air compressor wp400

S a u e r

C o m p r e s s o r

Type: WP 400

Operating Instructions

• High-pressure Compressor

• 2 Stages

• water-cooled

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

VO001AK1.fm

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Sauer compressor type approvals

Note!On this page only a few examples are shown. Further type ap-provals are available on request.

VO

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Genuine Sauer spare parts – certified safety

SPECIMEN

WP

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Inhaltsverzeichnis

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.1 At the outset . . . . . . . . . . . . . . . . . . . . . . . . . . 81.2 General information. . . . . . . . . . . . . . . . . . . . . 81.3 Warranty and Liability . . . . . . . . . . . . . . . . . . . 81.4 Type approval and genuine Sauer spare parts 91.5 Customer service of J.P. SAUER & SOHN . . 101.6 Organisation of these instructions . . . . . . . . . 11

2. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.1 Specified conditions of use . . . . . . . . . . . . . . 122.2 Prohibition of unauthorized conversion . . . . . 122.3 Safety information . . . . . . . . . . . . . . . . . . . . . 122.4 Safety markings on the machine . . . . . . . . . . 132.5 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . 142.6 Noise protection . . . . . . . . . . . . . . . . . . . . . . 142.7 Waste disposal . . . . . . . . . . . . . . . . . . . . . . . 142.8 Staff requirements . . . . . . . . . . . . . . . . . . . . . 152.9 Personal protection gear . . . . . . . . . . . . . . . . 15

3. Design and Function. . . . . . . . . . . . . . . . . . 163.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.2 Mode of Operation. . . . . . . . . . . . . . . . . . . . . 203.3 Indicators on the Sauer Compressor. . . . . . . 223.4 Indicators and controls of the compressor

control system . . . . . . . . . . . . . . . . . . . . . . . . 23

4. Technical Specifications . . . . . . . . . . . . . . 244.1 Specification data . . . . . . . . . . . . . . . . . . . . . 244.2 Compressed air system plan and cooling

water plan . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5. Transport and Installation . . . . . . . . . . . . . 285.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285.2 Storage before installation. . . . . . . . . . . . . . . 295.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 295.4 Connecting the compressor . . . . . . . . . . . . . 32

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5.5 Filling in oil . . . . . . . . . . . . . . . . . . . . . . . . . . 365.6 Checks after installation and before the first

start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 386.1 Safe operation. . . . . . . . . . . . . . . . . . . . . . . . 386.2 Operating modes. . . . . . . . . . . . . . . . . . . . . . 396.3 First Commissioning . . . . . . . . . . . . . . . . . . . 396.4 Routine operation . . . . . . . . . . . . . . . . . . . . . 40

7. Trouble-shooting. . . . . . . . . . . . . . . . . . . . . 42

8. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 468.1 Maintenance service by J.P. SAUER & SOHN 468.2 Maintenance safety . . . . . . . . . . . . . . . . . . . . 468.3 Maintenance schedule . . . . . . . . . . . . . . . . . 478.4 Table of tightening torques . . . . . . . . . . . . . . 498.5 Oil change. . . . . . . . . . . . . . . . . . . . . . . . . . . 498.6 Checking screwed connections. . . . . . . . . . . 518.7 Air filter cartridge replacement . . . . . . . . . . . 518.8 Checking valves . . . . . . . . . . . . . . . . . . . . . . 528.9 Checking the piston rings . . . . . . . . . . . . . . . 558.10 Replacing gudgeon pins/gudgeon pin

bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588.11 Replacing valves . . . . . . . . . . . . . . . . . . . . . . 588.12 Checking pistons and cylinders. . . . . . . . . . . 598.13 Checking the drive bearings . . . . . . . . . . . . . 598.14 Checking the coupling. . . . . . . . . . . . . . . . . . 608.15 Cleaning particle trap . . . . . . . . . . . . . . . . . . 618.16 Checking zinc protection . . . . . . . . . . . . . . . . 618.17 Burst disc . . . . . . . . . . . . . . . . . . . . . . . . . . . 628.18 Checking cooling water pump (optional) . . . . 62

9. Placing out of Service. . . . . . . . . . . . . . . . . 649.1 Safety when placing out of service and

dismounting. . . . . . . . . . . . . . . . . . . . . . . . . . 649.2 Shutting down the compressor temporarily. . 649.3 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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10. Lubricant Table . . . . . . . . . . . . . . . . . . . . . . 6610.1 Lubricating oils . . . . . . . . . . . . . . . . . . . . . . . 6710.2 Slushing oils . . . . . . . . . . . . . . . . . . . . . . . . . 68

11. Spare Parts and Accessories. . . . . . . . . . . 69

12. Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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1. General

1.1 At the outsetThe following main specifications of your Sauer compressor are found on the type label affixed to the crankcase:– Compressor type– Factory number– Year of constructionPlease enter this data in Chapter 11, "Spare Parts and Accesso-ries" as soon as possible.

1.2 General information

Conditions We presuppose that only authorised persons will operate and service the Sauer compressor. These persons must have read and understood the operating instructions.

Availability These instructions shall always be kept available at the site of op-eration.

Copyright The copyright for these instructions remains with J.P. SAUER & SOHN. These instructions, or parts thereof, shall not be copied, distributed or made available to third parties. Con-travention will be prosecuted.

1.3 Warranty and LiabilityWe exonerate the contractually agreed warranty claims and liabil-ity claims, if they can be attributed to at least one of the following:– use of the machine for non-intended purposes;– use of spare parts that are not genuine Sauer spare parts;– operation of the machine with faulty or not properly installed

safety devices and protection devices;– disregard of the operating instructions;– unauthorised modifications to the machine or its control sys-

tem;– inadequate monitoring of machine parts subject to wear;– improperly carried out repairs;– force majeure.

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1.4 Type approval and genuine Sauer spare parts • The type approval for the Sauer compressor is valid under the

condition that parts and components specified and qualified by J.P. SAUER & SOHN are used. The type approval is made by the Classification Society and the Declaration of EC-Conform-ity or EC Manufacturer's Declaration. Disregard of the specifi-cations may cause the type approval to expire.

• Only the use of genuine Sauer spare parts ensures compli-ance with these specifications and thus the perfect and safe operation of the Sauer compressor.

• If genuine Sauer spare parts are not used we reserve the right of exclusion of liability for personal injury and material damage.

• genuine Sauer spare parts are supplied with a Certificate of Conformity and a Certificate of Authenticity. A specimen of this document is shown before the table of contents of these in-structions. If spare parts are received without this certificate, there is a risk that these are not genuine Sauer spare parts. In such case please contact our customer service.

Do not use parts from the "grey market"…

… but only genuine Sauer spare parts with certificate!

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1.5 Customer service of J.P. SAUER & SOHNIn case of technical questions pertaining to maintenance or repair please contact our customer service:

SAUER & SOHN Maschinenbau GmbH Customer Service P.O. Box 92 13 D-24157 Kiel

Telephone (international):Technical information +49 431 39 40 -87Spare parts ordering +49 431 39 40 -86/886Telefax (international): +49 431 39 40 -89Emergency service (international): +49 172 4 14 63 94E-Mail: [email protected]: www.sauersohn.de

Note!In case of queries regarding your Sauer compressor please in-dicate the compressor-type and the factory number (see Chap-ter 11. "Spare parts and Accessories” or type label on the crankcase).

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1.6 Organisation of these instructions

Lists General lists are denoted by horizontal bars. Example:The cooling system consists of– fan wheel,– fan wheel cage, and– cooler assembly.

Actions Individual instructions or multiple instructions, where the se-quence is of no importance are normally given as bulleted lists.Example:• Check oil level.

Instructions to be carried out in a certain sequence are num-bered. Example:1. Turn the main switch ON.2. Choose the operating mode.3. Turn the control ON.

Results Results of actions carried out are denoted by a check mark. Example:✓ The control light lights up.

Safety instructions Safety instructions are distinguished by pictographs and signal words. Safety instructions are described in Chapter 2. "Safety" in detail.

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2. Safety

2.1 Specified conditions of useThis Sauer compressor must be used for the compressing of air only. The Sauer compressor must not be used at ambient temper-atures of below +5 °C. Any other use is not as specified and re-quires the explicit consent in writing by J.P. SAUER & SOHN. Observance of these operating instructions, the installation re-quirements detailed in the instructions, and the keeping of main-tenance rates are part of the specified conditions of use as well.

2.2 Prohibition of unauthorized conversionUnauthorized conversion and modification of the Sauer compres-sor is not permitted, since they could endanger humans and may lead to machine damage. Contact J.P. SAUER & SOHN when planning conversions or mo-difications to obtain a written permission.

2.3 Safety informationThe safety information in these instructions is divided in two clas-ses. The following pictographs and signal words are used:

Danger! High risk. Disregard of this safety information may cause personal injury and substantial material damage.

Note!Average risk. Disregard of this safety information may cause damage to the machine.

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2.4 Safety markings on the machine

Sauer compressor models with an EC Manufacturer's Declarati-on or EC Declaration of Conformity are marked with the following safety markings:

Location of safety markings (top view)

Caution! Safety markings affixed to the machine must not be altered or re-moved. Replace damaged or lost safety markings immediately, true to the original.

Safety marking Meaning Safety marking Meaning

Danger! High voltage! Read instructions!

Compressor starts auto-matically without warning!

Wear hearing protection!

Hot surface! Rotational direction ofCrankshaft

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2.5 Safety devices

Safety valves Every pressure compartment of a stage of the Sauer compressor is equipped with a safety valve, which will blow off when the blo-wing-off pressure is reached. Safety valves are installed at these locations: – 1st compression stage: in the back cooler cover of the 2nd in-

tercooler; – 2nd compression stage: in the final separator behind the stage;

Temperature switch

The Sauer compressor is fitted with a temperature switch for mo-nitoring the compressor cooling. This will turn the compressor off if the temperature of the compressed air exceeds the limit.

2.6 Noise protectionSound pressure level details are found in the Technical Specifica-tions (see chapter 4). If necessary the Sauer compressor can be equipped with a noise protection hood, which is available as optional accessory from J.P. SAUER & SOHN.

2.7 Waste disposal

Danger! Safety devices must not be adjusted, disabled or removed. The safety devices must be periodically tested and checked. Safety valves must be – installed sealed and – replaced, adjusted and sealed by authorised personnel only.

Danger!When the compressor is operated without noise protection hood, hearing protection should be worn near the compressor.

Note!Under the laws and regulations in force, the following materials arising from the operation of the compressor need to be dis-posed of ecologically safe: – condensate (oil and water saturated) arising from recooling in

the compression process; – used oil and grease and rags soiled by it; – cleaning material and rags soiled by it.

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2.8 Staff requirementsOnly authorised persons are permitted to service the Sauer Com-pressor! Before commencing work they must have read and un-derstand the operating manual and must be familiar with the safety devices and safety regulations.In addition to the instructions in this operating manual and manuf-acturer documentation, accepted technical standards must be observed as well as all regional laws, standards and regulations such as the– Equipment and Product Safety Act (Geräte- und Produktsi-

cherheitsgesetz), – Ordinance on Industrial Safety and Health (Betriebssicher-

heitsverordnung),– Regulations for accident prevention pertaining to compres-

sors,– VDE regulations and – Regulations on environmental protection.In addition, where appropriate, regulations of the responsible classification society as well as operational regulations must be observed.Persons authorised to operate the compressor are the attending specialists introduced to the job and trained by the operator. Persons authorised to service the compressor are the trained specialists of the operator and of the manufacturer.

2.9 Personal protection gearThe operator has to provide the personal protection gear (hearing protection, safety boots, etc.) for the personnel carrying out any work on the Sauer compressor.

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3. Design and Function

3.1 Overview

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Item Name

1 Cylinder 1st stage

2 Cylinder 2nd stage

3 Safety valve 1st stage (not visible)

4 Safety valve 2nd stage

5 Air filter

6 Oil filler

7 Cooling water outlet (not visible)

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8 Compressed air outlet

9 Drain valve 1st stage (not visible)

10 Drain valve of 2nd stage:

11 Compressed air temperature switch

12 Burst disc

13 Zinc protection 1st stage

14 Zinc protection 2nd stage

15 Oil dip stick

16 Cooling water inlet

17 Particle trap

18 Oil drain valve

19 Oil pressure switch

20 Cooling water stop valve

Item Name

Note!Details of parts and spare parts are found in the spare parts ca-talogue.

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Longitudinal sec-tion

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1

2

3

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Item Name

1 Crankcase

2 Crankshaft

3 Connecting rod 1st stage

4 Connecting rod 2nd stage

5 Lubricating oil supply

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Cross section

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Item Name

1 1st stage: cylinder with head and valve

2 Piston 1st stage

3 2nd stage: cylinder with head and valve

4 Piston 2nd stage

5 Valve cover 1st stage

6 Plate valve

7 Air lines

8 Valve cover 2nd stage

9 Lamellar valve

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3.2 Mode of Operation

Compressor The Sauer compressor is a two stage water-cooled air compres-sor with three cylinders. The 1st stage and the 2nd stage are re-spectively fitted with two and one single acting trunk pistons each. The connecting rods of all the pistons sit on a common crankpin of the double bearing crankshaft.

Drive The Sauer compressor is driven by an electric motor directly flan-ged to the transmission bell housing of the crankcase, where the power is transmitted by means of a flexible coupling.

Compressor cont-rol

The Sauer compressor with electric drive is electrically controlled and monitored by a compressor control system. This control sys-tem must comply with the legal provisions. Optionally, J.P. SAUER & SOHN supply a suitable compressor control sys-tem.

Compression The compressor takes in ambient air through a sheet filter with tube silencer and compresses it in the two cylinders of the 1st stage. The air is led to the cylinder of the 2nd stage and com-pressed to the ultimate pressure. The air is after-cooled after each cylinder. A replaceable wet liner with double O-ring sealing is fitted in each cylinder.The cylinders in W-shape configuration are equipped with plate-valves or lamellar valves, which have a long service life and are easy to service.

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Cooling The compressor is cooled with fresh water. Sea water cooling is possible optionally. The air compressed in the 1st and 2nd stage is recooled in straight cooler pipes, which are expanded into the cylinders. The cooling water flows directly past the cooler pipes and the replaceable liners in the cylinder. The cooling water cavi-ties are protected against corrosion with zinc electrodes.Optionally, the compressor can be fitted with an inbuilt cooling water pump. This pump is not self-priming and is driven by an electric motor.

When the compressor is not fitted with a cooling water pump, the cooling water supply is cut off when the compressor is shutdown using a solenoid valve at the cooling water inlet.The functioning of the compressor cooling is monitored by the compressed air-temperature control. The compressor is stopped immediately if the compressed air temperature exceeds the up-per limit.

Condensate sepa-ration

Condensate accumulating in the 1st stage is collected in collec-ting tanks of the back cooler covers of 1st stage. The 2nd stage has a separate condensate separator for the oil and water contai-ning condensate arising from compression and recooling.

Condensate drai-ning/Pressure reli-ef

The condensate is drained through drain lines. Drain lines are fit-ted with solenoid valves. These must be open when the Sauer compressor is unpressurized. The drain valves should close a few seconds after starting and the Sauer compressor should ac-celerate against pressure. The solenoid valves should drain the machine at predetermined intervals during operation. The sole-noids valves are controlled by the compressor control system.

Lubrication/oil pressure

An oil gear pump driven by the crankshaft sucks the lubrication oil from the crankcase and supplies it to the friction bearings of the connecting rods. Crankshaft bearing, gudgeon pin bearing and piston are lubricated by the splash oil present in the crankca-se. The oil pressure is monitored with an oil pressure switch. The compressor control system stops the compressor immedia-tely if the oil pressure falls to the lower limit.

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3.3 Indicators on the Sauer Compressor

Item Name Indication

1 Pressure gauge 1st stage

Compressed air pressure after the 1st stage

2 Pressure gauge 2nd stage

Compressed air pressure after the 2nd stage

3 Thermometer 1st stage (not visible)

Compressed air temperature after the

1st stage

4 Thermometer 2nd stage (not visible)

Compressed air temperature after the

2nd stage

5 Oil pressure gauge Oil pressure of the oil pump

6 Cooling water thermo-meter (not visible)

Temperature of the cooling water at the cooling water outlet

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3.4 Indicators and controls of the compressor control system

At the front of the compressor control the following indicators and control elements are found:

Note!If the compressor control system is supplied by J.P. SAUER & SOHN take notice of the documentation sup-plied.

Indicator/Control element

Description

Signal lamp “Ope-ration”

Lights when the compressor is running.

Fault indicator lamp “Oil pressure”

Lights if the compressor has been shut off because of low oil pressure.

Fault indicator lamp “Air tempera-ture”

Lights if the compressor has been shut off because of excessive outlet air temperature.

Fault indicator lamp “Overcurrent”

Lights if the compressor has been shut off because of excess motor current.

Working hour meter

Indicates the working hours of the compressor.

Operating mode selector

• Selector position “Manual”:Starting the compressor manually. The compressor starts up and continues to run until it is manually turned off.

• Selector position “0”:Turns compressor manually OFF. Any pending fault messages are reset.

• Selector position “Auto”:The compressor is started and stopped by the ope-ning and closing of an external switching contact (e.g. pressure switch of the compressed air recei-ver).

Main switch Interrupts the power supply from the compressor control to the compressor. A main switch should be installed if required by local laws and regulations.

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4. Technical Specifications

4.1 Specification data

Description Data

Compressor type WP 400

Number of cylinders 3

Number of compression stages 2

Cylinder diameter 1st stage 195 mm

Cylinder diameter 2nd stage 110 mm

Piston stroke 90 mm

Maximum speed 1800 rpm

Direction of rotation (as seen on flywheel) clockwise

Maximum operating pressure 30 bar

Set pressures of safety valves:

1st stage 8 bar

2nd stage 5 % higher than the ultimate pressure

Oil filling quantity 13.5 l

Oil quantity between dip stick markings 5 l

Oil type see chapter 10. “Lubricant table”

Oil pressure switch:

Maximum switching current 6A / 220 V

Setting opens at 1 bar fallingapprox. 15 seconds starting bypass

Switch function change-over contact

Drain valves:

Pick-up and holding power 18 VA / 14 W

Setting normally open; starting relief: approx. 15 seconds; intermediate draining: 15 seconds every 15 minutes.

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Ultimate pressure switch (optional):


Setting to customer's specifications


Temperature switch:


Setting opens at 80 °C rising


Max. allowable primary pressure at cooling water inlet:

5 bar in absence of cooling water pump2.5 bar with cooling water pump

Bursting pressure of the burst disc in the cooling water system:

> 6 bar

Temperature of cooling water at the outlet. optimal 30 °C…45 °C, max. 50 °C

Cooling water stop valve Holding capacity: 36 WSetting: Closed when compressor is shutdown; Valve is closed dead

Cooling water pump (optional)

Electrical connection 440 V/60 Hz 1.1 kW or 400 V/50 Hz 1 kW

Setting non-self-priming, should start and stop in syn-chronisation with the compressor

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

maximum 92 dB(A)

Weight and dimensions see installations plan

Description Data

Note!Please refer to the order-specific documentation for data specific to your compressor, such as ultimate pressure, speed, power re-quirements, etc.

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4.2 Compressed air system plan and cooling water plan

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Item Name

1 Drive motor

2 Safety valve

3 Compressor stage

4 Intercooler and aftercooler

5 Compressed air pressure gauge

6 Oil pressure switch

7 Condensate separator

8 Drain

9 Solenoid drain valve

10 Air filter/silencer

11 Oil pump

12 Pressure relief valve

13 Oil filter

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14 Oil pressure gauge

15 Non-return valve

16 Ultimate pressure switch

17 Compressed air thermometer

18 Compressed air temperature switch

19 Cooling water hand valve

20 Cooling water pump (optional)

21 Cooling water thermometer

22 Cooling water stop valve

Item Name

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5. Transport and Installation

5.1 Transport

Shipping The machine is packed suitable for shipping.• Immediately on receipt of the Sauer compressor it should be

checked for completeness and damage.• The transport company and J.P. SAUER & SOHN must be im-

mediately notified of any damage to the packing or the machi-ne.

Transportation The Sauer compressor must be transported by a forklift truck or hoisted by crane.

Danger!Suspended load when transported. The forklift truck/crane must have sufficient load bearing capaci-ty.• Ensure that no persons stay within the danger area of the sus-

pended load and the forklift truck/crane.• Sling the unpacked compressor at the lifting eyes on the

crankcase and the motor (see illustration). • Lift, move, and set down carefully.

Lifting eyes

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5.2 Storage before installationIf the Sauer compressor has to be stored before installation, do not unpack and store at the following conditions:– temperature: +5 to +40 °C;– relative humidity 30 … 95%, not condensating;– dry, under a roof and protected against dew;– protected against soiling;– protected against vibrations and shocks.

5.3 Installation

Follow the installation instructions and the following conditions during installation.

Installation conditions

– The place of installation must be dry and free of dust.– The place of installation must be ventilated in such way that

the heat generated during operation is dissipated.– Room temperature while the Sauer compressor is running:

+5 … +55 °C (deviating temperatures only if confirmed in writing by J.P. SAUER & SOHN)

Note!The standard factory conservation is sufficient for a maximum storage period of 12 months.

Note!In case of doubts regarding the suitability of the installation room and place or in case of queries regarding compressor cooling contact J.P. SAUER & SOHN in time. There you will also get help with the design of a ventilating system, if it is required at the place of installation.

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

Note!The air temperature at the installation place of the compressor must not exceed +55 °C. Room conditions and the heat genera-ted by the compressor and other machines installed in the room must be taken into consideration.• If necessary, install a ventilation or exhaust system at the

place of installation.• Install the fresh air feed in such way that the fresh air stream

is not directed straight at the compressor. Otherwise there is a risk of condensation of water inside the machine and sub-sequent damage.

Do not install fresh air feed this way!

This way is correct!

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heated or the Sauer compressor must be equipped with a he-ating system.

– Choose the location such that the Sauer compressor is acces-sible and has sufficient clearance to walls and other machinery (see installation documents).

Foundation

1. Check early enough if there are foundation vibrations in the 10 Hz range.

2. If in doubt, check with J.P. SAUER & SOHN to see if a modi-fied resilient-mount bedding can be used.

Note!The Sauer-Compressor is cooled with fresh water. Sea water cooling is also possible optionally; however, depending upon the temperature and composition the sea water can have corrosive effect. The cooling water quantity must be so adjusted that the maximum cooling water outlet temperatures specified in section 4.1 are not exceeded.By aligning the cooling water inlet and outlet, the cooling water cavities are automatically deaerated.

Note!J.P. SAUER & SOHN would be glad to advise you on the instal-lation of the compressors.

Note!The resilient-mount bedding delivered as standard has a reso-nant frequency of approx. 10 Hz. The excitation of the intended compressor-foundation by vibra-tions from the machines installed in the vicinity must not be in the 10 Hz range. Otherwise there is a risk that the standard delivery resilient-mount bedding is destroyed by sympathetic vibration.

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5.4 Connecting the compressor

Pipelines The compressed air outlet, coiling water inlet and outlet as well as the and the drain outlets of the Sauer compressor must be connected to the stationary pipelines by hose lines.

Danger!The compressor should only be connected by qualified technici-ans. Any work on the electrical installation must be carried out by qualified electricians only.

Hose lines

Danger!Compressed air escapes from the drain outlets when the com-pressor starts and when the condensate is drained. Do not ope-rate compressor without the hose lines connected.

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Hose lines have to be installed free of tension and untwisted.

Draining

Not this way!


Note!Condensate that is formed contains oil. It may only be disposed of in compliance with applicable legal provisions.J.P. SAUER & SOHN can supply condensate collecting pots for separating air from the condensate, as well as condensate treat-ment units for separating the oil from the condensate.

Note!We recommend connecting the compressor's drain separately.When the drain lines of several compressors are to be connec-ted to a common pipe, observe the following:– Choose a sufficient nominal diameter for the common drain

line.– Connect drain lines of the individual compressors at an acute

angle to the common drain line, so no pressure can build up in the drain line of a stopped compressor.

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Not this way!

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Connections The illustration below shows the connections and fittings for the operation of the standard version Sauer compressor.

3

2

7

4

1

65

Note!For technical specifications of the individual items please refer to Chapter 4All toggle switches are factory set.As an option, the subsystems can be prewired in a terminal box.

Item Name Type Function

1 Non-return valve Plate valve Prevent air back-flow

2Ultimate pressure switch

Toggle switch Stops/starts the compressor

3 Drain Solenoid valve Starting relief and draining

4Compressed air tem-perature switch

Toggle switch Stops compressor in case of excess tempera-ture

5Cooling water pump(optional)

Centrifugal pump non-self-priming

Pumps cooling water

6 Oil pressure switch Toggle switch Stops compressor when oil level is low

7Cooling water stop valve

Solenoid valve Cuts off cooling water flow when machine is shutdown

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5.5 Filling in oilThe Sauer compressor is supplied without oil.

1. Unscrew oil filler plug (red).2. Fill in oil and check level with the dipstick.

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

Danger!Oil must be filled into the compressor's crankcase before initial operation! Use lubricating oil (see chapter 10. “Lubricant table”). Note filling amount (see chapter 4. “Technical Specifications”).

Dipstick

Oil filler plug

Note!Fill only to the upper marking on the dipstick. Otherwise the oil consumption of the compressor will increase.

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5.6 Checks after installation and before the first start– Does electrical connection correspond to the type label data?– Are all connections between compressor and the surrounding

compressed air unit correctly installed? Pay special attention to the compressed air outlet.

– Are drain lines properly connected? (See Section "Draining”.)– Are cooling water lines opened?– Is oil filled in the crankcase?– Have all tools and foreign objects been removed from the com-

pressor?– Has the air filter been turned to operating position from trans-

port position (see overprint on the filter housing)?– Is the entire unit clean?

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6. Operation

6.1 Safe operation

Danger! Only authorized persons are permitted to commission and ope-rate the Sauer compressor!

Danger! Turn on and start the compressor only if– it has been checked for proper working condition;– all tools and foreign objects are removed from the machine.

Caution! Turn compressor immediately OFF when persons or objects are endangered. Start compressor only when the danger is over.

Danger! In Automatic mode the compressor starts automatically without warning!

Danger! Risk of burns by hot surfaces of the compressor when it is run-ning. Wear gloves.

Danger! Risk of hearing damage due to the sound pressure level when the compressor is running! Wear hearing protection near the compressor.

Note!Turn compressor OFF in the case of faults, abnormal ratings or irregularities. Refer to chapter 7. “Trouble Shooting” to remove cause.

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6.2 Operating modesAfter the power supply to the Sauer compressor is turned ON, it can be started with the operating mode selector in one of the fol-lowing two operating modes: – Operating mode “Manual”:

The compressor starts and continues to run until it is stopped or turned OFF with either the operating mode selector or the main switch.

– Operating mode “Automatic”: Starting and stopping of the compressor is controlled by exter-nal devices (e.g. by the pressure switch of the compressed air receiver).

When the Sauer compressor starts, it starts loadless with opened relief valves. Several seconds after starting the valves close and the compressor runs up against pressure.

6.3 First Commissioning

Checking the di-rection of rotation

At first, let the Sauer compressor run only for a few seconds to check the direction of rotation.1. Turn the power supply ON.2. Set the operating mode selector to “Manual” to start the com-

pressor in Manual mode.3. Immediately check the compressor's direction of rotation. It

must rotate in the direction indicated by the arrow on the crankcase.

4. Set the operating mode selector to “0” to stop the compres-sor.

5. Turn the power supply OFF.6. If the direction of rotation is incorrect, have polarity of the

electric motor changed by a qualified electrician.7. Checking the direction of rotation of the optional cooling

water pump: Switch the pump motor ON for a short duration. The motor must not reach its operating speed during this. The direction of rotation must be the same as the one indicated by the arrow on the pump. Otherwise, see Point 6. Pump and suction pipe must be filled with cooling water.

Danger!The cooling water pump must never run dry.

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Test run 1. Turn the power supply ON.2. Set the operating mode selector to “Manual” to start the com-

pressor in manual mode.✓ If correctly set the drain valves will close after approx. 15 se-

conds and the compressor accelerates against pressure.3. Check pressure gauges of the stages as well as the oil pres-

sure guage and compare with nominal values (for nominal va-lues see stage pressure chart in section 6.4 "Routine Operation”).

4. Check the functioning of the automatic intermediate draining.✓ It must drain every 15 minutes for approx. 15 seconds. This is

recognisable by the pressure drop at the pressure gauges.5. Check the cooling water flow-rate.✓ The temperature of the cooling water at the outlet should be

as indicated in section 4.1 "Specification Data“. The tempera-ture can be read with the cooling water thermometer at the cooling water outlet. If these temperatures are exceeded or fallen short of, the cooling water flow-rate must be increased or decreased accordingly. In case of aggregates with built in cooling water pump the flow rate can be regulated with the gate valve on the pump.

6. Set the operating mode selector to “0” to stop the compres-sor.

7. Turn the power supply OFF.8. If necessary, remedy the causes for deviations from nominal

values and faults. Also see Chapter 7. "Trouble-shooting” for this purpose.

6.4 Routine operation

Cleaning • Keep compressor site clean.• Keep indicators and control elements clean.

Checks • Inspect connections, pipelines and electric cables for damage.• Check the oil level once a week before starting, top up if ne-

cessary. Do not fill oil beyond the maximum mark.

Danger!No oil pressure if the direction of rotation of the compressor is wrong. Risk of subsequent damage.

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Operation 1. Turn power supply ON.2. Open cooling water lines.3. Set operating mode selector to “Auto” to operate the com-

pressor in Automatic Mode.

Observation • Pay attention to abnormal operating sounds.• Pay attention to leakages (compressed air, oil, condensate).

The temperature of the cooling water at the outlet should be as indicated in section 4.1 "Specification Data“.

• During operation the pressure indicated by the pressure gauge of the first stage should be within the shaded region of the sta-ge pressure chart (see below).

• The oil pressure should be between 1.8 bar and 4 bar. In case of deviations see Chapter 7. "Trouble-shooting”.

Stage pressure chart 1st stage

Ulti

mat

e pr

essu

re [b

ar]

1st stage [bar]

Note!Depending on the desired ultimate pressure of the 2nd stage the permissible pressure for the 1st stage can be read from the chart.

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7. Trouble-shootingF

Note!• In case of malfunctions, first check the indicators on the com-

pressor control and the compressor .• Try to remedy the fault by following the information given in

the table below.• If the cause for the fault cannot be eliminated, contact

J.P. SAUER & SOHN customer service.

Fault Likely cause Remedy

The compressor does not start or does not switch OFF.

No supply voltage / no control voltage.

Check fuses. Replace blown fuses.

Compressor was switched off, fault indicator lamp "Oil Pressure" glowing.

The oil level is too low. Check the oil level, add oil as required.

The oil pump is faulty or leak-ing.

Check the oil pump. Fix the leak or replace the oil pump, as required.

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

The motor is overheated. Excessive current drawn.

Determine the cause of the fault and correct it. The compressor can be started again after being allowed to cool off.

Piston seizure Check liner and piston for score marks, replace if necessary.

Safety valve of 1st stage blows off:

Pressure exceeds blow-ing-off pressure (8 bar)

2nd stage valve is not working properly.

Check 2nd stage valve, replace if nec-essary.

Sealing between inlet and out-

let side of the 2nd stage is faulty.

Replace gasket.

Pressure below blow-ing-off pressure (8 bar)

Safety valve is faulty. Replace the safety valve.

Pressure in the 1st stage excessively high.

Valve of 1st stage leaky. Check the valve for damage and replace if necessary; replace gaskets.

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2nd stage safety valve blows off:

Pressure exceeds blow-ing-off pressure (ulti-mate pressure + 5%)

Valve in air line to the com-pressed air receiver closed.

Open the valve.

Pressure switch set too high. Reduce set pressure.

Pressure below blow-ing-off pressure (ulti-mate pressure + 5%)

Safety valve set too low or is faulty.

Replace the safety valve.

Pressure in the 2nd stage inadmissibly high.

Valve of 2nd stage leaky. Check the valve for damage and replace if necessary; replace gaskets.

Pressure gauge of the 1st stage indicates too low a pressure.

Valve of 1st stage leaky. Check 1st stage valve, replace if neces-sary.

Air filter very dirty. Replace air filter cartridge.

Drain valve of 1st stage leaky. Clean drain valve and rebuild the valve seat if necessary.

No pressure indicated in 1st

and 2nd stage pressure gauges.

No power at drain valve. Check drain valve power supply.

Drain valve faulty. Check drain valve, replace if neces-sary.

Air escaping from com-pressed air lines

Gaskets of connections leak-ing.

Replace relevant gasket.

Compression ring connec-tions leaking.

Turn compressor OFF. Wait until all parts are relieved of pressure (check pressure gauges). Then tighten unions.

Compressor was switched off, fault indicator lamp "Air Temperature" glowing.

Compressed air temperature at outlet too high due to cool-ing water deficiency.

Increase cooling water flow-rate (only in case of the version with cooling water pump: open the gate valve behind the pump further), check the functioning of the cooling water stop valve; clean particle trap.

Compressed air-temperature at the outlet too high due to too high cooling water inlet temperature.

Check cooling water-inlet temperature (max. 40 °C).

Compressed air-temperature at the outlet too high due to poor heat transfer in the cooler as a result of boiler scale for-mation.

Clean cooling water cavities with boiler cleaning compound.

Drain valve does not close. No supply voltage. Check fuses, replace blown fuses.

Solenoid faulty. Replace solenoid.

Foreign matter in drain valve. Clean drain valve.


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Intermediate drainage is not functioning.

Timer not set or not set cor-rectly.

Set timer to 15 s drainage and 15 min closing interval.

Cooling water stop valve does not open.

No supply voltage. Check fuses, replace blown fuses.

Solenoid faulty. Replace solenoid.

Foreign bodies in the cooling water stop valve.

Clean cooling water-stop valve.

Compressor makes loud noises.

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.

Oil leaking from crankcase. Gasket or shaft seal faulty. Screws not tight.

Tighten screws.If there is heavy leakage, check to see which gasket is faulty, then replace it.Minor traces of oil on the crankcase or oil drops below the compressor are harmless. Wipe off with a rag.

Water is leaking at the relief groove of the cylinder flange surface.

Liner O-ring above the relief groove is faulty.

Replace the O-ring.

Oil is leaking at the relief groove of the cylinder flange surface.

Liner O-ring below the relief groove is faulty.

Replace the O-ring.

Water in oil Compressor is overcooled because of – too high cooling water flow-

rate – improper room ventilation– very short compressor run-

ning time.

Reduce cooling water flow-rate. Change the room ventilation in such a way that it does not blow directly at the compressor; increase the compressor running time

Insufficient drainage. Check drain lines and drain intervals.


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Burst disc in the cooling water circuit responds.

Leakages in the cooler. Re-expansion of the cooler pipes in the cylinder housing. For this purpose, separate working instructions and tool under the article code 066367 are available on request.

Pressure peaks in the cooling water circuit, which lead to the overstepping of the bursting pressure of the burst disc.

Identify the causes for pressure peaks and eliminate or reduce them (starting of additional stronger pumps, actua-tion of electromagnetic stop valve or alternating check valves or similar.)

Premature breaking of valve plates, valve springs or valve disks.

Insufficient drainage. Check drain lines and drain intervals.

Note: Indentation marks appearing on the valve plate due to valve impact are normal.


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8. Maintenance

8.1 Maintenance service by J.P. SAUER & SOHNThe J.P. SAUER & SOHN customer service offers different maintenance services – e.g. full maintenance or valve replace-ment service.

8.2 Maintenance safety

Before servicing 1. Disconnect the power supply to the compressor.2. Post danger sign “Caution Maintenance Work!” at the power

supply.

Danger!Only authorised persons are permitted to service and make ad-justments to the Sauer compressor!

Danger! Risk of injury from hot surfaces! Let compressor cool off after turning OFF.

Danger!Risk of injury from pressurised compressor components! Check the pressure gauges before servicing to ensure the com-pressor is completely relieved of pressure.

Danger! Danger! High voltage!– Never assume that a circuit is de-energised – always check

for your own safety!– The main switch is energised, even when it is turned OFF.– Components being worked on should only be energised if this

is explicitly specified.

Danger!Danger of death from missing safety devices and missing isola-ting protection devices! Reinstall all safety devices and isolating protection devices after servicing. This also applies to electrical protection devices (e.g. earth wires).

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8.3 Maintenance schedule

Instructions for the maintenance schedule

• Use the maintenance schedule as master template or copy the respective page from the digital document and save it as a se-parate file under a suitable name. Use the maintenance sche-dule as guide and for documentation.

• Regularly check the maintenance schedule to see which main-tenance intervals, subject to the number of operating hours, are due. The intervals are shown in the table's column hea-ders.

• Check the column of each maintenance interval to see which maintenance work is to be carried out at the end of each main-tenance interval. The required tasks are indicated by check bo-xes. Description and chapter number of the tasks are shown in the first column.

• Carry out all maintenance work of a maintenance interval and tick the appropriate check boxes of the maintenance schedu-le. Then enter operating hours count, date and your signature.

• When beginning a new maintenance schedule– enter: main specifications, date of commissioning, number

of maintenance schedule, current date and operating hours count

– tick: beginning after commissioning/after major overhaul

Danger! Section 8.4 “Table of tightening torques” must be followed for specific screws during all maintenance work.

Note!The maintenance intervals specified in the maintenance schedu-le must be adhered to. Shortening the maintenance intervals is of no advantage with regard to operating performance or service life of the Sauer compressor.Note!After a major overhaul (=12,000 operating hours) the mainte-nance schedule begins all over again.

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Maintenance Schedule No. Compressor type

Beginning of this mainte-nance schedule

Type series 2W

❏after commissioning Compressor number

❏after major overhaul Factory no.:

Date: Year of construction:

Operating hours count: Date of commissioning:50

aft

er in

itia

l op

erat

ion

50 a

fter

maj

or

ove

rhau

l

At

leas

t ye

arly

if <

1,0

00 /

year

1,00

0

2,00

0

3,00

0

4,00

0

5,00

0

6,00

0

7,00

0

8,00

0

9,00

0

10,0

00

11,0

00

12,0

00 =

maj

or

over

hau

l

as r

equ

ired

Checking screwed connections 8.6

❏ ❏

Oil change 8.5 ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏Air filter cartridge replacement 8.7

❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏

Checking valves 8.8 ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏Checking piston rings 8.9 ❏ ❏Replacing gudgeon pins/gud-geon pin bearings 8.10

❏ ❏

Replacing valves 8.11 ❏Checking pistons and cylinders 8.12

❏ ❏

Checking drive bearings 8.13 ❏Checking coupling 8.14 ❏ ❏Cleaning particle trap 8.15 ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏Checking zinc protection 8.16 ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏Burst disc 8.17 ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏Checking cooling water pump (optional) 8.18

❏

Operating hours count:

Date

Signature (initials)

Maintenance work

Interval(operating hours)

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8.4 Table of tightening torques

8.5 Oil change

Note!Check compressor 50 hours after every maintenance work is carried out. Check all screws affected by the maintenance work to see if they are tight.

Screw(s) Tightening torque

Connecting rod screws 115 Nm

Flywheel fastening screw 550 Nm

Valve cover screws (1st/2nd stage) 160 Nm

Bursting plate flange 54 Nm

Retaining screw of the 2nd stage valve on the valve cover

9 Nm

Note!Use oil as per Lubricant Table (see chapter 10).

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1. Place oil sump (of sufficient capacity to hold the complete oil filling, see chapter 4) under the oil drain plug.

2. Remove the oil drain plug.3. Wait until all oil is drained.4. Replace the oil drain plug.5. Unscrew oil filler plug (red).6. Fill in oil and check level with the dipstick.✓ The level shall be between the upper and lower mark on the

dipstick. 7. Put dipstick back in and screw the oil filler plug back on.

Oil filler plug

Dipstick

Oil drain plug

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8.6 Checking screwed connectionsCheck all unions and screwed connections for tightness, retigh-ten if necessary. This concerns– cooler and air lines;– unions of pipe lines and hose lines;– cylinder heads;– cylinders;– electric motor and intermediate flange;– measuring and switching devices;– bedding;– accessories and equipment parts.

8.7 Air filter cartridge replacement

1. Open clips and take the air filter cap off.2. Remove the used air filter cartridge.3. Put new air filter cartridge in.4. Put cap back on and close the clips.

Air filter cap

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8.8 Checking valves

Checking the plate valve (1st stage)

1. Loosen the clamp and remove air filter.2. Loosen the hose of the crankcase vent at the union and re-

move with nipple.3. Loosen the valve cover nuts and pull the valve cover uniformly

with the two M12 screws.4. Take out valve carefully.

5. Unscrew nut. For this purpose, clamp the valve in "soft jaws" is such a way that the the valve mating surfaces do not get da-maged.

Note!Plate valves and particularly lamellar valves are those pats of a reciprocating compressor, that are subject to the most stress. In order to achieve the guaranteed maintenance intervals, these valve are specially matched to the individual compression sta-ges as high-quality precision parts, and their functioning careful-ly checked before delivery. Repair by the maintenance and operating personnel requires special knowledge, which may not be available every time. For such cases J.P. SAUER & SOHN offer a valve replacement service. In case it should be necessary please contact the Sauer service department. In case of two stage water-cooled compressors, the high final compression temperature can lead to untimely soiling of valves if ambient conditions are unfavourable or poor varieties oil are used. In such cases, some other oil is to be used or the mainte-nance intervals are to be shortened.

Note!While reinstalling valves use only new gaskets and rings everyti-me. Do not reuse the used rings under any circumstances. Do-ing so leads to leakage within a short time.Use only genuine Sauer spare parts. They are precision parts with defined and tested dimensions and material characteristics, specially designed for use in Sauer compressors. Installation of other gaskets may lead to leakage and could cause substantial damage to the compressor.

Note!When removing, cleaning and installing the plate valve, take care that no valve parts are damaged. This applies particularly to the sealing surfaces and the valve springs. Slight damage to the raised faces of the valve seats can be removed by refacing on a lapping plate.

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6. Disassemble valve.7. Clean all valve parts. For this purpose soak them in an oil dis-

solving fluid (e.g. petroleum or benzene).8. Check valve parts for damage. Replace damaged valve parts.

9. Carefully reassemble valve (see illustration), tighten nut.10. Use a pin with round tip to check the valve plate's smoothness

of action against the spring pressure.11. Fit plate valve and valve cover. Use new sealing rings in the

valve cover while doing so (see illustration). Observe the tigh-tening torque (see section 8.4).

12. Fit the hose of the crankcase vent and fix with clamp.13. Mount air filter and fix with clamp.

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Checking lamellar valve (2nd stage)

1. Loosen the for flange screws of the compressed air manifold on the valve cover of the 2nd stage. Loosen flange connec-tion on the two cylinders of the 2nd stage.

2. Loosen the valve cover nuts and pull the valve cover uniformly with the two M12 screws.

3. Remove the retaining screw on the valve cover and take out valve carefully.

4. Examine the valve. If lamellar valve is heavily carbonised or damaged, replace complete valve.

5. Fix the lamellar valve on the valve cover with the retaining screw. Observe the tightening torque (see section 8.4).

6. Fit lamellar valve and valve cover. Use new sealing rings while doing so (see illustration). Observe the tightening torque (see section 8.4).

O-ring

Note!Lamellar valves require very little maintenance and function even in presence of small quantities of dirt in contrast to plate valves. Normally the plates have the same service life as the val-ve body which, due to its geometry, can not be refaced or lapped. Therefore a replacement of individual plates is not recommen-ded. Should a plate be broken prematurely nevertheless (e.g. through impact of foreign objects), contact our service.

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8.9 Checking the piston rings

1st stage 1. Remove valve cover and valves as described in section 8.8, “Checking valves”.

2. Dismantle inspection hole cover on the crankcase.3. Remove connecting rod bolts and remove connecting rod be-

aring cover with bearing bush. Push piston together with con-necting rod upper part out of the cylinder.

4. Remove all piston rings from the pistons.5. Place piston rings in their respective cylinders and measure

the gap clearance with a feeler gauge.6. Replace piston rings if the gap clearance exceeds the follo-

wing limits.

7. Install piston rings on the respective piston.

O-ring

O-ring

Compression ring 1.80 mm

Oil scraper ring 1.80 mm

Note!Always replace all pistons rings of a piston when one of the pis-ton rings exceeds the limit.

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8. Put connecting rod back with sufficient oil and screw on the bottom part with hand.

✓ It should be possible to screw in the connecting rod bolts completely with hand. Only then the correct seat on the crankshaft can be guaranteed. After tightening, the connec-ting rod should rotate easily on the crankshaft.

2nd stage 1. Loosen the flange connection and dismantle compressed air manifold.

2. Loosen screwed pipe connections and dismantle the com-pressed 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, dismantle cooling water inlet pipe. The screw connection nipple remains on the cylinder.

5. Remove the union nut of the cooling water hose between the cylinders of the 1st and 2nd stage and remove the cooling wa-ter hose. The bend remains on the cylinder of the 2nd stage.

6. Dismantle both the inspection hole covers from the crankca-se.

7. Loosen the connecting rod bolts and remove them from the

Note!Use an assembly sleeve for pushing the piston into the liner from above (see Chapter 11 "Spare parts and Accessories“).

Note!Numbers are punched on the upper and lower parts of the con-necting rod. These must match in any case . See illustration.

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crankcase together with bearing cover. Push the connecting rod upper part with the piston up in the cylinder.

8. Loosen the four nuts at the foot of the cylinder of the 2nd sta-ge.

9. Turn the two M16 lifting eye nuts (see Chapter 11 "Spare parts and Accessories“) on both the upper studs of the valve cover and pull the cylinder out of the crankcase with a suitable lifting device (weight approx. 100 kg).

10. Pull cylinder further up along with connecting rod with piston. Pull connecting rod towards front from the crankcase ope-ning.

11. Put cylinder down at the side and pull connecting rod with pis-ton down from the cylinder.

12. Remove all piston rings from the pistons.13. Place piston rings in their respective cylinders and measure

the gap clearance with a feeler gauge.14. Replace piston rings if the gap clearance exceeds the follo-

wing limits.

15. Fit piston rings. Fit N-ring in the third groove from above. Make sure they are in the correct position: piston rings having an asymmetric cross section are marked on one of the sur-faces with “TOP”. The marked face must be at the top when the piston ring is installed. See illustration.

16. Sequence of assembly is exactly opposite to that of dismant-ling.

17. Put connecting rod back with sufficient oil and screw on the bottom part with hand (see section 8.4 for tightening torque).

Compression ring 0.75 mm

Oil scraper ring 0.65 mm

TOP

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✓ It should be possible to screw in the connecting rod bolts completely with hand. Only then the correct seat on the crankshaft can be guaranteed. After tightening, the connec-ting rod should rotate easily on the crankshaft.

8.10 Replacing gudgeon pins/gudgeon pin bearings1. Remove valve covers and valves as described in section 8.8,

“Checking valves”.2. Remove cylinder and piston with connecting rod as described

in Section 8.9 "Checking piston rings”.3. Remove circlip of the gudgeon pin and push the gudgeon pin

out.4. Press gudgeon pin bearing out of the connecting rod's small

end.

5. Replace gudgeon pin and gudgeon pin bearing.6. Press gudgeon pin bearing into the connecting rod's small

end.7. Assemble piston with connecting rod and cylinder as descri-

bed in Section 8.9 "Checking piston rings".8. Assemble valves and valve covers as described in Section

8.8 "Checking valves”.

8.11 Replacing valvesRemove and install valves as detailed in section 8.8 “Checking valves”. Replace complete valve.

Note!Numbers are punched on the upper and lower parts of the con-necting rod. These must match in any case . See illustration.

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8.12 Checking pistons and cylinders1. Remove valve cover and valves as described in section 8.8,

“Checking valves”.2. Remove cylinders and pistons as described in section 8.9,

“Checking the piston rings”.3. Check liner and pistons for scouring and excessive wearing

marks. Replace relevant parts.4. Measure liner and replace if the following wear limits are ex-

ceeded:

5. If the liners were to be pulled out, fit them back with new sealing rings.

6. Fit cylinders and pistons as described in section 8.9, “Che-cking the piston rings”.

7. Assemble valve cover and valve as described in section 8.8, “Checking valves”.

8.13 Checking the drive bearings1. Remove valve cover and valves as described in section 8.8

“Checking the valves”.2. Remove cylinder and piston with connecting rod as described

in Section 8.9 "Checking piston rings”.3. Inspect the connecting rod bearing for score marks and ex-

cessive wear marks and replace in case of heavy wear.4. Dismantle electric motor with intermediate flange, coupling

and flywheel as described in Section 8.14 "Checking coup-ling“.

5. Remove bearing bracket.6. Pull crankshaft out.7. Inspect the crankshaft bearing for score marks and excessive

wear marks and replace in case of heavy wear. If required, use new shaft seal.

8. Fit crankshaft.9. Install bearing bracket. If necessary use new gasket.10. Fit electric motor with intermediate flange, coupling and fly-

wheel. Observe the tightening torque (see section 8.4).11. Assemble piston with connecting rod and cylinder as descri-

bed in Section 8.9 "Checking piston rings".12. Assemble valves and valve covers as described in Section

Cylinder Wear limit of diameter

1st stage 195.15 mm

2nd stage 110.15 mm

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fm

8.8 "Checking valves”.

8.14 Checking the coupling

Visual check 1. Remove protection cover on the transmission bell housing on the first stage. Through the inspection port check the coup-ling's flexible gear rim for damage. The teeth of the flexible gear rim must not be deformed.

2. Fix protection cover back. 3. If necessary, replace the flexible gear rim as described below.

Removing the gear rim

4. Support compressor under the transmission bell housing.5. Remove the electric motor mounting screws.6. Lift the electric motor carefully using the lifting eye (see sec-

tion 5.1 "Transport”).7. Pull electric motor carefully away from the intermediate flan-

ge.8. Replace flexible gear rim.

Protection cover

60

Maintenance
I_
WA

005_

1.fm

9. Slide electric motor gently against the intermediate flange and tighten the motor mounting screws.

10. Remove support from under the transmission bell housing.

8.15 Cleaning particle trap1. Block cooling water inlet.2. Loosen the cap of the particle trap (in front of the cooling wa-

ter-control valve) and remove the strainer.3. Clean the strainer. 4. Fit the strainer back, screw on the cap.

8.16 Checking zinc protectionThe zinc protections for the cylinders of the 1st stage are located laterally on the cylinder.The zinc protection for the cylinder of the 2nd stage is located la-terlly on the cylinder beside the burst disc flange.1. Unscrew the zinc protection and remove loose parts.2. Check the zinc protection.

Minimum diameter is 24 mm. Regenerate the zinc protection if the consumption is too high.

3. Fit the zinc protection back with a new sealing ring.

Tooth of flexible gear rim

61

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5_1.

fm

8.17 Burst disc1. Remove screw and dismantle pressure flange on the cylinder

of the 2nd stage.2. Remove burst disc and sealing ring.3. Clean sealing surface.4. Insert new gasket and new burst disc. Pay attention to the

correct position of the gasket. Fit first the gasket and then the burst disc into the cylinder.

5. Bolt the pressure flange back.

8.18 Checking cooling water pump (optional)The pump should be checked as follows in case of abnormal run-ning sound or leakages from the pump:

Disassembling the pump

1. Block the cooling water inlet and outlet.2. Disconnect electrical connection.3. Remove the drain plug located below on the cylinder of the

2nd stage and drain the cooling water of the compressor.4. Loosen the flange connections on the cooling water inlet and

outlet of the pump.5. Loosen the bolted fastening of the pump at the foot and remo-

ve pump from the console.

Replacing the floa-ting ring seals

The floating ring seals are maintainance-free. In case heavy lea-kages are noticed after long running time, the floating ring seal is to be replaced as a complete unit.6. Remove impeller and shaft retaining ring.7. Pull the entire floating ring seal with the cap out from the

shaft.

Caution:A great deal of care and cleanliness is essential required during the assembly of new floating ring seal. The gliding surfaces must never be touched with fingers. Any damage must in any case be avoided. Moisten the elastomers with low surface tension water to facilitate easier assembly.Caution:Floating ring seals must never come in contact with grease or oil! The shape of spare floating ring seals can be different from that of the built in floating ring seals. The spare floating ring seal ho-wever has the same assembly dimensions and is interchangeab-

Note!Note the diagram of the pump in the Spare Parts Catalogue.

62

Maintenance
I_
WA

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1.fm

le. The floating ring seal must be carefully slid onto the shaft with rotating motion.

Assembling the pump

8. Assemble the pump back in the reverse sequence.9. Checking the direction of rotation of the optional cooling

water pump: Switch the pump motor ON for a short duration. The motor must not reach its operating speed during this. The direction of rotation must be the same as the one indicated by the arrow on the pump. The pump and the suction pipe must be completely filled with cooling water.

Note!The motor bearing should be replaced if the shaft has noticeable play. A possibly damaged pump impeller must likewise be re-placed.

63

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9. Placing out of Service

9.1 Safety when placing out of service and dismounting

9.2 Shutting down the compressor temporarilyEvery 4 weeks perform a test run for at least 30 minutes. Then ad-ditional corrosion prevention measures are not required.When the Sauer compressor is to be shut down for more than 12 weeks, conservation with slushing oil is recommended. In this case periodic test runs are not necessary.

1. Run compressor for approx. 5 minutes with drain valves and pressure line open.

✓ Any existing condensate is blown off.2. Drain compressor oil and dispose it of in an environmentally

friendly manner.3. Fill about 10 litres of slushing oil. 4. Start compressor and run for approx. 5 minutes with drain val-

ves and pressure line opened.5. Stop compressor.6. Unscrew both the air filters.7. Start compressor and slowly inject approx. 100 cc slushing oil

into the intake ports.8. Wait until oil mist comes out of the pressure line.9. Stop compressor.10. Fit both air filters back.11. If necessary, post a sign that the compressor has been trea-

Danger! The compressor shall only be placed out of service and dis-mounted by instructed and trained specialists of the operator. The specialists must be familar with the protection devices and regulations before starting the work. Any work on the electrical installation must be carried out by qualified electricians only. In addition, information contained in the documentation of out-side vendors is to be observed.

Note!Use one of the slushing oils recommended in Chapter 10 "Lub-ricant Table" for corrosion protection.The slushing oil has satisfactory running properties. In case of emergency the machine can be started for a short time with a slushing oil filling.

64

Placing out of Service
I_
DE

004_

1.fm

ted with anticorrosion measures and is placed out of service.12. If necessary disconnect mains supply.

Restarting 1. Connect power supply, if necessary.2. Drain slushing oil and fill with compressor oil.3. Proceed as described in section 6.3 "Commissioning”.

9.3 Dismantling

Dismantling 1. Turn compressor OFF and disconnect from power supply.2. Make sure by reading the pressure gauges before servicing

that the compressor is completely relieved of pressure.3. Disconnect power lines from the mains supply.4. Remove oil and lubricants and dispose of in an environmen-

tally friendly manner.5. Drain any remaining condensate and dispose of in an envi-

ronmentally friendly manner.

Disposal

Material/component How to dispose

Lubricants as hazardous waste

Steel/iron as metal scrap

Electric cables as hazardous waste

Electronic components as electronic waste

Plastics as hazardous waste

65

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ST001AD1.fm

10. Lubricant TableScope The lubricant table applies to all Sauer compressors intended for

the compression of air.The lubricant table does not apply to– Sauer compressors for the compression of neutral gases;– temperature ranges outside of 5 … 55 °C.

General recom-mendation

We recommend mineral oils of the viscosity class in accordance with ISO VG 100 for the temperature range 5 … 55 °C. The lubri-cating oils should at least conform to the group VCL in accord-ance with DIN 51506.

Note!The recommended oil types bring down the carbonisation in the compressor valves and the connected pipes and fittings to a minimum.Lubricants not mentioned in the lubricant table may only be used after approval by J.P. SAUER & SOHN. Otherwise the warranty will lapse. Please contact our customer service when selecting oils not list-ed here or in case of deviating operating conditions.

66

Lubricant Table
S
T00

1AD

1.fm

10.1 Lubricating oils

Brand Name Group

Agip Diesel Gamma 30 VCL-100

Dicrea 100 VDL-100

Acer 100 VCL-100

Motor Oil HD 30 SAE 30

Cladium 50 SAE 30

ARAL Motanol HE 100 VDL-100

Kowal M 30 VCL-100

Disola M 30 SAE 30

AVIA Avilub Compressor Oil VDL-100 VDL-100

Avilub Compressor Oil VDL-100 VCL-100

Motor oil HDC 30 SAE 30

Motor oil HD 30 SAE 30

BP Energol RC 100 VDL-100

Energol IC-DG 30 VCL-100

Energol DL-MP 30 SAE 30

Energol OE-HT 30 SAE 30

Vanellus C3 SAE 30 SAE 30

Castrol Aircol PD 100 VDL-100

Marine CDX 30 SAE 30

Chevron HD Compressor Oil 100 VDL-100

Delo 1000 Marine 30 SAE 30

Veritas 800 Marine 30 SAE 30

RPM Heavy Duty Motor 30 SAE 30

DEA Actro EP VDL-100 VDL-100

Trion EP VDL-100 VDL-100

Regis SAE 30 SAE 30

Esso Exxcolub 77 VDL

Exxcolub 100 VDL-100

Compressor Oil 3021 N VDL-100

Exxmar 12 TP 30 SAE 30

Exxmar XA SAE 30

Essolube HDX Plus +30 SAE 30

Mobil Rarus 427 VDL-100

DTE Oil Heavy VDL

Mobilgard 300 SAE 30

Shell Corena Oil P 100 VDL-100

Rimula X 30 SAE 30

Melina S Oil 30 SAE 30

Melina Oil 30 SAE 30

Gadinia Oil 30 SAE 30

67

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fm

10.2 Slushing oils

TEXACO Compressor Oil EP VDL 100 VDL-100

Regal R&O 100 VCL-100

Ursatex 30 SAE 30

DORO AR 30 SAE 30

TOTAL Dacnis P 100 VDL-100

Carprano TD 30 SAE 30

Milcano TC 30 SAE 30

Disola M 3015 SAE 30

Brand Name Group

Brand Name

Agip Rustica C SAE 30

ARAL Konit Motor Oil SAE 30

AVIA MK 1540 S

Avilub MK 3000

BP MEK 20 W-20

Castrol Running-in and Preservation Oil

DEA Deamot EKM 642 SAE 30

ELF Stockage 30

Esso MZK Motor Oil HD 30

Antirust MZ 110

FINA Rusan NF Motor Oil SAE 30

Mobil Mobilarma 524

Shell Ensis Motor Oil 30

TEXACO Engine Oil EKM 146 SAE 30

68

Spare Parts and AccessoriesE

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1.fm

69

11. Spare Parts and Accessories

J.P. SAUER & SOHN garantee the complete spare parts supply over the entire service life of the Sauer compressor. Our genuine Sauer spare parts are subject to constant quality control and further development. They conform to the latest tech-nical developments.In addition to the genuine Sauer spare parts, our delivery pro-gram comprises a large number of accessories for your Sauer compressor and special components to complete your air sys-tem, such as:– fully automatic controls;– adsorption dryers;– refrigerated air dryers;– filters;– silencing cabinets;– compressed air receivers;– fittings.We supply instructions and a maintenance manual for each ac-cessory.

Spare parts cata-logue

The spare parts catalogue is found in the annex to these instruc-tions. – With the help of overviews, illustrations and lists the required

parts is quickly found.– The spare parts catalogue, including the operating instructions

is also available on CD-ROM. Here, an order form can be filled in, printed out and send immediately. For doing so, you need the main specifications of your Sauer compressor from the table below. If they have not yet been en-tered there, they can be found on the type label affixed to the crankcase.

Furthermore, the number of operating hours should be stat-ed, if possible.

Note!Please note the information in chapter 1. “General” regading our genuine Sauer spare parts.

Compressor type

Factory no.:

Year of construc-tion:

70

AN

001A

A1.

fm

12. AnnexThis Annex to the operating instructions contains– documentation supplied by outside vendors;– data sheets.

AnnexA

N00

1AA

1.fm

71

S a u e r

C o m p r e s s o r

Type: WP 400

Spare Part List

Spare Part List

WP 400 Sauer compressor

Reference No. Subassemblies Page

WP 400 Sauer compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

064 140 crankcase .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

064 448 protection device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

064 142 crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

063 864 connecting rod 1st stage.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

064 144 connecting rod 2nd stage .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

064 261 piston 1st stage .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

064 145 piston 2nd stage .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

063 866 cylinder 1st stage .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

063 915 cylinder 2nd stage .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

063 868 valve cover 1st stage.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

063 869 valve cover 2nd stage.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

037 134 concentric valve 1st stage .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

036 959 lamellar valve 2nd stage .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

064 146 air pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

064 147 cooling water pipes compr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

064 366 cooling water lines unit without pump .. . . . . . . . . . . . . . . . . . .

066 143 cooling water lines unit with pump .. . . . . . . . . . . . . . . . . . . . . . .

038 238 cooling water pump.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

064 148 crankcase venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

063 985 lubricating oil supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

064 038 measuring device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

064 308 auxiliary tools, compl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

064 151 resilient mounts f. motor 280 S/M.. . . . . . . . . . . . . . . . . . . . . . . .

064 039 automatic drainage .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

063 950 compressor monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Note: Explanation of the subassemblies in chapter 3 "Design and Function"of the operating instructions

E - 3


4.. . . . . . . . . . . . . . . . . .

6. . . . . . . . . . . . . . . . . . .

8. . . . . . . . . . . . . . . . . . .

10. . . . . . . . . . . . . . . . .

12. . . . . . . . . . . . . . . . .

14. . . . . . . . . . . . . . . . .

16. . . . . . . . . . . . . . . . .

18. . . . . . . . . . . . . . . . .

20. . . . . . . . . . . . . . . . .

22. . . . . . . . . . . . . . . . .

24. . . . . . . . . . . . . . . . .

26. . . . . . . . . . . . . . . . .

28. . . . . . . . . . . . . . . . .

30. . . . . . . . . . . . . . . . .

32. . . . . . . . . . . . . . . . .

34. . . . . . . . . . . . . . . . .

36. . . . . . . . . . . . . . . . .

38. . . . . . . . . . . . . . . . .

41. . . . . . . . . . . . . . . . .

46. . . . . . . . . . . . . . . . .

48. . . . . . . . . . . . . . . . .

50. . . . . . . . . . . . . . . . .

52. . . . . . . . . . . . . . . . .

54. . . . . . . . . . . . . . . . .

56. . . . . . . . . . . . . . . . .

58. . . . . . . . . . . . . . . . .


E - 4

Spare Part List


Item Reference No. Designation Qty.

1 064 140 crankcase 12 064 142 crankshaft 13 063 864 connecting rod 1st stage 14 064 144 connecting rod 2nd stage 15 064 261 piston 1st stage 16 064 145 piston 2nd stage 17 063 866 cylinder 1st stage 18 063 915 cylinder 2nd stage 19 063 868 valve cover 1st stage 110 063 869 valve cover 2nd stage 111 037 134 concentric valve 1st stage 112 036 959 lamellar valve 2nd stage 113 064 146 air pipes 114 064 147 cooling water pipes compr. 115 064 366 cooling water lines unit without pump 116 066 143 cooling water lines unit with pump 117 064 148 crankcase venting 118 063 985 lubricating oil supply 119 064 038 measuring device 120 033 423 flex.coupling f. motor 280 S/M 122 064 308 auxiliary tools, compl. 123 064 151 resilient mounts f. motor 280 S/M 124 063 950 compressor monitor 125 064 039 automatic drainage 1

E - 5

064 140 crankcase

E - 6

Spare Part List

064 140 crankcase


1 063 786 crankcase 12 064 394 housing cover 13 051 883 inspection hole cover 24 036 897 oil sieve 15 064 257 dipstick 16 063 748 inspecting hole cover packing 27 063 749 housing cover packing 19 030 743 shaft seal 110 004 635 union 111 000 971 plug 212 005 001 gasket 213 035 984 cock 114 005 009 Ring 115 038 102 stud 616 001 620 hexagon nut 617 036 960 stud 1218 001 621 hexagon head nut 1219 001 408 stud 1620 002 031 hexagon nut 1627 064 331 blind flange 128 064 332 blind flange packing 129 000 494 Socket Head Cap Screw 430 064 448 protection device 131 030 556 o-ring 1

E - 7

064 448 protection device

E - 8

Spare Part List

064 448 protection device


1 064 449 protection cover 13 001 408 stud 24 002 031 hexagon nut 25 002 156 washer 2

E - 9

064 142 crankshaft

E - 10

Spare Part List

064 142 crankshaft


1 064 143 crankshaft 12 063 544 driving plate 13 063 732 washer 14 063 811 flywheel 16 005 297 hexagon head screw 17 033 994 cylinder head screw 28 036 961 cylinder roller bearing 29 000 542 cylinder head screw 10

E - 11

063 864 connecting rod 1st stage

E - 12

Spare Part List

063 864 connecting rod 1st stage


1 063 712 connecting rod 12 061 857 connecting rod bearing 13 035 823 needle roller bearing 14 061 676 connecting rod screw 2

E - 13

064 144 connecting rod 2nd stage

E - 14

Spare Part List

064 144 connecting rod 2nd stage


1 063 826 connecting rod 12 061 857 connecting rod bearing 13 037 058 needle roller bearing 14 061 676 connecting rod screw 2

E - 15

064 261 piston 1st stage

E - 16

Spare Part List

064 261 piston 1st stage


1 036 983 piston 12 036 078 piston pin 13 002 716 R-ring 24 035 962 G-ring 15 002 985 circlip 2

E - 17

064 145 piston 2nd stage

E - 18

Spare Part List

064 145 piston 2nd stage


1 063 815 piston 12 064 150 piston pin 13 033 571 R-ring 24 002 634 N-ring 15 002 605 S-ring 16 012 682 circlip 2

E - 19

063 866 cylinder 1st stage

E - 20

Spare Part List

063 866 cylinder 1st stage


1 063 779 cylinder housing 1st stage 12 061 822 zinc protection 14 063 660 cylinder cover 15 063 656 cooler cover, rear 16 063 652 cooler cover, front 17 063 776 finished bushing 18 063 747 cylinder cover packing 19 063 797 cooler cover packing, rear 110 063 796 cooler cover packing, front 112 000 497 cylinder head screw 614 001 533 stud 615 000 507 cylinder head screw 1916 000 523 cylinder head screw 217 000 977 plug 118 001 016 plug 319 035 390 plug 122 001 621 hexagon head nut 623 005 023 gasket 324 005 009 Ring 326 036 962 o-ring 4

E - 21

063 915 cylinder 2nd stage

E - 22

Spare Part List

063 915 cylinder 2nd stage


1 064 442 cylinder housing 2nd stage 12 061 822 zinc protection 13 054 883 protection cover 15 063 662 cylinder cover 16 064 395 cooler cover, rear 17 063 654 cooler cover, front 18 063 808 finished bushing 19 063 747 cylinder cover packing 110 063 751 cooler cover packing, rear 111 063 750 cooler cover packing, front 112 051 530 protection cover packing 113 061 942 bursting plate 114 000 505 cylinder head screw 415 000 551 cylinder head screw 2116 000 497 cylinder head screw 617 001 533 stud 419 001 621 hexagon head nut 420 001 016 plug 121 000 977 plug 122 035 390 plug 123 005 023 gasket 324 005 009 Ring 125 030 131 o-ring 4

E - 23

063 868 valve cover 1st stage

E - 24

Spare Part List

063 868 valve cover 1st stage


1 064 236 valve cover 12 036 394 dry air filter 13 037 151 o-ring 14 030 912 o-ring 15 036 395 Filter insert for air filter 1

E - 25

063 869 valve cover 2nd stage

E - 26

Spare Part List

063 869 valve cover 2nd stage


1 063 743 valve cover 12 036 964 hexagon head screw 13 003 493 gasket 14 036 963 o-ring 15 035 970 o-ring 1

E - 27

037 134 concentric valve 1st stage

E - 28

Spare Part List

037 134 concentric valve 1st stage


1 037 187 suction valve plate 12 037 188 delivery valve plate 13 037 189 delivery valve plate 14 037 190 delivery valve spring 25 037 191 delivery valve spring 26 037 192 suction valve spring 2

E - 29

036 959 lamellar valve 2nd stage

E - 30

Spare Part List

036 959 lamellar valve 2nd stage


1 037 186 suction plate DIA 124 12 037 236 delivery plate 83 037 237 delivery spring plate 8

E - 31

064 146 air pipes

E - 32

Spare Part List

064 146 air pipes


1 063 812 collecting tube 12 063 121 separator 14 056 335 packing 26 000 054 hexagon head screw 127 000 137 hexagon head screw 28 002 151 washer 29 036 157 union 110 006 193 union 111 005 946 stud adaptor 112 030 751 safety valve 113 030 752 safety valve 114 005 009 Ring 115 005 016 safety valve gasket 216 005 023 gasket 2

E - 33

064 147 cooling water pipes compr.

E - 34

Spare Part List

064 147 cooling water pipes compr.


1 037 144 angle 42 037 265 angle 14 037 194 union 36 038 390 hose 29 004 661 union 410 036 967 union 111 034 875 adaptor 112 037 305 reducer 1

E - 35

064 366 cooling water lines unit without pump

E - 36

Spare Part List

064 366 cooling water lines unit without pump


1 037 142 soleniod valve 12 032 679 dirt trap 13 032 725 connector 24 037 930 connector 15 037 265 angle 16 037 266 connector 17 036 967 union 18 037 267 reducer 1

E - 37

066 143 cooling water lines unit with pump

E - 38

Spare Part List



1 066 442 holder 12 066 145 ledge 23 066 144 L-profil 14 005 265 hexagon head screw 85 012 851 hexagon head screw 46 000 155 hexagon head screw 27 000 594 cylinder head screw 28 001 620 hexagon nut 29 002 051 hexagon nut 810 038 201 reducer 113 032 725 connector 114 002 161 washer 415 037 267 reducer 116 037 144 angle 117 037 265 angle 218 002 166 washer 419 036 967 union 120 032 679 dirt trap 121 037 150 solenoid valve 122 064 396 gate valve 123 038 238 cooling water pump 125 038 386 hose 126 037 493 clamp 127 037 293 flange 128 036 614 flange 129 030 658 packing 130 037 441 packing 131 037 930 connector 132 037 305 reducer 133 000 119 hexagon head screw 234 000 048 hexagon head screw 235 002 153 washer 436 002 156 washer 8

E - 39



37 002 025 hexagon nut 238 002 031 hexagon nut 640 037 851 union 141 004 666 union 1

E - 40

Spare Part List

E - 41

038 238 cooling water pump

E - 42

Spare Part List


E - 43

E - 44

Spare Part List



1 038 290 packing kit 1

E - 45

064 148 crankcase venting

E - 46

Spare Part List

064 148 crankcase venting


1 038 407 pipe adaptor 12 038 268 distribution piece 13 033 087 reducer 14 034 612 LP-hose 15 035 254 hose clamp 46 037 139 hose union 47 037 140 bend 28 037 185 connector 19 037 144 angle 110 037 194 union 111 035 824 filling cover 112 037 264 LP-hose 114 033 952 hose 1

E - 47

063 985 lubricating oil supply

E - 48

Spare Part List

063 985 lubricating oil supply


1 063 543 oil pump 12 057 916 overpressure valve 17 003 438 oil pump gasket 18 000 452 cylinder head screw 410 056 318 packing 111 036 363 lubricating oil supply packing 112 030 544 packing 1

E - 49

064 038 measuring device

E - 50

Spare Part List

064 038 measuring device


1 035 009 Pressure gauge 32 035 010 Pressure gauge 13 035 061 Gasket ring 46 038 073 angle thermometer 0-250°C 37 005 009 Ring 38 005 016 safety valve gasket 19 035 906 adaptor 110 030 182 angle thermometer 112 030 509 plug 1

E - 51

064 308 auxiliary tools, compl.

E - 52

Spare Part List

064 308 auxiliary tools, compl.


1 037 225 lifting eye nut 22 064 306 assembly bushing 13 064 309 turning rod 1

E - 53

064 151 resilient mounts f. motor 280 S/M

E - 54

Spare Part List

064 151 resilient mounts f. motor 280 S/M


1 066 595 cooling water hose lines 22 033 531 countersunk screw 83 000 589 cylinder head screw 84 046 837 resilient mount 85 034 763 HP - hose 16 035 942 HP - hose 28 004 701 union 29 065 664 non-return valve 110 063 947 rail 2

E - 55

064 039 automatic drainage

E - 56

Spare Part List

064 039 automatic drainage


1 049 129 tube clamp 12 033 961 stud adaptor 13 006 187 union 14 004 647 union 25 005 964 union 16 004 973 union 17 035 555 solenoid valve 28 000 434 Socket Head Cap Screw 29 005 009 Ring 210 006 000 union 111 006 455 stud adaptor 112 008 663 pipe 113 008 672 pipe 1

E - 57

063 950 compressor monitor

E - 58

Spare Part List

063 950 compressor monitor


1 064 018 temperature monitor 13 030 082 oil pressure switch 14 000 409 socket head cap screw 25 004 596 union 26 033 017 reducer 18 008 633 pipe 1

E - 59

E - 60

Index

Reference No. Designation Page Pos.

000 048 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 34000 054 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 6000 119 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 33000 137 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 7000 155 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 6000 409 socket head cap screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 4000 434 Socket Head Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 8000 452 cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 8000 494 Socket Head Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 29000 497 cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 12000 497 cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 16000 505 cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 14000 507 cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 15000 523 cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 16000 542 cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 9000 551 cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 15000 589 cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 3000 594 cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 7000 971 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 11000 977 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 17000 977 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 21001 016 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 18001 016 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 20001 408 stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 19001 408 stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3001 533 stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 14001 533 stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 17001 620 hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 16001 620 hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 8001 621 hexagon head nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 18001 621 hexagon head nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 22001 621 hexagon head nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 19002 025 hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 37002 031 hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 20002 031 hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4002 031 hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 38002 051 hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 9002 151 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 8002 153 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 35002 156 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 5002 156 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 36002 161 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 14002 166 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 18002 605 S-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5002 634 N-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4002 716 R-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3002 985 circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5003 438 oil pump gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 7003 493 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 3004 596 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 5004 635 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 10004 647 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 4

E - 61


004 661 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 9004 666 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 41004 701 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 8004 973 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 6005 001 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 12005 009 Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 14005 009 Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 24005 009 Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 24005 009 Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 14005 009 Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 7005 009 Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 9005 016 safety valve gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 15005 016 safety valve gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 8005 023 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 23005 023 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 23005 023 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 16005 265 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4005 297 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6005 946 stud adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 11005 964 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 5006 000 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 10006 187 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 3006 193 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 10006 455 stud adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 11008 633 pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 8008 663 pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 12008 672 pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 13012 682 circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 6012 851 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 5030 082 oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 3030 131 o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 25030 182 angle thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 10030 509 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 12030 544 packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 12030 556 o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 31030 658 packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 29030 743 shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 9030 751 safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 12030 752 safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 13030 912 o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4032 679 dirt trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 2032 679 dirt trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 20032 725 connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 3032 725 connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 13033 017 reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 6033 087 reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 3033 423 flex.coupling f. motor 280 S/M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 20033 531 countersunk screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 2033 571 R-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 3033 952 hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 14033 961 stud adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 2033 994 cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 7

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Index


034 612 LP-hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 4034 763 HP - hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 5034 875 adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 11035 009 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 1035 010 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 2035 061 Gasket ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 3035 254 hose clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 5035 390 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 19035 390 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 22035 555 solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 7035 823 needle roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3035 824 filling cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 11035 906 adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 9035 942 HP - hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 6035 962 G-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4035 970 o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5035 984 cock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 13036 078 piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2036 157 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 9036 363 lubricating oil supply packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 11036 394 dry air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2036 395 Filter insert for air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 5036 614 flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 28036 897 oil sieve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4036 959 lamellar valve 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 12036 960 stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 17036 961 cylinder roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 8036 962 o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 26036 963 o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 4036 964 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2036 967 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 10036 967 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 7036 967 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 19036 983 piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1037 058 needle roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3037 134 concentric valve 1st stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 11037 139 hose union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 6037 140 bend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 7037 142 soleniod valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 1037 144 angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 1037 144 angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 16037 144 angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 9037 150 solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 21037 151 o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 3037 185 connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 8037 186 suction plate DIA 124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 1037 187 suction valve plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 1037 188 delivery valve plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 2037 189 delivery valve plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 3037 190 delivery valve spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 4037 191 delivery valve spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5037 192 suction valve spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 6

E - 63


037 194 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 4037 194 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 10037 225 lifting eye nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 1037 236 delivery plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 2037 237 delivery spring plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3037 264 LP-hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 12037 265 angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 2037 265 angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 5037 265 angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 17037 266 connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 6037 267 reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 8037 267 reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 15037 293 flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 27037 305 reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 12037 305 reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 32037 441 packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 30037 493 clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 26037 851 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 40037 930 connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 4037 930 connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 31038 386 hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 25038 073 angle thermometer 0-250°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 6038 102 stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 15038 201 reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 10038 238 cooling water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 23038 268 distribution piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 2038 290 packing kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 1038 390 hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 6038 407 pipe adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 1046 837 resilient mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 4049 129 tube clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 1051 530 protection cover packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 12051 883 inspection hole cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3054 883 protection cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3056 318 packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 10056 335 packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 4057 916 overpressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 2061 676 connecting rod screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4061 676 connecting rod screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4061 822 zinc protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2061 822 zinc protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2061 857 connecting rod bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2061 857 connecting rod bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2061 942 bursting plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 13063 121 separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 2063 543 oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 1063 544 driving plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2063 652 cooler cover, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 6063 654 cooler cover, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 7063 656 cooler cover, rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 5063 660 cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4063 662 cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5

E - 64

Index


063 712 connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1063 732 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3063 743 valve cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1063 747 cylinder cover packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 8063 747 cylinder cover packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 9063 748 inspecting hole cover packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 6063 749 housing cover packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7063 750 cooler cover packing, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 11063 751 cooler cover packing, rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 10063 776 finished bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 7063 779 cylinder housing 1st stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1063 786 crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1063 796 cooler cover packing, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 10063 797 cooler cover packing, rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 9063 808 finished bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 8063 811 flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4063 812 collecting tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 1063 815 piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1063 826 connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1063 864 connecting rod 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3063 866 cylinder 1st stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 7063 868 valve cover 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 9063 869 valve cover 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 10063 915 cylinder 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 8063 947 rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 10063 950 compressor monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 24063 985 lubricating oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 18064 018 temperature monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 1064 038 measuring device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 19064 039 automatic drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 25064 140 crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1064 142 crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2064 143 crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1064 144 connecting rod 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4064 145 piston 2nd stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 6064 146 air pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 13064 147 cooling water pipes compr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 14064 148 crankcase venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 17064 150 piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2064 151 resilient mounts f. motor 280 S/M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 23064 236 valve cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1064 257 dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5064 261 piston 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5064 306 assembly bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 2064 308 auxiliary tools, compl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 22064 309 turning rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 3064 331 blind flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 27064 332 blind flange packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 28064 366 cooling water lines unit without pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 15064 394 housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2064 395 cooler cover, rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 6064 396 gate valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 22

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064 442 cylinder housing 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1064 448 protection device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 30064 449 protection cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1065 664 non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 9066 143 cooling water lines unit with pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 16066 144 L-profil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 3066 145 ledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2066 442 holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 1066 595 cooling water hose lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 1

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air compressor wp400

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