170 D Nautic ...

Page 103: ...stiklager Motorwippe Plastic Spacer Motor Plate 7 001040 Zylinderschraube M8x20mm DIN912 8 8 ZN Allen Screw M8x20mm DIN912 8 8 ZN 8 001181 U Scheibe A8 DIN125 ZN Washer A8 DIN125 ZN 9 001159 Stoppmutter M8 DIN985 ZN Lock Nut M8 DIN985 ZN 10 001107 Sechskant Schraube M10x75mm DIN933 8 8 ZN Hexagon Screw M10x75mm DIN933 8 8 ZN 11 001186 U Scheibe A10 DIN125 ZN Washer A10 DIN125 ZN 12 001164 Stoppmut...

Page 104: ...B Version 17 10 2016 Kompressorrahmen LW 170 E Nautic Compressor Frame LW 170 E Nautic 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 B 8 LW 170 E Nautic LW 170 D Nautic ...

Page 105: ...ilager Motorwippe Rubber Mount Engine Base Plate 7 001040 Zylinderschraube M8x20mm DIN912 8 8 ZN Allen Screw M8x20mm DIN912 8 8 ZN 8 001181 U Scheibe A8 DIN125 ZN Washer A8 DIN125 ZN 9 001159 Stoppmutter M8 DIN985 ZN Lock Nut M8 DIN985 ZN 10 001098 Sechskant Schraube M10x16mm DIN933 8 8 ZN Hexagon Screw M10x16mm DIN933 8 8 ZN 11 001186 U Scheibe A10 DIN125 ZN Washer A10 DIN125 ZN 12 001164 Stoppmu...

Page 106: ...B Version 17 10 2016 Kompressorrahmen LW 170 D Nautic Compressor Frame LW 170 D Nautic 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 B 10 LW 170 E Nautic LW 170 D Nautic ...

Page 107: ...ing Pipe 2nd to 3rd stage 4 000008 Kühlrohr 1 Stufe zu 2 Stufe Cooling Pipe 1st to 2nd Stage 5 000007 Kühlrohr komplett 2 Stufe Wasserabscheider Cooling Pipe 2nd Stage Water Separator 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 co...

Page 108: ...B Version 13 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 B 12 LW 170 E Nautic LW 170 D Nautic ...

Page 109: ...heibe 1610 28 Clamp sleeve for pulley 1610 28 6 000148 Keilriemen SPA1282 V Belt SPA1282 7 001102 Sechskant Schraube M10x40mm DIN933 8 8 ZN Hexagon Screw M10x40mm DIN933 8 8 ZN 8 001104 Sechskant Schraube M10x50mm DIN933 8 8 ZN Hexagon Screw M10x50mm DIN933 8 8 ZN 9 001164 Stoppmutter M10 DIN985 ZN Lock Nut M10 DIN985 ZN 10 006123 Augenschraube M10x90 mm DIN444 Form B verzinkt 4 6 Eye Bolt M10x90 ...

Page 110: ...B Version 17 10 2016 E Motor 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 B 14 LW 170 E Nautic LW 170 D Nautic ...

Page 111: ...1108 25 4 000148 Keilriemen SPA1282 V Belt SPA1282 5 001104 Sechskantschraube M10x50mm DIN933 8 8 ZN Hexagon Screw M10x50mm DIN933 8 8 ZN 6 001105 Sechskantschraube M10x60mm DIN933 8 8 ZN Hexagon Screw M10x60mm DIN933 8 8 ZN 7 001164 Stoppmutter M10 DIN985 ZN Lock Nut M10 DIN985 ZN 8 006122 Augenschraube M10x60mm DIN444 Form B verzinkt 4 6 Eye Bolt M10x60mm DIN444 Form B verzinkt 4 6 9 001186 U Sc...

Page 112: ...B Version 17 10 2016 Diesel Motor 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 B 16 LW 170 E Nautic LW 170 D Nautic ...

Page 113: ...e 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 Ø7 5 x 2 3 NBR90 Entwässerungsspin del O Ring Ø7 5 x 2 3 NBR90 Condensate Drain Spindle 13 000016 O Ring Ø54 x 3 0 NBR90 Gehäuse O Ring Ø54 x 3 0 NBR90 Hou...

Page 114: ... 2016 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 000287 1 B 18 LW 170 E Nautic LW 170 D Nautic ...

Page 115: ...ection 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 Dichtscheibe Kupfer Seal Washer Copper 26 002809 CU Ring Kupfer CU Ring Copper 27 000088 Kupferdichtung Copper Washer 30 003099 O Ring Ø7 x 2 ...

Page 116: ...Version 10 05 2017 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 000161 1 37 B 20 LW 170 E Nautic LW 170 D Nautic ...

Page 117: ... S T Pos Best Nr P N Benennung Description 115 000027 Lüfterrad Cooling Fan Wheel 116 002801 Keilriemenscheibe V belt pulley 117 001082 Sechskantschraube M8x25 DIN933 8 8 ZN Hexagon screw M8x25 DIN933 8 8 ZN 118 004096 Unterlegscheibe A08 DIN 125 Washer A08 DIN 125 B 21 LW 170 E Nautic LW 170 D Nautic ...

Page 118: ...B Version 17 10 2016 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 22 LW 170 E Nautic LW 170 D Nautic ...

Page 119: ...ve 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 Sicherheitsventil B...

Page 120: ...Version 13 02 2014 B 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 24 LW 170 E Nautic LW 170 D Nautic ...

Page 121: ...001428 4 000747 Verschraubung GE08L1 4NPTCFX Connection GE08L1 4NPTCFX 5 000765 Schneidring PSR 08 LX Olive Seal PSR 08 LX 6 000766 Mutter M08LCFX Union Nut M08LCFX 7 000767 Mutter 8S M16x1 5 Union Nut 8S M16x1 5 2 004925 Halterung für Druckminderer 001428 Bracket Pressure Reducer 001428 8 000498 U Scheibe A6 Washer A6 9 001030 Zylinderschraube M6x16mm DIN912 8 8 ZN Allen Bolt M6x16mm DIN912 8 8 Z...

Page 122: ...B Version 17 10 2016 Druckminderer Pressure Reducer 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 B 26 LW 170 E Nautic LW 170 D Nautic ...

Page 123: ...iption 120 000084 Flansch Ansaugfilter Air Intake Flange 121 000068 Blechgehäuse Ansaugfilter Metal intake filter housing 122 000012 Dichtring Ansaugfiltergehäuse Sealing Rubber Intake Filter housing 123 000119 Ansaugfilter Intake Filter 124 000083 Unterlegscheibe Washer 125 000082 Senkkopfschraube Counter sunk screw B 27 LW 170 E Nautic LW 170 D Nautic ...

Page 124: ...B Version 07 02 2014 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 28 LW 170 E Nautic LW 170 D Nautic ...

Page 125: ...hluss 200 bar DIN Filling Connection 200 bar 11 000697 DIN Füllanschluss 300 bar DIN Filling Connection 300 bar 12 002911 Sinterfilter DIN Flaschenanschluss Sintered filter DIN filling connection 13 001237 O Ring Ø12 37 x Ø2 62 NBR90 O ring Ø12 37 x Ø2 62 NBR90 16 000102 Halter DIN Füllanschluss G5 8 Bracket DIN Filling Connector G5 8 3 000949 Flachkopfzylinderschraube M6x12mm DIN6912 8 8 ZN Pan H...

Page 126: ...lling Hose 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 Andere verfügbare Füllanschlüsse Other available filling connectors Benennung Description Best Nr CGA 346 200bar 000706 CGA 347 300bar 000704 INT Yoke 200 232 bar 002306 B 30 LW 170 E Nautic LW 170 D Nautic ...

Page 127: ...D A T T A C H M E N T Version 11 12 E ...

Page 128: ...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 129: ...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 130: ...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...