C H A P T E R O V E RV I EW
Operating Instructions
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Technical Data Sheet
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Spare Parts Lists
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Options (if equipped)
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Attachment
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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
Version: 03.08.2013
S E R V IC E I N F O R M A T I O N / W A R R A N T Y
Compressor information
Type designation
Serial number
Date of construction
Purchase information
Purchase date
First commissioned on
Warranty period
Dealer's stamp
Warranty
L&W will uphold warranty claims made during a period of 12 months from the invoice date.
If the compressor was purchased from an official L&W dealer, the date on the dealer's invoice is
valid. Warranty claims can only be made on presentation of the 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 parts become the property of L&W. If maintenance work is carried out without our
knowledge or permission by the purchaser or a third party, we are absolved from any liability for
warranty claims. As a matter of principle, warranty claims can only be made by the initial purchaser.
Version: 03.08.2013
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Operating Instructions
Breathing Air Compressor
LW 300 D MC
Version: 19.06.2017
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LW 300 D MC
Version: 19.06.2017
T A B L E O F C O N T E N T S
General Information and Technical Data
General Information / Description of Warning Symbols .................................................................... 4
Scope of Delivery .............................................................................................................................. 5
Technical Data .................................................................................................................................. 6
Unit Assembly ................................................................................................................................... 7
Start Device ...................................................................................................................................... 8
Flow Chart ........................................................................................................................................ 9
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
Ventilation ...................................................................................................................................... 21
Electrical Installation ................................................................................................................ 22 - 23
Operation
Important Operation Instructions ................................................................................................... 22
First Commissioning ................................................................................................................ 23 - 25
Daily Commissioning ...................................................................................................................... 26
Filling Procedure ............................................................................................................................. 27
Switch off the Compressor ............................................................................................................. 28
Remedying Faults
............................................................................................................. 30 - 33
Maintenance and Service
Service, Repair and Maintenance .................................................................................................... 35
Maintenance Lists / Maintenance Intervals ............................................................................... 36 - 39
Service Kits ..................................................................................................................................... 40
Check V-Belt Tension / Tension V-Belt .............................................................................................. 41
Compressor Lubrication / Check Oil Level ........................................................................................ 42
Check Oil Level ................................................................................................................................ 43
Oil Change ...................................................................................................................................... 44
Oil Sieve Change .............................................................................................................................. 45
Oil Filter Maintenance ..................................................................................................................... 46
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LW 300 D MC
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T A B L E O F C O N T E N T S
Maintenance and Service
Manuele Condensation Dump System ............................................................................................ 47
Oil / Water Separators 2nd Stage - Maintenance ............................................................................ 48
Filter Housing / Filter Cartridge ....................................................................................................... 49
Filter Cartridge Change LW 300 D MC ............................................................................................. 50
Filter Housing - Maintenance ........................................................................................................... 51
Inlet Filters / Inlet Filter Cartridge Change ....................................................................................... 52
Cylinder Heads and Valves .............................................................................................................. 53
Fan Protection Cover Dismantling / Mounting the Fan Protection Cover .......................................... 54
Replace Inlet and Outlet Valve 1st Stage .................................................................................. 55 - 56
Replace Inlet and Outlet Valve 2nd Stage ................................................................................ 57 - 58
Replace Inlet and Outlet Valve 3rd Stage ........................................................................................ 59
Safety Valves ................................................................................................................................... 60
Pressure Maintaining / Non Return Valve ........................................................................................ 61
Adjust Pressure Maintaining Valve .................................................................................................. 62
O-Rings—Filling Valve and Filling Hose ............................................................................................ 63
Test of Pressure Equipment ............................................................................................................. 64
Maintenance Records .............................................................................................................. 66 - 70
Storage
Conservation / Storage of the Compressor ....................................................................................... 71
De-Conservation, Commissioning ................................................................................................... 71
Transportation Instructions / Disposal ............................................................................................. 72
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LW 300 D MC
Version: 19.06.2017
Warning
Indicates a potentially hazardous situation which, if not avoided, could result in physical
injury or damage to the product or environment.
Caution
Indicates an imminently hazardous situation which, if not avoided, could result in serious
injury, physical injury or death.
General Information
We strongly recommend reading this manual thoroughly prior to operation and follow all the safety
precautions precisely. Damage resulting from any deviation 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
operation manual.
G E N E R A L I N F O R M A T IO N
!
!
Note
Indicates additional information on how to use the unit.
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Description of Marks and Warning Signs
The following warning signs are used in this document to identify the corresponding warning notes
which require particular attention by the user. The warning signs are defined as follows:
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LW 300 D MC
Version: 19.06.2017
D E S C R I P T I O N
Scope of Delivery
The new MC Series from L&W has been created for dive centers, ships, boats and places with limited
space. These are suitable for continuous operation and guarantee low maintenance costs due to
long service intervals. Comes ready to start. A super lightweight aluminum frame enables mobile
applications, combined with very high filling capacity.
Versions
Filling pressure versions:
• PN 225 bar
• PN 330 bar
• PN 225 / 330 bar
Specifications
Options
• Automatic condensate drain incl. collecting
tank
• Automatic stop at final pressure
• Additional filling hoses c/w filling valves
• 200 and 300 bar parallel filling pressures
• Switch Over Device 200+300bar
• Oil– and interstage pressure gauges
• Oil pressure monitoring c/w auto shut down
• Additional high pressure outlet
• Wheel set
• Air Cooler Connection Kit
• Puracon filter monitoring
• Diesel Engine
• Painted lightweight aluminium frame in RAL
7001
• Hour counter
• Manual condensate drain
• 2 x Filling hose c/w filling valve
• Pressure maintaining and non return valve
• All pistons c/w steel piston rings
• Low pressure oil pump
• Oil filter with bypass
• Oil- / Water separators after 2nd and 3rd
stage
• Safety valves after each stage
• 3 x concentric suction/pressure valves
• Filling pressure to your choice (200 or 300
bar)
• Connections to your choice
(DIN 200 bar or 300 bar, CGA 200 bar or
300 bar and INT)
• Breathing air purification in accordance to EN
12021
• 1.7 l filter system (Filter capacity 750 m³ at
+20°C)
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LW 300 D MC
Version: 19.06.2017
D E S C R I P T I O N
Technical Data
Technical Data LW 300 D MC
Capacity [l/min]: 300
Max. Operating Pressure [bar]: 350
RPM [min-1]: 1300
Number of Pressure Stages: 3
Cylinder Bore 1st Stage [mm]: Ø 95
Cylinder Bore 2nd Stage [mm]: Ø 36
Cylinder Bore 3rd Stage [mm]: Ø 16
Medium: Compressed Air / Breathing Air
Intake Pressure: atmospheric
Oil Pressure [bar]: +2.5 (±0,5)
Oil Capacity [l]: 1,8
Intake Temperature [°C]: 0 < +45
Ambient Temperature [°C]: +5 < +45
Drive Power [kW]: 7,4
Motor: Yanmar - Diesel Engine
RPM Motor [min-1]: 3600
Start: Electric start / Hand start
Noise level from a distance of 1 m [dB(A)]: 95,9
Dimensions W x D x H [mm]: 1410 x 510 x 826
Weight [kg]: 195
Content Volume Filter housing [l]: 0,54
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LW 300 D MC
Version: 19.06.2017
Unit Assembly
D E S C R I P T I O N
No. Designation
1 Filling Hose
2 Carrying Handle
3 Final Pressure Gauge
4 Filter Housing
5 Filling Valve
3
5
4
1
2
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LW 300 D MC
Version: 19.06.2017
Start Device
D E S C R I P T I O N
No. Designation
1 Hand Start
2 E-Starter (Key Switch)
Fig. - Hand Start LW 300 D MC
Fig. - Key Switch LW 300 D MC
2 1 2
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LW 300 D MC
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D E S C R I P T IO N
Flow Chart
1. Air Intake Filter
2. 1st Pressure Stage
3. Safety Valve 1st Stage
4. Cooling Pipe 1st Stage
5. 2nd Pressure Stage
6. Safety Valve 2nd Stage
7. Cooling Pipe 2nd Stage
8. Condensate Release Hose
9. Condensate Release Valve
10. Oil-/Water Separator
11. 3rd Pressure Stage
12. Endpressure-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. Distributor Block
20. Hose Pressure Gauge
21. Pressure Gauge (Filling Pressure)
22. Filling Hose
23. Unit Filling Valve "Cross Design"
24. Plug 1/4"
25. Filling Valve
26. Filling Connector
27. Vent Valve
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S A F E T Y P R E C A U T I O N S
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LW 300 D MC
Version: 19.06.2017
Intended Use
Only use the unit in perfect condition for its intended purpose, safety and intended use and observe
the operating instructions! In particular disorders that may affect safety have to be eliminated
immediately!
Use the unit exclusively for the determined medium (see "Technical Data"). Any other use that is not
specified is not authorized. The manufacturer/supplier shall not be liable for any damages resulting
from such use. Such risk lies entirely with the user. Authorization for use is also under the condition
that the 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 and briefed for the use of the compressor.
Qualified personnel
Qualified personnel are persons who are entitled to repair, service, modify and maintain the system.
S A F E T Y P R E C A U T I O N S
Warning
Only trained personnel are permitted to work on the unit!
!
Warning
Work on the electrical equipment on / with the machine / unit may only be carried out by
qualified electricians.
!
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LW 300 D MC
Version: 19.06.2017
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!
Warning
Hot surfaces!
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LW 300 D MC
Version: 19.06.2017
S A F E T Y P R E C A U T I O N S
General Safety Precautions
• Read the Operating Instructions of this product carefully prior to use.
• Strictly follow the instructions. The user must fully understand and strictly observe the
instructions. Use the product only for the purposes specified in the intended use section of this
document.
• Do not dispose the operating instructions. Ensure that they are retained and appropriately used
by the product user.
• Only trained 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 incomplete products. Do not modify the product.
• Inform L&W in the event of any product or component fault or failure.
• The quality of the air supply must meet EN 12021 specifications for breathing air.
• Do not use the product in areas prone to explosion or in the presence of flammable gases. The
product is not designed for these applications. An explosion might be the result if certain
conditions apply.
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LW 300 D MC
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S A F E T Y P R E C A U T I O N S
Unit Customised Safety Notices
Organisational measures
• In addition to the instruction manual, observe and comply with universally valid legal and other
obligatory regulations regarding accident prevention and environment protection.
• In addition to the instruction manual, provide supplementary instructions for supervision and
monitoring duties taking into consideration exceptional factors e.g. with regard to organisation
of work, production, personnel employed.
• Supervise personnel’s work in accordance with the instruction manual, taking into account safety
and danger factors.
• Observe all safety and danger notices on the compressor and check readability and
completeness.
Safety instructions operation
• Take measures to ensure 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
responsible department / person immediately if anything is not as is should be (including
operation performance). Shut down the machine immediately if necessary and lock it.
• In case of malfunction, stop the compressor immediately and lock it. Repair malfunctions
immediately.
• If there is a failure in the electric energy supply, shut the machine / unit down immediately.
• Ensure safe and environmentally friendly disposal of consumables and old parts.
• The stipulated hearing protectors must be worn.
• Soundproofing equipment on the compressor has to be activated in safety function during
operation.
• When handling with fats, oils and other chemical agents, observe the note for the productrelated safety.
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LW 300 D MC
Version: 19.06.2017
S A F E T Y P R E C A U T I O N S
Maintenance Instructions
• Hoses have to be checked by the operator (pressure and visual inspection) at reasonable
intervals, even if no safety-related defects have been detected.
• Immediately repair any damage. Escaping compressed air can cause injury.
• Depressurise system and pressure lines before beginning repair work.
• Pressurised air lines must be laid and mounted by qualified personnel. Connections must not be
mixed up. Fittings, length and quality of the piping must correspond to requirements.
• Adjustment, maintenance and inspection activities and keep appointments, including
information on replacement parts / equipment, prescribed in the operating instructions have to
be respected.
• If the machine / equipment is completely off during maintenance and repair work, it must be
protected against unexpected restart. Turn off main control device and remove the key and/or
display 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 pipes for leaks, loose connections, chafing and damage. Immediately
eliminate any faults.
• Always retighten any screw connections loosened for maintenance or repair work.
• If it is necessary to remove safety devices for maintenance and repair work, these must be
replaced and checked immediately after completion of the maintenance or repair work.
• The electrical equipment of the compressor must be regularly checked. Defects, such as loose
screw connections or burnt wires, must be immediately rectified by electrically skilled personnel.
• Only personnel with particular knowledge and experience with pneumatics may carry out work
on pneumatic equipment.
• Only personnel with particular knowledge and experience in gas equipment may carry out work
on gas equipment.
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LW 300 D MC
Version: 19.06.2017
S A F E T Y P R E C A U T I O N S
Transportation Instructions
• Parts which need to be dismantled for transport purposes must be carefully replaced and secured
before taking into operation.
• The transport may only be carried out by trained personnel.
• For transportation, only use lifting devices and equipment with sufficient lifting power.
• 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
carried out by the manufacturer or by authorised expert personnel. No guarantees whatsoever
are valid for damage caused or favoured by the non-consideration of these directions for use.
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I N S T A L L A T I O N
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LW 300 D MC
Version: 19.06.2017
I N S T A L L A T I O N
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.
No operation in explosion-hazard areas.
The unit is not approved for operation in areas prone to explosion.
!
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 be free from noxious gas e.g. smoke, solvent vapours, exhaust fumes etc.
• Observe the specified operating temperature (see "Technical Data")!
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LW 300 D MC
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I N S T A L L A T I O N
Dimensions
Fig. - Dimensions
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LW 300 D MC
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I N S T A L L A T I O N
Minimum Distances
• Make sure that the compressor 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
Note
Minimum distances must be adhered!
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500
500
500
1500
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O P E R A T I O N
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LW 300 D MC
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O P E RA T I O N
Important Operation Instructions
Note
Ensure that all persons handling the compressor are familiar with function and operation
of the unit.
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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.
!
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LW 300 D MC
Version: 19.06.2017
F I R S T C O M M I S S I O N IN G
Prior to first Commissioning, observe the following:
Necessary steps are described in the following.
• Ensure that cooling air can flow freely.
• Position compressor in direction of wind so that exhaust fumes are blown away from the unit.
• Take protection measures to avoid damages or injury by exhaust gases/exhaust pipe.
• Check fuel capacity.
• Check drive motor oil level.
• Check compressor oil level by using the oil dipstick (see page A-25).
• Check all connections and retighten if necessary.
• Check if the filter cartridge is in place (see "Service and Maintenance").
• Check the V-belt tension.
• Read carefully the handbook of the petrol engine.
• Check if all filling valves are closed. Open one filling valve and hold tight manually!
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LW 300 D MC
Version: 19.06.2017
F I R S T C O M M I S S I O N IN G
Start the Compressor (LW 300 D MC)
1. Open condensate valves
2. Open fuel tab (Fig.3)
3. Open filling valve
4. Slide throttle lever (Fig.2)
5. Start the compressor with the key switch or hand start
(Fig.1).
If the compressor should be started by the hand start, you
have to move the decompression lever before.
6. Close condensate valves
7. Run the compressor for about 2 minutes
8. Close the open filling valve carefully
9. 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 with the
key switch (see chapter "Remedying faults").
10. Stop the compressor with the key switch
11. Close fuel tap
12. Check the compressor unit for leaks (see "Service and
Maintenance")
13. Now check the condensate drain valves:
- If correct, air escapes of the condensate drain
14. Open all condensate valves and the filling valves carefully to
vent
15. After venting close all condensate valves and the filling
valves
Fig. 1 - Hand Start & E-Starter
Fig. 2 - Throttle lever
Fig. 3 - Fuel tap
Fig. 4 - Decompression Lever
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LW 300 D MC
Version: 19.06.2017
F I R S T C O M M I S S I O N IN G
Check Oil Level
Check the oil level before each operation of the unit by using
the oil dipstick.
Oil level check as follows:
• Unscrew oil dipstick
• Wipe off oil residues
• Insert the oil dipstick back into its tube and screw it until
stop
• Unscrew oil dipstick again
The oil level should be between the notch and the end of the
oil dipstick. If there is no oil between the notch and the end
of the oil dipstick, refill immediately new full synthetic
compressor oil.
Warning
Check oil level daily. Never start the compressor with a too low oil level. Risk of accidental
loss, destruction or deterioration.
!
Check V-belt tension
The V-belts could lose tension during transportation. Please check the V-belt tension before starting
the compressor.
Tension V-belts
To tighten V-belt tension, loosen 4 mounting nuts of the drive motor. Use the tensioning screw to
move the drive motor until the V-belt tension is sufficient (V-belt pulley and flywheel must be
aligned). Then, tighten mounting nuts and check V-belt tension.
We recommend using a V-belt tension gauge.
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 Type Initial Installation Operation after running in
Drive Motor LW 300 D MC 500N 400N
Settings
Fig. - Oil dipstick
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D A I L Y C O M M I S S I O N I N G
Prior to Daily Operation, observe the following:
• Ensure cooling air can flow freely.
• Position compressor in direction of wind so that exhaust fumes are blown away from the unit.
• Take protection measures to avoid damages or injury by exhaust gases/exhaust pipe.
• Check compressor oil level by using the oil dipstick.
• Check if filter cartridge is in place / observe filter cartridge life!
• Check fuel capacity.
• Check drive motor oil level.
• Ensure toxic-free, pure intake air.
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LW 300 D MC
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O P E RA T I O N
Filling Procedure
Caution! Only fill 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.
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Note
The unit must be stopped manually when final pressure is reached. No serial auto shut
down. The unit must also be started manually.
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1. Close all filling valves.
2. Connect the closed compressed air cylinders.
3. Open cylinder valves.
4. Start the compressor with hand start or key switch.
5. When filling pressure gauge increases, open filling valves slowly.
6. Fill the compressed air cylinders to the desired pressure; subsequently close the filling valves
slowly.
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
Vent condensate drain valves every 15-30 minutes manually.
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O P E RA T I O N
Switch off the Compressor
The compressor unit is not 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 every time by using the key switch or close
the fuel tap.
Note
After switching off, open condensate drain valves manually to vent the unit.
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