.

... "\

.-,
.-
-

I I

, I ,
Type: WP 4351

- - -- -
. - .. . -
. .
-

Ein M llJlltd dc.

SAUER-Gmppc

Versioo 3- 3
-- ~-------------------
,,
-
,
I,

-
I

-
(
-

Ed ition : 7-24-2012
Ed ited by: SAU ER USA - Tec hnical Documentation
(

Vers ion 3 - 3
 t

Sauer compressor Type Approvals

q,)cr11l,1II1schrr I Jopll

n :I(']ll"1t '.\I I: i ll 'I \I'I: .u'I'IU""I

...... _---_ ...--_ ... _.-.

- - - " -'-
--,--
>t _
'~-""--""
_ _ _ _ .., ... ..... ,,,. _ . _
~

--'- --
=.-::--=~.: ~..=:"' ";':!;"'- ...
_ ... ...
---'........
.",

__ .. ......'.. c
EC "*<;~ tOon 0 1 Con lOlml1)"
--=:~

--_ __ .-_.
-- . . .
.. . . " ' ~'. ' I~ I ... ' , ~ .... , " ' , , "
-.-- ..
,- ....... -,-_ ..........

_r_._-...
__.. _._._. w

,-,,-,
~,---~- ...... -~ ....
("""-_~~_

----_ - -_ ..
"'_ .........c. _ ......
..
I'~
IC

--
-..1_--
ww_. __
~--

-~
... _

mClT.l
DET NOR SKE VERITA $
T y pE. ApPROVAL CERTI Fler\TE
............ .......
'''''-'''-'''-

.-.-- '!.,
" . . . .... " ' 10. . . . . . , . " . . . . "
=:".:.....
~ ""-
-----
" " " '. '" ' .. L . .......

J.t ." .w ... ,

""- ...... "
'I.""'"'''' ....." .. .'"

,._.. .......
. ."............"._............... - ... ,..
"', . ....,. ,............
" .~

---
-_ ..
' .... --
' ~.- -
_".- ,

,.........
'''''''--

Note!
On this page only a few exampl es are shown. Furth er TypeAp-
proval s are available on request.

Vers ion 3 - 3
 Genuine Sauer spare parts
certified safety

Certificate of Conformity and Authenticity

With this Certifi cate ofConformil y and Au thent 1cil)' we the

~~~c1~t\~ ~<i~ 24157 Kic l - Germany

('
certi fy tha t tht.: ite rns,lotu l no. _ _ _ and on ly these it ems
which have been delivered wit h allachcd shipping note
numbe r an:

~I~,:~,~:,~ r .
s a~;;~~~~~
wnnes, r!' .~l~~~Y OIl ' he
attache . 1 ' not \ c ce rti fica te ilsclf w ill make this
cc rlifi e. i '. . In thi s case the re arcjuslifi cd ev idences
lila! grey ma rket spares of inferior q uality have bee n
dcl i vcn~ d .

If you want to be informr:d a bout your ad vantages when

using Genuine Sa uer Spa re Parts or in case of do ubts. please
contact Oll r Scrvict: Department:
1111. -49-431 -39 40 -8&187 (Fax -89).
e-ma il: scrvicc@J..,.lILcr,ohn.dc
or visi t Ollf webs ite hnpllwww''''lllcr:'>ohn. dc .

('

I'

Kid, _ _ _ _ _ _ _ __

Version 3 - 3
 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 ........... . . ..... ... 22
3.3 Indicators on the Sauer Compressor .. .... . 23
3.4 Indicators and controls of the compressor control
system ............ . .... . ....... ..... 25

4. Technical specifications ............ . .. 26

4.1 Data table . . .. .. . . ....... . ... . .. . . . .. 26
4.2 P&I-diagram ... . .... ... . . . .. .. .... .... 28

5. Transport and Installation ............. 30

5.1 Transport . ..... . ........ . ........ . ... 30
5.2 Storage before installation .. . .. . ... . ..... 31
.sN 5.3 Installation ............... . ... . ... . ... 31
>
5.4 Connecting the compressor .. . . . . . ... . . . . 34
"<,
"',
~
5.5 Filling with oil .. . .......... .. ... .. . .... 38
M

~ 5.6 Setting the ultimate pressure switch . . . . ... 39

~

Ve rsion 3 - 3
5
 ,.

f
5.7 Checks after installation and before the first
~art ........ ................ ........ 39

6. Operation ........................... 40
6.1 Safe operation ..... .. ......... .. ...... 40
6.2 Operating modes ... .. ................. 41
6.3 Initial operation ..... . . .. . ....... .. . . .. 41 I'
6.4 Routine operation .... .. . .. . .. .. . . . .. .. 42
f
7. Trouble-shooting .................... . 44 f

8. Maintenance ................... . .... 47

8.1 Maintenance service by SAUER USA I'
............. ........ ..... ...... ... 47 I'
8.2 Maintenance safety .......... ........ .. 47
8.3 Maintenance schedule ........... . ..... 48
8.4 Table of tightening torques .. . . ... ..... . . 50
8.5 Oil change ..... . ... . ....... ... ... . ... 50
8.6 Check screwed connections. . . . . . . . . . . . . 51
8.7 Air filter cartridge replacement . . . . . . . .... 52
8.8 Checking valves .. ... ........ . . .. ..... 52
8.9 Checking the piston rings ............... 60
8.10 Replacing piston pins/piston pin
bearings .... ...... ........ .... .. .. .. 61
8.11 Replacing valves ..... ..... .... . . .. . ... 62
8.12 Checking pistons and cylinders ........... 62
8.13 Checking the drive bearings .. . ......... . 63
8.14 Checking the coupling .................. 64

9. Placing out of Service ................. 66

9.1 Safety when placing out of service and
dismounting .......... .. ..... ...... ... 66
9.2 Shutting down the compressor temporarily .. 66
9.3 Dismantling ............ ... ........... 68

10. Lubricant Table ..... . ................ 69 ..

N
10.1 Lubricating oils .... ... . ............... 70 ::i
;:;'
10.2 Slushing oils ..... ......... ... . .. . . . .. 71 '
a.
~

Version 3 . 3
6
11. Spare Parts and Accessories ......... . . 72

12. Annex ............ . .. . .. . . . . .... .. .. 73

Version 3 3
7
1. Preliminary note
1.1 Important information
Th e following main spec ifi cations 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 thi s information in chapter
11 . "Spare Parts and Accessories".

Conditions We presuppose that only authori sed persons will operate and
se rvice the Sauer com pressor. These persons mu st have read
and understood the operating instructions.

Availability These instructions shall always be kept ava il able at the site of op-
eration.

Copyright Th e copyri ght for these in structi ons remains with

SAU ER USA. Th ese in structions, or parts thereof, shall
not be copied , distributed or made available to third parti es. Con-
travention will be prosecuted.

1.2 Warranty and Liability

We exonerate the contractually agreed wa rranty claims and liabil-
ity claims, if they can be attributed to at least one of th e 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 instruction s;
- unauthorized modifications of the machine or its control sys-
tem;
- inadequate monitoring of machine parts subject to wea r;
- inexpert repairs;
- force majeure.

8 Version 3 - 3
 Preliminary note

1.3 Type approval and genuine Sauer spare parts

- Th e type approva l for the Sa uer compressor is valid under the

condition that parts and components specified and qualified by
SAU ER USA are used . The type approval is made by
the Classification Society and the EC Declaration of Conform -
ity or EC Manufacturer's Declaration . Pl ease note that if non-
genuine parts are used , in th e event of damage the in surance
cover wi ll cease to apply.
Only the use of genuine Sauer spare parts ens ures compli-
ance with these specifications and thus the perfect and safe
operation of the Sauer compressor.
If genuine Sauer spare parts are not used we reserve the right
of exclusion of li ability for personal injury and material dam -
age.
Genuine Saue r spare parts are supplied with a Certificate of
Conformity and a Ce rtificate of Au th en ticity. A specimen of this
document is shown before the Table of Contents in these in-
structions. If spare parts are received without thi s certificate,
there is a risk th at 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"!

V ersion 3 ~ 3
--- ~------------------
1.4 SAUER USA customer service
Shou ld you have any techn ical questions relat ing to ma intenance
or repair, please contact our Customer Service :

SAUER USA
64 Log Canoe Cir.
Stevensville. MD 21666

Te lephone: 410-604-3142
Fax: 410-6 04-3209
E-Ma il : service@sa uerusa .com
Web: www.saue rusa.com

Note!
If you have questions rega rding your Sauer Comp ressor, please
state Compressor model and serial number (see chapter 11
"Spare Parts and Accesso ries" or nameplate on the compres-
sor).

10 Version 3 - 3
,.
 Preliminary note
t

1.S Ho'f 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:
.I 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".

Version 3 - 3 11
2. Safety
2.1 Specified conditions of use
Thi s Sauer compressor must be used for th e compressing of air
only. The Saue r compressor must not be used at ambie nt tempe
ratures below +4 1 of . Any oth er use is not as specified and requires
the explicit consent in writi ng by SAU ER U SA.
Observance of th ese operating in structions, the in stall ation re-
quirements detailed in the instructions, and the keepi ng of main-
tenance rates are part of th e specified condition s of use as well.

2.2 Prohibition of unauthorized conversion

Unauthorized conve rsion and modification of the Sauer compres-
sor is not permitted , since they could endanger humans 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 informa ti on in these instructions is divided in two clas
ses. Th e foll owing pictographs and signal words are used:
I
Danger!
High risk.
Disregard of this safety inform ation may cause personal injury
and substantial material damage.

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

I
~'
;;
,
in

12 Ve rsion 3 - 3
 Safety

2.4 Safety markings on the machine

Danger!
Safety markings affixed to the machine must not be altered or re-
moved . Repl ace dam aged or lost safety markings imm ed iately,
true to the origina l.
Sauer compressor models with an EC Manufactu rer's Declarati-
on or EC Decl aration of Conformity are marked with the foll owing
safety markings:

Safety marking Meaning Safety marking Meaning

Danger l High voltage I Re ad instru ctions!

~ 0

Compressor starts a ut o Wear hea ring protection!

~
matica lly without wa rning!

Hot surface! Rotati onal directi on of

6l\ Crankshaft

Location of safety markings (top view)

~'

""-'
Version 3 - 3 13
2.5 Safety devi ces
Danger! r
Safety devices must not be adjusted, disabl ed or removed .
Th e safety devices must be periodically tested and checked.
Safety valves mu st be
- installed in sealed condition and
- shou ld be repl aced, adjusted and sealed by authorised pe r
sonne I only.

Safety val ves Every pressure compartment of a stage of th e Sauer compressor

is eq uipped wilh a safety valve , which wi ll blow off whe n the blo-
wing-off pressure is reached.
Safety valves are installed at these locations:
- 1st compression stage: in the 1st stage's honeycomb rad iator;
- 2 nd compression stage: in a trun k after th e condensate se pa-
rator of th e second stage;
- 3 rd compression stage: in th e condensate separator of th e
th ird stage;
- 4 th compression stage: in the condensate separator of th e
fourth stage (final separator).

Contact thermo- The Sa uer compressor is fitted with a contact thermometer for
,.
meter monitoring the comp ressor cooling. This wi ll turn the compressor I'
off if the temperatu re of the compressed ai r exceeds the limit.

2.6 Noise protection

Sound pressure level details are found in the Technica l Specifica-
tions (see chapte r 4).
If necessa ry th e Sauer co mpresso r can be eq uipped with a noise
protection hood, whi ch is avail abl e as optional accessory fro m
SAUER USA.

Danger!
When the compressor is operated without noise protection hood,
hea ring protection shou ld be wo rn near the compressor.

~'

"- '
in

14 Version 3 - 3
 Safety

2.7 Waste disposal
Note!
Under the laws and regulations in force , the following materials
arising from the operati on of the compressor need to be dis-
posed of ecologically safe:
- condensate (oil and water saturated) arising from recooling in
the compression process;
- used oil and grease and rags soiled by it;
- cleaning material and rags soiled by it.

2.8 Staff requirements

Only authorised persons are permitted to service the Sauer Com-
pressor l Before commenci ng work they must have read and un-
derstand the operating manual and must be familiar with the
safety devices and safety regulations .
In addition to the instructions in this operating manual and manuf-
acturer documentation, accepted technical standards must be
observed as well as all regional laws, standards and regulations
such as the
- Equipment and Product Safety Act (Gerate- und Produktsi-
cherheitsgesetz) ,
- Ordinance on Industrial Safety and Health (Betriebssicher-
heitsverordnung),
- Regulation s 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 mu st be
observed.
Persons authorised to operate the compressor are the attending
specialists introduced to the job and trained by the operator.
Persons authorised to se rvice the compressor are the trained
specialists of the operator and of the manufacturer.

2.9 Pe~'sonal 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.

Version 3 ~ 3 15
3. Design and Function
3.1 Overview

9 1 , 15 5 3 6, 11 4 8 , 13 7 16

10 18 17 2 12 14 ;

<
,

<;
~
~

-'
16 Version 3 - 3
 Design and Function
I

Item Name

1 Cylinder 15 ' stage (not visible)

2 Cylinder 2 nd stage

3 Cylinder 3,d stage

4 Cylinder 4 'h stage

5 Sa fety va lve 15 ' stage (not visible)

6 Safety valve 2 nd stage (not visible)

7 Safety va lve 3,d stage

8 Sa fety va lve 4'h stage (n ot visible)

9 Coole r

10 Condensate sepa rator 1 st stage

11 Condensate sepa rator 2nd stage (not visible)

12 Condensate sepa rator 3,d stage

13 Condensate sepa rator 4'h stage (final sepa rator, not visible)

14 Condensa te collecting vessel

15 Air fi lter (not visible)

16 Electric motor

17 Oil level indicator

18 Oil drain

Version 3 - 3 17
 I
r ---- - --I------ l
I
;- - - - - - - -,- - - - - - - -\
{ C:- -- - -~--------

"'
'"
'"
'"c:
0
.
Q)

>
0
~

OJ
 Design and Function

Item Name

1 Connec tin g rod bolts, 1st and 2nd stage

2 Cooler 3,d stage

3 Cooler 4'h stage

4 Fa n whee l

5 Crankcase vent

6 Flexible coupling

7 Transmi ssion bell housing

8 Flywheel

9 Oil suction filter

10 Crankshaft

11 Lubricating oil pump

.
~
,

"- '
~
~

Version 3 - 3 19
Cross section

6 5 7 8

9 10

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

20 Version 3 - 3
 Design and Function

Item Name

1 1SI stage: cylinder with head and va lve

2 Piston 15t stage

3 2nd stage: cy linder with head and va lve

4 Piston 2nd stage

5 3 ,d stage: cylinder with head and valve

6 Piston 3 rd stage

7 4th stage: cylinder with head and valve

8 Piston 4th stage

9 Crankcase

10 Connecting rod

Version 3 - 3 21
 ,

3.2 Mode of operation

Drive The Sauer Compressors are driven by an electric motor directly
flange-mounted to the clutch bell housing of the cra nkcase , whe-
re the power is transmitted by means of a flexible coupling.
Alternati vely a diesel eng in e can be used to drive the comp res- I
sor. This is attached by means of a special flange. It transmits po-
wer by mea ns 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 statutory regulations. Optionally,
SAUER USA can supply a suitable compressor control
system.

Compression The compressor takes in amb ient air throug h a sheet filter with
tube silencer and compresses it in four single-stage cyl inders to
the ultimate pressure. Each cyl inder is a comp ression stage, after
which the air is after-cooled .
I
Splitting the entire pressure ratio into four stages results in espe-
cially low compression end temperatures. The final tempera tures
are below th e flash po int of standard motor oils (mineral oils).
Th e cylinders arranged in a fan-shape are fitted with easy-to-ser-
vice plate or lamellar valves with long service lives. Due to the low
compression end tem pe ratures, the susceptibility of the valves to
carbonisation is extremely low.

Cooling An axial fan located on the crankshaft draws cool ai r in from the
surroundings and blows it over th e cylinder, cooler, valves and oil
sump.
The recooling is carried ou t
- afte r the 1sl and 2 nd stage in an aluminium honeycomb cooler;
- after the 3 rd and 41h stage in an externall y galvanised gilled
pipe radiator.

Condensate sepa- Condensate containing oil and water, that is form ed during com-
ration pression an d after-COOling, accumulates in the cond ensate sepa-
rator behind eve ry stage.

22 Version 3 - 3
 Design and Function
f I

Condensate drai- The condensate is led to a condensate collecting vessel through

ninglPressure reli- a drain line and drained off using a hose. Drain lines are fitted with
drain valves. The draining of the 1st and 2 nd stage is carried out
ef
with a solenoid valve. Pneumatic relief valves are provided for the
draining of the 3,d and 4th stage. These are activated by the so-
lenoid valve of the 2nd stage. These drain valves must be open
when the Sauer Compressor is unpressurized. The drain valves
should close a few seconds after starting and the Sauer Com-
pressor should accelerate against pressure. The drain valves
should drain the machine at predetermined intervals during ope-
ration. The drain valves are controlled using a control unit of the
compressor control.

Lubrication / oil An oil gear pump driven by the crankshaft draws in lubricating oil
pressure from the crankcase and feeds it to the bearings of the connecting
rod and the compression side of piston of the 4th stage.
Crankshaft bearings, piston pin bearings and pistons are lub-
ricated by the splash oil in the crankcase. The oil pressure is mo-
nitored by an oil pressure switch.
The compressor control system stops the compressor immedia-
tely if the oil pressure falls to the lower limit value.

3.3 Inulicators on the Sauer Compressor

5 8 7 1 10 4 9 3

11

Version 3 - 3 23
 Item Name Ind ication

Pressure gauge 1 SI Compressed ai r pressure after th e 1 51

1
stage sta ge

2 Pressu re gauge 2nd Compressed ai r pressure alte r the 2 nd

stage stage

Pressure gauge 3 rd Compressed air pressure afte r the 3 rd

3
stage stage

Pressure gauge 4th Ultimate pressure

4
stag e

T hermomete r 1 51 Compressed ai r temperature after the

5
stage 151 stage

Thermomete r 2 nd Com pressed air temperature after the

6
stage 2 nd stage

Therm ome te r 3 rd Compressed air temperat ure afte r the

7
stag e 3,d stage

T hermomete r 4th Co mpressed a ir temperature after the

8
stage 41h stage

Compressed air-con- Compressed air-outlet te mpe ratu re

9
tact thermomete r

10 Oil pressure gauge Oil pressure of oil pump

11 Oi l leve l indicator Oil level in cra nkcase

<i
.'
0;
"- '
~

24 Vers ion 3 - 3
 Design and Function
J

3.4 Indicators and controls of the compressor control system

Note!
If the compressor control system is supplied by
SAUER USA take notice of the documentation sup-
plied.
At the front of the compressor control the following indicators and
control elements are found :

Indicator!
Description
Control element

Signal lamp "Ope- Lights when the compressor is running .

rati on"

Fault indica tor Light s il th e compressor has been shut 011 becau se
lamp "Oil pressure" of low oil pressure.

Fault indicator Lights il the compressor has been shut 011 because
lamp "Air tempera- of excessive outlet ai r temperature.
ture"

Fault indicator Lights il the compresso r has been shut 011 because
lamp "Overcurrent" of excess motor current .

Working hou r Indicates th e work ing hours of th e co mpressor.

meter

Operating mode Selector position "Manual":

selector Starting the compressor manually. The comp res-
sor sta rts up and continues to run until it is manu-
ally turned 011.
Selector position "0":
Turn s comp ressor manually OFF. Any pending lault
messages are reset.
Selecto r posi tion "Auto":
The compressor is started and stopped by th e ope-
ning and closing of an external switching contact
(e.g. pressure switch of the compressed air recei-
ver).

Main switch Interrupt s the power supply Irom th e compressor

control to the compressor.
A main switch should be installed if required by local
laws and regulations.

Ve rsion 3 - 3 25
4. Technical specifications
4.1 Data table

Name Data

Compressor type WP 435 1

Number of cy linders 4

Number of compression stages 4

Cylinder diameter 1st stage 160 mm

Cylinder diamete r 2 nd stage 88 mm

Cylinder diameter 3,d stage 46mm

Cylinder diameter 4th stage 22mm

Piston stroke 80 mm

Maximum pump speed 1800 rpm

Direction of rotation (as seen on fl yw heel) clockwise

Maximum operating pressure 5075 psi

Set pressures of sa fety valves:

1sl s tage 73 psi

2 nd stage 247 psi

3,d sta ge 1305 psi

4th stage 5 % higher th an the ultimate pressure

Oil filling quantity 4.23 gat

Oil quantity between dip stick markings 2.64 gal

Oil type see Chapter 10 "Lubricant table"

Oil pressure switch:

Maximum switching current 6A 1220 V

Setting opens at 15 psi falling,

closes at 30 psi rising
approx . 15 sec. start ing bypass

26 Version 3 . 3
 Technical specifications
I
I
Name Data

Switch functi on change-over contact

Drain va lve 1kt and 2nd stage:

Pick-up and holding power 18VA / 14W

Setting dead open ; starting relief: approx. 15 seconds;

intermediate draining: 15 seconds every 15 minu-
tes.

Ultimate pressure switch (optional):

Maximum switching current 6A 1220 V

Setting to customer's specifications

Switch functi on change-over contact

Compressed air-contact thermometer:

Maximum switching current 5A 1250 V

Setting closes at 176 of wh il e increasing

Switch fu nction normall y open contact

Non-return va lve:

Response pressure approx. 15 psi

Sound p res~ure level (in free sound field at dis- maximum 93 dB(A)
tance of 1m)

Weight and dimensions see install ation plan

Note!
Please refer to the ord er-specific documentation of your com-
pressor for specific data, such as ultimate pressure , speed , po-
we r requirements, etc.

8r
-'
Version 3 - 3 27
4.2 P&I-diagram

16 6 2 6 2 6 2 6 2 12

7 11 3 4 3 4 3 4 3 4 5 18

Inlet
at m.

Outlet

14 15 9 5 9 5 10 5 8

17 13 8 8 19 8 10

28 Version 3 - 3
 Technical specifications

Item Name

1 Drive motor

2 Safely valve

3 Compressor stage

4 Inlercooler and aftercooler

5 Compressed air-pressure gauge

6 Compressed air-thermometer

7 Oil pressure switch

8 Condensate separa tor

9 Solenoid valve

10 Pneumatic relief va lve

11 Inlake fi ller

12 Compre ssed air-contact thermometer

13 Oil pump

14 Pressure relief va lve

15 Oil filter

16 Oil pressure gauge

17 Drive lubricati on

18 Non-return valve

19 Condensate co llecting vessel

Vers ion 3 - 3 29
5. Transport and Installation
5.1 Transport
Shipping The machine is packed su itable for shipping .
Immediately on receipt of the Sauer Comp ressor it should be
checked for co mpleteness and damage.
The transport company and SAUER US A must be im-
mediately notified of any damage to th e packing or the machi-
ne.

Transportation The Sauer Comp ressor must be transported by a forklift truck or

hoisted by crane.

Danger!
Suspended load when transported.
The forklift tru ck/c rane must have suffi cient load bearing capac i-
ty.
Ensure th at no persons stay withi n the danger area of the sus-
pended load and the forklift truck/cra ne.
Sling the unpacked compressor at the three lifting eyes (see
illu st ration).
Lift, move, and set down carefully.

Lifting eye

Lifting eyes

30 Version 3 - 3
 Transport and Installation

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: +41 to +104 of;
- relative humidity 30 ... 95%, not condensating ;
- dry, under a roof and protected against dew;
- protected against soiling;
- protected against vibrations and shocks.

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

5.3 Installation
Note!
In case of doubt regarding the suitability of the intended place of
installation and room , contact SAUER USA in time be-
fore the installation. There you will also get help with the design
of a ventilating system at the place of installation if required .
For installation observe the installation instructions and the follo-
wing conditions.

Installation condi- - The place of installation must be dry and free of dust.
tions - The place of installation must be ventilated in such way that
the heat generated during operation is dissipated .
- Room temperature whi le the Sauer Compressor is running:
w.~~131 OF
+41 ... +131 of
(deviating temperatures only if confirmed in writing by
SAUER USA)
min 41 F

Version 3 - 3 31
 Note!
Th e air temperatu re at the coolin g ai r intake of the compresso r
must not exceed + 131 F when th e compressor is running . Room
conditions and the heat , generated by the comp resso r and other
machines installed in th e room , must be taken into considerati-
on .
If necessa ry, in stall a ventilati on or exha ust system at the
place of insta ll ation.
Install th e fresh ai r feed in such way that the fresh air stream
is not directed straight at the compressor. Otherwise there is
a risk of condensation of wate r inside the machin e and sub-
seque nt damage.

This way is correct!

Do not install fresh air feed this way

E
- At a room temperature of below +4 1 of th e room needs to be ~
heated or th e Sauer Compressor must be eq uipped with a he-
atln g system . ~,

32 Vers ion 3 - 3
 Transport and Installation

- Choose the location such that the Sauer Compressor is acces-
sible and has sufficient clearance to walls and oth er machinery
(see in stall ation documents).
- Do not position the motor side in a niche in the place of in stal -
lation , so the Saue r Compressor will not take in the warmed-
up cooling air aga in .
- Do not position severa l compressors one after th e other, to
prevent one compressor from taking in the wa rmed-up cooling
air of another compressor.

Note!
SAUER USA would be glad to advise you on the instal-
lation of the compressors.

Foundation
Note!
The resilient-mount bedding delivered as standard has a reso-
nant frequency of approx. 7 Hz.
Th e excitation of the intended compressor-foundation by vibra-
tions from the machines in stalled in the vicinity must not be in the
7 Hz range . Otherwi se there is a risk th at the sta ndard delivery
resilient-mount bedding is destroyed by sympathetic vibratio n.
1. Check early enough if there are fou ndation vibrations in the 7
Hz range.
2. If in doubt, check with SAUER USA to see if a modi-
fi ed resilient-mou nt bedding can be used.

Version 3 - 3 33
5.4 Connecting the compressor
Danger!
The compressor should only be connected by qualified technici -
ans. Any wo rk on the electrical installation may only be carried
out by qualified electricians.

Note!
The crankcase ve nt is in sulated using a section of hose. Do not
remove th e insulating material .

Pipelines The com pressed air outlet and the condensate collecting vessel
of the Sauer Compressor mu st be connected to the perm anently
fitted pipelines using hose lines.

Insulation

Hose lines

34 Ve rsion 3 - 3
 Transport and Installation

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

",
\
'-.. \
\ \ This way is correct!
I

Q
!IIdC::::::S - - - - - - - CldOl

Draining
Note!
IQjF Condensate that is formed contains oil. It may only be disposed
of in compliance with applicable legal provisions.
I SAUER USA offer condensate treatment units for sepa-
rating oil from the condensate.

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

.. - Connect drain lines of the individual compressors at an acute

angle to the common drain line, so no pressure can build up
~I in the drain line of a stationary compressor .
8
"- '
Version 3 - 3 35
 t!#
~
;
~ f.
~ f

..- +
~ ~ ~
This way is correct!

t!#
~
~
~

Not this way!

~
~I
M

8::;
-'
36 Ve rsion 3 - 3
 Transport and Installation

Connections The illu stration below shows the connection s and fittin gs for ope-
rating the standard version Sauer Comp ressors.
r -- - - - - - - - 6

r---~~----- 5

3 - - -- - -______

7 -----------~

4 -----------------~

Note!
IQiP For technical specificati ons 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 D r~ in valve Solenoid valve Starting relief and drainage

Drain valve P neum at ic relief Starting relief and drainage

2
valve

3 Drive motor 3-phase motor Compressor drive

,
Ultimate pressure Toggle switch Stops/star ts th e com pre ssor
4
switch (optional):

Oillpressure switch Toggle switch Stops co mpresso r when oil level is low
5
(not visible)

-" 6
CorPressed air-con- Touch switch Stops compressor in the event of excess lempe-
~I tact the rm omete r ratu re

8
~
7 Non-return va lve Plug valve Prevent the air from fl owi ng back
-'
Vers ion 3 - 3 37
5.5 Filling with oil
Th e Sa uer Compresso r is supplied without oil.

Danger!
Oi l mu st be fi lled into th e compresso r's crankcase before initi al
operation!
Use lubricatin g oil (see chapter 10: "Lubricant Table").
Note fi lling amount (see chapter 4: "Technical Specifi cations").

Oi l fill er plu g

f'

Oil level indicator

1. Un screw oil fill er plu g (red).

2. Fill the oil and check the level on th e oil level indicator.

Note!
Fill onl y to the upper marking on th e oi l leve l indicator. Oth erwise
(
the oi l consumption of th e compressor will increase.

3. Un sc rew the oil fill er plug.

38 V ersion 3 - 3
 Transport and Installation

5.6 Setting the ultimate pressure switch

Note!
The ultimate pressure switch should be connected up directly to
the compressed gas tank to ensure smooth and even compres-
sor operations.
When selecting the maximum set pressure, always note the pres-
sure loss between compressor and compressed gas tank. 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?

8~
-'
Version 3 - 3 39
6. Operation
6.1 Safe operation
Danger!
Only authorized persons are perm itted to commission and ope-
rate the Sauer compressor!

Danger!
Turn on and start the compressor on ly if
- it has been checked for prope r working condition ;
- all tools and fo reign objects are removed from the machine.

Danger!
Tu rn compressor immediately OFF when pe rsons or objects are
endange red. Start compressor only when the danger is over.

Danger!
In Automatic mode the compressor sta rts automatically without
warning!

Danger! I
Risk of burns by hot surfaces of the compressor when it is run- f
ning. Wea r gloves.

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

Note!
Tu rn comp ressor OFF in the case of fau lts, abnormal ratings or I'
irregu larities. Refer to chapter 7. "Trouble Shooting" to remove
I'
cause .

,
f

,
.<
-,
N

"
W

'",
40 Version 3 - 3
 Operation
,

6.2 Operating modes

After the power supply to the Sauer compressor is turned ON , it
I can be started with the operating mode selector in one of the fol-
lowing two operating modes:
- Operating mode "Manual":
The compressor starts and continues to run until it is stopped
or turned OFF with either the operating mode selector or the
main switch.
- Operating mode "Automatic":
Starting and stopping of the compressor is controlled by exter-
nal devices (e .g. by the pressure switch of the compressed air
receiver).
When the Sauer compressor starts, it starts loadless with opened
drain valves. Several seconds after starting the valves close and
the compressor runs up against pressure.

6.3 Inihal operation

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

Danger!
No oil pressure at incorrect direction of rotation. Risk of subse-
quent damage.

Test run 1. Turn the power supply ON.

2. Set the operating mode selector to "Manual" to start the com-
pressor in Manual mode.
,I If correctly set the drain valves will close after approx. 15 se-
conds and the compressor runs up against pressure.
3. Check the pressure gauges of the stages and the oil pressure
gauge and compare with the nominal values (for nominal va-

Version 3 - 3 41
 ,.

lues see chapter 6.4 "Routin e operation"}.

4. Check the functionin g of the automatic intermediate draining .
./ It mu st drain every 15 minutes for approx. 15 seconds. This is
recognizable by the pressure drop at the pressu re 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. See
also chapter 7. "Trouble Shooting".

6.4 Routine operation

Cleaning Keep compresso r 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 1. Turn power supply ON.

2. Set operating mode selector to "Auto" to operate the com-
pressor in Automatic Mode.

Observation Note abnormal operating sounds.

Pay attention to leakages (compressed air, oi l, condensate).
f
During operation the pressure reading of the pressure gauge
should be within the shaded region of the stage pressure chart (
(see below).
Th e oil pressure shou ld be between 25.1 psi and 58 psi.
In the event of deviation s, see Chapter 7 "Troubleshooting".

42 Version 3 - 3
 Operation

Stage press ure chart 1 sl, 2 nd and 3 rd stage

~ 5800 I

<J)

3 4350 - /
<l>
0> - / /
co
en 2900
..c - -
V/
~
- /
/
1450

A 1\
a y y
14 .5 29 43.5 58 160 174 189 203 218 232 247 580 725 870 101511 60 1305
nd
1s l stage [psi] 2 stage [psi] 3 rd stage [psi] - -

Note!
I@= Depending on the desi red ultimate pressu re of the 41h stage the
pe rmissible pressure for the 1sl, 2 nd and 3 rd stage can be read
from the chart.

Version 3 - 3 43
 ,.

7. Trouble-shooting
Note!
In the event of malfunctions, fi rst check the indicators on the
compressor control and the compressor.
Try to remedy the fault by followi ng the information given in th e ,.
table below.
('
If th e cause for th e fault cannot be eliminated , contact
SAUER USA customer se rvice.

Fault Likely cau se Remedy

The compressor does not No supply voltage I no control Check fu ses. Replace blown fuses.
start or does not switch voltage.
OFF.

Compressor was switched The oil level is 100 low. Check Ihe oil level, add oil as required.
off, faull indicalor lamp "Oil
Pressure" glowing. Oil pipe blocked up. Clean oil pipe.

Oil too viscous. Fill oil in accordance to recommenda-

l ions. If required, preheallhe oil.

Oil filler blocked up. Clean oil filler.

The oil pump is faully or leak- Check the oil pump. Fix Ihe leak or
ing. replace Ihe oil pump, as req uired.

Compressor was switched The motor is overheated. Determine Ihe cause of Ihe fault and
off, Fault indicalor lamp Excessive current drawn. correct it. The compressor can be
"Overcurrent" glowing. slarled again alter being allowed to
cool off.

Oil too viscous. Fill oit in accordance to recommenda-

tion s. If required , preheallhe oil.

Piston seizure Check cylinder and pislon for score

marks, replace if necessa ry.

Safely va lve of 1sl slage f'

blows off:
Pressure exceeds blowing- 2nd slage valve is nol working Check 2nd stage valve, replace if nec-
off pressure (72.5 psi) properly. essary.

Sealing between inlel and oUI- Replace gasket.

nd
lei side of Ihe 2 slage is
faulty. r
P ressure below blowing-off Safely valve is faulty. Replace the sa fety valve.
pressure (72.5 psi)

nd
2 stage sa fety va lve blows
off:

44 Version 3 - 3
 Trouble-shooting

Fault Li ke ly ca use Rem edy

Pressure excreds blowing- 3 rd stage valve is not working Check 3rd stage valve, replace il nec-
off pressure (, 47 psi) properly. essary.

Sealing between inlet and out- Replace gasket.

let side of the 3rd stage is
faulty.

Pressure below blowing-off Safety va lve is faulty. Replace the safety va lve.
pressure (247 psi)

Safety valve of 3" stage

blows off: I
Pressure exceeds blowing- 4th stage valve is not working Check 3rd stage valve, replace if nec-
off pressure (1305 psi) properly. essary.

Sealing between inlet and out- Replace gasket.

let side of the 4th stage is
fau lty.
Pressu re below blowing-off Safety va lve is faulty. Replace the safety valve.
pressure (1305 psi)

Safety valve of 4th stage

blows off:

Pressure exceeds blow- Valve in a ir line to compressed Open the valve.

ing-off pressure (ulti - air receive r closed.
mate pressure + 5%)
Pressure switch set too high. Reduce set pressure.

Pressu re below blow- Safety va lve set too low or Replace the safety va lve.
ing-off pressure (ulti- fau lty.
mate pressure + 5%)
Too much pressure loss in the Reduce pressure losses.
air line to the compressed air
receiver.

Pressure gauges of a ll Va lve of 1st stage leaking . Check 1 sl stage valve , replace if neces-
stages indicate too low sary.
pressure.
Air filte r very di rty. Clean or rep lace air filter cartridge .

Pressure gauges of all Keine Spannung am Magnet- Check power supply of solenoid valve.
stages indicate no pressu re. ventil der Entwasserung 1.
oder 2.pStufe.

Magnetventil der Entwasse- Check solenoid va lve and replace if

rung 1. oder 2.pStufe defekt. necessary.

Pneumatic relief valve of the Check pneumati c relief valve and

3rd or 4th stage is fau lty. replace if necessa ry.
I
Air escaping from com- Gaskets of connections leak- Replace relevant gasket.
pressed air ines ing .

Compression ri ng connections Turn compressor OFF. Wait until all

leaking. part s are relieved of pressure (check
I pressure gauges). Then tight en unions.

I
I Version 3 - 3 45

Fault
Compressor was switched
off, fault indicator famp "Air
Temperature" glowing .
Solenoid valve does not
close.
Pneumatic relief valve does
not close.
Intermediate drainage is not
functioning.
Compressor makes loud
noises.
Oil leaking from crankcase.
Air discharge between cylin-
der and valve cover.
Water in oil
Premature breaking of valve
plates, valve spring s or
valve disks.
46
Likely cause
Temperature of compressed
air too high at outlet; insu ffi-
cient cooling by faulty fan .
Very dirty cooler; insufficient
ve ntilation.
No supply voltage.
Solenoid faulty.
Foreign matter in solenoid
valve.
Foreign matter in relief valve.
Timer not set or not set cor-
rectl y.
Connecti ng rod bearing faulty.
Piston pin bearing faulty.
Crank shaft bearing faulty.
Motor bearing faulty.
Gasket or shalt seal faulty.
Screws not tight.
Gasket or a-ring of the liner
above the relief groove faulty.
Incorrect ve ntilation (compres-
sor is undercooted) .
Insufficient drainage.
Very short compressor run-
ning ti me.
Insulating sleeve of crankcase
vent missing or damaged .
Insufficient drainage.
Version 3 - 3
f'
Rem edy
Replace fan .
Clean the cooler. Check the room ven -
lilalion.
Check fuses, replace blown fu ses.
Replace solenoid.
Clean solenoid va lve .
,
Clean relief valve.
Set timer to 15 s drainage and 15 min
closing interval.
Check connecting rod bearing, replace
if necessary. Ch eck oil supply.
Check piston pin bearing , replace if
necessary.
Check crank shaft bearing , replace if
necessary. ('
Check motor bearing , replace if neces- t
sary.
Tighten screws.
"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 .
Replace gaske t or a-ring .
Change the room vent ilation .
,.
Check drain lines and drain intervals.
Extend compressor running time.
Replace insulating sleeve.
Check drain lines and drain intervals.
Note: Indentation marks appearing on
th e valve plate due to valve impact are
normal.
 Maintenance

8. Maintenance
8.1 Maintenance service by SAUER USA
The SAUER USA customer service offers different main-
tenance services - e.g. full maintenance or valve replacement
service.

8.2 ML ntenance safety

Before Serr cing 1. Disconnect the power supply to the compressor.
2. Post danger sign "Caution Maintenance Work l" at the power
supply.

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

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

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

I~ Danger!
Danger! High voltage!
- Never assume that a circuit is de-energised - always check
for your own safetyl
- The main switch is energised, even when it is turned OFF.
- Components being worked on should only be energised if this
is explicitly specified.

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

Version 3 - 3 47
8.3 Maintenance sc hedule
Danger!
For all maintenance work chapter 8.4 "Tabl e of tightening to r-
qu es" must be obse rved for specific sc rews.
Note!
The maintenance intervals specifie d in the maintena nce sc he-
,.
dul e must be adhered to. Shorteni ng th e mainte nance intervals
is of no advantage with rega rd to operating pe rform ance or se r-
vice life of th e Sauer compressor.
Note!
After a major ove rh au l (= 12,000 operating hours) the mai nte-
nance sc hedu le beg ins all over again.

Instructions for Use the maintenance schedule as master te mplate or copy th e

the maintena nce respective page from the digital docum ent an d save it as a se-
pa rate fil e un der a suitabl e name. Use the maintenance sche-
schedule
dule as guide and evidence .
Reg ularly check th e maintena nce schedule to see which mai n-
tena nce intervals, depe ndin g upon the numb er of operating
hours, are due. The interva ls are shown in th e table's co lu mn
heade rs. ('
Check th e column of each maintenance interva l to see whi ch
maintenance work is to be ca rried out at the end of each main-
tenance interva l. Th e required tasks are indicated by check
boxes. Description and chapter numbe r of the tasks are shown
in th e first column .
Carry out all mai nte nance work of a maintenance inte rval and
t ick th e appropriate check boxes of th e mai ntenance sched u-
le. Th en enter ope rati ng hours count, date and your signature.
When beginn in g a new maintena nce schedul e
enter: main specifications, date of commissioning, number
of mainte nance schedul e, curre nt date and ope rating hours
count
tick: begin nin g after commi ssioning/after major overhaul

48 Versi on 3 - 3
 Maintenance

Maintenance Schedule No. Compressor type

Beginning of /thi S maintenance Type series H
schedule
D after comm1issioning Compressor number

D after major overhaul Factory no.:

Date: Year of construction:
Operating ho1
u rs count: Date of commissioning :

Interval ~

(operating hours ) '">-

Q)

'" '" -
Cl :; :;
" .s:::
~
0
0
'"Q;
.s:::
0 Q) 0
'iii > N >
.~ 0 0
E
E
0
u
-
'" '"
~
0

E
v

~
0
0
0
N
0
0
0
.f
0
0
0
<Ii
0
0
0
<Xi
0
0
0
0
~
~
0

'"
E
~
Q)
:=
~
Q)
:=
Q)
>- 0
0
"
u;
'"
0 '"
0
'"
.!'!
0_
N

Maintenanc1e work
"' "' ;;:
~

Check screwed connections 8.6 0 0

Oil change 8.5 0 0 0 0 0 0 0 0 0
Ai r liller carl ridge replacemenl 8.7 0 0 0 0 0 0 0
Checking valyes 8.8 0 0 0 0 0
Checking Ihe pislon rin gs 8.9 0 0
Replacing pislon pi ns/pisl on pin 0 0
bearings 8. 10
Replacing valves 8.11 0
Checking pisfons and cylinders 8.12 0
Checking drive bearings 8. 13 0
Replace sha I seals 8.13 0
Checking co upling 8.14 0 0
Operating hi urs counl :

Dal e

Signature
i
(inilial s)
I
Note!
@= Check comp resso r 50 hours after every maintenance work is
ca rri ed out. Check all sc rews affected by the maintenance wo rk
to see if th ey are ti ght.

I
N

.'
~,
Ve rs ion 3 * 3 49
 ,.

8.4 Table of ti ghtenin g torques .

,

Screw(s) Tightening torque

Connecting rod screws 52 ft-Ibs

Flywheel fastening screw 258 ft-Ibs

Cylinder head screws 151 stage 55 ft-Ibs

Cylinder head screws 2 nd and 3rd stage 55 ft- Ibs

ylinder head screws 41h stage 184 ft-Ibs

8.5 Oil change

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

Oil fil ler plug

Oil drain plug Oil leve l indi cator .

N
,

~,
50 Version 3 3
 Maintenance
,
1. Place oil sump (of sufficient capacity to hold the complete oil
filling , see chapter 4 "Technical data ") under the oil drain plug.
2 . Remove the oil drain plug.
3. Wait until all oil is drained.
4. Replace the oil drain plug .
5. Unscrew oil filler plug (red).
6. Fill oil and check the level with the oil level indicator.
,/ The level should be between the upper and lower mark on the
dipstick.
7. Screw the oil filler plug shut.

8.6 Check screwed connections

Check all unions for tightness and tighten if necessary. It con-
cerns:
- Cooler and air lines;
- Unions of pipe and hose lines;
- Cylinder head;
- Cylinder;
- E-Motor;
- Measuring equipment and switchgear;
- bearings;
- accessories and equipment accessories.

Version 3 . 3 51
8.7 Air filter cartridge replacement
Air filter cap

II'
,.
II'

1. Open clips and take the air filt er cap off.

2. Remove the used air filter cartridge.
3. Insert new air filter cartridge.
4. Put cap back on and close the clips.

Note!
~ The intake side of the air filter should be pointing downwards.
~

8.8 Checking valves

Note!
Plate valves and particularly lamellar valves are the parts of a re-
ciprocating compressor that are subject to the most stress. In or-
der to achieve the guaranteed maintenance intervals, these
valve are high-quality precision parts, specially matched to the
individual compression stages and their function wi ll have been
checked carefully before delivery. Repair by the maintenance
and operating personnel requires special knowledge, which may
not be present in all instances. Fo r such cases
SAUER USA offer a valve replacement service. If re-
quired, please contact the Sauer se rvice department. ,
".,
N

~,
52 Ve rsion 3 - 3
 Maintenance

w Note!
While refitting valves, only ever use new gaskets and rings. Do
not reuse the used rings under any circumstances. DOing so will
\ result in leakage within a short time.
Use only genuine Sauer spare parts. These are precision parts
with defined and tested dimensions and material characteristics,
specially designed for use in Sauer compressors . Fitting other
gaskets may result in leaks and could cause substantial damage
to the compressor.

Valve removal 1. Loosen unions and hose line at the cylinder heads.
2. Loosen off cylinder head nuts and remove the cylinder heads.
3. Take out the valves with care .

Check plate valves

Note!
Plate valves are fitted in the cylinders of the 1 st , 3rd and 4th sta-
ge.
When removing, cleaning and installing the plate valve , ensure
that no valve parts are damaged. This applies particularly to the
seat faces and the valve springs. Slight damage to the sealing
strips of the valve seats can be removed by relapping on a lap-
ping plate.
4. Unscrew nut. For this purpose, clamp the valve in "soft jaws"
in such a way that the valve mating surfaces are not dama-
ged.
5. Disassemble valve.
6. Clean all valve parts. For this purpose soak them in an oil dis-
solving fluid (e.g. petroleum or benzene).
7. Check valve parts for damage.
8 . If necessary, lap the sealing strips on a lapping plate with a
3F abrading grit. Then clean the grit off the valve following the
instructions provided by the grit manufacturer and dry with
compressed air.
.I The sealing strips are good if the surface is uniformly matt-
grey. If there are any shining spots left on the sealing strips ,
repeat the procedure.
9. After lapping , dry all the valve parts with compressed air and
rub them with oil.
10. Replace damaged valve parts.

Version 3 - 3 53
 "'<?'
= ~
;.s...c::::71 'S>d

II

11 . Assemble the valve of 151 stage carefully (see illustration abo-

ve) and tighten the nut.

54 Version 3 - 3
 Maintenance

0=>
""
"" '"
"" '"

=-====i===~
==- =::::.

12. Assemble the valve of 3 rd stage carefully (see illustration abo-

ve) and tighten the nut.

-"N,
~

~ __________________________
~ ~~------------------~
55

Version 3 - 3
 ~ I

~ I :::::::
~
I
I

~
~
!
13. Assemble the valve of 4th stage careful ly (see illustration abo-
ve) and tighten the nut.
14. Use a pin with round tip to check the va lve plate's ease of mo-
vement against the spring pressure.

Check lamellar
valve
Note!
One lamellar valve is fitted in the cylinder of the 2nd stage.
Lamellar valves require very little maintenance and unlike plate
valves, even function in presence of small quantities of dirt. Nor-
mally the plates have the same service life as the valve body
which , due to its geometry, cannot be refaced or lapped. We
would therefore not recommend replacing individual plates.
Should a plate neve rtheless be broken prematurely (e.g. through
the influence of foreign objects) , contact our service.
15. Examine the va lve. If lamellar valve is heavily carbonised or
damaged, replace complete valve.

a
~
-'
~
56~-------------------------------------------------------
Ve rsion 3 - 3
 Maintenance

Valve installation

Low tolerance gasket

I

Cylinder head gasket

16. Fit valve and cylinder head of the 1st stage. Use new cylinder
head gasket and new low tolerance gaskets while doing so
(see illustration above).

Note!
Do not reuse the used rings under any circumstances . Doin g so
wi ll result in leakage within a short time.

Ve rsion 3 - 3 57
 ;j
;j
\ - - ' i / /I'~--'--------I%f---

Cyli nder head gasket

17. Fit valve and cylinder head of the 2 nd stage. Use new cylinder
head gasket in the process (see illustrati on above).

Low tolerance gasket

/ /

Cylinde r head gasket

18. Fit valve and cy linder head of the 3 rd stage. Use new cyl in der
head gaskets and new low tolerance gaskets whi le dOing so
(see illustration above).

58 Version 3 - 3

I
 Maintenance
L C i IU

Low tolerance gasket

Precision gasket
V / ~ /
5/1 I / /

;}
O-ring
J ~

, ,
//
1-11/
v~
/ / /

19. Fit valve and cylinder head of the 4th stage . Use new cylinder
he ad gasket, new low tolerance gasket as well as new O-ring
while doing so (see illustration above).
20. Attach screwed pipe connections and hose line to the cylinder
heads.

Ve rsion 3 - 3 59
8.9 Checking the piston rings
1. Remove cylinder heads and valves as described in Chapter
8.8 "C hecking the valves".
2. Remove cylinder base nuts.
3. Pull cylinder off. Secure the piston until the cylind er has been
pulled off.

Note!
If the piston is not secured when pulling the cylinder off, it will
strike the crankcase.

4. Remove circlips of piston pins, push piston pin out and

take piston off.
5. Remove all piston rings from the piston for all stages.
6. Insert the piston rings as well as spacer rings in the respecti-
ve cylinder and measure the gap clearance with a feeler gau-
ge.
7 . Replace piston rings if th e gap clearance exceeds th e follo-
wing limits.
1st stage 1.50 mm
2 nd stage 0.75 mm

3 rd stage 0.55 mm

Note!
Always replace all piston rings of a piston when one of the piston
rings exceeds the limit.
8. Fit piston rings in the respective piston. Make sure they are in
the correct position: piston rings with an asymmetric cross
section are marked on one of the surfaces with "TOP". The
marked face must be at the top when the piston ring is in
stal led. See illustration .

1 st stage 2nd stage 3rd stage

TOP

60 Ve rsion 3 3
 Maintenance

9. Fix pistons on the connecting rods. For this purpose press the
piston pin in and insert circlip.
10. Fit a new cylinder base gasket for each cylinder.
11. Push cylinder onto the pistons.
12. Tighten cylinder base nuts.
13. Fit cylinder heads and valves as described in Chapter 8.8
"Checking the valves".

8.10 Replacing piston pins/piston pin bearings

1. Remove cylinder heads and valves as described in section
8.8 "Checking the valves".
2. Remove cylinders and pistons as described in section 8.9,
"Checking the piston rings".
3. Take off inspection hole cover.
4. Remove connecting rod bolts and remove connecting rod be-
aring cover with bearing bush. Lift connecting rod out.
5 . Press piston pin bearing out of the connecting rod's small
end.
6. Replace piston pin and piston pin bearing.
7. Press piston pin bearing into the connecting rod's small
end.
8. Put connecting rod back with sufficient oil and screw on the
bottom part with hand.

14

Note!
Numbers are punched on the upper and lower parts of the con-
necting rod . These must match in any case (see illustration) .
.I It should be possible to screw in the connecting rod bolts
E completely with hand . Only then the correct seat on the
N
.' crankshaft can be guaranteed. After tightening , the connec-

~
ting rod should rotate easily on the crankshaft. Observe the
-' tightening torque (see section 8.4).
Vers ion 3 - 3 61
 I

9. Fit in spection hole cover. I

10. Fit cylinders and pistons as described in section 8.9, "Che- t
cking the piston rings". f
11 . Fit cylinder heads and valves as described in section 8.8,
"Checkin g the va lves". I
I

8.11 Replacing valves

Remove and in stall va lves as detailed in section 8.8 "C heckin g
valves". Replace complete valve.

8.12 Checking pi ston s and cylinders

1. Remove cylinder heads and valves as described in Chapte r
8.8 "Checking the valves".
2. Remove cylinders and pistons as descri bed in Chapter 8.9
"Checking the piston rings".
3. Check cylinders and pistons for scourin g and excessive wea-
ring marks. Replace relevant parts.
4. Measure cyl inder and rep lace if the following wear limits are
exceeded:

Cylinder Wear limit of diameter

1 sl stage 160.15 mm

2 nd stage 88.10 mm

Upper part: 46 .10 mm

3,d stage
Guide part: 88 .10 mm

Liner: 22 .1 0 mm
41h stage
Guide part: 88.10 mm

Note!
Note th e following when replacing the 4th stage liner:
- Always exercise extreme care when handling or working with
the bush to prevent damage. Th e upper edge of th e bu sh col-
lar must not be damaged when replacing the lin er.
- Carefully clean the liner and hole before in stallation.
- Coat along outer edge wi th molybdenum disulphide before in -
stalling the liner.
- Press the lin er in with a hand press at room temperature .
5. Fit cylind ers and pistons as described in Chapter 8.9 "Che-
cking the piston rings".
6. Fit cylinder heads and valves as described in Chapter 8.8
"Checking the valves".

62 Version 3 - 3
 Maintenance
L

8.13 Chec\Gng the drive bearings

1. Remove cylinder heads and valves as described in Chapter
8.8 "Checking the valves".
2. Remove cylinders and pistons as described in Chapter 8.9
"Checking the piston rings" .
3 . Remove fan cover, fan wheel and the entire cooler unit.
4. Remove electric motor with coupling hub.
5. Remove flexible gear rim.
6. Remove flywheel with coupling flange.
7 . Take off inspection hole cover and remove connecting rod as
described in Chapter 8.10 "Replacing piston pin/piston
pin bearing".
8. Remove bearing bracket.
9. Remove crankshaft.
10. Check connecting rod bearings, replace if substantially worn .

Note!
Only replace shaft seals of crankshaft bearing if the bearing bra-
cket and crankshaft are removed!

11. Check crankshaft bearings , replace if substantially worn . If

necessary use new shaft seals.
12. Fit crankshaft.
13. Fit bearing bracket. Use new gasket.
14. Fit connecting rod s as described in Chapter 8.10 "Replacing
piston pin/piston pin bearing".
15. Fit inspection hole cover. Use new gasket.
16. Fit flywheel with coupling flange. Observe the tightening
torque (see Chapter 8.4).
17. Insert flexible gear rim .
18. fit electric motor with coupling hub.
19. Fit cooler unit, fan wheel and fan cover.
20. Fit cylinders and pistons as described in Chapter 8.9 "Che-
cking the piston rings" .
21 . Fit cylinder heads and valves as described in Chapter 8.8
"Checking the valves".

Ve rsion 3 - 3 63
 I

8.14 Checking the coupling

Visual check 1. Remove screw plug from crankcase. Through Ihe inspection
port, check the coupling's flexible gear rim for damage. Th e
teet h of the flexible gear rim must not be deformed.
I
2. Replace sc rew plug.
3. If necessary, replace th e fl exible gear rim as described below.
I

In spection port wi th
screw plug

Removing the gear 4. Support comp ressor under the transmission be ll housing. I
rim 5. Remove the elect ric motor mounting screws. /
6. Carefully lift the electric motor usi ng the lifting eyes (see
Ch apter 5.1: "Transport").
7. Pull elect ric motor ca refully away from crankcase .

It:=~{-- Tooth of flexible gear rim

I
E
N
,

~I
64 Version 3 3
 Maintenance

8. Slide electric motor gently against crankcase and tighten the

electric motor mounting screws.
9. Remove support from under the transmission bell housing .

Version 3 - 3 65
9. Placing out of Service
9. 1 Safety when placing out of service and dismounting
Danger!
The comp ressor shall only be placed out of service and dis-
mounted by instructed and trained speciali sts of the ope rator.
The specialists must be fami lar with th e protection devices and
regulations before sta rting the work. Any work on the elect rical
in sta llation must be carried out by qualified electricians only.
In add ition , information contained in the documentation of out-
side vend ors is to be obse rved.

9.2 Shutting down the compressor temporaril y

Every 4 weeks , perform a test run for at least 30 minutes. Additi-
onal co rrosion prevention measures are not then requ ired.
When the Sauer comp ressor is to be shut down for more than
12 weeks , preservation using slu shing oil is recommended. Re-
gular test runs are not th en needed.

Note!
Use one of th e slu sh ing oi ls recommended in Chapter 10 "Lu b-
rican t Ta ble" for corrosion protection.
Th e slushin g oi l has satisfactory running properties. In an emer-
gency, th e machin e can be started for a short duration with a
slushin g oil fill ing .

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

pressure line open.
,f Any condensate present is blown off.
2. Drai n compressor oil and dispose of it in an environmentally
fri end ly manne r.
3. Fill abo ut 12 litres of slu sh ing oil.
4. Start compressor and run for approx. 5 minutes with drain val-
ves and pressure lin e ope ned.
5. Stop compressor. I
6. Un screw air filter on cylinde r head of 1st stage (see illustrati-
on in Chapte r 3.1 "Overview").

8
w
' ,
:,.
66 Ve rsion 3 - 3

I
 Placing out of Service

7. Unsc rew locking screw on cylinder head of 2nd stage (see

above illustration).
8. Unscrew the screwed pipe connections on the suction side of
the cylinders of 3rd and 4th stages.
9. Inject approx. 15 ccm of slushing oil into the suction compart-
ment of the 1st stage.
10. Inject approx. 5 ccm of slushing oil into the suction compart-
ments of the 2nd, 3rd and 4th stages respectively.
11. Fit air filter, locking screw and pipeline. Use new gasket for
the locking screw.
12. Start compressor and run it for approx. 15 s and then stop.
13. Drain slushing oil from the crankcase.
14. If necessary, post a sign indicating that the compressor has
been treated with anticorrosion agents and shut down .
15. Disconnect power lines from the mains supply, if necessary.

Restarting 1. If necessary connect the mains supply.

2. Fill compressor oil as described in Chapter 5.5 "Filling Oil".
3. Proceed as de scribed in Chapter 6.3 "Commissioning".

-"
8'w
o
-'
Version 3 - 3 67
 I

9.3 Dismantling
Dismantling 1. Turn compressor OFF and disconnect from power supp ly.
2. Make su re 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 oi l 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 dis po se

Lubricants as hazardous waste

Steel/iron as metal scrap

Electric cables as hazardous waste

Electronic components as electronic waste

Plastics as hazard ous waste

.E
8'
w
D,

68 Version 3 - 3
 Lubricant Table
,
10. Lubricant Table
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 41 .. 131 OF.

General re'10m- We recommend mineral oils of the viscosity class in accordance

mendation with ISO VG 100 for the temperature range 41 ... 131 F. The lubri-
cating oils should at least conform to the group Vel in accord-
ance with DIN 51506.

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

Version 3 - 3 69
 I

10.1 Lubricating oils

I
Brand Name Group
Agip Diesel Gamma 30 VCL-100
Dierea 100 VDL-100
Aee r1 00 VCL-100
Motor Oil HD 30 SAE 30
Cladium 50 SAE 30 I

ARAL Motanol HE 100 VDL-100

Kowal M 30 VCL-100
Disola M 30 SAE 30
AVIA Avilub Compressor Oil VDL-1 00 VDL-100
Avilub Compressor Oil VDL-1 00 VCL-100
Motor oil HDC 30 SAE 30
Motor oil HD 30 SAE 30
BP Energol RC 100 VDL-100
Energol IC-DG 30
Energol DL-M P 30
VCL-100
SAE 30
,
Energol OE-HT 30 SAE 30 I

Castrol
Vanellus C3 SAE 30
Aireol PD 100
Marine CDX 30
SAE 30
VDL-100
SAE 30
,
t

Chevron HD Compressor Oil 100 VDL-100

Delo 1000 Marine 30 SAE 30
Ve ritas 800 Marine 30 SAE 30
RPM Heavy Duty Motor 30 SAE 30
DEA Aetro EP VDL -100 VDL-100
Trion EP VDL -100 VDL-100
Regi s SAE 30 SAE 30 /
Esso Exxeolub 77 VDL
Exxeolub 100 VDL-100
Compressor Oil 302 1 N VDL-100
Exxmar 12 TP 30 SAE 30
Exxmar XA SAE 30
Essolube HDX Plus +30 SAE 30
Mobil Raru s 427 VDL-100
DTE Oil Heavy VDL I
Mobilga rd 300 SAE 30
I
Shell Corena Oil P 100 VDL-100
Rimula X 30 SAE 30
Melina SOil 30 SAE 30
Melina Oil 30 SAE 30
Gadinia Oil 30 SAE 30

70 Vers ion 3 - 3

I
 Lubricant Table

Brand Name Group

TEXACO Compressor Oil EP VOL 100 VOL- 100
Regal R&O 100 VCL-100
Ursatex 30 SAE 30
I OOROAR 30 SAE 30
Oacnis P 100 VOL-100
TOTAL
I Carprano TO 30 SAE 30
Milcano TC 30 SAE 30
I Oisola M 3015 SAE 30

10.2 Slu ~ hin g oils

Brand Name

Agip Rustica C SAE 30

ARAL Konit Motor Oil SAE 30

AVIA MK 1540S

Avilu b MK 3000

BP MEK 20 W-20

Ca strol Running-in and Prese rvation Oil

OEA Oeamot EKM 642 SAE 30

ELF Stockage 30

Esso MZK Motor Oil HO 30

Antirust MZ 11 0

FINA Rusan NF Motor Oil SAE 30

Mobil Mobilarma 524

Shell Ensis Motor Oil 30

TEXACO Engine Oil EKM 146 SAE 30

Version 3 - 3
 I

I
11. Spare Parts and Accessories I

Note!
Please note the information in chapter 1 . "General" regading our
genuine Sauer spare parts. I
SAUER USA guran tee the complete spare parts supp ly
over the entire service life of the Sauer compressor. ,
Our genuine Sauer spare parts are subject to constant quality
I
control and further development. They conform to the latest tech-
nical developments.
In addition to the genuine Saue r spa re parts, our delivery pro-
gram comp rises a large number of accessories for you r Sauer
compressor and special components to complete your air sys-
tem , such as:
- fully automatic controls;
- adsorption dryers;
- refrigera ted air dryers;
- filters;
- silencing cabi nets;
- compressed air receivers ;
- fittings .
We supply instructions and a maintenance manual for each ac-
cessory.

Spare parts cata- The spare parts catalog ue is found in the annex to these in struc-
logue tions.
- With the help of overviews, illu strations and lists the required
parts is quickly found .
- The spa re parts catalogue , including the operating instructions
is also available on CD- ROM . Here, an order form can be fill ed
in , printed out and se nd immediately.
For doing so , you need th e main specifications of your Sauer
compressor from th e table below. If they have not yet been en-
tered th ere, th ey can be fou nd on the type label aHixed to the
crankcase.

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

Furthermore, the number of operating hours should be stat- ~
ed, if possible. iii
i;j

72 Version 3 - 3
 Annex

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

Vers ion 3 - 3 73
 ,
i
I

74 Version 3 - 3


I '

I
, I

Type: WP 4351

Spare Part List

Eon Mill-lied du
SAUER- Gruppe

Verzm 3- 3
. ------------------

E -2 Version 3 - 3
 Spare Part List
I

WP 4351 Sauer compressor

Ref erence No. Subassemblies Page

WP 4351 Sauer compressor ..... .. .. . . ... .. .. . . . . .. . . . . .5

066 165 crankcase . .. 8

066 160 cranksha ft 10

064568 connecting rod ... 12

,)
033185 piston 1st stage ....... . ... . .. . ... . 14

057520 piston 2nd stage ...... . ...... . . ... . . 16

065681 piston 3rd stage . 18

066271 piston 4th stage .... ... 20

066 185 cylinder wi th head and va lve 1st stage .. . . .. 22

0332 10 concentric valve 1st stage .. ... .. . . . .. 24

064409 cylinder wi th head and va lve 2nd stage .. ... . . ... . ...... . ... . ... . ... . . . . 26

066283 cylinder wi th head and valve 3rd stage .... . ... . ... . . .. ... .... .. . ... . .... 28

03 1 526 concentric valve 3rd stage . . .. . ..... 30

066 179 cylinder with head and va lve 4th stage. . .. . ..... 32

035793 concen tric valve 4th stage ..... . .. . ..... 34

066222 cooler compl. ...................... . . ... 36

066207 air lines with separator ....... . . ... ... . ... .. . . .... . ... . . . .. . . .... . , .. . , . .. . 38

063 121 separator 3rd stage. .. .. ........... 44

056648 sepa rator 4th stage ..... .. ...... .. ..... 46

064 119 lubri ca ting oil pu mp and drive ..... . .... ... .. .. . .. .. .... .. ..... .. .. .. ..... 48

066 303 measu ring device ..... .. 50

066284 crankcase ven ting . .. ..... 55

otc: Ex planation of the subassem blies in chapter 3 "Des ign and Functi on"
of the operating instructio ns

Version 3 - 3 E -3
~ ------------------
i

Reference No. Subassemblies Page

066305 aulomatic drainage ... ........ . . . .. . . .. . . . 58

061 078 pneumatic rel ieve valve ... . . ... 62

033432 fl exible coupling... .. . .... . .... . ... 64

066306 resilient mounts . ... .... 66

E -4 Version 3 - 3
 Spare Part List

Version 3 - 3 E -5
~ ------------------
WP 4351 Saue." comp."essor

E "6 Version 3 " 3

 Spare Part List

WP 4351 Sauer compressor

Item Referemce No. Designation Qty.

1 066 165 crankcase 1

2 066 160 crankshaft 1
3 064568 connecti ng rod 4
4 033185 piston 1st stage 1
5 057520 piston 2nd stage 1
6 06568 1 piston 3rd stage 1
7 06627 1 piston 4th stage 1
8 066185 cylinder with head and va lve 1st stage 1
9 064409 cylind er with head and valve 2nd stage 1
10 066283 cylinder with head and va lve 3rd stage 1
11 066 179 cylinder with head and va lve 4th stage 1
12 03321 0 concentric va lve 1st stage 1
13 031 526 concentric va lve 3rd stage 1
14 035793 concentric va lve 4th stage 1
.. 15
16
066222
066207
cooler compl.
air lines with separator
1
1
17 063 121 sepa rator 3rd stage 1
18 056648 separator 4th stage 1
19 064 119 lubricating oi l pump and drive 1
20 066303 measuring device 1
21 066284 crankcase venting 1
22 066305 automatic drainage 1
23 061 078 pneumatic reli eve va lve 1
24 033432 flexible coupling 1
25 066306 resilient mounts 1

Version 3 3 E -7
~ ----------------------
066 165 cl-ankcase

8 25 8

\
21
\7
15 10 , 16

10 , 16
ffiW1Ifl)\-- -

4,6

A,,".~_ 9 , 17
2

4,

14

23

E -8 Ve rsion 3 - 3
 Spare Part List
t

066 165 cl-an kcase

Item RefJ rence No Designation Qty.

1 066 1157 crankcase 1

2 037 ,844 oil level indicator 1
3 064 '079 bearing bracket 1
4 051 883 inspection hole cove r 2
5 064095 packing for bearing bracket 1
6 063748 packing for cover 2
7 066 184 oil strainer 1
8 0001270 Lifting eye bolt 2
9 001 411 stud 16
10 033717 cylinder foot stud 16
11 005930 stud 8
12 001 1459 stud 4
13 001 009 plug 2
14 030744 plug 1
15 001 021 plug 2
16 002098 hexagon nut 16
17 002031 hexagon nut 24
18 002094 hexagon nut 4
19 0021 46 washer 4
21 004635 union 1
22 005001 gasket 2
23 005009 gasket 1
24 0050 29 gasket 1
25 001 9 10 shaft seal 1
26 030831 shaft seal 1
29 035824 filling cover 1

Ve rsion 3 - 3 E -9
~ -----------------------
066 160 crankshaft

6 1 15 14
2
13
11 3
! ~~j;l8" jL.:----1];ru~ 9
12

E -1 0 Ve rsion 3 - 3
 Spare Part List

066 160 cran kshaft

Item Reference No Designation Qty.

1 066 159 crankshaft 1

2 064 345 flywheel 1
3 064420 pressure washer flywheel 1
4 056264 pressure washer fan wheel 1
6 037 j790 fan wheel 1
8 000057 hexagon head cap screw 1
9 00021 6 hexagon head cap screw 1
11 001 675 lock plate 1
12 004472 tension bush 1
13 032430 fitting key 1
14 03457 5 Cylindrical roller bearing 1
15 03321 5 Cylindrical roller bearing 1

Version 3 - 3 E -11
~ ----------------------
064 568 connecting rod

E -12 Version 3 - 3
 Spare Part List

064 568 connecting rod

Item Reference No Designation Qty .

1 064352 con necting rod 1

2 056 1272 co nnecting rod bearing 1
3 033213 needle roller bearing 1
4 056316 connecting rod screw 2

Version 3 - 3 E - 13
~ ------------------
033 185 piston I st stage

I
I I \
6 2 1

E -14 Version 3 - 3
 Spare Part List
r

033 185 piston 1st stage

Item Referen ce No Designation Qty.

1 033 186 piston 1

2 033 187 piston pin 1
3 0351 99 M-ring 1
4 03 3 188 N-ring 1
5 035200 G-ring 1
6 002984 circlip 2

Ve rsion 3 - 3 E -15
 ,.

~ ------------------
057 520 piston 2nd stage

,.
1

4
f'

m-_ - - 5

2 f'
r

f'
f'

E -16 Ve rsion 3 - 3

f
 Spare Part List

057 520 pisto n 2 nd stage

Item Re~ere nce No . Designation Qty .

1 0575 19 piston 2nd stage 1

2 053727 piston pin 1
3 002984 ci rci ip 1
4 03 3 220 R-ring 1
5 034213 N-ring 1
6 033 221 S-ring 1

V ersion 3 - 3 E - 17
. ------------------
065 681 piston 3rd stage

1t=====~ 5
~=::::::======-- 6

___ 2

E -1 8 Version 3 - 3
 Spare Part List
L

065 681 pisto n 3rd stage

I
Item Reference No Designation Qty.
I
1 053 727 piston pin 1
2 065 682 piston 1
4 002 984 circiip 2
5 002 662 R-ring 2
6 002 543 N-ring 2

Version 3 . 3 E -1 9
~ ------------------
066 27] piston 4th stage

124
3
\\
,

E -20 Version 3 - 3
 Spare Part List

066271 piston 4th stage

Item Reference No . Designation Qty.

1 066172 piston 1
2 053727 piston pin 1
3 038249 R-ring 16
4 002984 circlip 2

Vers ion 3 - 3 E -21

~ ------------------
066 185 cylinder with head and valve 1st stage

9
7
8

3
I

10
,
3

E -22 Ve rsion 3 - 3
 Spare Part List

066 185 cyli nder with head and va lve 1st stage

Item Refe rence No Designation Qty.

1 064481 cylinder head 1st stage 1

2 0562 16 cylinder 1st stage 1
3 0562 37 cylind er head packing 1st stage 2
4 0562 39 low tolera nce gasket 1
5 062375 cylinder foot packing 1st stage 1
6 037477 cylind er head stud 6
7 001 620 hexago n nut 6
8 002 161 was her 6
9 036394 air filter 1
10 0332 10 conce ntric va lve 1st stage 1

Version 3 - 3 E - 23
~ ------------------
033210 concentric va lve 1st stage

E -24 Ve rsion 3 - 3
 Spare Part List

033 210 conce ntric valve 1st stage

Item Reference No Designation Qty .

1 03 3 405 suction valve plate 1

2 033406 suction valve spring 2
3 033407 delivery va lve plate 1
5 036431 delivery valve spring 1
6 036432 suction valve plate 1

Version 3 - 3 E -25
~ ------------------
064 409 cylinder with head and valve 2nd stage

I
_____________ 7 ~

8 I

10
11
I
I
1 I
I

3
I

~~--2

E -26 Ve rsion 3 - 3
 Spare Part List
i !

064409 cyli" der with head and valve 2nd stage

Item Re~ere nce No Designation Qty.

1 064347 cylinder head 2nd stage 1

2 064346 cylinder 2nd stage 1
3 060266 cylinder head packing 2nd stage 1
4 062376 cylinder foot packing 3rd stage 1
7 001 519 cylinder head stud 4
8 001 620 hexagon nut 4
9 035787 lamellar valve 2nd stage 1
10 005009 gasket 1
11 OOp 972 plug 1

Version 3 - 3 E -27
. ------------------
066 283 cylinder with head and valve 3rd stage
,
.

/ ,--:==,-_ - 2

12 , 13

~~- 1

~6

I
I
I

E -28 Ve rsion 3 - 3
 Spare Part List
:a: J

066283 cylinder with head and valve 3rd stage

Item Re~e re nce No. Designation Qty.

1 065685 cylinder 3rd stage 1

2 065481 cylinder head 3rd stage 1
4 065666 cylinder head packi ng 3rd stage 2
5 065665 low toleran ce gasket 1
6 062376 cylinder foot packing 3rd stage 1
8 031 526 concentric va lve 3rd stage 1
10 036362 cylinder head stud 4
11 00 1 620 hexago n nut 4
12 000976 plug 1
13 005016 gasket 1

Version 3 - 3 E -29
~ ------------------
03J 526 concentric va lve 3rd stage

~ i I 5

--- 4

~~=~~=~ , I

I
I

::===="=~ 3

E -30 Ve rsi on 3 - 3
 Spare Part List
t

031 526 concen tric va lve 3rd stage

Item Reference No Designation Qty.

1 03 3 899 suction va lve plate 1

2 033900 delivery va lve plate 1
3 033901 suction va lve spring 2
4 033902 deli very valve spring 4
5 03431 1 se lf lockin g nut 1

Ve rsion 3 - 3 E -31
 ,
~ ------------------
066 179 cylinder with head and va lve 4t h stage

,
,
2

3
7
8

&t%f71--- 11

10

E -32 Version 3 - 3
 Spare Part List

066 179 cyli nde r with head and valve 4th stage

Item Reference No Designation Qty.

1 066 163 cylinder 4th stage 1

2 066 175 cylinder head 4th stage 1
3 066 186 low tolerance packing 1
4 062376 cylinder foot packing 3rd stage 1
5 038220 cylinder head stud 6
6 002058 hexagon nut 6
7 035793 concentric valve 4th stage 1
8 035 893 O-ring 1
9 035826 low tolerance gasket 1
10 066 171 liner 4th stage 1
11 061 844 packing 1

Version 3 - 3 E - 33
~ ------------------
035 793 concentric valve 4th stage I
,
t

~3
I 4

I ---- _ --. 1
I

~ 2 /

!
E -34 Version 3 - 3
 Spare Part List

035 793 concen tric va lve 4th stage

Item Re~ere nce No Designation Qty .

1 035 794 va lve ring 1

2 035 796 sine spring 4
3 035 795 valve rin g 1
4 035 797 sine spring 3
5 046555 se lf lockin g nut 1

Version 3 - 3 E - 35
~ ------------------
066 222 cooler compl.

10 17,20 9 7 6 8 14 , 20 13 8

14 , 20

23 , 24

22

18

4 16 7, 12 5 , 11 2 , 3,15,19

E -36 Version 3 - 3
 Spare Part List

066 222 cooler co mpl.

Item Reference No. Designation Qty.

1 065 194 pipehold er 3

2 066227 angle rail 1
3 0662 28 ang le rail 1
4 0022 16 washer 2
5 064042 clamp 2
6 064075 cla mp 1
7 065046 clamp 3
8 064342 pipe 6
9 066230 pi pe 6
10 037776 cooler 1st + 2nd stage 1
11 066224 cooler 3rd stage 1
12 066225 cooler 4th stage 1
13 065234 clamp 1
14 033532 hexagon head cap screw 6
15 03? 20 1 stud 8
16 012 851 hexagon head cap screw 2
17 000 119 hexagon head cap screw 6
18 000 124 hexagon head cap screw 6
19 00 1 620 hexagon nut 8
20 003 114 locking washer " Schnorr" 12
22 035 932 clamp 1
23 036007 cla mp 1
24 000 444 Socket Head Cap Screw 2

Version 3 - 3 E -37
~ ------------------
066 207 air lines with separator
,
f
t

44 , 63
33 , 58 43 , 63
31 , 75 21
33 , 75
31 , 58 11
\ 43
,;:\17'1
\.-'~ )
10 , 15 , 56
()c
1 50 , 60

13,59 ,
1 9 I

49 , 63
r
"I ,
66 , 76 54

3
37

35

17 67 6 , 10 , 53 , 68
16 I

36 , 60 I
60 , 72 , 76 34 , 60

E -38 Version 3 - 3
 Spare Part List
L

066 207 air lines with separator

r 12 , 42 , 59 , 63 27,45

38 , 59 26 , 65
38 , 59
19 22 10 , 15 , 56 , 57 , 63
14 , 59

\
46
32 , 58,77
48,61 23
32,58,77
I
29 , 47 , 61

7 , 51 , 62
10, 15 , 56

5,55,69 I

8,52 4
\ ''\ \ \
38 , 40 , 59 , 64 2 18 41 ,58
8,52 39 , 64 38

Version 3 - 3 E -39
~ ------------------
066 207 air li nes with separator

25 , 59 43,65

24 \

43,63 - -i
73 ~ r o 51 , 62
~

-I 1 o
- -1
70,45 -
I

25 , 59 - -I
<-
24 ~ 1
~ 1
25,59

71
20 30,39 , 59

E -40 Version 3 . 3
 Spare Part List

066 207 air lines with separ-a tor

Item Reference No Designation Qty.

1 036555 separator 1st slage 1

2 0372 21 separator 2nd stage 1
3 063 121 separator 3rd stage 1
4 056648 separator 4th stage 1
5 066665 holder 1
6 066577 suction flange 1
7 065599 trunk 1
8 064567 clamp 2
9 060486 intermed iate piece 1
10 056334 packing 5
11 038089 safley valve 1st stage 1
12 033602 safley valve 2nd stage 1
13 062090 safley valve 3rd stage 1
14 050233 safley valve 4th stage 1
15 06,6 265 Rectangle flange 4
16 06,6 497 block 1
17 066210 pipe 1
18 066 211 pipe 1
19 066 212 pipe 1
20 066 214 pipe 1
21 066 215 pipe 1
22 066216 pipe 1
23 066 250 pipe 144mm long 1
24 066 693 Connecting block for thermometers 2
25 006 385 reducer 4
26 066 213 pipe 1
27 066 217 pipe 1
29 006454 stud adaptor 1
30 004730 union 1
31 038253
, stud ada ptor 2
32 Op6231 union 2
33 004673 union 2
34 005946 stud adaptor 1

Version 3 - 3 E -41
. ---------
066 207 air lines with separator

Item Reference No.1 Designation Qty.

35 006452 stud adaptor 1

36 006227 union 1
37 000979 plug 1
38 004655 uni on 4
39 006225 union 2
40 031 833 stud adaptor 1
41 011 448 reducer 1
42 045847 reducer 1
43 006219 union 4
44 006213 union 1
45 038350 cutting ring 2
46 004713 union 1
47 006209 union 1 t
48 011 119 union 1
49 006216 union 1
50 006386 reducer 1
51 001 009 plug 2
52 000482 Socket Head Cap Screw 4
53 000565 Socket Head Cap Screw 4
54 000 147 hexagon head cap screw 2 I
55 000 117 hexagon head cap screw 2 I
56 000548 Socket Head Cap Screw 16 J
57 030744 plug 2
I
58 005029 gasket 5
59 005016 gasket 11
60 005023 gasket 4
61 005006 gasket 2
62 005001 gasket 2
63 005009 gasket 7
64 030586 o-ri ng 2
65 037966 cu tting ring 2
66 036157 union 1
67 006319 union 1

E -42 Version 3 - 3
 Spare Part List
I
066207 air li nes with separator

Item Reference No Designation Qty.

68 002186 washer 4
69 002 153 washer 2
70 004639 union 1
71 034820 stud adaptor 1
72 004661 union 1
73 066704 Air defiector sheet metal 2
75 032401 o-ring 2
76 037948 Gutting ring 2
77 038671 Gutti ng ri ng 2

Version 3 - 3 E -43
 I

~ ----------------------
063 121 separator 3rd stage I
,

8 10 3 7 6

/ /

11 , 12

E -44 Ve rsion 3 - 3
 Spare Part List

063 121 separator 3rd stage

Item Referen ce No Designation Qty.

1 063228 separator hous ing 1

2 063229 separator inse rt 1
3 062328 cone 1
4 060342 fusibl e plug 1
6 006390 red ucer 1
7 005029 gasket 1
8 005 009 gasket 1
9 004; 181 o-ring 1
10 036041 hexago n head cap screw 1
11 00 1 007 plug 1
12 003496 gasket 1

Version 3 - 3 E -45
~ ------------------
056 648 separator 4th stage

----
I

3 ----V~;1tl

E -46 Ve rsion 3 - 3
 Spare Part List
, ,
056648 separator 4th stage

Item Reference No Designation Qty .

1 065495 sepa rator head 1

2 065497 sepa rator housing 1
3 030834 o-ring 1

Version 3 - 3 E -47
~ ------------------
064119 lubricating oil pump and drive

3 8

18

14
4
15
5 16
6

11 , 12
2 17

1,7,9, 10

E -48 Ve rsion 3 - 3
 Spare Part List

064 119 lubricating oil pump and drive

Item Re~ere nce No Designation Qty.

1 0579 16 ove rpressure va lve 1

2 062909 gearwheel oil pump 1
3 064098 gearwheel 1
4 056730 gearwheel 1
5 056318 packing 1
6 030545 pa cking 1
7 000970 plug 1
8 001 942 fitting key 1
9 003496 gasket 1
10 003438 gasket 1
11 001 009 plug 1
12 005001 gasket 1
13 001 459 stud 4
14 00,2 094 hexagon nut 4
15 002 146 was her 4
16 036897 oil sieve 1
17 004635 union 1
18 063 824 packing 1

Versi on 3 - 3 E -49
~ ------------------
066 303 measuring device

30 16 8 I

6
4
7
1 .27

35 . 37
31
- 31
12.25
4.28 . 29
15 .23
= .\ ,k.!' 12
iO'
' 1 ~l!
.. J :, I
.-+._~---.J" / : 31
'
T.:tr :f -
/

1 .22 31 22 . 41 39.40

E -50 Version 3 - 3
 Spare Part List

066 303 measu r ing device

19 . 20 21 . 33
18
18 . 32

L-
31 I

2
3

31
;:til .II
I

lJ c_ ~
" rr 1

1-'-
-~ -t.{ "
= = = = - ~"

Ve rsion 3 - 3 E -5 1
~ 0
b
.
066303 measunn devIce

I
I

.1
13,24
39,40
35,37

36,37
31

13,24

E -52 Ve rsion 3 - 3
 Spare Part List

066303 meas ur ing dev ice

Item Reference No Designation Qty.

1 065032 gauge pan el 1

2 059573 tube 1
3 059577 armafiex - hose 75mm long 1
4 030082 oi l pressure switch 1
5 086136 pressure gauge 1st stage/oil 1
6 086141 pressu re gauge 2nd stage 1
7 086142 pressure gauge 3rd stage 1
8 086143 pressu re gauge 4th stage 1
9 034796 contacting thermometer 1
10 037 839 thermometer 3
11 038073 angled thermomete r 1
12 033704 union 3
13 0305 10 union 2
14 006078 union 1
15 0330 17 reducer 1
16 067259 pressu re gauge 1
17 031 193 non-return va lve 1
18 006266 union 4
19 035438 union 1
20 035906 adaptor 1
21 035061 gasket 1
22 005009 ga sket 3
23 005 006 ga sket 1
24 005 001 gasket 2
25 003496 ga sket 1
26 037904 ga sket 1
27 032702 Socket Head Cap Screw 2
28 0000 10 hexagon head cap screw 2
29 002 144 washer 2
30 008633 pipe 800mm long 1
31 008633 pipe 800mm long 7
32 038030 union 3
33 034793 union 1

Ve rsion 3 - 3 E - 53
~ ------------------
066303 measuring device

Item Reference No Designation Qty.

35 005316 clam p 2
36 005320 clamp 1
37 000401 Socket Head Cap Screw 6 J
39 001 025 plug 2
40 034090 gasket 2
41 000972 plug 1
42 013 180 pipe 8mm long 2

E -54 Version 3 - 3
 Spare Part List

Vers ion 3 - 3 E -55

~ ----------------------
066284 cl-ankcase venting

12

11
8

E -56 Ve rsion 3 - 3
 Spare Part List
j

066 284 crankcase venting

Item Reference No Designation Qty.

1 063 171 stud 1

2 000976 plug 1
3 033952 Armaflex-hose 140mm long 1
5 012 193 hexagon nut 1
7 0062 16 union 1
8 008663 pipe 150mm long 1
9 006385 reducer 1
11 035254 hose clamp 2
12 034375 hose 600mm long 1

Ve rsion 3 - 3 E -57
~ ------------------
066305 automatic drainage

5,23
28
15 ,5

13 , 16 , 23

40 ,7
15 5 , 23
14 31 1
6,22, 19

5 , 15 1413 15, 16

E -58 Version 3 - 3
 Spare Part List

066 305 automatic drainage

0 0 1

00
6 , 18

6,9

6 ,34 ~=:~~~~~~~~~~~~JJ~~;1
17 -Ltt-tl=l~~
2 , 39 , 4 1 ----,----tl-++I-
j-.

6 , 20 L----1t--H~

6 , 10 I
38

21

27

21 37 3 , 6 33 6 , 20 5,23 5,24
6 , 23 6 , 8 , 19 32

Vers ion 3 ~ 3 E -59

~ ----------------------

E -60 Version 3 - 3
 Spare Part List

066305 autom a tic drainage

Item Refk rence No Designation Qty.

1 065686 expa nsions recei ver 1

2 061 078 pneumatic relieve va lve 1
3 065649 flow control 1
5 005009 gasket 6
6 005001 gasket 9
7 003 11 5 locking washer" Schnorr" 4
8 033614 union 1
9 030510 union 1
10 004612 union 1
13 033 1961 stud adaptor 2
14 037 1680 solenoid valve 2
15 00621 6 union 4
16 030207 o-ring 2
17 006 179 union 1
18 035670 union 1
19 036082 union 2
20 006205 union 2
21 004619 union 2
22 035925 union 1
23 004 641 union 5
24 006186 union 1
27 008637 pipe 200mm long 1
28 008663 pipe 150mm long 1
31 008663 pipe 150mm long 1
32 008663 pipe 150mm long 1
33 008663 pipe 150mm long 1
34 008 ,663 pipe 150mm long 1
36 012 (766 pipe 250mm long 1
37 012 ]7 66 pipe 250mm long 1
38 012766 pipe 250mm long 1
39 000028 hexagon head cap screw 2
40 000036 hexagon head cap screw 4
41 002 1153 washer 2

I
I Ve rsIon 3 - 3 E -6 1
~ ------------------
061 078 pneumatic reHeve valve

3
8
8
7 7
1 2

11 ~~\ 1
11
2
9
9
4 4

! ~

10

E -62 Ve rsion 3 - 3
 Spare Part List
i
061 078 pneumatic relieve valve

Item Reference No. Designation Qty.

1 054871 valve piston 2

2 05671 9 valve cover 2
3 056721 housing cover 1
4 056927 housing flange 2
7 030 149 lip-ring 2
8 004083 O-ring 2
9 004045 O-ring 2
10 0001466 cylinder head screw 16
11 030340 O-ring 2

Version 3 - 3 E -63
~ ----------------------
033432 flexible coupling

E -64 Version 3 - 3
 Spare Part List
&

033 432 flexibl e coupling

Item Refk rence No Designation Qty.

1 033 423 flexible gear rim 1

Ve rsion 3 - 3 E -65
~ ------------------
066306 resilient mounts

9 1,2 4 ,6 8 1,2 3,5

E -66 Vers ion 3 - 3

 Spare Part List
I
066306 resilient mounts

Item Reference No. Designation Qty.

1 0468 37 resilient mou nt 4

2 037 172 base plate 4
3 000066 hexagon head ca p screw 2
4 000068 hexago n head cap screw 2
5 002 166 washer 2
6 00 1 637 U-was her 2
7 038405 HP-hose 1
8 062338 drain hose 1
9 034333 non-return va lve 1

Version 3 ~ 3 E -67
 !'

- ~- - - - - -

,
r
!'

r
r

r
r
f

r
f

E -68 Ve rsion 3 - 3
 Index
t

Reference No. Designation Page Pos .

000010 hexagon head ca p screw 53 28

000028 he xagon head cap screw . . . ..... . 61 39
000036 hexagon head cap screw . .. . ... . . . 61 40
000057 hexagon head cap screw 11 8
000066 hexago n head cap screw . 67 3
000068 hexago n head cap screw . 67 4
000117 hexagon head cap screw . 42 55
000119 hexago n head cap screw 37 17
000 124 hexagon head cap screw . 37 18
000147 hexago n head cap screw . 42 54
000216 hexagon head cap screw . 11 9
000270 Lifting eye boll. 9 8
000401 Socket Head Cap Screw . 54 37
000444 Socket Head Cap Screw . 37 24
000466 cylinder head screw . . .. .. . ... . . . .. .. .. . .. . . . .. .. . . . . 63 10
000482 Socket Head Cap Screw . 42 52
000548 Socket Head Cap Screw . 42 56
000565 Socket H ead Cap Screw . 42 53
000970 plug . . .. . . ... .. .. . . .. ... .. . . . .. ....... .. . 49 7
000972 plug. 27 11
000972 plug. 54 41
000976 plug . .. ... . .. . . . . 29 12
000976 plug .. . . .. . .. . . . . 57 2
000979 plu g .. .. ... . . . . . 42 37
001 007 plug . . ... . . . . . . . . 45 11
001 009 plug ...... . . .. . 9 13
001 009 plug . . . . . . . . . 42 51
001 009 plug . ..... . . . . . . 49 11
001 021 plug 9 15
001 025 plug ... . . . .. . 54 39
00 1 41 1 stud .. . . . .. . . 9 9
001 459 stu d . . 9 12
001 459 stud . .. . . ...... .. . . ... . 49 13
001 519 cylind er head stud. 27 7
001 620 hexagon nut. .. . . .. . .. . . 23 7
001 620 hexagon nut. .... . . . . . . . . 27 8
001 620 hexagon nut . .. .. . .. . . .. . 29 11
001 620 hexagon nut. 37 19
001 637 U-washer .. . . . .. . . . 67 6
00 1 675 lock plate . .. . . . . . . . 11 11
001 9 10 shaft seal . . ..... . . . . . . .. .. .. . . 9 25
001 942 fitting key. 49 8
002031 hexagon nut. . 9 17
002058 hexagon nut. .. .. . . .. . . 33 6
002094 hexagon nut. 9 18
002094 hexagon nul . . . . .. . . . . . 49 14
002098 hexagon nul. . 9 16
002 144 washer . . 53 29
002146 washer . 9 19
002146 wa sher . 49 15
002 153 washer . 43 69

Vers ion 3 - 3 E -69

 I
Reference No. Desig nation Page Pos .
I
002 153 washer..... ... ........ .. ... .
!
002161 washer ........ . .......... . . .
61
23
41
8
,
002 166 washer ..... .. ........ . . 67 5
002 186 washer ... .. . .... ....... .. . . 43 68
t
002216 washer .. 37 4 t
002543 N-ring. 19 6
002662 R-ring .... .... .... . 19 5 f
002984 ci rcli p . ... , 15 6 f
002984 circlip .. 17 3
002984 circlip . ..... j 19 4
002984 circlip . .. 21 4
003 114 locking washer" Schnorr .. .... ~ 37 20
003115 locking washer " Schnorr .. . . . . . . ......... . . .. ~ 61 7
003438 gasket . .... . ..... . ... . 49 10
003496
003496
003496
gasket
gasket .. ........ ... ..... .
gasket ....... .
45
49
12
9
,
53 25
004045
004083
004 18 1
O-ring
O-ring ..
o-ring ... .... . .. . ..... .
63
63
45
9
8
9
,
I

004472 tension bush 11 12

004612 union 61 10 I
004619 union 61 21
004 635 union ................ ... . 9 21 /
004635 union ........ . . 49 17
004639 union . . .. .... . . 43 70
004641 union 61 23
004655 union . 42 38
004661 union .
I
43 72
004673 union 41 33
004713 union . 42 46
005001 gasket ... ..... . 9 22
I
005001 gasket ... ................ .... . 42 62
005001 gasket 49 12
005001 gasket ...... . . . .......... . 53 24
005001 gasket ....... . . 61 6
005006 gasket . 42 61
005006 gasket 53 23
005009 gasket 9 23
005009 gasket ... .. . . . . 27 10
005009 gasket 42 63
005009 gaske t . 45 8
005009 gasket ...... .. . . . .. . . . 53 22
005009 gasket . ..... . ........ . . . 61 5
005016 gasket .... .. .... .. . 29 13
005016 gaske t ..... ....... . 42 59
005023 gasket 42 60
005029 gaske t . . .. . .... . 9 24
005029 gasket . 42 58
005029 gaske t .. 45 7
005316 clam p ....... . ... . . 54 35

E -70 Ve rsion 3 - 3
 Index

Reference No. De signation Page P os .

005320 cla mp. 54 36

005930 stud . . 9 11
005946 stud adaptor ..... . . . . . . . . . . 41 34
006078 union ...... . . . . .. ... .. . . 53 14
006179 union . 61 17
006 186 union ........ . . 61 24
006205 union ........ . 61 20
006209 union ......... . 42 47
006213 union ........ . . 42 44
006216 union ... ...... . 42 49
006216 union .. ....... . 57 7
006216 union . . 61 15
0062 19 union . . 42 43
006225 union. 42 39
006227 union. 42 36
00623 1 union 41 32
006266 union ........ . ....... . .. .. ... . .... . ... . . 53 18
0063 19 union . . 42 67
006385 reducer 41 25
006385 reducer 57 9
006386 reducer. 42 50
006390 reducer . 45 6
006 452 stud adaptor . 42 35
006454 stud adaptor . 41 29
008633 pipe 800mm long ... .... . . .. . . . 53 30
008633 pipe 800mm long. 53 31
008637 pipe 200mm long. 61 27
008663 pipe 150mm long. 57 8
008663 pipe 150mm long. 61 28
008663 pipe 150mm long. 61 31
008663 pipe 150mm long ......... . 61 32
008663 pipe 150mm long. 61 33
008663 pipe 150mm long ... . ..... . 61 34
011119 union ............ . .. ..... . 42 48
011 448 reducer. 42 41
012 193 hexagon nut. . ..... . ... . . .. . . 57 5
012766 pipe 250mm long .. ... . . . . . . . 61 36
012766 pip e 250m m long . . .. ..... . . .. . 61 37
012766 pipe 250m m long . 61 38
012851 hexagon head cap screw .. .. .... . . . . .. . 37 16
013 180 pipe 8mm long . 54 42
030082 oil pressure switch . 53 4
030 149 lip-ring ...... .. .. ...... .. . 63 7
030207 o-ring. 61 16
030340 O-ring . . ... .... ... .... ... .. ..... . 63 11
086143 pressure gauge 4th stage. 53 8
030510 un ion . 53 13
030510 union . 61 9
030545 packing . 49 6
086 136 pressure gauge 1 sl stage/oil .. .... ... ... . . .. .. . ... .. 53 5
030586 o-ring. 42 64

Vers ion 3 - 3 E -7 1
 Reference No. Designation Page Pes .

030744 plug .. ... ...... . . 9 14

030744 plug. 42 57
030831 shaft seal . .. . .. ..... . .. . 9 26
030834 a-ring. 47 3
031 193 non-return valve. 53 17
031 526 concentric valve 3rd stage 7 13
031 526 conce ntric valve 3rd stage 29 8
031 833 stud adaptor . . ...... . . . 42 40
032401 o-ring . .. .. . ......... . 43 75
032430 fitting key . ...................... . 11 13
086141 pressure gauge 2nd stage 53 6
086142 pressure gauge 3rd stage . 53 7
032702 Socket Head Cap Screw . .. ... , 53 27
033017 reducer. 53 15
033 185 piston 1st stage ......... . 7 4
033186 piston .. . .. .......... . . .. 15 1
033187 piston pin .. 15 2
033188 N-ring . . ....................... . .. . . 15 4
033210 concentric valve 1st stage . ..... .. .. . 7 12
033210 concentric va lve 1 st stage . ....... ... . 23 10
0332 13 needle roll er bearing . ......... .. . 13 3
0332 15 Cylindrical roller bearing . ..... . . . . 11 15
033220 R-ring. 17 4
033221 S-ring . . . .. .......... . 17 6
033405 suction va lve plate. 25 1
033406 suction valve spring . 25 2
033407 delivery valve plate . 25 3
033423 flexible gear rim . 65 1
033432 flexible coupling. 7 24
033532 hexagon head cap screw . . .. .. .. . .... ... . ... . . . . . . .. 37 14
033602 saftey va lve 2nd stage . . . . . . . . . .. . . ... .. .. ... ..... .. 41 12
033614 union . 61 8
033704
033717
union
cylinder foot stud
53
9
12
10 ,
033899
033900
suction valve plate .
delivery valve plate . ......... . .
31
31
1
2 ,
03390 1 suction valve spring. 31 3
033902 de livery valve sprin g . ........... .. . 31 4 f
033952 Armaflex-hose 140mm long . .... . . . . . . 57 3
033961
034090
stud adaptor .... ..... . .
gasket.
61
54
13
40
,
034213 N-ring . 17 5
034 311 self locking nut. 31 5
034 333 non-return valve . 67 9
034 375 hose 600mm long .. 57 12
034575 Cylindrical roller bearing . 11 14
034 793 union .......... . 53 33
034796 contacting thermometer . 53 9
034820
035061
035 199
stud adaptor .. . . ......... .
gasket.
M-ring.
. .... , .. , .
. ........ ... .
43
53
15
71
21
3
,
,
E -72 Version 3 - 3 ,
 Index
L

Referen ce No. Designation Page Pos.

035200 G-ring 15 5
035254 hose clamp . 57 11
035438 union . . 53 19
035787 lamellar valve 2nd stage . 27 9
035793 concentric valve 4th stage . . . ... . . . . 7 14
035793 concentric valve 4th stage ... .. . . . . .... . . . .. . . . 33 7
035794 valve ring .. . ... .. . . ............. . 35 1
035795 valve ring . 35 3
035796 sine spring . . 35 2
035797 sine spring. 35 4
035824 fi ll ing cover. 9 29
035826 low tolerance gasket. 33 9
035893 O-ring 33 8
035906 adaptor . . .. .. ... . ...... . 53 20
035925 union. 61 22
035932 clamp . ... .. .... .. .......... . . . . 37 22
036007 clamp . . 37 23
036041 hexagon head cap screw .. 45 10
036082 union ........ . . . ...... . .. ....... . . 61 19
036 157 union ..... . ...... . .... . .. . . ...... . 42 66
036362 cylinder he ad stud . . 29 10
036394 air filter . .... . ............. . . 23 9
036431 delivery va lve spring . 25 5
036432 suction valve plate. 25 6
036555 separator 1sl stage . . 41 1
036897 oil sieve ...... . .. . ... ... . . 49 16
037 172 base plate. 67 2
037201 stud . . 37 15
037 221 separator 2nd stage .. .... . . . . . ... . 41 2
037477 cylinder head stud. 23 6
037680 solenoid va lve . . .. ...... . .. . . . .. .. . ... . 61 14
037776 cooler 1st + 2nd stage. . . . . .. . .. . . .. . 37 10
037790 fan wheel. 11 6
037839 the rmometer . 53 10
037844 oil leve l indicator .. .. .. . . . . . . 9 2
037904 gasket . . .... .. ... . 53 26
037948 cutting ring . .. ....... . .. . 43 76
037966 cutting ring . 42 65
038030 union ..... .... ... ........ . 53 32
038073 angled thermometer . ........ . 53 11
038089 saftey valve 1 st stage . .. ... ... . 41 11
038220 cylinder head stud . 33 5
038249 R-ring .. ....... ... .. . .... . .... . 21 3
038253 stud adaptor 41 31
038350 cutting ri ng . . ..... . . . 42 45
038405 HP-hose . . ........ . 67 7
03867 1 cutting ring. 43 77
045847 redu ce r . 42 42
046555 self locking nut . .. . ........ . 35 5
046837 resilient mount . 67
050233 saftey valve 4th stage . ...... .... . . . 41 14

Version 3 - 3 E -73
~ ------------------
Reference No. Designation Page Pas.

051 883 inspection hole cover . 9 4

053727 pis ton pin . . . . . . . .... . ....... ... . 17 2
053727 piston pin . . . .. ......... .... . . . . ... . . . 19 1
053727 piston pin . .. . .... . .. . .... . . ... ..... ...... ... . . ... . . . . . .. . 21 2
054871 valve piston . 63 1
0562 16 cylinder 1sl stage . . . . . . . . .. . . . . .... ... .... . . 23 2
056237 cyl inder head packing 1sl stage . . ... . ......... . . . . . . 23 3
056239 low tolerance gasket . 23 4
056264 pressure washe r fan wheel . ......... . .. . 11 4
056272 conne cting rod bearing . 13 2
056316 connecting rod screw. 13 4
056318 packing . . . . . ... .. .. . . 49 5
056 334 packing . 41 10
056648 separator 4th stage . 7 18
056648 separator 4th stage . 41 4
056719 va lve cover . . 63 2
05672 1 housing cover . .. .. .. ... .. . 63 3
056730 gearwheel. 49 4
056927 housing flange ... . .. . . . 63 4
057519 piston 2nd stage. 17 1
057 520 piston 2nd stag e . 7 5
057916 overpressure va lve . .... . . . ..... .. . . . 49 1
059573 tube. . .. . . ... .. . . . . . . . . . .. ... ... . . . 53 2
059577 armaflex hose 75mm long ... . . . . .... . . . . . 53 3
060266 cylind er head packing 2nd stage . . 27 3
060342 fusible plug. 45 4
060486 intermediate piece . 41 9
061 078 pneumatic relieve valve 7 23
061 078 pneumatic relieve valve. 61 2
061844 packing . 33 11
062090 saftey valve 3rd stage 41 13
062328 co ne. 45 3
062338 drain hose . 67 8
062375 cylinder foot packing 1st stage . 23 5
062 376 cylinder foot packing 3rd stage. 27 4
062 376 cylinde r foot packing 3rd stage 29 6
062376 cylinde r fool packing 3rd stage 33 4
062909 gearwheel oil pump. 49 2
06312 1 separator 3rd stage. 7 17
063 121 separator 3rd stage. 41 3
063171 stud . 57
063228 separator housing . . .... . . . . . . . 45 1
063229 separator insert ... . .. ... . 45 2
063748 packing for cover . .. . ..... . 9 6
063824 packing . 49 18
064042 clamp. 37 5
064075 clamp. 37 6
064079 bearing bracket. . .. .. .. . . .. .... .. . . 9 3
064095 packing for bearing bracket . 9 5
064 098 gearwheeL 49 3
064 119 lubricating oil pump and drive 7 19

E -74 Ve rsion 3 . 3
 Index
h I

Refe rence No. Designation Page Pos.

064 342 pipe . 37 8

064345 flywheel . 11 2
064346 cylinder 2nd stage . 27 2
064347 cyl inder head 2nd stage. 27 1
064352 connecting rod. 13 1
064409 cylinder with head and valve 2nd stage . 7 9
064420 pressure washer flywheel . 11 3
064481 cylinder head 1st stage. 23 1
064567 clamp . 41 8
064568 connecting rod . 7 3
065032 gauge panel. . . . . .... . 53 1
065046 cla mp. 37 7
065 194 pipeholder . 37
065234 clamp. . ... . ...... . .. .. . 37 13
065481 cylinder head 3rd stage . .... .. . . . 29 2
065495 sepa rator head. 47 1
065497 separator housing . ... . . . .. . .. . 47 2
065 599 tru nk .. . . .... ... . . ....... . . 41 7
065649 flow control.. 61 3
065665 low tolerance gaske t . ... ... ... . . ... . . 29 5
065666 cylinder head packing 3rd stage. . .. . ... . .. . .. . . 29 4
065681 piston 3rd stage. . ...... . . . . . .. . . . . 7 6
065682 piston. 19 2
065685 cylinder 3rd stage . 29
065686 expansions receiver. 61
066157 crankcase. 9
066159 crankshaft . ........... . . . . . .. . . . . . 11 1
066 160 crankshaft. 7 2
066 163 cylinde r 4th stage . 33
066165 crankcase. 7 1
066171 liner 4th stage . . . . . ... . . . ... . . . . . 33 10
066 172 piston . . 21 1
066175 cylinder head 4th stage. 33 2
066179 cylind er with head and va lve 4th stage . . 7 11
066 184 oil strainer . . 9 7
066 185 cylind er wilh head and valve 1sl stage . ......... . 7 8
066 186 low tolerance packing . 33 3
066207 air lines with separalor . 7 16
066210 pipe. 41 17
066211 pipe ..... ... . ... .... . 41 18
066212 pipe. 41 19
066213 pipe 41 26
0662 14 pipe 41 20
066215 pipe. 41 21
066216 pipe. 41 22
066217 pipe .... . ............ . . . ... . 41 27
066222 cooler compl ......... . 7 15
066224 cooler 3rd stage 37 11
066225 cooler 4th stage .. ........ . 37 12
066227
066228
I
I
angle rail.
angle rail . .... .... . ...... .
37
37
2
3

Version 3 - 3 E -75
. ------------------
R eference No. Designation Page Pas.

(
066230 pipe . 37 9
066250 pipe 144mm long . 41 23 f
066265 Rectangle flange . 41 15
I
066271 piston 4th stage. . . ... . ... . ................ . . 7 7
066283 cylinder with head and valve 3rd stage . 7 10
066284 crankcase venting. 7 21
066303 measuring device . 7 20
066305 automatic drainage 7 22
066306 resilient mounts . ... .. . .... . 7 25
066497 block. 41 16
066577 suction flange. 41 6
066665 holder . 41 5
066693 Connecting block for thermometers . 41 24
066 704 Air deflector sheet metal . 43 73
067 259 pressure gauge 53 16
004730 union. 41 30
035670 union. 61 18

E -76 Vers ion 3 - 3

 II

~ I I
I I
)
I
) !
)
)
)

~
~
~
~
~

, ~

~
~
~
~
")
~
~
~
 -/
'.'
"

(
(
~
~
~
~
~
.. ~
~

~
~
~
~
~
~
~
if