VO001AM1.

fm

VO001AM1.fm

Edited by: 6DXHU86$5HY732 – Technical Documentation

 Sauer Compressor Type Approvals

Note!
VO002AA2.fm

On this page only a few examples are shown. Further Type

Approvals are available on request.
Genuine Sauer Spare Parts –
certified Safety

MEN
EC I
SP VO002AA2.fm
 Contents
1. Preliminary Note . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Important Information . . . . . . . . . . . . . . . . . . . 8
1.2 Warranty and Liability . . . . . . . . . . . . . . . . . . . 8
1.3 Type Approval and genuine Sauer
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 SAUER USA Customer Service . . . . . . . . . . . 10
1.5 How these Instructions are organized . . . . . . 11

2. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Specified conditions of use . . . . . . . . . . . . . . 12
2.2 Prohibition of unauthorized conversion . . . . . 12
2.3 Safety information . . . . . . . . . . . . . . . . . . . . . 12
2.4 Safety markings on the machine . . . . . . . . . . 13
2.5 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6 Noise Protection . . . . . . . . . . . . . . . . . . . . . . 14
2.7 Waste disposal . . . . . . . . . . . . . . . . . . . . . . . 15
2.8 Staff Requirements . . . . . . . . . . . . . . . . . . . . 15
2.9 Personal protection gear . . . . . . . . . . . . . . . . 15

3. Design and Function . . . . . . . . . . . . . . . . . . 16

3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Mode of Operation. . . . . . . . . . . . . . . . . . . . . 20
3.3 Indicators on the Sauer Compressor. . . . . . . 22
3.4 Displays and control elements on the
compressor control . . . . . . . . . . . . . . . . . . . . 23

4. Technical Specifications. . . . . . . . . . . . . . . 24
4.1 Specification data . . . . . . . . . . . . . . . . . . . . . 24
4.2 P&I-diagram. . . . . . . . . . . . . . . . . . . . . . . . . . 26
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 5. Transport and Installation . . . . . . . . . . . . . 27
5.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2 Storage before installation . . . . . . . . . . . . . . 28
5.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.4 Connecting the compressor . . . . . . . . . . . . . 32
5.5 Filling in oil . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.6 Setting the ultimate pressure switch . . . . . . . 39
5.7 Checks after installation and before the
first start . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.1 Safe operation. . . . . . . . . . . . . . . . . . . . . . . . 40
6.2 Operating mode . . . . . . . . . . . . . . . . . . . . . . 40
6.3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . 41
6.4 Routine operation . . . . . . . . . . . . . . . . . . . . . 43

7. Troubleshooting . . . . . . . . . . . . . . . . . . . . . 45

8. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 48
8.1 SAUER USA maintenance service . . . . . . . . . 48
8.2 Safety during maintenance . . . . . . . . . . . . . . 48
8.3 Maintenance schedule . . . . . . . . . . . . . . . . . 49
8.4 Table of torques . . . . . . . . . . . . . . . . . . . . . . 51
8.5 Checking screwed connections. . . . . . . . . . . 51
8.6 Replacing air filter cartridge . . . . . . . . . . . . . 51
8.7 Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.8 Checking valves . . . . . . . . . . . . . . . . . . . . . . 53
8.9 Replacing valves . . . . . . . . . . . . . . . . . . . . . . 55
8.10 Replacing piston rings, piston pins
and piston pin bearings. . .. . . . . . . . . . . . . . . 55
8.11 Checking pistons and cylinders. . . . . . . . . . . 56
8.12 Renewing flexible gear rim . . . . . . . . . . . . . . 57
8.13 Cleaning condensate separators . . . . . . . . . 58
8.14 Overhauling water drain valves. . . . . . . . . . . 59
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 9. Placing out of service . . . . . . . . . . . . . . . . . 60
9.1 Safety when placing out of service and
dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9.2 Shutting down the compressor temporarily . . 60
9.3 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . 61

10. Lubricant Table . . . . . . . . . . . . . . . . . . . . . . 62

10.1 Lubricating oils. . . . . . . . . . . . . . . . . . . . . . . . 63
10.2 Slushing oils . . . . . . . . . . . . . . . . . . . . . . . . . 64

11. Spare Parts and Accessories . . . . . . . . . . . 65

12. Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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1. Preliminary Note
1.1 Important Information
The following main specifications of your Sauer compressor are
found on the type label affixed to the crankcase:
– compressor type
– factory number
– year of construction
We recommend you write down this information in chapter
11. “Spare Parts and Accessories”.

Conditions We presuppose that only authorised persons will operate and

service the Sauer compressor. These persons must have read
and understood the operating instructions.

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

Copyright The copyright for these instructions remains with

SAUER USA. These instructions, or parts thereof, shall
not be copied, distributed or made available to third parties. Con-
travention will be prosecuted.

1.2 Warranty and Liability

We exonerate the contractually agreed warranty claims and liabil-
ity claims, if they can be attributed to at least one of the following:
– use of the machine not as specified;
– use of spare parts that are not genuine Sauer spare parts;
– operation of the machine with faulty or improperly installed
safety devices and protection devices;
– disregard of the operating instructions;
– unauthori]ed modifications of the machine or its control sys-
tem;
– inadequate monitoring of machine parts subject to wear;
– inexpert repairs;
– force majeure.
AL001AA2.fm

8
 Preliminary Note

1.3 Type Approval and genuine Sauer Spare Parts

• The type approval for the Sauer compressor is valid under the
condition that parts and components specified and qualified by
SAUER USA are used. The type approval is made by
the Classification Society and the EC Declaration of Conform-
ity or EC Manufacturer's Declaration. Please note that if non-
genuine parts are used, in the event of damage the insurance
cover will cease to apply.
• Only the use of genuine Sauer spare parts ensures compli-
ance with these specLficationsand thus the perfect and safe
operation of the Sauer compressor.
• If genuine Sauer spare parts are not used we reserve the right
of exclusion of liability for personal injury and material dam-
age.
• Genuine Sauer spare parts are supplied with a Certificate of
Conformity and a Certificate of Authenticity. A specimen of this
document is shown before the Table of &ontents in these in-
structions. If spare parts are received without this certificate,
there is a risk that these are not genuine Sauer spare parts. In
such case please contact our customer service.

Correct Incorrect

Only use genuine Sauer spare Do not use parts from

parts with certificate! the „grey market“!
AL001AA2.fm

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 Preliminary Note

1.5 How these Instructions are organized

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

Action Individual instructions or multiple instructions, where the se-

quence is of no importance are normally denoted by bullets.
Example:
• Check oil level.

Instructions to be carried out in a certain sequence are num-

bered.
Example:
1. Turn the main switch ON.
2. Choose the operating mode.
3. Turn the control ON.

Results Results of actions carried out are denoted by a check mark.

Example:
✓ The control light is on.

Safety instructions Safety instructions are emphasized by pictographs and signal

words. The safety instructions are described in detail in chapter
2. “Safety”.
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2. Safety
2.1 Specified conditions of use
This Sauer compressor must be used for the compressing of air
only. The Sauer compressor must not be used at ambient tem-
peratures below + °). Any other use is not as specified and re-
quires the explicit consent in writing by SAUER USA.
Observance of these operating instructions, the installation re-
quirements detailed in the instructions, and the keeping of main-
tenance rates are part of the specified conditions of use as well.

2.2 Prohibition of unauthorized conversion

Unauthorized conversion and modification of the Sauer compres-
sor is not permitted, since they could endanger personnel and
may lead to machine damage.
Contact SAUER USA when planning conversions or mo-
difications to obtain a written permission.

2.3 Safety information

The safety information in these instructions is divided in two
classes. The following pictographs and signal words are used:

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

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

2.4 Safety markings on the machine

Danger!
Safety markings affixed to the machine must not be altered or re-
moved. Replace damaged or lost safety markings immediately,
true to the original.
Sauer compressor models with an EC Manufacturer's Declarati-
on or EC Declaration of Conformity are marked with the following
safety markings:

Safety marking Meaning Safety marking Meaning

Danger! High voltage! Read instructions!

(Only on Sauer compres-
sor with electric motor)

Compressor starts auto- Wear hearing protection!

matically without warning!

Hot surface! Rotational direction of

Crankshaft

Location of safety markings (top view)

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2.5 Safety devices
Danger!
Safety devices must not be adjusted, disabled or removed.
The safety devices must be tested and checked on a regular ba-
sis.
Safety valves must be
– installed sealed and
– should only be replaced, adjusted and sealed by authorised
personnel.

Safety valves Every pressure compartment of a stage of the Sauer compressor

is equipped with a safety valve, which will blow off when the
blowing-off pressure is reached.
Safety valves are installed at the following locations:
– 1st compression stage: on the cylinder head of
cylinder of 2nd stage;
– 2nd compression stage: in the condensate separator behind
the stage;

Fusible plug / tem- A fusible plug is fitted in the condensate separator of the 2nd
perature control stage to monitor cooling. It melts at  °) and allows the com-
pressed air to escape, when its temperature exceeds the
threshold value. This protects the compressor against overhea-
ting.
The fusible plug can only be used once. If it blows, it needs to be
replaced with a new one.
As an alternative to the fusible plug, the Sauer compressor can
be fitted with a temperature control. This will turn the compressor
off if the temperature of the compressed air exceeds the limit.

2.6 Noise Protection

Sound pressure level details are found in the Technical Specifica-
tions (see Chapter 4).
If necessary the Sauer compressor can be equipped with a noise
protection hood, which is available as optional accessory from
SAUER USA.

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

2.7 Waste disposal

Note!
Under the laws and regulations in force, the following materials
arising from the operation of the compressor need to be dispo-
sed of ecologically safe:
– condensate (oil and water saturated) arising from recooling in
the compression process;
– used oil and grease and rags soiled by it;
– cleaning agents and rags soiled by it.

2.8 Staff Requirements

Only authorised personnel is permitted to service the Sauer
Compressor! Before commencing work they must have read and
understood the operating manual and must be familiar with the
safety devices and safety regulations.
In addition to the instructions in this operating manual and manuf-
acturer documentation, accepted technical standards must be
observed, as well as all local laws, standards and regulations
such as the
– Equipment and Product Safety Act,
– Ordinance on Industrial Safety and Health,
– Regulations for accident prevention pertaining to compres-
sors,
– VDE regulations and
– Regulations on environmental protection.
In addition, where appropriate, regulations of the responsible
classification society as well as operational regulations must be
observed.
Persons authorised to operate the compressor are the attending
specialists introduced to the job and trained by the operator.
Persons authorised to service the compressor are the trained
specialists of the operator and of the manufacturer.

2.9 Personal protection gear

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

3 10 1 2 4 5 11

9 6 8 7 8
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 Design and Function

Item Name

1 Cylinder 1st stage

2 Cylinder 2nd stage

3 Cooler

4 Safety valve 1st stage

5 Safety valve 2nd stage

6 Condensate separator 1st stage

7 Condensate separator 2nd stage (final separator)

8 Drain valve

9 Oil dip stick

10 Air filter

11 Drive (electric motor or diesel engine)

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Longitudinal sec-
tion

2 1

3 6 7

8 4

Item Name

1 Cooler 1st stage

2 Cooler 2nd stage

3 Fan wheel

4 Connecting rod

Coupling (flexible coupling for electric motor drives; centrifugal

5
clutch for diesel engine drive)

6 Flywheel

7 Transmission bell housing

I_FK008_1A.fm

8 Crankshaft

9 Bearing bracket

18
 Design and Function

Cross section
1 3

2 4

6 7

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

Item Name

1 1st stage: cylinder with head and valve

2 Piston 1st stage

3 2nd stage: cylinder with head and valve

4 Piston 2nd stage

5 Crankcase

6 Connecting rod
I_FK008_1A.fm

7 Dipper

19
3.2 Mode of Operation
Drive The Sauer compressor is driven by an electric motor directly flan-
ged to the transmission bell housing of the crankcase, where the
power is transmitted by means of a flexible coupling.
Alternatively a diesel engine can be used to drive the compres-
sor. This is attached by means of a special flange. It transmits po-
wer by means of a centrifugal clutch.

Compressor cont- The Sauer compressor with electric drive is electrically controlled
rol and monitored by a compressor control system. This control sys-
tem must comply with the legal provisions. Optionally,
SAUER USA supply a suitable compressor control sys-
tem.

Compression The compressor takes in ambient air through a sheet filter with
tube silencer and compresses it in two single-stage cylinders to
the ultimate pressure. Each cylinder is a compression stage, after
which the air is after-cooled.
The final compression temperatures are below the flash point of
standard motor oils (mineral oils).
The cylinders arranged in shape of the letter V are fitted with
easy-to-service lamellar valves with long service life. Due to the
low compression end temperatures the susceptibility of the val-
ves to carbonisation is extremely low.

Cooling An axial fan located on the crankshaft draws cool air in from the
surrounding and blows it over the cylinder, cooler, valves and oil
sump.
The after-cooling takes place after every stage in externally gal-
vanised gilled pipe radiator.

Condensate sepa- Condensate containing oil and water, that is formed during com-
ration pression and after-cooling, accumulates in the condensate sepa-
rator behind every stage.
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 Design and Function

Condensate drai- The condensate is drained through drain lines. Solenoid valves
ning/Pressure reli- are fitted in the drain lines of the Sauer compressor with electric
motor drive. These solenoid valves must be open when the Sauer
ef
compressor is unpressurized. The drain valves should close a
few seconds after starting and the Sauer compressor should ac-
celerate against pressure. The solenoid valves should drain the
machine at predetermined intervals during operation. The sole-
noids valves are controlled by the compressor control system.
Hand valves are fitted in the drain lines of the Sauer compressor
with diesel engine drive. Solenoid valves can be fitted optionally.

Lubrication The drive is lubricated by the splash oil in the crankcase. A dipper
on the connecting rod of the 1st stage dips in the oil sump and
splashes lubricating oil on lubricating points.
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3.3 Indicators on the Sauer Compressor

1 2

Item Name Indication

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

stage stage

Pressure gauge 2nd Ultimate pressure

2
stage

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 Design and Function

3.4 Displays and control elements on the compressor control

Note!
The standard version of Sauer compressor with diesel engine
does not have a compressor control.
If the compressor control is supplied by SAUER USA,
refer the documentation in addition.
The following display and control elements should be present on
the front side of the compressor control:

Display/
Explanation
control element

"Operation" signal Glows when the compressor is running.

lamp

"Oil level" fault indi- Glows if the compressor is cut-off due to oil defi-
cator lamp (optio- ciency.
nal)

"Air temperature " Glows if the compressor is cut-off due to too high a
fault indicator lamp compressed air outlet temperature.
(optional)

"Overcurrent" fault Glows if the compressor is cut-off due to too high a

indicator lamp motor current.

Operating hour Displays the hours of operation of the compressor.

meter

Operating mode • Switch position "Manual":

selector To switch on the compressor manually. Compres-
sor starts and continues to operate until it is manu-
ally switched off.
• Switch position "0"
To switch off the compressor manually. Fault indi-
cators, if any, are reset.
• Switch position "Auto“:
Compressor is started and stopped due to the ope-
ning and closing of an external make-and-break
contact (e.g. pressure switch of the compressed air
receiver).

Main switch Disconnects the power supply from the compressor

control to the compressor.
A main switch should be provided, if required by the
legal or regulatory provisions.
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4. Technical Specifications
4.1 Specification data

Name Data

Compressor type WP 65 L

Number of cylinders 2

Number of compression stages 2

Cylinder diameter 1st stage 136 mm

Cylinder diameter 2nd stage 60 mm

Piston stroke 66 mm

Maximum pump speed 1800 rpm

Direction of rotation (as seen on flywheel) clockwise

Maximum working pressure 580 psi

Set pressures of safety valves:

1st stage 115 psi

2nd stage 5 % higher than the ultimate pressure

Oil filling quantity JDO

Oil quantity between dip stick markings JDO

Oil type see chapter 10. “Lubricant table”

Oil level switch (optional)

Holding capacity 10 VA

Operating current 0.5 A

Setting Opens when oil level is falling

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 Technical Specifications

Name Data

Solenoid valves (standard for operation with elec-

tric motor; optional for operation with diesel
engine):

Pick-up and holding power 18 VA / 14 W

Setting normally open; starting relief: approx.

15 seconds;
intermediate draining: 15 seconds every 15 minu-
tes.

Ultimate pressure switch (standard for operation

with electric motor; optional for operation with die-
sel engine):

Maximum switching current 6A / 220 V

Setting to customer's specifications

Switch function change-over contact

Temperature switch (optional):

Maximum switching current 16A / 440 V

Setting opens at  °) rising

Switch function change-over contact

Non-return valve:

Response pressure approx. 15 psi

Sound pressure level (in free sound field at 1 m maximum 88 dB(A)

distance)

Weight and dimensions see Installation Plan

Note!
Please refer to the order-specific documentation of your com-
pressor for specific data, such as ultimate pressure, speed, po-
wer requirements, etc.
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4.2 P&I-diagram
1 3 4 5 2 3 4 5 10 2

Outlet

Inlet atm.

6 9 8 7 8 7

Item Name

1 Drive motor

2 Safety valve

3 Compressor stage

4 Intercooler and aftercooler

5 Pressure gauge

6 Oil level switch (optional)

7 Condensate separator

Drain valve (for operation with electric motor: solenoid valve; for
8
operation with diesel engine: hand valve)

9 Intake filter

10 Temperature switch (optional)

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 Transport and Installation

5. Transport and Installation

5.1 Transport
Shipping The machine is packed suitable for shipping.
• Immediately on receipt of the Sauer compressor it should be
checked for completeness and damage.
• The transport company and SAUER USA must be im-
mediately notified of any damage to the packing or the machi-
ne.

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

hoisted by crane.

Danger!
Suspended load when transported.
The forklift truck/crane must have sufficient load bearing capaci-
ty.
• Ensure that no persons stay within the danger area of the sus-
pended load and the forklift truck/crane.
• Sling the unpacked compressor at the two lifting eyes on the
crankcase and electric motor or diesel engine as the case
may be (see illustration).
• Lift, move, and set down carefully.

Lifting eyes on the

Sauer compressor
with electric motor
I_MO007_2A.fm

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 Lifting eyes on the
Sauer compressor
with diesel engine

5.2 Storage before installation

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

Note!
Thecompressor
The standard factory conservation
is preserved at theisfactory
sufficient for a maximum
for either 6, 12 or
storage
24 period
months. of 12
If you aremonths.
unaware of your preservation period,
please contact the factory at [email protected].

5.3 Installation
Note!
When in doubt if the intended place of installation and room are
suitable, contact SAUER USA in time before the instal-
lation. There you will also get helpwith the design of a ventilating
system, if required at the place of installation.
For installation observe the installation instructions and the follo-
I_MO007_2A.fm

wing conditions.

28
 Transport and Installation

Installation condi- – The place of installation must be dry and free of dust.
tions – The place of installation must be vented in such way that the
heat generated during operation is dissipated.
– Room temperature while the Sauer compressor is running:
+ … + °)
(deviating temperatures only if confirmed in writing by
SAUER USA)

Note!
The air temperature at the cooling air intake of the compressor
must not exceed + °) when the compressor is running. Room
conditions and the heat, generated by the compressor and other
machines installed in the room, must be taken into considerati-
on.
• If necessary, install a ventilation or exhaust system at the
place of installation.
• Install any ventilation system in such way that the fresh air
stream is not directly directed against the compressor. Other-
wise there is a risk of condensation of water inside the machi-
ne and subsequent damage.
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This way is correct!

Do not install fresh

air feed this way!

Installation condi- – At a room temperature of below + °) the room needs to be

tions (cont'd) heated or the Sauer compressor must be equipped with a he-
ating system.
– Choose the location so that ht e Sauer compressor is accessib-
le and has sufficient clearance to walls and other machinery
(see installation documents).
– Do not position the motor side in a room niche, so the Sauer
compressor will not take in the warmed-up cooling air again.
– Do not position several compressors one after the other, to
prevent one compressor from taking in the warmed-up cooling
air of another compressor.
Note!
I_MO007_2A.fm

SAUER USA is glad to advise you on the installation of

the compressors.

30
 Transport and Installation

Foundation
Note!
The standard delivery resilient-mount bedding has a resonant
frequency of approx. 10 Hz.
Generation of oscillations ofthe intended foundation by other ne-
arby machinery must not be at 10 Hz. Otherwise there is a risk
that the standard delivery resilient-mount bedding is destroyed
by sympathetic vibration.
1. Check early enough if there are foundation vibrations in the
10 Hz range.
2. If in doubt, check with SAUER USA to see if a modi-
fied resilient-mount bedding can be used.
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5.4 Connecting the compressor
Danger!
The compressor should only be connected by qualified technici-
ans. Any work on the electrical installation must be carried out
by qualified electricians only.

Note!
The oil filler tube is insulated using a section of hose. Do not re-
move the insulating material.

Pipelines The compressed air outlet and the drain outlet of the Sauer com-
pressor must be connected to the permanently fitted pipelines
using hose lines (see illustration).
Insulation

Hose lines on the Sauer compres-

sor with electric motor
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 Transport and Installation

Insulation

Hose lines on the Sauer com-

pressor with diesel engine

Danger!
Compressed air escapes from the drain outlets when the com-
pressor starts and when the condensate is drained. Do not ope-
rate compressor without the hose lines connected.
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 Hose lines have to be installed free of tension and untwisted.

This way is correct!

Not this way!

Drain
Note!
Condensate build-up is oil-saturated. It may only be disposed of
in compliance with applicable legal regulations.
SAUER USA can supply condensate collecting pots for
separating condensate, as well as condensate treatment units
for separating the oil from the condensate.

Note!
We recommend connecting the compressor's drainage separa-
tely.
When the drain lines of several compressors are to be connec-
ted to a common pipe, observe the following:
– Choose a sufficient nominal diameter for the common drain
line.
– Connect drain lines of the individual compressors at a sharp
I_MO007_2A.fm

angle to the common drain line, so no pressure can build up

in the drain line of a stopped compressor.

34
 Transport and Installation

This way is correct!

Not this way!

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35
Connections The illustrations show the connections and fittings for the opera-
tion of the standard version Sauer compressor.

5 6 3

1 4 1 2

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

Item Name Type Function

1 Drain valve Solenoid valve Starting relief and draining

2 Drive motor 3-phase motor Drive of the compressor

Ultimate pressure Toggle switch Stops/starts the compressor

3
switch

Oil level switch (opti- Toggle switch Stops compressor in case of low oil level
4
onal)

Temperature control Toggle switch Stops compressor in case of excess tempera-

5
(optional) ture

6 Non-return valve Plug valve Prevent air backflow

I_MO007_2A.fm

36
 Transport and Installation

5 6 3

4 1 7 1 7 2

Item Name Type Function

1 Drain valve Hand valve Starting relief and draining

2 Drive motor Diesel engine Drive of the compressor

Ultimate pressure Toggle switch Stops/starts the compressor

3
switch (optional):

Oil level switch (opti- Toggle switch Stops compressor in case of low oil level
4
onal)

Temperature control Toggle switch Stops compressor in case of excess tempera-

5
(optional) ture

6 Non-return valve Plug valve Prevent air backflow

7 Drain valve (optional) Solenoid valve Starting relief and draining

I_MO007_2A.fm

37
5.5 Filling in oil
The Sauer compressor is supplied without oil.

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

Oil filler plug

Dipstick

1. Unscrew oil filler plug (red).

2. Fill in oil and check level with the dipstick.

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

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

I_MO007_2A.fm

38
 Transport and Installation

5.6 Setting the ultimate pressure switch

Note!
The ultimate pressure switch must be connected directly to the
compressed air receiver to ensure a quiet and uniform compres-
sor operation.
The pressure loss between the compressor and compressed air
receiver must be taken into account for selecting the maximum
set pressure. Too high a set pressure can cause the safety valve
of the final stage to blow off.

5.7 Checks after installation and before the first start

– Electrical connection corresponds with the type label data?
– Are all connections between compressor and the pressurized
air unit supplied correctly installed? Pay special attention to
the compressed air outlet.
– Are drain lines properly connected? See section “Drainage”
– Oil filled into crankcase?
– Have all tools and foreign objects been removed from the com-
pressor?
– Air filter turned from transport position to operating position?
– Entire unit clean?
I_MO007_2A.fm

39
6. Operation
6.1 Safe operation
Danger!
Only authorized personnel is permitted to commission and ope-
rate the Sauer compressor!

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

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

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

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

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

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

6.2 Operating mode

Note!
Applicable to Sauer compressor with compressor control.

After switching on the power supply to Sauer compressor it can

I_BE013_1.fm

be started in one of the following two operating modes using the

operating mode selector :

40
 Operation

– "Manual" operating mode:

Compressor starts and keeps on operating until it is stopped
or switched off using the operating mode selector or the main
switch respectively.
– "Automatic" operating mode:
The starting and stopping of the compressor is controlled ex-
ternally (e.g. by the pressure switch of the compressed air re-
ceiver).
When the Sauer compressor starts, it does so without any load
with the drain valves open. The valves close after a few seconds
and the compressor accelerates against pressure.

6.3 Commissioning
Checking the di-
rection of rotation
Note!
Applicable to Sauer compressor with compressor control.

At first, let the Sauer compressor run only for a few seconds to
check the direction of rotation.
1. Turn power supply ON.
2. Set the operating mode selector to “Manual” to start the com-
pressor in Manual mode.
3. Immediately check the compressor's direction of rotation. It
must rotate in the direction indicated by the arrow on the
crankcase.
4. Set the operating mode selector to “0” to stop the compres-
sor.
5. Turn the power supply OFF.
6. If the direction of rotation is incorrect, have polarity of the
electric motor changed by a qualified electrician.

Test run for Sauer 1. Turn power supply ON.

compressor with 2. Set the operating mode selector to “Manual” to start the com-
electric motor pressor in Manual mode.
✓ If correctly set the drain valves will close after approx. 15 se-
conds and the compressor accelerates against pressure.
3. Check pressure gauges of the stages and compare with no-
minal values (for nominal values see chapter 6.4 "Routine
Operation”).
4. Check the functioning of the automatic intermediate draining.
I_BE013_1.fm

✓ It must drain every 15 minutes for approx. 15 seconds. This is

41
 recognizable by the pressure drop at the pressure gauges.
5. Set the operating mode selector to “0” to stop the compres-
sor.
6. Turn the power supply OFF.
7. If necessary, remove causes for deviations and faults. Also
see Chapter 7. "Trouble-shooting” for this purpose.

Test run for Sauer

compressorwith
diesel engine
Danger!
The Sauer compressor is fitted with a centrifugal clutch for star-
ting relief. The switch-on speed of the clutch is approx.
1000 rpm.
The speed setting must not be changed. Otherwise power trans-
mission starting with about 1400 rpm cannot be guaranteed.

Note!
For Sauer compressor with compressor control see section
"Test-run for Sauer Compressor with Electric Motor”.

1. Open the drain valves on thecondensate separators of the 1st

and 2nd stage.
2. Start the diesel engine.
3. Close both the drain valves.
✓ The compressor accelerates against pressure.
4. Check pressure gauges of the stages and compare with no-
minal values (for nominal values see chapter 6.4 "Routine
Operation”).
5. Open both the drain valves every 15…20 min., drain the con-
densate and close them again.
6. Open both the drain valves.
7. Stop the diesel engine.
8. If necessary, remove causes for deviations and faults. Also
see Chapter 7. "Trouble-shooting” for this purpose.
I_BE013_1.fm

42
 Operation

6.4 Routine operation

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

Checks • Inspect connections, pipelines and electric cables for damage.

• Check the oil level once a week before starting, top up if ne-
cessary. Do not fill oil beyond the maximum mark.

Operation with 1. Turn power supply ON.

compressor cont- 2. Set operating mode selector to “Auto” to operate the com-
rol pressor in Automatic Mode.

Operation without 1. Open the drain valves on the condensate separators of the
compressor cont- 1st and 2nd stage.
rol 2. Start the diesel engine.
3. Close both the drain valves.
4. Open both the drain valves every 15…20 min., drain the con-
densate and close them again.

Observation • Pay attention to abnormal operating sounds.

• Pay attention to leakages (compressed air, oil, condensate).
• During operation the pressure reading of the pressure gauge
should be within the shaded region of the stage pressure chart
(see below).
• In case of deviations see Chapter 7. "Trouble-shooting”.
I_BE013_1.fm

43
 Stage pressure chart 1st stage

580
2nd stage [SVL]

435

290

145

0
0 14.5 29 43.5 58 72.5 87
1st stage [SVL]

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

I_BE013_1.fm

44
 HI001AF2.fm

Troubleshooting

7. Troubleshooting
Note!
• In case of malfunctions, first check the indicators on the com-
pressor control and the compressor .
• Try to remedy the fault by following the information given in
the table below.
• If the cause for the fault cannot be eliminated, contact
SAUER 86$ customer service.

Fault Likely cause Remedy

Operation with compressor No supply voltage / no control Check fuses. Replace blown fuses.
control: compressor does voltage.
not start or is cut-off.

Operation with compressor The oil level is too low. Check the oil level, add oil as required.
control: compressor was
cut-off, "Oil level" fault indi-
cator lamp" (optional) is
glowing.

Operation with compressor The motor is overheated. Determine the cause of the fault and
control: compressor was Excessive current drawn. remedy. The compressor can be
cut-off, "Overcurrent" fault started again after being allowed to
indicator lamp" is glowing. cool off.

Piston seizure Check cylinder and piston for striation,

replace if necessary.

Safety valve of 1st stage

blows off:

Pressure exceeds blow- 2nd stage valve is not working Check 2nd stage valve, replace if nec-
ing-off pressure (SVL) properly. essary.

Pressure below blow- Safety valve is faulty. Replace the safety valve.
ing-off pressure (SVL)

2nd stage safety valve blows

off:

Pressure exceeds blow- Valve in air line to compressed Open the valve.
ing-off pressure (ulti- air receiver closed.
mate pressure + 5%)
Pressure switch set too high. Reduce set pressure.

Pressure below blow- Safety valve set too low or Increase set pressure or replace
ing-off pressure (ulti- faulty. safety valve.
mate pressure + 5%)
Pressure loss in the com- Reduce pressure losses.
pressed air line to the air
receiver too high.
HI001AF2.fm

Maximum pressure is Valve of 2nd stage leaky. Check valve for damage, replace if
exceed in the 1st stage. necessary.

45
 Fault Likely cause Remedy

Pressure gauges of 1st and Valve of 1st stage leaky. Check 1st stage valve, replace if nec-
2nd stage displaying insuffi- essary.
cient pressure.
Air filter very dirty. Replace air filter cartridge.

No pressure indicated in 1st Sauer compressor with electric Check power supply of the solenoid
motor: no voltage at solenoid valve.
and 2nd stage pressure
valve.
gauges.
Sauer compressor with electric Check solenoid valves, replace if nec-
motor: solenoid valve defec- essary.
tive.

Sauer compressor with diesel Close hand valves.

engine: hand valve open.

Air escaping from com- Gaskets of connections leak- Replace relevant gasket.
pressed air lines ing.

Compression ring connections Turn compressor OFF. Wait until all

leaking. parts are relieved of pressure (check
pressure gauges). Then tighten
unions.

Air escaping from the over- Temperature of compressed air Replace fan. Replace fusible plug.
flow opening of the final too high at outlet; insufficient
separator's fusible plug. cooling by faulty fan.

Very dirty cooler; insufficient Clean the cooler. Check room ventila-
ventilation. tion. Replace fusible plug.

Operation with compressor Temperature of compressed air Replace fan.

control: compressor was too high at outlet; insufficient
cut-off, "Air temperature" cooling by faulty fan.
fault indicator lamp"
(optional) is glowing. Very dirty cooler; insufficient Clean the cooler. Check the room ven-
ventilation. tilation.

Operation with compressor No supply voltage. Check fuses, replace blown fuses.
control: solenoid valve does
not close. Solenoid faulty. Replace solenoid.

Foreign matter in solenoid Clean solenoid valve.

valve.

Compressor makes loud Connecting rod bearing faulty. Check connecting rod bearing, replace
noises. if necessary. Check oil supply.

Piston pin bearing faulty. Check piston pin bearing, replace if

necessary.

Crank shaft bearing faulty. Check crank shaft bearing, replace if

necessary.
HI001AF2.fm

46
 Troubleshooting

Fault Likely cause Remedy

Oil leaking from crankcase. Gasket or shaft seal faulty. Tighten screws.
Screws not tight. If there is heavy leaking, check to
see which gasket is faulty, then
replace it.
Minor traces of oil on the crankcase
or oil drops below the compressor are
harmless. Wipe off with a rag.

Water in oil Incorrect ventilation (compres- Change the room ventilation.

sor is undercooled).

Insufficient drainage. Check drain lines and drain intervals.

Insulating sleeve of crankcase Replace insulating sleeve.

vent missing or damaged.

Very short compressor run Extend compressor running time.

time.

Premature breaking of valve Insufficient drainage. Check drain lines and drain intervals.
plates, valve springs or
valve disks. Note: Indentation marks appearing on
the valve plate due to valve impact are
normal.
HI001AF2.fm

47
8

8. Maintenance
8.1 SAUER USA maintenance service
SAUER USA customer service offers various mainte-
nance services: inspections, maintenance, major overhauls, re-
conditioned compressors and service contracts.

8.2 Safety during maintenance

Before mainte- 1. Interrupt power supply to the compressor.
nance work 2. Fit 'Warning: maintenance work' warning sign to power sup-
ply.
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 shouldonly be energised if this
is explicitly specified.
I_WA008_3.fm

48
 Maintenance

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

8.3 Maintenance schedule

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

Use of the mainte- • Use the maintenance schedule as a master template or copy
nance schedule 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 main-
tenance intervals are due depending upon the number of op-
erating 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 main-
tenance interval. The required tasks are indicated by check-
boxes. 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 sched-
ule following commissioning or following the last mainte-
nance routine.
I_WA008_3.fm

49
 Maintenance

8.4 Table of torques

Bolt(s) Torque

Flywheel bolt 1IWOEV

Cylinder head nuts, 1st stageIWOEV

Cylinder head nuts, 2nd stage IWOEV

8.5 Checking screwed connections

Check 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

Wing nut

1. Unscrew wing nut and take air filter cap off.

2. Remove used air filter cartridge.
3. Insert new cartridge into air filter.
4. Place cap back on and screw on wing nut.
I_WA008_3.fm

51
8.7 Changing oil
Note!

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

Oil filler cap

Dipstick

Oil drain plug

1. Run compressor for approx. 5 minutes until operating temper-

ature is reached.
2. Place drip tray (of a capacity sufficient to hold the complete
oil filling quantity, 5.2 l) below the oil drain plug.
3. Unscrew oil filler cap (red),unscrew oil drain plug and pull out
dipstick.
4. Wait until all oil is drained.
5. Screw on oil drain plug with a new ring.
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.
I_WA008_3.fm

52
 Maintenance

8.8 Checking valves

Removing valves 1. Remove hose line of crankcase vent from 1st-stage cylinder
head.
2. Remove cylinder head nuts and remove cylinder heads.
3. Carefully remove valves.

Checking valves 4. Check valves externally for:

(1st- and 2nd- damage,
stage) oiling,
carbonisation,
corrosion and
moisture.
Replace damaged, severely carbonised or corroded valves.
Determine cause.
5. Clean all sealing surfaces.

Note!
Refit all valves with new gaskets and rings only. Only use original
Sauer spare parts.
Fitting other gaskets may result in leaks and could cause sub-
stantial damage to the compressor.

Installing valves
Low tolerance gasket

Cylinder head gasket

I_WA008_3.fm

53
 Note!
Never reuse or turn over and reuse an old low tolerance gasket.
This can lead to leaks in a short time.

6. Insert 1st-stage valve with new original Sauer gaskets.

7. Screw on cylinder head nuts tightly.
Observe tightening torque (see section 8.4).

Cylinder head
gasket

O-ring

8. Insert new O-ring into groove under valve in 2nd-stage cylin-

der.
9. Insert new original Sauer cylinder head gasket between valve
and cylinder head.
10. Attach 2nd-stage cylinder head. Fasten all screwed connec-
tions hand-tight.
11. Screw on cylinder head nuts tightly. Observe tightening
torque (see section 8.4).
12. Screw unions and hose line to the cylinder heads.

Note!
Valves are those parts of a reciprocating compressor that are
subject to the most stress. In order to achieve the guaranteed
maintenance routines, these valves are high-quality precision
parts which have been co-ordinated especially to the individual
compression stages and checked carefully for proper functioning
before delivery.
I_WA008_3.fm

54
 Maintenance

8.9 Replacing valves

Remove and install valves as described in section 8.8, 'Checking
valves'. Replace complete valve.

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

8.10 Replacing piston rings, piston pins and piston pin bear-
ings
1. Remove cylinder heads and valves as described in section
8.8, 'Checking valves'. Carefully clean all sealing surfaces.
2. Remove cylinder head nuts.
3. Remove cylinders. Grab and hold the piston before you have
completely removed the cylinder.

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

4. Remove the safety rings of the piston pins, press the piston
pins out and remove the pistons.
5. Clean piston and replace all piston rings. Make sure they are
in the correct positions: piston rings with asymmetric cross
sections are marked on one of the surfaces with 'TOP'. The
marked face must be at the top when the piston ring is in-
stalled. See illustration.

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.
I_WA008_3.fm

55
 1st stage 2nd stage
TOP
TOP
TOP
TOP

6. Press the piston pin bearing out from the connecting rod
eye using suitable tools and renew.
7. Install piston with the new, halfway-inserted piston pin in
the cylinder.

Note!
The piston ring gap must be staggered.

8. Insert new original Sauer cylinder base gasket.

9. Assemble piston together with cylinder by pressing the pist-
on pin in at the connecting rod. Observe tightening torque
(see section 8.4).
10. Insert circlips precisely into grooves.
11. Install valves and cylinder heads as described in section 8.8,
'Checking valves'.

8.11 Checking pistons and cylinders

1. Remove cylinder heads and valves as described in section
8.9, 'Checking valves'.
2. Remove cylinders and pistons as described in section 8.10,
'Replacing piston rings'.
3. Check cylinders and pistons for scoring and heavy wear and
tear marks. Replace relevant parts.
4. Measure cylinders and replace if the following wear limits are
exceeded:

Cylinders Wear limit for diameter

1st stage 136.15 mm

I_WA008_3.fm

2nd stage 60.10 mm

56
 Maintenance

5. Install cylinders and pistons asdescribed in section 8.10, 'Re-

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

8.12 Renewing flexible gear rim

Note!
This applies to Sauer compressors with electric motors.

Renewing flexible 1. Support compressor under the coupling bell housing.

gear rim 2. Remove the electric motor mounting screws.
3. Carefully lift the electric motor using the lifting eyes (see sec-
tion 5.1, 'Transport').
4. Carefully pull the electric motor away from the compressor.
5. Replace flexible gear rim.
6. Carefully slide electric motor against the compressor and
tighten the motor mounting screws.
7. Remove support from under the coupling bell housing.

Flexible gear rim

Compressor Motor

8. Reinstall separated connecting lines and pipes.

I_WA008_3.fm

57
8.13 Cleaning condensate separators

Strainer Screw plug

1. Remove screw plug.

2. Pull out strainer.
3. Check separator for obstructions.
4. Insert new strainer.
5. Screw in plug.
I_WA008_3.fm

58
 Maintenance

8.14 Overhauling water drain valves

Hexagon nut

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

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

11. Correctly position the plasticthreaded part and press onto the
armature.
12. Carefully position hexagon nut by hand and screw on.
13. Lightly tighten hexagon nut using a spanner.
I_WA008_3.fm

59
9. Placing out of service
9.1 Safety when placing out of service and dismounting
Danger!
The compressor shall only be placed out of service and dis-
mounted by instructed and trained specialists of the operator.
The specialists must be familar with the protection devices and
regulations before starting the work. Any work on the electrical
installation must be carried out by qualified electricians only.
In addition, information contained in the documentation of sub-
suppliers is to be observed.

9.2 Shutting down the compressor temporarily

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

Note!
Use one of the slushing oils recommended in Chapter 10 "Lubri-
cant Table" for corrosion protection.
The slushing oil has satisfactory running properties. In case of
emergency the machine can be started for a short duration with
slushing oil filling.
1. Run compressor for approx. 5 minutes with drain valves and
pressure line open.
✓ Any existing condensate is blown off.
2. Open the oil drain plug (see illustration in chapter 8.5 "Oil
change“), drain compressor oil and dispose it off in an envi-
ronmentally friendly manner. Close the oil drain plug again.
3. Fill about 3 litres of slushing oil.
4. Start compressor and run for approx. 5 minutes with drain val-
ves and pressure line opened.
5. Stop compressor.
6. Remove the air filter onthe cylinder head of the 1st stage (see
illustration in section 3.1 "Overview"). For this purpose,
loosen the clamp and lift off the air filter.
7. Unscrew the safety valve of the 1st stage on the cylinder head
of the 2nd stage (see illustration in section 3.1 "Overview“).
I_DE006_1.fm

8. Start compressor and slowly inject approx. 15 cc slushing oil

60
 Placing out of service

into the intake port of the 1st stage.

9. Slowly inject approx. 10 cc slushing oil in the opening in the
cylinder head of the 2nd stage.
10. Wait until oil mist comes out of the pressure line.
11. Stop compressor.
12. Fit air filter and safety valve back. Use new gasket for the sa-
fety valve.
13. If necessary, post a sign that the compressor has been trea-
ted with anticorrosion agents and is shut down.
14. Disconnect power lines from the mains supply, if necessary.

Placing back into 1. Connect to power supply, if necessary.

service 2. Drain slushing oil and fill with compressor oil. Proceed as de-
scribed in chapter 6.3 "Commissioning”.

9.3 Dismantling
Dismantling 1. Turn compressor OFF and disconnect from power supply.
2. Make sure by reading the pressure gauges before servicing
that the compressor is completely relieved of pressure.
3. Disconnect power lines from the mains supply.
4. Remove oil and lubricants and dispose of in an environmen-
tally friendly manner.
5. Drain any remaining condensate and dispose of in an envi-
ronmentally friendly manner.

Disposal

Material/component How to dispose

Lubricants as hazardous waste

Steel/iron as metal scrap

Electric cables as hazardous waste

Electronic components as electronic waste

Plastics as hazardous waste

I_DE006_1.fm

61
ST001AC1.fm

10. Lubricant Table

Note!
Lubricants not mentioned in the lubricant table may only be used
after approval by SAUER86$. Otherwise the warranty
will expire. Contact customer service in case of need.
Take note of all information about the lubricants given in this
chapter.

Area of validity The lubricant table applies to all Sauer compressors intended for
the compression of air.
The lubricant table does not apply to
– Sauer compressors for the compression of neutral gases;
– temperature ranges outside of  …  °).

General recom- The following recommendations apply to the  …  °) temper-

mendation ature range:
– Use mineral oils of viscosity class ISO VG 100 or SAE 30.
– Lubricating oils should conform to group VCL according to
DIN 51506.

Note!
In the case of 2-stage 435 psi compressors the use of synthet-
ic lubricating oils may be beneficial. Please contact us for more
information about synthetic lubricating oils approved by us.

ST001AC1.fm

62
 Lubricant Table

10.1 Lubricating oils

Brand Name Group
Agip Diesel Gamma 30 VCL-100
Dicrea 100 VDL-100
Acer 100 VCL-100
Motor Oil HD 30 SAE 30
Cladium 50 SAE 30
ARAL Motanol HE 100 VDL-100
Kowal M 30 VCL-100
Disola M 30 SAE 30
AVIA Avilub Compressor Oil VDL-100 VDL-100
Avilub Compressor Oil VDL-100 VCL-100
Motor oil HDC 30 SAE 30
Motor oil HD 30 SAE 30
BP Energol RC 100 VDL-100
Energol IC-DG 30 VCL-100
Energol DL-MP 30 SAE 30
Energol OE-HT 30 SAE 30
Vanellus C3 SAE 30 SAE 30
Castrol Aircol PD 100 VDL-100
Marine CDX 30 SAE 30
Chevron HD Compressor Oil 100 VDL-100
Delo 1000 Marine 30 SAE 30
Veritas 800 Marine 30 SAE 30
RPM Heavy Duty Motor 30 SAE 30
DEA Actro EP VDL-100 VDL-100
Trion EP VDL-100 VDL-100
Regis SAE 30 SAE 30
Esso Exxcolub 77 VDL
Exxcolub 100 VDL-100
Compressor Oil 3021 N VDL-100
Exxmar 12 TP 30 SAE 30
Exxmar XA SAE 30
Essolube HDX Plus +30 SAE 30
Mobil Rarus 427 VDL-100
DTE Oil Heavy VDL
Mobilgard 300 SAE 30
Shell Corena Oil P 100 VDL-100
Rimula X 30 SAE 30
Melina S Oil 30 SAE 30
ST001AC1.fm

Melina Oil 30 SAE 30

Gadinia Oil 30 SAE 30

63
 Brand Name Group
TEXACO Compressor Oil EP VDL 100 VDL-100
Regal R&O 100 VCL-100
Ursatex 30 SAE 30
DORO AR 30 SAE 30
TOTAL Dacnis P 100 VDL-100
Carprano TD 30 SAE 30
Milcano TC 30 SAE 30
Disola M 3015 SAE 30

10.2 Slushing oils

Brand Name

Agip Rustica C SAE 30

ARAL Konit Motor Oil SAE 30

AVIA MK 1540 S

Avilub MK 3000

BP MEK 20 W-20

Castrol Running-in and Preservation Oil

DEA Deamot EKM 642 SAE 30

ELF Stockage 30

Esso MZK Motor Oil HD 30

Antirust MZ 110

FINA Rusan NF Motor Oil SAE 30

Mobil Mobilarma 524

Shell Ensis Motor Oil 30

TEXACO Engine Oil EKM 146 SAE 30

ST001AC1.fm

64
 Spare Parts and Accessories

11. Spare Parts and Accessories

Note!
Please note the inIRrmation in chapter 1. “General” regading our
genuine Sauer spare parts.
SAUER USA gXaranteeV the complete spare parts supply
over the entire service life of the Sauer compressor.
Our genuine Sauer spare parts are subject to constant quality
control and further development. They conform to the latest tech-
nical developments.
In addition to the genuine Sauer spare parts, our delivery pro-
gram comprises a large number of accessories for your Sauer
compressor and special components to complete your air sys-
tem, such as:
– fully automatic controls;
– adsorption dryers;
– refrigerated air dryers;
– filters;
– silencing cabinets;
– compressed air receivers;
– fittings.
We supply instructions and a maintenance manual for each ac-
cessory.

Spare parts cata- The spare parts catalogue is found in the annex to these instruc-
logue tions.
– With the help of overviews, illustrations and lists the required
parts is quickly found.
– The spare parts catalogue, including the operating instructions
is also available on CD-ROM.Here, an order form can be filled
in, printed out and send immediately.
For doing so, you need themain specifications of your Sauer
compressor from the table below. If they have not yet been en-
tered there, they can be found on the type label affixed to the
crankcase.

Compressor type
Factory no.:
Year of construc-
tion:
EZ001AA1.fm

Furthermore, the number of operating hours should be stat-

ed, if possible.

65
12. Annex
This Annex to the operating instructions contains
– documentation supplied by outside vendors;
– data sheets.

AN001AA1.fm

66
E -2 Version 3 - 3
 Spare Part List

WP 65L Sauer compressor

Reference No. Subassemblies Page

WP 65L Sauer compressor . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . 4

064 478 crankrcase. . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . 6

064 058 crankshaft . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 10

064 059 connectig rod 1st stage . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 12

064 060 connectig rod 2nd stage . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 14

031 881 piston 1st stage . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 16

064 061 piston 2nd stage . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 18

064 062 cylinder with head and valve 1st stage .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 20

064 063 cylinder with head and valve 2nd stage . . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 22

065 910 cooler compl. . . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 24

065 909 air lines . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 28

064 072 crankcase venting . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 30

064 071 measuring device . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 32

037 219 flexible coupling f. E-Motor . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 34

037 331 centrifugal clutch f. Diesel engine. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 36

064 070 resilient mounts f.E-Motor . . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 38

064 778 resilient mounts f. Diesel engine . . . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 40

060 354 automatic drainage .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 42

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

of the operating instructions

Version 3 - 3 E -3
 WP 65L Sauer compressor

E -4 Version 3 - 3
 Spare Part List

WP 65L Sauer compressor

Item Reference No. Designation Qty.

1 064 478 crankrcase 1

2 064 058 crankshaft 1
3 064 059 connectig rod 1st stage 1
4 064 060 connectig rod 2nd stage 1
5 031 881 piston 1st stage 1
6 064 061 piston 2nd stage 1
7 064 062 cylinder with head and valve 1st stage 1
8 064 063 cylinder with head and valve 2nd stage 1
9 065 910 cooler compl. 1
10 065 909 air lines 1
11 064 072 crankcase venting 1
12 064 071 measuring device 1
13 037 219 flexible coupling f. E-Motor 1
14 037 331 centrifugal clutch f. Diesel engine 1
15 064 070 resilient mounts f.E-Motor 1
16 064 778 resilient mounts f. Diesel engine 1
17 060 354 automatic drainage 1

Version 3 - 3 E -5
 064 478 crankrcase

E -6 Version 3 - 3
 Spare Part List

064 478 crankrcase

Version 3 - 3 E -7
E -8 Version 3 - 3
 Spare Part List

064 478 crankrcase

Item Reference No. Designation Qty.

1 064 268 crankcase 1

2 064 122 bearing bracket 1
5 064 047 packing for bearing bracket 1
6 005 029 gasket 1
7 000 979 plug 1
8 064 064 dipstick 1
10 001 620 hexagon nut 4
11 000 269 eye bolt 1
12 005 930 stud 7
13 037 152 cylinder head stud 2nd stage 4
14 037 153 cylinder head stud 1st stage 6
15 030 744 plug 1
16 002 031 hexagon nut 13
17 002 156 washer 7
19 005 009 gasket 1
20 001 886 shaft seal 1
21 030 831 shaft seal 1
30 035 520 o-ring 2

Version 3 - 3 E -9
 064 058 crankshaft

E -10 Version 3 - 3
 Spare Part List

064 058 crankshaft

Item Reference No. Designation Qty.

1 064 124 crankshaft 1

2 064 382 flywheel 1
3 064 054 pressure washer flywheel 1
4 056 887 pressure washer fan wheel 1
5 064 642 washer 1
7 033 502 fan wheel 1
9 000 119 hexagon head screw 1
10 000 188 hexagon head screw 1
12 001 667 locking plate 1
13 002 439 circlip 1
14 004 458 tension bushing 1
15 001 982 fitting key 2
16 002 266 cylinder roller bearing 1
17 037 154 cylinder roller bearing 1

Version 3 - 3 E - 11
 064 059 connectig rod 1st stage

E -12 Version 3 - 3
 Spare Part List

064 059 connectig rod 1st stage

Item Reference No. Designation Qty.

1 066 719 pin 1

2 064 126 connecting rod 1st stage 1
4 002 094 hexagon nut 1
5 037 155 connecting rod bearing 1
6 036 107 piston pin bearing 2

Version 3 - 3 E - 13
 064 060 connectig rod 2nd stage

E -14 Version 3 - 3
 Spare Part List

064 060 connectig rod 2nd stage

Item Reference No. Designation Qty.

2 064 128 connecting rod 2nd stage 1

5 037 155 connecting rod bearing 1
6 037 156 piston pin bearing 1

Version 3 - 3 E - 15
 031 881 piston 1st stage

E -16 Version 3 - 3
 Spare Part List

031 881 piston 1st stage

Item Reference No. Designation Qty.

2 031 883 piston pin 1

3 012 512 M-ring 1
4 031 901 N-ring 1
5 031 902 G-ring 1
6 002 976 circlip 2

Version 3 - 3 E - 17
 064 061 piston 2nd stage

E -18 Version 3 - 3
 Spare Part List

064 061 piston 2nd stage

Item Reference No. Designation Qty.

1 064 129 piston 2nd stage 1

2 064 074 piston pin 1
3 031 541 R-ring 2
4 002 548 N-ring 1
5 031 542 S-ring 1
6 002 980 circlip 2

Version 3 - 3 E - 19
 064 062 cylinder with head and valve 1st stage

E -20 Version 3 - 3
 Spare Part List

064 062 cylinder with head and valve 1st stage

Item Reference No. Designation Qty.

1 064 130 cylinder 1st stage 1

2 064 134 cylinder head 1st stage 1
3 064 048 cylinder foot packing 1st stage 1
4 063 059 cylinder head packing 1st stage 1
5 056 235 low tolerance gasket 1
7 030 911 air filter 1
8 037 157 lamellar valve 1st stage 1
9 03  filter insert for air filter 1

Version 3 - 3 E - 21
 064 063 cylinder with head and valve 2nd stage

E -22 Version 3 - 3
 Spare Part List

064 063 cylinder with head and valve 2nd stage

Item Reference No. Designation Qty.

1 064 132 cylinder 2nd stage 1

2 064 135 cylinder head 2nd stage 1
3 064 049 cylinder foot packing 2nd stage 1
4 064 051 cylinder head packing 2nd stage 1
5 006 385 reducer tube 1
6 037 158 lamellar valve 2nd stage 1
7 030 915 safety valve 1st stage 1
8 005 016 gasket 1
9 037 526 o-ring 1

Version 3 - 3 E - 23
 065 910 cooler compl.

E -24 Version 3 - 3
 Spare Part List

065 910 cooler compl.

Version 3 - 3 E -25
E -26 Version 3 - 3
 Spare Part List

065 910 cooler compl.

Item Reference No. Designation Qty.

1 065 905 cooler 1st stage 1

2 064 068 cooler 2nd stage 1
3 056 914 fan cover 1
4 064 341 pipe 4
5 064 139 cooler flange 1
6 064 041 cooler ledge 3
7 064 050 packing 1
8 064 042 clamp 3
9 064 075 clamp 3
10 064 643 pipe 1
11 005 247 hexagon head screw 3
12 033 532 hexagon head screw 9
13 000 123 hexagon head screw 6
14 000 493 cylinder head screw 4
15 003 114 locking washer 12
16 006 186 union 1
17 012 862 cutting ring 2

Version 3 - 3 E - 27
 065 909 air lines

E -28 Version 3 - 3
 Spare Part List

065 909 air lines

Item Reference No. Designation Qty.

1 063 121 final separator 1

2 064 567 clamp 1
4 066 170 pipe 1
6 000 147 hexagon head screw 2
7 005 671 socket head cap screw 2
8 006 187 union 2
9 006 186 union 1
10 006 225 union 2
11 006 386 reducer tube 1
12 006 385 reducer tube 1
14 037 221 separator 1st stage 1
15 030 752 safety valve 2nd stage 1
17 005 009 gasket 1
18 005 016 gasket 2
19 005 023 gasket 1
20 030 340 O-ring 1

Version 3 - 3 E - 29
 064 072 crankcase venting

E -30 Version 3 - 3
 Spare Part List

064 072 crankcase venting

Item Reference No. Designation Qty.

1 035 824 filling cover 1

2 006 380 reducer 1
3 006 205 union 1
4 033 487 stud adaptor 1
5 037 138 reducer 1
6 037 137 distribution piece 1
7 064 522 pipe adaptor 1
8 005 009 gasket 1
9 034 612 hose 400mm long 1
10 033 952 hose 120mm long 1
11 035 254 hose clamp 2
12 012 766 pipe 40mm long 1

Version 3 - 3 E - 31
 064 071 measuring device

E -32 Version 3 - 3
 Spare Part List

064 071 measuring device

Item Reference No. Designation Qty.

1 087 057 pressure gauge 1st stage 1

2 062 408 connector 1
3 035 061 gasket 3
4 037 160 adaptor 1
5 003 500 gasket 1
6 086 138 pressure gauge 2nd stage 1
7 038 264 pressure gauge angle 90° 1

Version 3 - 3 E - 33
 037 219 flexible coupling f. E-Motor

E -34 Version 3 - 3
 Spare Part List

037 219 flexible coupling f. E-Motor

Item Reference No. Designation Qty.

1 033 494 flexible gear rim 1

Version 3 - 3 E - 35
 037 331 centrifugal clutch f. Diesel engine

E -36 Version 3 - 3
 Spare Part List

037 331 centrifugal clutch f. Diesel engine

Item Reference No. Designation Qty.

3 033 494 flexible gear rim 1

Version 3 - 3 E - 37
 064 070 resilient mounts f.E-Motor

E -38 Version 3 - 3
 Spare Part List

064 070 resilient mounts f.E-Motor

Item Reference No. Designation Qty.

2 061 001 hose lines 2

3 000 068 hexagon head screw 1
4 001 637 washer 1
5 031 149 resilient mount 3
6 037 172 fixing rail 3
7 000 066 hexagon head screw 2
8 002 166 washer 2
9 037 746 hp-hose 1
10 033 488 non return valve 1

Version 3 - 3 E - 39
 064 778 resilient mounts f. Diesel engine

E -40 Version 3 - 3
 Spare Part List

064 778 resilient mounts f. Diesel engine

Item Reference No. Designation Qty.

2 061 001 hose lines 2

3 034 172 resilient mount 4
4 037 172 fixing rail 4
5 000 066 hexagon head screw 4
6 002 166 washer 4
7 037 746 hp-hose 1

Version 3 - 3 E - 41
 060 354 automatic drainage

E -42 Version 3 - 3
 Spare Part List

060 354 automatic drainage

Item Reference No. Designation Qty.

1 037 680 solenoid valve 1

3 006 455 stud adaptor 1
4 006 381 reducer 1
5 004 635 union 1

Version 3 - 3 E - 43
E -44 Version 3 - 3
 Index

Reference No. Designation Page Pos.

000 066 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 7

000 066 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 5
000 068 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 3
000 119 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 9
000 123 hexagon head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 13
000 147 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 6
000 188 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 10
000 269 eye bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 11
000 493 cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 14
000 979 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
001 620 hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 10
001 637 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4
001 667 locking plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 12
001 886 shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 20
001 982 fitting key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 15
002 031 hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 16
002 094 hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4
002 156 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 17
002 166 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 8
002 166 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 6
002 266 cylinder roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 16
002 439 circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 13
002 548 N-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4
002 976 circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6
002 980 circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 6
003 114 locking washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 15
003 500 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 5
004 458 tension bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 14
004 635 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 5
005 009 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 19
005 009 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 17
005 009 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 8
005 016 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 8
005 016 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 18
005 023 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 19
005 029 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6
005 247 hexagon head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 11
005 671 socket head cap screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 7
005 930 stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 12
006 186 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 16
006 186 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 9
006 187 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 8
006 205 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3
006 225 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 10
006 380 reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 2
006 381 reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 4
006 385 reducer tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5
006 385 reducer tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 12
006 386 reducer tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 11
006 455 stud adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 3
012 512 M-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3

Version 3 - 3 E -45
 Reference No. Designation Page Pos.

012 766 pipe 40mm long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 12

012 862 cutting ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 17
030 340 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 20
086 138 pressure gauge 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 6
030 744 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 15
030 752 safety valve 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 15
030 831 shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 21
030 911 air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 7
030 915 safety valve 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 7
031 149 resilient mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 5
031 541 R-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 3
031 542 S-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5
031 881 piston 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5
031 883 piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2
031 901 N-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4
031 902 G-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5
033 291 filter insert for air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 9
033 487 stud adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 4
033 488 non return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 10
033 494 flexible gear rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 1
033 494 flexible gear rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 3
033 502 fan wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 7
033 532 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 12
033 952 hose 120mm long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 10
034 172 resilient mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 3
034 612 hose 400mm long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 9
035 061 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 3
035 254 hose clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 11
035 520 o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 30
035 824 filling cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 1
036 107 piston pin bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 6
037 137 distribution piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 6
037 138 reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5
037 152 cylinder head stud 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 13
037 153 cylinder head stud 1st stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 14
037 154 cylinder roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 17
037 155 connecting rod bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 5
037 155 connecting rod bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 5
037 156 piston pin bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 6
037 157 lamellar valve 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 8
037 158 lamellar valve 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 6
037 160 adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 4
037 172 fixing rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 6
037 172 fixing rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4
037 219 flexible coupling f. E-Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 13
037 221 separator 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 14
037 331 centrifugal clutch f. Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 14
037 526 o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 9
037 680 solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 1
037 746 hp-hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 9
037 746 hp-hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 7

E -46 Version 3 - 3
 Index

Reference No. Designation Page Pos.

038 264 pressure gauge angle 90° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 7

056 235 low tolerance gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 5
056 887 pressure washer fan wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4
056 914 fan cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 3
060 354 automatic drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 17
061 001 hose lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2
061 001 hose lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 2
062 408 connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 2
063 059 cylinder head packing 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4
063 121 final separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 1
064 041 cooler ledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 6
064 042 clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 8
064 047 packing for bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 5
064 048 cylinder foot packing 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3
064 049 cylinder foot packing 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3
064 050 packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 7
064 051 cylinder head packing 2nd stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 4
064 054 pressure washer flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3
064 058 crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2
064 059 connectig rod 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3
064 060 connectig rod 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4
064 061 piston 2nd stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 6
064 062 cylinder with head and valve 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 7
064 063 cylinder with head and valve 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 8
064 064 dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 8
064 068 cooler 2nd stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2
064 070 resilient mounts f.E-Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 15
064 071 measuring device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 12
064 072 crankcase venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 11
064 074 piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2
064 075 clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 9
064 122 bearing bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2
064 124 crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1
064 126 connecting rod 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2
064 128 connecting rod 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2
064 129 piston 2nd stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1
064 130 cylinder 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1
064 132 cylinder 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1
064 134 cylinder head 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2
064 135 cylinder head 2nd stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2
064 139 cooler flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5
064 268 crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1
064 341 pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 4
064 382 flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2
064 478 crankrcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1
064 522 pipe adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 7
064 567 clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 2
064 642 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5
064 643 pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 10
064 778 resilient mounts f. Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 16
065 905 cooler 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1

Version 3 - 3 E -47
 Reference No. Designation Page Pos.

065 909 air lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 10

065 910 cooler compl.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 9
066 170 pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 4
087 057 pressure gauge 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 1
066 719 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1

E -48 Version 3 - 3