air compressor(2)

S a u e rC o m p r e s s o rTyp: WP 400

Operator Manual

• High-pressure Compressor• 2-stage• water-cooled

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Ausgabe: 05 / 2008Redaktion: Edited by: J.P. Sauer & Sohn Maschinenbau – Technical Documentation

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Sauer compressor Type Approvals

Note!On this page only a few examples are shown. FurtherType Ap-provals are available on request.

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Genuine Sauer spare parts – certified safety

SPECIMEN

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Table of Contents

1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.2 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.3 Warranty and Liability . . . . . . . . . . . . . . . . . . . . . . . . . . 91.4 Type Approval and Genuine Sauer Spare Parts. . . . . 101.5 J.P. SAUER & SOHN Customer Service . . . . . . . . . . 111.6 Text Conventions Used in This Operator Manual . . . . 12

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.1 Conditions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.2 Unauthorised modification. . . . . . . . . . . . . . . . . . . . . . 132.3 Safety Information - Warning and Caution . . . . . . . . . 142.4 Safety Warnings on the Machine . . . . . . . . . . . . . . . . 152.5 Safety and protection devices . . . . . . . . . . . . . . . . . . . 162.6 Noise protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.7 Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.8 Safety requirements for personnel . . . . . . . . . . . . . . . 182.9 Personal protective equipment . . . . . . . . . . . . . . . . . . 19

3 Design and Function. . . . . . . . . . . . . . . . . . . . . . . . . 203.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . 263.3 Displays on the Sauer compressor . . . . . . . . . . . . . . . 283.4 Indicators and operating elements on the

compressor control . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4 Technical Specification . . . . . . . . . . . . . . . . . . . . . . 304.1 Specification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304.2 P&I Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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5 Transport and Installation . . . . . . . . . . . . . . . . . . . .365.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365.2 Storage before Installation . . . . . . . . . . . . . . . . . . . . .385.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .395.4 Connecting the Compressor . . . . . . . . . . . . . . . . . . . .425.5 Filling with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .475.6 Checks to be carried out after installation and

before the first start-up. . . . . . . . . . . . . . . . . . . . . . . . .48

6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .496.1 Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .496.2 Operating modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . .506.3 Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .516.4 Routine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

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

8 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .598.1 J.P. SAUER & SOHN maintenance service. . . . . . . . . .598.2 Safety during maintenance . . . . . . . . . . . . . . . . . . . . .598.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . .608.4 Table of torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . .628.5 Checking screwed connections. . . . . . . . . . . . . . . . . .628.6 Replacing air filter cartridge. . . . . . . . . . . . . . . . . . . . .628.7 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .638.8 Cleaning the oil strainer. . . . . . . . . . . . . . . . . . . . . . . .648.9 Checking the valves . . . . . . . . . . . . . . . . . . . . . . . . . .648.10 Replacing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . .668.11 Draining the cooling water . . . . . . . . . . . . . . . . . . . . . .678.12 Replacing piston rings, gudgeon pins and

gudgeon pin bearings . . . . . . . . . . . . . . . . . . . . . . . . .678.13 Checking pistons and cylinders . . . . . . . . . . . . . . . . . .718.14 Wear limits for cylinder diameters . . . . . . . . . . . . . . . .718.15 Checking coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . .718.16 Renewing flexible gear rim . . . . . . . . . . . . . . . . . . . . .728.17 Inspecting the condensate separator . . . . . . . . . . . . .738.18 Overhauling water drain valves . . . . . . . . . . . . . . . . . .738.19 Cleaning particle trap. . . . . . . . . . . . . . . . . . . . . . . . . .748.20 Replacing the zinc protection . . . . . . . . . . . . . . . . . . .748.21 Replacing the bursting disc . . . . . . . . . . . . . . . . . . . . .748.22 Checking the cooling water pump . . . . . . . . . . . . . . . .75

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9 Storage, Preservation – “lay-up” procedure . . . . . 779.1 Safety when storing and removing . . . . . . . . . . . . . . . 779.2 Temporary preservation and storage . . . . . . . . . . . . . 789.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

10 Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8110.1 Lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8210.2 Preservation oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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

12 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8612.1 Commissioning certificate . . . . . . . . . . . . . . . . . . . . . . 8712.2 Return of goods and notification of claim . . . . . . . . . . 88

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1 General

1.1 ForewordThis Operator Manual provides installation guidance, safe operation, maintenance and repair instructions with illustrated parts breakdown.The following unique specification for the Sauer compressor can be found on the nameplate affixed to the compressor:– Compressor type– Serial number– Year of construction:We recommend you record this information in Chapter 11 “Spare Parts and Accessories” and always provide this data when requesting parts and any repair instructions.

1.2 Precautions

Specific precautions

We recommend that only authorised and trained personnel operate and service the Sauer compressor. Such responsible personnel should be thoroughly familiar with, and frequently review, the Operator Manual.These instructions should always be readily available at the compressor installation.

Copyright The copyright for this Operator Manual remains with J.P. SAUER & SOHN. These instructions, or parts thereof, shall not be copied, distributed or made available to third parties. Contravention will result in prosecution.

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1.3 Warranty and LiabilitySauer can no longer cover warranty, be liable for any claims, if a failure is attributed to any of the following:– use of the machine not as specified;– substitution of parts not manufactured or approved by Sauer;– use of spare parts that are not genuine Sauer spare parts;– operation of the machine with faulty or improperly installed

safety and/or protection devices;– failure to observe operating instructions;– unauthorised modification to the machine or its control system;– inadequate monitoring of machine parts subject to wear;– failure to maintain/repair in accordance with Sauer

instructions;– force majeure.

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1.4 Type Approval and Genuine Sauer Spare Parts• Type approval for the Sauer compressor is valid under

the condition that parts and components specified and qualified by J.P. SAUER & SOHN are used. Type approval is provided by the classification society and the EC Declaration of Conformity or EC Manufacturer's Declaration. Failure to observe these requirements may void type approval.

• Only the use of genuine Sauer spare parts will ensure compliance with these specifications and, therefore, reliable and safe operation of the Sauer compressors.

• If non-genuine Sauer spare parts are used, we reserve the right of exclusion from liability for personal injury and material damage.

• Genuine Sauer spare parts are supplied with a Certificate of Conformity and a Certificate of Authenticity. An example of this document is shown just before the Table of Contents in these instructions. If spare parts are received without this certificate, there is a risk that these are not genuine Sauer spare parts. In such an instance please contact our Customer Service.

Note!Be aware this is a high-pressure compressor, for your own safety and for reliable compressor operation, only use genuine Sauer parts.

Only use genuine Sauer spare partswith a certificate!

Do not use parts from the“grey market”!

Correct Incorrect

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1.5 J.P. SAUER & SOHN Customer ServiceShould you have any technical questions relating to maintenance or repair, please contact our Customer Service:

J.P. SAUER & SOHN Maschinenbau GmbH Customer Service P.O. Box 92 13 24157 Kiel, Germany

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

Note!If you have questions regarding your Sauer compressor, please specify the compressor model and serial number (see Chapter 11 “Spare Parts and Accessories” or nameplate on the compressor).

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1.6 Text Conventions Used in This Operator Manual

Part lists General lists are marked using a dash. Example:Compressor cooling consists of– cooler assembly– cooling water lines.

Instructions Individual instructions or multiple instructions requiring action but where the sequence is of no importance are normally denoted by a bullet-point.Example:• Check oil level.

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

Results of actions carried out are denoted by a tick mark. Example:

The control light is on.

Safety instructions

Safety and warning instructions are presented pictorially with clear instructions. The safety instructions are described in detail in Chapter 2 “Safety”.

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2 Safety

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

2.2 Unauthorised modificationUnauthorised modification of the Sauer compressor is not permitted. Modifications may lead to an accident that can be life-threatening, cause personal injury or result in damage to the equipment. Contact J.P. SAUER & SOHN when planning any modification to obtain written approval.

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2.3 Safety Information - Warning and CautionThe safety information in these instructions is presented as ‘high’ risk and ‘lower’ risk, as follows.

Warning - Danger!High risk.Ignoring these safety instructions can cause personal injury, or death, and significant equipment damage.

Caution - Note!Less risk.Disregarding this safety note may cause damage to the equipment.

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2.4 Safety Warnings on the Machine

The Sauer compressor with an EC Manufacturer's Declaration or EC Declaration of Conformity is marked with the following safety labelling:

Location of safety markings

Danger!Safety labeling affixed to the machine must not be altered or removed. Replace damaged or lost safety labels immediately with an approved replacement.

Safety label Meaning Safety label Meaning

High voltage! Danger to life!

Read Operator Manual!

Compressor starts automatically without warning!

Wear hearing protection!

Hot surface! Rotational direction of crankshaft

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2.5 Safety and protection devices

Safety valves Each compression stage of the Sauer compressor is equipped with a safety valve, which will fully discharge air when the blow-off pressure is reached.Safety valves are installed at the following locations:– 1. Compression stage: in the rear cooler cover of stage 1.2;– 2. Compression stage: at the final separator after the 2nd

stage.

High air tempera-ture switch

The Sauer compressor is equipped with a temperature sensor. The high air temperature switch shuts down the compressor if the compressed air temperature exceeds the limit value.

Low oil pressure switch

The Sauer compressor comes supplied with a low oil pressure switch which trips when the pressure drops below p < 1 bar.

Danger!Safety devices must not be adjusted, tampered with or removed. The safety devices must be periodically tested and checked: Safety valves must be installed with a lock-seal should be replaced, adjusted and re-sealed only by authorised personnel

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2.6 Noise protectionSound pressure level details are found in the Technical Specification (see Chapter 4). The Sauer compressor can be equipped with a sound-dampening enclosure to reduce noise, available as an accessory from J.P. SAUER & SOHN.

2.7 Waste disposal

Danger!When the compressor is operated without sound-dampening enclosure, hearing protection should be worn when working near the compressor.

Note!The following materials which accumulate during operation of the compressor must be disposed of in an environmentally sound manner in accordance with applicable laws. – condensate (oil/water) arising from inter-cooling in the

compression process– used oil and grease, and used oil and grease and materials

soiled by such lubricants– cleaning agents and rags soiled by such agents.

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2.8 Safety requirements for personnelOnly personnel authorised by J.P. SAUER & SOHN are permitted to service the Sauer compressor! Before commencing work they must have read and understood the instructions in the Operator Manual, and must be familiar with all safety devices and safety regulations.In addition to the instructions in this Operator Manual and supplier documentation, accepted engineering standards must be observed as well as all local laws, standards and regulations such as– The Equipment and Product Safety Act,– The regulations for industrial safety,– The regulations for accident prevention pertaining to

compressors,– Provision of the Verband Deutscher Elektrotechniker (VDE/

German electrical engineering industry association)– Regulations on environmental protection.Additionally, where appropriate classification society and operational regulations must be observed.Only those trained and thoroughly familiar with the compressor operation should be authorised to operate the compressor.Personnel authorised to service the compressor must be trained technical specialists of the owner and manufacturer.

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2.9 Personal protective equipmentThe owner should provide personal protection equipment (e.g. hearing protection, safety boots, etc.) for personnel carrying out any work on the Sauer compressor.

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3 Design and Function

3.1 Overview

Note!Details of parts and spare parts can be found in the spare parts catalogue.

4 57 15

13 12 11

1

2

3

8

69

10

14

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Item Designation

1 Cylinder stage 1.1


3 Cylinder 2nd stage

4 Safety valve 1st stage

5 Safety valve 2nd stage

6 Air filter

7 Oil fill pipe

8 Oil dipstick

9 Sump oil drain

10 Low oil pressure switch

11 Drain valve 1st stage

12 Drain valve 2nd stage

13 Compressed air temperature sensor

14 Cooling water stop valve

15 Motor

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Vertical sectional view

Item Designation

1 Crankcase

2 Crankshaft

3 Flywheel

4 Coupling

5 Connecting rod stage 1.1


7 Connecting rod 2nd stage

8 Lubricating oil supply

9 Compressor monitoring and control

2

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5

6

7

8

9

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Horizontal sectional view

1

4

7

1013

16

Stage 1.1

3

6

9

12

15

18

Stage 2

2

5

8 11

14

17

Stage 1.2

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Item Designation



3 Cylinder 2nd stage

4 Piston stage 1.1

5 Piston stage 1.2

6 Piston 2nd stage

7 Valve cover stage 1.1

8 Valve cover stage 1.2

9 Valve cover 2nd stage

10 Concentric valve stage 1.1

11 Concentric valve stage 1.2

12 Lamellar valve 2nd stage

13 Cooler stage 1.1

14 Cooler stage 1.2

15 Cooler 2nd stage



18 Connecting rod 2nd stage

19 Crankcase vent

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3.2 Functional description

Drive The Sauer Compressor is driven by an electric motor flange-mounted to the crankcase bell-housing. The power is transmitted by means of a flexible coupling.

Compressor control

Driven by an AC motor drive, the Sauer compressor is controlled and monitored by an electrical compressor control. This control system must comply with legal regulations. Optionally, J.P. SAUER & SOHN supplies a suitable compressor control.

Compression The compressor takes in the ambient air via a layered filter with a tube silencer and compresses it in two compression stages with a total of three single-stage cylinders to the final pressure, with the 1st stage consisting of two cylinders of the same design connected in parallel. The air in each cylinder is inter-cooled with cooling water. A replaceable wet liner with a double O-ring gasket is installed in each cylinder.The cylinders arranged in a W-configuration are equipped with concentric valves and with lamellar valves which are easy to maintain and have a long service life.

Cooling The compressor is cooled with fresh water. Cooling with sea water is available as an option.Inter-cooling of the compressed air in the 1st and 2nd stage takes place in the U-shaped cooling pipes which are press fitted via a cartridge version between the cylinder housing and cylinder cover.

The cooling pipe and the replaceable liners are directly immersed in cooling water in the cylinder. The cooling water spaces are protected by zinc anodes against corrosion. When at a complete standstill, the cooling water supply is interrupted by a solenoid valve at the cooling water inlet.The compressor cooling is monitored by a temperature sensor. The compressor is immediately stopped if the compressed air temperature exceeds the upper limit value.Optionally, the compressor can be fitted with a cooling water pump driven by its own electric motor.

Cooler pipe

Cylinder cover

Cylinder housing

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Condensate separation

Condensate which builds up in the 1st stage accumulates in the collecting vessels of the 1st stage cooler cover. The 2nd stage has its own condensate separator for the oil/water condensate, which collects during compression and inter-cooling.

Oil/water draining and pressure relief

Condensate is drained via drain lines. There are solenoid valves installed in the drain lines. The drain valves must be open when the Sauer compressor is unpressurised. A few seconds after starting, the drain valves should close and the compressor should power up against system pressure. The drain valves should drain the system during operation at preset intervals. The control of the drain valves (solenoid valves) is carried out by the compressor control.

Lubrication/Oil Pressure

A gearwheel oil pump, driven by the crankshaft, draws the lubricating oil from the crankcase, and then pumps it to the connecting rod bearings. Crankshaft main-end bearings, gudgeon pin bearings and pistons (final stage also receives a small amount of injected oil) are lubricated by oil splash or mist present in the crankcase. The oil pressure is monitored by a low oil pressure switch. The compressor control must stop the compressor immediately if the oil pressure falls to the limit value.

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3.3 Displays on the Sauer compressor

3

2

1

7Stage 1.1

Stage 2

Stage 1.2

4

5

6

Item Designation Display

1 Pressure gauge 1st stage Compressed air pressure after 1st stage

2 Pressure gauge 2nd stage Compressed air pressure after 2nd stage

3 Thermometer stage 1.1 Compressed air temperature after stage 1.1

4 Thermometer stage 1.2 Compressed air temperature after stage 1.2

5 Thermometer 2nd stage Compressed air temperature after 2nd stage

6 Oil pressure gauge Oil pressure of oil pump

7 Cooling water thermometer Temperature of cooling water

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3.4 Indicators and operating elements on the compressor control

On the front of the Compressor Control, the following indicators and control features can be found:

Note!If the compressor control is supplied by J.P. SAUER & SOHN read the documentation supplied.

Display/Operating element

Explanation

Signal lamp “Operation” Illuminates when the compressor is running.

Fault indicator lamp “Oil pressure”

Illuminates if the compressor has shut down because of low oil pressure.

Fault indicator lamp “Air temperature”

Illuminates if the compressor has shut down because of high outlet gas temperature.

Fault indicator lamp “Overcurrent”

Illuminates if the compressor has shut down because of excess motor current.

Run time counter Indicates the hours the compressor has run.

Operation mode selector

“Manual” mode:Starts the compressor manually. The compressor starts up and continues to run until it is manually turned off again.Selector position “0”:Turn the compressor off manually. Any pending fault messages are reset.“Auto” mode:The compressor starts and stops with the opening and closing of a remote contact (e.g. pressure switch at a compressed air vessel).

Main switch

Disconnects the power supply from the compressor control to the compressor. A main isolator switch should be installed if required by local law and regulations.

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4 Technical Specification

4.1 Specification data

Designation 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 100 mm

Maximum speed 1800 rpm

Direction of rotation (when looking toward flywheel)

clockwise

Maximum working pressure. 30 bar

Set pressures for safety valves:

1. stage 8 bar

2. stage 5 % above final pressure

Oil sump capacity 13.5 l

Oil refill quantity – dipstick MAX/MIN 5 l

Oil type see Chapter 10 “Lubricant Table”

Oil pressure switch:

Maximum switching current 6 A/220 V

Setting opens at 1 bar fallingapproximately 15 s delay on start instruction

Switch function Change-over contact

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Drain valves

Pickup and holding power 18 VA/14 W

Setting currentless openrelief starting: approx.15 secautomatic drainage: every 15 min for 15 s

Final pressure sensor (option):


Setting As required by customer


Air temperature switch:


Setting opens at 80 °C rising


Maximum permissible entry pressure at the cooling water inlet

5 bar without cooling water pump2.5 bar with cooling water pump

Bursting pressure of the burst discin the cooling water system:

> 6 bar

Cooling water temperature at the outlet 40 to 50 °C

Cooling water stop valve Holding power: 36 WValve is currentless closed

Cooling water pump (option):

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

Setting not self-priming, should start and stop in synchronisation with the compressor

Sound pressure levelfree field at 1 m

max. 92 dB(A)

Weight and dimensions See installation drawing

Designation Data

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Note!Please refer to the order-specific documentation of your compressor for data such as final pressure, speed, power requirements, etc.

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4.2 P&I Flow Diagram

Air intake

Compressed air outlet

Cooling waterinlet

Cooling wateroutlet

Condensate

M

M1.1 1.2 2

atm

31 12 10

45 6

14 15

16

30 29 3432 33

12 3 28

11 13 16217

8 9

17 1819

20

27 2625

2423

22

Drivelubrication

Filter

Suction filter

Inter-cooler

Separator

Solenoid valve

Safety valve

Non-return valve

Pressure relief valve

Oil pressure switch

Temperatureswitch

Pressure gauge

MotorMotor

Compressorstage

Pump

M

Temperature

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Item Designation Item Designation

1 Compression stage 1.1 22 Pressure relief valve

2 Compression stage 1.2 23 Drive lubrication

3 2. Compression stage 24 Oil filter

4 Cooler stage 1.1 25 Oil pump

5 Cooler stage 1.2 26 Oil pressure gauge

6 Cooler 2nd stage 27 Oil pressure switch / trip

7 Separator stage 1.1 28 Drive motor

8 Separator stage 1.2 29 Cooling water particle trap

9 Separator 2nd stage 30 Cooling water stop valve

10 Safety valve 1st stage 31 Cooling water thermometer

11 Safety valve 2nd stage 32 Cooling water pump (option)

12 Pressure gauge 1st stage 33 Motor cooling water pump

13 Pressure gauge 2nd stage 34Cooling water manual valve(only with optional cooling water pump)

14 Thermometer stage 1.1

15 Thermometer stage 1.2

16 Thermometer 2nd stage

17 Solenoid valve(drainage) 1st stage

18 Solenoid valve(drainage) 2nd stage

19 Intake air filter stage 1.1

20 Intake air filter stage 1.2

21 Non-return valve

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5 Transport and Installation

5.1 Transport

Shipping The machine is packed ready for shipping.• The Sauer compressor should be checked for completeness

and any damage immediately upon receipt.• Damage to the packaging or the machine should be reported

to the transport firm and J.P. SAUER & SON immediately.

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

Danger!Suspended load during transport. The forklift truck/crane must have sufficient load-bearing capacity.Ensure that no personnel are within the danger area of the suspended load and the forklift truck/crane.Sling the unpacked compressor using the four lifting eye bolts (see illustration). Raise, move into position and set down with care.

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Lifting eye bolts

Transport by crane

Lifting point

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5.2 Storage before InstallationIf the Sauer compressor has to be stored before installation, do not unpack, and store under the following conditions:– temperature: +5 to +40 °C;– relative humidity 30 to 95 %, non-condensing;– in a dry area, under a roof and protected from the weather;– protected from being soiled;– protected against vibration and shock.

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

Note!High pressure hoses can be stored for up to five years after delivery.

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5.3 Installation

For proper installation follow the installation instructions and observe the following.

Installation requirements

– The installation area must be dry and free from dust.– Ensure that the installation is ventilated in such a way that the

heat generated during operation is removed.– Room temperature during operation of the Sauer compressor:

+5 °C to +55 °C (If it is intended to operate the compressor outside this temperature range, please contact J.P. SAUER & SOHN).

– For proper installation, follow the installation instructions and observe the following conditions.

Note!If in doubt regarding the suitability of the intended installation area, please contact J.P. SAUER & SOHN. If required for the installation area, Sauer can provide help with the design of a ventilation system.

min. 5 °C

max. 55 °C

Note!The air temperature at the location where the compressor is installed must not exceed +55 °C. Conditions in the area of installation as well as the heat generated by the compressor and any other machines installed in the same area must be kept in mind.If necessary, install a ventilation or air extraction system in the area.Install the fresh air feed in such a way that the cooling air stream is never directed at the compressor. Otherwise, there is a danger that condensation will occur within the machine, with corresponding consequential damage.

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– At room temperatures below +5 °C the room must be heated or a heater must be installed on the Sauer compressor.

– The installation location must be selected in such a way that the Sauer compressor is easily accessible.

The cooling water spaces are automatically kept vented through the arrangement of the cooling water inlet and outlet.The quantity of cooling water must be set at a level such that the cooling water outlet temperature is between 40 °C and 50 °C. A maximum cooling water outlet temperature of 50 °C must not be exceeded.

Incorrect ventilationCorrect ventilation

40 °C

50 °C

Note!The Sauer compressor is cooled with fresh water.Seawater can be used for cooling if desired, but according to its temperature and chemical composition seawater can be very corrosive.

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Foundation

1. Check whether there are vibrations of the machine foundation in the 10 Hz range.

2. If in doubt, contact J.P. SAUER & SOHN in order to clarify whether a different anti-vibration mount can be used.

Note!J.P. SAUER & SOHN would be pleased to advise on the installation of the compressors.

Note!The standard delivery anti-vibration mount has a resonant frequency of approx. 10 Hz. Excitation of the compressor foundation by vibrations from other machines installed in the vicinity must not be in the 10 Hz range. Otherwise there is a danger that the standard anti-vibration mount could be destroyed by resonating vibration.

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5.4 Connecting the Compressor

Pipelines Compressed air outlet, cooling water inlet and outlet, and drainage connections of the Sauer compressor must be connected by hose connections to any of the system owner’s permanent piping.

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

High pressure hosefor compressed air

Hose linefor condensate

Hose linefor cooling water

Cooling waterconnection

Danger!At the compressor start-up and during drainage compressed air escapes from the drainage connections. Consequently, do not operate the compressor without hose lines connected.

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The hose lines must be installed free of tension and not twisted.

Drainage

Incorrect installationCorrect installation

Note!Accumulated condensate contains oil. It may only be disposed of in compliance with applicable legal regulations.J.P. SAUER & SOHN offers condensate collection containers for separating air from condensate as well as condensate processing systems for separating oil from condensate.

Note!We recommend connecting up the compressor drainage separately.If you wish to combine the drainage of several compressors, please observe the following:Choose a sufficient nominal diameter for the common drainage line;Connect the drainage lines of the individual compressors at a sharp angle to the common drainage line, so that no pressure can build up in the drainage line of a compressor that is not in operation.

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Incorrect connectionCorrect connection

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Connections The illustration below shows the connections and the fittings for the operation of a typical Sauer compressor.

21 3 4

567

8

9

Item Designation Type Function

1 Drive motor AC motor Compressor drive

2 Non-return valve Plate valve Prevent air flowing back

3 Final pressure switch

Change-over switch

Start/stop control for the compressor

4 Safety valve Spring-loaded safety valve

To limit excessive pressure on the parts subjected to pressure

5 Drainage valve Solenoid valve Start relief and drainage

6 High air temperature switch

Change-over switch

Switch off compressor if temperature is too high

7 Oil pressure switch

Change-over switch

Switch off the compressor if oil pressure is too low

8 Cooling water stop valve

Solenoid valve Prevent flow of cooling water when machine is not operating

9 Cooling waterpump (option)

Centrifugal pump, not self-priming

Circulate cooling water

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Note!For technical specifications of the individual items, please refer to Chapter 4.All change-over switches are factory adjusted.If desired, the components are supplied pre-wired to a terminal box.

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5.5 Filling with oilThe Sauer compressor is delivered without oil.

1. Unscrew the oil fill cap (red).2. Pour in oil and check the oil level with the dipstick (red).

3. Replace the dipstick and screw the oil fill cap back in.

Dipstick

Oil fill cap

Danger!Make sure to fill the crankcase of the compressor with oil before initial operation! Use an appropriate lubricating oil (see Chapter 10 “Lubricant Table”). Note the amount of oil needed (see Chapter 4 “Technical Specification”).

Note!Only fill with oil up to the upper level gauge mark on dipstick.Overfilling increases the oil consumption of the compressor.

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5.6 Checks to be carried out after installation and before the first start-up.

– Check that the electricity connection matches the data on the nameplate.

– Check that all connections between the compressor and the compressed air equipment are properly installed.Pay particular attention to the compressed air connection.

– Are the drainage lines properly connected?– Are the cooling water lines open?– Has the crankcase been filled with oil?– Have all tools and foreign objects been removed from the

compressor?– Is the entire unit clean?

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6 Operation

6.1 Safe operation

Danger!Only authorised persons are permitted to put into operation and operate the Sauer compressor!

Danger!Only switch on and start the compressor whenit has been checked that it is in perfect condition;all tools and foreign objects have been removed from the machine.

Danger!Immediately turn compressor off if personnel and property are endangered. Only re-start compressor when there is no more danger or possible damage.

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

Danger!Risk of burns from touching hot surfaces of the compressor during operation. Wear protective gloves.

Danger!Risk of hearing damage because of the sound pressure level while the compressor is running! Wear hearing protection near the compressor.

Note!Switch compressor off in the event of any abnormal/fault conditions or unexpected events. Eliminate the cause of the problem with the help of Chapter 7 “Troubleshooting.”

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6.2 Operating modesAfter you have turned on the power supply to the Sauer compressor, it can be started with one of the following two operating modes using the mode selector switch: – “Manual” operating mode:

The compressor starts and continues to run until it is stopped or turned off either by using the mode selector switch or the main switch.

– “Automatic” operating mode: Starting and stopping the compressor is controlled by external devices (for example using the pressure switch of the pressure vessel).

When the Sauer compressor starts, it starts without load with the drainage valves open. After a few seconds the valves close and the compressor powers up against system pressure.

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6.3 Initial operation

Check the direction of rotation

Allow the Sauer compressor to run only for a few seconds to check the direction of rotation.1. Switch the power supply on.2. Set the mode selector switch to “Manual” to start the

compressor in manual mode.3. Immediately check the compressor’s direction of rotation. It

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

4. Set the mode selector switch to “0” to stop the compressor.5. Switch off the power supply.6. If the direction of rotation is incorrect, the polarity of the

electric motor should be changed by a qualified electrician.

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

Danger!If the crank shaft rotates in the wrong direction, no oil pressure builds up. Risk of subsequent damage.

Danger!The cooling water pump must not be allowed to run dry.

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Test run 1. Switch the power supply on.2. Set the mode selector switch to “Manual” to start the

compressor in manual mode.If correctly adjusted, the drain valves should close after about 15 seconds and the compressor should power up against system pressure.

3. Check the pressure gauges of each stage as well as the oil pressure gauge and compare readings with the nominal values (see Chapter 6.4 “Routine Operation”).

4. Check the function of the automatic drainage.It is required to drain for about 15 seconds every 15 minutes. This is indicated by a drop in pressure on the pressure gauge.

5. Check that cooling water is flowing.The temperature of the cooling water at the outlet must stay within the range given in the “Data table” in Chapter 4.1. The temperature can be read from the cooling water thermometer at the cooling water outlet. If these temperatures are exceeded or not reached the flow of cooling water must be increased or decreased accordingly.In the case of machines with an integrated cooling water pump, the flow rate can be regulated with the slide on the pump.

6. Set the mode selector switch to “0” to stop the compressor.7. Switch off the power supply.8. If necessary eliminate the cause of deviations from nominal

values and malfunctions. See also Chapter 7 “Troubleshooting”.

9. Complete the commissioning certificate and send it to J.P. SAUER & SOHN Customer Service. The commissioning certificate is in the Appendix.

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6.4 Routine operation

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

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

necessary. Do not overfill with oil beyond the maximum mark.

Operation 1. Switch the power supply on.2. Open the cooling water lines.3. Set mode selector switch to “Auto“ to operate the compressor

in Automatic mode.

Watch out for • Abnormal operating noise.• Pay attention to leaks (compressed air, oil, condensate). The

temperature of the cooling water at the outlet must remain within the area shown in the “Data table” in Chapter 4.1.

• The pressure indicated on the pressure gauge must remain within the grey zone in the stage pressure diagram (see below).

• The oil pressure should be between 1.8 bar and 4 bar. In the event of deviations, see Chapter 7 “Troubleshooting”.

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Stage pressure diagram 1st stage

2nd S

tage

[bar

]

1st Stage [bar]1 2 3 4 5

10

20

30

6

Note!Depending on the desired final pressure in the 2nd stage, the allowable pressure for the 1st stage can be read from the above diagram.

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7 Troubleshooting guide

Note!Should a malfunction occur, first check the ’User Interface’ on the compressor Control Panel and on the compressor.Try to correct the fault with the help of the table below.If the fault cannot be corrected, please contact J.P. SAUER & SOHN Customer Service. The fault description journal is in the Appendix of this Operator Manual.

Fault Probable cause RemedyCompressor does not start or switches off.

No input power supply/no control voltage.

Check the fuses. Replace blown fuses.

Compressor was switched off because the oil pressure cutout switch tripped.

Oil level too low. Check oil level and top up if necessary. Check for leaks.

Oil too viscous. Fill with recommended oil.Check that room temperature is > + 5°C.

Oil filter blocked. Clean the oil filter.

Oil pipe blocked. Clean oil pipe.

Oil pump faulty or leaking. Check oil pump. If necessary eliminate leak or replace oil pump.

Compressor was switched off by overcurrent relay.

Excessive current drawn. Check supply voltage and electrical connections. The compressor can be started again after a cooling down period.

Check whether the crankshaft can easily be turned by hand. If not, disconnect and ascertain whether the problem has to do with the motor or the compressor.

Piston seizure Check cylinders and pistons for any score marks, replace as necessary.

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Safety valve of 1st stage blows off:

Pressure exceeds blow-off pressure (8 bar)

2nd stage valve is not working properly.

Check the valve of the 2nd stage and replace if necessary.

Gasket between suction and pressure side of the 2nd stage is faulty.

Replace gasket.

Pressure below blow-off pressure (8 bar)

Safety valve is faulty. Replace safety valve.

Safety valve of 2nd stage blows off:

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

Valve in the air line to the compressed air vessel is closed.

Open valve.

Pressure switch is set too high.

Lower the pressure setting.

Excessively high pressure losses in the air line to the compressed air vessel.

Reduce the pressure losses.

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

Safety valve is set too low or is faulty.

Replace safety valve.

Pressure gauge of the 1st stage is showing excessive pressure.

Valve of the 2nd stage is leaking.

Check the valve of the 2nd stage and replace if necessary. Replace gaskets.

Pressure gauge of the 1st stage is showing insufficient pressure.

Valve of the 1st stage is leaking.

Check the valve of the 1st stage and replace if necessary.

Air filter very dirty. Clean the air filter insert or replace it.

The pressure gauges of all stages show no pressure.

No power at solenoid drainage valve.

Check solenoid valve power supply.

Solenoid valve of the drainage is faulty.

Check the solenoid valve and replace it if necessary.

Air escaping from the compressed air lines.

Connection gaskets or seals leaking.

Replace faulty gasket or seal.

Cutting rings leaking. Switch compressor off. Wait until all parts are no longer under pressure; check the pressure gauge for this. Tighten all screws.

Fault Probable cause Remedy

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Compressor was switched off, temperature switch has tripped.

Compressed air temperature at the outlet too high as a result of shortage of cooling water.

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

Compressed air temperature at the outlet too high because of poor thermal transition in the cooler as a result of scaling in the chamber.

Clean the cooling water containers with a descaling agent.

Solenoid valve (drainage) valve does not close.

No power supply. Check fuses, replace blown fuses.

Solenoid faulty. Replace solenoid.

Foreign matter in solenoid valve.

Replace solenoid valve.

Cooling water stop valve does not open.

No power supply. Check fuses, replace blown fuses.

Solenoid faulty. Replace solenoid.

Foreign matter in solenoid valve.

Replace solenoid valve.

Abnormal compressor noise.

Connecting rod bearing faulty. Check connecting rod bearing, replace if necessary.Check oil supply.

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

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

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

Oil leaking from crankcase. Gasket or shaftseal faulty. Screws not tight.

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

Water escaping at the relief groove of the cylinder flange surface.

O-ring of the liner is faulty above the relief groove.

Replace O-ring.

Oil escaping at the relief groove of the cylinder flange surface.

O-ring of the liner is faulty below the relief groove.

Replace O-ring.


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Water in the oil Excessive cooling of compressor due to- flow of cooling water too high- unfavourable room

ventilation- very short compressor

running time

Reduce flow of cooling water. Change room ventilation so that air stream is not blown directly against compressor. Extend compressor running time

Poor drainage. Check drainage lines and drainage intervals.

Burst disc in the cooling water circuit triggersORCooling water safety valve triggers.

Leaks in cooler. Replace cooler insert.

Pressure peaks in the cooling water circuit cause the burst disc bursting pressure or the safety valve preset pressure to be exceeded.

Determine the cause of the pressure peaks and eliminate these causes (startup of additional pumps, actuation of electromagnetic stop valves or shuttle valves, or similar causes)

Premature fracture of valve plates, valve springs or valve plates

Poor drainage. Check drainage lines and drainage intervals.

Note: Indentations in the gasket contact surface of the valve plate are normal.


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Maintenance

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8 Maintenance

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

8.2 Safety during maintenance

Before maintenance work

1. Interrupt power supply to the compressor.2. Fit 'Warning: maintenance work' warning sign to power

supply.3. Shut off the compressor and secure to prevent restarting.

Danger!Risk of injury due to incorrect operation!Only authorised personnel are permitted to service and adjust the Sauer compressor!

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

Danger!Risk of injury due to pressurised components! Before undertaking any maintenance work, use pressure gauge to ensure that there is no more pressure in the compressor.

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

for your own safety!– The mains isolator remains energised, even when it is turned

OFF.– Components being worked on should only be energised if this

is explicitly specified.

Danger!Danger of death if there are no safety devices or no isolating protection devices! After undertaking servicing work, always refit all safety devices and isolating protection devices. This also applies to electrical protection devices.

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8.3 Maintenance schedule

Use of the maintenance schedule

• Use the maintenance schedule as a master template or copy the relevant page from the digital document and save it as a separate file under a suitable name. Use the maintenance schedule as a guide and for verification.

• Regularly check the maintenance schedule to see which maintenance intervals are due depending upon the number of operating hours. The intervals are shown in the table's column headers.

• Check the column for each maintenance interval to see which maintenance work is to be carried out at the end of the maintenance interval. The required tasks are indicated by checkboxes. A description and the section number of the tasks are shown in the first column.

• Carry out all maintenance tasks for a maintenance interval and tick the appropriate check boxes of the maintenance schedule. Then enter hours of operation, date and signature.

• When beginning a new maintenance schedule:– enter: maintenance schedule number, date and hours of

operation, main specifications and date of commissioning;– mark with a cross: beginning of this maintenance

schedule following commissioning or following the last maintenance routine.

Danger! Whenever undertaking maintenance work, observe section 8.4, 'Table of tightening torques', for particular bolts.Note!The maintenance intervals specified in the maintenance schedule must be observed. Shortening the maintenance intervals is of no advantage with regard to the operating performance or service life of the Sauer compressor.Note!After the final maintenance routine, the maintenance schedule starts from the beginning.

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Maintenance Schedule No. Compressor type WP400Beginning of this maintenance schedule

Type series 2W

❑ after commissioning Compressor number:

❑ after last maintenance routine Factory no.:

Date: Year of construction:Hours of operation: Date of commissioning:

Interval[hours of operation]

50 h

afte

r co

mm

issi

onin

g50

h a

fter

last

mai

nten

ance

rout

ine

or re

pair

At l

east

ann

ually

at

< 1

000

h

1000

h

200

0 h

3000

h

4000

h

Maintenance work

Maintenance set item no.06

9234

0692

35

0692

34

0692

36

Check screwed connections, section 8.5 ❏ ❏Replace air filter cartridge, section 8.6 ❏ ❏ ❏ ❏ ❏Carry out oil change, section 8.7 ❏ ❏ ❏ ❏ ❏ ❏ ❏Clean oil strainer, section 8.8 ❏Check 1st-stage valves, section 8.9 ❏ ❏Replace 1st-stage valves, section 8.10 ❏ ❏Replace 2nd-stage valves, section 8.10 ❏ ❏ ❏ ❏Replace 1st-stage piston rings, gudgeon pins and gudgeon pin bearings, section 8.12

❏

Replace 2nd-stage piston rings, gudgeon pins and gudgeon pin bearings, section 8.12

❏

Check piston and cylinder, section 8.13 ❏Renew flexible gear rim, section 8.16 ❏Check condensate separator, section 8.17 ❏Overhaul drain valves (as per order), section 8.18

❏

Clean particle trap, section 8.19 ❏ ❏ ❏ ❏Replace zinc protection (freshwater operation), section 8.20

❏

Replace bursting disc, section 8.21 ❏ ❏ ❏ ❏Check cooling water pump, section 8.22

Hours of operationDateSignature (initials)

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8.4 Table of torques

8.5 Checking screwed connectionsCheck all unions and screwed connections for tightness and re-tighten if necessary. This relates to:– cooler and air lines;– unions on pipe and hose lines;– cylinder heads;– cylinders;– electric motor;– measuring and switching devices;– bearing; and– accessories and equipment parts.

8.6 Replacing air filter cartridge

Screw(s) Torque

Connecting rod screws 115 Nm

Flywheel fastening screw 550 Nm

Valve cover nuts (1st/2nd stage) 82 Nm

Bursting disc flange 54 Nm

Valve retaining screw 9 Nm

Air filter cap

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1. Open clips and take air filter cap off.2. Remove used cartridge.3. Clean filter housing with a suitable solvent and wipe out with

a lint-free cloth.4. Insert new cartridge into air filter.5. Put on cap and close clips.

8.7 Changing the oil

Note!Use oil according to the lubricant table (see section 10).

Oil filler cap

Dipstick

Oil drain valve cap

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1. Run compressor for approx. 15 minutes until operating temperature is reached.

2. Place drip tray (of a capacity sufficient to hold the complete oil filling quantity, 13.5 l) below the oil drain valve.

3. Unscrew oil filler cap and oil drain valve cap, open oil drain valve and pull out dipstick.

4. Wait until all oil is drained.5. Close oil drain valve and screw on cap.6. Top up oil and check level with the dipstick.✓ The level should be between the upper and lower marks on

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

8.8 Cleaning the oil strainer1. Unscrew nuts on inspection hole cover.2. Take off inspection hole cover.3. Unscrew union on oil strainer.4. Take out oil strainer.5. Wash out oil strainer in a suitable solvent.6. Carefully clean sealing surface for inspection hole cover

gasket.7. Position inspection hole cover with new original Sauer

gasket.8. Tightly refasten oil strainer.9. Tighten nuts on inspection hole cover.

8.9 Checking the valves

Removing valves 1. Loosen clamp on air filter and take out air filter.2. Loosen unions and hose lines at the valve covers.3. Undo valve cover screws and take off valve covers. Prise off

using the screws if necessary.4. Carefully take out 1st-stage valve.5. Undo valve retaining screw and take out 2nd-stage valve.

Note!When removing and installing a valve, take care that no valve parts are damaged. This particularly applies to the sealing surfaces.

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Checking valves 1. Check valves externally for:damage,carbonisation,oiling,corrosion andmoisture.Replace damaged, severely carbonised or corroded valves.Determine cause (see section 7, 'Troubleshooting').

2. Clean all sealing surfaces.

Removing valves

1. Install valves and valve covers. Insert new O-rings (see illustrations).

2. Attach 1st-stage valve cover. Fasten all screwed connections hand-tight.

Note!Refit all valves with new gaskets and rings only. Only use original Sauer spare parts. Installing other gaskets may lead to compressor leaks and damage.

Note!Never reuse old rings. This may lead to leaks.

O-ring1st stage

Gasket

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3. Fasten valve to valve cover using valve retaining screw.4. Attach 2nd-stage valve cover. Fasten all screwed

connections hand-tight.5. Fasten valve cover nuts tightly. Observe tightening torques

(see section 8.4).6. Attach unions and hose lines to the valve covers.7. Mount air filter and tighten clamp.

8.10 Replacing valvesRemove and install valves as described in section 8.9, 'Checking valves'. Replace complete valve.

O-ring

2nd stage Valve retaining screw

Note!Valves whose service life has expired must be replaced and disposed of.Due to material fatigue, we recommend that used valves not be repaired.

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8.11 Draining the cooling water

1. Block the cooling water inlet and outlet.2. Remove the hoses for the cooling water inlet and outlet from

the cylinders.3. Unscrew the drain plugs and drain the cooling water.

8.12 Replacing piston rings, gudgeon pins and gudgeon pin bearings

1. Remove valve covers and valves as described in section 8.9, 'Checking the valves'.

2. Remove cylinder base nuts.3. Remove cylinder. Grab and hold the piston before you have

completely removed the cylinder.

Drain plug

Note!If you do not hold the the piston while you remove the cylinder, it will collide with the crankcase.

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1st stage 4. Remove valve covers and valves as described in section 8.9, 'Checking valves'.

5. Dismantle the inspection hole cover from the crankcase.6. Remove connecting rod bolts and remove connecting rod

bearing cover with bearing bush. 7. Push piston together with connecting rod upper part out of the

cylinder.8. Remove all piston rings from the pistons and clean pistons.

9. Fit piston rings in the respective piston.

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

✓ It must be possible for the connecting rod bolts to be fully screwed in by hand. This is the only way of ensuring that they are seated correctly on the crankshaft. The connecting rod must be able to rotate easily on the crankshaft once

Note!Replace all piston rings with new ones! The following damage may occur on removal of the piston rings:• the edges of the piston rings may be damaged on the wearing

edges in the cylinder; • fine cracks which can lead to material fracture may appear if

the piston rings are bent up repeatedly.

Note!Use an assembly sleeve for pushing the piston into the liner from above (see section 11, 'Spare parts and accessories').

Note!Figures are hammered into the upper and lower sections of the connecting rods. They must match. See illustration.

22

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tightened.11. Tighten connecting rod bolts; see tightening torque in section

8.4.

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

2. Loosen both unions and dismantle the compressed air line from the cylinder of the 2nd stage to the final separator.

3. Block the cooling water inlet, remove the drain plug located below on the cylinder of the 2nd stage and drain the cooling water.

4. Loosen screwed pipe connections on the cylinder and dismantle cooling water inlet pipe. The screw connection nipple remains on the cylinder.

5. Unscrew the cooling water hose line between the 1st and the 2nd stage and remove.

6. Dismantle both the inspection hole covers from the crankcase.

7. Loosen the connecting rod bolts and remove them from the crankcase together with bearing cover. Push the connecting rod upper part with the piston up in the cylinder.

8. Loosen the four nuts at the base of the cylinder of the 2nd stage.

9. On both sides of the cylinder unscrew the two M10 × 25 upper retaining screws on the cooler cover and replace with M10 × 100 screws. Attach a suitable hoist to the screws and pull the cylinder sideways out of the crankcase (weight: approx. 100 kg).

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

11. Put cylinder down at the side and pull connecting rod with piston down from the cylinder.

12. Remove all piston rings from the pistons.

13. Sequence of assembly is exactly opposite to that of dismantling. Replace the screws on the cooler covers on both sides of the cylinder with the M10 × 25 retaining screws.

Note!Replace all piston rings with new ones! The following damage may occur on removal of the piston rings:• the edges of the piston rings may be damaged on the wearing

edges in the cylinder; • fine cracks which can lead to material fracture may appear if

the piston rings are bent up repeatedly.

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

✓ It must be possible for the connecting rod bolts to be fully screwed in by hand. This is the only way of ensuring that they are seated correctly on the crankshaft. The connecting rod must be able to rotate easily on the crankshaft once tightened.

15. Tighten connecting rod bolts; see tightening torque in section 8.4.

16. Install new piston rings in the respective pistons. Make sure they are in the correct positions: piston rings with asymmetrical cross sections are marked on one of the surfaces with 'TOP'. During installation this face must face upwards (see illustration).

Note!Figures are hammered into the upper and lower sections of the connecting rods. These must match in any case (see illustration).

22

TOP

2nd stage1st stage

TOP

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8.13 Checking pistons and cylinders1. Remove cylinder heads and valves as described in section

8.9, 'Checking valves'.2. Remove cylinders and pistons as described in section 8.12,

'Replacing piston rings'.3. Check cylinders and pistons for scoring and heavy wear and

tear marks. Replace relevant parts.

4. Check wear limits as described in section 8.14, 'Wear limits for cylinder diameters'.

5. Install cylinders and pistons as described in section 8.12, 'Replacing piston rings, gudgeon pins and gudgeon pin bearings'.

6. Install valves and cylinder heads as described in section 8.9, 'Checking valves'.

8.14 Wear limits for cylinder diameters1. Measure cylinder and replace if the following wear limits are

exceeded:

8.15 Checking coupling

Note!If the piston running surface in the cylinder reveals perceptible wearing edges, the edges must be broken up with a honing brush or Scotch-Brite abrasive cloth. Otherwise the edges will damage the new piston rings on installation of the pistons.

Cylinders Wear limit of diameter

1st stage 195,15 mm

2nd stage 110,15 mm

Note! This applies to Sauer compressors with electric motors.

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Visual inspection

1. Remove the electric motor from the copmressor as described in section 8.16, 'Renewing flexible gear rim'.

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

'Renewing flexible gear rim'.

8.16 Renewing flexible gear rim

Renewing flexible gear rim

1. Support compressor under the coupling bell housing.2. Remove the electric motor mounting screws.3. Carefully lift the electric motor using the lifting eyes (see

section 5.1, 'Transport').4. Carefully pull the electric motor away from the compressor.5. Replace flexible gear rim.6. Carefully slide electric motor against the compressor and

tighten the motor mounting screws.7. Remove support from under the coupling bell housing.

8. Reinstall separated connecting lines and pipes.

Note! This applies to Sauer compressors with electric motors.

Flexible gear rim

Motor Compressor

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8.17 Inspecting the condensate separator

1. Remove pipes and check separator for obstructions.

8.18 Overhauling water drain valves

1. Unscrew hexagon nut.2. Carefully lift up plastic threaded part with the screwdriver.3. Remove coil from armature.4. Unscrew the four Allen screws.5. Remove upper section of valve.6. Replace following parts:

conical spring, diaphragm and two O-rings.

Hexagon nut

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7. In case of severe soiling: clean nozzle.8. Position upper section of valve.9. Tighten the four Allen screws.10. Place the coil on the armature.

11. Correctly position the plastic threaded part and press onto the armature.

12. Carefully position hexagon nut by hand and screw on.13. Lightly tighten hexagon nut using a spanner.

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

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

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

8.21 Replacing the bursting disc1. Drain the cooling water.2. Undo the screws and remove the pressure flange on the

cylinder of the 2nd stage.3. Remove the bursting disc and ring.4. Clean the sealing surfaces.5. Install a new ring and new bursting disc. Check that the

gasket is correctly installed. Fit first the gasket and then the bursting disc into the cylinder.

6. Screw on the pressure flange; see tightening torque in section 8.4.

Note!The coil and the armature must always be dry.

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8.22 Checking the cooling water pump

The cooling water pump should be checked as follows in case of abnormal running sound or leaks:

Removing the pump

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

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

outlet of the pump. Remove rings and clean sealing surfaces.5. Loosen the bolted fastening of the pump at the foot and

remove pump from the console.

Replacing the floating ring seals

The floating ring seals are maintainance-free. In case heavy leakages are noticed after a long running time, the floating ring seal is to be replaced as a complete unit.

6. Remove impeller and shaft retaining ring.7. Pull the entire floating ring seal with the cap out from the

shaft.

8. Carefully slide new floating ring seal on to shaft with a rotating motion.

Note!The cooling water pump is an optional component and is not supplied as a standard component.

Note!Note the diagram of the pump in the Spare Parts Catalogue.Please refer to the operating instructions provided by the pump manufacturer.

Note!The floating ring seals are delicate elastomers and must not come into contact with grease or oil.Avoid touching them with your fingers (use clean gloves or cloth).Do not soil or damage floating ring seals.Moisten the gaskets with low surface tension water to facilitate assembly.

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

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Mounting the pump

1. Assemble the pump back in the reverse sequence. Insert new flange gaskets.

2. Fill pump and suction pipe completely with cooling water.3. Connect electrical connection.

Checking the direction of rotation

Briefly switch on pump motor. The motor must not reach its operating speed during this. The direction of rotation must be the same as the one indicated by the arrow on the pump housing.

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Storage, Preservation – “lay-up” procedure

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9 Storage, Preservation – “lay-up” procedure

9.1 Safety when storing and removing

Danger!The compressor shall only be removed and “laid up” by trained specialists of the owner. These specialists must be familiar with the protection devices and regulations before starting the work. Any work on the electrical installation must be carried out by qualified electricians only.In addition, information contained in suppliers’ documentation must be observed.

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9.2 Temporary preservation and storageIf idle, every 4 weeks perform a test run for at least 30 minutes. Additional corrosion prevention measures are not required.When the Sauer compressor is to be laid up for more than 12 weeks, preservation with a preservation oil is recommended. When preservation is completed, periodic test runs are not needed.

1. Run compressor for approx. 5 minutes with drain valves and final pressure line open.Any existing oil/water is removed.

2. Blow out compressor oil and dispose of in an environmentally safe manner.

3. Fill with about 10 litres of preservation oil. 4. Start compressor and run for approx. 5 minutes with drain

valves and final pressure line open.5. Stop compressor.6. Unscrew both air filters on the 1st stage cylinder head.7. Start compressor and slowly inject approx. 100 to 125 cm3 of

preservation oil into each of the 1st stage intake fittings.

Note!Use one of the preservation oils recommended in Chapter 10 “Lubricant Table” for corrosion protection.The preservation oil has satisfactory running properties. In an emergency the machine can be started for a short duration when filled with preservation oil.

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8. Remove hexagon head screw on the 2nd stage valve cover.9. Slowly inject about 100 to 125 cm3 of preservation oil into the

opening.10. Wait until oil mist comes out of the final pressure line.11. Stop compressor.12. Reattach both air filters on the 1st stage cylinder head.13. Screw the hexagon head screw on the 2nd stage cover back

in.14. If necessary, put up a sign that the compressor was

preserved and taken out of service.15. If necessary, disconnect mains supply cables.

Putting back into service

1. If necessary, connect the mains supply cables.2. Drain preservation oil and pour in compressor oil as

described in Chapter 5.6 “Filling with Oil”.3. Follow the instructions given in Chapter 6.3 “Initial

Operation”.

Oil

Intake fittings

Hexagonscrew

Oil

2nd stage

Oil

Stage 1.2

Stage 1.1

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9.3 Disassembly

Follow these steps for disassembly:

1. Turn compressor off and disconnect from power supply.2. Read the gas pressure display to ensure that the compressor

is completely depressurised.3. Disconnect the mains supply cables.4. Remove oil and lubricants and dispose of in an

environmentally safe manner.5. Drain any remaining condensate and dispose of in an

environmentally safe manner.

Disposal

Material/system component Disposal method

Lubricants as hazardous waste

Steel/iron as metal scrap

Electric cables as hazardous waste

Electronic components as scrap electronic waste

Plastics as hazardous waste

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10 Lubricant tableScope The lubricant table applies to all Sauer compressors which are

designed to compress air.The lubricant table does not apply to– Sauer compressors designed to compress neutral gasses;– temperatures outside the 5 to 55 °C range.

General recommendation

For temperatures lying within the 5 to 55 °C range we recommend mineral oil meeting the ISO VG 100 viscosity grade. At minimum, the lubricating oil should correspond to the group VCL as per DIN 51506 .Two-stage water-cooled compressors may cause premature soiling of the valves due to the high compression temperatures combined with unfavourable ambient conditions or inferior types of oil. Use another oil in such cases or carry out maintenance at shorter intervals.

Note!The recommended types of oil reduce the level of coking in the compressor valves and the upstream pipe lines and fittings to a minimum.Lubricants which are not listed in the lubricant table may only be used after approval has been given by J.P. SAUER & SOHN. Otherwise the guarantee is made void.Please contact our Customer Service when selecting oils not listed, or if operating conditions differ from those recommended.

Note!Unless otherwise ordered, Sauer compressorsare delivered without oil.

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10.1 Lubricating oilsThe following mineral oils ma be used in Sauer compressors; Shell Corena P 100 mineral oil is the standard type used to fill and operate the unit.

Brand Product name GroupAgip Diesel Gamma 30 VCL-100

Dicrea 100 VDL-100Acer 100 VCL-100Motor Oil HD 30 SAE 30Cladium 50 SAE 30

ARAL Kowal M30 VCL-100

AVIA Avilub compressor oil VDL-100 VDL-100

BP Energol RC 100 VDL-100Energol IC-DG 30 VCL-100Vanellus C3 SAE 30 SAE 30Aircol PD 100 VDL-100

CHEVRON HD Compressor Oil 100 VDL-100Delo 1000 Marine 30 SAE 30Veritas 800 Marine 30 SAE 30

ESSO Rarus 426 VDL-100Rarus 427 VDL-100Mobilgard 300 SAE 30Mobilgard 312 SAE 30Delvac 1230 SAE 30

Shell Corena P 100 VDL-100Rimula X 30 SAE 30Melina S Oil 30 SAE 30Melina Oil 30 SAE 30Gadinia Oil 30 SAE 30

TEXACO Compressor Oil EP VDL 100 VDL-100Regal EP 100 VCL-100Ursatex 30 SAE 30Veritas 800 Marine 30 SAE 30

TOTAL Dacnis P 100 VDL-100Disola M 3015 SAE 30

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The following mineral oils may alternatively be used without restriction in marine applications:

10.2 Preservation oilsThe standard oil used by Sauer for compressor preservation is Mobilarma 524.Alternatively, the following preservation oils can be used:

Brand Product name GroupNATO classified O - 278 VDL-120NATO classified OMD 113 VDL-100

Brand Product name

Agip Rustica C SAE 30

ARAL Konit Motoröl SAE 30

AVIA MK 1540 S

BP MEK 20 W-20

DEA Deamot EKM 642 SAE 30

Esso MZK HD 30 motor oil

Antirust MZ 110

Mobil Mobilarma 524

Shell Ensis Motor Oil 30

Note!The product name may vary by country.

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11 Spare Parts and Accessories

J.P. SAUER & SOHN guarantee the complete spare parts supply over the entire service life of the Sauer compressor. Our genuine Sauer spare parts are subject to constant quality control and further development. They conform to the latest technical developments.In addition to genuine Sauer spare parts, our range of supply includes many accessories for your Sauer compressor as well as special equipment for your entire compressed air system, including:– Fully automatic controls;– Adsorption dryers;– Refrigerant type dryers;– Filters;– Sound-dampening enclosures;– Compressed air vessels;– and fittings.We supply instructions and a maintenance manual for each accessory.

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

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Spare parts catalogue

The spare parts catalogue is in the Appendix to this Operator Manual. – The required parts can be quickly found with the help of

diagrams, illustrations and lists.– The spare parts catalogue and Operator Manual are also

available on CD-ROM. This makes it easy to fill out an order form, print it out and send it in immediately. To do so, you need the main specification of your Sauer compressor from the table below. If the data has not yet been entered, it can be found on the nameplate affixed to the crankcase.

You should additionally indicate the number of operating hours.

Compressor type:

Factory no.:

Year of construction:

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12 AppendixThis Appendix to the operating instructions contains– Form for commissioning certificate;– Form for Return of Goods / Notification of Claim;– Supplier documentation;– Data sheets.

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Commissioning certificate for compressors J.P. SAUER & SOHNMaschinenbau GmbH

Brauner Berg 15 - 24159 Kiel, Phone: +49 - 431- 39 40 - 0Fax: +49 - 431- 39 40 - 89

E-mail:[email protected]

Purchaser Owner Installation siteCompany CompanyStreet StreetPostcode PostcodeContact ContactPhone number Phone numberCustomer numberOrder numberCompressor type Serial no.Delivery date Operation hoursDate commissionedSauer service engineer Company/Name

Company/NameCompany/NameCompany/Name

Installation of compressor/complete system Check of rotational direction

Good Faults Compression temperature

°C

Ventilation Suction temperature °C Good Faults Start/stop pressure

Ambient conditions Oil level check Good Faults Control system check

Voltage? Test run Good Faults

Vibration behaviour of compressor Good Faults

Accessories Installation of complete system carried out by:Compressed air vesselsRefrigerant type dryersAdsorption dryers Good FaultsFilterCondensate removalOperating personnel have received instruction and are familiar with the safety and maintenance requirements.The maintenance instructions are available to the owner.The operating company has been advised to use only genuine SAUER & SOHN spare parts.Notes / Faults:

The system has been accepted by the owner. City: Date:

Purchaser Owner Authorised Sauer Service Partner

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Return of goodsNotification of claim

Date:

J.P. SAUER & SOHNMaschinenbau GmbHBrauner Berg 15 - 24159 Kiel, GermanyPhone: +49 - 431- 39 40 - 0Fax: +49 - 431- 39 40 - 89E-mail: [email protected]

To b

e co

mpl

eted

by

man

ufac

ture

r

Manufacturer: Please always complete:Company Compressor type:StreetPostcode/CityCustomer no. Serial no.:LocationEnd customer: Operation hours:CompanyStreet Date of fault:Postcode/CityCustomer no. Ambient temperature:LocationSpare parts Reason for returnDesignation Quantity Part no. Report on fault

RepairChecking as customer serviceGoods taken back against credit note

Short description of fault:

To b

e co

mpl

eted

by

man

ufac

ture

r onl

y Report

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Appendix
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Maintenance Schedule No. Compressor type WP400Beginning of this maintenance schedule

Type series 2W

❑ after commissioning Compressor number:

❑ after last maintenance routine Factory no.:

Date: Year of construction:Hours of operation: Date of commissioning:

Interval[hours of operation]

50 h

afte

r co

mm

issi

onin

g50

h a

fter

last

mai

nten

ance

rout

ine

or re

pair

At l

east

ann

ually

at

< 1

000

h

1000

h

200

0 h

3000

h

4000

h

Maintenance work

Maintenance set item no.06

9234

0692

35

0692

34

0692

36

Check screwed connections, section 8.5 ❏ ❏Replace air filter cartridge, section 8.6 ❏ ❏ ❏ ❏ ❏Carry out oil change, section 8.7 ❏ ❏ ❏ ❏ ❏ ❏ ❏Clean oil strainer, section 8.8 ❏Check 1st-stage valves, section 8.9 ❏ ❏Replace 1st-stage valves, section 8.10 ❏ ❏Replace 2nd-stage valves, section 8.10 ❏ ❏ ❏ ❏Replace 1st-stage piston rings, gudgeon pins and gudgeon pin bearings, section 8.12

❏

Replace 2nd-stage piston rings, gudgeon pins and gudgeon pin bearings, section 8.12

❏

Check piston and cylinder, section 8.13 ❏Renew flexible gear rim, section 8.16 ❏Check condensate separator, section 8.17 ❏Overhaul drain valves (as per order), section 8.18

❏

Clean particle trap, section 8.19 ❏ ❏ ❏ ❏Replace zinc protection (freshwater operation), section 8.20

❏

Replace bursting disc, section 8.21 ❏ ❏ ❏ ❏Check cooling water pump, section 8.22

Hours of operationDateSignature (initials)

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90

S a u e rC o m p r e s s o rType: WP 400

Spare parts catalogue

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Edition: 03 / 2008Edited by: J.P. Sauer & Sohn Maschinenbau – Technical Documentation

WP400_ET_Titel_en_08.fm

Spare parts catalogueW

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066 148 / 064 344 Compressor WP 400

Ref. No. Assembly PageE-

066 148 Compressor WP 400 with cooling water pump.................... 6

064 344 Compressor WP 400 without cooling water pump............... 10

064 035 Compressor WP 400-100.................................................... 14

064 140 Crankcase ........................................................................... 18

064 257 Dipstick ................................................................................ 22

064 142 Crankshaft ........................................................................... 24

063 864 Connecting rod stage 1.1 and 1.2 ....................................... 26

064 144 Connecting rod 2nd stage .................................................... 28

064 261 Piston stage 1.1 and 1.2...................................................... 30

064 145 Piston 2nd stage................................................................... 32

067 735 Cylinder stage 1.1 and 1.2................................................... 34

061 822 Zinc protection..................................................................... 38

067 737 Cylinder 2nd stage ............................................................... 40

063 868 Valve cover stage 1.1 and 1.2 ............................................. 44

063 869 Valve cover 2nd stage .......................................................... 46

064 146 Air lines................................................................................ 48

063 121 Separator............................................................................. 50

064 147 Cooling water lines .............................................................. 52

063 985 Lubricating oil supply ........................................................... 54

063 543 Gear oil pump...................................................................... 56

057 916 Pressure relief valve............................................................ 58

064 148 Crankcase vent ................................................................... 60

064 038 Compressor monitoring and control .................................... 62

064 448 Protective device ................................................................. 64

037 134 Concentric valve stage 1.1. and 1.2 .................................... 66

063 950 Compressor monitor ............................................................ 68

064 018 Temperature monitoring....................................................... 70

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064 039 Automatic drainage system ................................................. 72

066 143 Cooling water lines with pump............................................. 74

038 238 Cooling water pump............................................................. 78

064 366 Cooling water lines without pump........................................ 80

064 151 Anti-vibration resilient mount ............................................... 82

066 595 Hose line.............................................................................. 84

065 664 Non-return valve .................................................................. 86

Flexible coupling .................................................................. 88

Note:Erläuterungen der Baugruppen in Kapitel 3 „Aufbau undFunktion“ der Betriebsanleitung.

Ref. No. Assembly PageE-


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066 148 Compressor WP 400with cooling water pump

1, 17, 18

3 15, 16

9, 11, 12 14

8

Stage 1.1

Stage 1.2

Stage 2


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2

E - 8

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Item No. Ref. No. Designation Quantity

1 064 035 Compressor WP 400-100 1

2 063 950 Compressor monitor 1

3 064 039 Automatic drainage system 1

4 066 143 Cooling water lines with pump 1

8 063 800 Motor attachment rail 2

9 064 370 Spacer ring 1

11 037 057 Motor half coupling 1

12 033 423 Coupling flexible insert 1

14 037 067 AC motor 1

15 002 170 Washer 4

16 000 216 Hexagon head screw 4

17 036 960 Stud screw 8

18 001 621 Hexagon nut 8

E - 10

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066 344 Compressor WP 400without cooling water pump

1, 17, 18

15, 16

9, 11, 12 14

3 8

Stage 1.1

Stage 1.2

Stage 2


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2

4

E - 12

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E - 13



1 064 035 Compressor WP 400-100 1

2 063 950 Compressor monitor 1

3 064 039 Automatic drainage system 1

4 064 366 Cooling water lines (unit without pump) 1

8 063 800 Motor attachment rail 2

9 064 370 Spacer ring 1

11 037 057 Motor half coupling 1

12 033 423 Coupling flexible insert 1

14 037 067 AC motor 1

15 002 170 Washer 4


17 036 960 Stud screw 8


E - 14

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064 035 Compressor WP 400-100

27

22

2

13

15

3

1

4

X


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Stage 1.1

Stage 1.2

Stage 2

9

97 235

23

7

5

17

1024

6

8

E - 16

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fm


X

Stage 1.1

Stage 1.2

Stage 2

26, 30

14

12

11

19, 20, 25

31


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E - 17



1 064 140 Crankcase 1

2 064 142 Crankshaft 1

3 063 864 Connecting rod stage 1.1 and 1.2 2

4 064 144 Connecting rod 2nd stage 1

5 064 261 Piston stage 1.1 and 1.2 2

6 064 145 Piston 2nd stage 1

7 067 735 Cylinder stage 1.1 and 1.2 2

8 067 737 Cylinder 2nd stage 1

9 063 868 Valve cover stage 1.1 and 1.2 2

10 063 869 Valve cover 2nd stage 1

11 064 146 Air lines 1

12 064 147 Cooling water lines 1

13 063 985 Lubricating oil supply 1

14 064 148 Crankcase vent 1

15 064 038 Compressor monitoring and control 1

17 064 448 Protective device 1

19 064 331 Blind flange 1

20 064 332 Gasket 1

22 036 333 Compressor half coupling 1

23 037 134 Concentric valve stage 1.1. and 1.2 2

24 036 959 Lamellar valve 2nd stage 1

25 000 494 Cap screw 4

26 005 546 Stud screw 2

27 000 543 Cap screw 10

30 037 225 Lifting eye bolt nut 2

31 004 411 Locking pin 4

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064 140 Crankcase

941013, 14

11, 12

11, 12

1615

7


P400

_ET_

en_0

8.fm

E - 19

064 140 Crankcase

2 1

Stage 1.1

Stage 1.2

Stage 2

19

20

36

17

18

18 17 18 17

5

19

20

3

6

E - 20

WP4

00_E

T_en

_08.

fm

064 140 Crankcase


P400

_ET_

en_0

8.fm

E - 21

064 140 Crankcase

1) Item 10, 004 635 Insert fitting with Loctite 542.


1 063 786 Crankcase 1

2 064 394 Housing cover 1

3 051 883 Crankcase inspection cover 2

4 036 897 Oil strainer 1

5 064 257 Dipstick 1

6 063 748 Gasket 2

7 063 749 Gasket 1

9 030 743 Shaft seal 1

101) 004 635 Plug 1

11 000 971 Plug 2

12 005 001 O-ring 2

13 035 984 Drain cock 1

14 005 009 O-ring 1

15 038 102 Stud screw 6


17 036 960 Stud screw 12


19 001 408 Stud screw 16


E - 22

WP4

00_E

T_en

_08.

fm

064 257 Dipstick

1

2


P400

_ET_

en_0

8.fm

E - 23

064 257 Dipstick


1 064 256 Dipstick 1

2 030 556 O-ring 1

E - 24

WP4

00_E

T_en

_08.

fm

064 142 Crankshaft

6

550 Nm

3

4

8

1

Z

Z

7

2


P400

_ET_

en_0

8.fm

E - 25

064 142 Crankshaft


1 064 143 Crankshaft 1

2 063 544 Driving disc 1

3 063 732 Washer 1

4 063 811 Flywheel 1


7 033 994 Cap screw 2

8 036 961 Cylindrical roller bearing 2

E - 26

WP4

00_E

T_en

_08.

fm

063 864 Connecting rod stage 1.1 and 1.2

4115 Nm

2

1

3


P400

_ET_

en_0

8.fm

E - 27

063 864 Connecting rod stage 1.1 and 1.2

1) Item 4, Connecting rod bolt 056 316 is part of assembly 063 712.


1 063 712 Connecting rod 1

2 061 857 Connecting rod bearing 1

3 035 823 Small-end bearing 1

41) 061 676 Connecting rod bolt 2

E - 28

WP4

00_E

T_en

_08.

fm

064 144 Connecting rod 2nd stage

4115 Nm

3

1

2


P400

_ET_

en_0

8.fm

E - 29

064 144 Connecting rod 2nd stage

1) Item 4, Connecting rod bolt 061 676is part of assembly 063 826.


1 063 826 Connecting rod 1

2 037 058 Small-end bearing 1

3 061 857 Connecting rod bearing 1

41) 061 676 Connecting rod bolt 2

E - 30

WP4

00_E

T_en

_08.

fm

064 261 Piston stage 1.1 and 1.2

7

5

2

1

4

3


P400

_ET_

en_0

8.fm

E - 31

064 261 Piston stage 1.1 and 1.2

1) Item 7, Small-end bearing 035 823 is part of assembly 063 864.


1 036 983 Piston 1

2 036 078 Gudgeon pin 1

3 002 716 Plain ring 2

4 035 962 Oil scraper ring 1

5 002 985 Circlip 2

71) 035 823 Small-end bearing 1

E - 32

WP4

00_E

T_en

_08.

fm

064 145 Piston 2nd stage

7

3

45

2

6

1


P400

_ET_

en_0

8.fm

E - 33

064 145 Piston 2nd stage

1) Item 7, Small-end bearing 037 058 is part of assembly 064 144.


1 063 815 Piston 1

2 064 150 Gudgeon pin 1

3 033 571 Plain ring 2

4 002 634 Nose ring 1

5 002 605 Oil scraper ring 1

6 012 682 Circlip 2

71) 037 058 Small-end bearing 1

E - 34

WP4

00_E

T_en

_08.

fm

067 735 Cylinder stage 1.1 and 1.2

FE

A - B

E - F

C

D

A B

1 19, 23 9 3 10

26

7 17, 23

18, 24

16

13

5

15


P400

_ET_

en_0

8.fm

E - 35


1422

18, 24

8

4

12

2

23

C - D

E - 36

WP4

00_E

T_en

_08.

fm



P400

_ET_

en_0

8.fm

E - 37



1 067 734 Cylinder housing 2nd stage 1

2 061 822 Zinc protection 1

3 067 738 Cooler insert 1st stage 1

4 063 660 Cylinder cover 1st stage 1

5 067 708 Cooler cover 1st stage 1

7 063 776 Liner 1

8 063 747 Gasket 1

9 067 739 Gasket 1

10 067 741 Gasket 1

12 000 497 Cap screw 6

13 000 475 Cap screw 2

14 001 533 Stud screw 6

15 000 509 Cap screw 9

16 000 519 Cap screw 2

17 000 977 Plug 1

18 001 016 Plug 3

19 035 390 Plug 1


23 005 023 O-ring 3

24 005 009 O-ring 3

26 036 962 O-ring 4

E - 38

WP4

00_E

T_en

_08.

fm

061 822 Zinc protection

2 3 1


P400

_ET_

en_0

8.fm

E - 39

061 822 Zinc protection

061 822 Zinc protection is ordered as a complete spare part.


1 061 820 Plug 1

2 061 821 Zinc cartridge 1

3 001 463 Stud screw 1

E - 40

WP4

00_E

T_en

_08.

fm

067 737 Cylinder 2nd stage

DC

A - B

A B

C - D21, 238

25

17 191 22, 23

11

10

18

15

6

4

5, 93, 12, 13142, 2316


P400

_ET_

en_0

8.fm

E - 41


20, 24

26, 27

E - 42

WP4

00_E

T_en

_08.

fm



P400

_ET_

en_0

8.fm

E - 43



1 067 718 Cylinder housing 2nd stage 1

2 061 822 Zinc protection 1

3 054 883 Protecting cap 1

4 067 715 Cooler insert 2nd stage 1

5 063 662 Cylinder cover 2nd stage 1

6 067 710 Cooler cover 2nd stage 1

8 063 808 Liner 1

9 063 747 Gasket 1

10 067 716 Gasket 1

11 067 717 Gasket 1

12 051 530 Gasket 1

13 051 531 Burst disc 1

14 000 505 Cap screw 4

15 000 554 Cap screw 11

16 000 497 Cap screw 6

17 001 533 Stud screw 4

18 000 509 Cap screw 3


20 001 016 Plug 1

21 000 977 Plug 1

22 035 390 Plug 1

23 005 023 O-ring 3

24 005 009 O-ring 1

25 030 131 O-ring 4

26 005 001 O-ring 1

27 000 971 Plug 1

E - 44

WP4

00_E

T_en

_08.

fm

063 868 Valve cover stage 1.1 and 1.2

2, 5

1

4

3


P400

_ET_

en_0

8.fm

E - 45

063 868 Valve cover stage 1.1 and 1.2

1) Item 5, Filter insert 036 395 is part of assembly 036 394.


1 064 236 Valve cover 1

2 036 394 Dry air filter 1

3 037 151 O-ring 1

4 030 912 O-ring 1

51) 036 395 Filter insert 1

E - 46

WP4

00_E

T_en

_08.

fm

063 869 Valve cover 2nd stage

2, 3

4

1

5


P400

_ET_

en_0

8.fm

E - 47

063 869 Valve cover 2nd stage


1 063 743 Valve cover 1


3 003 493 O-ring 1

4 036 963 O-ring 1

5 035 970 O-ring 1

E - 48

WP4

00_E

T_en

_08.

fm

064 146 Air lines

11, 16 12, 15

1, 4, 6

10, 16

9, 15

13, 14

7, 8

2


P400

_ET_

en_0

8.fm

E - 49

064 146 Air lines


1 067 729 Compressed air manifold 1

2 063 121 Separator 1

4 056 335 Gasket 3



8 002 151 Washer 2

9 036 157 Plug 1

10 006 193 Plug 1

11 005 946 Stub 1

12 030 751 Safety valve stage 1.2 1

13 030 752 Safety valve 2nd stage 1

14 005 009 O-ring 1

15 005 016 O-ring 2

16 005 023 O-ring 2

E - 50

WP4

00_E

T_en

_08.

fm

063 121 Separator

11, 12

2

91

4

8

10

3

7

6Working pressure 80 barTest pressure 160 bar


P400

_ET_

en_0

8.fm

E - 51

063 121 Separator

1) 121°C / 250 °F


1 063 228 Separator housing 1

2 063 229 Separator head 1

3 062 328 Baffle cone 1

41) 060 342 Fusible plug 1

6 006 390 Reducing union 1

7 005 029 O-ring 1

8 005 009 O-ring 1

9 036 171 O-ring 1


11 001 007 Plug 1

12 003 496 O-ring 1

E - 52

WP4

00_E

T_en

_08.

fm

064 147 Cooling water lines

Stage 1.1

Stage 1.2

2nd stage

1

4

1

6, 9

10

1

6, 9


P400

_ET_

en_0

8.fm

E - 53

064 147 Cooling water lines

1) Inserted with hemp.2) Inserted with seal tape.


11) 037 144 Angle piece 4


41) 037 194 Extension piece 1

6 038 390 High pressure hose 2

92) 004 661 Plug 4

101) 036 967 Pipe fitting 1

111) 034 875 T-joint 1

121) 037 305 Pipe reducing adaptor 1

E - 54

WP4

00_E

T_en

_08.

fm

063 985 Lubricatin oil supply

27

8

1


P400

_ET_

en_0

8.fm

E - 55

063 985 Lubricatin oil supply


1 063 543 Gear oil pump 1

2 057 916 Pressure relief valve 1

7 003 438 O-ring 1

8 000 456 Cap screw 4

E - 56

WP4

00_E

T_en

_08.

fm

063 543 Gear oil pump

7

8

6

3

2

1, 5


P400

_ET_

en_0

8.fm

E - 57

063 543 Gear oil pump


1 036 767 Oil pump gear wheel 1

2 036 360 Oil pump housing 1

3 056 318 Gasket 1

5 036 359 Gear wheel 1

6 033 212 Oil pump cover 1

7 036 363 Gasket 1

8 030 544 Gasket 1

E - 58

WP4

00_E

T_en

_08.

fm

057 916 Pressure relief valve

3 5


P400

_ET_

en_0

8.fm

E - 59

057 916 Pressure relief valve


3 054 164 Spring 1

5 002 962 Circlip 1

E - 60

WP4

00_E

T_en

_08.

fm

064 148 Crankcase vent

Stage 1.1

Stage 1.2

2nd stage

5, 6, 7 12

9, 10

14

1

4

5, 6, 732 115, 6, 8


P400

_ET_

en_0

8.fm

E - 61

064 148 Crankcase vent

1) Inserted with hemp and Fermit sealing cement.2) Inserted with seal tape.


11) 038 407 Pipe nipple joint 1

21) 038 268 T reducer 1


4 034 612 Low-pressure hose 1

5 035 254 Worm drive hose clip 4

6 037 139 Hose sleeve 4


82) 037 185 T-joint 1


101) 037 194 Extension piece 1

11 035 824 Filling cover 1

12 037 264 Low-pressure hose 1

14 033 952 Insulation hose 1

E - 62

WP4

00_E

T_en

_08.

fm

064 038 Compressor monitoring and control

1, 3, 9

3, 13

2, 3, 14

6, 7

6, 7

6, 7

8, 12

10

Stage 1.1

Stage 1.2

Stage 2


P400

_ET_

en_0

8.fm

E - 63

064 038 Compressor monitoring and control


1 035 009 Pressure gauge oil 1

2 030 664 Pressure gauge 2nd stage 1

3 035 061 O-ring 4

6 038 941 Thermometer compressed air 3

7 005 009 O-ring 3

8 005 016 O-ring 1

9 035 906 Socket fitting 1

10 030 182 Cooling water thermometer 1

12 030 509 Plug 1

13 038 288 Pressure gauge 1st stage 1

14 065 352 Double ended stud end 1

E - 64

WP4

00_E

T_en

_08.

fm

064 448 Protective device

3, 4, 5

1


P400

_ET_

en_0

8.fm

E - 65

064 448 Protective device


1 064 449 Guard plate 1

2 001 408 Stud screw 2


6 002 156 Washer 2

E - 66

WP4

00_E

T_en

_08.

fm

037 134 Concentric valve stage 1.1. and 1.2

4

3

5

2

1

6


P400

_ET_

en_0

8.fm

E - 67

037 134 Concentric valve stage 1.1. and 1.2


1 037 187 Suction valve plate 1

2 037 188 Delivery valve plate 1

3 037 189 Delivery valve plate 1

4 037 190 Delivery valve spring 2

5 037 191 Delivery valve spring 2

6 037 192 Suction valve spring 2

E - 68

WP4

00_E

T_en

_08.

fm

063 950 Compressor monitor

1

3, 4 5, 6 5, 8


P400

_ET_

en_0

8.fm

E - 69

063 950 Compressor monitor


1 064 018 Temperature monitoring 1

3 030 082 Low oil pressure switch 1

4 000 409 Cap screw 2

5 004 596 Plug 2


8 008 633 Pipe 1

E - 70

WP4

00_E

T_en

_08.

fm

064 018 Temperature monitoring

2, 41


P400

_ET_

en_0

8.fm

E - 71

064 018 Temperature monitoring


1 035 468 High air temperature switch 1

2 000 410 Cap screw 2

4 002 144 Washer 2

E - 72

WP4

00_E

T_en

_08.

fm

064 039 Automatic drainage system

Z52, 9

7

4

13

6 12

43, 7, 11101, 8

Z


P400

_ET_

en_0

8.fm

E - 73

064 039 Automatic drainage system

1) Specify voltage and frequency for order!2) The order number for the solenoid valve is order-specific.


1 049 129 Pipe clamp 1

2 033 961 Stub 1

3 006 187 Plug 1

4 004 647 Plug 2

5 005 964 Plug 1

6 004 973 Plug 1

71) 036 6542) Solenoid valve 2

8 000 434 Cap screw 2

9 005 009 O-ring 2

10 006 000 Plug 1

11 006 455 Stub 1

12 008 663 Pipe 1

13 008 672 Pipe 1

E - 74

WP4

00_E

T_en

_08.

fm

066 143 Cooling water lines with pump

3119

15

17

21

4, 9,27, 29

10

4, 9, 18, 28, 30

6, 8, 14

26 1

33, 35, 37

34, 36, 38


P400

_ET_

en_0

8.fm

E - 75


23

32

22

16

40

3

5 17 2, 7 20 1325 41

E - 76

WP4

00_E

T_en

_08.

fm



1 066 442 Support plate 1

2 066 145 Attachment rail 2

3 066 144 Angle steel bar 1




7 000 594 Cap screw 2



101) 038 201 Reducing union 1

132) 032 725 Pipe adaptor 1

14 002 161 Washer 1

151) 037 267 Reducing nipple 1

161) 037 144 Pipe bend 2

171) 037 265 Pipe bend 2

18 002 166 Washer 4


202) 032 679 Particle trap 1

213) 037 1504) Solenoid valve

22 064 396 Sliding socket 1

23 038 238 Cooling water pump 1


265) 037 493 Clamp, two-part 1

27 037 293 Flange 1

281) 036 614 Threaded flange 1

29 030 658 Gasket 1

30 037 441 Gasket 1


P400

_ET_

en_0

8.fm

E - 77

1) Fitting with cylindrical threading is sealed with seal tape.2) Fitting with conical threading is sealed with hemp and Fermit sealing cement.3) Specify voltage and frequency for solenoid valve order!4) The order number for the solenoid valve is order-specific.5) Item 26, 037 493 Clamp installed without rubber insert.


321) 037 305 Pipe reducing adaptor 1



35 002 153 Washer 4

36 002 156 Washer 8



401) 037 851 Plug 1

411) 004 666 Plug 1


E - 78

WP4

00_E

T_en

_08.

fm

038 238 Cooling water pump

DN 32

DN

40

1, 2, 3

Motor terminal box

Cabe entry

X

X


P400

_ET_

en_0

8.fm

E - 79

038 238 Cooling water pump

1) Repair kit 038 257 can be supplied.

Technical specification

1) Also available to customer-specific specifications upon request.


1 Cooling water pump 1

2 038 290 Gasket kit 1

31) 038 257 Repair kit 1

Pump:

Max. working pressure: 10 bar

Pump capacity: 67 l/min against 19 m water column100 l/min against 18 m water column

Medium: fresh water

Max. working pressure: 55 °C

AC motor1) :

Capacity: 1.1 kW, IP 55

Voltage and frequency: 400/440 V, 50/60 Hz

Max. ambient temperature: 55 °C

E - 80

WP4

00_E

T_en

_08.

fm

064 366 Cooling water lines without pump

4

6

3

2

3

5

1 8 7


P400

_ET_

en_0

8.fm

E - 81

064 366 Cooling water lines without pump

1) Specify voltage and frequency for solenoid valve order!2) The order number for the solenoid valve is order-specific.3) Screw into place sealed with hemp and Fermit sealing cement and rotate into correct

position.


11), 3) 037 1422) Solenoid valve 1

23) 032 679 Particle trap 1



53) 037 265 Pipe bend 1

63) 037 266 Socket 1


8 037 267 Reducing nipple 1

E - 82

WP4

00_E

T_en

_08.

fm

064 151 Anti-vibration resilient mount

11)

2

1

9

5

6 8

3

10 4

1) Type with cooling water pump:installation of hose line on the pump intake fittings


P400

_ET_

en_0

8.fm

E - 83

064 151 Anti-vibration resilient mount


1 066 595 Hose line 2

2 033 531 Countersunk screw 8

3 000 589 Cap screw 8

4 046 837 Anti-vibration resilient mount 8



8 004 701 Plug 2

9 065 664 Non-return valve 1

10 063 947 Rail 2

E - 84

WP4

00_E

T_en

_08.

fm

066 595 Hose line

2 21


P400

_ET_

en_0

8.fm

E - 85

066 595 Hose line



2 004 666 Plug 2

E - 86

WP4

00_E

T_en

_08.

fm

065 664 Non-return valve

3 1 2

2835


P400

_ET_

en_0

8.fm

E - 87

065 664 Non-return valve


1 037 883 Non-return valve 1

2 004 661 Plug 1

3 037 851 Plug 1

E - 88

WP4

00_E

T_en

_08.

fm

Flexible coupling

1 2

3

Compressor Motor


P400

_ET_

en_0

8.fm

E - 89

Flexible coupling

1) Item 1, Compressor half coupling 036 333 is part of assembly 064 035.2) Item 2, Motor half coupling 037 057 is part of assembly 066 148.3) Item 3, Coupling flexible insert 033 423 is part of assembly 066 148.


11) 036 333 Compressor half coupling 1

22) 037 057 Motor half coupling 1

33) 033 423 Coupling flexible insert 1

E - 90

WP4

00_E

T_en

_08.

fm

IndexW

P400

_ET_

Inde

x_en

_08.

fm

E - 91

Parts List by Ref. No.

Ref. No. Designation Assembly PageE - Item

000 048 Hexagon head screw ............................. 066 143 74 34






000 409 Cap screw .............................................. 063 950 68 4

000 410 Cap screw .............................................. 064 018 70 2

064 366 Cooling water lines without pump .......... 064 344 11 4

000 434 Cap screw .............................................. 064 039 72 8

000 456 Cap screw .............................................. 063 985 54 8

000 475 Cap screw .............................................. 067 735 34 13

000 494 Cap screw .............................................. 064 035 16 25

000 497 Cap screw .............................................. 067 735 35 12

000 497 Cap screw .............................................. 067 737 40 16

000 505 Cap screw .............................................. 067 737 40 14

000 509 Cap screw .............................................. 067 735 34 15

000 509 Cap screw .............................................. 067 737 40 18

000 519 Cap screw .............................................. 067 735 34 16

000 543 Cap screw .............................................. 064 035 15 27

000 554 Cap screw .............................................. 067 737 40 15

000 589 Cap screw .............................................. 064 151 82 3

000 594 Cap screw .............................................. 066 143 75 7

035 823 Small-end bearing .................................. 063 864 30 7

000 971 Plug ........................................................ 064 140 18 11

000 971 Plug ........................................................ 067 737 41 27

000 977 Plug ........................................................ 067 735 34 17

E - 92

WP4

00_E

T_In

dex_

en_0

8.fm

000 977 Plug ........................................................ 067 737 40 21

001 007 Plug ........................................................ 063 121 50 11

001 016 Plug ........................................................ 067 735 34, 35 18

001 016 Plug ........................................................ 067 737 41 20

001 408 Stud screw .............................................. 064 140 19 19

001 408 Stud screw .............................................. 064 448 64 2

001 463 Stud screw .............................................. 061 822 38 3

001 533 Stud screw .............................................. 067 735 35 14

001 533 Stud screw .............................................. 067 737 40 17

001 620 Hexagon nut ........................................... 064 140 18 16

001 620 Hexagon nut ........................................... 066 143 74 8

001 621 Hexagon nut ........................................... 064 140 19 18

001 621 Hexagon nut ........................................... 064 344 10 18

001 621 Hexagon nut ........................................... 066 148 6 18

001 621 Hexagon nut ........................................... 067 735 35 22

001 621 Hexagon nut ........................................... 067 737 40 19

002 025 Hexagon nut ........................................... 066 143 74 37

002 031 Hexagon nut ........................................... 064 140 19 20

002 031 Hexagon nut ........................................... 064 448 64 3

002 031 Hexagon nut ........................................... 066 143 74 38

002 051 Hexagon nut ........................................... 066 143 76 9

002 144 Washer ................................................... 064 018 70 4

002 151 Washer ................................................... 064 146 48 8

002 153 Washer ................................................... 066 143 74 35

002 156 Washer ................................................... 064 448 64 6

002 156 Washer ................................................... 066 143 74 36

002 161 Washer ................................................... 066 143 74 14

002 166 Washer ................................................... 066 143 74 18

002 170 Washer ................................................... 064 344 10 15


IndexW

P400

_ET_

Inde

x_en

_08.

fm

E - 93

002 170 Washer ................................................... 066 148 6 15

002 605 Oil scraper ring ....................................... 064 145 32 5

002 634 Nose ring ................................................ 064 145 32 4

002 716 Plain ring ................................................ 064 261 30 3

002 962 Circlip ..................................................... 057 916 58 5

002 985 Circlip ..................................................... 064 261 30 5

003 438 Gasket .................................................... 063 985 54 7

003 493 Gasket .................................................... 063 869 46 3

003 496 Gasket .................................................... 063 121 50 12

004 411 Locking pin ............................................. 064 035 16 31

004 596 Plug ........................................................ 063 950 68 5

004 635 Plug ........................................................ 064 140 18 10

004 647 Plug ........................................................ 064 039 72 4

004 661 Plug ........................................................ 064 147 52 9

004 661 Plug ........................................................ 065 664 86 2

004 666 Plug ........................................................ 066 143 75 41

004 666 Plug ........................................................ 066 595 84 2

004 701 Plug ........................................................ 064 151 82 8

004 973 Plug ........................................................ 064 039 72 6

005 001 Gasket .................................................... 064 140 18 12

005 001 Gasket .................................................... 067 737 41 26

005 009 Gasket .................................................... 063 121 50 8

005 009 Gasket .................................................... 064 038 62 7

005 009 Gasket .................................................... 064 039 72 9

005 009 Gasket .................................................... 064 140 18 14

005 009 Gasket .................................................... 064 146 48 14

005 009 Gasket .................................................... 067 735 34, 35 24

005 009 Gasket .................................................... 067 737 41 24

005 016 Gasket .................................................... 064 038 62 8


E - 94

WP4

00_E

T_In

dex_

en_0

8.fm

005 016 Gasket .................................................... 064 146 48 15

005 023 Gasket .................................................... 064 146 48 16

005 023 Gasket .................................................... 067 735 34, 35 23

005 023 Gasket .................................................... 067 737 40 23

005 029 Gasket .................................................... 063 121 50 7

005 265 Hexagon head screw .............................. 066 143 74 4




005 546 Stud screw .............................................. 064 035 16 26

005 946 Stub ........................................................ 064 146 48 11

005 964 Plug ........................................................ 064 039 72 5

006 000 Plug ........................................................ 064 039 72 10

006 187 Plug ........................................................ 064 039 72 3

006 193 Plug ........................................................ 064 146 48 10

006 390 Reducing union ...................................... 063 121 50 6

006 455 Stub ........................................................ 064 039 72 11

008 633 Pipe ........................................................ 063 950 68 8

008 663 Pipe ........................................................ 064 039 72 12

008 672 Pipe ........................................................ 064 039 72 13

012 982 Circlip ..................................................... 064 145 32 6

030 082 Low oil pressure switch .......................... 063 950 68 3

030 131 O-ring ..................................................... 067 737 40 25

030 182 Cooling water thermometer .................... 064 038 62 10

030 509 Plug ........................................................ 064 038 62 12

030 544 Gasket .................................................... 063 543 56 8

030 556 O-ring ..................................................... 064 257 22 2

030 658 Gasket .................................................... 066 143 74 29

030 664 Pressure gauge 2nd stage ..................... 064 038 62 2


IndexW

P400

_ET_

Inde

x_en

_08.

fm

E - 95

030 743 Shaft seal ............................................... 064 140 18 9

030 751 Safety valve stage 1.2 ............................ 064 146 48 12

030 752 Safety valve 2nd stage ........................... 064 146 48 13

030 912 O-ring ..................................................... 063 868 44 4

032 679 Particle trap ............................................ 064 366 80 2

032 679 Particle trap ............................................ 066 143 75 20

032 725 Pipe adaptor ........................................... 064 366 80 3

032 725 Pipe adaptor ........................................... 066 143 75 13

033 017 Reducing union ...................................... 063 950 68 6

033 087 Reducing union ...................................... 064 148 60 3

033 212 Oil pump cover ....................................... 063 543 56 6

033 423 Coupling flexible insert ........................... 066 148 88 3

033 423 Coupling flexible insert / elastic coupling insert ......................................................

064 344 10 12


066 148 6 12

033 531 Countersunk screw ................................ 064 151 82 2

033 571 Plain ring ................................................ 064 145 32 3

033 952 Insulation hose ....................................... 064 148 60 14

033 961 Stub ........................................................ 064 039 72 2

033 994 Cap screw .............................................. 064 142 24 7

034 612 Low-pressure hose ................................ 064 148 60 4

034 763 High pressure hose ................................ 064 151 82 5

034 875 T-joint ..................................................... 064 147 52 11

035 009 Pressure gauge oil ................................. 064 038 62 1

035 061 Gasket .................................................... 064 038 62 3

035 254 Worm drive hose clip .............................. 064 148 60 5

035 390 Plug ........................................................ 067 735 34 19

035 390 Plug ........................................................ 067 737 40 22

035 468 High air temperature switch ................... 064 018 70 1


E - 96

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T_In

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en_0

8.fm


035 824 Filling cover ............................................ 064 148 60 11

035 906 Socket fitting ........................................... 064 038 62 9


035 962 Oil scraper ring ....................................... 064 261 30 4

035 970 O-ring ..................................................... 063 869 46 5

035 984 Drain cock .............................................. 064 140 18 13


036 078 Gudgeon pin ........................................... 064 261 30 2

036 157 Plug ........................................................ 064 146 48 9

036 171 O-ring ..................................................... 063 121 50 9

036 333 Compressor half coupling ....................... 064 035 15 22


036 359 Gear wheel ............................................. 063 543 56 5

036 360 Oil pump housing ................................... 063 543 56 2

036 363 Gasket .................................................... 063 543 56 7

036 394 Dry air filter ............................................. 063 868 44 2

036 395 Filter insert .............................................. 036 394 44 5

036 614 Threaded flange ..................................... 066 143 74 28

036 654 Solenoid valve ........................................ 064 039 72 7

036 767 Oil pump gear wheel .............................. 063 543 56 1

036 897 Oil strainer .............................................. 064 140 18 4

036 959 Lamellar valve 2nd stage ....................... 064 035 15 24

036 960 Stud screw .............................................. 064 140 19 17

036 960 Stud screw .............................................. 064 344 10 17

036 960 Stud screw .............................................. 066 148 6 17

036 961 Cylindrical roller bearing ......................... 064 142 24 8

036 962 O-ring ..................................................... 067 735 34 26

036 963 O-ring ..................................................... 063 869 46 4


IndexW

P400

_ET_

Inde

x_en

_08.

fm

E - 97


036 967 Pipe fitting .............................................. 064 147 52 10

036 967 Pipe fitting .............................................. 064 366 80 7

036 967 Pipe fitting .............................................. 066 143 74 19

036 983 Piston ..................................................... 064 261 30 1

037 057 Motor half coupling ................................. 064 035 88 2





037 067 AC motor ................................................ 064 344 10 14

037 067 AC motor ................................................ 066 148 6 14

037 134 Concentric valve stage 1.1. and 1.2 ....... 064 035 15 23

037 139 Hose sleeve ........................................... 064 148 60 6

037 140 Angle piece ............................................ 064 148 60 7

037 142 Solenoid valve ........................................ 064 366 80 1

037 144 Angle piece ............................................ 064 147 52 1

037 144 Angle piece ............................................ 064 148 60 9

037 144 Pipe bend ............................................... 066 143 75 16

037 150 Solenoid valve ........................................ 066 143 74 21

037 151 O-ring ..................................................... 063 868 44 3

037 185 T-joint ..................................................... 064 148 60 8

037 187 Suction valve plate ................................. 037 134 66 1

037 188 Delivery valve plate ................................ 037 134 66 2


037 190 Delivery valve spring .............................. 037 134 66 4


037 192 Suction valve spring ............................... 037 134 66 6

037 194 Extension piece ...................................... 064 147 52 4


E - 98

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8.fm

037 194 Extension piece ...................................... 064 148 60 10

037 225 Lifting eye bolt nut .................................. 064 035 16 30

037 264 Low-pressure hose ................................. 064 148 60 12

037 265 Angle piece ............................................ 064 147 52 2

037 265 Pipe bend ............................................... 064 366 80 5

037 265 Pipe bend ............................................... 066 143 74, 75 17

037 266 Socket .................................................... 064 366 80 6

037 267 Reducing nipple ...................................... 064 366 80 8

037 267 Reducing nipple ...................................... 066 143 74 15

037 293 Flange .................................................... 066 143 74 27

037 305 Pipe reducing adaptor ............................ 064 147 52 12


037 441 Gasket .................................................... 066 143 74 30

037 493 Clamp, two-part ...................................... 066 143 74 26

037 851 Plug ........................................................ 065 664 86 3

037 851 Plug ........................................................ 066 143 75 40

037 883 Non-return valve ..................................... 065 664 86 1

037 930 Pipe adaptor ........................................... 064 366 80 4

037 930 Pipe adaptor ........................................... 066 143 74 31

038 102 Stud screw .............................................. 064 140 18 15

038 201 Reducing union ...................................... 066 143 74 10

038 238 Cooler water pump ................................. 066 143 75 23

038 257 Repair kit ................................................ 038 238 78 3

038 268 T reducer ................................................ 064 148 60 2

038 288 Pressure gauge 1st stage ...................... 064 038 62 13

038 290 Gasket kit ............................................... 038 238 78 2





IndexW

P400

_ET_

Inde

x_en

_08.

fm

E - 99

038 407 Pipe nipple joint ...................................... 064 148 60 1

038 941 Thermometer compressed air ................ 064 038 62 6

046 837 Anti-vibration resilient mount .................. 064 151 82 4

049 129 Pipe clamp ............................................. 064 039 72 1

051 530 Gasket .................................................... 067 737 40 12

051 531 Burst disc ............................................... 067 737 40 13

051 883 Crankcase inspection cover ................... 064 140 19 3

054 164 Spring ..................................................... 057 916 58 3

054 883 Protecting cap ........................................ 067 737 40 3

056 318 Gasket .................................................... 063 543 56 3

056 335 Gasket .................................................... 064 146 48 4

057 916 Pressure relief valve .............................. 063 985 54 2

060 342 Fusible plug ............................................ 063 121 50 4

061 820 Plug ........................................................ 061 822 38 1

061 821 Zinc cartridge ......................................... 061 822 38 2

061 822 Zinc protection ....................................... 067 735 35 2

061 822 Zinc protection ....................................... 067 737 40 2

061 857 Connecting rod bearing .......................... 063 864 26 2


062 328 Baffle cone ............................................. 063 121 50 3

063 121 Separator ............................................... 064 146 48 2

063 228 Separator housing .................................. 063 121 50 1

063 229 Separator head ...................................... 063 121 50 2

063 543 Gear oil pump ........................................ 063 985 54 1

063 544 Driving disc ............................................ 064 142 24 2

063 660 Cylinder cover ........................................ 067 735 35 4

063 662 Cylinder cover 2nd stage ....................... 067 737 40 5

063 712 Connecting rod ....................................... 063 864 26 1

063 732 Washer ................................................... 064 142 24 3


E - 100

WP4

00_E

T_In

dex_

en_0

8.fm

063 743 Valve cover ............................................. 063 869 46 1

063 747 Gasket .................................................... 067 735 35 8

063 747 Gasket .................................................... 067 737 40 9

063 748 Gasket .................................................... 064 140 19 6

063 749 Gasket .................................................... 064 140 18 7

063 776 Liner ....................................................... 067 735 34 7

063 786 Crankcase .............................................. 064 140 19 1

063 800 Motor attachment rail .............................. 064 344 10 8

063 800 Motor attachment rail .............................. 066 148 6 8

063 808 Liner ....................................................... 067 737 40 8

063 811 Flywheel ................................................. 064 142 24 4

063 815 Piston ..................................................... 064 145 32 1

063 826 Connecting rod ....................................... 064 144 28 1

063 864 Connecting rod stage 1.1 and 1.2 .......... 064 035 15 3

063 868 Valve cover stage 1.1 and 1.2 ................ 064 035 15 9

063 869 Valve cover 2nd stage ............................ 064 035 15 10

063 947 Rail ......................................................... 064 151 82 10

063 950 Compressor monitoring .......................... 064 344 11 2


063 985 Lubricating oil supply .............................. 064 035 15 13

064 018 Temperature monitoring ......................... 063 950 68 1

064 035 Compressor WP 400-100 ....................... 064 344 10 1

064 035 Compressor WP 400-100 ....................... 066 148 6 1

064 038 Compressor monitoring and control ....... 064 035 15 15

064 039 Automatic drainage system .................... 064 344 10 3


064 140 Crankcase .............................................. 064 035 15 1

064 142 Crankshaft .............................................. 064 035 15 2

064 143 Crankshaft .............................................. 064 142 24 1


IndexW

P400

_ET_

Inde

x_en

_08.

fm

E - 101

064 144 Connecting rod 2nd stage ...................... 064 035 15 4

064 145 Piston ..................................................... 064 035 15 6

064 146 Air lines .................................................. 064 035 16 11

064 147 Cooler water lines .................................. 064 035 16 12

064 148 Crankcase vent ...................................... 064 035 16 14

064 150 Gudgeon pin .......................................... 064 145 32 2

064 236 Valve cover ............................................. 063 868 44 1

064 256 Dipstick .................................................. 064 257 22 1

064 257 Dipstick .................................................. 064 140 19 5

064 261 Piston stage 1.1 and 1.2 ........................ 064 035 15 5

064 331 Blind flange ............................................ 064 035 16 19

064 332 Gasket .................................................... 064 035 16 20

064 370 Spacer ring ............................................. 064 344 10 9

064 370 Spacer ring ............................................. 066 148 6 9

064 394 Housing cover ........................................ 064 140 19 2

064 396 Sliding socket ......................................... 066 143 75 22

064 448 Protective device .................................... 064 035 15 17

064 449 Guard plate ............................................ 064 448 64 1

065 352 Double ended stud end .......................... 064 038 62 14

065 664 Non-return valve .................................... 064 151 82 9

066 143 Cooling water lines with pump ............... 066 148 7 4

066 144 Angle steel bar ....................................... 066 143 75 3

066 145 Attachment rail ....................................... 066 143 75 2

066 442 Support plate .......................................... 066 143 74 1

066 595 Hose line ................................................ 064 151 82 1

067 708 Cooler cover ........................................... 067 735 34 5

067 710 Cooler cover 2nd stage .......................... 067 737 40 6

067 715 Cooler insert 2nd stage .......................... 067 737 40 4

067 716 Gasket .................................................... 067 737 40 10


E - 102

WP4

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en_0

8.fm

067 717 Gasket .................................................... 067 737 40 11

067 718 Cylinder housing 2nd stage .................... 067 737 40 1

067 729 Compressed air manifold ....................... 064 146 48 1

067 734 Cylinder housing ..................................... 067 735 34 1

067 735 Cylinder stage 1.1 and 1.2 ..................... 064 035 15 7

067 737 Cylinder 2nd stage ................................. 064 035 15 8

067 738 Cooler insert ........................................... 067 735 34 3

067 739 Gasket .................................................... 067 735 34 9

067 741 Gasket .................................................... 067 735 34 10

Cooler water pump ................................. 038 238 78 1


IndexW

P400

_ET_

Inde

x_en

_08.

fm

E - 103

Parts List by Ref. No.


037 067 AC motor ................................................ 064 344 10 14

037 067 AC motor ................................................ 066 148 6 14

064 146 Air lines .................................................. 064 035 16 11

037 140 Angle piece ............................................ 064 148 60 7

037 144 Angle piece ............................................ 064 147 52 1

037 144 Angle piece ............................................ 064 148 60 9

037 265 Angle piece ............................................ 064 147 52 2

066 144 Angle steel bar ....................................... 066 143 75 3

046 837 Anti-vibration resilient mount .................. 064 151 82 4

066 145 Attachment rail ....................................... 066 143 75 2



062 328 Baffle cone ............................................. 063 121 50 3

064 331 Blind flange ............................................ 064 035 16 19

051 531 Burst disc ............................................... 067 737 40 13

000 409 Cap screw .............................................. 063 950 68 4

000 410 Cap screw .............................................. 064 018 70 2

000 434 Cap screw .............................................. 064 039 72 8

000 456 Cap screw .............................................. 063 985 54 8

000 475 Cap screw .............................................. 067 735 34 13

000 494 Cap screw .............................................. 064 035 16 25

000 497 Cap screw .............................................. 067 735 35 12

000 497 Cap screw .............................................. 067 737 40 16

000 505 Cap screw .............................................. 067 737 40 14

000 509 Cap screw .............................................. 067 735 34 15

000 509 Cap screw .............................................. 067 737 40 18

000 519 Cap screw .............................................. 067 735 34 16

E - 104

WP4

00_E

T_In

dex_

en_0

8.fm

000 543 Cap screw .............................................. 064 035 15 27

000 554 Cap screw .............................................. 067 737 40 15

000 589 Cap screw .............................................. 064 151 82 3

000 594 Cap screw .............................................. 066 143 75 7

033 994 Cap screw .............................................. 064 142 24 7

002 962 Circlip ..................................................... 057 916 58 5

002 985 Circlip ..................................................... 064 261 30 5

012 982 Circlip ..................................................... 064 145 32 6

037 493 Clamp, two-part ...................................... 066 143 74 26

067 729 Compressed air manifold ....................... 064 146 48 1





064 038 Compressor monitoring and control ....... 064 035 15 15

064 035 Compressor WP 400-100 ....................... 064 344 10 1

064 035 Compressor WP 400-100 ....................... 066 148 6 1

037 134 Concentric valve stage 1.1. and 1.2 ....... 064 035 15 23

063 712 Connecting rod ....................................... 063 864 26 1

063 826 Connecting rod ....................................... 064 144 28 1

064 144 Connecting rod 2nd stage ...................... 064 035 15 4



063 864 Connecting rod stage 1.1 and 1.2 .......... 064 035 15 3

067 708 Cooler cover ........................................... 067 735 34 5

067 710 Cooler cover 2nd stage .......................... 067 737 40 6

067 738 Cooler insert ........................................... 067 735 34 3

067 715 Cooler insert 2nd stage .......................... 067 737 40 4

064 147 Cooler water lines ................................... 064 035 16 12


IndexW

P400

_ET_

Inde

x_en

_08.

fm

E - 105

038 238 Cooler water pump ................................. 066 143 75 23

066 143 Cooling water lines with pump ............... 066 148 7 4

064 366 Cooling water lines without pump .......... 064 344 11 4

030 182 Cooling water thermometer .................... 064 038 62 10

033 531 Countersunk screw ................................ 064 151 82 2

033 423 Coupling flexible insert ........................... 066 148 88 3


064 344 10 12


066 148 6 12

063 786 Crankcase .............................................. 064 140 19 1

064 140 Crankcase .............................................. 064 035 15 1

051 883 Crankcase inspection cover ................... 064 140 19 3

064 148 Crankcase vent ...................................... 064 035 16 14

064 142 Crankshaft .............................................. 064 035 15 2

064 143 Crankshaft .............................................. 064 142 24 1

067 737 Cylinder 2nd stage ................................. 064 035 15 8

063 660 Cylinder cover ........................................ 067 735 35 4

063 662 Cylinder cover 2nd stage ....................... 067 737 40 5

067 734 Cylinder housing .................................... 067 735 34 1

067 718 Cylinder housing 2nd stage .................... 067 737 40 1

067 735 Cylinder stage 1.1 and 1.2 ..................... 064 035 15 7

036 961 Cylindrical roller bearing ........................ 064 142 24 8





064 256 Dipstick .................................................. 064 257 22 1

064 257 Dipstick .................................................. 064 140 19 5

065 352 Double ended stud end .......................... 064 038 62 14


E - 106

WP4

00_E

T_In

dex_

en_0

8.fm

035 984 Drain cock .............................................. 064 140 18 13

063 544 Driving disc ............................................. 064 142 24 2

036 394 Dry air filter ............................................. 063 868 44 2

037 194 Extension piece ...................................... 064 147 52 4

037 194 Extension piece ...................................... 064 148 60 10

035 824 Filling cover ............................................ 064 148 60 11

036 395 Filter insert .............................................. 036 394 44 5

037 293 Flange .................................................... 066 143 74 27

063 811 Flywheel ................................................. 064 142 24 4

060 34 2 Fusible plug ............................................ 063 121 50 4

003 438 Gasket .................................................... 063 985 54 7

003 493 Gasket .................................................... 063 869 46 3

003 496 Gasket .................................................... 063 121 50 12

005 001 Gasket .................................................... 064 140 18 12

005 001 Gasket .................................................... 067 737 41 26

005 009 Gasket .................................................... 063 121 50 8

005 009 Gasket .................................................... 064 038 62 7

005 009 Gasket .................................................... 064 039 72 9

005 009 Gasket .................................................... 064 140 18 14

005 009 Gasket .................................................... 064 146 48 14

005 009 Gasket .................................................... 067 735 34, 35 24

005 009 Gasket .................................................... 067 737 41 24

005 016 Gasket .................................................... 064 038 62 8

005 016 Gasket .................................................... 064 146 48 15

005 023 Gasket .................................................... 064 146 48 16

005 023 Gasket .................................................... 067 735 34, 35 23

005 023 Gasket .................................................... 067 737 40 23

005 029 Gasket .................................................... 063 121 50 7

030 544 Gasket .................................................... 063 543 56 8


IndexW

P400

_ET_

Inde

x_en

_08.

fm

E - 107

030 658 Gasket .................................................... 066 143 74 29

035 061 Gasket .................................................... 064 038 62 3

036 363 Gasket .................................................... 063 543 56 7

037 441 Gasket .................................................... 066 143 74 30

051 530 Gasket .................................................... 067 737 40 12

056 318 Gasket .................................................... 063 543 56 3

056 335 Gasket .................................................... 064 146 48 4

063 747 Gasket .................................................... 067 735 35 8

063 747 Gasket .................................................... 067 737 40 9

063 748 Gasket .................................................... 064 140 19 6

063 749 Gasket .................................................... 064 140 18 7

064 332 Gasket .................................................... 064 035 16 20

067 716 Gasket .................................................... 067 737 40 10

067 717 Gasket .................................................... 067 737 40 11

067 739 Gasket .................................................... 067 735 34 9

067 741 Gasket .................................................... 067 735 34 10

038 290 Gasket kit ............................................... 038 238 78 2

063 543 Gear oil pump ........................................ 063 985 54 1

036 359 Gear wheel ............................................. 063 543 56 5

064 449 Guard plate ............................................ 064 448 64 1

036 078 Gudgeon pin .......................................... 064 261 30 2

064 150 Gudgeon pin .......................................... 064 145 32 2









E - 108

WP4

00_E

T_In

dex_

en_0

8.fm






001 620 Hexagon nut ........................................... 064 140 18 16

001 620 Hexagon nut ........................................... 066 143 74 8

001 621 Hexagon nut ........................................... 064 140 19 18

001 621 Hexagon nut ........................................... 064 344 10 18

001 621 Hexagon nut ........................................... 066 148 6 18

001 621 Hexagon nut ........................................... 067 735 35 22

001 621 Hexagon nut ........................................... 067 737 40 19

002 025 Hexagon nut ........................................... 066 143 74 37

002 031 Hexagon nut ........................................... 064 140 19 20

002 031 Hexagon nut ........................................... 064 448 64 3

002 031 Hexagon nut ........................................... 066 143 74 38

002 051 Hexagon nut ........................................... 066 143 76 9

035 468 High air temperature switch .................... 064 018 70 1






066 595 Hose line ................................................ 064 151 82 1

037 139 Hose sleeve ............................................ 064 148 60 6

064 394 Housing cover ........................................ 064 140 19 2

033 952 Insulation hose ....................................... 064 148 60 14

036 959 Lamellar valve 2nd stage ....................... 064 035 15 24

037 225 Lifting eye bolt nut .................................. 064 035 16 30


IndexW

P400

_ET_

Inde

x_en

_08.

fm

E - 109

063 776 Liner ....................................................... 067 735 34 7

063 808 Liner ....................................................... 067 737 40 8

004 411 Locking pin ............................................. 064 035 16 31

030 08 2 Low oil pressure switch .......................... 063 950 68 3



063 985 Lubricating oil supply ............................. 064 035 15 13

063 800 Motor attachment rail ............................. 064 344 10 8

063 800 Motor attachment rail ............................. 066 148 6 8




037 883 Non-return valve .................................... 065 664 86 1

065 664 Non-return valve .................................... 064 151 82 9

002 634 Nose ring ................................................ 064 145 32 4

033 212 Oil pump cover ....................................... 063 543 56 6

036 767 Oil pump gear wheel .............................. 063 543 56 1

036 360 Oil pump housing ................................... 063 543 56 2

002 605 Oil scraper ring ....................................... 064 145 32 5

035 962 Oil scraper ring ....................................... 064 261 30 4

036 897 Oil strainer .............................................. 064 140 18 4

030 131 O-ring ..................................................... 067 737 40 25

030 556 O-ring ..................................................... 064 257 22 2

030 912 O-ring ..................................................... 063 868 44 4

035 970 O-ring ..................................................... 063 869 46 5

036 171 O-ring ..................................................... 063 121 50 9

036 962 O-ring ..................................................... 067 735 34 26

036 963 O-ring ..................................................... 063 869 46 4

037 151 O-ring ..................................................... 063 868 44 3


E - 110

WP4

00_E

T_In

dex_

en_0

8.fm

032 679 Particle trap ............................................ 064 366 80 2

032 679 Particle trap ............................................ 066 143 75 20

008 633 Pipe ........................................................ 063 950 68 8

008 663 Pipe ........................................................ 064 039 72 12

008 672 Pipe ........................................................ 064 039 72 13

032 725 Pipe adaptor ........................................... 064 366 80 3

032 725 Pipe adaptor ........................................... 066 143 75 13

037 930 Pipe adaptor ........................................... 064 366 80 4

037 930 Pipe adaptor ........................................... 066 143 74 31

037 144 Pipe bend ............................................... 066 143 75 16

037 265 Pipe bend ............................................... 064 366 80 5

037 265 Pipe bend ............................................... 066 143 74, 75 17

049129 Pipe clamp .............................................. 064 039 72 1

036 967 Pipe fitting .............................................. 064 147 52 10

036 967 Pipe fitting .............................................. 064 366 80 7

036 967 Pipe fitting .............................................. 066 143 74 19

038 407 Pipe nipple joint ...................................... 064 148 60 1



036 983 Piston ..................................................... 064 261 30 1

063 815 Piston ..................................................... 064 145 32 1

064 145 Piston ..................................................... 064 035 15 6

064 261 Piston stage 1.1 and 1.2 ......................... 064 035 15 5

002 716 Plain ring ................................................ 064 261 30 3

033 571 Plain ring ................................................ 064 145 32 3

000 971 Plug ........................................................ 064 140 18 11

000 971 Plug ........................................................ 067 737 41 27

000 977 Plug ........................................................ 067 735 34 17

000 977 Plug ........................................................ 067 737 40 21


IndexW

P400

_ET_

Inde

x_en

_08.

fm

E - 111

001 007 Plug ........................................................ 063 121 50 11

001 016 Plug ........................................................ 067 735 34, 35 18

001 016 Plug ........................................................ 067 737 41 20

004 596 Plug ........................................................ 063 950 68 5

004 635 Plug ........................................................ 064 140 18 10

004 647 Plug ........................................................ 064 039 72 4

004 661 Plug ........................................................ 065 664 86 2

004 661 Plug ........................................................ 064 147 52 9

004 666 Plug ........................................................ 066 143 75 41

004 666 Plug ........................................................ 066 595 84 2

004 701 Plug ........................................................ 064 151 82 8

004 973 Plug ........................................................ 064 039 72 6

005 964 Plug ........................................................ 064 039 72 5

006 000 Plug ........................................................ 064 039 72 10

006 187 Plug ........................................................ 064 039 72 3

006 193 Plug ........................................................ 064 146 48 10

030 509 Plug ........................................................ 064 038 62 12

035 390 Plug ........................................................ 067 735 34 19

035 390 Plug ........................................................ 067 737 40 22

036 157 Plug ........................................................ 064 146 48 9

037 851 Plug ........................................................ 065 664 86 3

037 851 Plug ........................................................ 066 143 75 40

061 820 Plug ........................................................ 061 822 38 1

038 288 Pressure gauge 1st stage ...................... 064 038 62 13

030 66 4 Pressure gauge 2nd stage ..................... 064 038 62 2

035 009 Pressure gauge oil ................................. 064 038 62 1

057 916 Pressure relief valve .............................. 063 985 54 2

054 883 Protecting cap ........................................ 067 737 40 3

064 448 Protective device .................................... 064 035 15 17


E - 112

WP4

00_E

T_In

dex_

en_0

8.fm

063 947 Rail ......................................................... 064 151 82 10

037 267 Reducing nipple ...................................... 064 366 80 8

037 267 Reducing nipple ...................................... 066 143 74 15

006 390 Reducing union ...................................... 063 121 50 6

033 017 Reducing union ...................................... 063 950 68 6

033 087 Reducing union ...................................... 064 148 60 3

038 201 Reducing union ...................................... 066 143 74 10

038 257 Repair kit ................................................ 038 238 78 3

030 752 Safety valve 2nd stage ........................... 064 146 48 13

030 751 Safety valve stage 1.2 ............................ 064 146 48 12

063 121 Separator ................................................ 064 146 48 2

063 229 Separator head ....................................... 063 121 50 2

063 228 Separator housing .................................. 063 121 50 1

030 743 Shaft seal ............................................... 064 140 18 9

064 396 Sliding socket ......................................... 066 143 75 22





037 266 Socket .................................................... 064 366 80 6

035 906 Socket fitting ........................................... 064 038 62 9

036 654 Solenoid valve ........................................ 064 039 72 7

037 142 Solenoid valve ........................................ 064 366 80 1

037 150 Solenoid valve ........................................ 066 143 74 21

064 370 Spacer ring ............................................. 064 344 10 9

064 370 Spacer ring ............................................. 066 148 6 9

054 164 Spring ..................................................... 057 916 58 3

005 946 Stub ........................................................ 064 146 48 11

006 455 Stub ........................................................ 064 039 72 11


IndexW

P400

_ET_

Inde

x_en

_08.

fm

E - 113

033 961 Stub ........................................................ 064 039 72 2

001 408 Stud screw ............................................. 064 140 19 19

001 408 Stud screw ............................................. 064 448 64 2

001 463 Stud screw ............................................. 061 822 38 3

001 533 Stud screw ............................................. 067 735 35 14

001 533 Stud screw ............................................. 067 737 40 17

005 546 Stud screw ............................................. 064 035 16 26

036 960 Stud screw ............................................. 064 140 19 17

036 960 Stud screw ............................................. 064 344 10 17

036 960 Stud screw ............................................. 066 148 6 17

038 102 Stud screw ............................................. 064 140 18 15

037 187 Suction valve plate ................................. 037 134 66 1

037 192 Suction valve spring ............................... 037 134 66 6

066 442 Support plate .......................................... 066 143 74 1

038 268 T reducer ................................................ 064 148 60 2

064 018 Temperature monitoring ......................... 063 950 68 1

038 941 Thermometer compressed air ................ 064 038 62 6

036 614 Threaded flange ..................................... 066 143 74 28

034 875 T-joint ..................................................... 064 147 52 11

037 185 T-joint ..................................................... 064 148 60 8

063 743 Valve cover ............................................. 063 869 46 1

064 236 Valve cover ............................................. 063 868 44 1

063 869 Valve cover 2nd stage ............................ 064 035 15 10

063 868 Valve cover stage 1.1 and 1.2 ................ 064 035 15 9

002 144 Washer ................................................... 064 018 70 4

002 151 Washer ................................................... 064 146 48 8

002 153 Washer ................................................... 066 143 74 35

002 156 Washer ................................................... 064 448 64 6

002 156 Washer ................................................... 066 143 74 36


E - 114

WP4

00_E

T_In

dex_

en_0

8.fm

002 161 Washer ................................................... 066 143 74 14

002 166 Washer ................................................... 066 143 74 18

002 170 Washer ................................................... 064 344 10 15

002 170 Washer ................................................... 066 148 6 15

063 732 Washer ................................................... 064 142 24 3

035 254 Worm drive hose clip .............................. 064 148 60 5

061 821 Zinc cartridge .......................................... 061 822 38 2

061 822 Zinc protection ........................................ 067 735 35 2

061 822 Zinc protection ........................................ 067 737 40 2

Cooler water pump ................................. 038 238 78 1


air compressor(2)

Documents

compressor control

safety requirements

safety warnings

maintenance schedule608

cooling water

safe operation

sauer sohn customer

safety information warning