Manual WP311L

S a u e r
C o m p r e s s o r
Type: WP 311 L
Operating Manual
• High-Pressure Compressor
• 3 Stages
• Air Cooled
Version 2 - 2
VO001AC3.fm
VO001AC3.fm
Edited by: ZINDEL – Technical Documentation, www.zindel.de
Version 2 - 2
Sauer compressor type approvals
Note!
VO002AA2.fm
On this page only a few examples are shown. Further type ap-
provals are available on request.
Version 2 - 2
Genuine Sauer spare parts –
certified safety
E N
E C IM
SP VO002AA2.fm
Version 2 - 2
Contents
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 At the outset . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 General information . . . . . . . . . . . . . . . . . . . . . 8
1.3 Warranty and Liability . . . . . . . . . . . . . . . . . . . 8
1.4 Type approval and genuine Sauer spare
parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 J.P. SAUER & SOHN customer service . . . . 10
1.6 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 Functional description . . . . . . . . . . . . . . . . . . 22
3.3 Indicators on the Sauer compressor . . . . . . . 24
3.4 Indicators and controls of the compressor
control system . . . . . . . . . . . . . . . . . . . . . . . . 25
4. Technical Specifications . . . . . . . . . . . . . . 26
4.1 Specification data . . . . . . . . . . . . . . . . . . . . . 26
4.2 Compressed air wiring diagram. . . . . . . . . . . 28
WP311L_BA_2IVZ.fm
Version 2 - 2 5
5. Transport and Installation . . . . . . . . . . . . . 29
5.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2 Storage before installation . . . . . . . . . . . . . . 30
5.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4 Connecting the compressor . . . . . . . . . . . . . 33
5.5 Filling in oil . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.6 Checks after installation and before the first
start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1 Safe operation. . . . . . . . . . . . . . . . . . . . . . . . 39
6.2 Operating modes. . . . . . . . . . . . . . . . . . . . . . 40
6.3 Initial operation . . . . . . . . . . . . . . . . . . . . . . . 40
6.4 Routine operation . . . . . . . . . . . . . . . . . . . . . 41
7. Troubleshooting . . . . . . . . . . . . . . . . . . . . . 43
8. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 46
8.1 Maintenance service by J.P. SAUER & SOHN 46
8.2 Maintenance safety . . . . . . . . . . . . . . . . . . . . 46
8.3 Maintenance schedule . . . . . . . . . . . . . . . . . 47
8.4 Table of tightening torques . . . . . . . . . . . . . . 49
8.5 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.6 Checking screwed connections. . . . . . . . . . . 50
8.7 Air filter cartridge replacement . . . . . . . . . . . 50
8.8 Checking the valves . . . . . . . . . . . . . . . . . . . 51
8.9 Checking the piston rings . . . . . . . . . . . . . . . 53
8.10 Replacing gudgeon pins/gudgeon pin
bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.11 Replacing valves . . . . . . . . . . . . . . . . . . . . . . 55
8.12 Checking pistons and cylinders. . . . . . . . . . . 55
8.13 Checking the drive bearings . . . . . . . . . . . . . 55
8.14 Checking the coupling. . . . . . . . . . . . . . . . . . 56
WP311L_BA_2IVZ.fm
6 Version 2 - 2
9. Placing out of Service . . . . . . . . . . . . . . . . . 58
9.1 Safety when placing out of service and
dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.2 Placing the compressor out of service for a
limited time . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.3 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10. Lubricant Table . . . . . . . . . . . . . . . . . . . . . . 61

10.1 Lubricating oils . . . . . . . . . . . . . . . . . . . . . . . 62
10.2 Preservation oils . . . . . . . . . . . . . . . . . . . . . . 63
11. Spare Parts and Accessories . . . . . . . . . . . 64
12. Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
WP311L_BA_2IVZ.fm
Version 2 - 2 7
1. General
1.1 At the outset
The following main specifications of your Sauer compressor are
found on the type label affixed to the crankcase:
– compressor type
– factory number
– year of construction
We recommend you write down this information in chapter
11. “Spare Parts and Accessories”.
1.2 General information

Conditions We presuppose that only authorized persons will operate and
service the Sauer compressor. These persons must have read
and understood the operating instructions.
Availability These instructions shall always be kept available at the site of op-
eration.
Copyright The copyright for these instructions remains with

J.P. SAUER & SOHN. These instructions, or parts thereof, shall
not be copied, distributed or made available to third parties. Con-
travention will be prosecuted.
1.3 Warranty and Liability

We exonerate the contractually agreed warranty claims and liabil-
ity claims, if they can be attributed to at least one of the following:
– use of the machine not as specified;
– use of spare parts that are not genuine Sauer spare parts;
– operation of the machine with faulty or not properly installed
safety devices and protection devices;
– disregard of the operating instructions;
– unauthorized modifications of the machine or its control sys-
tem;
– inadequate monitoring of machine parts subject to wear;
– inexpert repairs;
– force majeure.
AL001AA1.fm
8 Version 2 - 2
General
1.4 Type approval and genuine Sauer spare parts

• The type approval for the Sauer compressor is valid under the
condition that parts and components specified and qualified by
J.P. SAUER & SOHN are used. The type approval is made by
the Classification Society and the EC Declaration of Conform-
ity or EC Manufacturer's Declaration. Disregard of the specifi-
cations may cause the type approval to expire.
• Only the use of genuine Sauer spare parts ensures compli-
ance with these specfications and thus the perfect and safe
operation of the Sauer compressor.
• If genuine Sauer spare parts are not used we reserve the right
of exclusion of liability for personal injury and material damage.
• genuine Sauer spare parts are supplied with a Certificate of
Conformity and a Certificate of Authenticity. A specimen of this
document is shown before the table of contents of these in-
structions. If spare parts are received without this certificate,
there is a risk that these are not genuine Sauer spare parts. In
such case please contact our customer service.
Do not use parts from

the „grey market“…
… but only genuine Sauer

spare parts with certificate!
AL001AA1.fm
Version 2 - 2 9
1.5 J.P. SAUER & SOHN customer service
In case of technical questions pertaining to maintenance or repair
please contact our customer service:
J.P. SAUER & SOHN Maschinenbau GmbH

Customer Service
P.O. Box 92 13
D-24157 Kiel
Telephone (international):
Technical information +49 431 39 40 -87
Spare parts ordering +49 431 39 40 -86/886
Telefax (international): +49 431 39 40 -89
Emergency service (international): +49 172 4 14 63 94
E-Mail: [email protected]
Web: www.sauersohn.de
Note!
If you have questions regarding your Sauer compressor please
state compressor type and factory number (see chapter
11. “Spare Parts and Accessories” or type label on the crank-
case).
AL001AA1.fm
10 Version 2 - 2
General
1.6 How these instructions are organized

Listings General listings are denoted by horizontal bars.
Example:
The cooling consists of
– fan wheel,
– fan wheel cage, and
– cooler assembly.
Action Individual instructions or multiple instructions, where the se-

quence is of no importance are normally denoted by bullets.
Example:
• Check oil level.
Instructions to be carried out in a certain sequence are num-

bered.
Example:
1. Turn the main switch ON.
2. Choose the operating mode.
3. Turn the control ON.
Results Results of actions carried out are denoted by a check mark.

Example:
✓ The control light is on.
Safety instructions Safety instructions are emphasized by pictographs and signal

words. The safety instructions are described in detail in chapter
2. “Safety”.
AL001AA1.fm
Version 2 - 2 11
2. Safety
2.1 Specified conditions of use
This Sauer compressor must be used for the compressing of air
only. The Sauer compressor must not be used at ambient tempe-
ratures of below +5 °C. Any other use is not as specified and re-
quires the explicit consent in writing by J.P. SAUER & SOHN.
Observance of these operating instructions, the installation re-
quirements detailed in the instructions, and the keeping of main-
tenance rates are part of the specified conditions of use as well.
2.2 Prohibition of unauthorized conversion

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

The safety information in these instructions is divided in two clas-
ses. The following pictographs and signal words are used:
Danger!
High risk.
Disregard of this safety information may cause personal injury
and substantial material damage.
Note!
Average risk.
Disregard of this safety information may cause damage to the
machine.
I_SI003_2.fm
12 Version 2 - 2
Safety
2.4 Safety markings on the machine

Caution!
Safety markings affixed to the machine must not be altered or re-
moved. Replace damaged or lost safety markings immediately,
true to the original.
Sauer compressor models with an EC Manufacturer's Declarati-
on or EC Declaration of Conformity are marked with the following
safety markings:
Safety marking Meaning Safety marking Meaning
Danger! High voltage! Read instructions!
Compressor starts auto- Wear hearing protection!

matically without warning!
Hot surface! Rotational direction of

crankshaft
Location of safety markings (top view)

I_SI003_2.fm
Version 2 - 2 13
2.5 Safety devices
Danger!
Safety devices must not be adjusted, disabled or removed.
The safety devices shall be periodically tested and checked.
Safety valves must be
– installed sealed and
– shall be replaced, adjusted and sealed by authorized person-
nel only.
Safety valves Every pressure compartment of a stage of the Sauer compressor

is equipped with a safety valve, which will blow off when the blo-
wing-off pressure is reached.
Safety valves are installed at these locations:
– 1st compression stage: in the 1st stage's honeycomb radiator;
– 2nd compression stage: in the 2nd stage's honeycomb radiator;
– 3rd compression stage: in the final separator.
Fusible plug/ tem- To monitor the cooling, a fusible plug is installed in the final sepa-
perature control rator. It will melt at 121 °C, opening an exhaust port for the com-
pressed air when it has exceeded the temperature limit. This
protects the compressor from overheating.
The fusible plug works only once. Once it has responded it must
be replaced by a new fusible plug.
As an alternative to the fusible plug the Sauer compressor can be
equipped with a temperature control. This will turn the compres-
sor off if the temperature of the compressed air exceeds the limit.
2.6 Noise protection

Sound pressure level details are found in the Technical Specifica-
tions (see chapter 4).
If necessary the Sauer compressor can be equipped with a noise
protection hood, which is available as optional accessory from
J.P. SAUER & SOHN.
Danger!
When the compressor is operated without noise protection hood,
hearing protection should be worn near the compressor.
I_SI003_2.fm
14 Version 2 - 2
Safety
2.7 Waste disposal

Note!
Under the laws and regulations in force, the following materials
arising from the operation of the compressor need to be 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! Before commencing work they must have read and un-
derstand the operating manual and must be familiar with the
safety devices and safety regulations.
In addition to the instructions in this operating manual and manuf-
acturer documentation, accepted technical standards must be
observed as well as all regional laws, standards and regulations
such as the
– Equipment and Product Safety Act (Geräte- und Produktsi-
cherheitsgesetz),
– Ordinance on Industrial Safety and Health (Betriebssicher-
heitsverordnung),
– Regulations for accident prevention pertaining to compres-
sors,
– VDE regulations and
– Regulations on environmental protection.
In addition, where appropriate, regulations of the responsible
classification society as well as operational regulations must be
observed.
Persons authorised to operate the compressor are the attending
specialists introduced to the job and trained by the operator.
Persons authorised to service the compressor are the trained
specialists of the operator and of the manufacturer.
2.9 Personal protection 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.
I_SI003_2.fm
Version 2 - 2 15
3. Design and Function
3.1 Overview
16 2 12 9
5
1
6, 14
4
15
7 10
13 3
8
11
I_FK002_1A.fm
16 Version 2 - 2
Design and Function
Item Designation
1 Cylinder 1st stage
2 Cylinder 2nd stage
3 Cylinder 3rd stage
4 Safety valve 1st stage (not visible)
5 Safety valve 2nd stage
6 Safety valve 3rd stage
7 Cooler 1st and 2nd stage
8 Condensate separator 2nd stage
9 Condensate separator 3rd stage (final separator)
10 Condensate collecting pot
11 Drain valves 1st, 2nd, 3rd stage

12 Oil pressure monitor
13 Oil dip stick
14 Fusible plug (not visible)
15 Electric motor
16 Crankcase vent with insulating sleeve (not visible)

I_FK002_1A.fm
Version 2 - 2 17
Longitudinal section
4
3
11
10 8 7
9
I_FK002_1A.fm
18 Version 2 - 2
Design and Function
Item Designation
1 Cooler 1st and 2nd stage

2 Fan wheel
3 Cooler 3rd stage

4 Connecting rod
5 Flexible coupling
6 Transmission bell housing
7 Flywheel
8 Oil suction filter
9 Crankshaft
10 Lubricating oil pump
11 Bearing bracket
I_FK002_1A.fm
Version 2 - 2 19
Cross section
2 4
8 7
Note!
Details of parts and spare parts are found in the spare parts ca-
talogue.
I_FK002_1A.fm
20 Version 2 - 2
Design and Function
Item Designation
1 1st stage: cylinder with head and valve
2 Piston 1st stage
3 2nd stage: cylinder with head and valve
4 Piston 2nd stage
5 3rd stage: cylinder with head and valve
6 Piston 3rd stage
7 Crankcase
8 Connecting rod
I_FK002_1A.fm
Version 2 - 2 21
3.2 Functional description
Drive The Sauer Kompressors is driven by an electric motor directly
flanged to the transmission bell housing of the crankcase, where
the force is transferred by means of a flexible coupling.
Alternatively a diesel engine can be used to drive the compres-
sor. This is installed by means of a special flange. It transfers the
power by means of a centrifugal clutch.
Compressor cont- The Sauer Kompressor with electric drive is controlled and moni-
rol tored by an electric compressor control system. This control sys-
tem must comply with the legal regulations. Optionally,
J.P. SAUER & SOHN supplies a suitable compressor control
system.
Compression The compressor takes in ambient air through a sheet filter with
tube silencer and compresses it in three single-stage cylinders to
the ultimate pressure. Each cylinder is a compression stage, be-
hind which the air is recooled.
Splitting the entire pressure ratio into three stages results in es-
pecially low compression end temperatures. The final temperatu-
res are below the flash point of standard motor oils (mineral oils).
The cylinders in W-shape configuration are equipped with plate-
type valves or lamellar valves, which have a long service life and
are easy to service. Due to the low compression end temperatu-
res the susceptibility of the valves to coking is extremely low.
Cooling An axial fan on the crankshaft takes in ambient air and blows it on
cylinders, intercoolers, valves and oil sump.
Recooling takes place
– after the 1st and 2nd stage in an aluminium honeycomb radia-
tor;
– after the 3rd stage in a steel gilled pipe radiator.
I_FK002_1A.fm
22 Version 2 - 2
Design and Function
Condensate sepa- Condensate arising from the 1st stage is collected in the 1st stage
ration intercooler's collecting tank. Both 2nd and 3nd stage each have a
separate condensate separator for the oil- and water-saturated
condensate arising from compressing and recooling.
Condensate drai- The condensate is drained through drain lines. The drain lines
ning/pressure reli- have solenoid valves built-in. These must be open when the Sau-
ef er Kompressor is unpressurized. The drain valves should close
several seconds after starting and the Sauer Kompressor run up
against pressure. During operation the solenoid valves shall drain
the machine at predetermined intervals. The solenoids valves are
controlled by the compressor control system.
Lubrication/oil An oil gear pump driven by the crankshaft primes the lubrication
pressure oil from the crankcase and supplies it to the friction bearings of
the connecting rods. Crankshaft bearings, gudgeon pin bearings
and pistons are lubricated by the splash oil in the crankcase. The
oil pressure is monitored by an oil pressure monitor.
The compressor control system will stop the compressor imme-
diately if the oil pressure falls to the lower limit.
I_FK002_1A.fm
Version 2 - 2 23
3.3 Indicators on the Sauer compressor
5 1
4 7
3
Item Designation Display
1 Pressure gauge 1st Compressed air pressure after the 1st

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

stage stage
Pressure gauge 3st Ultimate pressure

3
stage
Thermometer 1st Compressed air temperature after the

4
stage 1st stage
Thermometer 2nd Compressed air temperature after the

5
stage 2nd stage
Thermometer 3st Compressed air temperature after the

6
stage 3st stage
7 Oil pressure gauge Oil pressure of oil pump

I_FK002_1A.fm
24 Version 2 - 2
Design and Function
3.4 Indicators and controls of the compressor control system

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

ration”
Fault indicator Lights if the compressor has been shut off because
lamp “Oil pressure” of low oil pressure.
lamp “Air tempera- of excessive outlet air temperature.
ture”
lamp “Overcurrent” of excess motor current.
Working hour Indicates the working hours of the compressor.

meter
Operating mode • Selector position “Manual”:

selector Starting the compressor manually. The compressor
starts up and continues to run until it is manually
turned off.
• Selector position “0”:
Turns compressor manually OFF. Any pending fault
messages are reset.
• Selector position “Auto”:
The compressor is started and stopped by the ope-
ning and closing of an external switching contact
(e.g. pressure switch of the compressed air recei-
ver).
Main switch Interrupts the power supply from the compressor

control to the compressor.
A main switch should be installed if required by local
laws and regulations.
I_FK002_1A.fm
Version 2 - 2 25
4. Technical Specifications
4.1 Specification data
Description Data
Compressor type WP 311 L
Number of cylinders 4
Number of compression stages 3
Cylinder diameter 1st stage 2 x 160 mm
Cylinder diameter 2st stage 120 mm
Cylinder diameter 3rd stage 70 mm
Piston stroke 100 mm
Maximum pump speed 1800 rpm
Direction of rotation (when looking at flywheel) right hand
Maximum working pressure 40 bar
Set pressures of safety valves:
1st stage 4 bar
2nd stage 12 bar
3rd stage 5 % higher than the ultimate pressure
Oil filling quantity 21.5L
Oil quantity between dip stick markings 4.5L
Oil type see chapter 10. “Lubricant table”
Oil pressure monitor
Maximum switching current 6A / 220 V
Setting opens at 1 bar falling

closes at 2 bar rising
approx. 15 sec. starting bypass
Switch function change-over contact

I_TD003_1A.fm
26 Version 2 - 2
Technical Specifications
Description Data
Drain valves:
Pick-up and holding power 30 VA / 8 W
Setting normally open; starting relief: approx.

15 seconds;
intermediate draining: 15 seconds every 15 min-
utes.
Ultimate pressure switch (optional):
Setting to customer's specifications
Temperature control (optional):
Setting opens at 80 °C rising
Sound pressure level (in free sound field at 1 m maximum 93 dB(A)

distance)
Weight and dimensions see plan of installations
Note!
Please refer to the order-specific documentation of your com-
pressor for specific data, such as ultimate pressure, speed, pow-
er requirements, etc.
I_TD003_1A.fm
Version 2 - 2 27
4.2 Compressed air wiring diagram
1 3 4 Inlet atm. 2 3 4 3 4 5 2 10 14
Outlet
12 11 13 9 15 8 5 7 8 2 5 8 7
Item Designation
1 Drive motor
2 Safety valve
3 Compressor stage
4 Intercooler and aftercooler
5 Pressure gauge
6 Oil pressure switch
7 Separator
8 Solenoid valve
9 Intake filter
10 Temperature switch (optional):
11 Oil pump
12 Overpressure valve
13 Oil filter
14 Non-return valve
15 Condensate collecting pot

I_TD003_1A.fm
28 Version 2 - 2
Transport and Installation
5. Transport and Installation

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

truck or hoisted by crane.
Danger!
Suspended load when transported.The forklift truck/crane must
have sufficient load bearing capacity.
• Ensure that no persons stay within the danger area of the sus-
pended load and the forklift truck/crane.
• Sling the unpacked compressor at the three lifting eyes (see
illustration).
• Lift, move, and set down carefully.
Lifting eye Lifting eyes

I_MO002_2A.fm
Version 2 - 2 29
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: +5 to +40 °C;
– relative humidity 30 … 95%, not condensating;
– dry, under a roof and protected against dew;
– protected against soiling;
– protected against vibrations and shocks.
Note!
The standard factory conservation is sufficient for a maximum
storage period of 12 months.
5.3 Installation
Note!
When in doubt if the intended place of installation and room are
suitable, contact J.P. SAUER & SOHN in time before the instal-
lation. There you will also get help with the design of a ventilating
system, if required at the place of installation.
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 vented in such way that the
heat generated during operation is dissipated.
– Room temperature while the Sauer compressor is running:
+5 … +55 °C
(deviating temperatures only if confirmed in writing by
J.P. SAUER & SOHN)
I_MO002_2A.fm
30 Version 2 - 2
Note!
The air temperature at the cooling air intake of the compressor
must not exceed +55 °C when the compressor is running. Room
conditions and the heat, generated by the compressor and other
machines installed in the room, must be taken into considerati-
on.
• If necessary, install a ventilation or exhaust system at the
place of installation.
• Install any ventilation system in such way that the fresh air
stream is not directly directed against the compressor. Other-
wise there is a risk of condensation of water inside the machi-
ne and subsequent damage.
This way is correct!
Do not install fresh

air feed this way!
I_MO002_2A.fm
Version 2 - 2 31
Installation condi- – At a room temperature of below +5 °C the room needs to be
tions (cont'd) heated or the Sauer compressor must be equipped with a he-
ating system.
– Choose the location so that the Sauer compressor is accessib-
le and has sufficient clearance to walls and other machinery
(see installation documents).
– Do not position the motor side in a room niche, so the Sauer
compressor will not take in the warmed-up cooling air again.
– Do not position several compressors one after the other, to
prevent one compressor from taking in the warmed-up cooling
air of another compressor.
Note!
J.P. SAUER & SOHN is glad to advise you on the installation of
the compressors.
Foundation
Note!
The standard delivery resilient-mount bedding has a resonant
frequency of approx. 10 Hz.
Generation of oscillations of the intended foundation by other ne-
arby machinery must not be at 10 Hz. Otherwise there is a risk
that the standard delivery resilient-mount bedding is destroyed
by sympathetic vibration.
1. Check early enough if there are foundation vibrations in the
10 Hz range.
2. If in doubt, check with J.P. SAUER & SOHN to see if a modi-
fied resilient-mount bedding can be used.
I_MO002_2A.fm
32 Version 2 - 2
5.4 Connecting the compressor

Danger!
The compressor should only be connected by qualified technici-
ans. Any work on the electrical installation must be carried out
by qualified electricians only.
Note!
The oil filler tube is insulated using a section of hose. Do not re-
move the insulating material.
Pipelines The compressed air outlet and the drain outlets of the Sauer com-
pressor must be connected to the stationary pipelines by hose li-
nes.
Hose lines
Danger!
Compressed air escapes from the drain outlets when the com-
pressor starts and when the condensate is drained. Do not ope-
rate compressor without the hose lines connected.
I_MO002_2A.fm
Version 2 - 2 33
Hose lines have to be installed free of tension and untwisted.
Not this way!
Drainage
Note!
Condensate build-up is oil-saturated. It may only be disposed of
in compliance with applicable legal regulations.
J.P. SAUER & SOHN can supply condensate collecting pots for
separating condensate, as well as condensate treatment units
for separating the oil from the condensate.
Note!
We recommend connecting the compressor's drainage separa-
tely.
When the drain lines of several compressors are to be connec-
ted to a common pipe, observe the following:
– Choose a sufficient nominal diameter for the common drain
line.
I_MO002_2A.fm
– Connect drain lines of the individual compressors at a sharp

angle to the common drain line, so no pressure can build up
in the drain line of a stopped compressor.
34 Version 2 - 2
Not this way!

I_MO002_2A.fm
Version 2 - 2 35
Connections The illustration below shows the connections and armatures for
the operation of the standard versionSauer compressor.
5 6 7 4
1 2 3
Note!
For technical specifications of the individual items please refer to
Chapter 4
All selective switches are factory set.
As an option, the subsystems can be prewired in a terminal box.
Item Designation Type Function

1 Drain valve Solenoid valve Starting relief and drainage
2 Drain valve Solenoid valve Starting relief and drainage
3 Drive motor 3-phase motor Drive of the compressor
Ultimate pressure Selective switch Stops/starts the compressor

4
switch
5 Oil pressure switch Selective switch Stops compressor when oil level is low
Temperature control Selective switch Stops compressor in case of excess tempera-
6
(optional) ture
7 Non-return valve Plate valve Prevent air backflow

I_MO002_2A.fm
36 Version 2 - 2
5.5 Filling in oil

The Sauer compressor is supplied without oil.
Danger!
Oil must be filled into the compressor's crankcase before initial
operation!Use lubricating oil (see chapter 10. “Lubricant table”).
Observe filling amount (see chapter 4. “Technical Specificati-
ons”).
Oil filler plug
Dipstick
1. Unscrew oil filler plug (red).

2. Fill in oil and check level with the dipstick.
Note!
Fill only to the upper marking on the dipstick.Otherwise the oil
consumption of the compressor will increase.
3. Put dipstick back in and replace the oil filler plug.

I_MO002_2A.fm
Version 2 - 2 37
5.6 Checks after installation and before the first start
– Electrical connection corresponds with the type label data?
– Are all connections between compressor and the pressurized
air unit supplied correctly installed? Pay special attention to
the compressed air outlet.
– Are drain lines properly connected? See section “Drainage”
– Oil filled into crankcase?
– Have all tools and foreign objects been removed from the com-
pressor?
– Air filter turned from transport position to operating position?
– Entire unit clean?
I_MO002_2A.fm
38 Version 2 - 2
Operation
6. Operation
6.1 Safe operation
Danger!
Only authorized persons are permitted to commission and oper-
ate the Sauer compressor!
Danger!
Turn on and start the compressor only if
– it has been checked for proper working condition;
– all tools and foreign objects are removed from the machine.
Caution!
Turn compressor immediately OFF when persons or objects are
endangered. Start compressor only when the danger is over.
Danger!
In Automatic mode the compressor starts automatically without
warning!
Danger!
Risk of burns by hot surfaces of the compressor when it is run-
ning. Wear gloves.
Danger!
Risk of hearing damage due to the sound pressure level when
the compressor is running! Wear hearing protection near the
compressor.
Note!
Turn compressor OFF in the case of faults, abnormal ratings or
irregularities. Refer to chapter 7. “Trouble Shooting” to remove
cause.
I_BE001_2.fm
Version 2 - 2 39
6.2 Operating modes
After the power supply to the Sauer compressor is turned ON, it
can be started with the operating mode selector in one of the fol-
lowing two operating modes:
– Operating mode “Manual”:
The compressor starts and continues to run until it is stopped
or turned OFF with either the operating mode selector or the
main switch.
– Operating mode “Automatic”:
Starting and stopping of the compressor is controlled by exter-
nal devices (e.g. by the pressure switch of the compressed air
receiver).
When the Sauer compressor starts, it starts loadless with opened
relief valves. Several seconds after starting the valves close and
the compressor runs up against pressure.
6.3 Initial operation

Checking the di- At first, let the Sauer compressor run only briefly for a few sec-
rection of rotation onds 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.
I_BE001_2.fm
40 Version 2 - 2
Operation
Test run 1. Turn the power supply ON.

2. Set the operating mode selector to “Manual” to start the com-
pressor in Manual mode.
✓ If correctly set the drain valves will close after approx. 15 sec-
onds 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 val-
ues see section 6.4 “Routine operation”).
4. Check the functioning of the automatic intermediate draining.
✓ It must drain every 15 minutes for approx. 15 seconds. This is
recognizable by the pressure drop at the pressure gauges.
5. Set the operating mode selector to “0” to stop the compres-
sor.
6. Turn the power supply OFF.
7. If necessary, remove causes for deviations and faults. See
also chapter 7. “Trouble Shooting”.
6.4 Routine operation

Cleaning • Keep compressor site clean.
• Keep indicators and control elements clean.
Checks • Inspect connections, pipelines and electric cables for damage.

• Once a week check the oil level before starting, top up if nec-
essary.
Operation 1. Turn power supply ON.

2. Set operating mode selector to “Auto” to operate the com-
pressor in Automatic mode.
Observation • Pay attention to abnormal operating sounds.

• Pay attention to leakages (compressed air, oil, condensate).
• During operation the pressure indicated by the pressure gaug-
es shall be within the shaded range of the stage pressure chart
(see below).
• The oil pressure shall be between 1.8 bar and 4 bar.
In case of deviation see chapter 7. “Trouble Shooting”.
I_BE001_2.fm
Version 2 - 2 41
Stage pressure chart 1st and 2nd stage
3rd stage [bar]
1st stage [bar] 2nd stage [bar]
Note!
Dependent on the desired ultimate pressure of the 3rd stage the
permissible pressure for the 1st and 2nd stage can be taken from
the chart.
I_BE001_2.fm
42 Version 2 - 2
HI001AA2.fm
Troubleshooting
7. Troubleshooting
Note!
• In case of malfunctions, first check the compressor control
and compressor displays.
• Try to remedy the fault by following the information given in the
table below.
• If the cause for the fault cannot be eliminated, contact
J.P. SAUER & SOHN customer service.
Fault Likely cause Remedy
The compressor does not No supply voltage / no control Check fuses. Replace blown fuses.
start or does not switch voltage.
OFF.
The oil pressure monitor The oil level is too low. Check the oil level, add oil as required.
has responded.
The oil pump is faulty or leak- Check the oil pump. Fix the leak or
ing. replace the oil pump, as required.
The compressor has been The motor is overheated. Determine the cause of the fault and
shut down by the overcur- Excessive current draw. remedy. The compressor can be
rent relay of the control sys- started again after being allowed to
tem. cool off.
Piston seizure Check cylinder and piston for striation,

replace if necessary.
Safety valve of 1st stage

blows off:
Pressure exceeds blow- 2nd stage valve is not working Check 2nd stage valve, replace if nec-
ing-off pressure (4 bar) properly. essary.
Sealing between inlet and out- Replace gasket.

let side of the 2nd stage is
faulty.
Pressure below blow- Safety valve is faulty. Replace the safety valve.
ing-off pressure (4 bar)
2nd stage safety valve blows

off:
Pressure exceeds blow- 3rd stage valve is not working Check 3rd stage valve, replace if nec-
ing-off pressure (12 bar) properly. essary.
Sealing between inlet and out- Replace gasket.

let side of the 3rd stage is
faulty.
HI001AA2.fm
Pressure below blow- Safety valve is faulty. Replace the safety valve.
ing-off pressure (12 bar)
Version 2 - 2 43
3rd stage safety valve blows

off:
Pressure exceeds blow- Valve in air line to compressed Open the valve.
ing-off pressure (ulti- air receiver closed.
mate pressure + 5%)
Pressure switch set too high. Reduce set pressure.
Pressure below blow- Safety valve set too low or Replace safety valve.
ing-off pressure (ulti- faulty.
mate pressure + 5%)
Too much pressure loss in the Reduce pressure losses.
compressed air lines to the
receivers.
Maximum pressure is 2nd stage valve leaking. Check valve for damage, replace if nec-
exceed in the 1st stage. essary.
Maximum pressure is 3rd stage valve leaking. Check valve for damage, replace if nec-
exceeded in the 2nd stage. essary.
Pressure gauges of 1st, 2nd, 1st stage valve leaking. Check 1st stage valve, replace if neces-
and 3rd stage displaying sary.
insufficient pressure.
Air filter very dirty. Replace air filter cartridge.
No pressure indicated in 1st, No power at solenoid valve. Check solenoid valve power supply.
2nd and 3rd stage pressure Solenoid valve faulty. Check solenoid valve, replace if neces-
gauges. sary.
Air escaping from com- Gaskets of connections leak- Replace relevant gasket.
pressed air lines ing.
Compression fittings leaking. Turn compressor OFF. Wait until all

parts are relieved of pressure (check
pressure gauges). Then tighten unions.
Air escaping from the over- Temperature of compressed Replace fan. Replace fusible plug.
flow opening of the final air too high at outlet; insuffi-
separator's fusible plug. cient cooling by faulty fan.
Very dirty cooler; insufficient Clean cooler. Check room ventilation.

ventilation. Replace fusible plug.
Temperature control has Temperature of compressed Replace fan.

responded. air too high at outlet; insuffi-
cient cooling by faulty fan.
Very dirty cooler; insufficient Clean the cooler. Check the room ven-
ventilation. tilation.
Drain valve does not close. No supply voltage. Check fuses, replace blown fuses.
Solenoid faulty. Replace solenoid.
Foreign matter in solenoid Clean solenoid valve.

valve.
HI001AA2.fm
44 Version 2 - 2
Troubleshooting
Compressor makes loud Connecting rod bearing faulty. Check connecting rod bearing, replace
noises. if necessary. Check oil supply.
Gudgeon pin bearing faulty. Check gudgeon pin bearing, replace if

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

necessary.
Oil leaking from crankcase. Gasket or shaft seal faulty. Tighten screws.
Screws not tight. If there is heavy leaking, check to see
which gasket is faulty, then replace it.
Minor traces of oil on the crankcase
or oil drops below the compressor are
harmless. Wipe off with a rag.
Water is leaking at the relief Liner o-ring above the relief Replace the o-ring.
groove of the cylinder flange groove is faulty.
surface.
Oil is leaking at the relief Liner o-ring below the relief Replace the o-ring.
groove of the cylinder flange groove is faulty.
surface.
Water in oil Incorrect ventilation (compres- Change the room ventilation.

sor is undercooled).
Insufficient drainage. Check drain lines and drain intervals.
Insulating sleeve of crankcase Replace insulating sleeve.

vent missing or damaged. Extend compressor operating time.
Premature breaking of valve Insufficient drainage. Check drain lines and drain intervals.
plates, valve springs or
valve disks. Note: Indentation marks appearing on
the valve plate due to valve impact are
normal.
HI001AA2.fm
Version 2 - 2 45
8. Maintenance
8.1 Maintenance service by J.P. SAUER & SOHN
The J.P. SAUER & SOHN customer service offers different
maintenance services – e.g. full maintenance or valve replace-
ment service.
8.2 Maintenance safety

Before servicing 1. Disconnect the power supply to the compressor.
2. Post danger sign “Caution Maintenance Work!” at the power
supply.
Danger!
Only authorised persons are permitted to service and make ad-
justments to the Sauer compressor!
Danger!
Risk of injury from hot surfaces!
Let compressor cool off after turning OFF.
Danger!
Risk of injury from pressurised compressor components!
Check the pressure gauges before servicing to ensure the com-
pressor is completely relieved of pressure.
Danger!
Danger! High voltage!
– Never assume that a circuit is de-energised – always check
for your own safety!
– The main switch is energised, even when it is turned OFF.
– Components being worked on should only be energised if this
is explicitly specified.
Danger!
Danger of death from missing safety devices and missing isola-
ting protection devices!
Reinstall all safety devices and isolating protection devices after
servicing. This also applies to electrical protection devices (e.g.
earth wires).
I_WA002_2.fm
46 Version 2 - 2
Maintenance
8.3 Maintenance schedule

Danger!
For all maintenance work section 8.4 “Table of tightening tor-
ques” must be observed for specific screws.
Note!
The maintenance rates specified in the maintenance schedule
must be kept.Shortening the maintenance rates is of no advan-
tage with regard to operating performance or service life of the
Sauer compressor.
Note!
After a major overhaul (=12,000 operating hours) the mainte-
nance schedule begins all over again.
Instructions for • Use the maintenance schedule as master template for copying
the maintenance or copy the respective page from the digital document and
schedule save it as a separate file under a suitable name. Use the main-
tenance schedule as guide and for documentation.
• Regularly check the maintenance schedule to see which main-
tenance rates, subject to the number of operating hours, are
due.The intervals are shown in the table's column headers.
• Check the column of each maintenance rate to see which
maintenance work is to be carried out at the end of each main-
tenance rate.The required tasks are indicated by check bo-
xes.Description and chapter number of the tasks are shown in
the first column.
• Carry out all maintenance work of a maintenance rate and
tick the appropriate check boxes of the maintenance schedu-
le.Then enter operating hours meter count, date and your sig-
nature.
• When beginning a new maintenance schedule
– enter: main specifications, date of initial operation, number
of maintenance schedule, current date and operating hours
meter count
– tick: begins with initial operation/after major overhaul
I_WA002_2.fm
Version 2 - 2 47
Maintenance Schedule No. Compressor type
Beginning of this maintenance schedule Type series 3L
❏ after initial operation Compressor number
❏ after major overhaul Factory no.:
Date: Year of construction:
Operating hours count: Date of initial operation:
Interval
At least yearly if < 1.000/year
(operating hours)
12.000 = major overhaul

50 after initial operation
50 after major overhaul
10.000
11.000
1.000
2.000
3.000
4.000
5.000
6.000
7.000
8.000
9.000
Maintenance work
Check screwed connec- ❏ ❏

tions 8.6
Oil change 8.5 ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏
Air filter cartridge replace- ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏
ment 8.7
Checking valves 8.8 ❏ ❏ ❏ ❏ ❏
Checking the piston rings ❏ ❏
8.9
Replacing gudgeon pins/ ❏ ❏
gudgeon pin bearings
8.10
Replacing valves 8.11 ❏
Checking pistons and ❏
cylinders 8.12
Check drive bearings 8.13 ❏
Check coupling 8.14 ❏ ❏
Operating hours meter
count:
Date
Signature
(abbrev.)
Note!
Check compressor 50 hours after every maintenance work
has been carried out.Check all screws affected by the mainte-
I_WA002_2.fm
nance work to see if they are tight.
48 Version 2 - 2
Maintenance
8.4 Table of tightening torques
Screw(s) Tightening torque
Connecting rod screws 70 Nm
Flywheel fastening screw 350 Nm
Cylinder head screws 75 Nm
8.5 Oil change

Note!
Use oil as per Lubricant Table (see chapter10).
Oil filler plug
Dipstick
Oil drain plug

I_WA002_2.fm
Version 2 - 2 49
1. Place oilpan (of sufficent capacity to hold the complete oil fil-
ling, see chapter 4) under the oil drain plug.
2. Remove the oil drain plug.
3. Wait until all oil has drained.
4. Replace the oil drain plug.
5. Unscrew oil filler plug (red).
6. Fill in oil and check level with the dipstick.
✓ The level shall be between the upper and lower mark on the
dipstick.
7. Put dipstick back in and screw the oil filler plug back on.
8.6 Checking screwed connections

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

Air filter cap
1. Open clips and take the air filter cap off.

2. Take the used air filter cartridge out.
3. Put new air filter cartridge in.
I_WA002_2.fm
4. Put cap back on and close the clips.
50 Version 2 - 2
Maintenance
8.8 Checking the valves

Note!
Install all valves with new gaskets and rings only. Use only genu-
ine Sauer spare parts.They are precision parts with defined and
tested dimensions and material characteristics, specially desig-
ned for use in Sauer compressors.Installation of other gaskets
may lead to leakage and could cause substancial damage to the
compressor.
Valve removal 1. Loosen unions and hose line at the cylinder heads.
2. Remove cylinder head bolts and remove the cylinder heads.
3. Carefully take the valves out.
Check plate valve

Note!
When removing, cleaning and installing the plate valve, take
care that no valve parts are damaged.This applies particularly to
the seat faces and the valve springs.Slight damage to the pa-
cking strips of the valve seats can be removed by refacing on a
lapping plate.
4. Unscrew nut.Do to so, hold valve in vice fitted with fibre grips
in order to prevent damage to the valve's faces.
5. Dissamble valve.
6. Clean all valve parts.
7. Check valve parts for damage.Replace damaged valve parts.
I_WA002_2.fm
Version 2 - 2 51
8. Carefully reassemble valve (see illustration), tighten nut.
9. Use a pin with round tip to check the valve plate's smoothness
of action against the spring pressure.
Valve installation 10. Install concentric valve and cylinder head of 1st, 2nd and 3rd
stage, using new cylinder head gaskets and a new low tole-
rance gasket (see illustration).
Low tolerance gasket
Cylinder head
gaskets
I_WA002_2.fm
52 Version 2 - 2
Maintenance
Note!
Never turn the old low tolerance gasket upside down.Doing so
leads to leakage within a short time.
11. Attach unions and hose line to the cylinder heads.
Note!
Concentric plate valves are the parts of a piston compressor
subject to highest stress. In order to achieve the guaranteed
maintenance rates, these valve are high-quality precision parts,
specially matched to the individual compression stages and their
functioning carefully checked before delivery.Repair by the main-
tenance and operating personnel requires special knowledge,
not in any case given.For such cases J.P. SAUER & SOHN offer
a valve replacement service.In case it should be necessary ple-
ase contact the Sauer service department.
8.9 Checking the piston rings

1. Remove cylinder heads and valves as described in section
8.8 “Checking the valves”.
2. Remove cylinder base nuts.
3. Pull cylinder off. Hold the piston before the cylinder comes off.
Note!
If the piston is not held when pulling the cylinder off, it will fall
against the crankcase.
4. Remove circlips of gudgeon pins, push gudgeon pin out and

take piston off.
5. Remove all piston rings from the pistons.
6. Place piston rings in their respective cylinders and measure
the gap clearance with a feeler gauge.
7. Replace piston rings if the gap clearance exceeds the follo-
wing limits.
1st stage 1.50 mm
2nd stage 1.10 mm
3rd stage 0.70 mm
Note!
Always replace all pistons rings of a piston when one of the pis-
I_WA002_2.fm
ton rings exceeds the limit.

8. Install piston rings on the respective piston. Make sure they
Version 2 - 2 53
are in the correct position: piston rings having 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
installed. See illustration.
1st stage 2nd stage 3rd stage

TOP
TOP TOP
TOP
TOP
9. Install pistons on the connecting rods. To do so, push gud-

geon pin in and install the circlips of the gudgeon pins.
10. Fit a new cylinder base gasket for each cylinder.
11. Push cylinder onto the pistons.
12. Tighten cylinder base nuts.
13. Install cylinder heads and valves as described in section 8.8
“Checking the valves”.
8.10 Replacing gudgeon pins/gudgeon pin bearings

1. Uninstall cylinder heads and valves as detailed in section
8.8 “Checking valves”.
2. Uninstall cylinder and pistons as detailed in section
8.9 “Checking the piston rings”.
3. Take inspection hole cover off and remove connecting rods.
4. Press gudgeon pin bearing out of the connecting rod's small
end.
5. Replace gudgeon pin and gudgeon pin bearing.
6. Press gudgeon pin bearing into the connecting rod's small
end.
7. Install connecting rods. Make sure the connecting rods are in
their correct position on the crankshaft. (See cross-sectional
drawing in 3.1 “Overview”.) Observe tightening torque.
8. Install inspection hole cover.
9. Install cylinder and pistons as detailed in 8.9 “Checking the
piston rings”.
10. Install cylinder heads and valves as detailed in section
8.8 “Checking valves”.
I_WA002_2.fm
54 Version 2 - 2
Maintenance
8.11 Replacing valves

Remove and install valves as detailed in section 8.8 “Checking
valves”. Replace complete valve.
8.12 Checking pistons and cylinders

8.8 “Checking the valves”.
2. Remove cylinders and pistons as described in section 8.9
“Checking the piston rings”.
3. Check cylinders and pistons for scoring and excessive wea-
ring marks. Replace relevant parts.
4. Measure cylinders and replace if the following wear limits are
exceeded:
Cylinder Wear limit of diameter
1st stage 160.15 mm
2nd stage 120.15 mm
Upper part: 70.10 mm

3rd stage Guide part: 88.10 mm
5. Install cylinders and pistons as described in section 8.9 “Che-

cking the piston rings”.
6. Install cylinder heads and valves as described in section 8.8
8.13 Checking the drive bearings

8.8, “Checking the valves”.
2. Remove cylinders and pistons as described in section 8.9,
3. Uninstall fan cover, fan wheel and the entire cooler unit.
4. Uninstall intermediate flange, coupling and flywheel.
5. Take inspection hole cover off and remove connecting rods.
6. Remove bearing bracket.
7. Pull crankshaft out.
8. Check connecting rod bearings, replace if substantially worn.
Note!
The shaft seals of the crank shaft bearing should only be re-
I_WA002_2.fm
placed after the bearing brackets have been removed!
Version 2 - 2 55
9. Check crankshaft bearings, replace if substantially worn.
10. Install crankshaft.
11. Install bearing bracket.
12. Install connecting rods, making sure they are in the correct
position. Observe the tightening torque (see section 8.4).
13. Install inspection hole cover.
14. Install electric motor with intermediate flange, coupling and
flywheel. Observe the tightening torque (see section 8.4).
15. Install cooler unit, fan wheel and fan cover.
16. Install cylinders and pistons as described in section 8.9,
17. Install cylinder heads and valves as described in section 8.8,
8.14 Checking the coupling

Visual check • Remove screw plug from crankcase. Through the inspection
port check the coupling's flexible gear rim for damage. The
teeth of the flexible gear rim must not be deformed.
• Replace screw plug.
• If necessary, replace the flexible gear rim as detailed below.
Inspection port with
screw plug
Removing the gear 1. Support compressor under the transmission bell housing.
rim 2. Remove the motor mounting screws.
3. Lift electric motor carefully at the lifting eyes (see section
5.1 “Transport”).
4. Pull electric motor carefully away from the intermediate flan-
ge.
I_WA002_2.fm
56 Version 2 - 2
Maintenance
Tooth of flexible gear rim
5. Slide electric motor gently against the intermediate flange

and tighten the motor mounting screws.
6. Remove support from under the transmission bell housing.
I_WA002_2.fm
Version 2 - 2 57
9. Placing out of Service
9.1 Safety when placing out of service and dismounting
Danger!
The compressor shall only be placed out of service and dis-
mounted by instructed and trained specialists of the operator.
The specialists must be familar with the protection devices and
regulations before starting the work. Any work on the electrical
installation must be carried out by qualified electricians only.
In addition, information contained in the documentation of out-
side vendors is to be observed.
9.2 Placing the compressor out of service for a limited time

Every 4 weeks perform a test run for at least 30 minutes. Then ad-
ditional corrosion prevention measures are not required.
When the Sauer compressor is to be placed out of service for
more than 12 weeks, conservation with slushing oil is recom-
mended. In this case periodic test runs are not necessary.
Note!
Use one of the slushing oils recommended in the Chapter 10.
“Lubricant Table”.
The slushing oil has sufficient running properties. In case of
emergency the machine can be started on short notice with a
slushing oil filling.
1. Run compressor for approx. 5 minutes with open drain valves

and opened pressure line.
✓ Any existing condensate is blown off.
2. Drain compressor oil and dispose of in an environmentally
friendly manner.
3. Fill in approx. 15 litres of slushing oil.
4. Start compressor and run for approx. 5 minutes with open
drain valves and opened pressure line.
5. Stop compressor.
6. Remove air filter.
I_DE002_1.fm
58 Version 2 - 2
Placing out of Service
7. Remove screw plug with pressure gauge from the cylinder

head of the 2nd stage.
screw plug
8. Inject approx. 10 cc of slushing oil into the cylinder head

opening.
9. Replace screw plug of the 2nd stage's cylinder head.
10. Remove screw plug from the intake flange of the 3rd stage.
screw plug
11. Inject approx. 10 cc of slushing oil into the cylinder head

opening.
12. Replace screw plug.
13. Start compressor and slowly inject approx. 15 cc slushing oil
into the intake ports.
14. Wait until oil mist comes out of the pressure line.
15. Stop compressor.
16. Replace the air filter.
17. If necessary, post a sign that the compressor has been treat-
ed with anti-corrosion measures and is placed out of service.
18. Disconnect from power supply, if necessary.
Placing back into 1. Connect to power supply, if necessary.

service 2. Drain slushing oil and fill with compressor oil.
3. Proceed as detailed in Section 6.3 “Initial operation”.
I_DE002_1.fm
Version 2 - 2 59
9.3 Dismantling
Dismantling 1. Turn compressor OFF and disconnect from power supply.
2. Make sure by reading the pressure gauges before servicing
that the compressor is completely relieved of pressure.
3. Disconnect power lines from the mains supply.
4. Remove oil and lubricants and dispose of in an environmen-
tally friendly manner.
5. Drain any remaining condensate and dispose of in an envi-
ronmentally friendly manner.
Disposal
Material/component How to dispose
Lubricants as hazardous waste
Steel/iron as metal scrap
Electric cables as hazardous waste
Electronic components as electronic waste
Plastics as hazardous waste
I_DE002_1.fm
60 Version 2 - 2
ST001AA3.fm
Lubricant Table
10. Lubricant Table

Note!
Lubricants not mentioned in the lubricant table may only be used
after approval by J.P. SAUER & SOHN. Otherwise the warranty
will expire. Contact our service in case of need.
Take note of all information about the lubricants given in this sec-
tion.
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 5 … 55 °C.
General recom- The following recommendations apply to the 5 … 55 °C temper-

mendation ature range:
– Use mineral oils of viscosity class ISO VG 100 or SAE 30.
– Lubricating oils should conform to group VCL according to
DIN 51506.
Note!
Only for 2-stage 30 bar compressors the use of synthetic lu-
bricating oils may be of advantage. In case of need we will
name the synthetic lubricating oils approved by us.
In general we do not permit the use of synthetic lubricating oils
for the following reasons:
– The good water separation ability of these oils causes con-
densation of moisture in the crankcase. Risk of corrosion
damage and drive damage.
– Because of their design, 3-stage air-cooled compressors
have low compression end temperatures, rendering the high
temperature stability of these oils useless.
ST001AA3.fm
Version 2 - 2 61
10.1 Lubricating oils
Brand Description Group
Agip Diesel Gamma 30 VCL-100
Dicrea 100 VDL-100
Acer 100 VCL-100
Motor Oil HD 30 SAE 30
Cladium 50 SAE 30
ARAL Motanol HE 100 VDL-100
Kowal M 30 VCL-100
Disola M 30 SAE 30
AVIA Avilub Compressor Oil VDL-100 VDL-100
Avilub Compressor Oil VDL-100 VCL-100
Motor oil HDC 30 SAE 30
Motor oil HD 30 SAE 30
BP Energol RC 100 VDL-100
Energol IC-DG 30 VCL-100
Energol DL-MP 30 SAE 30
Energol OE-HT 30 SAE 30
Vanellus C3 SAE 30 SAE 30
Castrol Aircol PD 100 VDL-100
Marine CDX 30 SAE 30
Chevron HD Compressor Oil 100 VDL-100
Delo 1000 Marine 30 SAE 30
Veritas 800 Marine 30 SAE 30
RPM Heavy Duty Motor 30 SAE 30
DEA Actro EP VDL-100 VDL-100
Trion EP VDL-100 VDL-100
Regis SAE 30 SAE 30
Esso Exxcolub 77 VDL
Exxcolub 100 VDL-100
Compressor Oil 3021 N VDL-100
Exxmar 12 TP 30 SAE 30
Exxmar XA SAE 30
Essolube HDX Plus +30 SAE 30
Mobil Rarus 427 VDL-100
DTE Oil Heavy VDL
Mobilgard 300 SAE 30
Shell Corena Oil P 100 VDL-100
Rimula X 30 SAE 30
Melina S Oil 30 SAE 30
ST001AA3.fm
Melina Oil 30 SAE 30

Gadinia Oil 30 SAE 30
62 Version 2 - 2
Lubricant Table
Brand Description Group

TEXACO Compressor Oil EP VDL 100 VDL-100
Regal R&O 100 VCL-100
Ursatex 30 SAE 30
DORO AR 30 SAE 30
TOTAL Dacnis P 100 VDL-100
Carprano TD 30 SAE 30
Milcano TC 30 SAE 30
Disola M 3015 SAE 30
10.2 Preservation oils
Brand Description
Agip Rustica C SAE 30
ARAL Konit Motor Oil SAE 30
AVIA MK 1540 S
Avilub MK 3000
BP MEK 20 W-20
Castrol Running-in and Preservation Oil
DEA Deamot EKM 642 SAE 30
ELF Stockage 30
Esso MZK Motor Oil HD 30
Antirust MZ 110
FINA Rusan NF Motor Oil SAE 30
Mobil Mobilarma 524
Shell Ensis Motor Oil 30
TEXACO Engine Oil EKM 146 SAE 30

ST001AA3.fm
Version 2 - 2 63
11. Spare Parts and Accessories
Note!
Please note the information in chapter 1. “General” regading our
genuine Sauer spare parts.
J.P. SAUER & SOHN garantee the complete spare parts supply
over the entire service life of the Sauer compressor.
Our genuine Sauer spare parts are subject to constant quality
control and further development. They conform to the latest tech-
nical developments.
In addition to the genuine Sauer spare parts, our delivery pro-
gram comprises a large number of accessories for your Sauer
compressor and special components to complete your air sys-
tem, such as:
– fully automatic controls;
– adsorption dryers;
– refrigerated air dryers;
– filters;
– silencing cabinets;
– compressed air receivers;
– fittings.
We supply instructions and a maintenance manual for each ac-
cessory.
Spare parts cata- The spare parts catalogue is found in the annex to these instruc-
logue tions.
– With the help of overviews, illustrations and lists the required
parts is quickly found.
– The spare parts catalogue, including the operating instructions
is also available on CD-ROM. Here, an order form can be filled
in, printed out and send immediately.
For doing so, you need the main specifications of your Sauer
compressor from the table below. If they have not yet been en-
tered there, they can be found on the type label affixed to the
crankcase.
Compressor type
Factory no.:
Year of construc-
tion:
EZ001AA1.fm
Furthermore, the number of operating hours should be stat-

ed, if possible.
64 Version 2 - 2
Annex
12. Annex
This Annex to the operating instructions contains
– documentation supplied by outside vendors;
– data sheets.
AN001AA1.fm
Version 2 - 2 65
AN001AA1.fm
66 Version 2 - 2
S a u e r
C o m p r e s s o r
Type: WP 311 L
Spare Part List
Version 2 - 2
E-2 Version 2 - 2
Spare Part List
WP 311 L Sauer compressor
Reference No. Subassemblies Page
WP 311 L Sauer compressor . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . 4

065 173 crankcase . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . 6
065 187 crankshaft . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . 8
064 568 connecting rod 1st and 2nd stage . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 10
064 848 connecting rod 3rd stage .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 12
033 185 piston 1st stage . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 14
037 049 piston 2nd stage . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 16
063 305 piston 3rd stage. . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 18
064 408 cylinder with head and valve 1st stage .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 20
037 460 concentric valve 1st stage . . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 22
065 175 cylinder with head and valve 2nd stage . . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 24
034 591 concentric valve 2nd stage . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 26
065 176 cylinder with head and valve 3rd stage.. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 28
033 893 concentric valve 3rd stage . . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 30
065 177 crankcase venting . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 32
065 178 cooler and air lines .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 34
064 119 lubricating oil pump and drive . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 37
065 180 measuring device . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 40
063 121 final separator, compl.. . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 42
034 129 flexible coupling. . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 44
065 169 resilient mounts . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 46
065 181 automatic drainage .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 48
Note: Explanation of the subassemblies in chapter 3 "Design and Function"

of the operating instructions
Version 2 - 2 E-3
E-4 Version 2 - 2
Spare Part List
Item Reference No. Designation Qty.

1 065 173 crankcase 1
2 065 187 crankshaft 1
3 064 568 connecting rod 1st and 2nd stage 3
4 064 848 connecting rod 3rd stage 1
5 033 185 piston 1st stage 2
6 037 049 piston 2nd stage 1
7 063 305 piston 3rd stage 1
8 064 408 cylinder with head and valve 1st stage 2
9 065 175 cylinder with head and valve 2nd stage 1
10 065 176 cylinder with head and valve 3rd stage 1
11 037 460 concentric valve 1st stage 1
12 034 591 concentric valve 2nd stage 1
13 033 893 concentric valve 3rd stage 1
14 065 177 crankcase venting 1
15 065 178 cooler and air lines 1
16 064 119 lubricating oil pump and drive 1
17 065 180 measuring device 1
18 063 121 final separator, compl. 1
19 034 129 flexible coupling 1
20 065 169 resilient mounts 1
21 065 181 automatic drainage 1
Version 2 - 2 E- 5
065 173 crankcase
E-6 Version 2 - 2
Spare Part List
065 173 crankcase

1 065 117 crankcase 1
2 064 064 dipstick 1
3 064 079 bearing bracket 1
4 051 883 inspection hole cover 2
5 064 095 packing 1
6 063 748 packing 2
7 065 348 oil sieve 1
8 000 270 eye bolt 2
9 001 411 stud 16
10 033 717 stud 16
11 005 930 stud 8
12 001 459 stud 4
13 001 009 plug 1
14 030 744 plug 1
15 001 021 plug 1
16 002 098 hexagon nut 16
19 002 146 washer 4
21 004 635 union 1
22 005 001 gasket 1
25 007 123 shaft seal 1
26 030 831 shaft seal 1
27 004 641 union 1
28 035 310 union 1
30 008 663 pipe 300mm long 1
31 035 520 o-ring 2
Version 2 - 2 E- 7
065 187 crankshaft
E-8 Version 2 - 2
Spare Part List
065 187 crankshaft

1 065 190 crankshaft 1
2 064 345 flywheel 1
3 064 420 pressure washer flywheel 1
4 056 264 pressure washer fan wheel 1
6 037 790 fan wheel 1
8 000 057 hexagon head screw 1
11 001 675 locking plate 1
12 004 472 tension bushing 1
13 032 430 fitting key 1
14 034 575 cylinder roller bearing 1
15 033 215 cylinder roller bearing 1
Version 2 - 2 E- 9
064 568 connecting rod 1st and 2nd stage
E - 10 Version 2 - 2
Spare Part List
064 568 connecting rod 1st and 2nd stage

1 064 352 connecting rod 1
2 056 272 connecting rod bearing 1
3 033 213 piston pin bearing 1
4 056 316 connecting rod screw 2
Version 2 - 2 E -11
064 848 connecting rod 3rd stage
Spare Part List
064 848 connecting rod 3rd stage

1 064 849 connecting rod 1
2 056 272 connecting rod bearing 1
3 034 552 piston pin bearing 1
4 056 316 connecting rod screw 2
Version 2 - 2 E -13
033 185 piston 1st stage
Spare Part List
033 185 piston 1st stage

1 033 186 piston 1st stage 1
2 033 187 piston pin 1
3 035 199 M-ring 1
4 033 188 N-ring 1
5 035 200 G-ring 1
6 002 984 circlip 2
Version 2 - 2 E -15
037 049 piston 2nd stage
Spare Part List
037 049 piston 2nd stage

3 037 050 M-ring 1
4 002 566 N-ring 1
5 037 051 G-ring 1
6 002 984 circlip 2
Version 2 - 2 E -17
063 305 piston 3rd stage
Spare Part List
063 305 piston 3rd stage

1 063 304 piston 3rd stage 1
3 002 988 circlip 2
4 002 748 R-ring 1
5 002 552 N-ring 1
6 037 656 R-ring 1
7 004 442 pin 1
Version 2 - 2 E -19
064 408 cylinder with head and valve 1st stage
Spare Part List
064 408 cylinder with head and valve 1st stage

1 064 481 cylinder head 1st stage 1
2 056 216 cylinder 1st stage 1
3 056 237 cylinder head packing 1st stage 2
4 056 239 low tolerance gasket 1
5 062 375 cylinder foot packing 1st stage 1
8 037 477 stud 6
10 002 161 washer 6
11 036 394 air filter 1
12 037 460 concentric valve 1st stage 1
13 036 395 filter insert for air filter 1
Version 2 - 2 E -21
037 460 concentric valve 1st stage
Spare Part List
037 460 concentric valve 1st stage

1 037 468 suction valve plate 1
2 037 469 suction valve spring 1
3 037 470 delivery valve plate 2
4 037 471 delivery valve spring 1
Version 2 - 2 E -23
065 175 cylinder with head and valve 2nd stage
Spare Part List
065 175 cylinder with head and valve 2nd stage

1 056 222 cylinder head 2nd stage 1
2 059 286 cylinder 2nd stage 1
3 059 393 cylinder head packing 2nd stage 2
5 062 376 cylinder foot packing 3rd stage 1
8 001 520 stud 6
10 034 591 concentric valve 2nd stage 1
11 000 976 plug 1
12 005 016 gasket 1
Version 2 - 2 E -25
034 591 concentric valve 2nd stage
Spare Part List
034 591 concentric valve 2nd stage

Version 2 - 2 E -27
065 176 cylinder with head and valve 3rd stage
Spare Part List
065 176 cylinder with head and valve 3rd stage

1 056 278 cylinder head 3rd stage 1
2 063 303 cylinder 3rd stage 1
3 056 282 cylinder head packing 3rd stage 2
5 062 376 cylinder foot packing 3rd stage 1
8 001 519 stud 4
10 033 893 concentric valve 3rd stage 1
Version 2 - 2 E -29
033 893 concentric valve 3rd stage
Spare Part List
033 893 concentric valve 3rd stage

Version 2 - 2 E -31
065 177 crankcase venting
Spare Part List
065 177 crankcase venting

1 035 824 filling cover 1
2 006 380 reducer 2
3 006 205 union 1
4 033 614 union 1
5 033 487 stud adaptor 1
6 037 138 reducer 1
7 037 137 distribution piece 1
8 064 523 pipe adaptor 1
9 033 952 hose 220mm long 1
10 034 612 LP-hose 1
11 034 225 LP-hose 1
12 012 766 pipe 70mm long 3
13 035 254 hose clamp 4
Version 2 - 2 E -33
065 178 cooler and air lines
Spare Part List

1 065 120 pressure air channel 1
2 065 122 bend flange 1
3 064 581 flange 1
4 065 389 ledge 1
5 065 195 distance bush 9
6 065 197 pipe 1
7 065 198 pipe 1
8 065 200 pipe 1
9 056 335 packing 4
10 056 369 packing 1
11 065 376 ledge 1
12 065 194 pipe holder 3
13 064 075 clamp 5
14 065 235 clamp 1
15 065 234 clamp 2
16 065 229 cooler 3rd stage 1
17 065 159 suction lines 1
18 065 160 pressure air lines 1
19 065 310 pressure air lines 1
25 000 558 cylinder head screw 2
26 000 540 cylinder head screw 8
27 030 744 plug 2
30 004 707 union 1
31 037 851 union 2
32 036 157 union 1
33 006 186 union 2
Version 2 - 2 E -35

34 006 193 union 1
35 006 197 union 1
36 006 231 union 1
37 006 391 reducer 1
38 001 007 union 1
40 002 166 washer 2
41 036 555 condensat separator 1
42 036 081 union 1
43 033 224 safety valve 1
46 003 496 gasket 1
47 005 009 gasket 3
48 005 016 gasket 3
49 056 334 packing 5
50 005 023 gasket 2
51 030 340 o-ring 1
52 032 401 o-ring 1
54 037 776 cooler 1
Spare Part List
Version 2 - 2 E - 37
064 119 lubricating oil pump and drive
Spare Part List
064 119 lubricating oil pump and drive

1 057 916 overpressure valve 1
2 062 909 gearwheel oil pump 1
3 064 098 gearwheel 1
4 056 730 gearwheel 1
5 056 318 packing 1
6 030 545 packing 1
7 000 970 plug 1
8 001 942 fitting key 1
9 003 496 gasket 1
10 003 438 gasket 1
Version 2 - 2 E -39
065 180 measuring device
Spare Part List
065 180 measuring device

3 064 365 tube 1
4 065 352 tube 1
5 065 353 tube 1
12 002 144 washer 2
14 004 598 union 1
17 030 510 union 1
18 033 912 union 1
19 005 016 gasket 1
20 033 017 reducer 1
21 035 009 pressure gauge 1st stage 1
22 033 262 pressure gauge 2nd stage 1
23 030 664 pressure gauge 3rd stage 1
24 033 223 thermometer 2
25 005 006 gasket 1
26 005 001 gasket 1
27 005 009 gasket 3
28 035 061 gasket 4
29 030 082 oil pressure switch 1
31 033 261 pressure gauge , oil 1
32 008 633 pressure gauge pipe 750mm long 1
33 008 633 pressure gauge pipe 750mm long 1
34 037 839 thermometer 1
Version 2 - 2 E -41
063 121 final separator, compl.
Spare Part List
063 121 final separator, compl.

4 060 342 fusible plug 1
6 006 390 reducer 1
7 005 029 gasket 1
8 005 009 gasket 1
9 004 181 o-ring 1
11 001 007 union 1
12 003 496 gasket 1
Version 2 - 2 E -43
034 129 flexible coupling
Spare Part List
034 129 flexible coupling

1 034 423 flexible gear rim 1
Version 2 - 2 E -45
065 169 resilient mounts
Spare Part List
065 169 resilient mounts

2 065 216 rail 2
6 002 166 washer 4
7 001 637 washer 2
8 031 149 resilient mount 6
9 034 763 pressure air hose 1
10 033 531 countersunk screw 6
11 065 388 non-return valve, connection 28 -
12 037 883 non-return valve, RV1-25 1
13 004 661 union 2
Version 2 - 2 E -47
065 181 automatic drainage
Spare Part List
065 181 automatic drainage

2 063 120 expansion receiver 1
3 062 481 flow control 1
4 062 478 drainage hose 1
9 003 115 locking washer "Schnorr" 4
10 004 641 union 1
13 006 216 union 5
14 033 961 stud adaptor 2
15 037 680 solenoid valve 3
16 030 744 plug 1
17 008 663 pipe 300mm long 1
18 008 663 pipe 300mm long 1
19 008 663 pipe 300mm long 1
Version 2 - 2 E -49
Index
Reference No. Designation Page Pos.
000 010 hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 9

000 036 hexagon head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 8
000 162 hexagon head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 21
000 270 eye bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 8
000 540 cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 26
000 558 cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 25
000 970 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 7
000 976 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 11
001 007 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 38
001 007 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 11
001 009 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 13
001 021 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 15
001 411 stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 9
001 459 stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 12
001 519 stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 8
001 520 stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 8
001 620 hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 9
001 620 hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 9
001 620 hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 9
001 637 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 7
001 675 locking plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 11
001 942 fitting key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 8
002 031 hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 17
002 094 hexagon nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 18
002 098 hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 16
002 144 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 12
002 146 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 19
002 161 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 10
002 166 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 40
002 166 washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 6
002 552 N-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5
002 566 N-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4
002 748 R-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4
002 984 circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 6
002 984 circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6
002 988 circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 3
003 115 locking washer "Schnorr". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 9
003 438 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 10
003 496 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 46
003 496 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 9
003 496 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 12
004 181 o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 9
004 442 pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 7
Version 2 - 2 E -51
004 472 tension bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 12

004 598 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 14
004 635 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 21
004 641 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 27
004 641 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 10
004 661 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 13
004 707 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 30
005 001 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 22
005 001 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 26
005 006 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 25
005 009 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 47
005 009 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 27
005 009 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 8
005 016 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 12
005 016 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 48
005 016 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 19
005 023 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 50
005 029 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 7
005 930 stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 11
006 186 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 33
006 193 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 34
006 197 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 35
006 205 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 3
006 216 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 13
006 231 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 36
006 380 reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 2
006 390 reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 6
006 391 reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 37
007 123 shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 25
008 633 pressure gauge pipe 750mm long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 32
008 633 pressure gauge pipe 750mm long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 33
008 663 pipe 300mm long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 30
008 663 pipe 300mm long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 17
008 663 pipe 300mm long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 18
008 663 pipe 300mm long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 19
012 766 pipe 70mm long. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 12
030 082 oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 29
030 340 o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 51
030 510 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 17
030 545 packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 6
030 664 pressure gauge 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 23
030 744 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 14
030 744 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 27
030 744 plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 16
030 752 safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 45
030 831 shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 26
031 149 resilient mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 8
032 289 piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2
032 401 o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 52
032 430 fitting key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 13
Index
033 017 reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 20

033 185 piston 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5
033 186 piston 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1
033 187 piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2
033 188 N-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4
033 213 piston pin bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3
033 215 cylinder roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 15
033 223 thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 24
033 224 safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 43
033 261 pressure gauge , oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 31
033 262 pressure gauge 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 22
033 487 stud adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 5
033 531 countersunk screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 10
033 614 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 4
033 714 safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 44
033 717 stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 10
033 893 concentric valve 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 13
033 893 concentric valve 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 10
033 903 suction valve plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 1
033 904 suction valve spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 2
033 905 delivery valve plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3
033 906 delivery valve spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 4
033 912 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 18
033 952 hose 220mm long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 9
033 961 stud adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 14
034 129 flexible coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 19
034 225 LP-hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 11
034 423 flexible gear rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 1
034 552 piston pin bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3
034 575 cylinder roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 14
034 591 concentric valve 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 12
034 591 concentric valve 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 10
034 593 suction valve spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2
034 612 LP-hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 10
034 763 pressure air hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 9
035 009 pressure gauge 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 21
035 061 gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 28
035 199 M-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3
035 200 G-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 5
035 254 hose clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 13
035 310 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 28
035 520 o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 31
035 824 filling cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 1
036 081 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 42
036 157 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 32
036 394 air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 11
036 395 filter insert for air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 13
036 555 condensat separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 41
Version 2 - 2 E -53
037 049 piston 2nd stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 6

037 050 M-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3
037 051 G-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5
037 137 distribution piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 7
037 138 reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 6
037 460 concentric valve 1st stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 11
037 460 concentric valve 1st stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 12
037 469 suction valve spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2
037 477 stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 8
037 656 R-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 6
037 680 solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 15
037 776 cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 54
037 790 fan wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6
037 839 thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 34
037 851 union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 31
037 883 non-return valve, RV1-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 12
051 883 inspection hole cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4
056 216 cylinder 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2
056 222 cylinder head 2nd stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1
056 235 low tolerance gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4
056 237 cylinder head packing 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3
056 264 pressure washer fan wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4
056 272 connecting rod bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2
056 272 connecting rod bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2
056 278 cylinder head 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 1
056 282 cylinder head packing 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 3
056 316 connecting rod screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4
056 316 connecting rod screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4
056 318 packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 5
056 334 packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 49
056 335 packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 9
056 369 packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 10
056 730 gearwheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4
057 916 overpressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 1
059 286 cylinder 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2
059 298 piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2
059 393 cylinder head packing 2nd stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 3
060 342 fusible plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 4
062 375 cylinder foot packing 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 5
062 376 cylinder foot packing 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 5
062 376 cylinder foot packing 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5
062 478 drainage hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 4
062 481 flow control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 3
062 909 gearwheel oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2
063 120 expansion receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 2
063 121 final separator, compl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 18
Index
063 303 cylinder 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 2

063 304 piston 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1
063 305 piston 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 7
063 748 packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 6
064 064 dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2
064 075 clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 13
064 079 bearing bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3
064 095 packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5
064 098 gearwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 3
064 119 lubricating oil pump and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 16
064 345 flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2
064 352 connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1
064 365 tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 3
064 408 cylinder with head and valve 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 8
064 420 pressure washer flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3
064 481 cylinder head 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1
064 523 pipe adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 8
064 568 connecting rod 1st and 2nd stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3
064 581 flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3
064 848 connecting rod 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4
064 849 connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1
065 117 crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1
065 120 pressure air channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 1
065 122 bend flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 2
065 159 suction lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 17
065 160 pressure air lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 18
065 169 resilient mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 20
065 173 crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1
065 175 cylinder with head and valve 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 9
065 176 cylinder with head and valve 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 10
065 177 crankcase venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 14
065 178 cooler and air lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 15
065 180 measuring device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 17
065 181 automatic drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 21
065 187 crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2
065 190 crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1
065 194 pipe holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 12
065 195 distance bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 5
065 197 pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 6
065 198 pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 7
065 200 pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 8
065 216 rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 2
065 229 cooler 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 16
065 234 clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 15
065 235 clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 14
065 310 pressure air lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 19
065 348 oil sieve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7
065 352 tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4
065 353 tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 5
065 376 ledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 11
065 388 non-return valve, connection 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 11
065 389 ledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 4
Version 2 - 2 E -55

Manual WP311L

Uploaded by

Copyright:

Available Formats

Manual WP311L

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual WP311L

Uploaded by

Copyright:

Available Formats

S a u e r

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

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

10. Lubricant Table . . . . . . . . . . . . . . . . . . . . . . 61

11. Spare Parts and Accessories . . . . . . . . . . . 64

1.2 General information

Copyright The copyright for these instructions remains with

1.3 Warranty and Liability

1.4 Type approval and genuine Sauer spare parts

Do not use parts from

… but only genuine Sauer

J.P. SAUER & SOHN Maschinenbau GmbH

1.6 How these instructions are organized

Action Individual instructions or multiple instructions, where the se-

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

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

Safety instructions Safety instructions are emphasized by pictographs and signal

2.2 Prohibition of unauthorized conversion

2.3 Safety information

2.4 Safety markings on the machine

Safety marking Meaning Safety marking Meaning

Danger! High voltage! Read instructions!

Compressor starts auto- Wear hearing protection!

Hot surface! Rotational direction of

Location of safety markings (top view)

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

2.6 Noise protection

2.7 Waste disposal

2.8 Staff requirements

2.9 Personal protection gear

1 Cylinder 1st stage

2 Cylinder 2nd stage

3 Cylinder 3rd stage

4 Safety valve 1st stage (not visible)

5 Safety valve 2nd stage

6 Safety valve 3rd stage

7 Cooler 1st and 2nd stage

8 Condensate separator 2nd stage

9 Condensate separator 3rd stage (final separator)

10 Condensate collecting pot

11 Drain valves 1st, 2nd, 3rd stage

13 Oil dip stick

14 Fusible plug (not visible)

16 Crankcase vent with insulating sleeve (not visible)

1 Cooler 1st and 2nd stage

3 Cooler 3rd stage

6 Transmission bell housing

8 Oil suction filter

10 Lubricating oil pump

1 1st stage: cylinder with head and valve

2 Piston 1st stage

3 2nd stage: cylinder with head and valve

4 Piston 2nd stage

5 3rd stage: cylinder with head and valve

6 Piston 3rd stage

Item Designation Display

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

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

Pressure gauge 3st Ultimate pressure

Thermometer 1st Compressed air temperature after the