Air Compressor WP400

S a u e r C o m p r e s s o r
Type: WP 400 Operating Instructions

High-pressure Compressor 2 Stages water-cooled
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VO001AK1.fm
Edited by: ZINDEL Technical Documentation, www.zindel.de

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Sauer compressor type approvals
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Note! On this page only a few examples are shown. Further type approvals are available on request.
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Genuine Sauer spare parts certied safety
EC SP
EN IM
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Inhaltsverzeichnis
1. 1.1 1.2 1.3 1.4 1.5 1.6 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3. 3.1 3.2 3.3 3.4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 At the outset . . . . . . . . . . . . . . . . . . . . . . . . . . 8 General information . . . . . . . . . . . . . . . . . . . . . 8 Warranty and Liability . . . . . . . . . . . . . . . . . . . 8 Type approval and genuine Sauer spare parts 9 Customer service of J.P. SAUER & SOHN . . 10 Organisation of these instructions . . . . . . . . . 11 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specified conditions of use . . . . . . . . . . . . . . Prohibition of unauthorized conversion . . . . . Safety information . . . . . . . . . . . . . . . . . . . . . Safety markings on the machine . . . . . . . . . . Safety devices . . . . . . . . . . . . . . . . . . . . . . . . Noise protection . . . . . . . . . . . . . . . . . . . . . . Waste disposal . . . . . . . . . . . . . . . . . . . . . . . Staff requirements . . . . . . . . . . . . . . . . . . . . . Personal protection gear . . . . . . . . . . . . . . . . Design and Function . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode of Operation. . . . . . . . . . . . . . . . . . . . . Indicators on the Sauer Compressor. . . . . . . Indicators and controls of the compressor control system . . . . . . . . . . . . . . . . . . . . . . . . 12 12 12 12 13 14 14 14 15 15 16 16 20 22 23
4. 4.1 4.2
Technical Specifications . . . . . . . . . . . . . . 24 Specification data . . . . . . . . . . . . . . . . . . . . . 24 Compressed air system plan and cooling water plan . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Transport and Installation . . . . . . . . . . . . . Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage before installation. . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the compressor . . . . . . . . . . . . .
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5. 5.1 5.2 5.3 5.4
28 28 29 29 32
5
5.5 5.6
Filling in oil . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Checks after installation and before the first start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe operation. . . . . . . . . . . . . . . . . . . . . . . . Operating modes. . . . . . . . . . . . . . . . . . . . . . First Commissioning . . . . . . . . . . . . . . . . . . . Routine operation . . . . . . . . . . . . . . . . . . . . . 38 38 39 39 40
6. 6.1 6.2 6.3 6.4 7. 8. 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 8.15 8.16 8.17 8.18 9. 9.1 9.2 9.3
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Trouble-shooting. . . . . . . . . . . . . . . . . . . . . 42 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . Maintenance service by J.P. SAUER & SOHN Maintenance safety . . . . . . . . . . . . . . . . . . . . Maintenance schedule . . . . . . . . . . . . . . . . . Table of tightening torques . . . . . . . . . . . . . . Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking screwed connections. . . . . . . . . . . Air filter cartridge replacement . . . . . . . . . . . Checking valves . . . . . . . . . . . . . . . . . . . . . . Checking the piston rings . . . . . . . . . . . . . . . Replacing gudgeon pins/gudgeon pin bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing valves . . . . . . . . . . . . . . . . . . . . . . Checking pistons and cylinders. . . . . . . . . . . Checking the drive bearings . . . . . . . . . . . . . Checking the coupling. . . . . . . . . . . . . . . . . . Cleaning particle trap . . . . . . . . . . . . . . . . . . Checking zinc protection . . . . . . . . . . . . . . . . Burst disc . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking cooling water pump (optional) . . . . Placing out of Service. . . . . . . . . . . . . . . . . Safety when placing out of service and dismounting. . . . . . . . . . . . . . . . . . . . . . . . . . Shutting down the compressor temporarily. . Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . .
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10. 10.1 10.2 11. 12.
Lubricant Table . . . . . . . . . . . . . . . . . . . . . . 66 Lubricating oils . . . . . . . . . . . . . . . . . . . . . . . 67 Slushing oils . . . . . . . . . . . . . . . . . . . . . . . . . 68 Spare Parts and Accessories . . . . . . . . . . . 69 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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1.
1.1
General
At the outset
The following main specications of your Sauer compressor are found on the type label afxed to the crankcase: Compressor type Factory number Year of construction Please enter this data in Chapter 11, "Spare Parts and Accessories" as soon as possible.
1.2
General information
We presuppose that only authorised persons will operate and service the Sauer compressor. These persons must have read and understood the operating instructions. These instructions shall always be kept available at the site of operation. The copyright for these instructions remains with J.P. SAUER & SOHN. These instructions, or parts thereof, shall not be copied, distributed or made available to third parties. Contravention will be prosecuted.
Conditions
Availability Copyright
1.3
Warranty and Liability

We exonerate the contractually agreed warranty claims and liability claims, if they can be attributed to at least one of the following: use of the machine for non-intended purposes; use of spare parts that are not genuine Sauer spare parts; operation of the machine with faulty or not properly installed safety devices and protection devices; disregard of the operating instructions; unauthorised modifications to the machine or its control system; inadequate monitoring of machine parts subject to wear; improperly carried out repairs; force majeure.
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General
1.4 Type approval and genuine Sauer spare parts
The type approval for the Sauer compressor is valid under the condition that parts and components specied and qualied by J.P. SAUER & SOHN are used. The type approval is made by the Classication Society and the Declaration of EC-Conformity or EC Manufacturer's Declaration. Disregard of the specications may cause the type approval to expire. Only the use of genuine Sauer spare parts ensures compliance with these specications and thus the perfect and safe operation of the Sauer compressor. If genuine Sauer spare parts are not used we reserve the right of exclusion of liability for personal injury and material damage. genuine Sauer spare parts are supplied with a Certicate of Conformity and a Certicate of Authenticity. A specimen of this document is shown before the table of contents of these instructions. If spare parts are received without this certicate, there is a risk that these are not genuine Sauer spare parts. In such case please contact our customer service.
Do not use parts from the "grey market"
but only genuine Sauer spare parts with certicate!

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1.5
Customer service of J.P. SAUER & SOHN

In case of technical questions pertaining to maintenance or repair please contact our customer service: SAUER & SOHN Maschinenbau GmbH Customer Service P.O. Box 92 13 D-24157 Kiel Telephone (international): Technical information +49 431 39 40 -87 Spare parts ordering +49 431 39 40 -86/886 Telefax (international): +49 431 39 40 -89 Emergency service (international): +49 172 4 14 63 94 E-Mail: service@sauersohn.de Web: www.sauersohn.de Note! In case of queries regarding your Sauer compressor please indicate the compressor-type and the factory number (see Chapter 11. "Spare parts and Accessories or type label on the crankcase).
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General
1.6
Lists
Organisation of these instructions

General lists are denoted by horizontal bars. Example: The cooling system consists of fan wheel, fan wheel cage, and cooler assembly. Individual instructions or multiple instructions, where the sequence is of no importance are normally given as bulleted lists. Example: Check oil level. Instructions to be carried out in a certain sequence are numbered. Example: 1. Turn the main switch ON. 2. Choose the operating mode. 3. Turn the control ON.
Actions
Results
Results of actions carried out are denoted by a check mark. Example: The control light lights up. Safety instructions are distinguished by pictographs and signal words. Safety instructions are described in Chapter 2. "Safety" in detail.
Safety instructions
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2.
2.1
Safety
Specied conditions of use
This Sauer compressor must be used for the compressing of air only. The Sauer compressor must not be used at ambient temperatures of below +5 C. Any other use is not as specied and requires the explicit consent in writing by J.P. SAUER & SOHN. Observance of these operating instructions, the installation requirements detailed in the instructions, and the keeping of maintenance rates are part of the specied conditions of use as well.
2.2
Prohibition of unauthorized conversion

Unauthorized conversion and modication of the Sauer compressor is not permitted, since they could endanger humans and may lead to machine damage. Contact J.P. SAUER & SOHN when planning conversions or modications to obtain a written permission.
2.3
Safety information
The safety information in these instructions is divided in two classes. The following pictographs and signal words are used: Danger! High risk. Disregard of this safety information may cause personal injury and substantial material damage. Note! Average risk. Disregard of this safety information may cause damage to the machine.
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Safety
2.4 Safety markings on the machine
Caution! Safety markings afxed to the machine must not be altered or removed. Replace damaged or lost safety markings immediately, true to the original. Sauer compressor models with an EC Manufacturer's Declaration or EC Declaration of Conformity are marked with the following safety markings:
Safety marking Meaning Danger! High voltage! Safety marking Meaning Read instructions!
Compressor starts automatically without warning!
Wear hearing protection!
Hot surface!
Rotational direction of Crankshaft
Location of safety markings (top view)
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2.5
Safety devices
Danger! Safety devices must not be adjusted, disabled or removed. The safety devices must be periodically tested and checked. Safety valves must be installed sealed and replaced, adjusted and sealed by authorised personnel only.
Safety valves
Every pressure compartment of a stage of the Sauer compressor is equipped with a safety valve, which will blow off when the blowing-off pressure is reached. Safety valves are installed at these locations: 1st compression stage: in the back cooler cover of the 2nd intercooler; 2nd compression stage: in the final separator behind the stage; The Sauer compressor is tted with a temperature switch for monitoring the compressor cooling. This will turn the compressor off if the temperature of the compressed air exceeds the limit.
Temperature switch
2.6
Noise protection
Sound pressure level details are found in the Technical Specications (see chapter 4). If necessary the Sauer compressor can be equipped with a noise protection hood, which is available as optional accessory from J.P. SAUER & SOHN. Danger! When the compressor is operated without noise protection hood, hearing protection should be worn near the compressor.
2.7
Waste disposal
Note! Under the laws and regulations in force, the following materials arising from the operation of the compressor need to be disposed of ecologically safe: condensate (oil and water saturated) arising from recooling in the compression process; used oil and grease and rags soiled by it; cleaning material and rags soiled by it.
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Safety
2.8 Staff requirements
Only authorised persons are permitted to service the Sauer Compressor! Before commencing work they must have read and understand the operating manual and must be familiar with the safety devices and safety regulations. In addition to the instructions in this operating manual and manufacturer documentation, accepted technical standards must be observed as well as all regional laws, standards and regulations such as the Equipment and Product Safety Act (Gerte- und Produktsicherheitsgesetz), Ordinance on Industrial Safety and Health (Betriebssicherheitsverordnung), Regulations for accident prevention pertaining to compressors, VDE regulations and Regulations on environmental protection. In addition, where appropriate, regulations of the responsible classication society as well as operational regulations must be observed. Persons authorised to operate the compressor are the attending specialists introduced to the job and trained by the operator. Persons authorised to service the compressor are the trained specialists of the operator and of the manufacturer.
2.9
Personal protection gear

The operator has to provide the personal protection gear (hearing protection, safety boots, etc.) for the personnel carrying out any work on the Sauer compressor.
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3.
3.1
Design and Function

Overview
5 13 1 6 7 13 5 3 2
1 20 19
17 4 16
9 18 15 14 12 11 10
Item 1 2 3 4 5 6 7 Cylinder 1st stage Cylinder 2nd stage
Name
Safety valve 1st stage (not visible) Safety valve 2nd stage Air lter
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Oil ller Cooling water outlet (not visible)
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Design and Function

Item 8 9 10 11 12 13 14 15 16 17 18 19 20 Compressed air outlet Drain valve 1st stage (not visible) Drain valve of 2nd stage: Compressed air temperature switch Burst disc Zinc protection 1st stage Zinc protection 2nd stage Oil dip stick Cooling water inlet Particle trap Oil drain valve Oil pressure switch Cooling water stop valve Name
Note! Details of parts and spare parts are found in the spare parts catalogue.
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Longitudinal section
3 4
2 1
Item 1 2 3 4 5 Crankcase Crankshaft Connecting rod 1st stage Connecting rod 2nd stage Lubricating oil supply
Name
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Design and Function

Cross section
5 6 2
8 5 9 6 1 4 2 3
Item 1 2 3 4 5 6 7 8 9
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Name 1st stage: cylinder with head and valve Piston 1st stage 2nd stage: cylinder with head and valve Piston 2nd stage Valve cover 1st stage Plate valve Air lines Valve cover 2nd stage Lamellar valve
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3.2
Mode of Operation
The Sauer compressor is a two stage water-cooled air compressor with three cylinders. The 1st stage and the 2nd stage are respectively tted with two and one single acting trunk pistons each. The connecting rods of all the pistons sit on a common crankpin of the double bearing crankshaft. The Sauer compressor is driven by an electric motor directly anged to the transmission bell housing of the crankcase, where the power is transmitted by means of a exible coupling. The Sauer compressor with electric drive is electrically controlled and monitored by a compressor control system. This control system must comply with the legal provisions. Optionally, J.P. SAUER & SOHN supply a suitable compressor control system. The compressor takes in ambient air through a sheet lter with tube silencer and compresses it in the two cylinders of the 1st stage. The air is led to the cylinder of the 2nd stage and compressed to the ultimate pressure. The air is after-cooled after each cylinder. A replaceable wet liner with double O-ring sealing is tted in each cylinder. The cylinders in W-shape conguration are equipped with platevalves or lamellar valves, which have a long service life and are easy to service.
Compressor
Drive
Compressor control
Compression
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Design and Function

Cooling
The compressor is cooled with fresh water. Sea water cooling is possible optionally. The air compressed in the 1st and 2nd stage is recooled in straight cooler pipes, which are expanded into the cylinders. The cooling water ows directly past the cooler pipes and the replaceable liners in the cylinder. The cooling water cavities are protected against corrosion with zinc electrodes. Optionally, the compressor can be tted with an inbuilt cooling water pump. This pump is not self-priming and is driven by an electric motor. When the compressor is not tted with a cooling water pump, the cooling water supply is cut off when the compressor is shutdown using a solenoid valve at the cooling water inlet. The functioning of the compressor cooling is monitored by the compressed air-temperature control. The compressor is stopped immediately if the compressed air temperature exceeds the upper limit.
Condensate separation
Condensate accumulating in the 1st stage is collected in collecting tanks of the back cooler covers of 1st stage. The 2nd stage has a separate condensate separator for the oil and water containing condensate arising from compression and recooling. The condensate is drained through drain lines. Drain lines are tted with solenoid valves. These must be open when the Sauer compressor is unpressurized. The drain valves should close a few seconds after starting and the Sauer compressor should accelerate against pressure. The solenoid valves should drain the machine at predetermined intervals during operation. The solenoids valves are controlled by the compressor control system. An oil gear pump driven by the crankshaft sucks the lubrication oil from the crankcase and supplies it to the friction bearings of the connecting rods. Crankshaft bearing, gudgeon pin bearing and piston are lubricated by the splash oil present in the crankcase. The oil pressure is monitored with an oil pressure switch. The compressor control system stops the compressor immediately if the oil pressure falls to the lower limit.
Condensate draining/Pressure relief
Lubrication/oil pressure
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3.3
Indicators on the Sauer Compressor
6 3 4 1
Item 1
Name Pressure gauge 1st stage Pressure gauge 2nd stage Thermometer 1st stage (not visible) Thermometer 2nd stage (not visible) Oil pressure gauge Cooling water thermometer (not visible)
Indication Compressed air pressure after the 1st stage Compressed air pressure after the 2nd stage Compressed air temperature after the 1st stage Compressed air temperature after the 2nd stage Oil pressure of the oil pump Temperature of the cooling water at the cooling water outlet
5 6
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Design and Function

3.4 Indicators and controls of the compressor control system
Note! If the compressor control system is supplied by J.P. SAUER & SOHN take notice of the documentation supplied. At the front of the compressor control the following indicators and control elements are found:
Indicator/ Control element Signal lamp Operation Fault indicator lamp Oil pressure Fault indicator lamp Air temperature Fault indicator lamp Overcurrent Working hour meter Operating mode selector Description Lights when the compressor is running. Lights if the compressor has been shut off because of low oil pressure. Lights if the compressor has been shut off because of excessive outlet air temperature. Lights if the compressor has been shut off because of excess motor current. Indicates the working hours of the compressor. Selector position Manual: Starting the compressor manually. The compressor starts up and continues to run until it is manually turned off. Selector position 0: Turns compressor manually OFF. Any pending fault messages are reset. Selector position Auto: The compressor is started and stopped by the opening and closing of an external switching contact (e.g. pressure switch of the compressed air receiver). Interrupts the power supply from the compressor control to the compressor. A main switch should be installed if required by local laws and regulations.
Main switch
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4.
4.1
Technical Specications
Specication data
Description Data WP 400
Compressor type
Number of cylinders Number of compression stages Cylinder diameter 1st stage Cylinder diameter 2nd stage Piston stroke Maximum speed Direction of rotation (as seen on ywheel)
3 2 195 mm 110 mm 90 mm 1800 rpm clockwise
Maximum operating pressure Set pressures of safety valves: 1st stage 2nd stage
30 bar
8 bar 5 % higher than the ultimate pressure
Oil lling quantity Oil quantity between dip stick markings Oil type
13.5 l 5l see chapter 10. Lubricant table
Oil pressure switch: Maximum switching current Setting Switch function 6A / 220 V opens at 1 bar falling approx. 15 seconds starting bypass change-over contact
Drain valves: Pick-up and holding power Setting 18 VA / 14 W normally open; starting relief: approx. 15 seconds; intermediate draining: 15 seconds every 15 minutes.
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Technical Specifications
Description Ultimate pressure switch (optional): Maximum switching current Setting Switch function 6A / 220 V to customer's specications change-over contact Data
Temperature switch: Maximum switching current Setting Switch function 16A / 440 V opens at 80 C rising change-over contact
Max. allowable primary pressure at cooling water inlet: Bursting pressure of the burst disc in the cooling water system: Temperature of cooling water at the outlet. Cooling water stop valve
5 bar in absence of cooling water pump 2.5 bar with cooling water pump > 6 bar optimal 30 C45 C, max. 50 C Holding capacity: 36 W Setting: Closed when compressor is shutdown; Valve is closed dead
Cooling water pump (optional) Electrical connection Setting 440 V/60 Hz 1.1 kW or 400 V/50 Hz 1 kW non-self-priming, should start and stop in synchronisation with the compressor
Sound pressure level (in free sound eld at 1 m distance)
maximum 92 dB(A)
Weight and dimensions
see installations plan
Note! Please refer to the order-specic documentation for data specic to your compressor, such as ultimate pressure, speed, power requirements, etc.
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4.2
Compressed air system plan and cooling water plan

21 5 4 3 4 5 22 2 5 4 17 3 1
19 14 6 17 20 11 3 12 13
10
8 10
9 18
15 16
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Drive motor Safety valve Compressor stage Intercooler and aftercooler
Name
Compressed air pressure gauge Oil pressure switch Condensate separator Drain Solenoid drain valve Air lter/silencer Oil pump
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Pressure relief valve Oil lter
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Technical Specifications
Item 14 15 16 17 18 19 20 21 22 Oil pressure gauge Non-return valve Ultimate pressure switch Compressed air thermometer Compressed air temperature switch Cooling water hand valve Cooling water pump (optional) Cooling water thermometer Cooling water stop valve Name
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5.
5.1
Transport and Installation

Transport
The machine is packed suitable for shipping. Immediately on receipt of the Sauer compressor it should be checked for completeness and damage. The transport company and J.P. SAUER & SOHN must be immediately notied of any damage to the packing or the machine. The Sauer compressor must be transported by a forklift truck or hoisted by crane. Danger! Suspended load when transported. The forklift truck/crane must have sufcient load bearing capacity. Ensure that no persons stay within the danger area of the suspended load and the forklift truck/crane. Sling the unpacked compressor at the lifting eyes on the crankcase and the motor (see illustration). Lift, move, and set down carefully.
Shipping
Transportation
Lifting eyes
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5.2 Storage before installation
If the Sauer compressor has to be stored before installation, do not unpack and store at the following conditions: temperature: +5 to +40 C; relative humidity 30 95%, not condensating; dry, under a roof and protected against dew; protected against soiling; protected against vibrations and shocks. Note! The standard factory conservation is sufcient for a maximum storage period of 12 months.
5.3
Installation
Note! In case of doubts regarding the suitability of the installation room and place or in case of queries regarding compressor cooling contact J.P. SAUER & SOHN in time. There you will also get help with the design of a ventilating system, if it is required at the place of installation. Follow the installation instructions and the following conditions during installation.
Installation conditions
The place of installation must be dry and free of dust. The place of installation must be ventilated in such way that the heat generated during operation is dissipated. Room temperature while the Sauer compressor is running: +5 +55 C (deviating temperatures only if confirmed in writing by J.P. SAUER & SOHN)
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Note! The air temperature at the installation place of the compressor must not exceed +55 C. Room conditions and the heat generated by the compressor and other machines installed in the room must be taken into consideration. If necessary, install a ventilation or exhaust system at the place of installation. Install the fresh air feed in such way that the fresh air stream is not directed straight at the compressor. Otherwise there is a risk of condensation of water inside the machine and subsequent damage.
This way is correct!
Do not install fresh air feed this way!

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At a room temperature of below +5 C the room needs to be

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heated or the Sauer compressor must be equipped with a heating system. Choose the location such that the Sauer compressor is accessible and has sufficient clearance to walls and other machinery (see installation documents). Note! The Sauer-Compressor is cooled with fresh water. Sea water cooling is also possible optionally; however, depending upon the temperature and composition the sea water can have corrosive effect. The cooling water quantity must be so adjusted that the maximum cooling water outlet temperatures specied in section 4.1 are not exceeded. By aligning the cooling water inlet and outlet, the cooling water cavities are automatically deaerated. Note!
J.P. SAUER & SOHN would be glad to advise you on the installation of the compressors.
Foundation
Note! The resilient-mount bedding delivered as standard has a resonant frequency of approx. 10 Hz. The excitation of the intended compressor-foundation by vibrations from the machines installed in the vicinity must not be in the 10 Hz range. Otherwise there is a risk that the standard delivery resilient-mount bedding is destroyed by sympathetic vibration. 1. Check early enough if there are foundation vibrations in the 10 Hz range. 2. If in doubt, check with J.P. SAUER & SOHN to see if a modied resilient-mount bedding can be used.
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5.4
Connecting the compressor

Danger! The compressor should only be connected by qualied technicians. Any work on the electrical installation must be carried out by qualied electricians only.
Pipelines
The compressed air outlet, coiling water inlet and outlet as well as the and the drain outlets of the Sauer compressor must be connected to the stationary pipelines by hose lines.
Hose lines
Danger! Compressed air escapes from the drain outlets when the compressor starts and when the condensate is drained. Do not operate compressor without the hose lines connected.
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Hose lines have to be installed free of tension and untwisted.
Not this way!
Draining
Note! Condensate that is formed contains oil. It may only be disposed of in compliance with applicable legal provisions. J.P. SAUER & SOHN can supply condensate collecting pots for separating air from the condensate, as well as condensate treatment units for separating the oil from the condensate. Note! We recommend connecting the compressor's drain separately. When the drain lines of several compressors are to be connected to a common pipe, observe the following: Choose a sufficient nominal diameter for the common drain line. Connect drain lines of the individual compressors at an acute angle to the common drain line, so no pressure can build up in the drain line of a stopped compressor.
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Not this way!
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Connections
The illustration below shows the connections and ttings for the operation of the standard version Sauer compressor.
1 2
7 6 5
Note! For technical specications of the individual items please refer to Chapter 4 All toggle switches are factory set. As an option, the subsystems can be prewired in a terminal box.
Item 1 2 3 4 5 6 7
Name Non-return valve Ultimate pressure switch Drain Compressed air temperature switch Cooling water pump (optional) Oil pressure switch Cooling water stop valve
Type Plate valve Toggle switch Solenoid valve Toggle switch Centrifugal pump non-self-priming Toggle switch Solenoid valve
Function Prevent air back-ow Stops/starts the compressor Starting relief and draining Stops compressor in case of excess temperature Pumps cooling water Stops compressor when oil level is low Cuts off cooling water ow when machine is shutdown
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5.5
Filling in oil
The Sauer compressor is supplied without oil. Danger! Oil must be lled into the compressor's crankcase before initial operation! Use lubricating oil (see chapter 10. Lubricant table). Note lling amount (see chapter 4. Technical Specications). Oil ller plug
Dipstick
1. Unscrew oil ller plug (red). 2. Fill in oil and check level with the dipstick. Note! Fill only to the upper marking on the dipstick. Otherwise the oil consumption of the compressor will increase.
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3. Put dipstick back in and replace the oil ller plug.
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5.6 Checks after installation and before the rst start
Does electrical connection correspond to the type label data? Are all connections between compressor and the surrounding compressed air unit correctly installed? Pay special attention to the compressed air outlet. Are drain lines properly connected? (See Section "Draining.) Are cooling water lines opened? Is oil filled in the crankcase? Have all tools and foreign objects been removed from the compressor? Has the air filter been turned to operating position from transport position (see overprint on the filter housing)? Is the entire unit clean?
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6.
6.1
Operation
Safe operation
Danger! Only authorized persons are permitted to commission and operate the Sauer compressor! Danger! Turn on and start the compressor only if it has been checked for proper working condition; all tools and foreign objects are removed from the machine. Caution! Turn compressor immediately OFF when persons or objects are endangered. Start compressor only when the danger is over. Danger! In Automatic mode the compressor starts automatically without warning! Danger! Risk of burns by hot surfaces of the compressor when it is running. Wear gloves. Danger! Risk of hearing damage due to the sound pressure level when the compressor is running! Wear hearing protection near the compressor. Note! Turn compressor OFF in the case of faults, abnormal ratings or irregularities. Refer to chapter 7. Trouble Shooting to remove cause.
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6.2 Operating modes
After the power supply to the Sauer compressor is turned ON, it can be started with the operating mode selector in one of the following two operating modes: Operating mode Manual: The compressor starts and continues to run until it is stopped or turned OFF with either the operating mode selector or the main switch. Operating mode Automatic: Starting and stopping of the compressor is controlled by external devices (e.g. by the pressure switch of the compressed air receiver). When the Sauer compressor starts, it starts loadless with opened relief valves. Several seconds after starting the valves close and the compressor runs up against pressure.
6.3
First Commissioning
At rst, let the Sauer compressor run only for a few seconds to check the direction of rotation. 1. Turn the power supply ON. 2. Set the operating mode selector to Manual to start the compressor in Manual mode. 3. Immediately check the compressor's direction of rotation. It must rotate in the direction indicated by the arrow on the crankcase. 4. Set the operating mode selector to 0 to stop the compressor. 5. Turn the power supply OFF. 6. If the direction of rotation is incorrect, have polarity of the electric motor changed by a qualied electrician. 7. Checking the direction of rotation of the optional cooling water pump: Switch the pump motor ON for a short duration. The motor must not reach its operating speed during this. The direction of rotation must be the same as the one indicated by the arrow on the pump. Otherwise, see Point 6. Pump and suction pipe must be lled with cooling water. Danger! The cooling water pump must never run dry.
Checking the direction of rotation
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Danger! No oil pressure if the direction of rotation of the compressor is wrong. Risk of subsequent damage.
Test run
1. Turn the power supply ON. 2. Set the operating mode selector to Manual to start the compressor in manual mode. If correctly set the drain valves will close after approx. 15 seconds and the compressor accelerates against pressure. 3. Check pressure gauges of the stages as well as the oil pressure guage and compare with nominal values (for nominal values see stage pressure chart in section 6.4 "Routine Operation). 4. Check the functioning of the automatic intermediate draining. It must drain every 15 minutes for approx. 15 seconds. This is recognisable by the pressure drop at the pressure gauges. 5. Check the cooling water ow-rate. The temperature of the cooling water at the outlet should be as indicated in section 4.1 "Specication Data. The temperature can be read with the cooling water thermometer at the cooling water outlet. If these temperatures are exceeded or fallen short of, the cooling water ow-rate must be increased or decreased accordingly. In case of aggregates with built in cooling water pump the ow rate can be regulated with the gate valve on the pump. 6. Set the operating mode selector to 0 to stop the compressor. 7. Turn the power supply OFF. 8. If necessary, remedy the causes for deviations from nominal values and faults. Also see Chapter 7. "Trouble-shooting for this purpose.
6.4
Routine operation
Keep compressor site clean. Keep indicators and control elements clean. Inspect connections, pipelines and electric cables for damage. Check the oil level once a week before starting, top up if necessary. Do not ll oil beyond the maximum mark.
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Operation
1. Turn power supply ON. 2. Open cooling water lines. 3. Set operating mode selector to Auto to operate the compressor in Automatic Mode. Pay attention to abnormal operating sounds. Pay attention to leakages (compressed air, oil, condensate). The temperature of the cooling water at the outlet should be as indicated in section 4.1 "Specication Data. During operation the pressure indicated by the pressure gauge of the rst stage should be within the shaded region of the stage pressure chart (see below). The oil pressure should be between 1.8 bar and 4 bar. In case of deviations see Chapter 7. "Trouble-shooting. Stage pressure chart 1st stage
Observation
Ultimate pressure [bar]
1st stage [bar] Note! Depending on the desired ultimate pressure of the 2nd stage the permissible pressure for the 1st stage can be read from the chart.
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7.
Trouble-shooting
F
Note! In case of malfunctions, rst check the indicators on the compressor control and the compressor . Try to remedy the fault by following the information given in the table below. If the cause for the fault cannot be eliminated, contact J.P. SAUER & SOHN customer service.
Fault The compressor does not start or does not switch OFF. Compressor was switched off, fault indicator lamp "Oil Pressure" glowing.
Likely cause No supply voltage / no control voltage. The oil level is too low. The oil pump is faulty or leaking. The motor is overheated. Excessive current drawn.
Remedy Check fuses. Replace blown fuses.
Check the oil level, add oil as required. Check the oil pump. Fix the leak or replace the oil pump, as required. Determine the cause of the fault and correct it. The compressor can be started again after being allowed to cool off. Check liner and piston for score marks, replace if necessary.
Compressor was switched off, Fault indicator lamp "Overcurrent glowing.
Piston seizure Safety valve of 1st stage blows off: Pressure exceeds blowing-off pressure (8 bar) 2nd stage valve is not working properly. Sealing between inlet and outlet side of the 2nd stage is faulty. Pressure below blowing-off pressure (8 bar) Pressure in the 1st stage excessively high. Safety valve is faulty. Valve of 1st stage leaky.
Check 2nd stage valve, replace if necessary. Replace gasket.
Replace the safety valve. Check the valve for damage and replace if necessary; replace gaskets.
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Trouble-shooting
Fault 2nd stage safety valve blows off: Pressure exceeds blowing-off pressure (ultimate pressure + 5%) Pressure below blowing-off pressure (ultimate pressure + 5%) Pressure in the 2nd stage inadmissibly high. Pressure gauge of the 1st stage indicates too low a pressure. Valve in air line to the compressed air receiver closed. Pressure switch set too high. Safety valve set too low or is faulty. Valve of 2nd stage leaky. Valve of 1st stage leaky. Air lter very dirty. Drain valve of 1st stage leaky. No pressure indicated in 1st and 2nd stage pressure gauges. Air escaping from compressed air lines No power at drain valve. Drain valve faulty. Gaskets of connections leaking. Compression ring connections leaking. Compressor was switched off, fault indicator lamp "Air Temperature" glowing. Compressed air temperature at outlet too high due to cooling water deciency. Open the valve. Reduce set pressure. Replace the safety valve. Likely cause Remedy
Check the valve for damage and replace if necessary; replace gaskets. Check 1st stage valve, replace if necessary. Replace air lter cartridge. Clean drain valve and rebuild the valve seat if necessary. Check drain valve power supply. Check drain valve, replace if necessary. Replace relevant gasket. Turn compressor OFF. Wait until all parts are relieved of pressure (check pressure gauges). Then tighten unions. Increase cooling water ow-rate (only in case of the version with cooling water pump: open the gate valve behind the pump further), check the functioning of the cooling water stop valve; clean particle trap. Check cooling water-inlet temperature (max. 40 C).
Compressed air-temperature at the outlet too high due to too high cooling water inlet temperature. Compressed air-temperature at the outlet too high due to poor heat transfer in the cooler as a result of boiler scale formation. Drain valve does not close. No supply voltage. Solenoid faulty. Foreign matter in drain valve.
Clean cooling water cavities with boiler cleaning compound.
Check fuses, replace blown fuses. Replace solenoid. Clean drain valve.
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Fault Intermediate drainage is not functioning. Cooling water stop valve does not open.
Likely cause Timer not set or not set correctly. No supply voltage. Solenoid faulty. Foreign bodies in the cooling water stop valve.
Remedy Set timer to 15 s drainage and 15 min closing interval. Check fuses, replace blown fuses. Replace solenoid. Clean cooling water-stop valve. Check connecting rod bearing, replace if necessary. Check oil supply. Check gudgeon pin bearing, replace if necessary. Check crank shaft bearing, replace if necessary. Tighten screws. If there is heavy leakage, check to see which gasket is faulty, then replace it. Minor traces of oil on the crankcase or oil drops below the compressor are harmless. Wipe off with a rag. Replace the O-ring.
Compressor makes loud noises.
Connecting rod bearing faulty. Gudgeon pin bearing faulty. Crankshaft bearing faulty.
Oil leaking from crankcase.
Gasket or shaft seal faulty. Screws not tight.
Water is leaking at the relief groove of the cylinder ange surface. Oil is leaking at the relief groove of the cylinder ange surface. Water in oil
Liner O-ring above the relief groove is faulty. Liner O-ring below the relief groove is faulty. Compressor is overcooled because of too high cooling water owrate improper room ventilation very short compressor running time. Insufcient drainage.
Replace the O-ring.
Reduce cooling water ow-rate. Change the room ventilation in such a way that it does not blow directly at the compressor; increase the compressor running time
Check drain lines and drain intervals.
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Fault Burst disc in the cooling water circuit responds. Likely cause Leakages in the cooler. Remedy Re-expansion of the cooler pipes in the cylinder housing. For this purpose, separate working instructions and tool under the article code 066367 are available on request. Identify the causes for pressure peaks and eliminate or reduce them (starting of additional stronger pumps, actuation of electromagnetic stop valve or alternating check valves or similar.) Check drain lines and drain intervals. Note: Indentation marks appearing on the valve plate due to valve impact are normal.
Pressure peaks in the cooling water circuit, which lead to the overstepping of the bursting pressure of the burst disc. Premature breaking of valve plates, valve springs or valve disks. Insufcient drainage.
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8.
8.1
Maintenance
Maintenance service by J.P. SAUER & SOHN
The J.P. SAUER & SOHN customer service offers different maintenance services e.g. full maintenance or valve replacement service.
8.2
Maintenance safety
1. Disconnect the power supply to the compressor. 2. Post danger sign Caution Maintenance Work! at the power supply. Danger! Only authorised persons are permitted to service and make adjustments to the Sauer compressor! Danger! Risk of injury from hot surfaces! Let compressor cool off after turning OFF. Danger! Risk of injury from pressurised compressor components! Check the pressure gauges before servicing to ensure the compressor is completely relieved of pressure. Danger! Danger! High voltage! Never assume that a circuit is de-energised always check for your own safety! The main switch is energised, even when it is turned OFF. Components being worked on should only be energised if this is explicitly specified. Danger! Danger of death from missing safety devices and missing isolating protection devices! Reinstall all safety devices and isolating protection devices after servicing. This also applies to electrical protection devices (e.g. earth wires).
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8.3 Maintenance schedule
Danger! Section 8.4 Table of tightening torques must be followed for specic screws during all maintenance work. Note! The maintenance intervals specied in the maintenance schedule must be adhered to. Shortening the maintenance intervals is of no advantage with regard to operating performance or service life of the Sauer compressor. Note! After a major overhaul (=12,000 operating hours) the maintenance schedule begins all over again.
Instructions for the maintenance schedule
Use the maintenance schedule as master template or copy the respective page from the digital document and save it as a separate le under a suitable name. Use the maintenance schedule as guide and for documentation. Regularly check the maintenance schedule to see which maintenance intervals, subject to the number of operating hours, are due. The intervals are shown in the table's column headers. Check the column of each maintenance interval to see which maintenance work is to be carried out at the end of each maintenance interval. The required tasks are indicated by check boxes. Description and chapter number of the tasks are shown in the rst column. Carry out all maintenance work of a maintenance interval and tick the appropriate check boxes of the maintenance schedule. Then enter operating hours count, date and your signature. When beginning a new maintenance schedule enter: main specifications, date of commissioning, number of maintenance schedule, current date and operating hours count tick: beginning after commissioning/after major overhaul
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Maintenance Schedule No. Beginning of this maintenance schedule
Compressor type Type series Compressor number Factory no.: Year of construction: Date of commissioning: At least yearly if < 1,000 / year 2W
after commissioning after major overhaul

Date: Operating hours count: Interval (operating hours)
12,000 = major overhaul
50 after initial operation
50 after major overhaul
Maintenance work Checking screwed connections 8.6 Oil change 8.5 Air lter cartridge replacement 8.7 Checking valves 8.8 Checking piston rings 8.9 Replacing gudgeon pins/gudgeon pin bearings 8.10 Replacing valves 8.11 Checking pistons and cylinders 8.12 Checking drive bearings 8.13 Checking coupling 8.14 Cleaning particle trap 8.15 Checking zinc protection 8.16 Burst disc 8.17 Checking cooling water pump (optional) 8.18 Operating hours count:
Date
as required
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10,000
Signature (initials)
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11,000
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
Maintenance
Note! Check compressor 50 hours after every maintenance work is carried out. Check all screws affected by the maintenance work to see if they are tight.
8.4
Table of tightening torques

Screw(s) Connecting rod screws Flywheel fastening screw Valve cover screws (1st/2nd stage) Bursting plate ange Retaining screw of the 2nd stage valve on the valve cover Tightening torque 115 Nm 550 Nm 160 Nm 54 Nm 9 Nm
8.5
Oil change
Note! Use oil as per Lubricant Table (see chapter 10).
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Oil ller plug
Dipstick
Oil drain plug
1. Place oil sump (of sufcient capacity to hold the complete oil lling, see chapter 4) under the oil drain plug. 2. Remove the oil drain plug. 3. Wait until all oil is drained. 4. Replace the oil drain plug. 5. Unscrew oil ller plug (red). 6. Fill in oil and check level with the dipstick. The level shall be between the upper and lower mark on the dipstick. 7. Put dipstick back in and screw the oil ller plug back on.
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8.6 Checking screwed connections
Check all unions and screwed connections for tightness, retighten if necessary. This concerns cooler and air lines; unions of pipe lines and hose lines; cylinder heads; cylinders; electric motor and intermediate flange; measuring and switching devices; bedding; accessories and equipment parts.
8.7
Air lter cartridge replacement

Air lter cap
1. 2. 3. 4.
Open clips and take the air lter cap off. Remove the used air lter cartridge. Put new air lter cartridge in. Put cap back on and close the clips.
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8.8
Checking valves
Note! Plate valves and particularly lamellar valves are those pats of a reciprocating compressor, that are subject to the most stress. In order to achieve the guaranteed maintenance intervals, these valve are specially matched to the individual compression stages as high-quality precision parts, and their functioning carefully checked before delivery. Repair by the maintenance and operating personnel requires special knowledge, which may not be available every time. For such cases J.P. SAUER & SOHN offer a valve replacement service. In case it should be necessary please contact the Sauer service department. In case of two stage water-cooled compressors, the high nal compression temperature can lead to untimely soiling of valves if ambient conditions are unfavourable or poor varieties oil are used. In such cases, some other oil is to be used or the maintenance intervals are to be shortened. Note! While reinstalling valves use only new gaskets and rings everytime. Do not reuse the used rings under any circumstances. Doing so leads to leakage within a short time. Use only genuine Sauer spare parts. They are precision parts with dened and tested dimensions and material characteristics, specially designed for use in Sauer compressors. Installation of other gaskets may lead to leakage and could cause substantial damage to the compressor.
Checking the plate valve (1st stage)
1. Loosen the clamp and remove air lter. 2. Loosen the hose of the crankcase vent at the union and remove with nipple. 3. Loosen the valve cover nuts and pull the valve cover uniformly with the two M12 screws. 4. Take out valve carefully. Note! When removing, cleaning and installing the plate valve, take care that no valve parts are damaged. This applies particularly to the sealing surfaces and the valve springs. Slight damage to the raised faces of the valve seats can be removed by refacing on a lapping plate.
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6. Disassemble valve. 7. Clean all valve parts. For this purpose soak them in an oil dissolving uid (e.g. petroleum or benzene). 8. Check valve parts for damage. Replace damaged valve parts.
9. Carefully reassemble valve (see illustration), tighten nut. 10. Use a pin with round tip to check the valve plate's smoothness of action against the spring pressure. 11. Fit plate valve and valve cover. Use new sealing rings in the valve cover while doing so (see illustration). Observe the tightening torque (see section 8.4). 12. Fit the hose of the crankcase vent and x with clamp. 13. Mount air lter and x with clamp.
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O-ring
Checking lamellar valve (2nd stage)
1. Loosen the for ange screws of the compressed air manifold on the valve cover of the 2nd stage. Loosen ange connection on the two cylinders of the 2nd stage. 2. Loosen the valve cover nuts and pull the valve cover uniformly with the two M12 screws. 3. Remove the retaining screw on the valve cover and take out valve carefully. 4. Examine the valve. If lamellar valve is heavily carbonised or damaged, replace complete valve. Note! Lamellar valves require very little maintenance and function even in presence of small quantities of dirt in contrast to plate valves. Normally the plates have the same service life as the valve body which, due to its geometry, can not be refaced or lapped. Therefore a replacement of individual plates is not recommended. Should a plate be broken prematurely nevertheless (e.g. through impact of foreign objects), contact our service. 5. Fix the lamellar valve on the valve cover with the retaining screw. Observe the tightening torque (see section 8.4). 6. Fit lamellar valve and valve cover. Use new sealing rings while doing so (see illustration). Observe the tightening torque (see section 8.4).
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O-ring
O-ring
8.9
Checking the piston rings

1. Remove valve cover and valves as described in section 8.8, Checking valves. 2. Dismantle inspection hole cover on the crankcase. 3. Remove connecting rod bolts and remove connecting rod bearing cover with bearing bush. Push piston together with connecting rod upper part out of the cylinder. 4. Remove all piston rings from the pistons. 5. Place piston rings in their respective cylinders and measure the gap clearance with a feeler gauge. 6. Replace piston rings if the gap clearance exceeds the following limits. Compression ring Oil scraper ring 1.80 mm 1.80 mm
1st stage
Note! Always replace all pistons rings of a piston when one of the piston rings exceeds the limit. 7. Install piston rings on the respective piston.
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Note! Use an assembly sleeve for pushing the piston into the liner from above (see Chapter 11 "Spare parts and Accessories). 8. Put connecting rod back with sufcient oil and screw on the bottom part with hand. Note! Numbers are punched on the upper and lower parts of the connecting rod. These must match in any case . See illustration.
7 7
It should be possible to screw in the connecting rod bolts completely with hand. Only then the correct seat on the crankshaft can be guaranteed. After tightening, the connecting rod should rotate easily on the crankshaft.
2nd stage
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1. Loosen the ange connection and dismantle compressed air manifold. 2. Loosen screwed pipe connections and dismantle the compressed air line from the cylinder of the 2nd stage to the nal separator. 3. Block the cooling water inlet, remove the drain plug located below on the cylinder of the 2nd stage and drain the cooling water. 4. Loosen screwed pipe connections on the cylinder, dismantle cooling water inlet pipe. The screw connection nipple remains on the cylinder. 5. Remove the union nut of the cooling water hose between the cylinders of the 1st and 2nd stage and remove the cooling water hose. The bend remains on the cylinder of the 2nd stage. 6. Dismantle both the inspection hole covers from the crankcase. 7. Loosen the connecting rod bolts and remove them from the
Maintenance
crankcase together with bearing cover. Push the connecting rod upper part with the piston up in the cylinder. 8. Loosen the four nuts at the foot of the cylinder of the 2nd stage. 9. Turn the two M16 lifting eye nuts (see Chapter 11 "Spare parts and Accessories) on both the upper studs of the valve cover and pull the cylinder out of the crankcase with a suitable lifting device (weight approx. 100 kg). 10. Pull cylinder further up along with connecting rod with piston. Pull connecting rod towards front from the crankcase opening. 11. Put cylinder down at the side and pull connecting rod with piston down from the cylinder. 12. Remove all piston rings from the pistons. 13. Place piston rings in their respective cylinders and measure the gap clearance with a feeler gauge. 14. Replace piston rings if the gap clearance exceeds the following limits. Compression ring Oil scraper ring 0.75 mm 0.65 mm
15. Fit piston rings. Fit N-ring in the third groove from above. Make sure they are in the correct position: piston rings having an asymmetric cross section are marked on one of the surfaces with TOP. The marked face must be at the top when the piston ring is installed. See illustration.
TOP
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16. Sequence of assembly is exactly opposite to that of dismantling. 17. Put connecting rod back with sufcient oil and screw on the bottom part with hand (see section 8.4 for tightening torque).
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Note! Numbers are punched on the upper and lower parts of the connecting rod. These must match in any case . See illustration.
7 7
It should be possible to screw in the connecting rod bolts completely with hand. Only then the correct seat on the crankshaft can be guaranteed. After tightening, the connecting rod should rotate easily on the crankshaft.
8.10 Replacing gudgeon pins/gudgeon pin bearings

1. Remove valve covers and valves as described in section 8.8, Checking valves. 2. Remove cylinder and piston with connecting rod as described in Section 8.9 "Checking piston rings. 3. Remove circlip of the gudgeon pin and push the gudgeon pin out. 4. Press gudgeon pin bearing out of the connecting rod's small end. 5. Replace gudgeon pin and gudgeon pin bearing. 6. Press gudgeon pin bearing into the connecting rod's small end. 7. Assemble piston with connecting rod and cylinder as described in Section 8.9 "Checking piston rings". 8. Assemble valves and valve covers as described in Section 8.8 "Checking valves.
8.11 Replacing valves

Remove and install valves as detailed in section 8.8 Checking valves. Replace complete valve.
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8.12 Checking pistons and cylinders
1. Remove valve cover and valves as described in section 8.8, Checking valves. 2. Remove cylinders and pistons as described in section 8.9, Checking the piston rings. 3. Check liner and pistons for scouring and excessive wearing marks. Replace relevant parts. 4. Measure liner and replace if the following wear limits are exceeded:
Cylinder 1st stage 2nd stage 195.15 mm 110.15 mm Wear limit of diameter
5. If the liners were to be pulled out, t them back with new sealing rings. 6. Fit cylinders and pistons as described in section 8.9, Checking the piston rings. 7. Assemble valve cover and valve as described in section 8.8, Checking valves.
8.13 Checking the drive bearings

1. Remove valve cover and valves as described in section 8.8 Checking the valves. 2. Remove cylinder and piston with connecting rod as described in Section 8.9 "Checking piston rings. 3. Inspect the connecting rod bearing for score marks and excessive wear marks and replace in case of heavy wear. 4. Dismantle electric motor with intermediate ange, coupling and ywheel as described in Section 8.14 "Checking coupling. 5. Remove bearing bracket. 6. Pull crankshaft out. 7. Inspect the crankshaft bearing for score marks and excessive wear marks and replace in case of heavy wear. If required, use new shaft seal. 8. Fit crankshaft. 9. Install bearing bracket. If necessary use new gasket. 10. Fit electric motor with intermediate ange, coupling and ywheel. Observe the tightening torque (see section 8.4). 11. Assemble piston with connecting rod and cylinder as described in Section 8.9 "Checking piston rings". 12. Assemble valves and valve covers as described in Section
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8.8 "Checking valves.
8.14 Checking the coupling

Visual check
1. Remove protection cover on the transmission bell housing on the rst stage. Through the inspection port check the coupling's exible gear rim for damage. The teeth of the exible gear rim must not be deformed. 2. Fix protection cover back. 3. If necessary, replace the exible gear rim as described below. Protection cover
Removing the gear rim
4. Support compressor under the transmission bell housing. 5. Remove the electric motor mounting screws. 6. Lift the electric motor carefully using the lifting eye (see section 5.1 "Transport). 7. Pull electric motor carefully away from the intermediate ange. 8. Replace exible gear rim.
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Tooth of exible gear rim
9. Slide electric motor gently against the intermediate ange and tighten the motor mounting screws. 10. Remove support from under the transmission bell housing.
8.15 Cleaning particle trap

1. Block cooling water inlet. 2. Loosen the cap of the particle trap (in front of the cooling water-control valve) and remove the strainer. 3. Clean the strainer. 4. Fit the strainer back, screw on the cap.
8.16 Checking zinc protection

The zinc protections for the cylinders of the 1st stage are located laterally on the cylinder. The zinc protection for the cylinder of the 2nd stage is located laterlly on the cylinder beside the burst disc ange. 1. Unscrew the zinc protection and remove loose parts. 2. Check the zinc protection. Minimum diameter is 24 mm. Regenerate the zinc protection if the consumption is too high. 3. Fit the zinc protection back with a new sealing ring.
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8.17 Burst disc

1. Remove screw and dismantle pressure ange on the cylinder of the 2nd stage. 2. Remove burst disc and sealing ring. 3. Clean sealing surface. 4. Insert new gasket and new burst disc. Pay attention to the correct position of the gasket. Fit rst the gasket and then the burst disc into the cylinder. 5. Bolt the pressure ange back.
8.18 Checking cooling water pump (optional)

The pump should be checked as follows in case of abnormal running sound or leakages from the pump:
Disassembling the pump
1. Block the cooling water inlet and outlet. 2. Disconnect electrical connection. 3. Remove the drain plug located below on the cylinder of the 2nd stage and drain the cooling water of the compressor. 4. Loosen the ange connections on the cooling water inlet and outlet of the pump. 5. Loosen the bolted fastening of the pump at the foot and remove pump from the console. The oating ring seals are maintainance-free. In case heavy leakages are noticed after long running time, the oating ring seal is to be replaced as a complete unit. 6. Remove impeller and shaft retaining ring. 7. Pull the entire oating ring seal with the cap out from the shaft. Note! Note the diagram of the pump in the Spare Parts Catalogue. Caution: A great deal of care and cleanliness is essential required during the assembly of new oating ring seal. The gliding surfaces must never be touched with ngers. Any damage must in any case be avoided. Moisten the elastomers with low surface tension water to facilitate easier assembly. Caution: Floating ring seals must never come in contact with grease or oil! The shape of spare oating ring seals can be different from that of the built in oating ring seals. The spare oating ring seal however has the same assembly dimensions and is interchangeab-
Replacing the floating ring seals
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Maintenance
le. The oating ring seal must be carefully slid onto the shaft with rotating motion. Note! The motor bearing should be replaced if the shaft has noticeable play. A possibly damaged pump impeller must likewise be replaced.
Assembling the pump
8. Assemble the pump back in the reverse sequence. 9. Checking the direction of rotation of the optional cooling water pump: Switch the pump motor ON for a short duration. The motor must not reach its operating speed during this. The direction of rotation must be the same as the one indicated by the arrow on the pump. The pump and the suction pipe must be completely lled with cooling water.
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9.
9.1
Placing out of Service

Safety when placing out of service and dismounting
Danger! The compressor shall only be placed out of service and dismounted by instructed and trained specialists of the operator. The specialists must be familar with the protection devices and regulations before starting the work. Any work on the electrical installation must be carried out by qualied electricians only. In addition, information contained in the documentation of outside vendors is to be observed.
9.2
Shutting down the compressor temporarily

Every 4 weeks perform a test run for at least 30 minutes. Then additional corrosion prevention measures are not required. When the Sauer compressor is to be shut down for more than 12 weeks, conservation with slushing oil is recommended. In this case periodic test runs are not necessary. Note! Use one of the slushing oils recommended in Chapter 10 "Lubricant Table" for corrosion protection. The slushing oil has satisfactory running properties. In case of emergency the machine can be started for a short time with a slushing oil lling. 1. Run compressor for approx. 5 minutes with drain valves and pressure line open. Any existing condensate is blown off. 2. Drain compressor oil and dispose it of in an environmentally friendly manner. 3. Fill about 10 litres of slushing oil. 4. Start compressor and run for approx. 5 minutes with drain valves and pressure line opened. 5. Stop compressor. 6. Unscrew both the air lters. 7. Start compressor and slowly inject approx. 100 cc slushing oil into the intake ports. 8. Wait until oil mist comes out of the pressure line. 9. Stop compressor. 10. Fit both air lters back. 11. If necessary, post a sign that the compressor has been trea-
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ted with anticorrosion measures and is placed out of service. 12. If necessary disconnect mains supply.
Restarting
1. Connect power supply, if necessary. 2. Drain slushing oil and ll with compressor oil. 3. Proceed as described in section 6.3 "Commissioning.
9.3
Dismantling
1. Turn compressor OFF and disconnect from power supply. 2. Make sure by reading the pressure gauges before servicing that the compressor is completely relieved of pressure. 3. Disconnect power lines from the mains supply. 4. Remove oil and lubricants and dispose of in an environmentally friendly manner. 5. Drain any remaining condensate and dispose of in an environmentally friendly manner.
Dismantling
Disposal
Material/component Lubricants Steel/iron Electric cables Electronic components Plastics How to dispose as hazardous waste as metal scrap as hazardous waste as electronic waste as hazardous waste
I_DE004_1.fm
Version 1 - 1
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ST001AD1.fm
10. Lubricant Table

Scope
The lubricant table applies to all Sauer compressors intended for the compression of air. The lubricant table does not apply to Sauer compressors for the compression of neutral gases; temperature ranges outside of 5 55 C. We recommend mineral oils of the viscosity class in accordance with ISO VG 100 for the temperature range 5 55 C. The lubricating oils should at least conform to the group VCL in accordance with DIN 51506. Note! The recommended oil types bring down the carbonisation in the compressor valves and the connected pipes and ttings to a minimum. Lubricants not mentioned in the lubricant table may only be used after approval by J.P. SAUER & SOHN. Otherwise the warranty will lapse. Please contact our customer service when selecting oils not listed here or in case of deviating operating conditions.
General recommendation
66
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ST001AD1.fm
Lubricant Table
10.1 Lubricating oils
Brand Agip Diesel Gamma 30 Dicrea 100 Acer 100 Motor Oil HD 30 Cladium 50 ARAL Motanol HE 100 Kowal M 30 Disola M 30 AVIA Avilub Compressor Oil VDL-100 Avilub Compressor Oil VDL-100 Motor oil HDC 30 Motor oil HD 30 BP Energol RC 100 Energol IC-DG 30 Energol DL-MP 30 Energol OE-HT 30 Vanellus C3 SAE 30 Castrol Chevron Aircol PD 100 Marine CDX 30 HD Compressor Oil 100 Delo 1000 Marine 30 Veritas 800 Marine 30 RPM Heavy Duty Motor 30 DEA Actro EP VDL-100 Trion EP VDL-100 Regis SAE 30 Esso Exxcolub 77 Exxcolub 100 Compressor Oil 3021 N Exxmar 12 TP 30 Exxmar XA Essolube HDX Plus +30 Mobil Rarus 427 DTE Oil Heavy Mobilgard 300 Shell Corena Oil P 100 Rimula X 30
ST001AD1.fm
Name VCL-100 VDL-100 VCL-100 SAE 30 SAE 30 VDL-100 VCL-100 SAE 30 VDL-100 VCL-100 SAE 30 SAE 30 VDL-100 VCL-100 SAE 30 SAE 30 SAE 30 VDL-100 SAE 30 VDL-100 SAE 30 SAE 30 SAE 30 VDL-100 VDL-100 SAE 30 VDL VDL-100 VDL-100 SAE 30 SAE 30 SAE 30 VDL-100 VDL SAE 30 VDL-100 SAE 30 SAE 30 SAE 30 SAE 30
Group
Melina S Oil 30 Melina Oil 30 Gadinia Oil 30
Version 1 - 1
67
Brand TEXACO Regal R&O 100 Ursatex 30 DORO AR 30 TOTAL Dacnis P 100 Carprano TD 30 Milcano TC 30 Disola M 3015
Name Compressor Oil EP VDL 100 VDL-100 VCL-100 SAE 30 SAE 30 VDL-100 SAE 30 SAE 30 SAE 30
Group
10.2 Slushing oils

Brand Agip ARAL AVIA Rustica C SAE 30 Konit Motor Oil SAE 30 MK 1540 S Avilub MK 3000 BP Castrol DEA ELF Esso MEK 20 W-20 Running-in and Preservation Oil Deamot EKM 642 SAE 30 Stockage 30 MZK Motor Oil HD 30 Antirust MZ 110 FINA Mobil Shell TEXACO Rusan NF Motor Oil SAE 30 Mobilarma 524 Ensis Motor Oil 30 Engine Oil EKM 146 SAE 30 Name
68
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ST001AD1.fm
Spare Parts and Accessories 11. Spare Parts and Accessories

Note! Please note the information in chapter 1. General regading our genuine Sauer spare parts.
J.P. SAUER & SOHN garantee the complete spare parts supply
over the entire service life of the Sauer compressor. Our genuine Sauer spare parts are subject to constant quality control and further development. They conform to the latest technical developments. In addition to the genuine Sauer spare parts, our delivery program comprises a large number of accessories for your Sauer compressor and special components to complete your air system, such as: fully automatic controls; adsorption dryers; refrigerated air dryers; filters; silencing cabinets; compressed air receivers; fittings. We supply instructions and a maintenance manual for each accessory.
Spare parts catalogue
The spare parts catalogue is found in the annex to these instructions. With the help of overviews, illustrations and lists the required parts is quickly found. The spare parts catalogue, including the operating instructions is also available on CD-ROM. Here, an order form can be filled in, printed out and send immediately. For doing so, you need the main specifications of your Sauer compressor from the table below. If they have not yet been entered there, they can be found on the type label affixed to the crankcase. Compressor type Factory no.: Year of construction:
EZ001AA1.fm
Furthermore, the number of operating hours should be stated, if possible.

Version 1 - 1
69
12. Annex
This Annex to the operating instructions contains documentation supplied by outside vendors; data sheets.
70
Version 1 - 1
AN001AA1.fm
Annex
AN001AA1.fm
Version 1 - 1
71
S a u e r C o m p r e s s o r
Type: WP 400 Spare Part List
Version 1 - 1
E-2
Version 1 - 1
Spare Part List

WP 400 Sauer compressor
Reference No. WP 400 064 140 064 448 064 142 063 864 064 144 064 261 064 145 063 866 063 915 063 868 063 869 037 134 036 959 064 146 064 147 064 366 066 143 038 238 064 148 063 985 064 038 064 308 064 151 064 039 063 950
Subassemblies
Page
Sauer compressor . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . 4 crankcase . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . 6 protection device. . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . 8 crankshaft . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 10 connecting rod 1st stage. .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 12 connecting rod 2nd stage .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 14 piston 1st stage . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 16 piston 2nd stage . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 18 cylinder 1st stage . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 20 cylinder 2nd stage . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 22 valve cover 1st stage. . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 24 valve cover 2nd stage . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 26 concentric valve 1st stage . . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 28 lamellar valve 2nd stage . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 30 air pipes. . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 32 cooling water pipes compr. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 34 cooling water lines unit without pump . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 36 cooling water lines unit with pump . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 38 cooling water pump.. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 41 crankcase venting . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 46 lubricating oil supply. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 48 measuring device . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 50 auxiliary tools, compl. . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 52 resilient mounts f. motor 280 S/M. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 54 automatic drainage .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 56 compressor monitor . . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 58
Note:
Explanation of the subassemblies in chapter 3 "Design and Function" of the operating instructions
Version 1 - 1
E-3
E-4
Version 1 - 1
Spare Part List

Item
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25
Reference No. Designation 064 140 064 142 063 864 064 144 064 261 064 145 063 866 063 915 063 868 063 869 037 134 036 959 064 146 064 147 064 366 066 143 064 148 063 985 064 038 033 423 064 308 064 151 063 950 064 039
Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
crankcase crankshaft connecting rod 1st stage connecting rod 2nd stage piston 1st stage piston 2nd stage cylinder 1st stage cylinder 2nd stage valve cover 1st stage valve cover 2nd stage concentric valve 1st stage lamellar valve 2nd stage air pipes cooling water pipes compr. cooling water lines unit without pump cooling water lines unit with pump crankcase venting lubricating oil supply measuring device flex.coupling f. motor 280 S/M auxiliary tools, compl. resilient mounts f. motor 280 S/M compressor monitor automatic drainage
Version 1 - 1
E- 5
064 140 crankcase
E-6
Version 1 - 1
Spare Part List

064 140 crankcase
Item
1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 27 28 29 30 31
Reference No. Designation 063 786 064 394 051 883 036 897 064 257 063 748 063 749 030 743 004 635 000 971 005 001 035 984 005 009 038 102 001 620 036 960 001 621 001 408 002 031 064 331 064 332 000 494 064 448 030 556
Qty. 1 1 2 1 1 2 1 1 1 2 2 1 1 6 6 12 12 16 16 1 1 4 1 1
crankcase housing cover inspection hole cover oil sieve dipstick inspecting hole cover packing housing cover packing shaft seal union plug gasket cock Ring stud hexagon nut stud hexagon head nut stud hexagon nut blind flange blind flange packing Socket Head Cap Screw protection device o-ring
Version 1 - 1
E- 7
064 448 protection device
E-8
Version 1 - 1
Spare Part List

064 448 protection device
Item
1 3 4 5
Reference No. Designation 064 449 001 408 002 031 002 156
Qty. 1 2 2 2
protection cover stud hexagon nut washer
Version 1 - 1
E- 9
064 142 crankshaft
E - 10
Version 1 - 1
Spare Part List

064 142 crankshaft
Item
1 2 3 4 6 7 8 9
Reference No. Designation 064 143 063 544 063 732 063 811 005 297 033 994 036 961 000 542
Qty. 1 1 1 1 1 2 2 10
crankshaft driving plate washer flywheel hexagon head screw cylinder head screw cylinder roller bearing cylinder head screw
Version 1 - 1
E -11
063 864 connecting rod 1st stage
E - 12
Version 1 - 1
Spare Part List

063 864 connecting rod 1st stage
Item
1 2 3 4
Qty. 1 1 1 2
connecting rod connecting rod bearing needle roller bearing connecting rod screw
Version 1 - 1
E -13
064 144 connecting rod 2nd stage
E - 14
Version 1 - 1
Spare Part List

064 144 connecting rod 2nd stage
Item
1 2 3 4
Qty. 1 1 1 2
connecting rod connecting rod bearing needle roller bearing connecting rod screw
Version 1 - 1
E -15
064 261 piston 1st stage
E - 16
Version 1 - 1
Spare Part List

064 261 piston 1st stage
Item
1 2 3 4 5
Reference No. Designation 036 983 036 078 002 716 035 962 002 985
Qty. 1 1 2 1 2
piston piston pin R-ring G-ring circlip
Version 1 - 1
E -17
064 145 piston 2nd stage
E - 18
Version 1 - 1
Spare Part List

064 145 piston 2nd stage
Item
1 2 3 4 5 6
Reference No. Designation 063 815 064 150 033 571 002 634 002 605 012 682
Qty. 1 1 2 1 1 2
piston piston pin R-ring N-ring S-ring circlip
Version 1 - 1
E -19
063 866 cylinder 1st stage
E - 20
Version 1 - 1
Spare Part List

063 866 cylinder 1st stage
Item
1 2 4 5 6 7 8 9 10 12 14 15 16 17 18 19 22 23 24 26
Reference No. Designation 063 779 061 822 063 660 063 656 063 652 063 776 063 747 063 797 063 796 000 497 001 533 000 507 000 523 000 977 001 016 035 390 001 621 005 023 005 009 036 962
Qty. 1 1 1 1 1 1 1 1 1 6 6 19 2 1 3 1 6 3 3 4
cylinder housing 1st stage zinc protection cylinder cover cooler cover, rear cooler cover, front finished bushing cylinder cover packing cooler cover packing, rear cooler cover packing, front cylinder head screw stud cylinder head screw cylinder head screw plug plug plug hexagon head nut gasket Ring o-ring
Version 1 - 1
E -21
063 915 cylinder 2nd stage
E - 22
Version 1 - 1
Spare Part List

063 915 cylinder 2nd stage
Item
1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25
Reference No. Designation 064 442 061 822 054 883 063 662 064 395 063 654 063 808 063 747 063 751 063 750 051 530 061 942 000 505 000 551 000 497 001 533 001 621 001 016 000 977 035 390 005 023 005 009 030 131
Qty. 1 1 1 1 1 1 1 1 1 1 1 1 4 21 6 4 4 1 1 1 3 1 4
cylinder housing 2nd stage zinc protection protection cover cylinder cover cooler cover, rear cooler cover, front finished bushing cylinder cover packing cooler cover packing, rear cooler cover packing, front protection cover packing bursting plate cylinder head screw cylinder head screw cylinder head screw stud hexagon head nut plug plug plug gasket Ring o-ring
Version 1 - 1
E -23
063 868 valve cover 1st stage
E - 24
Version 1 - 1
Spare Part List

063 868 valve cover 1st stage
Item
1 2 3 4 5
Qty. 1 1 1 1 1
valve cover dry air filter o-ring o-ring Filter insert for air filter
Version 1 - 1
E -25
063 869 valve cover 2nd stage
E - 26
Version 1 - 1
Spare Part List

063 869 valve cover 2nd stage
Item
1 2 3 4 5
Qty. 1 1 1 1 1
valve cover hexagon head screw gasket o-ring o-ring
Version 1 - 1
E -27
037 134 concentric valve 1st stage
E - 28
Version 1 - 1
Spare Part List

037 134 concentric valve 1st stage
Item
1 2 3 4 5 6
Qty. 1 1 1 2 2 2
suction valve plate delivery valve plate delivery valve plate delivery valve spring delivery valve spring suction valve spring
Version 1 - 1
E -29
036 959 lamellar valve 2nd stage
E - 30
Version 1 - 1
Spare Part List

036 959 lamellar valve 2nd stage
Item
1 2 3
Reference No. Designation 037 186 037 236 037 237
Qty. 1 8 8
suction plate DIA 124 delivery plate delivery spring plate
Version 1 - 1
E -31
064 146 air pipes
E - 32
Version 1 - 1
Spare Part List

064 146 air pipes
Item
1 2 4 6 7 8 9 10 11 12 13 14 15 16
Reference No. Designation 063 812 063 121 056 335 000 054 000 137 002 151 036 157 006 193 005 946 030 751 030 752 005 009 005 016 005 023
Qty. 1 1 2 12 2 2 1 1 1 1 1 1 2 2
collecting tube separator packing hexagon head screw hexagon head screw washer union union stud adaptor safety valve safety valve Ring safety valve gasket gasket
Version 1 - 1
E -33
064 147 cooling water pipes compr.
E - 34
Version 1 - 1
Spare Part List

064 147 cooling water pipes compr.
Item
1 2 4 6 9 10 11 12
Qty. 4 1 3 2 4 1 1 1
angle angle union hose union union adaptor reducer
Version 1 - 1
E -35
064 366 cooling water lines unit without pump
E - 36
Version 1 - 1
Spare Part List

064 366 cooling water lines unit without pump
Item
1 2 3 4 5 6 7 8
Qty. 1 1 2 1 1 1 1 1
soleniod valve dirt trap connector connector angle connector union reducer
Version 1 - 1
E -37
066 143 cooling water lines unit with pump
E - 38
Version 1 - 1
Spare Part List

Item
1 2 3 4 5 6 7 8 9 10 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 35 36
Reference No. Designation 066 442 066 145 066 144 005 265 012 851 000 155 000 594 001 620 002 051 038 201 032 725 002 161 037 267 037 144 037 265 002 166 036 967 032 679 037 150 064 396 038 238 038 386 037 493 037 293 036 614 030 658 037 441 037 930 037 305 000 119 000 048 002 153 002 156
Qty. 1 2 1 8 4 2 2 2 8 1 1 4 1 1 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 4 8
E -39
holder ledge L-profil hexagon head screw hexagon head screw hexagon head screw cylinder head screw hexagon nut hexagon nut reducer connector washer reducer angle angle washer union dirt trap solenoid valve gate valve cooling water pump hose clamp flange flange packing packing connector reducer hexagon head screw hexagon head screw washer washer
Version 1 - 1
Item
37 38 40 41
Qty. 2 6 1 1
hexagon nut hexagon nut union union
E - 40
Version 1 - 1
Spare Part List
Version 1 - 1
E - 41
038 238 cooling water pump
E - 42
Version 1 - 1
Spare Part List

Version 1 - 1
E -43
E - 44
Version 1 - 1
Spare Part List

Item
1
Reference No. Designation 038 290
Qty. 1
packing kit
Version 1 - 1
E -45
064 148 crankcase venting
E - 46
Version 1 - 1
Spare Part List

064 148 crankcase venting
Item
1 2 3 4 5 6 7 8 9 10 11 12 14
Reference No. Designation 038 407 038 268 033 087 034 612 035 254 037 139 037 140 037 185 037 144 037 194 035 824 037 264 033 952
Qty. 1 1 1 1 4 4 2 1 1 1 1 1 1
pipe adaptor distribution piece reducer LP-hose hose clamp hose union bend connector angle union filling cover LP-hose hose
Version 1 - 1
E -47
063 985 lubricating oil supply
E - 48
Version 1 - 1
Spare Part List

063 985 lubricating oil supply
Item
1 2 7 8 10 11 12
Reference No. Designation 063 543 057 916 003 438 000 452 056 318 036 363 030 544
Qty. 1 1 1 4 1 1 1
oil pump overpressure valve oil pump gasket cylinder head screw packing lubricating oil supply packing packing
Version 1 - 1
E -49
064 038 measuring device
E - 50
Version 1 - 1
Spare Part List

064 038 measuring device
Item
1 2 3 6 7 8 9 10 12
Reference No. Designation 035 009 035 010 035 061 038 073 005 009 005 016 035 906 030 182 030 509
Qty. 3 1 4 3 3 1 1 1 1
Pressure gauge Pressure gauge Gasket ring angle thermometer 0-250C Ring safety valve gasket adaptor angle thermometer plug
Version 1 - 1
E -51
064 308 auxiliary tools, compl.
E - 52
Version 1 - 1
Spare Part List

064 308 auxiliary tools, compl.
Item
1 2 3
Reference No. Designation 037 225 064 306 064 309
Qty. 2 1 1
lifting eye nut assembly bushing turning rod
Version 1 - 1
E -53
064 151 resilient mounts f. motor 280 S/M
E - 54
Version 1 - 1
Spare Part List

064 151 resilient mounts f. motor 280 S/M
Item
1 2 3 4 5 6 8 9 10
Reference No. Designation 066 595 033 531 000 589 046 837 034 763 035 942 004 701 065 664 063 947
Qty. 2 8 8 8 1 2 2 1 2
cooling water hose lines countersunk screw cylinder head screw resilient mount HP - hose HP - hose union non-return valve rail
Version 1 - 1
E -55
064 039 automatic drainage
E - 56
Version 1 - 1
Spare Part List

064 039 automatic drainage
Item
1 2 3 4 5 6 7 8 9 10 11 12 13
Reference No. Designation 049 129 033 961 006 187 004 647 005 964 004 973 035 555 000 434 005 009 006 000 006 455 008 663 008 672
Qty. 1 1 1 2 1 1 2 2 2 1 1 1 1
tube clamp stud adaptor union union union union solenoid valve Socket Head Cap Screw Ring union stud adaptor pipe pipe
Version 1 - 1
E -57
063 950 compressor monitor
E - 58
Version 1 - 1
Spare Part List

063 950 compressor monitor
Item
1 3 4 5 6 8
Qty. 1 1 2 2 1 1
temperature monitor oil pressure switch socket head cap screw union reducer pipe
Version 1 - 1
E -59
E - 60
Version 1 - 1
Index
Reference No.
000 048 000 054 000 119 000 137 000 155 000 409 000 434 000 452 000 494 000 497 000 497 000 505 000 507 000 523 000 542 000 551 000 589 000 594 000 971 000 977 000 977 001 016 001 016 001 408 001 408 001 533 001 533 001 620 001 620 001 621 001 621 001 621 002 025 002 031 002 031 002 031 002 051 002 151 002 153 002 156 002 156 002 161 002 166 002 605 002 634 002 716 002 985 003 438 003 493 004 596 004 635 004 647
Designation
hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . socket head cap screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Socket Head Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Socket Head Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . oil pump gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
39 33 39 33 39 59 57 49 7 21 23 23 21 21 11 23 55 39 7 21 23 21 23 7 9 21 23 7 39 7 21 23 40 7 9 40 39 33 39 9 39 39 39 19 19 17 17 49 27 59 7 57
Pos.
34 6 33 7 6 4 8 8 29 12 16 14 15 16 9 15 3 7 11 17 21 18 20 19 3 14 17 16 8 18 22 19 37 20 4 38 9 8 35 5 36 14 18 5 4 3 5 7 3 5 10 4
Version 1 - 1
E -61
Reference No.
004 661 004 666 004 701 004 973 005 001 005 009 005 009 005 009 005 009 005 009 005 009 005 016 005 016 005 023 005 023 005 023 005 265 005 297 005 946 005 964 006 000 006 187 006 193 006 455 008 633 008 663 008 672 012 682 012 851 030 082 030 131 030 182 030 509 030 544 030 556 030 658 030 743 030 751 030 752 030 912 032 679 032 679 032 725 032 725 033 017 033 087 033 423 033 531 033 571 033 952 033 961 033 994
Designation
union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . safety valve gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . safety valve gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . angle thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dirt trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dirt trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . flex.coupling f. motor 280 S/M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . countersunk screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
35 40 55 57 7 7 21 23 33 51 57 33 51 21 23 33 39 11 33 57 57 57 33 57 59 57 57 19 39 59 23 51 51 49 7 39 7 33 33 25 37 39 37 39 59 47 5 55 19 47 57 11
Pos.
9 41 8 6 12 14 24 24 14 7 9 15 8 23 23 16 4 6 11 5 10 3 10 11 8 12 13 6 5 3 25 10 12 12 31 29 9 12 13 4 2 20 3 13 6 3 20 2 3 14 2 7
E - 62
Version 1 - 1
Index
Reference No.
034 612 034 763 034 875 035 009 035 010 035 061 035 254 035 390 035 390 035 555 035 823 035 824 035 906 035 942 035 962 035 970 035 984 036 078 036 157 036 363 036 394 036 395 036 614 036 897 036 959 036 960 036 961 036 962 036 963 036 964 036 967 036 967 036 967 036 983 037 058 037 134 037 139 037 140 037 142 037 144 037 144 037 144 037 150 037 151 037 185 037 186 037 187 037 188 037 189 037 190 037 191 037 192
Designation
LP-hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HP - hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasket ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hose clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . needle roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . filling cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HP - hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricating oil supply packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dry air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter insert for air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . oil sieve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lamellar valve 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . needle roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . concentric valve 1st stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hose union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . soleniod valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . suction plate DIA 124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . suction valve plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . delivery valve plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . delivery valve plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . delivery valve spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . delivery valve spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . suction valve spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
47 55 35 51 51 51 47 21 23 57 13 47 51 55 17 27 7 17 33 49 25 25 39 7 5 7 11 21 27 27 35 37 39 17 15 5 47 47 37 35 39 47 39 25 47 31 29 29 29 29 29 29
Pos.
4 5 11 1 2 3 5 19 22 7 3 11 9 6 4 5 13 2 9 11 2 5 28 4 12 17 8 26 4 2 10 7 19 1 3 11 6 7 1 1 16 9 21 3 8 1 1 2 3 4 5 6
Version 1 - 1
E -63
Reference No.
037 194 037 194 037 225 037 236 037 237 037 264 037 265 037 265 037 265 037 266 037 267 037 267 037 293 037 305 037 305 037 441 037 493 037 851 037 930 037 930 038 386 038 073 038 102 038 201 038 238 038 268 038 290 038 390 038 407 046 837 049 129 051 530 051 883 054 883 056 318 056 335 057 916 061 676 061 676 061 822 061 822 061 857 061 857 061 942 063 121 063 543 063 544 063 652 063 654 063 656 063 660 063 662
Designation
union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lifting eye nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . delivery plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . delivery spring plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LP-hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . angle thermometer 0-250C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooling water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . distribution piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . packing kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pipe adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . resilient mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tube clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . protection cover packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inspection hole cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . protection cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overpressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connecting rod screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connecting rod screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . zinc protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . zinc protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connecting rod bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connecting rod bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bursting plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driving plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooler cover, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooler cover, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooler cover, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
35 47 53 31 31 47 35 37 39 37 37 39 39 35 39 39 39 40 37 39 39 51 7 39 39 47 45 35 47 55 57 23 7 23 49 33 49 13 15 21 23 13 15 23 33 49 11 21 23 21 21 23
Pos.
4 10 1 2 3 12 2 5 17 6 8 15 27 12 32 30 26 40 4 31 25 6 15 10 23 2 1 6 1 4 1 12 3 3 10 4 2 4 4 2 2 2 2 13 2 1 2 6 7 5 4 5
E - 64
Version 1 - 1
Index
Reference No.
063 712 063 732 063 743 063 747 063 747 063 748 063 749 063 750 063 751 063 776 063 779 063 786 063 796 063 797 063 808 063 811 063 812 063 815 063 826 063 864 063 866 063 868 063 869 063 915 063 947 063 950 063 985 064 018 064 038 064 039 064 140 064 142 064 143 064 144 064 145 064 146 064 147 064 148 064 150 064 151 064 236 064 257 064 261 064 306 064 308 064 309 064 331 064 332 064 366 064 394 064 395 064 396
Designation
connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . valve cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder cover packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder cover packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inspecting hole cover packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . housing cover packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooler cover packing, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooler cover packing, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . finished bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder housing 1st stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooler cover packing, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooler cover packing, rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . finished bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . collecting tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connecting rod 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . valve cover 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . valve cover 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . compressor monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricating oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . temperature monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . measuring device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . automatic drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connecting rod 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . piston 2nd stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . air pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooling water pipes compr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . crankcase venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . resilient mounts f. motor 280 S/M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . piston 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . assembly bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . auxiliary tools, compl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . turning rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . blind flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . blind flange packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooling water lines unit without pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooler cover, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gate valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
13 11 27 21 23 7 7 23 23 21 21 7 21 21 23 11 33 19 15 5 5 5 5 5 55 5 5 59 5 5 5 5 11 5 5 5 5 5 19 5 25 7 5 53 5 53 7 7 5 7 23 39
Pos.
1 3 1 8 9 6 7 11 10 7 1 1 10 9 8 4 1 1 1 3 7 9 10 8 10 24 18 1 19 25 1 2 1 4 6 13 14 17 2 23 1 5 5 2 22 3 27 28 15 2 6 22
Version 1 - 1
E -65
Reference No.
064 442 064 448 064 449 065 664 066 143 066 144 066 145 066 442 066 595
Designation
cylinder housing 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . protection device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . protection cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooling water lines unit with pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-profil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooling water hose lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
23 7 9 55 5 39 39 39 55
Pos.
1 30 1 9 16 3 2 1 1
E - 66
Version 1 - 1

Air Compressor WP400

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Air Compressor WP400

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S a u e r C o m p r e s s o r

Type: WP 400 Operating Instructions

High-pressure Compressor 2 Stages water-cooled

Edited by: ZINDEL Technical Documentation, www.zindel.de

Sauer compressor type approvals

Genuine Sauer spare parts certied safety

5. 5.1 5.2 5.3 5.4

10. 10.1 10.2 11. 12.

Warranty and Liability

Do not use parts from the "grey market"

but only genuine Sauer spare parts with certicate!

Customer service of J.P. SAUER & SOHN

Organisation of these instructions

Prohibition of unauthorized conversion

Compressor starts automatically without warning!

Wear hearing protection!

Rotational direction of Crankshaft

Location of safety markings (top view)

Personal protection gear

Design and Function

Item 1 2 3 4 5 6 7 Cylinder 1st stage Cylinder 2nd stage

Oil ller Cooling water outlet (not visible)

Design and Function

Design and Function

Design and Function

Condensate draining/Pressure relief

Indicators on the Sauer Compressor

Design and Function

3 2 195 mm 110 mm 90 mm 1800 rpm clockwise

8 bar 5 % higher than the ultimate pressure

13.5 l 5l see chapter 10. Lubricant table

Sound pressure level (in free sound eld at 1 m distance)

Weight and dimensions

see installations plan

Compressed air system plan and cooling water plan

Pressure relief valve Oil lter

Transport and Installation

Transport and Installation

This way is correct!

Do not install fresh air feed this way!

At a room temperature of below +5 C the room needs to be

Transport and Installation

Connecting the compressor

Transport and Installation

This way is correct!

Not this way!

This way is correct!

Not this way!

Transport and Installation

3. Put dipstick back in and replace the oil ller plug.

Transport and Installation

Checking the direction of rotation

Ultimate pressure [bar]

Remedy Check fuses. Replace blown fuses.

Compressor was switched off, Fault indicator lamp "Overcurrent glowing.

Check 2nd stage valve, replace if necessary. Replace gasket.

Clean cooling water cavities with boiler cleaning compound.

Compressor makes loud noises.

Oil leaking from crankcase.

Gasket or shaft seal faulty. Screws not tight.

Replace the O-ring.

Check drain lines and drain intervals.

Instructions for the maintenance schedule

Maintenance Schedule No. Beginning of this maintenance schedule