Air Compressor

S a u e r
C o m p r e s s o r
Typ: WP 400
Operator Manual
High-pressure Compressor
2-stage
water-cooled
Ausgabe: 05 / 2008
Redaktion: Edited by: J.P. Sauer & Sohn Maschinenbau Technical Documentation
WP400_BA_Titel_en_08.fm
WP400_BA_Titel_en_08.fm
Zertifikate_en_0.fm
Sauer compressor Type Approvals
Note!
On this page only a few examples are shown. FurtherType Approvals are available on request.
Genuine Sauer spare parts

certified safety
Zertifikate_en_0.fm
N
E
M
I
C
SPE
Table of Contents
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Warranty and Liability . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Type Approval and Genuine Sauer Spare Parts. . . . . 10
J.P. SAUER & SOHN Customer Service . . . . . . . . . . 11
Text Conventions Used in This Operator Manual . . . . 12
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Conditions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Unauthorised modification. . . . . . . . . . . . . . . . . . . . . . 13
Safety Information - Warning and Caution . . . . . . . . . 14
Safety Warnings on the Machine . . . . . . . . . . . . . . . . 15
Safety and protection devices . . . . . . . . . . . . . . . . . . . 16
Noise protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Safety requirements for personnel . . . . . . . . . . . . . . . 18
Personal protective equipment . . . . . . . . . . . . . . . . . . 19
3
3.1
3.2
3.3
3.4
Design and Function. . . . . . . . . . . . . . . . . . . . . . . . . 20

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Functional description . . . . . . . . . . . . . . . . . . . . . . . . . 26
Displays on the Sauer compressor . . . . . . . . . . . . . . . 28
Indicators and operating elements on the
compressor control . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4
4.1
4.2
Technical Specification . . . . . . . . . . . . . . . . . . . . . . 30
Specification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
P&I Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
WP400_BA_en_09IVZ.fm
1
1.1
1.2
1.3
1.4
1.5
1.6
5
5.1
5.2
5.3
5.4
5.5
5.6
Transport and Installation . . . . . . . . . . . . . . . . . . . .36

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Storage before Installation . . . . . . . . . . . . . . . . . . . . .38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Connecting the Compressor . . . . . . . . . . . . . . . . . . . .42
Filling with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Checks to be carried out after installation and
before the first start-up. . . . . . . . . . . . . . . . . . . . . . . . .48
6
6.1
6.2
6.3
6.4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Routine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . .55
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
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
J.P. SAUER & SOHN maintenance service. . . . . . . . . .59
Safety during maintenance . . . . . . . . . . . . . . . . . . . . .59
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . .60
Table of torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Checking screwed connections . . . . . . . . . . . . . . . . . .62
Replacing air filter cartridge. . . . . . . . . . . . . . . . . . . . .62
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Cleaning the oil strainer. . . . . . . . . . . . . . . . . . . . . . . .64
Checking the valves . . . . . . . . . . . . . . . . . . . . . . . . . .64
Replacing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Draining the cooling water . . . . . . . . . . . . . . . . . . . . . .67
Replacing piston rings, gudgeon pins and
gudgeon pin bearings . . . . . . . . . . . . . . . . . . . . . . . . .67
Checking pistons and cylinders . . . . . . . . . . . . . . . . . .71
Wear limits for cylinder diameters . . . . . . . . . . . . . . . .71
Checking coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Renewing flexible gear rim . . . . . . . . . . . . . . . . . . . . .72
Inspecting the condensate separator . . . . . . . . . . . . .73
Overhauling water drain valves . . . . . . . . . . . . . . . . . .73
Cleaning particle trap. . . . . . . . . . . . . . . . . . . . . . . . . .74
Replacing the zinc protection . . . . . . . . . . . . . . . . . . .74
Replacing the bursting disc . . . . . . . . . . . . . . . . . . . . .74
Checking the cooling water pump . . . . . . . . . . . . . . . .75
8.13
8.14
8.15
8.16
8.17
8.18
8.19
8.20
8.21
8.22
Storage, Preservation lay-up procedure . . . . . 77

Safety when storing and removing . . . . . . . . . . . . . . . 77
Temporary preservation and storage . . . . . . . . . . . . . 78
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10
10.1
10.2
Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Preservation oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
11
Spare Parts and Accessories. . . . . . . . . . . . . . . . . . 84
12
12.1
12.2
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Commissioning certificate . . . . . . . . . . . . . . . . . . . . . . 87
Return of goods and notification of claim . . . . . . . . . . 88
9
9.1
9.2
9.3
WP400_BA_K1_12_en_08.fm
General
1.1 Foreword
This Operator Manual provides installation guidance, safe
operation, maintenance and repair instructions with illustrated
parts breakdown.
The following unique specification for the Sauer compressor can
be found on the nameplate affixed to the compressor:
Compressor type
Serial number
Year of construction:
We recommend you record this information in Chapter 11 Spare
Parts and Accessories and always provide this data when
requesting parts and any repair instructions.
1.2 Precautions
We recommend that only authorised and trained personnel
operate and service the Sauer compressor. Such responsible
personnel should be thoroughly familiar with, and frequently
review, the Operator Manual.
These instructions should always be readily available at the
compressor installation.
Copyright
The copyright for this Operator Manual remains with J.P. SAUER
& SOHN. These instructions, or parts thereof, shall not be copied,
distributed or made available to third parties. Contravention will
result in prosecution.
WP400_BA_K1_12_en_08.fm
Specific
precautions
General
1.3 Warranty and Liability
WP400_BA_K1_12_en_08.fm
Sauer can no longer cover warranty, be liable for any claims, if a

failure is attributed to any of the following:
use of the machine not as specified;
substitution of parts not manufactured or approved by Sauer;
use of spare parts that are not genuine Sauer spare parts;
operation of the machine with faulty or improperly installed
safety and/or protection devices;
failure to observe operating instructions;
unauthorised modification to the machine or its control system;
inadequate monitoring of machine parts subject to wear;
failure to maintain/repair in accordance with Sauer
instructions;
force majeure.
1.4 Type Approval and Genuine Sauer Spare Parts

Type approval for the Sauer compressor is valid under
the condition that parts and components specified and
qualified by J.P. SAUER & SOHN are used. Type approval is
provided by the classification society and the EC Declaration
of Conformity or EC Manufacturer's Declaration. Failure to
observe these requirements may void type approval.
Only the use of genuine Sauer spare parts will ensure
compliance with these specifications and, therefore, reliable
and safe operation of the Sauer compressors.
If non-genuine Sauer spare parts are used, we reserve the
right of exclusion from liability for personal injury and material
damage.
Genuine Sauer spare parts are supplied with a Certificate of
Conformity and a Certificate of Authenticity. An example of this
document is shown just before the Table of Contents in these
instructions. If spare parts are received without this certificate,
there is a risk that these are not genuine Sauer spare parts. In
such an instance please contact our Customer Service.
Note!
Be aware this is a high-pressure compressor, for your own
safety and for reliable compressor operation, only use genuine
Sauer parts.
Only use genuine Sauer spare parts

with a certificate!
10
Incorrect
Do not use parts from the

grey market!
WP400_BA_K1_12_en_08.fm
Correct
General
1.5 J.P. SAUER & SOHN Customer Service
Should you have any technical questions relating to maintenance
or repair, please contact our Customer Service:
J.P. SAUER & SOHN Maschinenbau GmbH
Customer Service
P.O. Box 92 13
24157 Kiel, Germany
Phone (international):
Technical information
Spare parts orders
Fax (international):
Emergency service (international):
E-mail:
Web:
+49 431 39 40 -87

+49 431 39 40 -86/886
+49 431 39 40 -89
+49 172 4 14 63 94
service@sauersohn.de
www.sauersohn.de
WP400_BA_K1_12_en_08.fm
Note!
If you have questions regarding your Sauer compressor, please
specify the compressor model and serial number (see Chapter
11 Spare Parts and Accessories or nameplate on the
compressor).
11
1.6 Text Conventions Used in This Operator Manual

Part lists
General lists are marked using a dash.

Example:
Compressor cooling consists of
cooler assembly
cooling water lines.
Instructions
Individual instructions or multiple instructions requiring action but

where the sequence is of no importance are normally denoted by
a bullet-point.
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.
Results of actions carried out are denoted by a tick mark.
Example:
The control light is on.
Safety and warning instructions are presented pictorially with
clear instructions. The safety instructions are described in detail
in Chapter 2 Safety.
WP400_BA_K1_12_en_08.fm
Safety
instructions
12
Safety
2
Safety
2.1 Conditions of Use

This Sauer compressor must be used for the compression of air
only. The Sauer compressor must not be used at ambient
temperatures below +5 C. Any other unauthorised use requires
the express written approval of J.P. SAUER & SOHN.
In addition, specified conditions of use also includes observing
the Operator Manual and the installation requirements and
maintenance intervals described there.
Most accidents which occur during operation and maintenance of
machinery result from failure to observe basic safety rules or
precautions.
When handling, operating or carrying out maintenance,
personnel must observe safe engineering working practices and
local regulations.
2.2 Unauthorised modification
WP400_BA_K1_12_en_08.fm
Unauthorised modification of the Sauer compressor is not

permitted. Modifications may lead to an accident that can be lifethreatening, cause personal injury or result in damage to the
equipment.
Contact J.P. SAUER & SOHN when planning any modification to
obtain written approval.
13
2.3 Safety Information - Warning and Caution

The safety information in these instructions is presented as high
risk and lower risk, as follows.
Warning - Danger!
High risk.
Ignoring these safety instructions can cause personal injury, or
death, and significant equipment damage.
WP400_BA_K1_12_en_08.fm
Caution - Note!
Less risk.
Disregarding this safety note may cause damage to the
equipment.
14
Safety
2.4 Safety Warnings on the Machine
Danger!
Safety labeling affixed to the machine must not be altered or
removed. Replace damaged or lost safety labels immediately
with an approved replacement.
The Sauer compressor with an EC Manufacturer's Declaration or
EC Declaration of Conformity is marked with the following safety
labelling:
Safety label
Meaning
Safety label
Meaning
High voltage! Danger

to life!
Read Operator
Manual!
Compressor starts
automatically without
warning!
Wear hearing
protection!
Hot surface!
Rotational direction of
crankshaft
WP400_BA_K1_12_en_08.fm
Location of safety markings
15
2.5 Safety and protection devices

Danger!
Safety devices must not be adjusted, tampered with or removed.
The safety devices must be periodically tested and checked:
Safety valves must be
installed with a lock-seal
should be replaced, adjusted and re-sealed only by authorised
personnel
Each compression stage of the Sauer compressor is equipped
with a safety valve, which will fully discharge air when the blowoff pressure is reached.
Safety valves are installed at the following locations:
1. Compression stage: in the rear cooler cover of stage 1.2;
2. Compression stage: at the final separator after the 2nd
stage.
High air temperature switch
The Sauer compressor is equipped with a temperature sensor.

The high air temperature switch shuts down the compressor if the
compressed air temperature exceeds the limit value.
Low oil pressure

switch
The Sauer compressor comes supplied with a low oil pressure

switch which trips when the pressure drops below p < 1 bar.
WP400_BA_K1_12_en_08.fm
Safety valves
16
Safety
2.6 Noise protection
Sound pressure level details are found in the Technical
Specification (see Chapter 4).
The Sauer compressor can be equipped with a sounddampening enclosure to reduce noise, available as an accessory
from J.P. SAUER & SOHN.
Danger!
When the compressor is operated without sound-dampening
enclosure, hearing protection should be worn when working
near the compressor.
2.7 Waste disposal
WP400_BA_K1_12_en_08.fm
Note!
The following materials which accumulate during operation of
the compressor must be disposed of in an environmentally
sound manner in accordance with applicable laws.
condensate (oil/water) arising from inter-cooling in the
compression process
used oil and grease, and used oil and grease and materials
soiled by such lubricants
cleaning agents and rags soiled by such agents.
17
2.8 Safety requirements for personnel
WP400_BA_K1_12_en_08.fm
Only personnel authorised by J.P. SAUER & SOHN are permitted

to service the Sauer compressor! Before commencing work they
must have read and understood the instructions in the Operator
Manual, and must be familiar with all safety devices and safety
regulations.
In addition to the instructions in this Operator Manual and
supplier documentation, accepted engineering standards must
be observed as well as all local laws, standards and regulations
such as
The Equipment and Product Safety Act,
The regulations for industrial safety,
The regulations for accident prevention pertaining to
compressors,
Provision of the Verband Deutscher Elektrotechniker (VDE/
German electrical engineering industry association)
Regulations on environmental protection.
Additionally, where appropriate classification society and
operational regulations must be observed.
Only those trained and thoroughly familiar with the compressor
operation should be authorised to operate the compressor.
Personnel authorised to service the compressor must be trained
technical specialists of the owner and manufacturer.
18
Safety
2.9 Personal protective equipment
WP400_BA_K1_12_en_08.fm
The owner should provide personal protection equipment (e.g.

hearing protection, safety boots, etc.) for personnel carrying out
any work on the Sauer compressor.
19
Design and Function
3.1 Overview
Note!
Details of parts and spare parts can be found in the spare parts
catalogue.
13
12
11
15
14
10
20
WP400_BA_K1_12_en_08.fm
Design and Function
Item
Designation
Cylinder stage 1.1
Cylinder stage 1.2
Cylinder 2nd stage
Safety valve 1st stage
Safety valve 2nd stage
Air filter
Oil fill pipe
Oil dipstick
Sump oil drain
10
Low oil pressure switch
11
Drain valve 1st stage
12
Drain valve 2nd stage
13
Compressed air temperature sensor
14
Cooling water stop valve
15
Motor
WP400_BA_K1_12_en_08.fm
21
Vertical
sectional view
7
6
5
1
3
2
9
Item
Designation
Crankcase
Crankshaft
Flywheel
Coupling
Connecting rod stage 1.1
Connecting rod 2nd stage
Lubricating oil supply
Compressor monitoring and control
WP400_BA_K1_12_en_08.fm
22
WP400_BA_K1_12_en_08.fm
Design and Function
23
Horizontal
sectional view
17
8
Stage 1.2
11
14
5
2
Stage 1.1
Stage 2
7
9
10
13
4
12
6
15
3
16
18
WP400_BA_K1_12_en_08.fm
24
Design and Function
Item
Designation
Cylinder stage 1.1
Cylinder stage 1.2
Cylinder 2nd stage
Piston stage 1.1
Piston stage 1.2
Piston 2nd stage
Valve cover stage 1.1
Valve cover stage 1.2
Valve cover 2nd stage
10
Concentric valve stage 1.1
11
Concentric valve stage 1.2
12
Lamellar valve 2nd stage
13
Cooler stage 1.1
14
Cooler stage 1.2
15
Cooler 2nd stage
16
17
18
19
Crankcase vent
WP400_BA_K1_12_en_08.fm
25
3.2 Functional description

Drive
The Sauer Compressor is driven by an electric motor flangemounted to the crankcase bell-housing. The power is transmitted
by means of a flexible coupling.
Compressor
control
Driven by an AC motor drive, the Sauer compressor is controlled

and monitored by an electrical compressor control. This control
system must comply with legal regulations. Optionally, J.P.
SAUER & SOHN supplies a suitable compressor control.
Compression
The compressor takes in the ambient air via a layered filter with
a tube silencer and compresses it in two compression stages with
a total of three single-stage cylinders to the final pressure, with
the 1st stage consisting of two cylinders of the same design
connected in parallel. The air in each cylinder is inter-cooled with
cooling water. A replaceable wet liner with a double O-ring gasket
is installed in each cylinder.
The cylinders arranged in a W-configuration are equipped with
concentric valves and with lamellar valves which are easy to
maintain and have a long service life.
Cooling
The compressor is cooled with fresh water. Cooling with sea

water is available as an option.
Inter-cooling of the compressed air in the 1st and 2nd stage takes
place in the U-shaped cooling pipes which are press fitted via a
cartridge version between the cylinder housing and cylinder
cover.
Cooler pipe
Cylinder cover
The cooling pipe and the replaceable liners are directly immersed
in cooling water in the cylinder. The cooling water spaces are
protected by zinc anodes against corrosion. When at a complete
standstill, the cooling water supply is interrupted by a solenoid
valve at the cooling water inlet.
The compressor cooling is monitored by a temperature sensor.
The compressor is immediately stopped if the compressed air
temperature exceeds the upper limit value.
Optionally, the compressor can be fitted with a cooling water
pump driven by its own electric motor.
26
WP400_BA_K1_12_en_08.fm
Cylinder housing
Design and Function

Condensate which builds up in the 1st stage accumulates in the
collecting vessels of the 1st stage cooler cover. The 2nd stage has
its own condensate separator for the oil/water condensate, which
collects during compression and inter-cooling.
Oil/water
draining and
pressure relief
Condensate is drained via drain lines. There are solenoid valves

installed in the drain lines. The drain valves must be open when
the Sauer compressor is unpressurised. A few seconds after
starting, the drain valves should close and the compressor
should power up against system pressure. The drain valves
should drain the system during operation at preset intervals. The
control of the drain valves (solenoid valves) is carried out by the
compressor control.
Lubrication/Oil
Pressure
A gearwheel oil pump, driven by the crankshaft, draws the

lubricating oil from the crankcase, and then pumps it to the
connecting rod bearings. Crankshaft main-end bearings,
gudgeon pin bearings and pistons (final stage also receives a
small amount of injected oil) are lubricated by oil splash or mist
present in the crankcase. The oil pressure is monitored by a low
oil pressure switch.
The compressor control must stop the compressor immediately if
the oil pressure falls to the limit value.
WP400_BA_K1_12_en_08.fm
Condensate
separation
27
3.3 Displays on the Sauer compressor

3
Stage 1.1
7
4
6
Stage 1.2
1
2
Stage 2
Item
Designation
Display
Pressure gauge 1st stage
Compressed air pressure after 1st stage
Pressure gauge 2nd stage
Compressed air pressure after 2nd stage
Thermometer stage 1.1
Compressed air temperature after stage 1.1
Compressed air temperature after stage 1.2
Thermometer 2nd stage
Compressed air temperature after 2nd stage
Oil pressure gauge
Oil pressure of oil pump
Cooling water thermometer Temperature of cooling water
WP400_BA_K1_12_en_08.fm
28
Design and Function

3.4 Indicators and operating elements on the
compressor control
Note!
If the compressor control is supplied by J.P. SAUER & SOHN
read the documentation supplied.
On the front of the Compressor Control, the following indicators
and control features can be found:
Display/
Operating
element
Signal lamp
Operation
Explanation
Illuminates when the compressor is running.
WP400_BA_K1_12_en_08.fm
Fault indicator
Illuminates if the compressor has shut down because of low oil
lamp Oil pressure pressure.
Fault indicator
lamp Air
temperature
Illuminates if the compressor has shut down because of high

outlet gas temperature.
Fault indicator
lamp Overcurrent
Illuminates if the compressor has shut down because of excess

motor current.
Run time counter
Indicates the hours the compressor has run.
Operation mode
selector
Manual mode:
Starts the compressor manually. The compressor starts up and
continues to run until it is manually turned off again.
Selector position 0:
Turn the compressor off manually. Any pending fault messages
are reset.
Auto mode:
The compressor starts and stops with the opening and closing of
a remote contact (e.g. pressure switch at a compressed air
vessel).
Main switch
Disconnects the power supply from the compressor control to the

compressor.
A main isolator switch should be installed if required by local law
and regulations.
29
Technical Specification
4.1 Specification data

Designation
Data
Compressor type
WP 400
Number of cylinders
Number of compression stages
Cylinder diameter 1st stage
195 mm
Cylinder diameter 2nd stage
110 mm
Piston stroke
100 mm
Maximum speed
1800 rpm
Direction of rotation (when looking toward

flywheel)
clockwise
Maximum working pressure.
30 bar
Set pressures for safety valves:

1. stage
8 bar
2. stage
5 % above final pressure
Oil sump capacity
13.5 l
Oil refill quantity dipstick MAX/MIN
5l
Oil type
see Chapter 10 Lubricant Table
Maximum switching current
6 A/220 V
Setting
opens at 1 bar falling

approximately 15 s delay on start
instruction
Switch function
Change-over contact
30
WP400_BA_K1_12_en_08.fm
Oil pressure switch:
Designation
Data
Drain valves
Pickup and holding power
18 VA/14 W
Setting
currentless open
relief starting: approx.15 sec
automatic drainage: every 15 min for 15 s
Final pressure sensor (option):

6 A/220 V
Setting
As required by customer
Switch function
Change-over contact
Air temperature switch:

16 A/220 V
Setting
opens at 80 C rising
Switch function
Change-over contact
Maximum permissible entry pressure at

the
cooling water inlet
5 bar without cooling water pump

2.5 bar with cooling water pump
Bursting pressure of the burst disc

in the cooling water system:
> 6 bar
Cooling water temperature at the outlet
40 to 50 C
Holding power: 36 W
Valve is currentless closed
WP400_BA_K1_12_en_08.fm
Cooling water pump (option):

Electrical connection
440 V/60 Hz 1.1 kW or 400 V/50 Hz 1 kW
Setting
not self-priming, should start and stop in

synchronisation with the compressor
Sound pressure level

free field at 1 m
max. 92 dB(A)
Weight and dimensions
See installation drawing

31
WP400_BA_K1_12_en_08.fm
Note!
Please refer to the order-specific documentation of your
compressor for data such as final pressure, speed, power
requirements, etc.
32
WP400_BA_K1_12_en_08.fm
33
4.2 P&I Flow Diagram

10
12
31
Cooling water
outlet
5
4
30
14
27
26
25
23
24
34
32 33
15
1.1
29
16
1.2
11
17
20
13
16
Cooling water
inlet
21
19
28
18
Compressed air outlet
22
Air intake
atm
Condensate
Motor
Motor
Solenoid valve
Drive
lubrication
Compressor
stage
Safety valve
Filter
Non-return valve
Suction filter
Pressure relief valve
Intercooler
Oil pressure switch
Separator
Pump
Temperature
switch
Pressure gauge
34
WP400_BA_K1_12_en_08.fm
Temperature
Item
Designation
Item
Designation
Compression stage 1.1
22
Compression stage 1.2
23
Drive lubrication
2. Compression stage
24
Oil filter
Cooler stage 1.1
25
Oil pump
Cooler stage 1.2
26
Oil pressure gauge
Cooler 2nd stage
27
Oil pressure switch / trip
Separator stage 1.1
28
Drive motor
Separator stage 1.2
29
Cooling water particle trap
Separator 2nd stage
30
10
Safety valve 1st stage
31
Cooling water thermometer
11
32
Cooling water pump (option)
12
33
Motor cooling water pump
34
Cooling water manual valve

(only with optional cooling water
pump)
2nd
Pressure gauge
stage
14
15
16
Thermometer 2nd stage
17
Solenoid valve
(drainage) 1st stage
18
Solenoid valve
(drainage) 2nd stage
19
Intake air filter stage 1.1
20
Intake air filter stage 1.2
21
Non-return valve
WP400_BA_K1_12_en_08.fm
13
35
Transport and Installation
5.1 Transport
Shipping
The machine is packed ready for shipping.

The Sauer compressor should be checked for completeness
and any damage immediately upon receipt.
Damage to the packaging or the machine should be reported
to the transport firm and J.P. SAUER & SON immediately.
Transport
The Sauer compressor must be transported using a forklift truck

or be hoisted by a crane.
WP400_BA_K1_12_en_08.fm
Danger!
Suspended load during transport.
The forklift truck/crane must have sufficient load-bearing
capacity.
Ensure that no personnel are within the danger area of the
suspended load and the forklift truck/crane.
Sling the unpacked compressor using the four lifting eye bolts
(see illustration).
Raise, move into position and set down with care.
36
Transport by crane
Lifting eye bolts
WP400_BA_K1_12_en_08.fm
Lifting point
37
5.2 Storage before Installation

If the Sauer compressor has to be stored before installation, do
not unpack, and store under the following conditions:
temperature: +5 to +40 C;
relative humidity 30 to 95 %, non-condensing;
in a dry area, under a roof and protected from the weather;
protected from being soiled;
protected against vibration and shock.
Note!
The standard factory protective packing is sufficient for a
maximum storage period of 12 months.
WP400_BA_K1_12_en_08.fm
Note!
High pressure hoses can be stored for up to five years after
delivery.
38

5.3 Installation
Note!
If in doubt regarding the suitability of the intended installation
area, please contact J.P. SAUER & SOHN. If required for the
installation area, Sauer can provide help with the design of a
ventilation system.
For proper installation follow the installation instructions and
observe the following.
Installation
requirements
max. 55 C
min. 5 C
The installation area must be dry and free from dust.

Ensure that the installation is ventilated in such a way that the
heat generated during operation is removed.
Room temperature during operation of the Sauer compressor:
+5 C to +55 C
(If it is intended to operate the compressor outside this
temperature range, please contact J.P. SAUER & SOHN).
For proper installation, follow the installation instructions and
observe the following conditions.
WP400_BA_K1_12_en_08.fm
Note!
The air temperature at the location where the compressor is
installed must not exceed +55 C. Conditions in the area of
installation as well as the heat generated by the compressor and
any other machines installed in the same area must be kept in
mind.
If necessary, install a ventilation or air extraction system in the
area.
Install the fresh air feed in such a way that the cooling air stream
is never directed at the compressor. Otherwise, there is a danger
that condensation will occur within the machine, with
corresponding consequential damage.
39
Correct ventilation
Incorrect ventilation
At room temperatures below +5 C the room must be heated

or a heater must be installed on the Sauer compressor.
The installation location must be selected in such a way that
the Sauer compressor is easily accessible.
The cooling water spaces are automatically kept vented through
the arrangement of the cooling water inlet and outlet.
The quantity of cooling water must be set at a level such that the
cooling water outlet temperature is between 40 C and 50 C. A
maximum cooling water outlet temperature of 50 C must not be
exceeded.
50 C
Note!
The Sauer compressor is cooled with fresh water.
Seawater can be used for cooling if desired, but according to its
temperature and chemical composition seawater can be very
corrosive.
40
WP400_BA_K1_12_en_08.fm
40 C

Note!
J.P. SAUER & SOHN would be pleased to advise on the
installation of the compressors.
Foundation
Note!
The standard delivery anti-vibration mount has a resonant
frequency of approx. 10 Hz.
Excitation of the compressor foundation by vibrations from other
machines installed in the vicinity must not be in the 10 Hz range.
Otherwise there is a danger that the standard anti-vibration
mount could be destroyed by resonating vibration.
WP400_BA_K1_12_en_08.fm
1. Check whether there are vibrations of the machine

foundation in the 10 Hz range.
2. If in doubt, contact J.P. SAUER & SOHN in order to clarify
whether a different anti-vibration mount can be used.
41
5.4 Connecting the Compressor

Danger!
The compressor should only be connected by a qualified
technician. Any work on the electrical installation must be carried
out by qualified electricians only.
Pipelines
Compressed air outlet, cooling water inlet and outlet, and

drainage connections of the Sauer compressor must be
connected by hose connections to any of the system owners
permanent piping.
Hose line
for cooling water
High pressure hose

for compressed air
Cooling water
connection
Hose line
for condensate
WP400_BA_K1_12_en_08.fm
Danger!
At the compressor start-up and during drainage compressed air
escapes from the drainage connections. Consequently, do not
operate the compressor without hose lines connected.
42

The hose lines must be installed free of tension and not twisted.
Correct installation
Incorrect installation
Drainage
WP400_BA_K1_12_en_08.fm
Note!
Accumulated condensate contains oil. It may only be disposed
of in compliance with applicable legal regulations.
J.P. SAUER & SOHN offers condensate collection containers for
separating air from condensate as well as condensate
processing systems for separating oil from condensate.
Note!
We recommend connecting up the compressor drainage
separately.
If you wish to combine the drainage of several compressors,
please observe the following:
Choose a sufficient nominal diameter for the common drainage
line;
Connect the drainage lines of the individual compressors at a
sharp angle to the common drainage line, so that no pressure
can build up in the drainage line of a compressor that is not in
operation.
43
Incorrect connection
WP400_BA_K1_12_en_08.fm
Correct connection
44

Connections
The illustration below shows the connections and the fittings for
the operation of a typical Sauer compressor.
1
WP400_BA_K1_12_en_08.fm
Item
Designation
Type
Function
Drive motor
AC motor
Compressor drive
Non-return valve
Plate valve
Prevent air flowing back
Final pressure
switch
Change-over
switch
Start/stop control for the compressor
Safety valve
Spring-loaded
safety valve
To limit excessive pressure on the

parts subjected to pressure
Drainage valve
Solenoid valve
Start relief and drainage
High air
temperature
switch
Change-over
switch
Switch off compressor if temperature

is too high
Oil pressure
switch
Change-over
switch
Switch off the compressor if oil

pressure is too low
Cooling water
stop valve
Solenoid valve
Prevent flow of cooling water when

machine is not operating
Cooling water
pump (option)
Centrifugal pump,
not self-priming
Circulate cooling water
45
WP400_BA_K1_12_en_08.fm
Note!
For technical specifications of the individual items, please refer
to Chapter 4.
All change-over switches are factory adjusted.
If desired, the components are supplied pre-wired to a terminal
box.
46

5.5 Filling with oil
The Sauer compressor is delivered without oil.
Oil fill cap
Dipstick
Danger!
Make sure to fill the crankcase of the compressor with oil before
initial operation!
Use an appropriate lubricating oil (see Chapter 10 Lubricant
Table).
Note the amount of oil needed (see Chapter 4 Technical
Specification).
1. Unscrew the oil fill cap (red).
2. Pour in oil and check the oil level with the dipstick (red).
Note!
Only fill with oil up to the upper level gauge mark on dipstick.
Overfilling increases the oil consumption of the compressor.
WP400_BA_K1_12_en_08.fm
3. Replace the dipstick and screw the oil fill cap back in.
47
5.6 Checks to be carried out after installation and

before the first start-up.
WP400_BA_K1_12_en_08.fm
Check that the electricity connection matches the data on the

nameplate.
Check that all connections between the compressor and the
compressed air equipment are properly installed.
Pay particular attention to the compressed air connection.
Are the drainage lines properly connected?
Are the cooling water lines open?
Has the crankcase been filled with oil?
Have all tools and foreign objects been removed from the
compressor?
Is the entire unit clean?
48
Operation
6
Operation
6.1 Safe operation

Danger!
Only authorised persons are permitted to put into operation and
operate the Sauer compressor!
Danger!
Only switch on and start the compressor when
it has been checked that it is in perfect condition;
all tools and foreign objects have been removed from the
machine.
Danger!
Immediately turn compressor off if personnel and property are
endangered. Only re-start compressor when there is no more
danger or possible damage.
Danger!
In Automatic mode the compressor starts automatically without
warning.
Danger!
Risk of burns from touching hot surfaces of the compressor
during operation. Wear protective gloves.
WP400_BA_K1_12_en_08.fm
Danger!
Risk of hearing damage because of the sound pressure level
while the compressor is running! Wear hearing protection near
the compressor.
Note!
Switch compressor off in the event of any abnormal/fault
conditions or unexpected events. Eliminate the cause of the
problem with the help of Chapter 7 Troubleshooting.
49
6.2 Operating modes
WP400_BA_K1_12_en_08.fm
After you have turned on the power supply to the Sauer

compressor, it can be started with one of the following two
operating modes using the mode selector switch:
Manual operating mode:
The compressor starts and continues to run until it is stopped
or turned off either by using the mode selector switch or the
main switch.
Automatic operating mode:
Starting and stopping the compressor is controlled by external
devices (for example using the pressure switch of the pressure
vessel).
When the Sauer compressor starts, it starts without load with the
drainage valves open. After a few seconds the valves close and
the compressor powers up against system pressure.
50
Operation
6.3 Initial operation
Check the
direction of
rotation
Allow the Sauer compressor to run only for a few seconds to

check the direction of rotation.
1. Switch the power supply on.
2. Set the mode selector switch to Manual to start the
compressor in manual mode.
3. Immediately check the compressors direction of rotation. It
must rotate in the direction indicated by the arrow on the
crankcase.
4. Set the mode selector switch to 0 to stop the compressor.
5. Switch off the power supply.
6. If the direction of rotation is incorrect, the polarity of the
electric motor should be changed by a qualified electrician.
Danger!
If the crank shaft rotates in the wrong direction, no oil pressure
builds up. Risk of subsequent damage.
7. Checking the direction of rotation of the cooling water

pump (option):
Switch on the pump motor.
The motor must not be allowed to reach its operating speed.
The direction of rotation must agree with the rotation direction
arrow on the pump. If the direction of rotation is incorrect, the
polarity of the electric motor should be changed by a qualified
electrician.
Pump and suction pipe must be completely filled with cooling
water.
WP400_BA_K1_12_en_08.fm
Danger!
The cooling water pump must not be allowed to run dry.
51

2. Set the mode selector switch to Manual to start the
compressor in manual mode.
If correctly adjusted, the drain valves should close after about
15 seconds and the compressor should power up against
system pressure.
3. Check the pressure gauges of each stage as well as the oil
pressure gauge and compare readings with the nominal
values (see Chapter 6.4 Routine Operation).
4. Check the function of the automatic drainage.
It is required to drain for about 15 seconds every 15 minutes.
This is indicated by a drop in pressure on the pressure gauge.
5. Check that cooling water is flowing.
The temperature of the cooling water at the outlet must stay
within the range given in the Data table in Chapter 4.1. The
temperature can be read from the cooling water thermometer
at the cooling water outlet. If these temperatures are
exceeded or not reached the flow of cooling water must be
increased or decreased accordingly.
In the case of machines with an integrated cooling water
pump, the flow rate can be regulated with the slide on the
pump.
6. Set the mode selector switch to 0 to stop the compressor.
7. Switch off the power supply.
8. If necessary eliminate the cause of deviations from nominal
values and malfunctions. See also Chapter 7
Troubleshooting.
9. Complete the commissioning certificate and send it to J.P.
SAUER & SOHN Customer Service. The commissioning
certificate is in the Appendix.
WP400_BA_K1_12_en_08.fm
Test run
52
Operation
6.4 Routine operation
Keep compressor area clean.
Keep indicators and control elements clean.
Checks
Inspect connections, pipes and electric cables for damage.

Check the oil level once a week before starting, top up, if
necessary. Do not overfill with oil beyond the maximum mark.
Operation

2. Open the cooling water lines.
3. Set mode selector switch to Auto to operate the compressor
in Automatic mode.
Watch out for
Abnormal operating noise.

Pay attention to leaks (compressed air, oil, condensate). The
temperature of the cooling water at the outlet must remain
within the area shown in the Data table in Chapter 4.1.
The pressure indicated on the pressure gauge must remain
within the grey zone in the stage pressure diagram (see
below).
The oil pressure should be between 1.8 bar and 4 bar.
In the event of deviations, see Chapter 7 Troubleshooting.
WP400_BA_K1_12_en_08.fm
Cleaning
53
2nd Stage [bar]
Stage pressure diagram 1st stage
30
20
10
5
1st
6
Stage [bar]
WP400_BA_K1_12_en_08.fm
Note!
Depending on the desired final pressure in the 2nd stage, the
allowable pressure for the 1st stage can be read from the above
diagram.
54
Troubleshooting guide
7
Note!
Should a malfunction occur, first check the User Interface on
the compressor Control Panel and on the compressor.
Try to correct the fault with the help of the table below.
If the fault cannot be corrected, please contact J.P. SAUER &
SOHN Customer Service. The fault description journal is in the
Appendix of this Operator Manual.
Fault
Remedy
Compressor does not start

or switches off.
No input power supply/no

control voltage.
Check the fuses. Replace blown fuses.
Compressor was switched

off because the oil pressure
cutout switch tripped.
Oil level too low.
Check oil level and top up if necessary.

Check for leaks.
Oil too viscous.
Fill with recommended oil.

Check that room temperature is > +
5C.
Oil filter blocked.
Clean the oil filter.
Oil pipe blocked.
Clean oil pipe.
Oil pump faulty or leaking.
Check oil pump. If necessary eliminate

leak or replace oil pump.
Excessive current drawn.
Check supply voltage and electrical

connections. The compressor can be
started again after a cooling down
period.

off by overcurrent relay.
WP400_BA_K1_12_en_08.fm
Probable cause
Check whether the crankshaft can

easily be turned by hand. If not,
disconnect and ascertain whether the
problem has to do with the motor or the
compressor.
Piston seizure
Check cylinders and pistons for any

score marks, replace as necessary.
55
Fault
Probable cause
Remedy
Safety valve of 1st stage

blows off:
Pressure exceeds blowoff pressure (8 bar)
2nd stage valve is not working

properly.
Check the valve of the 2nd stage and

replace if necessary.
Gasket between suction and

pressure side of the 2nd stage
is faulty.
Replace gasket.
Safety valve is faulty.
Replace safety valve.
Valve in the air line to the

compressed air vessel is
closed.
Open valve.
Pressure switch is set too

high.
Lower the pressure setting.
Excessively high pressure

losses in the air line to the
compressed air vessel.
Reduce the pressure losses.
Safety valve is set too low or is

faulty.
Replace safety valve.
Pressure gauge of the 1st

stage is showing excessive
pressure.
Valve of the 2nd stage is

leaking.
Check the valve of the 2nd stage and

replace if necessary. Replace gaskets.
Pressure gauge of the 1st

stage is showing insufficient
pressure.
Valve of the 1st stage is

leaking.
Check the valve of the 1st stage and

replace if necessary.
Air filter very dirty.
Clean the air filter insert or replace it.
The pressure gauges of all

stages show no pressure.
No power at solenoid drainage

valve.
Check solenoid valve power supply.
Solenoid valve of the drainage

is faulty.
Check the solenoid valve and replace it

if necessary.
Connection gaskets or seals

leaking.
Replace faulty gasket or seal.
Cutting rings leaking.
Switch compressor off. Wait until all

parts are no longer under pressure;
check the pressure gauge for this.
Tighten all screws.
Pressure below blow-off

pressure (8 bar)
Pressure above blow-off

pressure (final pressure
+ 5%)
Pressure below blow-off

pressure (final pressure
+5%).
Air escaping from the

compressed air lines.
56
WP400_BA_K1_12_en_08.fm
Safety valve of 2nd stage

blows off:
Fault
Remedy
Compressed air temperature

at the outlet too high as a
result of shortage of cooling
water.
Increase flow of cooling water

(in the case of a cooling water pump
only: Open the slide at the rear of the
pump further);
Check the temperature of the cooling
water at the outlet and the functioning
of the cooling water stop valve;
clean the particle trap
Compressed air temperature

at the outlet too high because
of poor thermal transition in
the cooler as a result of
scaling in the chamber.
Clean the cooling water containers

with a descaling agent.
No power supply.
Check fuses, replace blown fuses.
Solenoid faulty.
Replace solenoid.
Foreign matter in solenoid

valve.
Replace solenoid valve.
No power supply.
Check fuses, replace blown fuses.
Solenoid faulty.
Replace solenoid.
Foreign matter in solenoid

valve.
Replace solenoid valve.
Connecting rod bearing faulty.
Check connecting rod bearing, replace

if necessary.
Check oil supply.
Gudgeon pin bearing faulty.
Check gudgeon pin bearing, replace if

necessary.
Crankshaft bearing faulty.
Check crank shaft bearing, replace if

necessary.
Motor bearing faulty.
Check motor bearing, replace if

necessary.
Oil leaking from crankcase.
Gasket or shaft
seal faulty. Screws not tight.
Tighten all screws.

If there is significant 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 lint-free rag.
Water escaping at the relief

groove of the cylinder flange
surface.
O-ring of the liner is faulty

above the relief groove.
Replace O-ring.
Oil escaping at the relief

groove of the cylinder flange
surface.
O-ring of the liner is faulty

below the relief groove.
Replace O-ring.

off, temperature switch has
tripped.
Solenoid valve (drainage)

valve does not close.

does not open.
Abnormal compressor
noise.
WP400_BA_K1_12_en_08.fm
Probable cause
57
Fault
Probable cause
Remedy
Excessive cooling of
compressor due to
- flow of cooling water too high
- unfavourable room
ventilation
- very short compressor
running time
Reduce flow of cooling water. Change

room ventilation so that air stream is
not blown directly against compressor.
Extend compressor running time
Poor drainage.
Check drainage lines and drainage

intervals.
Burst disc in the cooling

water circuit triggers
OR
Cooling water safety valve
triggers.
Leaks in cooler.
Replace cooler insert.
Pressure peaks in the cooling

water circuit cause the burst
disc bursting pressure or the
safety valve preset pressure to
be exceeded.
Determine the cause of the pressure

peaks and eliminate these causes
(startup of additional pumps, actuation
of electromagnetic stop valves or
shuttle valves, or similar causes)
Premature fracture of
valve plates, valve springs
or
valve plates
Poor drainage.
Check drainage lines and drainage

intervals.
Note: Indentations in the gasket
contact surface of the valve plate are
normal.
WP400_BA_K1_12_en_08.fm
Water in the oil
58
Maintenance
8
Maintenance
8.1 J.P. SAUER & SOHN maintenance service

J.P. SAUER & SOHN customer service offers various
maintenance services: inspections, maintenance, major
overhauls, reconditioned compressors and service contracts.
8.2 Safety during maintenance

Before
maintenance
work
1. Interrupt power supply to the compressor.

2. Fit 'Warning: maintenance work' warning sign to power
supply.
3. Shut off the compressor and secure to prevent restarting.
Danger!
Risk of injury due to incorrect operation!
Only authorised personnel are permitted to service and adjust
the Sauer compressor!
Danger!
Risk of injury from hot surfaces!
Let compressor cool down after turning OFF.
Danger!
Risk of injury due to pressurised components!
Before undertaking any maintenance work, use pressure gauge
to ensure that there is no more pressure in the compressor.
WP400_BA_K1_12_en_08.fm
Danger!
Danger! High voltage!
Never assume that a circuit is de-energised always check
for your own safety!
The mains isolator remains energised, even when it is turned
OFF.
Components being worked on should only be energised if this
is explicitly specified.
Danger!
Danger of death if there are no safety devices or no isolating
protection devices!
After undertaking servicing work, always refit all safety devices
and isolating protection devices. This also applies to electrical
protection devices.
59
8.3 Maintenance schedule

Danger!
Whenever undertaking maintenance work, observe section 8.4,
'Table of tightening torques', for particular bolts.
Note!
The maintenance intervals specified in the maintenance
schedule must be observed. Shortening the maintenance
intervals is of no advantage with regard to the operating
performance or service life of the Sauer compressor.
Note!
After the final maintenance routine, the maintenance schedule
starts from the beginning.
Use the maintenance schedule as a master template or copy
the relevant page from the digital document and save it as a
separate file under a suitable name. Use the maintenance
schedule as a guide and for verification.
Regularly check the maintenance schedule to see which
maintenance intervals are due depending upon the number of
operating hours. The intervals are shown in the table's column
headers.
Check the column for each maintenance interval to see which
maintenance work is to be carried out at the end of the
maintenance interval. The required tasks are indicated by
checkboxes. A description and the section number of the tasks
are shown in the first column.
Carry out all maintenance tasks for a maintenance interval
and tick the appropriate check boxes of the maintenance
schedule. Then enter hours of operation, date and signature.
When beginning a new maintenance schedule:
enter: maintenance schedule number, date and hours of
operation, main specifications and date of commissioning;
mark with a cross: beginning of this maintenance
schedule following commissioning or following the last
maintenance routine.
WP400_BA_K1_12_en_08.fm
Use of the
maintenance
schedule
60
Maintenance
Maintenance Schedule No.
Beginning of this maintenance
schedule
Compressor type
Type series
after commissioning
after last maintenance routine
Compressor number:
Date:
Hours of operation:
Date of commissioning:
WP400_BA_K1_12_en_08.fm
4000 h
069236
3000 h
069234
2000 h
069235
Check screwed connections, section 8.5

Replace air filter cartridge, section 8.6
Carry out oil change, section 8.7
Clean oil strainer, section 8.8
Check 1st-stage valves, section 8.9
Replace 1st-stage valves, section 8.10
Replace 2nd-stage valves, section 8.10
Replace 1st-stage piston rings, gudgeon
pins and gudgeon pin bearings, section 8.12
Replace 2nd-stage piston rings, gudgeon
Check piston and cylinder, section 8.13
Renew flexible gear rim, section 8.16
Check condensate separator, section 8.17
Overhaul drain valves (as per order), section
8.18
Clean particle trap, section 8.19
Replace zinc protection
(freshwater operation), section 8.20
Replace bursting disc, section 8.21
Check cooling water pump, section 8.22
1000 h
Maintenance set item no.
069234
Maintenance work
2W
Factory no.:
50 h after
commissioning
50 h after
last maintenance routine
or repair
At least annually
at < 1000 h
Interval
[hours of operation]
WP400
Hours of operation
Date
Signature (initials)
61
8.4 Table of torques

Screw(s)
Torque
Connecting rod screws
115 Nm
Flywheel fastening screw
550 Nm
Valve cover nuts (1st/2nd stage)
82 Nm
Bursting disc flange
54 Nm
Valve retaining screw
9 Nm
8.5 Checking screwed connections

Check all unions and screwed connections for tightness and retighten if necessary. This relates to:
cooler and air lines;
unions on pipe and hose lines;
cylinder heads;
cylinders;
electric motor;
measuring and switching devices;
bearing; and
accessories and equipment parts.
8.6 Replacing air filter cartridge
WP400_BA_K1_12_en_08.fm
Air filter cap
62
Maintenance
1. Open clips and take air filter cap off.
2. Remove used cartridge.
3. Clean filter housing with a suitable solvent and wipe out with
a lint-free cloth.
4. Insert new cartridge into air filter.
5. Put on cap and close clips.
8.7 Changing the oil

Note!
Use oil according to the lubricant table (see section 10).
Oil filler cap
Dipstick
WP400_BA_K1_12_en_08.fm
Oil drain valve cap
63
1. Run compressor for approx. 15 minutes until operating

temperature is reached.
2. Place drip tray (of a capacity sufficient to hold the complete
oil filling quantity, 13.5 l) below the oil drain valve.
3. Unscrew oil filler cap and oil drain valve cap, open oil drain
valve and pull out dipstick.
4. Wait until all oil is drained.
5. Close oil drain valve and screw on cap.
6. Top up oil and check level with the dipstick.
The level should be between the upper and lower marks on
the dipstick.
7. Put dipstick back in and screw oil filler cap back on.
8.8 Cleaning the oil strainer

1.
2.
3.
4.
5.
6.
Unscrew nuts on inspection hole cover.

Take off inspection hole cover.
Unscrew union on oil strainer.
Take out oil strainer.
Wash out oil strainer in a suitable solvent.
Carefully clean sealing surface for inspection hole cover
gasket.
7. Position inspection hole cover with new original Sauer
gasket.
8. Tightly refasten oil strainer.
9. Tighten nuts on inspection hole cover.
8.9 Checking the valves

1. Loosen clamp on air filter and take out air filter.
2. Loosen unions and hose lines at the valve covers.
3. Undo valve cover screws and take off valve covers. Prise off
using the screws if necessary.
4. Carefully take out 1st-stage valve.
5. Undo valve retaining screw and take out 2nd-stage valve.
Note!
When removing and installing a valve, take care that no valve
parts are damaged. This particularly applies to the sealing
surfaces.
64
WP400_BA_K1_12_en_08.fm
Removing valves
Maintenance
Checking valves
1. Check valves externally for:

damage,
carbonisation,
oiling,
corrosion and
moisture.
Replace damaged, severely carbonised or corroded valves.
Determine cause (see section 7, 'Troubleshooting').
2. Clean all sealing surfaces.
Removing valves
Note!
Refit all valves with new gaskets and rings only. Only use original
Sauer spare parts. Installing other gaskets may lead to
compressor leaks and damage.
1. Install valves and valve covers. Insert new O-rings (see
illustrations).
Note!
Never reuse old rings. This may lead to leaks.
WP400_BA_K1_12_en_08.fm
1st stage
O-ring
Gasket
2. Attach 1st-stage valve cover. Fasten all screwed connections
hand-tight.
65
2nd stage
Valve retaining screw
O-ring
3. Fasten valve to valve cover using valve retaining screw.
4. Attach 2nd-stage valve cover. Fasten all screwed
connections hand-tight.
5. Fasten valve cover nuts tightly. Observe tightening torques
(see section 8.4).
6. Attach unions and hose lines to the valve covers.
7. Mount air filter and tighten clamp.
8.10 Replacing valves

Remove and install valves as described in section 8.9, 'Checking
valves'. Replace complete valve.
WP400_BA_K1_12_en_08.fm
Note!
Valves whose service life has expired must be replaced and
disposed of.
Due to material fatigue, we recommend that used valves not be
repaired.
66
Maintenance
8.11 Draining the cooling water
Drain plug
1. Block the cooling water inlet and outlet.
2. Remove the hoses for the cooling water inlet and outlet from
the cylinders.
3. Unscrew the drain plugs and drain the cooling water.
8.12 Replacing piston rings, gudgeon pins and

gudgeon pin bearings
WP400_BA_K1_12_en_08.fm
1. Remove valve covers and valves as described in section 8.9,

'Checking the valves'.
2. Remove cylinder base nuts.
3. Remove cylinder. Grab and hold the piston before you have
completely removed the cylinder.
Note!
If you do not hold the the piston while you remove the cylinder, it
will collide with the crankcase.
67
1st stage
4. Remove valve covers and valves as described in section 8.9,

'Checking valves'.
5. Dismantle the inspection hole cover from the crankcase.
6. Remove connecting rod bolts and remove connecting rod
bearing cover with bearing bush.
7. Push piston together with connecting rod upper part out of the
cylinder.
8. Remove all piston rings from the pistons and clean pistons.
Note!
Replace all piston rings with new ones! The following damage
may occur on removal of the piston rings:
the edges of the piston rings may be damaged on the wearing
edges in the cylinder;
fine cracks which can lead to material fracture may appear if
the piston rings are bent up repeatedly.
9. Fit piston rings in the respective piston.
Note!
Use an assembly sleeve for pushing the piston into the liner from
above (see section 11, 'Spare parts and accessories').
10. Put connecting rod back with sufficient oil and screw on the
bottom part by hand.
Note!
Figures are hammered into the upper and lower sections of the
connecting rods. They must match. See illustration.
It must be possible for the connecting rod bolts to be fully

screwed in by hand. This is the only way of ensuring that they
are seated correctly on the crankshaft. The connecting rod
must be able to rotate easily on the crankshaft once
68
WP400_BA_K1_12_en_08.fm
2
2
Maintenance
tightened.
11. Tighten connecting rod bolts; see tightening torque in section
8.4.
WP400_BA_K1_12_en_08.fm
2nd stage
1. Loosen the flange connections and dismantle compressed air

manifold.
2. Loosen both unions and dismantle the compressed air line
from the cylinder of the 2nd stage to the final 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 and
dismantle cooling water inlet pipe. The screw connection
nipple remains on the cylinder.
5. Unscrew the cooling water hose line between the 1st and the
2nd stage and remove.
6. Dismantle both the inspection hole covers from the
crankcase.
7. Loosen the connecting rod bolts and remove them from the
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 base of the cylinder of the 2nd
stage.
9. On both sides of the cylinder unscrew the two M10 25
upper retaining screws on the cooler cover and replace with
M10 100 screws. Attach a suitable hoist to the screws and
pull the cylinder sideways out of the crankcase (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.
Note!
Replace all piston rings with new ones! The following damage
may occur on removal of the piston rings:
the edges of the piston rings may be damaged on the wearing
edges in the cylinder;
fine cracks which can lead to material fracture may appear if
the piston rings are bent up repeatedly.
13. Sequence of assembly is exactly opposite to that of
dismantling. Replace the screws on the cooler covers on both
sides of the cylinder with the M10 25 retaining screws.
69
14. Put connecting rod back with sufficient oil and screw on the
bottom part by hand.
Note!
Figures are hammered into the upper and lower sections of the
connecting rods. These must match in any case (see
illustration).
2
2
It must be possible for the connecting rod bolts to be fully

screwed in by hand. This is the only way of ensuring that they
are seated correctly on the crankshaft. The connecting rod
must be able to rotate easily on the crankshaft once
tightened.
15. Tighten connecting rod bolts; see tightening torque in section
8.4.
16. Install new piston rings in the respective pistons. Make sure
they are in the correct positions: piston rings with
asymmetrical cross sections are marked on one of the
surfaces with 'TOP'. During installation this face must face
upwards (see illustration).
1st stage
2nd stage
TOP
WP400_BA_K1_12_en_08.fm
TOP
70
Maintenance
8.13 Checking pistons and cylinders
1. Remove cylinder heads and valves as described in section
8.9, 'Checking valves'.
2. Remove cylinders and pistons as described in section 8.12,
'Replacing piston rings'.
3. Check cylinders and pistons for scoring and heavy wear and
tear marks. Replace relevant parts.
Note!
If the piston running surface in the cylinder reveals perceptible
wearing edges, the edges must be broken up with a honing
brush or Scotch-Brite abrasive cloth.
Otherwise the edges will damage the new piston rings on
installation of the pistons.
4. Check wear limits as described in section 8.14, 'Wear limits
for cylinder diameters'.
5. Install cylinders and pistons as described in section 8.12,
'Replacing piston rings, gudgeon pins and gudgeon pin
bearings'.
6. Install valves and cylinder heads as described in section 8.9,
'Checking valves'.
8.14 Wear limits for cylinder diameters

1. Measure cylinder and replace if the following wear limits are
exceeded:
Cylinders
Wear limit of diameter
1st stage
195,15 mm
2nd stage
110,15 mm
8.15 Checking coupling
WP400_BA_K1_12_en_08.fm
Note!
This applies to Sauer compressors with electric motors.
71
Visual
inspection
1. Remove the electric motor from the copmressor as described

in section 8.16, 'Renewing flexible gear rim'.
2. Check the coupling parts for damage.
The teeth of the coupling parts must not be deformed.
3. Replace flexible gear rim as described in section 8.16,
'Renewing flexible gear rim'.
8.16 Renewing flexible gear rim

Note!
This applies to Sauer compressors with electric motors.
Renewing
flexible gear rim
1. Support compressor under the coupling bell housing.

2. Remove the electric motor mounting screws.
3. Carefully lift the electric motor using the lifting eyes (see
section 5.1, 'Transport').
4. Carefully pull the electric motor away from the compressor.
5. Replace flexible gear rim.
6. Carefully slide electric motor against the compressor and
tighten the motor mounting screws.
7. Remove support from under the coupling bell housing.
Flexible gear rim
Motor
8. Reinstall separated connecting lines and pipes.
72
WP400_BA_K1_12_en_08.fm
Compressor
Maintenance
8.17 Inspecting the condensate separator
1. Remove pipes and check separator for obstructions.
8.18 Overhauling water drain valves
WP400_BA_K1_12_en_08.fm
Hexagon nut
1.
2.
3.
4.
5.
6.
Unscrew hexagon nut.

Carefully lift up plastic threaded part with the screwdriver.
Remove coil from armature.
Unscrew the four Allen screws.
Remove upper section of valve.
Replace following parts:
conical spring, diaphragm and two O-rings.
73
7. In case of severe soiling: clean nozzle.

8. Position upper section of valve.
9. Tighten the four Allen screws.
10. Place the coil on the armature.
Note!
The coil and the armature must always be dry.
11. Correctly position the plastic threaded part and press onto the
armature.
12. Carefully position hexagon nut by hand and screw on.
13. Lightly tighten hexagon nut using a spanner.
8.19 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.
8.20 Replacing the zinc protection

The zinc protection for the 1st-stage cylinder is situated laterally
on the cylinder cover at the top.
The zinc protection for the 2nd-stage cylinder is situated laterally
on the cylinder cover at the bottom beside the bursting disc
flange.
1. Drain the cooling water.
2. Unscrew the zinc protection.
3. Clean the sealing surface and thread.
4. Insert new zinc protection with new ring.
1. Drain the cooling water.

2. Undo the screws and remove the pressure flange on the
cylinder of the 2nd stage.
3. Remove the bursting disc and ring.
4. Clean the sealing surfaces.
5. Install a new ring and new bursting disc. Check that the
gasket is correctly installed. Fit first the gasket and then the
bursting disc into the cylinder.
6. Screw on the pressure flange; see tightening torque in
section 8.4.
74
WP400_BA_K1_12_en_08.fm
8.21 Replacing the bursting disc
Maintenance
8.22 Checking the cooling water pump
Note!
The cooling water pump is an optional component and is not
supplied as a standard component.
The cooling water pump should be checked as follows in case of
abnormal running sound or leaks:
Removing 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 flange connections on the cooling water inlet and
outlet of the pump. Remove rings and clean sealing surfaces.
5. Loosen the bolted fastening of the pump at the foot and
remove pump from the console.
Replacing the
floating ring
seals
The floating ring seals are maintainance-free. In case heavy

leakages are noticed after a long running time, the floating ring
seal is to be replaced as a complete unit.
Note!
Note the diagram of the pump in the Spare Parts Catalogue.
Please refer to the operating instructions provided by the pump
manufacturer.
6. Remove impeller and shaft retaining ring.
7. Pull the entire floating ring seal with the cap out from the
shaft.
WP400_BA_K1_12_en_08.fm
Note!
The floating ring seals are delicate elastomers and must not
come into contact with grease or oil.
Avoid touching them with your fingers (use clean gloves or
cloth).
Do not soil or damage floating ring seals.
Moisten the gaskets with low surface tension water to facilitate
assembly.
8. Carefully slide new floating ring seal on to shaft with a rotating
motion.
Note!
The motor bearing should be replaced if the shaft has noticeable
play. A possibly damaged pump impeller must likewise be
replaced.
75
1. Assemble the pump back in the reverse sequence. Insert

new flange gaskets.
2. Fill pump and suction pipe completely with cooling water.
3. Connect electrical connection.
Checking the
direction of
rotation
Briefly switch on pump motor. 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 housing.
WP400_BA_K1_12_en_08.fm
Mounting the
pump
76
WP400_BA_K1_12_en_08.fm
Storage, Preservation lay-up procedure

9
Storage, Preservation lay-up

procedure
9.1 Safety when storing and removing
WP400_BA_K1_12_en_08.fm
Danger!
The compressor shall only be removed and laid up by trained
specialists of the owner. These specialists must be familiar with
the protection devices and regulations before starting the work.
Any work on the electrical installation must be carried out by
qualified electricians only.
In addition, information contained in suppliers documentation
must be observed.
77
9.2 Temporary preservation and storage

If idle, every 4 weeks perform a test run for at least 30 minutes.
Additional corrosion prevention measures are not required.
When the Sauer compressor is to be laid up for more than 12
weeks, preservation with a preservation oil is recommended.
When preservation is completed, periodic test runs are not
needed.
Note!
Use one of the preservation oils recommended in Chapter 10
Lubricant Table for corrosion protection.
The preservation oil has satisfactory running properties. In an
emergency the machine can be started for a short duration when
filled with preservation oil.
WP400_BA_K1_12_en_08.fm
1. Run compressor for approx. 5 minutes with drain valves and

final pressure line open.
Any existing oil/water is removed.
2. Blow out compressor oil and dispose of in an environmentally
safe manner.
3. Fill with about 10 litres of preservation oil.
4. Start compressor and run for approx. 5 minutes with drain
valves and final pressure line open.
5. Stop compressor.
6. Unscrew both air filters on the 1st stage cylinder head.
7. Start compressor and slowly inject approx. 100 to 125 cm3 of
preservation oil into each of the 1st stage intake fittings.
78
Storage, Preservation lay-up procedure

Intake fittings
Oil
Stage 1.2
Oil
Stage 1.1
Oil
Hexagon
screw
2nd stage
8. Remove hexagon head screw on the 2nd stage valve cover.

9. Slowly inject about 100 to 125 cm3 of preservation oil into the
opening.
10. Wait until oil mist comes out of the final pressure line.
11. Stop compressor.
12. Reattach both air filters on the 1st stage cylinder head.
13. Screw the hexagon head screw on the 2nd stage cover back
in.
14. If necessary, put up a sign that the compressor was
preserved and taken out of service.
15. If necessary, disconnect mains supply cables.
1. If necessary, connect the mains supply cables.
2. Drain preservation oil and pour in compressor oil as
described in Chapter 5.6 Filling with Oil.
3. Follow the instructions given in Chapter 6.3 Initial
Operation.
WP400_BA_K1_12_en_08.fm
Putting back into

service
79
9.3 Disassembly
Follow these
steps for
disassembly:
1. Turn compressor off and disconnect from power supply.

2. Read the gas pressure display to ensure that the compressor
is completely depressurised.
3. Disconnect the mains supply cables.
4. Remove oil and lubricants and dispose of in an
environmentally safe manner.
5. Drain any remaining condensate and dispose of in an
environmentally safe manner.
Disposal
Material/system component
Disposal method
as hazardous waste
Steel/iron
as metal scrap
Electric cables
as hazardous waste
Electronic components
as scrap electronic waste
Plastics
as hazardous waste
WP400_BA_K1_12_en_08.fm
Lubricants
80
Lubricant table
10 Lubricant table
Scope
The lubricant table applies to all Sauer compressors which are

designed to compress air.
The lubricant table does not apply to
Sauer compressors designed to compress neutral gasses;
temperatures outside the 5 to 55 C range.
General
recommendation
For temperatures lying within the 5 to 55 C range we

recommend mineral oil meeting the ISO VG 100 viscosity grade.
At minimum, the lubricating oil should correspond to the group
VCL as per DIN 51506 .
Two-stage water-cooled compressors may cause premature
soiling of the valves due to the high compression temperatures
combined with unfavourable ambient conditions or inferior types
of oil. Use another oil in such cases or carry out maintenance at
shorter intervals.
Note!
The recommended types of oil reduce the level of coking in the
compressor valves and the upstream pipe lines and fittings to a
minimum.
Lubricants which are not listed in the lubricant table may only be
used after approval has been given by J.P. SAUER & SOHN.
Otherwise the guarantee is made void.
Please contact our Customer Service when selecting oils not
listed, or if operating conditions differ from those recommended.
WP400_BA_K1_12_en_08.fm
Note!
Unless otherwise ordered, Sauer compressors
are delivered without oil.
81
10.1 Lubricating oils

The following mineral oils ma be used in Sauer compressors;
Shell Corena P 100 mineral oil is the standard type used to fill and
operate the unit.
Agip
ARAL
AVIA
BP
CHEVRON
ESSO
Shell
TEXACO
TOTAL
82
Product name
Diesel Gamma 30
Dicrea 100
Acer 100
Motor Oil HD 30
Cladium 50
Kowal M30
Avilub compressor oil VDL100
Energol RC 100
Energol IC-DG 30
Vanellus C3 SAE 30
Aircol PD 100
HD Compressor Oil 100
Delo 1000 Marine 30
Veritas 800 Marine 30
Rarus 426
Rarus 427
Mobilgard 300
Mobilgard 312
Delvac 1230
Corena P 100
Rimula X 30
Melina S Oil 30
Melina Oil 30
Gadinia Oil 30
Compressor Oil EP VDL 100
Regal EP 100
Ursatex 30
Veritas 800 Marine 30
Dacnis P 100
Disola M 3015
Group
VCL-100
VDL-100
VCL-100
SAE 30
SAE 30
VCL-100
VDL-100
VDL-100
VCL-100
SAE 30
VDL-100
VDL-100
SAE 30
SAE 30
VDL-100
VDL-100
SAE 30
SAE 30
SAE 30
VDL-100
SAE 30
SAE 30
SAE 30
SAE 30
VDL-100
VCL-100
SAE 30
SAE 30
VDL-100
SAE 30
WP400_BA_K1_12_en_08.fm
Brand
Lubricant table
The following mineral oils may alternatively be used without
restriction in marine applications:
Brand
NATO classified
NATO classified
Product name
O - 278
OMD 113
Group
VDL-120
VDL-100
10.2 Preservation oils

The standard oil used by Sauer for compressor preservation is
Mobilarma 524.
Alternatively, the following preservation oils can be used:
Brand
Product name
Agip
Rustica C SAE 30
ARAL
Konit Motorl SAE 30
AVIA
MK 1540 S
BP
MEK 20 W-20
DEA
Deamot EKM 642 SAE 30
Esso
MZK HD 30 motor oil

Antirust MZ 110
Mobil
Mobilarma 524
Shell
Ensis Motor Oil 30
WP400_BA_K1_12_en_08.fm
Note!
The product name may vary by country.
83
11 Spare Parts and Accessories

Note!
Please note the information in Chapter 1 General regarding our
genuine Sauer spare parts.
WP400_BA_K1_12_en_08.fm
J.P. SAUER & SOHN guarantee 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 genuine Sauer spare parts, our range of supply
includes many accessories for your Sauer compressor as well as
special equipment for your entire compressed air system,
including:
Fully automatic controls;
Adsorption dryers;
Refrigerant type dryers;
Filters;
Sound-dampening enclosures;
Compressed air vessels;
and fittings.
We supply instructions and a maintenance manual for each
accessory.
84
Spare Parts and Accessories

Spare parts
catalogue
The spare parts catalogue is in the Appendix to this Operator

Manual.
The required parts can be quickly found with the help of
diagrams, illustrations and lists.
The spare parts catalogue and Operator Manual are also
available on CD-ROM. This makes it easy to fill out an order
form, print it out and send it in immediately.
To do so, you need the main specification of your Sauer
compressor from the table below. If the data has not yet been
entered, it can be found on the nameplate affixed to the
crankcase.
Compressor type:
Factory no.:
Year of
construction:
WP400_BA_K1_12_en_08.fm
You should additionally indicate the number of operating

hours.
85
12 Appendix
WP400_BA_K1_12_en_08.fm
This Appendix to the operating instructions contains

Form for commissioning certificate;
Form for Return of Goods / Notification of Claim;
Supplier documentation;
Data sheets.
86
Appendix
Commissioning certificate for compressors
J.P. SAUER & SOHN

Maschinenbau GmbH
Brauner Berg 15 - 24159 Kiel,
Phone: +49 - 431- 39 40 - 0
Fax: +49 - 431- 39 40 - 89
E-mail:service@sauersohn.de
Purchaser
Company
Street
Postcode
Contact
Phone number
Customer number
Order number
Compressor type
Delivery date
Date commissioned
Sauer service engineer
Owner
Company
Street
Postcode
Contact
Phone number
Serial no.
Operation hours
Company/Name
Company/Name
Company/Name
Company/Name
Installation of compressor/complete system
Good
Installation site
Faults
Ventilation
Good
Faults
Ambient conditions
Good
Faults
Voltage?
Good
Faults
Vibration behaviour of compressor
Good
Faults
Accessories
Compressed air vessels
Refrigerant type dryers
Adsorption dryers
Filter
Condensate removal
Check of rotational
direction
Compression
temperature
Suction temperature
Start/stop pressure
Oil level check
Control system check
Test run
C
C
Installation of complete system carried out by:
Good
Faults
Operating personnel have received instruction and are familiar with the safety and maintenance requirements.
The maintenance instructions are available to the owner.
The operating company has been advised to use only genuine SAUER & SOHN spare parts.
WP400_BA_K1_12_en_08.fm
Notes / Faults:
The system has been accepted by the owner.
City:
Purchaser
Authorised Sauer Service Partner
Owner
Date:
87

J.P. SAUER & SOHN
Return of goods
Notification of claim
Maschinenbau GmbH
Brauner Berg 15 - 24159 Kiel, Germany
Phone: +49 - 431- 39 40 - 0
Fax: +49 - 431- 39 40 - 89
E-mail: service@sauersohn.de
To be completed by manufacturer
Date:
Manufacturer:
Please always complete:
Company
Street
Postcode/City
Customer no.
Location
Compressor type:
End customer:
Operation hours:
Company
Street
Postcode/City
Customer no.
Location
Spare parts
Designation
Serial no.:
Date of fault:
Ambient temperature:
Quantity
Part no.
Reason for return

Report on fault
Repair
Checking as customer
service
Goods taken back against
credit note

88
Report
WP400_BA_K1_12_en_08.fm
To be completed by
manufacturer only
Short description of fault:
Appendix
Maintenance Schedule No.
Beginning of this maintenance
schedule
Compressor type
Type series
after commissioning
after last maintenance routine
Compressor number:
Date:
Hours of operation:
Date of commissioning:
WP400_BA_K1_12_en_08.fm
4000 h
069236
3000 h
069234
2000 h
069235
Check screwed connections, section 8.5

Replace air filter cartridge, section 8.6
Carry out oil change, section 8.7
Clean oil strainer, section 8.8
Check 1st-stage valves, section 8.9
Replace 1st-stage valves, section 8.10
Replace 2nd-stage valves, section 8.10
Replace 1st-stage piston rings, gudgeon
Replace 2nd-stage piston rings, gudgeon
Check piston and cylinder, section 8.13
Renew flexible gear rim, section 8.16
Check condensate separator, section 8.17
Overhaul drain valves (as per order), section
8.18
Clean particle trap, section 8.19
Replace zinc protection
(freshwater operation), section 8.20
Replace bursting disc, section 8.21
Check cooling water pump, section 8.22
1000 h
Maintenance set item no.
069234
Maintenance work
2W
Factory no.:
50 h after
commissioning
50 h after
last maintenance routine
or repair
At least annually
at < 1000 h
Interval
[hours of operation]
WP400
Hours of operation
Date
Signature (initials)
89
90
WP400_BA_K1_12_en_08.fm
S a u e r
C o m p r e s s o r
Type: WP 400
Spare parts catalogue
Edition: 03 / 2008
Edited by: J.P. Sauer & Sohn Maschinenbau Technical Documentation
WP400_ET_Titel_en_08.fm
WP400_ET_Titel_en_08.fm
WP400_ET_en_08.fm
WP400_ET_en_08.fm
E-2
WP400_ET_en_08.fm
WP400_ET_en_08.fm
066 148 / 064 344 Compressor WP 400

Page
E-
Ref. No.
Assembly
066 148
Compressor WP 400 with cooling water pump....................
064 344
Compressor WP 400 without cooling water pump...............
10
064 035
Compressor WP 400-100 ....................................................
14
064 140
Crankcase ...........................................................................
18
064 257
Dipstick ................................................................................
22
064 142
Crankshaft ...........................................................................
24
063 864
Connecting rod stage 1.1 and 1.2 .......................................
26
064 144
Connecting rod 2nd stage ....................................................
28
064 261
Piston stage 1.1 and 1.2......................................................
30
064 145
Piston 2nd stage...................................................................
32
067 735
Cylinder stage 1.1 and 1.2...................................................
34
061 822
Zinc protection .....................................................................
38
067 737
Cylinder 2nd stage ...............................................................
40
063 868
Valve cover stage 1.1 and 1.2 .............................................
44
063 869
Valve cover 2nd stage ..........................................................
46
064 146
Air lines................................................................................
48
063 121
Separator.............................................................................
50
064 147
Cooling water lines ..............................................................
52
063 985
Lubricating oil supply ...........................................................
54
063 543
Gear oil pump ......................................................................
56
057 916
Pressure relief valve ............................................................
58
064 148
Crankcase vent ...................................................................
60
064 038
Compressor monitoring and control ....................................
62
064 448
Protective device .................................................................
64
037 134
Concentric valve stage 1.1. and 1.2 ....................................
66
063 950
Compressor monitor ............................................................
68
064 018
Temperature monitoring.......................................................
70
E-3
Assembly
064 039
Automatic drainage system .................................................
72
066 143
Cooling water lines with pump .............................................
74
038 238
Cooling water pump.............................................................
78
064 366
Cooling water lines without pump ........................................
80
064 151
Anti-vibration resilient mount ...............................................
82
066 595
Hose line..............................................................................
84
065 664
Non-return valve ..................................................................
86
Flexible coupling ..................................................................
88
Note:
Erluterungen der Baugruppen in Kapitel 3 Aufbau und
Funktion der Betriebsanleitung.
E-4
WP400_ET_en_08.fm
Page
E-
Ref. No.
WP400_ET_en_08.fm
E-5
066 148 Compressor WP 400

with cooling water pump
1, 17, 18
14
9, 11, 12
15, 16
Stage 1.1
Stage 2
E-6
WP400_ET_en_08.fm
Stage 1.2

WP400_ET_en_08.fm
E-7
WP400_ET_en_08.fm

E-8

Ref. No.
Designation
Quantity
064 035
Compressor WP 400-100
063 950
Compressor monitor
064 039
Automatic drainage system
066 143
Cooling water lines with pump
063 800
Motor attachment rail
064 370
Spacer ring
11
037 057
Motor half coupling
12
033 423
Coupling flexible insert
14
037 067
AC motor
15
002 170
Washer
16
000 216
Hexagon head screw
17
036 960
Stud screw
18
001 621
Hexagon nut
WP400_ET_en_08.fm
Item No.
E-9

without cooling water pump
1, 17, 18
14
9, 11, 12
15, 16
Stage 1.1
Stage 2
E - 10
WP400_ET_en_08.fm
Stage 1.2

WP400_ET_en_08.fm
E - 11
WP400_ET_en_08.fm

E - 12

Ref. No.
Designation
Quantity
064 035
Compressor WP 400-100
063 950
Compressor monitor
064 039
Automatic drainage system
064 366
Cooling water lines (unit without pump)
063 800
Motor attachment rail
064 370
Spacer ring
11
037 057
Motor half coupling
12
033 423
14
037 067
AC motor
15
002 170
Washer
16
000 216
Hexagon head screw
17
036 960
Stud screw
18
001 621
Hexagon nut
WP400_ET_en_08.fm
Item No.
E - 13
064 035 Compressor WP 400-100
3
4
27
15
13
22
WP400_ET_en_08.fm
E - 14

23
Stage 1.2
Stage 1.1
Stage 2
10
24
23
7
6
WP400_ET_en_08.fm
17
E - 15

26, 30
X
14
Stage 1.2
12
Stage 1.1
Stage 2
11
31
WP400_ET_en_08.fm
19, 20, 25
E - 16
WP400_ET_en_08.fm

Item No.
Ref. No.
Designation
Quantity
064 140
Crankcase
064 142
Crankshaft
063 864
Connecting rod stage 1.1 and 1.2
064 144
064 261
Piston stage 1.1 and 1.2
064 145
Piston 2nd stage
067 735
Cylinder stage 1.1 and 1.2
067 737
Cylinder 2nd stage
063 868
Valve cover stage 1.1 and 1.2
10
063 869
Valve cover 2nd stage
11
064 146
Air lines
12
064 147
Cooling water lines
13
063 985
Lubricating oil supply
14
064 148
Crankcase vent
15
064 038
Compressor monitoring and control
17
064 448
Protective device
19
064 331
Blind flange
20
064 332
Gasket
22
036 333
Compressor half coupling
23
037 134
Concentric valve stage 1.1. and 1.2
24
036 959
Lamellar valve 2nd stage
25
000 494
Cap screw
26
005 546
Stud screw
27
000 543
Cap screw
10
30
037 225
Lifting eye bolt nut
31
004 411
Locking pin
E - 17
064 140 Crankcase
7
16
15
11, 12
11, 12
10
WP400_ET_en_08.fm
13, 14
E - 18

064 140 Crankcase
18
17
18
17
Stage 1.2
Stage 1.1
Stage 2
17
18
19
19
20
20
3
6
3
6
WP400_ET_en_08.fm
E - 19
WP400_ET_en_08.fm
064 140 Crankcase
E - 20

064 140 Crankcase
Item No.
Ref. No.
063 786
Crankcase
064 394
Housing cover
051 883
Crankcase inspection cover
036 897
Oil strainer
064 257
Dipstick
063 748
Gasket
063 749
Gasket
030 743
Shaft seal
101)
004 635
Plug
11
000 971
Plug
12
005 001
O-ring
13
035 984
Drain cock
14
005 009
O-ring
15
038 102
Stud screw
16
001 620
Hexagon nut
17
036 960
Stud screw
12
18
001 621
Hexagon nut
12
19
001 408
Stud screw
16
20
002 031
Hexagon nut
16
Quantity
Item 10, 004 635 Insert fitting with Loctite 542.
WP400_ET_en_08.fm
1)
Designation
E - 21
064 257 Dipstick
WP400_ET_en_08.fm
E - 22

064 257 Dipstick
Ref. No.
Designation
Quantity
064 256
Dipstick
030 556
O-ring
WP400_ET_en_08.fm
Item No.
E - 23
064 142 Crankshaft

8
6
550 Nm
Z
2
WP400_ET_en_08.fm
E - 24

064 142 Crankshaft
Ref. No.
Designation
Quantity
064 143
Crankshaft
063 544
Driving disc
063 732
Washer
063 811
Flywheel
005 297
Hexagon head screw
033 994
Cap screw
036 961
Cylindrical roller bearing
WP400_ET_en_08.fm
Item No.
E - 25
063 864 Connecting rod stage 1.1 and 1.2
WP400_ET_en_08.fm
4
115 Nm
E - 26

063 864 Connecting rod stage 1.1 and 1.2
Item No.
Ref. No.
063 712
Connecting rod
061 857
Connecting rod bearing
035 823
Small-end bearing
41)
061 676
Connecting rod bolt
Quantity
Item 4, Connecting rod bolt 056 316 is part of assembly 063 712.
WP400_ET_en_08.fm
1)
Designation
E - 27
064 144 Connecting rod 2nd stage
WP400_ET_en_08.fm
4
115 Nm
E - 28

064 144 Connecting rod 2nd stage
Item No.
Ref. No.
063 826
Connecting rod
037 058
Small-end bearing
061 857
Connecting rod bearing
41)
061 676
Connecting rod bolt
Quantity
Item 4, Connecting rod bolt 061 676is part of assembly 063 826.
WP400_ET_en_08.fm
1)
Designation
E - 29
064 261 Piston stage 1.1 and 1.2
3
4
1
WP400_ET_en_08.fm
E - 30

064 261 Piston stage 1.1 and 1.2
Item No.
Ref. No.
036 983
Piston
036 078
Gudgeon pin
002 716
Plain ring
035 962
Oil scraper ring
002 985
Circlip
71)
035 823
Small-end bearing
Quantity
Item 7, Small-end bearing 035 823 is part of assembly 063 864.
WP400_ET_en_08.fm
1)
Designation
E - 31
064 145 Piston 2nd stage
3
4
5
1
2
WP400_ET_en_08.fm
E - 32

064 145 Piston 2nd stage
Item No.
Ref. No.
063 815
Piston
064 150
Gudgeon pin
033 571
Plain ring
002 634
Nose ring
002 605
Oil scraper ring
012 682
Circlip
71)
037 058
Small-end bearing
Quantity
Item 7, Small-end bearing 037 058 is part of assembly 064 144.
WP400_ET_en_08.fm
1)
Designation
E - 33
067 735 Cylinder stage 1.1 and 1.2

A-B
19, 23
10
26
D
17, 23
E-F
15
5
13
16
18, 24
E - 34
WP400_ET_en_08.fm

22
14
C-D
8
4
12
23
WP400_ET_en_08.fm
18, 24
E - 35
WP400_ET_en_08.fm
E - 36

Ref. No.
Designation
Quantity
067 734
Cylinder housing 2nd stage
061 822
Zinc protection
067 738
Cooler insert 1st stage
063 660
Cylinder cover 1st stage
067 708
Cooler cover 1st stage
063 776
Liner
063 747
Gasket
067 739
Gasket
10
067 741
Gasket
12
000 497
Cap screw
13
000 475
Cap screw
14
001 533
Stud screw
15
000 509
Cap screw
16
000 519
Cap screw
17
000 977
Plug
18
001 016
Plug
19
035 390
Plug
22
001 621
Hexagon nut
23
005 023
O-ring
24
005 009
O-ring
26
036 962
O-ring
WP400_ET_en_08.fm
Item No.
E - 37
061 822 Zinc protection
WP400_ET_en_08.fm
E - 38

061 822 Zinc protection
Item No.
Ref. No.
Designation
Quantity
061 820
Plug
061 821
Zinc cartridge
001 463
Stud screw
WP400_ET_en_08.fm
061 822 Zinc protection is ordered as a complete spare part.
E - 39
067 737 Cylinder 2nd stage

A-B
17
19
22, 23
11
D
18
15
6
25
10
21, 23
C-D
E - 40
2, 23
14
3, 12, 13
5, 9
WP400_ET_en_08.fm
16

20, 24
WP400_ET_en_08.fm
26, 27
E - 41
WP400_ET_en_08.fm
E - 42
WP400_ET_en_08.fm

Item No.
Ref. No.
Designation
Quantity
067 718
Cylinder housing 2nd stage
061 822
Zinc protection
054 883
Protecting cap
067 715
Cooler insert 2nd stage
063 662
Cylinder cover 2nd stage
067 710
Cooler cover 2nd stage
063 808
Liner
063 747
Gasket
10
067 716
Gasket
11
067 717
Gasket
12
051 530
Gasket
13
051 531
Burst disc
14
000 505
Cap screw
15
000 554
Cap screw
11
16
000 497
Cap screw
17
001 533
Stud screw
18
000 509
Cap screw
19
001 621
Hexagon nut
20
001 016
Plug
21
000 977
Plug
22
035 390
Plug
23
005 023
O-ring
24
005 009
O-ring
25
030 131
O-ring
26
005 001
O-ring
27
000 971
Plug
E - 43
063 868 Valve cover stage 1.1 and 1.2
2, 5
WP400_ET_en_08.fm
E - 44

063 868 Valve cover stage 1.1 and 1.2
Item No.
Ref. No.
064 236
Valve cover
036 394
Dry air filter
037 151
O-ring
030 912
O-ring
51)
036 395
Filter insert
Quantity
Item 5, Filter insert 036 395 is part of assembly 036 394.
WP400_ET_en_08.fm
1)
Designation
E - 45
063 869 Valve cover 2nd stage

2, 3
WP400_ET_en_08.fm
E - 46

063 869 Valve cover 2nd stage
Ref. No.
Designation
Quantity
063 743
Valve cover
036 964
Hexagon head screw
003 493
O-ring
036 963
O-ring
035 970
O-ring
WP400_ET_en_08.fm
Item No.
E - 47
064 146 Air lines

11, 16
12, 15
1, 4, 6
10, 16
9, 15
13, 14
2
WP400_ET_en_08.fm
7, 8
E - 48

064 146 Air lines
Ref. No.
Designation
Quantity
067 729
Compressed air manifold
063 121
Separator
056 335
Gasket
000 054
Hexagon head screw
12
000 137
Hexagon head screw
002 151
Washer
036 157
Plug
10
006 193
Plug
11
005 946
Stub
12
030 751
Safety valve stage 1.2
13
030 752
14
005 009
O-ring
15
005 016
O-ring
16
005 023
O-ring
WP400_ET_en_08.fm
Item No.
E - 49
063 121 Separator
11, 12
9
1
4
8
10
3
7
6
WP400_ET_en_08.fm
Working pressure 80 bar

Test pressure 160 bar
E - 50

063 121 Separator
Item No.
Ref. No.
063 228
Separator housing
063 229
Separator head
062 328
Baffle cone
41)
060 342
Fusible plug
006 390
Reducing union
005 029
O-ring
005 009
O-ring
036 171
O-ring
10
036 041
Hexagon head screw
11
001 007
Plug
12
003 496
O-ring
Quantity
121C / 250 F
WP400_ET_en_08.fm
1)
Designation
E - 51
064 147 Cooling water lines
Stage 1.1
1
6, 9
10
1
Stage 1.2
6, 9
WP400_ET_en_08.fm
2nd stage
E - 52

064 147 Cooling water lines
Item No.
Ref. No.
11)
037 144
Angle piece
21)
037 265
Angle piece
41)
037 194
Extension piece
038 390
High pressure hose
92)
004 661
Plug
101)
036 967
Pipe fitting
111)
034 875
T-joint
121)
037 305
Pipe reducing adaptor
1)
Quantity
Inserted with hemp.

Inserted with seal tape.
WP400_ET_en_08.fm
2)
Designation
E - 53
063 985 Lubricatin oil supply
WP400_ET_en_08.fm
E - 54

063 985 Lubricatin oil supply
Ref. No.
Designation
Quantity
063 543
Gear oil pump
057 916
003 438
O-ring
000 456
Cap screw
WP400_ET_en_08.fm
Item No.
E - 55
063 543 Gear oil pump

7
8
3
2
1, 5
WP400_ET_en_08.fm
E - 56

063 543 Gear oil pump
Ref. No.
Designation
Quantity
036 767
Oil pump gear wheel
036 360
Oil pump housing
056 318
Gasket
036 359
Gear wheel
033 212
Oil pump cover
036 363
Gasket
030 544
Gasket
WP400_ET_en_08.fm
Item No.
E - 57
057 916 Pressure relief valve
WP400_ET_en_08.fm
E - 58

057 916 Pressure relief valve
Ref. No.
Designation
Quantity
054 164
Spring
002 962
Circlip
WP400_ET_en_08.fm
Item No.
E - 59
064 148 Crankcase vent

5, 6, 7
12
5, 6, 8 2
11
5, 6, 7
4
Stage 1.2
1
14
9, 10
2nd stage
WP400_ET_en_08.fm
Stage 1.1
E - 60

064 148 Crankcase vent
Item No.
Ref. No.
11)
038 407
Pipe nipple joint
21)
038 268
T reducer
033 087
Reducing union
034 612
Low-pressure hose
035 254
Worm drive hose clip
037 139
Hose sleeve
72)
037 140
Angle piece
82)
037 185
T-joint
91)
037 144
Angle piece
101)
037 194
Extension piece
11
035 824
Filling cover
12
037 264
Low-pressure hose
14
033 952
Insulation hose
1)
Quantity
Inserted with hemp and Fermit sealing cement.

Inserted with seal tape.
WP400_ET_en_08.fm
2)
Designation
E - 61
064 038 Compressor monitoring and control
1, 3, 9
6, 7
Stage 1.1
8, 12
10
6, 7
Stage 1.2
3, 13
6, 7
Stage 2
WP400_ET_en_08.fm
2, 3, 14
E - 62

064 038 Compressor monitoring and control
Ref. No.
Designation
Quantity
035 009
Pressure gauge oil
030 664
Pressure gauge 2nd stage
035 061
O-ring
038 941
Thermometer compressed air
005 009
O-ring
005 016
O-ring
035 906
Socket fitting
10
030 182
Cooling water thermometer
12
030 509
Plug
13
038 288
14
065 352
Double ended stud end
WP400_ET_en_08.fm
Item No.
E - 63
064 448 Protective device
WP400_ET_en_08.fm
3, 4, 5
E - 64

064 448 Protective device
Ref. No.
Designation
Quantity
064 449
Guard plate
001 408
Stud screw
002 031
Hexagon nut
002 156
Washer
WP400_ET_en_08.fm
Item No.
E - 65
037 134 Concentric valve stage 1.1. and 1.2
4
3
5
2
WP400_ET_en_08.fm
E - 66

037 134 Concentric valve stage 1.1. and 1.2
Ref. No.
Designation
Quantity
037 187
Suction valve plate
037 188
Delivery valve plate
037 189
Delivery valve plate
037 190
Delivery valve spring
037 191
Delivery valve spring
037 192
Suction valve spring
WP400_ET_en_08.fm
Item No.
E - 67
063 950 Compressor monitor
5, 6
5, 8
WP400_ET_en_08.fm
3, 4
E - 68

063 950 Compressor monitor
Ref. No.
Designation
Quantity
064 018
Temperature monitoring
030 082
Low oil pressure switch
000 409
Cap screw
004 596
Plug
033 017
Reducing union
008 633
Pipe
WP400_ET_en_08.fm
Item No.
E - 69
064 018 Temperature monitoring
2, 4
WP400_ET_en_08.fm
E - 70

064 018 Temperature monitoring
Ref. No.
Designation
Quantity
035 468
High air temperature switch
000 410
Cap screw
002 144
Washer
WP400_ET_en_08.fm
Item No.
E - 71
064 039 Automatic drainage system

6
12
1, 8
2, 9
10
3, 7, 11
4
5
13
E - 72
WP400_ET_en_08.fm

064 039 Automatic drainage system
Item No.
Ref. No.
049 129
Pipe clamp
033 961
Stub
006 187
Plug
004 647
Plug
005 964
Plug
004 973
Plug
71)
036 6542)
Solenoid valve
000 434
Cap screw
005 009
O-ring
10
006 000
Plug
11
006 455
Stub
12
008 663
Pipe
13
008 672
Pipe
1)
Quantity
Specify voltage and frequency for order!

The order number for the solenoid valve is order-specific.
WP400_ET_en_08.fm
2)
Designation
E - 73
066 143 Cooling water lines with pump

19
31
15
21
17
4, 9,
27, 29
10
4, 9, 18, 28, 30
26
34, 36, 38
33, 35, 37
WP400_ET_en_08.fm
6, 8, 14
E - 74

40
16
22
32
23
3
17
2, 7
25
41
20
13
WP400_ET_en_08.fm
E - 75

Ref. No.
066 442
Support plate
066 145
Attachment rail
066 144
Angle steel bar
005 265
Hexagon head screw
005 265
Hexagon head screw
005 265
Hexagon head screw
000 594
Cap screw
001 620
Hexagon nut
002 051
Hexagon nut
101)
038 201
Reducing union
132)
032 725
Pipe adaptor
14
002 161
Washer
151)
037 267
Reducing nipple
161)
037 144
Pipe bend
171)
037 265
Pipe bend
18
002 166
Washer
191)
036 967
Pipe fitting
202)
032 679
Particle trap
213)
037 1504)
Solenoid valve
22
064 396
Sliding socket
23
038 238
Cooling water pump
25
038 386
High pressure hose
265)
037 493
Clamp, two-part
27
037 293
Flange
281)
036 614
Threaded flange
29
030 658
Gasket
30
037 441
Gasket
E - 76
Designation
Quantity
WP400_ET_en_08.fm
Item No.

Item No.
Ref. No.
Designation
Quantity
311)
037 930
Pipe adaptor
321)
037 305
Pipe reducing adaptor
33
000 119
Hexagon head screw
34
000 048
Hexagon head screw
35
002 153
Washer
36
002 156
Washer
37
002 025
Hexagon nut
38
002 031
Hexagon nut
401)
037 851
Plug
411)
004 666
Plug
1)
Fitting with cylindrical threading is sealed with seal tape.

Fitting with conical threading is sealed with hemp and Fermit sealing cement.
3) Specify voltage and frequency for solenoid valve order!
4) The order number for the solenoid valve is order-specific.
5) Item 26, 037 493 Clamp installed without rubber insert.
WP400_ET_en_08.fm
2)
E - 77
038 238 Cooling water pump

1, 2, 3
DN 40
DN 32
Motor terminal box
WP400_ET_en_08.fm
Cabe entry
E - 78

038 238 Cooling water pump
Item No.
Ref. No.
1)
Designation
Quantity
Cooling water pump
038 290
Gasket kit
31)
038 257
Repair kit
Repair kit 038 257 can be supplied.
Technical specification
Pump:
Max. working pressure:
10 bar
Pump capacity:
67 l/min against 19 m water column

100 l/min against 18 m water column
Medium:
fresh water
Max. working pressure:
55 C
AC motor1) :
Capacity:
1.1 kW, IP 55
Voltage and frequency:
400/440 V, 50/60 Hz
Max. ambient temperature:
55 C
Also available to customer-specific specifications upon request.
WP400_ET_en_08.fm
1)
E - 79
064 366 Cooling water lines without pump
5
3
2
3
6
8
WP400_ET_en_08.fm
E - 80

064 366 Cooling water lines without pump
Item No.
Ref. No.
11), 3)
037 1422)
23)
Designation
Quantity
Solenoid valve
032 679
Particle trap
33)
032 725
Pipe adaptor
43)
037 930
Pipe adaptor
53)
037 265
Pipe bend
63)
037 266
Socket
73)
036 967
Pipe fitting
037 267
Reducing nipple
1)
Specify voltage and frequency for solenoid valve order!

The order number for the solenoid valve is order-specific.
3) Screw into place sealed with hemp and Fermit sealing cement and rotate into correct
position.
WP400_ET_en_08.fm
2)
E - 81
064 151 Anti-vibration resilient mount
9
1)
10
Type with cooling water pump:

installation of hose line on the pump intake fittings
WP400_ET_en_08.fm
1)
E - 82

064 151 Anti-vibration resilient mount
Ref. No.
Designation
Quantity
066 595
Hose line
033 531
Countersunk screw
000 589
Cap screw
046 837
Anti-vibration resilient mount
034 763
High pressure hose
035 942
High pressure hose
004 701
Plug
065 664
Non-return valve
10
063 947
Rail
WP400_ET_en_08.fm
Item No.
E - 83
066 595 Hose line
WP400_ET_en_08.fm
E - 84

066 595 Hose line
Ref. No.
Designation
Quantity
038 389
High pressure hose
004 666
Plug
WP400_ET_en_08.fm
Item No.
E - 85
28
35
065 664 Non-return valve
WP400_ET_en_08.fm
E - 86

065 664 Non-return valve
Ref. No.
Designation
Quantity
037 883
Non-return valve
004 661
Plug
037 851
Plug
WP400_ET_en_08.fm
Item No.
E - 87
Flexible coupling
3
Motor
WP400_ET_en_08.fm
Compressor
E - 88

Flexible coupling
Item No.
Ref. No.
Designation
Quantity
11)
036 333
Compressor half coupling
22)
037 057
Motor half coupling
33)
033 423
1)
Item 1, Compressor half coupling 036 333 is part of assembly 064 035.
Item 2, Motor half coupling 037 057 is part of assembly 066 148.
3) Item 3, Coupling flexible insert 033 423 is part of assembly 066 148.
WP400_ET_en_08.fm
2)
E - 89
E - 90
WP400_ET_en_08.fm
Index
WP400_ET_Index_en_08.fm
Parts List by Ref. No.
Assembly
Page
E-
Ref. No.
Designation
Item
000 048
Hexagon head screw .............................
066 143
74
34
000 054
064 146
48
000 119
066 143
74
33
000 137
064 146
48
000 216
064 344
10
16
000 216
066 148
16
000 409
Cap screw ..............................................
063 950
68
000 410
Cap screw ..............................................
064 018
70
064 366
Cooling water lines without pump ..........
064 344
11
000 434
Cap screw ..............................................
064 039
72
000 456
Cap screw ..............................................
063 985
54
000 475
Cap screw ..............................................
067 735
34
13
000 494
Cap screw ..............................................
064 035
16
25
000 497
Cap screw ..............................................
067 735
35
12
000 497
Cap screw ..............................................
067 737
40
16
000 505
Cap screw ..............................................
067 737
40
14
000 509
Cap screw ..............................................
067 735
34
15
000 509
Cap screw ..............................................
067 737
40
18
000 519
Cap screw ..............................................
067 735
34
16
000 543
Cap screw ..............................................
064 035
15
27
000 554
Cap screw ..............................................
067 737
40
15
000 589
Cap screw ..............................................
064 151
82
000 594
Cap screw ..............................................
066 143
75
035 823
Small-end bearing ..................................
063 864
30
000 971
Plug ........................................................
064 140
18
11
000 971
Plug ........................................................
067 737
41
27
000 977
Plug ........................................................
067 735
34
17
E - 91
Item
000 977
Plug ........................................................
067 737
40
21
001 007
Plug ........................................................
063 121
50
11
001 016
Plug ........................................................
067 735
34, 35
18
001 016
Plug ........................................................
067 737
41
20
001 408
Stud screw ..............................................
064 140
19
19
001 408
Stud screw ..............................................
064 448
64
001 463
Stud screw ..............................................
061 822
38
001 533
Stud screw ..............................................
067 735
35
14
001 533
Stud screw ..............................................
067 737
40
17
001 620
Hexagon nut ...........................................
064 140
18
16
001 620
Hexagon nut ...........................................
066 143
74
001 621
Hexagon nut ...........................................
064 140
19
18
001 621
Hexagon nut ...........................................
064 344
10
18
001 621
Hexagon nut ...........................................
066 148
18
001 621
Hexagon nut ...........................................
067 735
35
22
001 621
Hexagon nut ...........................................
067 737
40
19
002 025
Hexagon nut ...........................................
066 143
74
37
002 031
Hexagon nut ...........................................
064 140
19
20
002 031
Hexagon nut ...........................................
064 448
64
002 031
Hexagon nut ...........................................
066 143
74
38
002 051
Hexagon nut ...........................................
066 143
76
002 144
Washer ...................................................
064 018
70
002 151
Washer ...................................................
064 146
48
002 153
Washer ...................................................
066 143
74
35
002 156
Washer ...................................................
064 448
64
002 156
Washer ...................................................
066 143
74
36
002 161
Washer ...................................................
066 143
74
14
002 166
Washer ...................................................
066 143
74
18
002 170
Washer ...................................................
064 344
10
15
Designation
E - 92
Assembly
Page
E-
Ref. No.
Index
Assembly
Page
E-
Ref. No.
Designation
Item
002 170
Washer ...................................................
066 148
15
002 605
Oil scraper ring .......................................
064 145
32
002 634
Nose ring ................................................
064 145
32
002 716
Plain ring ................................................
064 261
30
002 962
Circlip .....................................................
057 916
58
002 985
Circlip .....................................................
064 261
30
003 438
Gasket ....................................................
063 985
54
003 493
Gasket ....................................................
063 869
46
003 496
Gasket ....................................................
063 121
50
12
004 411
Locking pin .............................................
064 035
16
31
004 596
Plug ........................................................
063 950
68
004 635
Plug ........................................................
064 140
18
10
004 647
Plug ........................................................
064 039
72
004 661
Plug ........................................................
064 147
52
004 661
Plug ........................................................
065 664
86
004 666
Plug ........................................................
066 143
75
41
004 666
Plug ........................................................
066 595
84
004 701
Plug ........................................................
064 151
82
004 973
Plug ........................................................
064 039
72
005 001
Gasket ....................................................
064 140
18
12
005 001
Gasket ....................................................
067 737
41
26
005 009
Gasket ....................................................
063 121
50
005 009
Gasket ....................................................
064 038
62
005 009
Gasket ....................................................
064 039
72
005 009
Gasket ....................................................
064 140
18
14
005 009
Gasket ....................................................
064 146
48
14
005 009
Gasket ....................................................
067 735
34, 35
24
005 009
Gasket ....................................................
067 737
41
24
005 016
Gasket ....................................................
064 038
62
E - 93
Item
005 016
Gasket ....................................................
064 146
48
15
005 023
Gasket ....................................................
064 146
48
16
005 023
Gasket ....................................................
067 735
34, 35
23
005 023
Gasket ....................................................
067 737
40
23
005 029
Gasket ....................................................
063 121
50
005 265
Hexagon head screw ..............................
066 143
74
005 265
066 143
75
005 265
066 143
74
005 297
064 142
24
005 546
Stud screw ..............................................
064 035
16
26
005 946
Stub ........................................................
064 146
48
11
005 964
Plug ........................................................
064 039
72
006 000
Plug ........................................................
064 039
72
10
006 187
Plug ........................................................
064 039
72
006 193
Plug ........................................................
064 146
48
10
006 390
Reducing union ......................................
063 121
50
006 455
Stub ........................................................
064 039
72
11
008 633
Pipe ........................................................
063 950
68
008 663
Pipe ........................................................
064 039
72
12
008 672
Pipe ........................................................
064 039
72
13
012 982
Circlip .....................................................
064 145
32
030 082
Low oil pressure switch ..........................
063 950
68
030 131
O-ring .....................................................
067 737
40
25
030 182
Cooling water thermometer ....................
064 038
62
10
030 509
Plug ........................................................
064 038
62
12
030 544
Gasket ....................................................
063 543
56
030 556
O-ring .....................................................
064 257
22
030 658
Gasket ....................................................
066 143
74
29
030 664
Pressure gauge 2nd stage .....................
064 038
62
Designation
E - 94
Assembly
Page
E-
Ref. No.
Index
Assembly
Page
E-
Ref. No.
Designation
Item
030 743
Shaft seal ...............................................
064 140
18
030 751
Safety valve stage 1.2 ............................
064 146
48
12
030 752
Safety valve 2nd stage ...........................
064 146
48
13
030 912
O-ring .....................................................
063 868
44
032 679
Particle trap ............................................
064 366
80
032 679
Particle trap ............................................
066 143
75
20
032 725
Pipe adaptor ...........................................
064 366
80
032 725
Pipe adaptor ...........................................
066 143
75
13
033 017
Reducing union ......................................
063 950
68
033 087
Reducing union ......................................
064 148
60
033 212
Oil pump cover .......................................
063 543
56
033 423
Coupling flexible insert ...........................
066 148
88
033 423
Coupling flexible insert / elastic coupling

insert ......................................................
064 344
10
12
033 423

insert ......................................................
066 148
12
033 531
Countersunk screw ................................
064 151
82
033 571
Plain ring ................................................
064 145
32
033 952
Insulation hose .......................................
064 148
60
14
033 961
Stub ........................................................
064 039
72
033 994
Cap screw ..............................................
064 142
24
034 612
Low-pressure hose ................................
064 148
60
034 763
High pressure hose ................................
064 151
82
034 875
T-joint .....................................................
064 147
52
11
035 009
Pressure gauge oil .................................
064 038
62
035 061
Gasket ....................................................
064 038
62
035 254
Worm drive hose clip ..............................
064 148
60
035 390
Plug ........................................................
067 735
34
19
035 390
Plug ........................................................
067 737
40
22
035 468
High air temperature switch ...................
064 018
70
1
E - 95
Item
035 823
063 864
26
035 824
Filling cover ............................................
064 148
60
11
035 906
Socket fitting ...........................................
064 038
62
035 942
064 151
82
035 962
Oil scraper ring .......................................
064 261
30
035 970
O-ring .....................................................
063 869
46
035 984
Drain cock ..............................................
064 140
18
13
036 041
063 121
50
10
036 078
Gudgeon pin ...........................................
064 261
30
036 157
Plug ........................................................
064 146
48
036 171
O-ring .....................................................
063 121
50
036 333
Compressor half coupling .......................
064 035
15
22
036 333
064 035
88
036 359
Gear wheel .............................................
063 543
56
036 360
Oil pump housing ...................................
063 543
56
036 363
Gasket ....................................................
063 543
56
036 394
Dry air filter .............................................
063 868
44
036 395
Filter insert ..............................................
036 394
44
036 614
Threaded flange .....................................
066 143
74
28
036 654
Solenoid valve ........................................
064 039
72
036 767
Oil pump gear wheel ..............................
063 543
56
036 897
Oil strainer ..............................................
064 140
18
036 959
Lamellar valve 2nd stage .......................
064 035
15
24
036 960
Stud screw ..............................................
064 140
19
17
036 960
Stud screw ..............................................
064 344
10
17
036 960
Stud screw ..............................................
066 148
17
036 961
Cylindrical roller bearing .........................
064 142
24
036 962
O-ring .....................................................
067 735
34
26
036 963
O-ring .....................................................
063 869
46
Designation
E - 96
Assembly
Page
E-
Ref. No.
Index
Assembly
Page
E-
Ref. No.
Designation
036 964
063 869
46
036 967
Pipe fitting ..............................................
064 147
52
10
036 967
Pipe fitting ..............................................
064 366
80
036 967
Pipe fitting ..............................................
066 143
74
19
036 983
Piston .....................................................
064 261
30
037 057
Motor half coupling .................................
064 035
88
037 057
064 344
10
11
037 057
066 148
11
037 058
064 144
28
037 058
064 144
32
037 067
AC motor ................................................
064 344
10
14
037 067
AC motor ................................................
066 148
14
037 134
Concentric valve stage 1.1. and 1.2 .......
064 035
15
23
037 139
Hose sleeve ...........................................
064 148
60
037 140
Angle piece ............................................
064 148
60
037 142
Solenoid valve ........................................
064 366
80
037 144
Angle piece ............................................
064 147
52
037 144
Angle piece ............................................
064 148
60
037 144
Pipe bend ...............................................
066 143
75
16
037 150
Solenoid valve ........................................
066 143
74
21
037 151
O-ring .....................................................
063 868
44
037 185
T-joint .....................................................
064 148
60
037 187
Suction valve plate .................................
037 134
66
037 188
Delivery valve plate ................................
037 134
66
037 189
037 134
66
037 190
Delivery valve spring ..............................
037 134
66
037 191
037 134
66
037 192
Suction valve spring ...............................
037 134
66
037 194
Extension piece ......................................
064 147
52
Item
E - 97
Item
037 194
Extension piece ......................................
064 148
60
10
037 225
Lifting eye bolt nut ..................................
064 035
16
30
037 264
Low-pressure hose .................................
064 148
60
12
037 265
Angle piece ............................................
064 147
52
037 265
Pipe bend ...............................................
064 366
80
037 265
Pipe bend ...............................................
066 143
74, 75
17
037 266
Socket ....................................................
064 366
80
037 267
Reducing nipple ......................................
064 366
80
037 267
Reducing nipple ......................................
066 143
74
15
037 293
Flange ....................................................
066 143
74
27
037 305
Pipe reducing adaptor ............................
064 147
52
12
037 305
066 143
75
32
037 441
Gasket ....................................................
066 143
74
30
037 493
Clamp, two-part ......................................
066 143
74
26
037 851
Plug ........................................................
065 664
86
037 851
Plug ........................................................
066 143
75
40
037 883
Non-return valve .....................................
065 664
86
037 930
Pipe adaptor ...........................................
064 366
80
037 930
Pipe adaptor ...........................................
066 143
74
31
038 102
Stud screw ..............................................
064 140
18
15
038 201
Reducing union ......................................
066 143
74
10
038 238
Cooler water pump .................................
066 143
75
23
038 257
Repair kit ................................................
038 238
78
038 268
T reducer ................................................
064 148
60
038 288
Pressure gauge 1st stage ......................
064 038
62
13
038 290
Gasket kit ...............................................
038 238
78
038 386
066 143
75
25
038 389
066 595
84
038 390
064 147
52
Designation
E - 98
Assembly
Page
E-
Ref. No.
Index
Assembly
Page
E-
Ref. No.
Designation
038 407
Pipe nipple joint ......................................
064 148
60
038 941
Thermometer compressed air ................
064 038
62
046 837
Anti-vibration resilient mount ..................
064 151
82
049 129
Pipe clamp .............................................
064 039
72
051 530
Gasket ....................................................
067 737
40
12
051 531
Burst disc ...............................................
067 737
40
13
051 883
Crankcase inspection cover ...................
064 140
19
054 164
Spring .....................................................
057 916
58
054 883
Protecting cap ........................................
067 737
40
056 318
Gasket ....................................................
063 543
56
056 335
Gasket ....................................................
064 146
48
057 916
Pressure relief valve ..............................
063 985
54
060 342
Fusible plug ............................................
063 121
50
061 820
Plug ........................................................
061 822
38
061 821
Zinc cartridge .........................................
061 822
38
061 822
Zinc protection .......................................
067 735
35
061 822
Zinc protection .......................................
067 737
40
061 857
Connecting rod bearing ..........................
063 864
26
061 857
064 144
28
062 328
Baffle cone .............................................
063 121
50
063 121
Separator ...............................................
064 146
48
063 228
Separator housing ..................................
063 121
50
063 229
Separator head ......................................
063 121
50
063 543
Gear oil pump ........................................
063 985
54
063 544
Driving disc ............................................
064 142
24
063 660
Cylinder cover ........................................
067 735
35
063 662
Cylinder cover 2nd stage .......................
067 737
40
063 712
Connecting rod .......................................
063 864
26
063 732
Washer ...................................................
064 142
24
Item
E - 99
Item
063 743
Valve cover .............................................
063 869
46
063 747
Gasket ....................................................
067 735
35
063 747
Gasket ....................................................
067 737
40
063 748
Gasket ....................................................
064 140
19
063 749
Gasket ....................................................
064 140
18
063 776
Liner .......................................................
067 735
34
063 786
Crankcase ..............................................
064 140
19
063 800
Motor attachment rail ..............................
064 344
10
063 800
Motor attachment rail ..............................
066 148
063 808
Liner .......................................................
067 737
40
063 811
Flywheel .................................................
064 142
24
063 815
Piston .....................................................
064 145
32
063 826
Connecting rod .......................................
064 144
28
063 864
Connecting rod stage 1.1 and 1.2 ..........
064 035
15
063 868
Valve cover stage 1.1 and 1.2 ................
064 035
15
063 869
Valve cover 2nd stage ............................
064 035
15
10
063 947
Rail .........................................................
064 151
82
10
063 950
Compressor monitoring ..........................
064 344
11
063 950
066 148
063 985
Lubricating oil supply ..............................
064 035
15
13
064 018
Temperature monitoring .........................
063 950
68
064 035
Compressor WP 400-100 .......................
064 344
10
064 035
Compressor WP 400-100 .......................
066 148
064 038
Compressor monitoring and control .......
064 035
15
15
064 039
Automatic drainage system ....................
064 344
10
064 039
066 148
064 140
Crankcase ..............................................
064 035
15
064 142
Crankshaft ..............................................
064 035
15
064 143
Crankshaft ..............................................
064 142
24
Designation
E - 100
Assembly
Page
E-
Ref. No.
Index
Assembly
Page
E-
Ref. No.
Designation
Item
064 144
Connecting rod 2nd stage ......................
064 035
15
064 145
Piston .....................................................
064 035
15
064 146
Air lines ..................................................
064 035
16
11
064 147
Cooler water lines ..................................
064 035
16
12
064 148
Crankcase vent ......................................
064 035
16
14
064 150
Gudgeon pin ..........................................
064 145
32
064 236
Valve cover .............................................
063 868
44
064 256
Dipstick ..................................................
064 257
22
064 257
Dipstick ..................................................
064 140
19
064 261
Piston stage 1.1 and 1.2 ........................
064 035
15
064 331
Blind flange ............................................
064 035
16
19
064 332
Gasket ....................................................
064 035
16
20
064 370
Spacer ring .............................................
064 344
10
064 370
Spacer ring .............................................
066 148
064 394
Housing cover ........................................
064 140
19
064 396
Sliding socket .........................................
066 143
75
22
064 448
Protective device ....................................
064 035
15
17
064 449
Guard plate ............................................
064 448
64
065 352
Double ended stud end ..........................
064 038
62
14
065 664
Non-return valve ....................................
064 151
82
066 143
Cooling water lines with pump ...............
066 148
066 144
Angle steel bar .......................................
066 143
75
066 145
Attachment rail .......................................
066 143
75
066 442
Support plate ..........................................
066 143
74
066 595
Hose line ................................................
064 151
82
067 708
Cooler cover ...........................................
067 735
34
067 710
Cooler cover 2nd stage ..........................
067 737
40
067 715
Cooler insert 2nd stage ..........................
067 737
40
067 716
Gasket ....................................................
067 737
40
10
E - 101
Designation
Item
067 717
Gasket ....................................................
067 737
40
11
067 718
Cylinder housing 2nd stage ....................
067 737
40
067 729
Compressed air manifold .......................
064 146
48
067 734
Cylinder housing .....................................
067 735
34
067 735
Cylinder stage 1.1 and 1.2 .....................
064 035
15
067 737
Cylinder 2nd stage .................................
064 035
15
067 738
Cooler insert ...........................................
067 735
34
067 739
Gasket ....................................................
067 735
34
067 741
Gasket ....................................................
067 735
34
10
038 238
78
Assembly
Page
E-
Ref. No.
E - 102
Index
Parts List by Ref. No.
Assembly
Page
E-
Ref. No.
Designation
Item
037 067
AC motor ................................................
064 344
10
14
037 067
AC motor ................................................
066 148
14
064 146
Air lines ..................................................
064 035
16
11
037 140
Angle piece ............................................
064 148
60
037 144
Angle piece ............................................
064 147
52
037 144
Angle piece ............................................
064 148
60
037 265
Angle piece ............................................
064 147
52
066 144
Angle steel bar .......................................
066 143
75
046 837
Anti-vibration resilient mount ..................
064 151
82
066 145
Attachment rail .......................................
066 143
75
064 039
064 344
10
064 039
066 148
062 328
Baffle cone .............................................
063 121
50
064 331
Blind flange ............................................
064 035
16
19
051 531
Burst disc ...............................................
067 737
40
13
000 409
Cap screw ..............................................
063 950
68
000 410
Cap screw ..............................................
064 018
70
000 434
Cap screw ..............................................
064 039
72
000 456
Cap screw ..............................................
063 985
54
000 475
Cap screw ..............................................
067 735
34
13
000 494
Cap screw ..............................................
064 035
16
25
000 497
Cap screw ..............................................
067 735
35
12
000 497
Cap screw ..............................................
067 737
40
16
000 505
Cap screw ..............................................
067 737
40
14
000 509
Cap screw ..............................................
067 735
34
15
000 509
Cap screw ..............................................
067 737
40
18
000 519
Cap screw ..............................................
067 735
34
16
E - 103
Item
000 543
Cap screw ..............................................
064 035
15
27
000 554
Cap screw ..............................................
067 737
40
15
000 589
Cap screw ..............................................
064 151
82
000 594
Cap screw ..............................................
066 143
75
033 994
Cap screw ..............................................
064 142
24
002 962
Circlip .....................................................
057 916
58
002 985
Circlip .....................................................
064 261
30
012 982
Circlip .....................................................
064 145
32
037 493
Clamp, two-part ......................................
066 143
74
26
067 729
Compressed air manifold .......................
064 146
48
036 333
064 035
15
22
036 333
064 035
88
063 950
064 344
11
063 950
066 148
064 038
Compressor monitoring and control .......
064 035
15
15
064 035
Compressor WP 400-100 .......................
064 344
10
064 035
Compressor WP 400-100 .......................
066 148
037 134
Concentric valve stage 1.1. and 1.2 .......
064 035
15
23
063 712
Connecting rod .......................................
063 864
26
063 826
Connecting rod .......................................
064 144
28
064 144
Connecting rod 2nd stage ......................
064 035
15
061 857
063 864
26
061 857
064 144
28
063 864
Connecting rod stage 1.1 and 1.2 ..........
064 035
15
067 708
Cooler cover ...........................................
067 735
34
067 710
Cooler cover 2nd stage ..........................
067 737
40
067 738
Cooler insert ...........................................
067 735
34
067 715
Cooler insert 2nd stage ..........................
067 737
40
064 147
Cooler water lines ...................................
064 035
16
12
Designation
E - 104
Assembly
Page
E-
Ref. No.
Index
Assembly
Page
E-
Ref. No.
Designation
Item
038 238
066 143
75
23
066 143
Cooling water lines with pump ...............
066 148
064 366
Cooling water lines without pump ..........
064 344
11
030 182
Cooling water thermometer ....................
064 038
62
10
033 531
Countersunk screw ................................
064 151
82
033 423
Coupling flexible insert ...........................
066 148
88
033 423

insert ......................................................
064 344
10
12
033 423

insert ......................................................
066 148
12
063 786
Crankcase ..............................................
064 140
19
064 140
Crankcase ..............................................
064 035
15
051 883
Crankcase inspection cover ...................
064 140
19
064 148
Crankcase vent ......................................
064 035
16
14
064 142
Crankshaft ..............................................
064 035
15
064 143
Crankshaft ..............................................
064 142
24
067 737
Cylinder 2nd stage .................................
064 035
15
063 660
Cylinder cover ........................................
067 735
35
063 662
Cylinder cover 2nd stage .......................
067 737
40
067 734
Cylinder housing ....................................
067 735
34
067 718
Cylinder housing 2nd stage ....................
067 737
40
067 735
Cylinder stage 1.1 and 1.2 .....................
064 035
15
036 961
Cylindrical roller bearing ........................
064 142
24
037 188
037 134
66
037 189
037 134
66
037 190
037 134
66
037 191
037 134
66
064 256
Dipstick ..................................................
064 257
22
064 257
Dipstick ..................................................
064 140
19
065 352
Double ended stud end ..........................
064 038
62
14
E - 105
Item
035 984
Drain cock ..............................................
064 140
18
13
063 544
Driving disc .............................................
064 142
24
036 394
Dry air filter .............................................
063 868
44
037 194
Extension piece ......................................
064 147
52
037 194
Extension piece ......................................
064 148
60
10
035 824
Filling cover ............................................
064 148
60
11
036 395
Filter insert ..............................................
036 394
44
037 293
Flange ....................................................
066 143
74
27
063 811
Flywheel .................................................
064 142
24
060 34 2
Fusible plug ............................................
063 121
50
003 438
Gasket ....................................................
063 985
54
003 493
Gasket ....................................................
063 869
46
003 496
Gasket ....................................................
063 121
50
12
005 001
Gasket ....................................................
064 140
18
12
005 001
Gasket ....................................................
067 737
41
26
005 009
Gasket ....................................................
063 121
50
005 009
Gasket ....................................................
064 038
62
005 009
Gasket ....................................................
064 039
72
005 009
Gasket ....................................................
064 140
18
14
005 009
Gasket ....................................................
064 146
48
14
005 009
Gasket ....................................................
067 735
34, 35
24
005 009
Gasket ....................................................
067 737
41
24
005 016
Gasket ....................................................
064 038
62
005 016
Gasket ....................................................
064 146
48
15
005 023
Gasket ....................................................
064 146
48
16
005 023
Gasket ....................................................
067 735
34, 35
23
005 023
Gasket ....................................................
067 737
40
23
005 029
Gasket ....................................................
063 121
50
030 544
Gasket ....................................................
063 543
56
Designation
E - 106
Assembly
Page
E-
Ref. No.
Index
Assembly
Page
E-
Ref. No.
Designation
Item
030 658
Gasket ....................................................
066 143
74
29
035 061
Gasket ....................................................
064 038
62
036 363
Gasket ....................................................
063 543
56
037 441
Gasket ....................................................
066 143
74
30
051 530
Gasket ....................................................
067 737
40
12
056 318
Gasket ....................................................
063 543
56
056 335
Gasket ....................................................
064 146
48
063 747
Gasket ....................................................
067 735
35
063 747
Gasket ....................................................
067 737
40
063 748
Gasket ....................................................
064 140
19
063 749
Gasket ....................................................
064 140
18
064 332
Gasket ....................................................
064 035
16
20
067 716
Gasket ....................................................
067 737
40
10
067 717
Gasket ....................................................
067 737
40
11
067 739
Gasket ....................................................
067 735
34
067 741
Gasket ....................................................
067 735
34
10
038 290
Gasket kit ...............................................
038 238
78
063 543
Gear oil pump ........................................
063 985
54
036 359
Gear wheel .............................................
063 543
56
064 449
Guard plate ............................................
064 448
64
036 078
Gudgeon pin ..........................................
064 261
30
064 150
Gudgeon pin ..........................................
064 145
32
000 048
066 143
74
34
000 054
064 146
48
000 119
066 143
74
33
000 137
064 146
48
000 216
064 344
10
16
000 216
066 148
16
005 265
066 143
74
E - 107
Item
005 265
066 143
75
005 265
066 143
74
005 297
064 142
24
036 041
063 121
50
10
036 964
063 869
46
001 620
Hexagon nut ...........................................
064 140
18
16
001 620
Hexagon nut ...........................................
066 143
74
001 621
Hexagon nut ...........................................
064 140
19
18
001 621
Hexagon nut ...........................................
064 344
10
18
001 621
Hexagon nut ...........................................
066 148
18
001 621
Hexagon nut ...........................................
067 735
35
22
001 621
Hexagon nut ...........................................
067 737
40
19
002 025
Hexagon nut ...........................................
066 143
74
37
002 031
Hexagon nut ...........................................
064 140
19
20
002 031
Hexagon nut ...........................................
064 448
64
002 031
Hexagon nut ...........................................
066 143
74
38
002 051
Hexagon nut ...........................................
066 143
76
035 468
High air temperature switch ....................
064 018
70
034 763
064 151
82
035 942
064 151
82
038 386
066 143
75
25
038 389
066 595
84
038 390
064 147
52
066 595
Hose line ................................................
064 151
82
037 139
Hose sleeve ............................................
064 148
60
064 394
Housing cover ........................................
064 140
19
033 952
Insulation hose .......................................
064 148
60
14
036 959
Lamellar valve 2nd stage .......................
064 035
15
24
037 225
Lifting eye bolt nut ..................................
064 035
16
30
Designation
E - 108
Assembly
Page
E-
Ref. No.
Index
Assembly
Page
E-
Ref. No.
Designation
Item
063 776
Liner .......................................................
067 735
34
063 808
Liner .......................................................
067 737
40
004 411
Locking pin .............................................
064 035
16
31
030 08 2
Low oil pressure switch ..........................
063 950
68
034 612
064 148
60
037 264
064 148
60
12
063 985
Lubricating oil supply .............................
064 035
15
13
063 800
Motor attachment rail .............................
064 344
10
063 800
Motor attachment rail .............................
066 148
037 057
064 035
88
037 057
064 344
10
11
037 057
066 148
11
037 883
Non-return valve ....................................
065 664
86
065 664
Non-return valve ....................................
064 151
82
002 634
Nose ring ................................................
064 145
32
033 212
Oil pump cover .......................................
063 543
56
036 767
Oil pump gear wheel ..............................
063 543
56
036 360
Oil pump housing ...................................
063 543
56
002 605
Oil scraper ring .......................................
064 145
32
035 962
Oil scraper ring .......................................
064 261
30
036 897
Oil strainer ..............................................
064 140
18
030 131
O-ring .....................................................
067 737
40
25
030 556
O-ring .....................................................
064 257
22
030 912
O-ring .....................................................
063 868
44
035 970
O-ring .....................................................
063 869
46
036 171
O-ring .....................................................
063 121
50
036 962
O-ring .....................................................
067 735
34
26
036 963
O-ring .....................................................
063 869
46
037 151
O-ring .....................................................
063 868
44
E - 109
Item
032 679
Particle trap ............................................
064 366
80
032 679
Particle trap ............................................
066 143
75
20
008 633
Pipe ........................................................
063 950
68
008 663
Pipe ........................................................
064 039
72
12
008 672
Pipe ........................................................
064 039
72
13
032 725
Pipe adaptor ...........................................
064 366
80
032 725
Pipe adaptor ...........................................
066 143
75
13
037 930
Pipe adaptor ...........................................
064 366
80
037 930
Pipe adaptor ...........................................
066 143
74
31
037 144
Pipe bend ...............................................
066 143
75
16
037 265
Pipe bend ...............................................
064 366
80
037 265
Pipe bend ...............................................
066 143
74, 75
17
049129
Pipe clamp ..............................................
064 039
72
036 967
Pipe fitting ..............................................
064 147
52
10
036 967
Pipe fitting ..............................................
064 366
80
036 967
Pipe fitting ..............................................
066 143
74
19
038 407
Pipe nipple joint ......................................
064 148
60
037 305
064 147
52
12
037 305
066 143
75
32
036 983
Piston .....................................................
064 261
30
063 815
Piston .....................................................
064 145
32
064 145
Piston .....................................................
064 035
15
064 261
Piston stage 1.1 and 1.2 .........................
064 035
15
002 716
Plain ring ................................................
064 261
30
033 571
Plain ring ................................................
064 145
32
000 971
Plug ........................................................
064 140
18
11
000 971
Plug ........................................................
067 737
41
27
000 977
Plug ........................................................
067 735
34
17
000 977
Plug ........................................................
067 737
40
21
Designation
E - 110
Assembly
Page
E-
Ref. No.
Index
Assembly
Page
E-
Ref. No.
Designation
Item
001 007
Plug ........................................................
063 121
50
11
001 016
Plug ........................................................
067 735
34, 35
18
001 016
Plug ........................................................
067 737
41
20
004 596
Plug ........................................................
063 950
68
004 635
Plug ........................................................
064 140
18
10
004 647
Plug ........................................................
064 039
72
004 661
Plug ........................................................
065 664
86
004 661
Plug ........................................................
064 147
52
004 666
Plug ........................................................
066 143
75
41
004 666
Plug ........................................................
066 595
84
004 701
Plug ........................................................
064 151
82
004 973
Plug ........................................................
064 039
72
005 964
Plug ........................................................
064 039
72
006 000
Plug ........................................................
064 039
72
10
006 187
Plug ........................................................
064 039
72
006 193
Plug ........................................................
064 146
48
10
030 509
Plug ........................................................
064 038
62
12
035 390
Plug ........................................................
067 735
34
19
035 390
Plug ........................................................
067 737
40
22
036 157
Plug ........................................................
064 146
48
037 851
Plug ........................................................
065 664
86
037 851
Plug ........................................................
066 143
75
40
061 820
Plug ........................................................
061 822
38
038 288
Pressure gauge 1st stage ......................
064 038
62
13
030 66 4
Pressure gauge 2nd stage .....................
064 038
62
035 009
Pressure gauge oil .................................
064 038
62
057 916
Pressure relief valve ..............................
063 985
54
054 883
Protecting cap ........................................
067 737
40
064 448
Protective device ....................................
064 035
15
17
E - 111
Item
063 947
Rail .........................................................
064 151
82
10
037 267
Reducing nipple ......................................
064 366
80
037 267
Reducing nipple ......................................
066 143
74
15
006 390
Reducing union ......................................
063 121
50
033 017
Reducing union ......................................
063 950
68
033 087
Reducing union ......................................
064 148
60
038 201
Reducing union ......................................
066 143
74
10
038 257
Repair kit ................................................
038 238
78
030 752
Safety valve 2nd stage ...........................
064 146
48
13
030 751
Safety valve stage 1.2 ............................
064 146
48
12
063 121
Separator ................................................
064 146
48
063 229
Separator head .......................................
063 121
50
063 228
Separator housing ..................................
063 121
50
030 743
Shaft seal ...............................................
064 140
18
064 396
Sliding socket .........................................
066 143
75
22
035 823
063 864
30
035 823
063 864
26
037 058
064 144
28
037 058
064 144
32
037 266
Socket ....................................................
064 366
80
035 906
Socket fitting ...........................................
064 038
62
036 654
Solenoid valve ........................................
064 039
72
037 142
Solenoid valve ........................................
064 366
80
037 150
Solenoid valve ........................................
066 143
74
21
064 370
Spacer ring .............................................
064 344
10
064 370
Spacer ring .............................................
066 148
054 164
Spring .....................................................
057 916
58
005 946
Stub ........................................................
064 146
48
11
006 455
Stub ........................................................
064 039
72
11
Designation
E - 112
Assembly
Page
E-
Ref. No.
Index
Assembly
Page
E-
Ref. No.
Designation
Item
033 961
Stub ........................................................
064 039
72
001 408
Stud screw .............................................
064 140
19
19
001 408
Stud screw .............................................
064 448
64
001 463
Stud screw .............................................
061 822
38
001 533
Stud screw .............................................
067 735
35
14
001 533
Stud screw .............................................
067 737
40
17
005 546
Stud screw .............................................
064 035
16
26
036 960
Stud screw .............................................
064 140
19
17
036 960
Stud screw .............................................
064 344
10
17
036 960
Stud screw .............................................
066 148
17
038 102
Stud screw .............................................
064 140
18
15
037 187
Suction valve plate .................................
037 134
66
037 192
Suction valve spring ...............................
037 134
66
066 442
Support plate ..........................................
066 143
74
038 268
T reducer ................................................
064 148
60
064 018
Temperature monitoring .........................
063 950
68
038 941
Thermometer compressed air ................
064 038
62
036 614
Threaded flange .....................................
066 143
74
28
034 875
T-joint .....................................................
064 147
52
11
037 185
T-joint .....................................................
064 148
60
063 743
Valve cover .............................................
063 869
46
064 236
Valve cover .............................................
063 868
44
063 869
Valve cover 2nd stage ............................
064 035
15
10
063 868
Valve cover stage 1.1 and 1.2 ................
064 035
15
002 144
Washer ...................................................
064 018
70
002 151
Washer ...................................................
064 146
48
002 153
Washer ...................................................
066 143
74
35
002 156
Washer ...................................................
064 448
64
002 156
Washer ...................................................
066 143
74
36
E - 113
Designation
Item
002 161
Washer ...................................................
066 143
74
14
002 166
Washer ...................................................
066 143
74
18
002 170
Washer ...................................................
064 344
10
15
002 170
Washer ...................................................
066 148
15
063 732
Washer ...................................................
064 142
24
035 254
Worm drive hose clip ..............................
064 148
60
061 821
Zinc cartridge ..........................................
061 822
38
061 822
Zinc protection ........................................
067 735
35
061 822
Zinc protection ........................................
067 737
40
038 238
78
Assembly
Page
E-
Ref. No.
E - 114

Air Compressor

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S a u e r

Sauer compressor Type Approvals

Genuine Sauer spare parts

Design and Function. . . . . . . . . . . . . . . . . . . . . . . . . 20

Transport and Installation . . . . . . . . . . . . . . . . . . . .36

Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . .55

Storage, Preservation lay-up procedure . . . . . 77

Spare Parts and Accessories. . . . . . . . . . . . . . . . . . 84

Sauer can no longer cover warranty, be liable for any claims, if a

1.4 Type Approval and Genuine Sauer Spare Parts

Only use genuine Sauer spare parts

Do not use parts from the

+49 431 39 40 -87

1.6 Text Conventions Used in This Operator Manual

General lists are marked using a dash.

Individual instructions or multiple instructions requiring action but

2.1 Conditions of Use

2.2 Unauthorised modification

Unauthorised modification of the Sauer compressor is not

2.3 Safety Information - Warning and Caution

High voltage! Danger

Location of safety markings

2.5 Safety and protection devices

High air temperature switch

The Sauer compressor is equipped with a temperature sensor.

Low oil pressure

The Sauer compressor comes supplied with a low oil pressure

2.7 Waste disposal

2.8 Safety requirements for personnel

Only personnel authorised by J.P. SAUER & SOHN are permitted

The owner should provide personal protection equipment (e.g.

Design and Function

Design and Function

Cylinder stage 1.2

Cylinder 2nd stage

Safety valve 1st stage

Safety valve 2nd stage

Oil fill pipe

Sump oil drain

Low oil pressure switch

Drain valve 1st stage

Drain valve 2nd stage

Compressed air temperature sensor

Cooling water stop valve

Connecting rod stage 1.1

Connecting rod stage 1.2

Connecting rod 2nd stage

Lubricating oil supply

Compressor monitoring and control

Design and Function

Design and Function

Cylinder stage 1.2

Cylinder 2nd stage

Piston stage 1.1

Piston stage 1.2

Piston 2nd stage

Valve cover stage 1.1

Valve cover stage 1.2

Valve cover 2nd stage

Concentric valve stage 1.1

Concentric valve stage 1.2

Lamellar valve 2nd stage

Cooler stage 1.1