Air Compressor(2)

March 23, 2018 | Author: Marius Condurache | Category: Valve, Gas Compressor, Piston, Cylinder (Engine), Pump
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S a u e rC o m p r e s s o r Typ: WP 400 Operator Manual • High-pressure Compressor • 2-stage • water-cooled Ausgabe: 05 / 2008 Redaktion: Edited by: J.P. Sauer & Sohn Maschinenbau – Technical Documentation WP400_BA_Titel_en_08.fm WP400_BA_Titel_en_08.fm Zertifikate_en_0.fm Sauer compressor Type Approvals Note! On this page only a few examples are shown. FurtherType Approvals are available on request. Genuine Sauer spare parts – certified safety Zertifikate_en_0.fm N E M I C SPE . . . . . . . . . . .2 2.5 1. . .4 Design and Function. 8 Warranty and Liability .2 1. . . . . . . . . . . . . . . . . . . . . . . . . . 18 Personal protective equipment . . .2 Technical Specification . . . . . . 30 P&I Flow Diagram . .fm 1 1. . . . . . . . . . . . . . . . . . . . . . . . 15 Safety and protection devices . . . . . .7 2. . . . . . . . . . . . . 8 Foreword . . . . . .4 1. . . . . . . . . . . . . . . . . . . . . . . 26 Displays on the Sauer compressor . . . . . 12 2 2. . 13 Safety Information . . . . . .6 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 WP400_BA_en_09IVZ. . . . . . . . . . . . . . . . . . . . . . . . . . .1 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .3 1. . . . . . . . . . . . . . . SAUER & SOHN Customer Service . . . . . . . . . . . . . . . 10 J. . . . . . 9 Type Approval and Genuine Sauer Spare Parts. . . . . . . . . . . 13 Unauthorised modification. . . . . . . . . . . . . . . . . . . . .8 2. . . . . 20 Overview . . . . . . . . . . . . .1 2. . . . . . . . . . . . . . . . . . . . . .3 2. . . 16 Noise protection . . . . . . . . . . . . . . . . . . . 14 Safety Warnings on the Machine . . . . . . . . .5 2. . . . . . . . . . . . . . .1 1. . . . . . . . . . . . . . . . . . . . . . . . 28 Indicators and operating elements on the compressor control . . 17 Waste disposal . . . . . . . . . . . . . . . . . . . . .4 2. . . . . . . . . . . . . . . . . . . 30 Specification data .9 Safety . . . . . . . . . 11 Text Conventions Used in This Operator Manual . . . . . . . . . . . . . . . . . . . .3 3. .Table of Contents General. . . . .1 4. . . .Warning and Caution . . . . 13 Conditions of Use .P.6 2.2 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Precautions . . . . . . 17 Safety requirements for personnel . . 19 3 3. . . . . . . . . . . . . . . . . . . . . . . . . . . 29 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Functional description . . . . . . . . . . . . .8 8. . . . . . . . . . . . . . . . . . . . . . . . . .38 Installation . . . . . . . . . . .59 J. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 8. . .19 8. . . . . . . . . . . .7 8.1 5. . . . . . . . . . . . . . . . .14 8. . .62 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . .15 8. . . . . . . . . . . . . . . .55 8 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 8. . . . . . .5 8. . . . . . . . . . . . .74 Replacing the zinc protection . . . . . . . .36 Transport . . . . . . . . . . . . .62 Checking screwed connections . . . . .71 Renewing flexible gear rim . . . . . . . . . . . . . . .22 6 . .21 8. . . . . . . . . . . . . . . . . . . . . . .4 8. . . . . . .48 6 6. . . . . . . . . .64 Replacing valves . . . . . .13 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Checks to be carried out after installation and before the first start-up. . . . . . . . . . . . . . . . .1 6. . . .73 Overhauling water drain valves . . . . . . . . . . . . . . . . . . . . . . .49 Safe operation . . . . . . . . . . .62 Replacing air filter cartridge. . . . .6 Transport and Installation . . . . .3 6.36 Storage before Installation . .16 8. . . . . . . .P. . . . . . . . . . . . . . . . . .49 Operating modes . . . . . .3 8. . . . . . . . .73 Cleaning particle trap. . . . .71 Checking coupling . . . gudgeon pins and gudgeon pin bearings . .51 Routine operation . . . . . . . . .66 Draining the cooling water . . . . . . . . . .39 Connecting the Compressor . . . .64 Checking the valves . . . . .5 5. . . . . . . . . . . . . . .50 Initial operation . . . . . . . . . . . . . . . . . . . . . . . . .59 Safety during maintenance . . . . . . .63 Cleaning the oil strainer. . . . . . . . . . . . . . . . . . . . . . .18 8. . . . . . .10 8. . . . . . . . . . .11 8.fm 8. .74 Checking the cooling water pump . . . . .67 Checking pistons and cylinders . . . . . . . . . . . . . . . . . . . . . . . . . .4 Operation . . .17 8. . .71 Wear limits for cylinder diameters . . . . . . . . .2 5. . . . . . . . . .67 Replacing piston rings. . . . . . . . . . . . . . . . .3 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 6. .59 Maintenance schedule . . . . . . . . . . . . . . . . .60 Table of torques . . . . . . . . . . . . . . . . .9 8. . . . . . . . .75 WP400_BA_en_09IVZ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Replacing the bursting disc . . . . . . . . . . . . . . . . . . . .53 7 Troubleshooting guide . . . . . . . . . . . . . . . . . .72 Inspecting the condensate separator . . . . . . .1 8. . . . .12 Maintenance. . . . . . . . .2 8. . . . . . . SAUER & SOHN maintenance service. . . . . . . . . . . . . . . . . . . . . .42 Filling with oil . . . . . . . . . . . . . . . . . .4 5. . . . . . . . . . . . . . . . . . . .5 5. . . . . . . . . . 77 Safety when storing and removing . . . . . .3 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 10 10. . 88 WP400_BA_en_09IVZ. . . . 81 Lubricating oils . . . . . . . . . 84 12 12.2 9. . . 77 Temporary preservation and storage . . . . . . 87 Return of goods and notification of claim . . . . . . . . . . . . . . . . . . . . .1 12. . . .Storage. .2 Lubricant table . . . . . . . . . . . . .1 9. . . . . . . . . . . . . . . . . . .2 Appendix . . . . . . . . . . . . . .1 10. . . . . . . 82 Preservation oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preservation – “lay-up” procedure . . . .fm 9 9. . . . . . . . . . . . . . . . 86 Commissioning certificate . . . . . . . . . . . . . . . . . . . . 78 Disassembly . . . . . 83 11 Spare Parts and Accessories. . . . . . . . . . . . or parts thereof. Copyright The copyright for this Operator Manual remains with J. The following unique specification for the Sauer compressor can be found on the nameplate affixed to the compressor: – Compressor type – Serial number – Year of construction: We recommend you record this information in Chapter 11 “Spare Parts and Accessories” and always provide this data when requesting parts and any repair instructions. safe operation. WP400_BA_K1_12_en_08.fm 1 General 1. Contravention will result in prosecution. Such responsible personnel should be thoroughly familiar with. 1. These instructions should always be readily available at the compressor installation. maintenance and repair instructions with illustrated parts breakdown. and frequently review. distributed or made available to third parties. shall not be copied.2 Precautions We recommend that only authorised and trained personnel operate and service the Sauer compressor.P.WP400_BA_K1_12_en_08.1 Foreword This Operator Manual provides installation guidance. the Operator Manual.fm Specific precautions 8 . SAUER & SOHN. These instructions. be liable for any claims.3 Warranty and Liability WP400_BA_K1_12_en_08. if a failure is attributed to any of the following: – use of the machine not as specified. – inadequate monitoring of machine parts subject to wear. – unauthorised modification to the machine or its control system. – substitution of parts not manufactured or approved by Sauer. – failure to maintain/repair in accordance with Sauer instructions. – force majeure.fm Sauer can no longer cover warranty.General 1. – failure to observe operating instructions. 9 . – operation of the machine with faulty or improperly installed safety and/or protection devices. – use of spare parts that are not genuine Sauer spare parts. SAUER & SOHN are used. there is a risk that these are not genuine Sauer spare parts. Only use genuine Sauer spare parts with a certificate! 10 Incorrect Do not use parts from the “grey market”! WP400_BA_K1_12_en_08.fm Correct . In such an instance please contact our Customer Service. Failure to observe these requirements may void type approval. • Only the use of genuine Sauer spare parts will ensure compliance with these specifications and. Type approval is provided by the classification society and the EC Declaration of Conformity or EC Manufacturer's Declaration. Note! Be aware this is a high-pressure compressor. only use genuine Sauer parts.1. • Genuine Sauer spare parts are supplied with a Certificate of Conformity and a Certificate of Authenticity.P.4 Type Approval and Genuine Sauer Spare Parts • Type approval for the Sauer compressor is valid under the condition that parts and components specified and qualified by J. for your own safety and for reliable compressor operation. An example of this document is shown just before the Table of Contents in these instructions. If spare parts are received without this certificate. therefore. we reserve the right of exclusion from liability for personal injury and material damage. reliable and safe operation of the Sauer compressors. • If non-genuine Sauer spare parts are used. de WP400_BA_K1_12_en_08.sauersohn. please specify the compressor model and serial number (see Chapter 11 “Spare Parts and Accessories” or nameplate on the compressor). 11 .5 J. SAUER & SOHN Maschinenbau GmbH Customer Service P.P.fm Note! If you have questions regarding your Sauer compressor. Germany Phone (international): Technical information Spare parts orders Fax (international): Emergency service (international): E-mail: Web: +49 431 39 40 -87 +49 431 39 40 -86/886 +49 431 39 40 -89 +49 172 4 14 63 94 [email protected] 1.O.de www. SAUER & SOHN Customer Service Should you have any technical questions relating to maintenance or repair. Box 92 13 24157 Kiel. please contact our Customer Service: J. Instructions to be carried out in a certain sequence are numbered. Example: The control light is on.6 Text Conventions Used in This Operator Manual Part lists General lists are marked using a dash. 2. Safety and warning instructions are presented pictorially with clear instructions. Turn the control ON. Instructions Individual instructions or multiple instructions requiring action but where the sequence is of no importance are normally denoted by a bullet-point. Results of actions carried out are denoted by a tick mark.fm Safety instructions 12 . Example: • Check oil level. Example: Compressor cooling consists of – cooler assembly – cooling water lines. 3.1. Turn the main switch ON. Choose the operating mode. Example: 1. The safety instructions are described in detail in Chapter 2 “Safety”. WP400_BA_K1_12_en_08. specified conditions of use also includes observing the Operator Manual and the installation requirements and maintenance intervals described there. SAUER & SOHN. personnel must observe safe engineering working practices and local regulations. cause personal injury or result in damage to the equipment. Modifications may lead to an accident that can be lifethreatening. The Sauer compressor must not be used at ambient temperatures below +5 °C.P.Safety 2 Safety 2. Most accidents which occur during operation and maintenance of machinery result from failure to observe basic safety rules or precautions. 2. In addition. operating or carrying out maintenance. When handling. Any other unauthorised use requires the express written approval of J.P.1 Conditions of Use This Sauer compressor must be used for the compression of air only. SAUER & SOHN when planning any modification to obtain written approval. 13 .2 Unauthorised modification WP400_BA_K1_12_en_08. Contact J.fm Unauthorised modification of the Sauer compressor is not permitted. Note! Less risk. Disregarding this safety note may cause damage to the equipment. 14 . Warning .2.Warning and Caution The safety information in these instructions is presented as ‘high’ risk and ‘lower’ risk.fm Caution . and significant equipment damage.3 Safety Information .Danger! High risk. WP400_BA_K1_12_en_08. Ignoring these safety instructions can cause personal injury. as follows. or death. Replace damaged or lost safety labels immediately with an approved replacement.4 Safety Warnings on the Machine Danger! Safety labeling affixed to the machine must not be altered or removed. The Sauer compressor with an EC Manufacturer's Declaration or EC Declaration of Conformity is marked with the following safety labelling: Safety label Meaning Safety label Meaning High voltage! Danger to life! Read Operator Manual! Compressor starts automatically without warning! Wear hearing protection! Hot surface! Rotational direction of crankshaft WP400_BA_K1_12_en_08.fm Location of safety markings 15 .Safety 2. 2. The high air temperature switch shuts down the compressor if the compressed air temperature exceeds the limit value.5 Safety and protection devices Danger! Safety devices must not be adjusted. adjusted and re-sealed only by authorised personnel Each compression stage of the Sauer compressor is equipped with a safety valve. which will fully discharge air when the blowoff pressure is reached. WP400_BA_K1_12_en_08.fm Safety valves 16 . High air temperature switch The Sauer compressor is equipped with a temperature sensor.2. – 2. Safety valves are installed at the following locations: – 1. The safety devices must be periodically tested and checked: Safety valves must be installed with a lock-seal should be replaced. Low oil pressure switch The Sauer compressor comes supplied with a low oil pressure switch which trips when the pressure drops below p < 1 bar. Compression stage: in the rear cooler cover of stage 1. tampered with or removed. Compression stage: at the final separator after the 2nd stage. 17 .7 Waste disposal WP400_BA_K1_12_en_08. Danger! When the compressor is operated without sound-dampening enclosure. The Sauer compressor can be equipped with a sounddampening enclosure to reduce noise.6 Noise protection Sound pressure level details are found in the Technical Specification (see Chapter 4). hearing protection should be worn when working near the compressor.Safety 2. and used oil and grease and materials soiled by such lubricants – cleaning agents and rags soiled by such agents. – condensate (oil/water) arising from inter-cooling in the compression process – used oil and grease. available as an accessory from J.P.fm Note! The following materials which accumulate during operation of the compressor must be disposed of in an environmentally sound manner in accordance with applicable laws. SAUER & SOHN. 2. and must be familiar with all safety devices and safety regulations. Only those trained and thoroughly familiar with the compressor operation should be authorised to operate the compressor. 18 . – The regulations for accident prevention pertaining to compressors. where appropriate classification society and operational regulations must be observed. Personnel authorised to service the compressor must be trained technical specialists of the owner and manufacturer.8 Safety requirements for personnel WP400_BA_K1_12_en_08. standards and regulations such as – The Equipment and Product Safety Act. accepted engineering standards must be observed as well as all local laws. – Provision of the Verband Deutscher Elektrotechniker (VDE/ German electrical engineering industry association) – Regulations on environmental protection.2.fm Only personnel authorised by J.P. In addition to the instructions in this Operator Manual and supplier documentation. – The regulations for industrial safety. Additionally. SAUER & SOHN are permitted to service the Sauer compressor! Before commencing work they must have read and understood the instructions in the Operator Manual. hearing protection. etc.9 Personal protective equipment WP400_BA_K1_12_en_08.Safety 2.) for personnel carrying out any work on the Sauer compressor. 19 .fm The owner should provide personal protection equipment (e.g. safety boots. fm 8 . 4 7 9 13 12 5 11 15 6 2 14 1 3 10 20 WP400_BA_K1_12_en_08.3 Design and Function 3.1 Overview Note! Details of parts and spare parts can be found in the spare parts catalogue. 2 3 Cylinder 2nd stage 4 Safety valve 1st stage 5 Safety valve 2nd stage 6 Air filter 7 Oil fill pipe 8 Oil dipstick 9 Sump oil drain 10 Low oil pressure switch 11 Drain valve 1st stage 12 Drain valve 2nd stage 13 Compressed air temperature sensor 14 Cooling water stop valve 15 Motor WP400_BA_K1_12_en_08.fm 1 21 .1 2 Cylinder stage 1.Design and Function Item Designation Cylinder stage 1. 2 7 Connecting rod 2nd stage 8 Lubricating oil supply 9 Compressor monitoring and control WP400_BA_K1_12_en_08.Vertical sectional view 7 6 5 1 3 2 9 4 8 Item Designation Crankcase 2 Crankshaft 3 Flywheel 4 Coupling 5 Connecting rod stage 1.fm 1 22 .1 6 Connecting rod stage 1. WP400_BA_K1_12_en_08.fm Design and Function 23 Horizontal sectional view 17 8 Stage 1.2 11 14 5 2 Stage 1.1 Stage 2 7 9 10 13 4 12 6 15 3 16 18 WP400_BA_K1_12_en_08.fm 1 24 Design and Function Item Designation Cylinder stage 1.1 2 Cylinder stage 1.2 3 Cylinder 2nd stage 4 Piston stage 1.1 5 Piston stage 1.2 6 Piston 2nd stage 7 Valve cover stage 1.1 8 Valve cover stage 1.2 9 Valve cover 2nd stage 10 Concentric valve stage 1.1 11 Concentric valve stage 1.2 12 Lamellar valve 2nd stage 13 Cooler stage 1.1 14 Cooler stage 1.2 15 Cooler 2nd stage 16 Connecting rod stage 1.1 17 Connecting rod stage 1.2 18 Connecting rod 2nd stage 19 Crankcase vent WP400_BA_K1_12_en_08.fm 1 25 3.2 Functional description Drive The Sauer Compressor is driven by an electric motor flangemounted to the crankcase bell-housing. The power is transmitted by means of a flexible coupling. Compressor control Driven by an AC motor drive, the Sauer compressor is controlled and monitored by an electrical compressor control. This control system must comply with legal regulations. Optionally, J.P. SAUER & SOHN supplies a suitable compressor control. Compression The compressor takes in the ambient air via a layered filter with a tube silencer and compresses it in two compression stages with a total of three single-stage cylinders to the final pressure, with the 1st stage consisting of two cylinders of the same design connected in parallel. The air in each cylinder is inter-cooled with cooling water. A replaceable wet liner with a double O-ring gasket is installed in each cylinder. The cylinders arranged in a W-configuration are equipped with concentric valves and with lamellar valves which are easy to maintain and have a long service life. Cooling The compressor is cooled with fresh water. Cooling with sea water is available as an option. Inter-cooling of the compressed air in the 1st and 2nd stage takes place in the U-shaped cooling pipes which are press fitted via a cartridge version between the cylinder housing and cylinder cover. Cooler pipe Cylinder cover The cooling pipe and the replaceable liners are directly immersed in cooling water in the cylinder. The cooling water spaces are protected by zinc anodes against corrosion. When at a complete standstill, the cooling water supply is interrupted by a solenoid valve at the cooling water inlet. The compressor cooling is monitored by a temperature sensor. The compressor is immediately stopped if the compressed air temperature exceeds the upper limit value. Optionally, the compressor can be fitted with a cooling water pump driven by its own electric motor. 26 WP400_BA_K1_12_en_08.fm Cylinder housing Design and Function Condensate which builds up in the 1st stage accumulates in the collecting vessels of the 1st stage cooler cover. The 2nd stage has its own condensate separator for the oil/water condensate, which collects during compression and inter-cooling. Oil/water draining and pressure relief Condensate is drained via drain lines. There are solenoid valves installed in the drain lines. The drain valves must be open when the Sauer compressor is unpressurised. A few seconds after starting, the drain valves should close and the compressor should power up against system pressure. The drain valves should drain the system during operation at preset intervals. The control of the drain valves (solenoid valves) is carried out by the compressor control. Lubrication/Oil Pressure A gearwheel oil pump, driven by the crankshaft, draws the lubricating oil from the crankcase, and then pumps it to the connecting rod bearings. Crankshaft main-end bearings, gudgeon pin bearings and pistons (final stage also receives a small amount of injected oil) are lubricated by oil splash or mist present in the crankcase. The oil pressure is monitored by a low oil pressure switch. The compressor control must stop the compressor immediately if the oil pressure falls to the limit value. WP400_BA_K1_12_en_08.fm Condensate separation 27 3.3 Displays on the Sauer compressor 3 Stage 1.1 7 4 6 Stage 1.2 1 2 Stage 2 5 Item Designation Display Pressure gauge 1st stage Compressed air pressure after 1st stage 2 Pressure gauge 2nd stage Compressed air pressure after 2nd stage 3 Thermometer stage 1.1 Compressed air temperature after stage 1.1 4 Thermometer stage 1.2 Compressed air temperature after stage 1.2 5 Thermometer 2nd stage Compressed air temperature after 2nd stage 6 Oil pressure gauge Oil pressure of oil pump 7 Cooling water thermometer Temperature of cooling water WP400_BA_K1_12_en_08.fm 1 28 Design and Function 3.4 Indicators and operating elements on the compressor control Note! If the compressor control is supplied by J.P. SAUER & SOHN read the documentation supplied. On the front of the Compressor Control, the following indicators and control features can be found: Display/ Operating element Signal lamp “Operation” Explanation Illuminates when the compressor is running. WP400_BA_K1_12_en_08.fm Fault indicator Illuminates if the compressor has shut down because of low oil lamp “Oil pressure” pressure. Fault indicator lamp “Air temperature” Illuminates if the compressor has shut down because of high outlet gas temperature. Fault indicator lamp “Overcurrent” Illuminates if the compressor has shut down because of excess motor current. Run time counter Indicates the hours the compressor has run. Operation mode selector “Manual” mode: Starts the compressor manually. The compressor starts up and continues to run until it is manually turned off again. Selector position “0”: Turn the compressor off manually. Any pending fault messages are reset. “Auto” mode: The compressor starts and stops with the opening and closing of a remote contact (e.g. pressure switch at a compressed air vessel). Main switch Disconnects the power supply from the compressor control to the compressor. A main isolator switch should be installed if required by local law and regulations. 29 30 bar Set pressures for safety valves: 1. stage 8 bar 2. stage 5 % above final pressure Oil sump capacity 13.4 Technical Specification 4.5 l Oil refill quantity – dipstick MAX/MIN 5l Oil type see Chapter 10 “Lubricant Table” Maximum switching current 6 A/220 V Setting opens at 1 bar falling approximately 15 s delay on start instruction Switch function Change-over contact 30 WP400_BA_K1_12_en_08.fm Oil pressure switch: .1 Specification data Designation Data Compressor type WP 400 Number of cylinders 3 Number of compression stages 2 Cylinder diameter 1st stage 195 mm Cylinder diameter 2nd stage 110 mm Piston stroke 100 mm Maximum speed 1800 rpm Direction of rotation (when looking toward flywheel) clockwise Maximum working pressure. 92 dB(A) Weight and dimensions See installation drawing 31 .15 sec automatic drainage: every 15 min for 15 s Final pressure sensor (option): Maximum switching current 6 A/220 V Setting As required by customer Switch function Change-over contact Air temperature switch: Maximum switching current 16 A/220 V Setting opens at 80 °C rising Switch function Change-over contact Maximum permissible entry pressure at the cooling water inlet 5 bar without cooling water pump 2.5 bar with cooling water pump Bursting pressure of the burst disc in the cooling water system: > 6 bar Cooling water temperature at the outlet 40 to 50 °C Cooling water stop valve Holding power: 36 W Valve is currentless closed WP400_BA_K1_12_en_08.Technical Specification Designation Data Drain valves Pickup and holding power 18 VA/14 W Setting currentless open relief starting: approx.1 kW or 400 V/50 Hz 1 kW Setting not self-priming. should start and stop in synchronisation with the compressor Sound pressure level free field at 1 m max.fm Cooling water pump (option): Electrical connection 440 V/60 Hz 1. etc. power requirements.WP400_BA_K1_12_en_08. speed.fm Note! Please refer to the order-specific documentation of your compressor for data such as final pressure. 32 . WP400_BA_K1_12_en_08.fm Technical Specification 33 . 1 29 16 2 1.2 P&I Flow Diagram 10 12 31 Cooling water outlet 6 5 4 30 14 27 26 25 23 24 34 32 33 15 1 2 1.fm Temperature .2 11 7 17 20 13 M 16 Cooling water inlet 21 9 8 19 M 28 3 18 Compressed air outlet 22 Air intake atm M Condensate Motor Motor Solenoid valve Drive lubrication Compressor stage Safety valve Filter Non-return valve Suction filter Pressure relief valve Intercooler Oil pressure switch Separator Pump Temperature switch Pressure gauge 34 WP400_BA_K1_12_en_08.4. 1 22 Pressure relief valve 2 Compression stage 1.fm 13 35 .1 28 Drive motor 8 Separator stage 1.2 26 Oil pressure gauge 6 Cooler 2nd stage 27 Oil pressure switch / trip 7 Separator stage 1.1 25 Oil pump 5 Cooler stage 1.2 16 Thermometer 2nd stage 17 Solenoid valve (drainage) 1st stage 18 Solenoid valve (drainage) 2nd stage 19 Intake air filter stage 1.2 21 Non-return valve WP400_BA_K1_12_en_08.2 23 Drive lubrication 3 2.Technical Specification Item Designation Item Designation 1 Compression stage 1. Compression stage 24 Oil filter 4 Cooler stage 1.1 20 Intake air filter stage 1.2 29 Cooling water particle trap 9 Separator 2nd stage 30 Cooling water stop valve 10 Safety valve 1st stage 31 Cooling water thermometer 11 Safety valve 2nd stage 32 Cooling water pump (option) 12 Pressure gauge 1st stage 33 Motor cooling water pump 34 Cooling water manual valve (only with optional cooling water pump) 2nd Pressure gauge stage 14 Thermometer stage 1.1 15 Thermometer stage 1. • Damage to the packaging or the machine should be reported to the transport firm and J. Raise. move into position and set down with care. WP400_BA_K1_12_en_08. • The Sauer compressor should be checked for completeness and any damage immediately upon receipt.P.fm Danger! Suspended load during transport. Ensure that no personnel are within the danger area of the suspended load and the forklift truck/crane. Sling the unpacked compressor using the four lifting eye bolts (see illustration). The forklift truck/crane must have sufficient load-bearing capacity.1 Transport Shipping The machine is packed ready for shipping. Transport The Sauer compressor must be transported using a forklift truck or be hoisted by a crane.5 Transport and Installation 5. 36 . SAUER & SON immediately. Transport and Installation Transport by crane Lifting eye bolts WP400_BA_K1_12_en_08.fm Lifting point 37 . – relative humidity 30 to 95 %. – protected against vibration and shock. do not unpack. – in a dry area.2 Storage before Installation If the Sauer compressor has to be stored before installation.fm Note! High pressure hoses can be stored for up to five years after delivery. 38 .5. – protected from being soiled. and store under the following conditions: – temperature: +5 to +40 °C. under a roof and protected from the weather. WP400_BA_K1_12_en_08. Note! The standard factory protective packing is sufficient for a maximum storage period of 12 months. non-condensing. P. SAUER & SOHN. 5 °C – The installation area must be dry and free from dust. 55 °C min.fm Note! The air temperature at the location where the compressor is installed must not exceed +55 °C. Sauer can provide help with the design of a ventilation system.Transport and Installation 5. there is a danger that condensation will occur within the machine. with corresponding consequential damage. – For proper installation. For proper installation follow the installation instructions and observe the following. If necessary. install a ventilation or air extraction system in the area. Conditions in the area of installation as well as the heat generated by the compressor and any other machines installed in the same area must be kept in mind.P. 39 .3 Installation Note! If in doubt regarding the suitability of the intended installation area. – Ensure that the installation is ventilated in such a way that the heat generated during operation is removed. please contact J. If required for the installation area. Otherwise. please contact J. – Room temperature during operation of the Sauer compressor: +5 °C to +55 °C (If it is intended to operate the compressor outside this temperature range. Install the fresh air feed in such a way that the cooling air stream is never directed at the compressor. WP400_BA_K1_12_en_08. Installation requirements max. SAUER & SOHN). follow the installation instructions and observe the following conditions. The cooling water spaces are automatically kept vented through the arrangement of the cooling water inlet and outlet. 50 °C Note! The Sauer compressor is cooled with fresh water.fm 40 °C . 40 WP400_BA_K1_12_en_08.Correct ventilation Incorrect ventilation – At room temperatures below +5 °C the room must be heated or a heater must be installed on the Sauer compressor. – The installation location must be selected in such a way that the Sauer compressor is easily accessible. The quantity of cooling water must be set at a level such that the cooling water outlet temperature is between 40 °C and 50 °C. A maximum cooling water outlet temperature of 50 °C must not be exceeded. but according to its temperature and chemical composition seawater can be very corrosive. Seawater can be used for cooling if desired. Excitation of the compressor foundation by vibrations from other machines installed in the vicinity must not be in the 10 Hz range.P. contact J.fm 1. Otherwise there is a danger that the standard anti-vibration mount could be destroyed by resonating vibration. Check whether there are vibrations of the machine foundation in the 10 Hz range. 10 Hz. 2.Transport and Installation Note! J. SAUER & SOHN in order to clarify whether a different anti-vibration mount can be used. Foundation Note! The standard delivery anti-vibration mount has a resonant frequency of approx. 41 . WP400_BA_K1_12_en_08.P. SAUER & SOHN would be pleased to advise on the installation of the compressors. If in doubt. Hose line for cooling water High pressure hose for compressed air Cooling water connection Hose line for condensate WP400_BA_K1_12_en_08.fm Danger! At the compressor start-up and during drainage compressed air escapes from the drainage connections.5. do not operate the compressor without hose lines connected. 42 . Any work on the electrical installation must be carried out by qualified electricians only. Consequently. and drainage connections of the Sauer compressor must be connected by hose connections to any of the system owner’s permanent piping.4 Connecting the Compressor Danger! The compressor should only be connected by a qualified technician. cooling water inlet and outlet. Pipelines Compressed air outlet. Connect the drainage lines of the individual compressors at a sharp angle to the common drainage line. please observe the following: Choose a sufficient nominal diameter for the common drainage line.Transport and Installation The hose lines must be installed free of tension and not twisted.P. It may only be disposed of in compliance with applicable legal regulations. J. Note! We recommend connecting up the compressor drainage separately.fm Note! Accumulated condensate contains oil. 43 . SAUER & SOHN offers condensate collection containers for separating air from condensate as well as condensate processing systems for separating oil from condensate. so that no pressure can build up in the drainage line of a compressor that is not in operation. Correct installation Incorrect installation Drainage WP400_BA_K1_12_en_08. If you wish to combine the drainage of several compressors. fm Correct connection 44 .Incorrect connection WP400_BA_K1_12_en_08. fm Item 7 Designation 6 2 3 4 5 Type Function 1 Drive motor AC motor Compressor drive 2 Non-return valve Plate valve Prevent air flowing back 3 Final pressure switch Change-over switch Start/stop control for the compressor 4 Safety valve Spring-loaded safety valve To limit excessive pressure on the parts subjected to pressure 5 Drainage valve Solenoid valve Start relief and drainage 6 High air temperature switch Change-over switch Switch off compressor if temperature is too high 7 Oil pressure switch Change-over switch Switch off the compressor if oil pressure is too low 8 Cooling water stop valve Solenoid valve Prevent flow of cooling water when machine is not operating 9 Cooling water pump (option) Centrifugal pump. not self-priming Circulate cooling water 45 .Transport and Installation Connections The illustration below shows the connections and the fittings for the operation of a typical Sauer compressor. 1 8 9 WP400_BA_K1_12_en_08. the components are supplied pre-wired to a terminal box.fm Note! For technical specifications of the individual items. please refer to Chapter 4. If desired. All change-over switches are factory adjusted. 46 .WP400_BA_K1_12_en_08. 47 . Overfilling increases the oil consumption of the compressor.fm 3.Transport and Installation 5. Note! Only fill with oil up to the upper level gauge mark on dipstick. 2. Unscrew the oil fill cap (red). Note the amount of oil needed (see Chapter 4 “Technical Specification”). WP400_BA_K1_12_en_08. Oil fill cap Dipstick Danger! Make sure to fill the crankcase of the compressor with oil before initial operation! Use an appropriate lubricating oil (see Chapter 10 “Lubricant Table”).5 Filling with oil The Sauer compressor is delivered without oil. 1. Replace the dipstick and screw the oil fill cap back in. Pour in oil and check the oil level with the dipstick (red). fm – Check that the electricity connection matches the data on the nameplate.6 Checks to be carried out after installation and before the first start-up. – Check that all connections between the compressor and the compressed air equipment are properly installed. Pay particular attention to the compressed air connection. WP400_BA_K1_12_en_08.5. – Are the drainage lines properly connected? – Are the cooling water lines open? – Has the crankcase been filled with oil? – Have all tools and foreign objects been removed from the compressor? – Is the entire unit clean? 48 . ” 49 .fm Danger! Risk of hearing damage because of the sound pressure level while the compressor is running! Wear hearing protection near the compressor.Operation 6 Operation 6. Wear protective gloves. all tools and foreign objects have been removed from the machine.1 Safe operation Danger! Only authorised persons are permitted to put into operation and operate the Sauer compressor! Danger! Only switch on and start the compressor when it has been checked that it is in perfect condition. Note! Switch compressor off in the event of any abnormal/fault conditions or unexpected events. Danger! Risk of burns from touching hot surfaces of the compressor during operation. Danger! Immediately turn compressor off if personnel and property are endangered. WP400_BA_K1_12_en_08. Danger! In Automatic mode the compressor starts automatically without warning. Eliminate the cause of the problem with the help of Chapter 7 “Troubleshooting. Only re-start compressor when there is no more danger or possible damage. 6.fm After you have turned on the power supply to the Sauer compressor.2 Operating modes WP400_BA_K1_12_en_08. it can be started with one of the following two operating modes using the mode selector switch: – “Manual” operating mode: The compressor starts and continues to run until it is stopped or turned off either by using the mode selector switch or the main switch. 50 . After a few seconds the valves close and the compressor powers up against system pressure. When the Sauer compressor starts. it starts without load with the drainage valves open. – “Automatic” operating mode: Starting and stopping the compressor is controlled by external devices (for example using the pressure switch of the pressure vessel). The direction of rotation must agree with the rotation direction arrow on the pump. 2.3 Initial operation Check the direction of rotation Allow the Sauer compressor to run only for a few seconds to check the direction of rotation. the polarity of the electric motor should be changed by a qualified electrician. 51 . 6. Set the mode selector switch to “0” to stop the compressor. Immediately check the compressor’s direction of rotation. WP400_BA_K1_12_en_08. The motor must not be allowed to reach its operating speed. If the direction of rotation is incorrect. Pump and suction pipe must be completely filled with cooling water. Risk of subsequent damage. Switch off the power supply.fm Danger! The cooling water pump must not be allowed to run dry. 7.Operation 6. Checking the direction of rotation of the cooling water pump (option): Switch on the pump motor. Switch the power supply on. the polarity of the electric motor should be changed by a qualified electrician. 4. Set the mode selector switch to “Manual” to start the compressor in manual mode. If the direction of rotation is incorrect. 5. 3. no oil pressure builds up. Danger! If the crank shaft rotates in the wrong direction. It must rotate in the direction indicated by the arrow on the crankcase. 1. If correctly adjusted. This is indicated by a drop in pressure on the pressure gauge. 6. Set the mode selector switch to “Manual” to start the compressor in manual mode. 8. Complete the commissioning certificate and send it to J. Check that cooling water is flowing. If necessary eliminate the cause of deviations from nominal values and malfunctions. The temperature of the cooling water at the outlet must stay within the range given in the “Data table” in Chapter 4. The commissioning certificate is in the Appendix. In the case of machines with an integrated cooling water pump. the drain valves should close after about 15 seconds and the compressor should power up against system pressure.fm Test run 52 . Switch the power supply on.P. 5. 2. SAUER & SOHN Customer Service. It is required to drain for about 15 seconds every 15 minutes. 7. See also Chapter 7 “Troubleshooting”.1. Switch off the power supply.4 “Routine Operation”). Set the mode selector switch to “0” to stop the compressor. Check the pressure gauges of each stage as well as the oil pressure gauge and compare readings with the nominal values (see Chapter 6. If these temperatures are exceeded or not reached the flow of cooling water must be increased or decreased accordingly.1. Check the function of the automatic drainage. 4. 9. WP400_BA_K1_12_en_08. the flow rate can be regulated with the slide on the pump. 3. The temperature can be read from the cooling water thermometer at the cooling water outlet. if necessary. The temperature of the cooling water at the outlet must remain within the area shown in the “Data table” in Chapter 4. Checks • Inspect connections.Operation 6. Open the cooling water lines. 2.4 Routine operation • Keep compressor area clean. Set mode selector switch to “Auto“ to operate the compressor in Automatic mode. see Chapter 7 “Troubleshooting”. Do not overfill with oil beyond the maximum mark. condensate).fm Cleaning 53 . 3. • The pressure indicated on the pressure gauge must remain within the grey zone in the stage pressure diagram (see below).1. Operation 1. In the event of deviations. • Keep indicators and control elements clean. Switch the power supply on. • Check the oil level once a week before starting. • The oil pressure should be between 1. WP400_BA_K1_12_en_08. • Pay attention to leaks (compressed air. Watch out for • Abnormal operating noise. top up. oil. pipes and electric cables for damage.8 bar and 4 bar. fm Note! Depending on the desired final pressure in the 2nd stage. the allowable pressure for the 1st stage can be read from the above diagram.2nd Stage [bar] Stage pressure diagram 1st stage 30 20 10 1 2 3 4 5 1st 6 Stage [bar] WP400_BA_K1_12_en_08. 54 . Check the fuses. Oil too viscous.Troubleshooting guide 7 Troubleshooting guide Note! Should a malfunction occur. The compressor can be started again after a cooling down period. If not. No input power supply/no control voltage. Oil filter blocked. WP400_BA_K1_12_en_08. Clean oil pipe. Piston seizure Check cylinders and pistons for any score marks. Oil pipe blocked. first check the ’User Interface’ on the compressor Control Panel and on the compressor. Check oil pump. Check supply voltage and electrical connections. 55 . Replace blown fuses. Compressor was switched off because the oil pressure cutout switch tripped. Check for leaks.fm Probable cause Check whether the crankshaft can easily be turned by hand. SAUER & SOHN Customer Service. Fill with recommended oil. disconnect and ascertain whether the problem has to do with the motor or the compressor. Fault Remedy Compressor does not start or switches off. Compressor was switched off by overcurrent relay. Oil pump faulty or leaking. Check that room temperature is > + 5°C. The fault description journal is in the Appendix of this Operator Manual.P. please contact J. If the fault cannot be corrected. Check oil level and top up if necessary. replace as necessary. Try to correct the fault with the help of the table below. Clean the oil filter. Excessive current drawn. If necessary eliminate leak or replace oil pump. Oil level too low. The pressure gauges of all stages show no pressure. Gasket between suction and pressure side of the 2nd stage is faulty. Valve of the 2nd stage is leaking. Pressure switch is set too high. Check solenoid valve power supply.Fault Probable cause Remedy Safety valve of 1st stage blows off: Pressure exceeds blowoff pressure (8 bar) 2nd stage valve is not working properly. Air filter very dirty. Pressure below blow-off pressure (8 bar) Pressure above blow-off pressure (final pressure + 5%) Pressure below blow-off pressure (final pressure +5%). Replace gasket. Replace safety valve. Check the valve of the 1st stage and replace if necessary. Safety valve is set too low or is faulty. Check the solenoid valve and replace it if necessary. Valve of the 1st stage is leaking. Connection gaskets or seals leaking. Pressure gauge of the 1st stage is showing insufficient pressure. Replace safety valve. Replace faulty gasket or seal.fm Safety valve of 2nd stage blows off: . Lower the pressure setting. Excessively high pressure losses in the air line to the compressed air vessel. Reduce the pressure losses. Safety valve is faulty. Clean the air filter insert or replace it. Check the valve of the 2nd stage and replace if necessary. Solenoid valve of the drainage is faulty. Check the valve of the 2nd stage and replace if necessary. 56 WP400_BA_K1_12_en_08. Replace gaskets. No power at solenoid drainage valve. Switch compressor off. Wait until all parts are no longer under pressure. Tighten all screws. Cutting rings leaking. Air escaping from the compressed air lines. Pressure gauge of the 1st stage is showing excessive pressure. Open valve. Valve in the air line to the compressed air vessel is closed. check the pressure gauge for this. clean the particle trap Compressed air temperature at the outlet too high because of poor thermal transition in the cooler as a result of scaling in the chamber. Minor traces of oil on the crankcase or oil drops below the compressor are harmless. Connecting rod bearing faulty. Oil leaking from crankcase. Check oil supply. Check motor bearing. Foreign matter in solenoid valve. replace if necessary. Check fuses. Replace solenoid. No power supply. Replace solenoid valve. No power supply. Cooling water stop valve does not open. Check crank shaft bearing. WP400_BA_K1_12_en_08. Check the temperature of the cooling water at the outlet and the functioning of the cooling water stop valve. Check gudgeon pin bearing. Replace solenoid valve. Tighten all screws. Wipe off with a lint-free rag. Replace solenoid. Motor bearing faulty. Clean the cooling water containers with a descaling agent. Replace O-ring. Foreign matter in solenoid valve. Solenoid faulty. Crankshaft bearing faulty. Screws not tight. Check fuses. replace blown fuses. Solenoid faulty. Gasket or shaft seal faulty. replace if necessary.Troubleshooting guide Fault Remedy Compressed air temperature at the outlet too high as a result of shortage of cooling water. Oil escaping at the relief groove of the cylinder flange surface. Abnormal compressor noise. temperature switch has tripped.fm Probable cause 57 . Replace O-ring. Gudgeon pin bearing faulty. Increase flow of cooling water (in the case of a cooling water pump only: Open the slide at the rear of the pump further). Solenoid valve (drainage) valve does not close. O-ring of the liner is faulty below the relief groove. If there is significant leakage check to see which gasket is faulty. O-ring of the liner is faulty above the relief groove. Water escaping at the relief groove of the cylinder flange surface. Check connecting rod bearing. replace blown fuses. replace if necessary. replace if necessary. Compressor was switched off. then replace it. very short compressor running time Reduce flow of cooling water. WP400_BA_K1_12_en_08. or similar causes) Premature fracture of valve plates. Replace cooler insert. actuation of electromagnetic stop valves or shuttle valves. Check drainage lines and drainage intervals. Pressure peaks in the cooling water circuit cause the burst disc bursting pressure or the safety valve preset pressure to be exceeded.fm Water in the oil 58 . Check drainage lines and drainage intervals.flow of cooling water too high . Determine the cause of the pressure peaks and eliminate these causes (startup of additional pumps.unfavourable room ventilation . Extend compressor running time Poor drainage.Fault Probable cause Remedy Excessive cooling of compressor due to . valve springs or valve plates Poor drainage. Note: Indentations in the gasket contact surface of the valve plate are normal. Burst disc in the cooling water circuit triggers OR Cooling water safety valve triggers. Leaks in cooler. Change room ventilation so that air stream is not blown directly against compressor. even when it is turned OFF. Fit 'Warning: maintenance work' warning sign to power supply. WP400_BA_K1_12_en_08. This also applies to electrical protection devices. 8. 2. Interrupt power supply to the compressor.P.2 Safety during maintenance Before maintenance work 1.P. – Components being worked on should only be energised if this is explicitly specified. always refit all safety devices and isolating protection devices. SAUER & SOHN customer service offers various maintenance services: inspections. Shut off the compressor and secure to prevent restarting.8 Maintenance 8 Maintenance 8.fm Danger! Danger! High voltage! – Never assume that a circuit is de-energised – always check for your own safety! – The mains isolator remains energised. reconditioned compressors and service contracts. 3. Danger! Danger of death if there are no safety devices or no isolating protection devices! After undertaking servicing work. Danger! Risk of injury due to pressurised components! Before undertaking any maintenance work. use pressure gauge to ensure that there is no more pressure in the compressor. 59 .1 J. major overhauls. maintenance. SAUER & SOHN maintenance service J. Danger! Risk of injury due to incorrect operation! Only authorised personnel are permitted to service and adjust the Sauer compressor! Danger! Risk of injury from hot surfaces! Let compressor cool down after turning OFF. • Regularly check the maintenance schedule to see which maintenance intervals are due depending upon the number of operating hours. • Carry out all maintenance tasks for a maintenance interval and tick the appropriate check boxes of the maintenance schedule. The intervals are shown in the table's column headers. A description and the section number of the tasks are shown in the first column. for particular bolts.8. Note! The maintenance intervals specified in the maintenance schedule must be observed. Use the maintenance schedule as a guide and for verification. Note! After the final maintenance routine. main specifications and date of commissioning. date and signature. • Check the column for each maintenance interval to see which maintenance work is to be carried out at the end of the maintenance interval. date and hours of operation. • Use the maintenance schedule as a master template or copy the relevant page from the digital document and save it as a separate file under a suitable name. observe section 8. Then enter hours of operation. • When beginning a new maintenance schedule: – enter: maintenance schedule number.3 Maintenance schedule Danger! Whenever undertaking maintenance work. – mark with a cross: beginning of this maintenance schedule following commissioning or following the last maintenance routine.4.fm Use of the maintenance schedule 60 . The required tasks are indicated by checkboxes. WP400_BA_K1_12_en_08. the maintenance schedule starts from the beginning. 'Table of tightening torques'. Shortening the maintenance intervals is of no advantage with regard to the operating performance or service life of the Sauer compressor. section 8. gudgeon pins and gudgeon pin bearings.10 Replace 2nd-stage valves. section 8. section 8.: 50 h after commissioning 50 h after last maintenance routine or repair At least annually at < 1000 h Interval [hours of operation] WP400 ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ Hours of operation Date Signature (initials) 61 .12 Replace 2nd-stage piston rings. section 8.13 Renew flexible gear rim.18 Clean particle trap.fm 4000 h ❏ ❏ 069236 ❏ 3000 h ❏ 069234 ❏ 2000 h ❏ 069235 Check screwed connections.10 Replace 1st-stage piston rings.7 Clean oil strainer. section 8. section 8. section 8. Beginning of this maintenance schedule Compressor type Type series ❑ after commissioning ❑ after last maintenance routine Compressor number: Date: Hours of operation: Year of construction: Date of commissioning: WP400_BA_K1_12_en_08. section 8. 069234 Maintenance work 2W Factory no. section 8.6 Carry out oil change.22 1000 h Maintenance set item no. section 8.21 Check cooling water pump. section 8.17 Overhaul drain valves (as per order).12 Check piston and cylinder.8 Check 1st-stage valves.20 Replace bursting disc.9 Replace 1st-stage valves. section 8. section 8. section 8. section 8.5 Replace air filter cartridge. section 8.19 Replace zinc protection (freshwater operation).16 Check condensate separator. section 8.Maintenance Maintenance Schedule No. gudgeon pins and gudgeon pin bearings. – unions on pipe and hose lines. and – accessories and equipment parts. 8.8. This relates to: – cooler and air lines. – cylinders.fm Air filter cap 62 .4 Table of torques Screw(s) Torque Connecting rod screws 115 Nm Flywheel fastening screw 550 Nm Valve cover nuts (1st/2nd stage) 82 Nm Bursting disc flange 54 Nm Valve retaining screw 9 Nm 8.6 Replacing air filter cartridge WP400_BA_K1_12_en_08. – electric motor. – cylinder heads. – measuring and switching devices.5 Checking screwed connections Check all unions and screwed connections for tightness and retighten if necessary. – bearing. 8.fm Oil drain valve cap 63 . Open clips and take air filter cap off.Maintenance 1. Insert new cartridge into air filter. Remove used cartridge. 5. 2. Clean filter housing with a suitable solvent and wipe out with a lint-free cloth. Put on cap and close clips. Oil filler cap Dipstick WP400_BA_K1_12_en_08. 3.7 Changing the oil Note! Use oil according to the lubricant table (see section 10). 4. 4.1. 3. Undo valve retaining screw and take out 2nd-stage valve. Tighten nuts on inspection hole cover. Wait until all oil is drained. Carefully clean sealing surface for inspection hole cover gasket. Place drip tray (of a capacity sufficient to hold the complete oil filling quantity. 3. Close oil drain valve and screw on cap. 2. 4. 7. 5. 64 WP400_BA_K1_12_en_08. open oil drain valve and pull out dipstick. Put dipstick back in and screw oil filler cap back on. 6. Wash out oil strainer in a suitable solvent. Take out oil strainer. Loosen clamp on air filter and take out air filter. Unscrew union on oil strainer. Unscrew oil filler cap and oil drain valve cap.fm Removing valves . Prise off using the screws if necessary. This particularly applies to the sealing surfaces. 13. 2. Top up oil and check level with the dipstick. Carefully take out 1st-stage valve. 6.8 Cleaning the oil strainer 1. 4. 2. 8. 3. Position inspection hole cover with new original Sauer gasket. Unscrew nuts on inspection hole cover. Undo valve cover screws and take off valve covers. 15 minutes until operating temperature is reached. 7. Run compressor for approx. 5. Loosen unions and hose lines at the valve covers. 5. Note! When removing and installing a valve.5 l) below the oil drain valve. 9. Tightly refasten oil strainer. Take off inspection hole cover.9 Checking the valves 1. take care that no valve parts are damaged. 8. ✓ The level should be between the upper and lower marks on the dipstick. 8. Attach 1st-stage valve cover. severely carbonised or corroded valves.fm 1st stage O-ring Gasket 2. Check valves externally for: damage. Replace damaged. Installing other gaskets may lead to compressor leaks and damage. Note! Never reuse old rings. oiling. Clean all sealing surfaces. This may lead to leaks. Only use original Sauer spare parts. 'Troubleshooting'). 2. 1. Insert new O-rings (see illustrations). corrosion and moisture. Determine cause (see section 7. WP400_BA_K1_12_en_08. Install valves and valve covers. carbonisation. Fasten all screwed connections hand-tight. Removing valves Note! Refit all valves with new gaskets and rings only. 65 .Maintenance Checking valves 1. 9. 8. 5. Attach 2nd-stage valve cover. Attach unions and hose lines to the valve covers.4). Fasten all screwed connections hand-tight. Mount air filter and tighten clamp.2nd stage Valve retaining screw O-ring 3. we recommend that used valves not be repaired. 6.10 Replacing valves Remove and install valves as described in section 8. Fasten valve cover nuts tightly. 'Checking valves'. 66 . 4. 7. WP400_BA_K1_12_en_08. Fasten valve to valve cover using valve retaining screw. Replace complete valve.fm Note! Valves whose service life has expired must be replaced and disposed of. Observe tightening torques (see section 8. Due to material fatigue. Maintenance 8.11 Draining the cooling water Drain plug 1. Block the cooling water inlet and outlet. 2. Remove the hoses for the cooling water inlet and outlet from the cylinders. 3. Unscrew the drain plugs and drain the cooling water. 8.12 Replacing piston rings, gudgeon pins and gudgeon pin bearings WP400_BA_K1_12_en_08.fm 1. Remove valve covers and valves as described in section 8.9, 'Checking the valves'. 2. Remove cylinder base nuts. 3. Remove cylinder. Grab and hold the piston before you have completely removed the cylinder. Note! If you do not hold the the piston while you remove the cylinder, it will collide with the crankcase. 67 1st stage 4. Remove valve covers and valves as described in section 8.9, 'Checking valves'. 5. Dismantle the inspection hole cover from the crankcase. 6. Remove connecting rod bolts and remove connecting rod bearing cover with bearing bush. 7. Push piston together with connecting rod upper part out of the cylinder. 8. Remove all piston rings from the pistons and clean pistons. Note! Replace all piston rings with new ones! The following damage may occur on removal of the piston rings: • the edges of the piston rings may be damaged on the wearing edges in the cylinder; • fine cracks which can lead to material fracture may appear if the piston rings are bent up repeatedly. 9. Fit piston rings in the respective piston. Note! Use an assembly sleeve for pushing the piston into the liner from above (see section 11, 'Spare parts and accessories'). 10. Put connecting rod back with sufficient oil and screw on the bottom part by hand. Note! Figures are hammered into the upper and lower sections of the connecting rods. They must match. See illustration. ✓ It must be possible for the connecting rod bolts to be fully screwed in by hand. This is the only way of ensuring that they are seated correctly on the crankshaft. The connecting rod must be able to rotate easily on the crankshaft once 68 WP400_BA_K1_12_en_08.fm 2 2 Maintenance tightened. 11. Tighten connecting rod bolts; see tightening torque in section 8.4. WP400_BA_K1_12_en_08.fm 2nd stage 1. Loosen the flange connections and dismantle compressed air manifold. 2. Loosen both unions and dismantle the compressed air line from the cylinder of the 2nd stage to the final separator. 3. Block the cooling water inlet, remove the drain plug located below on the cylinder of the 2nd stage and drain the cooling water. 4. Loosen screwed pipe connections on the cylinder and dismantle cooling water inlet pipe. The screw connection nipple remains on the cylinder. 5. Unscrew the cooling water hose line between the 1st and the 2nd stage and remove. 6. Dismantle both the inspection hole covers from the crankcase. 7. Loosen the connecting rod bolts and remove them from the crankcase together with bearing cover. Push the connecting rod upper part with the piston up in the cylinder. 8. Loosen the four nuts at the base of the cylinder of the 2nd stage. 9. On both sides of the cylinder unscrew the two M10 × 25 upper retaining screws on the cooler cover and replace with M10 × 100 screws. Attach a suitable hoist to the screws and pull the cylinder sideways out of the crankcase (weight: approx. 100 kg). 10. Pull cylinder further up along with connecting rod with piston. Pull connecting rod towards front from the crankcase opening. 11. Put cylinder down at the side and pull connecting rod with piston down from the cylinder. 12. Remove all piston rings from the pistons. Note! Replace all piston rings with new ones! The following damage may occur on removal of the piston rings: • the edges of the piston rings may be damaged on the wearing edges in the cylinder; • fine cracks which can lead to material fracture may appear if the piston rings are bent up repeatedly. 13. Sequence of assembly is exactly opposite to that of dismantling. Replace the screws on the cooler covers on both sides of the cylinder with the M10 × 25 retaining screws. 69 14. Put connecting rod back with sufficient oil and screw on the bottom part by hand. Note! Figures are hammered into the upper and lower sections of the connecting rods. These must match in any case (see illustration). 2 2 ✓ It must be possible for the connecting rod bolts to be fully screwed in by hand. This is the only way of ensuring that they are seated correctly on the crankshaft. The connecting rod must be able to rotate easily on the crankshaft once tightened. 15. Tighten connecting rod bolts; see tightening torque in section 8.4. 16. Install new piston rings in the respective pistons. Make sure they are in the correct positions: piston rings with asymmetrical cross sections are marked on one of the surfaces with 'TOP'. During installation this face must face upwards (see illustration). 1st stage 2nd stage TOP WP400_BA_K1_12_en_08.fm TOP 70 8. Check wear limits as described in section 8. 'Wear limits for cylinder diameters'. Install cylinders and pistons as described in section 8. 'Replacing piston rings. 4.12. 71 .15 Checking coupling WP400_BA_K1_12_en_08. 'Checking valves'. Measure cylinder and replace if the following wear limits are exceeded: Cylinders Wear limit of diameter 1st stage 195. Check cylinders and pistons for scoring and heavy wear and tear marks.9. 'Replacing piston rings'.9. the edges must be broken up with a honing brush or Scotch-Brite abrasive cloth.13 Checking pistons and cylinders 1.fm Note! This applies to Sauer compressors with electric motors. 5. Note! If the piston running surface in the cylinder reveals perceptible wearing edges. Remove cylinder heads and valves as described in section 8. 3.14.15 mm 2nd stage 110. Replace relevant parts. gudgeon pins and gudgeon pin bearings'.15 mm 8. Otherwise the edges will damage the new piston rings on installation of the pistons. Install valves and cylinder heads as described in section 8. 2.12.14 Wear limits for cylinder diameters 1. Remove cylinders and pistons as described in section 8. 'Checking valves'.Maintenance 8. 6. 'Renewing flexible gear rim'. Remove the electric motor mounting screws. 2.16. Renewing flexible gear rim 1. 7. 4. Carefully pull the electric motor away from the compressor. 6. Flexible gear rim Motor 8. Remove the electric motor from the copmressor as described in section 8.1. Reinstall separated connecting lines and pipes. Replace flexible gear rim.16 Renewing flexible gear rim Note! This applies to Sauer compressors with electric motors. 2.Visual inspection 1. Support compressor under the coupling bell housing.fm Compressor . Carefully lift the electric motor using the lifting eyes (see section 5. 'Transport'). 5. 8. 72 WP400_BA_K1_12_en_08. Carefully slide electric motor against the compressor and tighten the motor mounting screws. Replace flexible gear rim as described in section 8. 3. ✓ The teeth of the coupling parts must not be deformed. Check the coupling parts for damage.16. Remove support from under the coupling bell housing. 'Renewing flexible gear rim'. 3. 2.fm Hexagon nut 1. Replace following parts: conical spring. Remove upper section of valve. Remove coil from armature. Carefully lift up plastic threaded part with the screwdriver. 73 . Remove pipes and check separator for obstructions.18 Overhauling water drain valves WP400_BA_K1_12_en_08. diaphragm and two O-rings.Maintenance 8. 6. Unscrew the four Allen screws. 8. 4.17 Inspecting the condensate separator 1. 5. Unscrew hexagon nut. 3. Drain the cooling water. 2. Drain the cooling water. 2. 2. 8.7. Position upper section of valve. Block cooling water inlet. Unscrew the zinc protection.21 Replacing the bursting disc . Clean the strainer. The zinc protection for the 2nd-stage cylinder is situated laterally on the cylinder cover at the bottom beside the bursting disc flange. Check that the gasket is correctly installed. 6. Remove the bursting disc and ring. 3. Fit first the gasket and then the bursting disc into the cylinder. Install a new ring and new bursting disc. 1. see tightening torque in section 8. Fit the strainer back. Lightly tighten hexagon nut using a spanner. 74 WP400_BA_K1_12_en_08. Carefully position hexagon nut by hand and screw on.4. 4. Clean the sealing surfaces. 5. Screw on the pressure flange. Place the coil on the armature. In case of severe soiling: clean nozzle. 1. 13.fm 8. Loosen the cap of the particle trap (in front of the cooling water-control valve) and remove the strainer.19 Cleaning particle trap 1. Undo the screws and remove the pressure flange on the cylinder of the 2nd stage. 12. 3. 3. 9. Clean the sealing surface and thread. Tighten the four Allen screws. Insert new zinc protection with new ring. 4. screw on the cap. Note! The coil and the armature must always be dry. 4. 11. 10. Correctly position the plastic threaded part and press onto the armature.20 Replacing the zinc protection The zinc protection for the 1st-stage cylinder is situated laterally on the cylinder cover at the top. 8. 8. fm Note! The floating ring seals are delicate elastomers and must not come into contact with grease or oil. Replacing the floating ring seals The floating ring seals are maintainance-free. Please refer to the operating instructions provided by the pump manufacturer. Loosen the flange connections on the cooling water inlet and outlet of the pump. Remove rings and clean sealing surfaces. A possibly damaged pump impeller must likewise be replaced. 5. 3. WP400_BA_K1_12_en_08. 7. Remove impeller and shaft retaining ring. Disconnect electrical connection. The cooling water pump should be checked as follows in case of abnormal running sound or leaks: Removing the pump 1. Remove the drain plug located below on the cylinder of the 2nd stage and drain the cooling water of the compressor. Pull the entire floating ring seal with the cap out from the shaft. Note! Note the diagram of the pump in the Spare Parts Catalogue. Do not soil or damage floating ring seals. Moisten the gaskets with low surface tension water to facilitate assembly. Avoid touching them with your fingers (use clean gloves or cloth). Note! The motor bearing should be replaced if the shaft has noticeable play. 6. 2.Maintenance 8.22 Checking the cooling water pump Note! The cooling water pump is an optional component and is not supplied as a standard component. Block the cooling water inlet and outlet. In case heavy leakages are noticed after a long running time. 75 . Loosen the bolted fastening of the pump at the foot and remove pump from the console. the floating ring seal is to be replaced as a complete unit. 4. Carefully slide new floating ring seal on to shaft with a rotating motion. 8. The direction of rotation must be the same as the one indicated by the arrow on the pump housing. The motor must not reach its operating speed during this. Insert new flange gaskets. 2. Fill pump and suction pipe completely with cooling water. WP400_BA_K1_12_en_08. Assemble the pump back in the reverse sequence.1. 3. Connect electrical connection.fm Mounting the pump 76 . Checking the direction of rotation Briefly switch on pump motor. fm Storage.WP400_BA_K1_12_en_08. Any work on the electrical installation must be carried out by qualified electricians only.1 Safety when storing and removing WP400_BA_K1_12_en_08. Preservation – “lay-up” procedure 9 Storage. These specialists must be familiar with the protection devices and regulations before starting the work. information contained in suppliers’ documentation must be observed.fm Danger! The compressor shall only be removed and “laid up” by trained specialists of the owner. Preservation – “lay-up” procedure 9. In addition. 77 . Blow out compressor oil and dispose of in an environmentally safe manner. preservation with a preservation oil is recommended. 100 to 125 cm3 of preservation oil into each of the 1st stage intake fittings. In an emergency the machine can be started for a short duration when filled with preservation oil. 5 minutes with drain valves and final pressure line open. Stop compressor. 4. Run compressor for approx. Unscrew both air filters on the 1st stage cylinder head. Start compressor and run for approx.fm 1. WP400_BA_K1_12_en_08. every 4 weeks perform a test run for at least 30 minutes. 2.2 Temporary preservation and storage If idle. When the Sauer compressor is to be laid up for more than 12 weeks. periodic test runs are not needed. The preservation oil has satisfactory running properties.9. 3. 7. Fill with about 10 litres of preservation oil. Start compressor and slowly inject approx. Additional corrosion prevention measures are not required. 78 . 5. When preservation is completed. Note! Use one of the preservation oils recommended in Chapter 10 “Lubricant Table” for corrosion protection. 6. Any existing oil/water is removed. 5 minutes with drain valves and final pressure line open. Screw the hexagon head screw on the 2nd stage cover back in. Remove hexagon head screw on the 2nd stage valve cover.3 “Initial Operation”.Storage. 12.1 Oil Hexagon screw 2nd stage 8. 2. If necessary. 10. Wait until oil mist comes out of the final pressure line. WP400_BA_K1_12_en_08.2 Oil Stage 1. 15. Follow the instructions given in Chapter 6. Preservation – “lay-up” procedure Intake fittings Oil Stage 1. Slowly inject about 100 to 125 cm3 of preservation oil into the opening. If necessary. Stop compressor.fm Putting back into service 79 . connect the mains supply cables. 3. 1. If necessary. 13. disconnect mains supply cables.6 “Filling with Oil”. 9. 11. 14. Reattach both air filters on the 1st stage cylinder head. put up a sign that the compressor was preserved and taken out of service. Drain preservation oil and pour in compressor oil as described in Chapter 5. 4. Drain any remaining condensate and dispose of in an environmentally safe manner. 2. Turn compressor off and disconnect from power supply.fm Lubricants 80 . Remove oil and lubricants and dispose of in an environmentally safe manner.9. Disconnect the mains supply cables. Read the gas pressure display to ensure that the compressor is completely depressurised. 5. Disposal Material/system component Disposal method as hazardous waste Steel/iron as metal scrap Electric cables as hazardous waste Electronic components as scrap electronic waste Plastics as hazardous waste WP400_BA_K1_12_en_08.3 Disassembly Follow these steps for disassembly: 1. 3. The lubricant table does not apply to – Sauer compressors designed to compress neutral gasses. WP400_BA_K1_12_en_08. SAUER & SOHN.fm Note! Unless otherwise ordered. General recommendation For temperatures lying within the 5 to 55 °C range we recommend mineral oil meeting the ISO VG 100 viscosity grade. the lubricating oil should correspond to the group VCL as per DIN 51506 . Otherwise the guarantee is made void. Lubricants which are not listed in the lubricant table may only be used after approval has been given by J. Two-stage water-cooled compressors may cause premature soiling of the valves due to the high compression temperatures combined with unfavourable ambient conditions or inferior types of oil. Please contact our Customer Service when selecting oils not listed. – temperatures outside the 5 to 55 °C range.Lubricant table 10 Lubricant table Scope The lubricant table applies to all Sauer compressors which are designed to compress air. At minimum. or if operating conditions differ from those recommended. Sauer compressors are delivered without oil.P. 81 . Note! The recommended types of oil reduce the level of coking in the compressor valves and the upstream pipe lines and fittings to a minimum. Use another oil in such cases or carry out maintenance at shorter intervals. Shell Corena P 100 mineral oil is the standard type used to fill and operate the unit.10.fm Brand . Agip ARAL AVIA BP CHEVRON ESSO Shell TEXACO TOTAL 82 Product name Diesel Gamma 30 Dicrea 100 Acer 100 Motor Oil HD 30 Cladium 50 Kowal M30 Avilub compressor oil VDL100 Energol RC 100 Energol IC-DG 30 Vanellus C3 SAE 30 Aircol PD 100 HD Compressor Oil 100 Delo 1000 Marine 30 Veritas 800 Marine 30 Rarus 426 Rarus 427 Mobilgard 300 Mobilgard 312 Delvac 1230 Corena P 100 Rimula X 30 Melina S Oil 30 Melina Oil 30 Gadinia Oil 30 Compressor Oil EP VDL 100 Regal EP 100 Ursatex 30 Veritas 800 Marine 30 Dacnis P 100 Disola M 3015 Group VCL-100 VDL-100 VCL-100 SAE 30 SAE 30 VCL-100 VDL-100 VDL-100 VCL-100 SAE 30 VDL-100 VDL-100 SAE 30 SAE 30 VDL-100 VDL-100 SAE 30 SAE 30 SAE 30 VDL-100 SAE 30 SAE 30 SAE 30 SAE 30 VDL-100 VCL-100 SAE 30 SAE 30 VDL-100 SAE 30 WP400_BA_K1_12_en_08.1 Lubricating oils The following mineral oils ma be used in Sauer compressors. 83 . Alternatively. the following preservation oils can be used: Brand Product name Agip Rustica C SAE 30 ARAL Konit Motoröl SAE 30 AVIA MK 1540 S BP MEK 20 W-20 DEA Deamot EKM 642 SAE 30 Esso MZK HD 30 motor oil Antirust MZ 110 Mobil Mobilarma 524 Shell Ensis Motor Oil 30 WP400_BA_K1_12_en_08.278 OMD 113 Group VDL-120 VDL-100 10.Lubricant table The following mineral oils may alternatively be used without restriction in marine applications: Brand NATO classified NATO classified Product name O .fm Note! The product name may vary by country.2 Preservation oils The standard oil used by Sauer for compressor preservation is Mobilarma 524. We supply instructions and a maintenance manual for each accessory. They conform to the latest technical developments. – Refrigerant type dryers. – and fittings. our range of supply includes many accessories for your Sauer compressor as well as special equipment for your entire compressed air system.P. – Adsorption dryers. In addition to genuine Sauer spare parts. SAUER & SOHN guarantee the complete spare parts supply over the entire service life of the Sauer compressor. Our genuine Sauer spare parts are subject to constant quality control and further development.11 Spare Parts and Accessories Note! Please note the information in Chapter 1 “General” regarding our genuine Sauer spare parts. – Compressed air vessels.fm J. – Sound-dampening enclosures. – Filters. 84 . including: – Fully automatic controls. WP400_BA_K1_12_en_08. If the data has not yet been entered.Spare Parts and Accessories Spare parts catalogue The spare parts catalogue is in the Appendix to this Operator Manual. print it out and send it in immediately. – The spare parts catalogue and Operator Manual are also available on CD-ROM. To do so. illustrations and lists. – The required parts can be quickly found with the help of diagrams. This makes it easy to fill out an order form. Compressor type: Factory no.: Year of construction: WP400_BA_K1_12_en_08. you need the main specification of your Sauer compressor from the table below.fm You should additionally indicate the number of operating hours. it can be found on the nameplate affixed to the crankcase. 85 . – Form for Return of Goods / Notification of Claim.12 Appendix WP400_BA_K1_12_en_08.fm This Appendix to the operating instructions contains – Form for commissioning certificate. – Data sheets. 86 . – Supplier documentation. 0 Fax: +49 .24159 Kiel. The maintenance instructions are available to the owner.431.fm Notes / Faults: The system has been accepted by the owner. The operating company has been advised to use only genuine SAUER & SOHN spare parts.Appendix Commissioning certificate for compressors J. Phone: +49 . WP400_BA_K1_12_en_08. SAUER & SOHN Maschinenbau GmbH Brauner Berg 15 .431.39 40 .89 E-mail:service@sauersohn. City: Purchaser Authorised Sauer Service Partner Owner Date: 87 . Operation hours Company/Name Company/Name Company/Name Company/Name Installation of compressor/complete system  Good Installation site  Faults Ventilation  Good  Faults Ambient conditions  Good  Faults Voltage?  Good  Faults Vibration behaviour of compressor  Good  Faults Accessories Compressed air vessels Refrigerant type dryers Adsorption dryers Filter Condensate removal Check of rotational direction Compression temperature Suction temperature Start/stop pressure Oil level check Control system check Test run °C °C Installation of complete system carried out by:  Good  Faults Operating personnel have received instruction and are familiar with the safety and maintenance requirements.P.39 40 .de Purchaser Company Street Postcode Contact Phone number Customer number Order number Compressor type Delivery date Date commissioned Sauer service engineer Owner Company Street Postcode Contact Phone number Serial no. : Date of fault: Ambient temperature: Quantity Part no.24159 Kiel.431. Reason for return Report on fault Repair Checking as customer service Goods taken back against credit note     88 Report WP400_BA_K1_12_en_08. Location Compressor type: End customer: Operation hours: Company Street Postcode/City Customer no.89 E-mail: service@sauersohn. SAUER & SOHN Return of goods Notification of claim Maschinenbau GmbH Brauner Berg 15 .  J.39 40 .de To be completed by manufacturer Date: Manufacturer: Please always complete: Company Street Postcode/City Customer no.39 40 .431.0 Fax: +49 . Location Spare parts Designation Serial no.fm To be completed by manufacturer only Short description of fault: . Germany Phone: +49 .P. section 8.5 Replace air filter cartridge.21 Check cooling water pump. gudgeon pins and gudgeon pin bearings.13 Renew flexible gear rim. gudgeon pins and gudgeon pin bearings.9 Replace 1st-stage valves.19 Replace zinc protection (freshwater operation). Beginning of this maintenance schedule Compressor type Type series ❑ after commissioning ❑ after last maintenance routine Compressor number: Date: Hours of operation: Year of construction: Date of commissioning: WP400_BA_K1_12_en_08. section 8.20 Replace bursting disc.18 Clean particle trap. section 8. section 8. section 8.6 Carry out oil change. section 8. section 8. section 8.fm 4000 h 069236 ❏ 3000 h ❏ ❏ ❏ 069234 ❏ 2000 h ❏ 069235 Check screwed connections.Appendix Maintenance Schedule No. section 8.12 Replace 2nd-stage piston rings.10 Replace 2nd-stage valves.10 Replace 1st-stage piston rings. section 8. section 8.16 Check condensate separator. section 8. section 8.8 Check 1st-stage valves. section 8.: 50 h after commissioning 50 h after last maintenance routine or repair At least annually at < 1000 h Interval [hours of operation] WP400 ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ Hours of operation Date Signature (initials) 89 . section 8. section 8. 069234 Maintenance work 2W Factory no.7 Clean oil strainer. section 8.12 Check piston and cylinder.17 Overhaul drain valves (as per order).22 1000 h Maintenance set item no. fm .90 WP400_BA_K1_12_en_08. S a u e r C o m p r e s s o r Type: WP 400 Spare parts catalogue . Edition: 03 / 2008 Edited by: J.fm .P. Sauer & Sohn Maschinenbau – Technical Documentation WP400_ET_Titel_en_08.fm WP400_ET_Titel_en_08. WP400_ET_en_08.fm WP400_ET_en_08.fm Spare parts catalogue . E-2 WP400_ET_en_08.fm . .................. 26 064 144 Connecting rod 2nd stage ..1 and 1........ 18 064 257 Dipstick ................fm 066 148 / 064 344 Compressor WP 400 Page E- Ref.................................................................................................... 54 063 543 Gear oil pump ..............................................2 . 28 064 261 Piston stage 1......................... 32 067 735 Cylinder stage 1..................................... 52 063 985 Lubricating oil supply ..2 .................. 66 063 950 Compressor monitor ... 38 067 737 Cylinder 2nd stage ............................................................................................................................. 48 063 121 Separator.................. 14 064 140 Crankcase ........................... 22 064 142 Crankshaft .................................... 44 063 869 Valve cover 2nd stage ................................1 and 1....... 50 064 147 Cooling water lines .........Spare parts catalogue WP400_ET_en_08.......................2 ... 24 063 864 Connecting rod stage 1..... 10 064 035 Compressor WP 400-100 ..............................................2.1..................................................... Assembly 066 148 Compressor WP 400 with cooling water pump..................................... 60 064 038 Compressor monitoring and control ..............................................1 and 1...........................................................................................................1 and 1......................................... 34 061 822 Zinc protection ... and 1.................................. 62 064 448 Protective device ............................................... 40 063 868 Valve cover stage 1............2............................................................................................................................................................. 56 057 916 Pressure relief valve .................................................................................................... 30 064 145 Piston 2nd stage.......................................................... 58 064 148 Crankcase vent ......................................................... 64 037 134 Concentric valve stage 1................ 46 064 146 Air lines................................... 68 064 018 Temperature monitoring.............. 6 064 344 Compressor WP 400 without cooling water pump............................................................................... No........................................... 70 E-3 .......... .......................................................................................................................... 74 038 238 Cooling water pump................fm Page E- Ref............................................... 88 Note: Erläuterungen der Baugruppen in Kapitel 3 „Aufbau und Funktion“ der Betriebsanleitung.................................. 82 066 595 Hose line....................... 78 064 366 Cooling water lines without pump ............................ E-4 WP400_ET_en_08........... 84 065 664 Non-return valve ... No..................... 72 066 143 Cooling water lines with pump . ....................................................Assembly 064 039 Automatic drainage system ........................ 80 064 151 Anti-vibration resilient mount ................................. 86 Flexible coupling .......................................... fm Spare parts catalogue E-5 .WP400_ET_en_08. 17.1 Stage 2 E-6 WP400_ET_en_08. 18 14 9. 12 3 15.066 148 Compressor WP 400 with cooling water pump 1.fm Stage 1. 16 8 Stage 1. 11.2 . fm 4 E-7 .Spare parts catalogue 066 148 Compressor WP 400 with cooling water pump 2 WP400_ET_en_08. fm 066 148 Compressor WP 400 with cooling water pump E-8 .WP400_ET_en_08. Spare parts catalogue 066 148 Compressor WP 400 with cooling water pump Ref.fm Item No. No. Designation Quantity 1 064 035 Compressor WP 400-100 1 2 063 950 Compressor monitor 1 3 064 039 Automatic drainage system 1 4 066 143 Cooling water lines with pump 1 8 063 800 Motor attachment rail 2 9 064 370 Spacer ring 1 11 037 057 Motor half coupling 1 12 033 423 Coupling flexible insert 1 14 037 067 AC motor 1 15 002 170 Washer 4 16 000 216 Hexagon head screw 4 17 036 960 Stud screw 8 18 001 621 Hexagon nut 8 WP400_ET_en_08. E-9 . fm Stage 1.10 WP400_ET_en_08. 16 8 Stage 1.2 .066 344 Compressor WP 400 without cooling water pump 1. 12 3 15. 11.1 Stage 2 E . 17. 18 14 9. 11 .Spare parts catalogue 066 344 Compressor WP 400 without cooling water pump 4 WP400_ET_en_08.fm 2 E . fm 066 344 Compressor WP 400 without cooling water pump E .12 .WP400_ET_en_08. No. E .fm Item No.13 .Spare parts catalogue 066 344 Compressor WP 400 without cooling water pump Ref. Designation Quantity 1 064 035 Compressor WP 400-100 1 2 063 950 Compressor monitor 1 3 064 039 Automatic drainage system 1 4 064 366 Cooling water lines (unit without pump) 1 8 063 800 Motor attachment rail 2 9 064 370 Spacer ring 1 11 037 057 Motor half coupling 1 12 033 423 Coupling flexible insert 1 14 037 067 AC motor 1 15 002 170 Washer 4 16 000 216 Hexagon head screw 4 17 036 960 Stud screw 8 18 001 621 Hexagon nut 8 WP400_ET_en_08. fm 1 E .064 035 Compressor WP 400-100 3 4 27 15 X 13 22 2 WP400_ET_en_08.14 . fm 17 E .1 Stage 2 9 10 24 23 7 6 5 8 WP400_ET_en_08.Spare parts catalogue 064 035 Compressor WP 400-100 5 7 23 9 Stage 1.2 Stage 1.15 . 1 Stage 2 11 31 WP400_ET_en_08.064 035 Compressor WP 400-100 26. 25 E .2 12 Stage 1. 30 X 14 Stage 1.16 .fm 19. 20. 2 2 6 064 145 Piston 2nd stage 1 7 067 735 Cylinder stage 1.Spare parts catalogue WP400_ET_en_08. Designation Quantity 1 064 140 Crankcase 1 2 064 142 Crankshaft 1 3 063 864 Connecting rod stage 1.2 2 24 036 959 Lamellar valve 2nd stage 1 25 000 494 Cap screw 4 26 005 546 Stud screw 2 27 000 543 Cap screw 10 30 037 225 Lifting eye bolt nut 2 31 004 411 Locking pin 4 E . Ref.1 and 1.1 and 1.2 2 10 063 869 Valve cover 2nd stage 1 11 064 146 Air lines 1 12 064 147 Cooling water lines 1 13 063 985 Lubricating oil supply 1 14 064 148 Crankcase vent 1 15 064 038 Compressor monitoring and control 1 17 064 448 Protective device 1 19 064 331 Blind flange 1 20 064 332 Gasket 1 22 036 333 Compressor half coupling 1 23 037 134 Concentric valve stage 1.1. No.1 and 1.2 2 8 067 737 Cylinder 2nd stage 1 9 063 868 Valve cover stage 1.17 . and 1.1 and 1.fm 064 035 Compressor WP 400-100 Item No.2 2 4 064 144 Connecting rod 2nd stage 1 5 064 261 Piston stage 1. 12 10 4 9 WP400_ET_en_08. 14 E .18 .064 140 Crankcase 7 16 15 11.fm 13. 12 11. 1 Stage 2 17 18 5 19 19 20 20 3 6 3 6 1 WP400_ET_en_08.2 Stage 1.19 .Spare parts catalogue 064 140 Crankcase 18 17 18 17 Stage 1.fm 2 E . 20 .WP400_ET_en_08.fm 064 140 Crankcase E . Spare parts catalogue 064 140 Crankcase Item No.21 .fm 1) Designation E . No. WP400_ET_en_08. 004 635 Insert fitting with Loctite 542. 1 063 786 Crankcase 1 2 064 394 Housing cover 1 3 051 883 Crankcase inspection cover 2 4 036 897 Oil strainer 1 5 064 257 Dipstick 1 6 063 748 Gasket 2 7 063 749 Gasket 1 9 030 743 Shaft seal 1 101) 004 635 Plug 1 11 000 971 Plug 2 12 005 001 O-ring 2 13 035 984 Drain cock 1 14 005 009 O-ring 1 15 038 102 Stud screw 6 16 001 620 Hexagon nut 6 17 036 960 Stud screw 12 18 001 621 Hexagon nut 12 19 001 408 Stud screw 16 20 002 031 Hexagon nut 16 Quantity Item 10. Ref. fm 1 E .22 .064 257 Dipstick 2 WP400_ET_en_08. fm Item No.Spare parts catalogue 064 257 Dipstick Ref. Designation Quantity 1 064 256 Dipstick 1 2 030 556 O-ring 1 WP400_ET_en_08. No.23 . E . 064 142 Crankshaft 8 Z 6 550 Nm 3 4 1 Z 2 WP400_ET_en_08.24 .fm 7 E . Spare parts catalogue 064 142 Crankshaft Ref.25 . No. E .fm Item No. Designation Quantity 1 064 143 Crankshaft 1 2 063 544 Driving disc 1 3 063 732 Washer 1 4 063 811 Flywheel 1 6 005 297 Hexagon head screw 1 7 033 994 Cap screw 2 8 036 961 Cylindrical roller bearing 2 WP400_ET_en_08. 26 .063 864 Connecting rod stage 1.fm 4 115 Nm E .2 3 1 2 WP400_ET_en_08.1 and 1. fm 1) Designation E .Spare parts catalogue 063 864 Connecting rod stage 1.1 and 1. 1 063 712 Connecting rod 1 2 061 857 Connecting rod bearing 1 3 035 823 Small-end bearing 1 41) 061 676 Connecting rod bolt 2 Quantity Item 4. Ref.27 . Connecting rod bolt 056 316 is part of assembly 063 712. WP400_ET_en_08. No.2 Item No. fm 4 115 Nm E .064 144 Connecting rod 2nd stage 2 1 3 WP400_ET_en_08.28 . Ref.Spare parts catalogue 064 144 Connecting rod 2nd stage Item No.29 . Connecting rod bolt 061 676is part of assembly 063 826. No. WP400_ET_en_08.fm 1) Designation E . 1 063 826 Connecting rod 1 2 037 058 Small-end bearing 1 3 061 857 Connecting rod bearing 1 41) 061 676 Connecting rod bolt 2 Quantity Item 4. fm 7 E .2 3 4 1 2 5 WP400_ET_en_08.1 and 1.064 261 Piston stage 1.30 . 1 and 1. 1 036 983 Piston 1 2 036 078 Gudgeon pin 1 3 002 716 Plain ring 2 4 035 962 Oil scraper ring 1 5 002 985 Circlip 2 71) 035 823 Small-end bearing 1 Quantity Item 7.31 .fm 1) Designation E . No.2 Item No. Small-end bearing 035 823 is part of assembly 063 864.Spare parts catalogue 064 261 Piston stage 1. Ref. WP400_ET_en_08. 32 .fm 7 E .064 145 Piston 2nd stage 3 4 5 1 2 6 WP400_ET_en_08. No.Spare parts catalogue 064 145 Piston 2nd stage Item No. Ref.33 . WP400_ET_en_08. Small-end bearing 037 058 is part of assembly 064 144.fm 1) Designation E . 1 063 815 Piston 1 2 064 150 Gudgeon pin 1 3 033 571 Plain ring 2 4 002 634 Nose ring 1 5 002 605 Oil scraper ring 1 6 012 682 Circlip 2 71) 037 058 Small-end bearing 1 Quantity Item 7. 23 7 E-F 15 5 13 16 A 18. 24 E .2 A-B 1 19.34 WP400_ET_en_08.1 and 1.067 735 Cylinder stage 1.fm B . 23 9 3 10 C E F 26 D 17. 2 22 14 C-D 8 4 12 2 23 WP400_ET_en_08.35 .1 and 1.fm 18.Spare parts catalogue 067 735 Cylinder stage 1. 24 E . fm 067 735 Cylinder stage 1.36 .2 E .1 and 1.WP400_ET_en_08. 1 and 1.Spare parts catalogue 067 735 Cylinder stage 1.37 .fm Item No. No. Designation Quantity 1 067 734 Cylinder housing 2nd stage 1 2 061 822 Zinc protection 1 3 067 738 Cooler insert 1st stage 1 4 063 660 Cylinder cover 1st stage 1 5 067 708 Cooler cover 1st stage 1 7 063 776 Liner 1 8 063 747 Gasket 1 9 067 739 Gasket 1 10 067 741 Gasket 1 12 000 497 Cap screw 6 13 000 475 Cap screw 2 14 001 533 Stud screw 6 15 000 509 Cap screw 9 16 000 519 Cap screw 2 17 000 977 Plug 1 18 001 016 Plug 3 19 035 390 Plug 1 22 001 621 Hexagon nut 6 23 005 023 O-ring 3 24 005 009 O-ring 3 26 036 962 O-ring 4 WP400_ET_en_08.2 Ref. E . 38 .fm 2 E .061 822 Zinc protection 3 1 WP400_ET_en_08. Spare parts catalogue 061 822 Zinc protection Item No. E .39 .fm 061 822 Zinc protection is ordered as a complete spare part. Designation Quantity 1 061 820 Plug 1 2 061 821 Zinc cartridge 1 3 001 463 Stud screw 1 WP400_ET_en_08. Ref. No. 067 737 Cylinder 2nd stage A-B 1 17 19 22. 12. 9 WP400_ET_en_08.fm 16 B . 23 11 C D 18 15 6 25 4 10 8 21. 23 14 3. 13 5.40 2. 23 C-D A E . 27 E .fm 26. 24 WP400_ET_en_08.41 .Spare parts catalogue 067 737 Cylinder 2nd stage 20. WP400_ET_en_08.42 .fm 067 737 Cylinder 2nd stage E . fm 067 737 Cylinder 2nd stage Item No. Ref.43 . No.Spare parts catalogue WP400_ET_en_08. Designation Quantity 1 067 718 Cylinder housing 2nd stage 1 2 061 822 Zinc protection 1 3 054 883 Protecting cap 1 4 067 715 Cooler insert 2nd stage 1 5 063 662 Cylinder cover 2nd stage 1 6 067 710 Cooler cover 2nd stage 1 8 063 808 Liner 1 9 063 747 Gasket 1 10 067 716 Gasket 1 11 067 717 Gasket 1 12 051 530 Gasket 1 13 051 531 Burst disc 1 14 000 505 Cap screw 4 15 000 554 Cap screw 11 16 000 497 Cap screw 6 17 001 533 Stud screw 4 18 000 509 Cap screw 3 19 001 621 Hexagon nut 4 20 001 016 Plug 1 21 000 977 Plug 1 22 035 390 Plug 1 23 005 023 O-ring 3 24 005 009 O-ring 1 25 030 131 O-ring 4 26 005 001 O-ring 1 27 000 971 Plug 1 E . 5 1 4 WP400_ET_en_08.44 .2 2.063 868 Valve cover stage 1.1 and 1.fm 3 E . WP400_ET_en_08.45 .2 Item No.fm 1) Designation E . 1 064 236 Valve cover 1 2 036 394 Dry air filter 1 3 037 151 O-ring 1 4 030 912 O-ring 1 51) 036 395 Filter insert 1 Quantity Item 5. Filter insert 036 395 is part of assembly 036 394.1 and 1. Ref.Spare parts catalogue 063 868 Valve cover stage 1. No. 3 1 4 WP400_ET_en_08.fm 5 E .46 .063 869 Valve cover 2nd stage 2. E .47 . Designation Quantity 1 063 743 Valve cover 1 2 036 964 Hexagon head screw 1 3 003 493 O-ring 1 4 036 963 O-ring 1 5 035 970 O-ring 1 WP400_ET_en_08. No.fm Item No.Spare parts catalogue 063 869 Valve cover 2nd stage Ref. fm 7. 6 10.064 146 Air lines 11. 16 9. 8 E . 15 1.48 . 15 13. 4. 14 2 WP400_ET_en_08. 16 12. 2 1 13 030 752 Safety valve 2nd stage 1 14 005 009 O-ring 1 15 005 016 O-ring 2 16 005 023 O-ring 2 WP400_ET_en_08.49 .fm Item No. E . Designation Quantity 1 067 729 Compressed air manifold 1 2 063 121 Separator 1 4 056 335 Gasket 3 6 000 054 Hexagon head screw 12 7 000 137 Hexagon head screw 2 8 002 151 Washer 2 9 036 157 Plug 1 10 006 193 Plug 1 11 005 946 Stub 1 12 030 751 Safety valve stage 1. No.Spare parts catalogue 064 146 Air lines Ref. 50 . 12 9 1 4 8 10 3 7 6 WP400_ET_en_08.063 121 Separator 2 11.fm Working pressure 80 bar Test pressure 160 bar E . Ref.Spare parts catalogue 063 121 Separator Item No.fm 1) Designation E .51 . No. 1 063 228 Separator housing 1 2 063 229 Separator head 1 3 062 328 Baffle cone 1 41) 060 342 Fusible plug 1 6 006 390 Reducing union 1 7 005 029 O-ring 1 8 005 009 O-ring 1 9 036 171 O-ring 1 10 036 041 Hexagon head screw 1 11 001 007 Plug 1 12 003 496 O-ring 1 Quantity 121°C / 250 °F WP400_ET_en_08. 9 10 1 Stage 1.52 .064 147 Cooling water lines 4 Stage 1.2 6.fm 2nd stage E . 9 1 WP400_ET_en_08.1 1 6. Inserted with seal tape. 11) 037 144 Angle piece 4 21) 037 265 Angle piece 1 41) 037 194 Extension piece 1 6 038 390 High pressure hose 2 92) 004 661 Plug 4 101) 036 967 Pipe fitting 1 111) 034 875 T-joint 1 121) 037 305 Pipe reducing adaptor 1 1) Quantity Inserted with hemp. WP400_ET_en_08. Ref.53 .Spare parts catalogue 064 147 Cooling water lines Item No. No.fm 2) Designation E . 063 985 Lubricatin oil supply 1 8 2 WP400_ET_en_08.fm 7 E .54 . 55 . No.Spare parts catalogue 063 985 Lubricatin oil supply Ref.fm Item No. Designation Quantity 1 063 543 Gear oil pump 1 2 057 916 Pressure relief valve 1 7 003 438 O-ring 1 8 000 456 Cap screw 4 WP400_ET_en_08. E . 063 543 Gear oil pump 7 8 3 2 1.fm 6 E .56 . 5 WP400_ET_en_08. No.fm Item No.57 .Spare parts catalogue 063 543 Gear oil pump Ref. Designation Quantity 1 036 767 Oil pump gear wheel 1 2 036 360 Oil pump housing 1 3 056 318 Gasket 1 5 036 359 Gear wheel 1 6 033 212 Oil pump cover 1 7 036 363 Gasket 1 8 030 544 Gasket 1 WP400_ET_en_08. E . 58 .057 916 Pressure relief valve 5 WP400_ET_en_08.fm 3 E . No. E . Designation Quantity 3 054 164 Spring 1 5 002 962 Circlip 1 WP400_ET_en_08.fm Item No.59 .Spare parts catalogue 057 916 Pressure relief valve Ref. 7 4 Stage 1. 6. 7 12 5.064 148 Crankcase vent 5.60 .1 E . 10 2nd stage WP400_ET_en_08. 8 2 11 3 5. 6. 6.fm Stage 1.2 1 14 9. 11) 038 407 Pipe nipple joint 1 21) 038 268 T reducer 1 3 033 087 Reducing union 1 4 034 612 Low-pressure hose 1 5 035 254 Worm drive hose clip 4 6 037 139 Hose sleeve 4 72) 037 140 Angle piece 2 82) 037 185 T-joint 1 91) 037 144 Angle piece 1 101) 037 194 Extension piece 1 11 035 824 Filling cover 1 12 037 264 Low-pressure hose 1 14 033 952 Insulation hose 1 1) Quantity Inserted with hemp and Fermit sealing cement.fm 2) Designation E .61 . WP400_ET_en_08. Ref. Inserted with seal tape. No.Spare parts catalogue 064 148 Crankcase vent Item No. 2 3. 7 Stage 1.1 8. 9 6. 3. 14 E . 7 Stage 1. 7 Stage 2 WP400_ET_en_08.064 038 Compressor monitoring and control 1.fm 2. 12 10 6. 3.62 . 13 6. E .Spare parts catalogue 064 038 Compressor monitoring and control Ref.63 . No. Designation Quantity 1 035 009 Pressure gauge oil 1 2 030 664 Pressure gauge 2nd stage 1 3 035 061 O-ring 4 6 038 941 Thermometer compressed air 3 7 005 009 O-ring 3 8 005 016 O-ring 1 9 035 906 Socket fitting 1 10 030 182 Cooling water thermometer 1 12 030 509 Plug 1 13 038 288 Pressure gauge 1st stage 1 14 065 352 Double ended stud end 1 WP400_ET_en_08.fm Item No. 4.064 448 Protective device 1 WP400_ET_en_08.fm 3.64 . 5 E . Spare parts catalogue 064 448 Protective device Ref.65 . E . Designation Quantity 1 064 449 Guard plate 1 2 001 408 Stud screw 2 3 002 031 Hexagon nut 2 6 002 156 Washer 2 WP400_ET_en_08.fm Item No. No. 66 .2 4 3 5 2 1 WP400_ET_en_08.037 134 Concentric valve stage 1. and 1.fm 6 E .1. 67 .fm Item No. E . Designation Quantity 1 037 187 Suction valve plate 1 2 037 188 Delivery valve plate 1 3 037 189 Delivery valve plate 1 4 037 190 Delivery valve spring 2 5 037 191 Delivery valve spring 2 6 037 192 Suction valve spring 2 WP400_ET_en_08.1. No.Spare parts catalogue 037 134 Concentric valve stage 1.2 Ref. and 1. 4 E .063 950 Compressor monitor 1 5.fm 3.68 . 6 5. 8 WP400_ET_en_08. Designation Quantity 1 064 018 Temperature monitoring 1 3 030 082 Low oil pressure switch 1 4 000 409 Cap screw 2 5 004 596 Plug 2 6 033 017 Reducing union 1 8 008 633 Pipe 1 WP400_ET_en_08.Spare parts catalogue 063 950 Compressor monitor Ref. No.69 . E .fm Item No. 70 .fm 1 E . 4 WP400_ET_en_08.064 018 Temperature monitoring 2. Designation Quantity 1 035 468 High air temperature switch 1 2 000 410 Cap screw 2 4 002 144 Washer 2 WP400_ET_en_08.Spare parts catalogue 064 018 Temperature monitoring Ref. E . No.fm Item No.71 . 064 039 Automatic drainage system 6 12 Z 1. 7. 11 Z 4 5 7 13 E . 9 10 3.fm 4 .72 WP400_ET_en_08. 8 2. fm 2) Designation E . 1 049 129 Pipe clamp 1 2 033 961 Stub 1 3 006 187 Plug 1 4 004 647 Plug 2 5 005 964 Plug 1 6 004 973 Plug 1 71) 036 6542) Solenoid valve 2 8 000 434 Cap screw 2 9 005 009 O-ring 2 10 006 000 Plug 1 11 006 455 Stub 1 12 008 663 Pipe 1 13 008 672 Pipe 1 1) Quantity Specify voltage and frequency for order! The order number for the solenoid valve is order-specific.73 . Ref. WP400_ET_en_08.Spare parts catalogue 064 039 Automatic drainage system Item No. No. 18. 27. 9. 36.066 143 Cooling water lines with pump 19 31 15 21 17 4. 35.fm 6. 29 10 4. 8. 38 33. 14 1 E . 28. 30 26 34.74 . 9. 37 WP400_ET_en_08. 75 .fm 5 E .Spare parts catalogue 066 143 Cooling water lines with pump 40 16 22 32 23 3 17 2. 7 25 41 20 13 WP400_ET_en_08. 76 Designation Quantity WP400_ET_en_08. No. two-part 1 27 037 293 Flange 1 281) 036 614 Threaded flange 1 29 030 658 Gasket 1 30 037 441 Gasket 1 E . 1 066 442 Support plate 1 2 066 145 Attachment rail 2 3 066 144 Angle steel bar 1 4 005 265 Hexagon head screw 8 5 005 265 Hexagon head screw 4 6 005 265 Hexagon head screw 2 7 000 594 Cap screw 2 8 001 620 Hexagon nut 2 9 002 051 Hexagon nut 8 101) 038 201 Reducing union 1 132) 032 725 Pipe adaptor 1 14 002 161 Washer 1 151) 037 267 Reducing nipple 1 161) 037 144 Pipe bend 2 171) 037 265 Pipe bend 2 18 002 166 Washer 4 191) 036 967 Pipe fitting 1 202) 032 679 Particle trap 1 213) 037 1504) Solenoid valve 22 064 396 Sliding socket 1 23 038 238 Cooling water pump 1 25 038 386 High pressure hose 1 265) 037 493 Clamp. .066 143 Cooling water lines with pump Ref.fm Item No. Spare parts catalogue Item No. Ref. No. Designation Quantity 311) 037 930 Pipe adaptor 1 321) 037 305 Pipe reducing adaptor 1 33 000 119 Hexagon head screw 2 34 000 048 Hexagon head screw 2 35 002 153 Washer 4 36 002 156 Washer 8 37 002 025 Hexagon nut 2 38 002 031 Hexagon nut 6 401) 037 851 Plug 1 411) 004 666 Plug 1 1) Fitting with cylindrical threading is sealed with seal tape. Fitting with conical threading is sealed with hemp and Fermit sealing cement. 3) Specify voltage and frequency for solenoid valve order! 4) The order number for the solenoid valve is order-specific. 5) Item 26, 037 493 Clamp installed without rubber insert. WP400_ET_en_08.fm 2) E - 77 038 238 Cooling water pump 1, 2, 3 DN 40 DN 32 X X Motor terminal box WP400_ET_en_08.fm Cabe entry E - 78 Spare parts catalogue 038 238 Cooling water pump Item No. Ref. No. 1 1) Designation Quantity Cooling water pump 1 2 038 290 Gasket kit 1 31) 038 257 Repair kit 1 Repair kit 038 257 can be supplied. Technical specification Pump: Max. working pressure: 10 bar Pump capacity: 67 l/min against 19 m water column 100 l/min against 18 m water column Medium: fresh water Max. working pressure: 55 °C AC motor1) : Capacity: 1.1 kW, IP 55 Voltage and frequency: 400/440 V, 50/60 Hz Max. ambient temperature: 55 °C Also available to customer-specific specifications upon request. WP400_ET_en_08.fm 1) E - 79 064 366 Cooling water lines without pump 5 3 2 3 6 8 7 4 WP400_ET_en_08.fm 1 E - 80 Ref.81 .fm 2) E . 3) Screw into place sealed with hemp and Fermit sealing cement and rotate into correct position. No. 3) 037 1422) 23) Designation Quantity Solenoid valve 1 032 679 Particle trap 1 33) 032 725 Pipe adaptor 2 43) 037 930 Pipe adaptor 1 53) 037 265 Pipe bend 1 63) 037 266 Socket 1 73) 036 967 Pipe fitting 1 8 037 267 Reducing nipple 1 1) Specify voltage and frequency for solenoid valve order! The order number for the solenoid valve is order-specific. 11). WP400_ET_en_08.Spare parts catalogue 064 366 Cooling water lines without pump Item No. 064 151 Anti-vibration resilient mount 1 9 1) 1 5 10 4 2 6 8 3 Type with cooling water pump: installation of hose line on the pump intake fittings WP400_ET_en_08.fm 1) E .82 . 83 .fm Item No. E .Spare parts catalogue 064 151 Anti-vibration resilient mount Ref. Designation Quantity 1 066 595 Hose line 2 2 033 531 Countersunk screw 8 3 000 589 Cap screw 8 4 046 837 Anti-vibration resilient mount 8 5 034 763 High pressure hose 1 6 035 942 High pressure hose 2 8 004 701 Plug 2 9 065 664 Non-return valve 1 10 063 947 Rail 2 WP400_ET_en_08. No. 066 595 Hose line 1 2 WP400_ET_en_08.fm 2 E .84 . Spare parts catalogue 066 595 Hose line Ref. No.fm Item No. E .85 . Designation Quantity 1 038 389 High pressure hose 1 2 004 666 Plug 2 WP400_ET_en_08. fm 3 E .86 .28 35 065 664 Non-return valve 1 2 WP400_ET_en_08. fm Item No. Designation Quantity 1 037 883 Non-return valve 1 2 004 661 Plug 1 3 037 851 Plug 1 WP400_ET_en_08. E . No.Spare parts catalogue 065 664 Non-return valve Ref.87 . fm Compressor 2 E .Flexible coupling 3 1 Motor WP400_ET_en_08.88 . 3) Item 3.Spare parts catalogue Flexible coupling Item No. No.fm 2) E . Ref. Item 2.89 . Designation Quantity 11) 036 333 Compressor half coupling 1 22) 037 057 Motor half coupling 1 33) 033 423 Coupling flexible insert 1 1) Item 1. Compressor half coupling 036 333 is part of assembly 064 035. Motor half coupling 037 057 is part of assembly 066 148. WP400_ET_en_08. Coupling flexible insert 033 423 is part of assembly 066 148. 90 WP400_ET_en_08.fm .E . .. 064 344 11 4 000 434 Cap screw .................................. 066 143 75 7 035 823 Small-end bearing ............................................................. 063 985 54 8 000 475 Cap screw ............. 067 735 34 15 000 509 Cap screw ........... 064 035 16 25 000 497 Cap screw ..............................................fm Parts List by Ref.................... Assembly Page E- Ref........................................................... 067 735 34 13 000 494 Cap screw ................ No............................................................... 064 140 18 11 000 971 Plug ........................................ 067 737 40 16 000 505 Cap screw ........... 067 735 34 17 E ........... 067 737 40 18 000 519 Cap screw ..................................................................................... Designation Item 000 048 Hexagon head screw ........................................................... 063 864 30 7 000 971 Plug .... No................. 064 151 82 3 000 594 Cap screw ..................... 067 737 41 27 000 977 Plug ...............................................................................Index WP400_ET_Index_en_08........................ 067 735 35 12 000 497 Cap screw ................................. 064 039 72 8 000 456 Cap screw . 063 950 68 4 000 410 Cap screw ................. 067 737 40 14 000 509 Cap screw ......................................................... 064 035 15 27 000 554 Cap screw ........................................... 067 737 40 15 000 589 Cap screw ................ 064 146 48 6 000 119 Hexagon head screw .......................................................... 066 143 74 34 000 054 Hexagon head screw ................ 064 018 70 2 064 366 Cooling water lines without pump ........................... 066 148 6 16 000 409 Cap screw ................................................ 064 344 10 16 000 216 Hexagon head screw ................... 066 143 74 33 000 137 Hexagon head screw ........... 067 735 34 16 000 543 Cap screw .91 ............... 064 146 48 7 000 216 Hexagon head screw ........................................................................................... .................................................................... 066 143 74 35 002 156 Washer ............................................................................................................fm Designation E ......................... 064 018 70 4 002 151 Washer ........... 35 18 001 016 Plug ..... 066 148 6 18 001 621 Hexagon nut ....................................................................................................................................................... 067 737 41 20 001 408 Stud screw ................... 067 735 34............... 061 822 38 3 001 533 Stud screw ... .................................................. 064 140 19 20 002 031 Hexagon nut ............ 066 143 74 18 002 170 Washer ............................................. 063 121 50 11 001 016 Plug ..... 064 146 48 8 002 153 Washer ....................................Item 000 977 Plug .................................... No.................. 066 143 74 8 001 621 Hexagon nut ........................... 064 448 64 6 002 156 Washer .................................. 064 344 10 18 001 621 Hexagon nut ................................................................................................ 064 448 64 2 001 463 Stud screw ............... 067 735 35 14 001 533 Stud screw ................................................................................ 066 143 76 9 002 144 Washer .......................... 067 737 40 21 001 007 Plug ................................................................................................... 064 140 19 19 001 408 Stud screw ............ 064 140 18 16 001 620 Hexagon nut ............................. 067 737 40 17 001 620 Hexagon nut .......................................................... 066 143 74 38 002 051 Hexagon nut .................................................. 067 735 35 22 001 621 Hexagon nut ..................... 064 344 10 15 WP400_ET_Index_en_08................... 066 143 74 14 002 166 Washer ..................... 064 448 64 3 002 031 Hexagon nut ........................... 066 143 74 37 002 031 Hexagon nut ...................92 Assembly Page E- Ref.......................................... 067 737 40 19 002 025 Hexagon nut ...................................................... 064 140 19 18 001 621 Hexagon nut .......... 066 143 74 36 002 161 Washer ...................................... .................................... 064 035 16 31 004 596 Plug .................................................................................................................................. 064 261 30 3 002 962 Circlip .............................................................. 064 039 72 9 005 009 Gasket ... 063 950 68 5 004 635 Plug ..................................... 063 121 50 12 004 411 Locking pin ............................................................. 064 140 18 12 005 001 Gasket ......................... 064 147 52 9 004 661 Plug ...... 064 140 18 10 004 647 Plug ................................................... 064 039 72 6 005 001 Gasket ....................................................................................................................................................... 067 735 34.................................................. 064 146 48 14 005 009 Gasket ..... 066 143 75 41 004 666 Plug ................................................WP400_ET_Index_en_08.......................................................... Designation Item 002 170 Washer .... 064 140 18 14 005 009 Gasket .. 066 148 6 15 002 605 Oil scraper ring ..................... 064 038 62 7 005 009 Gasket . 064 145 32 4 002 716 Plain ring ............................... 066 595 84 2 004 701 Plug ............................................................. 064 261 30 5 003 438 Gasket ..... 063 869 46 3 003 496 Gasket ................................................... 35 24 005 009 Gasket ............................................................ 063 121 50 8 005 009 Gasket .................................................. 067 737 41 24 005 016 Gasket ............................................. 067 737 41 26 005 009 Gasket ......................................................................... 064 038 62 8 E ............................................ 065 664 86 2 004 666 Plug ........................................ No............93 ....................................................................fm Index Assembly Page E- Ref................. 057 916 58 5 002 985 Circlip ............................................................................................. 064 145 32 5 002 634 Nose ring ......... 063 985 54 7 003 493 Gasket ........ 064 039 72 4 004 661 Plug ......................................................................... 064 151 82 8 004 973 Plug ................................ ................. 064 146 48 11 005 964 Plug ........................................... 064 146 48 16 005 023 Gasket .................................... 067 737 40 23 005 029 Gasket ... 064 035 16 26 005 946 Stub .... 064 039 72 5 006 000 Plug ................. 063 121 50 7 005 265 Hexagon head screw . 063 950 68 3 030 131 O-ring ....................................................................... 064 142 24 6 005 546 Stud screw ...... 064 146 48 10 006 390 Reducing union .............................................................................................................................................................. 066 143 74 4 005 265 Hexagon head screw ................. 064 038 62 2 WP400_ET_Index_en_08........................................................... 35 23 005 023 Gasket .................................................. No........................................................ 064 146 48 15 005 023 Gasket ...................................................................... 064 039 72 10 006 187 Plug .........Item 005 016 Gasket .... 064 039 72 3 006 193 Plug ..................................................................... 063 543 56 8 030 556 O-ring .. ............................. 064 038 62 10 030 509 Plug ............................................................................................... 066 143 74 29 030 664 Pressure gauge 2nd stage .................................. 067 737 40 25 030 182 Cooling water thermometer .............................. 064 145 32 6 030 082 Low oil pressure switch ................. 064 039 72 11 008 633 Pipe ......fm Designation E .................................... 063 121 50 6 006 455 Stub ...................................................... 066 143 75 5 005 265 Hexagon head screw ........................................ 064 257 22 2 030 658 Gasket ............ 063 950 68 8 008 663 Pipe ...................................... 064 039 72 13 012 982 Circlip .............................. 064 038 62 12 030 544 Gasket ............................................................... 064 039 72 12 008 672 Pipe ............................. 067 735 34..............................................................................................94 Assembly Page E- Ref........................................ 066 143 74 6 005 297 Hexagon head screw ..................... .............................................. 064 344 10 12 033 423 Coupling flexible insert / elastic coupling insert ............. 064 038 62 1 035 061 Gasket .............. 064 148 60 4 034 763 High pressure hose .... 066 143 75 20 032 725 Pipe adaptor ............................................................................. 063 868 44 4 032 679 Particle trap ........ 066 143 75 13 033 017 Reducing union ............ 064 151 82 5 034 875 T-joint ...... Designation Item 030 743 Shaft seal .................................................. 066 148 88 3 033 423 Coupling flexible insert / elastic coupling insert .......................WP400_ET_Index_en_08... 064 145 32 3 033 952 Insulation hose ............................................... 064 366 80 2 032 679 Particle trap ................................... 064 148 60 5 035 390 Plug ........................... 067 735 34 19 035 390 Plug ......................................................................................................................fm Index Assembly Page E- Ref......................................................... 063 543 56 6 033 423 Coupling flexible insert ......................................... 064 140 18 9 030 751 Safety valve stage 1................. No............................................................ 067 737 40 22 035 468 High air temperature switch ............... 064 151 82 2 033 571 Plain ring ..................................................... 064 147 52 11 035 009 Pressure gauge oil ................. 064 366 80 3 032 725 Pipe adaptor ....... 064 146 48 12 030 752 Safety valve 2nd stage .......................... 064 038 62 3 035 254 Worm drive hose clip ................................................................. 064 148 60 3 033 212 Oil pump cover ........................................... 064 142 24 7 034 612 Low-pressure hose ........................................................................... 063 950 68 6 033 087 Reducing union . 064 039 72 2 033 994 Cap screw ................................................................................. 066 148 6 12 033 531 Countersunk screw ................ 064 146 48 13 030 912 O-ring ...................... 064 148 60 14 033 961 Stub ....................................95 ........2 .......................................... 064 018 70 1 E .... ......................... 064 261 30 4 035 970 O-ring ..... 064 142 24 8 036 962 O-ring ................. 063 868 44 2 036 395 Filter insert ........................................ 066 143 74 28 036 654 Solenoid valve ................ 064 151 82 6 035 962 Oil scraper ring ..................... No................................................................................................................................. 064 140 18 4 036 959 Lamellar valve 2nd stage ....................... 063 869 46 5 035 984 Drain cock ................................................................................. 063 869 46 4 WP400_ET_Index_en_08....................................... 063 543 56 7 036 394 Dry air filter ......................... 064 140 18 13 036 041 Hexagon head screw ..................................... 064 038 62 9 035 942 High pressure hose ................ 036 394 44 5 036 614 Threaded flange ...............................................................Item 035 823 Small-end bearing ... 063 543 56 5 036 360 Oil pump housing ........................................................................................... 063 543 56 2 036 363 Gasket ........................................................ 063 121 50 10 036 078 Gudgeon pin ............................. 064 035 15 22 036 333 Compressor half coupling .... 064 035 15 24 036 960 Stud screw ...... 064 146 48 9 036 171 O-ring ............96 Assembly Page E- Ref........... 064 039 72 7 036 767 Oil pump gear wheel ..................................................fm Designation E ................... 064 261 30 2 036 157 Plug .................................................................................... 064 148 60 11 035 906 Socket fitting .... 066 148 6 17 036 961 Cylindrical roller bearing ............ 067 735 34 26 036 963 O-ring ........................ ...... 063 543 56 1 036 897 Oil strainer ...... 064 344 10 17 036 960 Stud screw ...................................................................... 063 864 26 3 035 824 Filling cover ........................................................................................................................... 064 035 88 1 036 359 Gear wheel ......................... 063 121 50 9 036 333 Compressor half coupling .. 064 140 19 17 036 960 Stud screw .................. ................................ 064 144 28 2 037 058 Small-end bearing ...... 064 148 60 6 037 140 Angle piece ............................................................. 064 261 30 1 037 057 Motor half coupling .................................................................................................................................................................. 064 035 88 2 037 057 Motor half coupling ....................................................... 064 148 60 8 037 187 Suction valve plate ............. 066 148 6 11 037 058 Small-end bearing .................................fm Index Assembly Page E- Ref..................1.......................... 037 134 66 1 037 188 Delivery valve plate .....................2 ........................ 037 134 66 4 037 191 Delivery valve spring .... 064 035 15 23 037 139 Hose sleeve ............... No..... 063 868 44 3 037 185 T-joint ... 064 147 52 1 037 144 Angle piece .................. 064 366 80 1 037 144 Angle piece ................................ 064 148 60 9 037 144 Pipe bend ...... 064 344 10 14 037 067 AC motor ................................... 066 143 75 16 037 150 Solenoid valve ................................. 064 147 52 4 Item E .............. 064 144 32 7 037 067 AC motor . 037 134 66 2 037 189 Delivery valve plate ....WP400_ET_Index_en_08.......................................... Designation 036 964 Hexagon head screw ...................... 064 148 60 7 037 142 Solenoid valve ............... 037 134 66 3 037 190 Delivery valve spring ... 066 148 6 14 037 134 Concentric valve stage 1...................................................... 064 344 10 11 037 057 Motor half coupling ................................................................................. 063 869 46 2 036 967 Pipe fitting ...............97 ............................................................................ and 1................................. 066 143 74 21 037 151 O-ring ........ 037 134 66 5 037 192 Suction valve spring ...... 064 366 80 7 036 967 Pipe fitting ........................ 064 147 52 10 036 967 Pipe fitting ..................................................................................................... 066 143 74 19 036 983 Piston ....................... 037 134 66 6 037 194 Extension piece ........ ........................................................................ 066 143 74....... ..................................... 064 366 80 4 037 930 Pipe adaptor ........................................ 064 148 60 12 037 265 Angle piece .. 064 038 62 13 038 290 Gasket kit ..................................... 065 664 86 1 037 930 Pipe adaptor ............... 064 148 60 2 038 288 Pressure gauge 1st stage ............................................... 064 035 16 30 037 264 Low-pressure hose ...... 066 143 74 27 037 305 Pipe reducing adaptor ..................................... 066 143 74 10 038 238 Cooler water pump ..... 066 143 74 26 037 851 Plug .................. 064 366 80 6 037 267 Reducing nipple .. 065 664 86 3 037 851 Plug ..................................................... 064 366 80 8 037 267 Reducing nipple .......... 066 143 75 23 038 257 Repair kit ..................... 066 143 75 32 037 441 Gasket ................... 066 595 84 1 038 390 High pressure hose ..............fm Designation E ................................................................................................. 064 147 52 2 037 265 Pipe bend ............. 064 366 80 5 037 265 Pipe bend ................................................... 064 147 52 6 WP400_ET_Index_en_08............ 066 143 74 31 038 102 Stud screw .............. 066 143 75 25 038 389 High pressure hose .................................................................................Item 037 194 Extension piece ............................ two-part ............................................................................................................ 066 143 74 30 037 493 Clamp.... 066 143 74 15 037 293 Flange ...98 Assembly Page E- Ref............................................... 75 17 037 266 Socket . No........................................................................................... 064 140 18 15 038 201 Reducing union ....................... 066 143 75 40 037 883 Non-return valve ................................................... 064 147 52 12 037 305 Pipe reducing adaptor ............................. 064 148 60 10 037 225 Lifting eye bolt nut ......................................................... 038 238 78 3 038 268 T reducer ......................... 038 238 78 2 038 386 High pressure hose ............ ............ 061 822 38 1 061 821 Zinc cartridge ........................ 063 121 50 1 063 229 Separator head . 063 121 50 4 061 820 Plug ............. 064 148 60 1 038 941 Thermometer compressed air ............... 064 039 72 1 051 530 Gasket ......................................................................................................................................... 067 737 40 2 061 857 Connecting rod bearing .... 067 737 40 12 051 531 Burst disc .... 064 151 82 4 049 129 Pipe clamp ...................................................................... 063 864 26 2 061 857 Connecting rod bearing ........................................................................... 067 737 40 5 063 712 Connecting rod ......... No...................... Designation 038 407 Pipe nipple joint .......................................................................... 064 144 28 3 062 328 Baffle cone .......................... 064 038 62 6 046 837 Anti-vibration resilient mount .99 ................................... 067 737 40 3 056 318 Gasket ........................ 063 985 54 2 060 342 Fusible plug ......................... 063 985 54 1 063 544 Driving disc ....................fm Index Assembly Page E- Ref................................................................................ 064 142 24 3 Item E ................................ 064 140 19 3 054 164 Spring ................................................... 063 543 56 3 056 335 Gasket ......................... 067 735 35 2 061 822 Zinc protection ............................ 064 142 24 2 063 660 Cylinder cover ........................ 063 121 50 2 063 543 Gear oil pump ......................WP400_ET_Index_en_08.............................................. 067 735 35 4 063 662 Cylinder cover 2nd stage ......... 057 916 58 3 054 883 Protecting cap .............................................................................. 063 864 26 1 063 732 Washer ..... 061 822 38 2 061 822 Zinc protection .......................................................... 063 121 50 3 063 121 Separator .............................................. 064 146 48 4 057 916 Pressure relief valve ............. 067 737 40 13 051 883 Crankcase inspection cover ........... 064 146 48 2 063 228 Separator housing .................... ...........100 Assembly Page E- Ref........................................................................... 064 142 24 1 WP400_ET_Index_en_08.............. No................................ 064 151 82 10 063 950 Compressor monitoring ........................ 064 344 10 1 064 035 Compressor WP 400-100 ..................1 and 1............................ ..... 067 735 34 7 063 786 Crankcase .............. 064 035 15 9 063 869 Valve cover 2nd stage ....... 063 869 46 1 063 747 Gasket .....................fm Designation E ............................................ 064 035 15 10 063 947 Rail ........................................................................... 063 950 68 1 064 035 Compressor WP 400-100 ................................... 064 140 18 7 063 776 Liner ............................................................................................... 066 148 7 2 063 985 Lubricating oil supply .................................................................................... 064 035 15 13 064 018 Temperature monitoring ..................................... 064 344 10 8 063 800 Motor attachment rail ........................... 064 344 11 2 063 950 Compressor monitoring ............ 064 140 19 1 063 800 Motor attachment rail ............ 067 735 35 8 063 747 Gasket ...........................................2 .............Item 063 743 Valve cover .............2 .................................. 064 035 15 2 064 143 Crankshaft ........... 064 144 28 1 063 864 Connecting rod stage 1..................... 064 035 15 3 063 868 Valve cover stage 1.................................... 067 737 40 8 063 811 Flywheel ............ 066 148 6 3 064 140 Crankcase ............................... 067 737 40 9 063 748 Gasket ........................... 064 035 15 1 064 142 Crankshaft ......... 064 140 19 6 063 749 Gasket .... 064 344 10 3 064 039 Automatic drainage system ...................... 066 148 6 8 063 808 Liner .........................................1 and 1........................... 064 145 32 1 063 826 Connecting rod ..... 066 148 6 1 064 038 Compressor monitoring and control .... 064 142 24 4 063 815 Piston ............................................ 064 035 15 15 064 039 Automatic drainage system . ........................................... 066 143 74 1 066 595 Hose line .......................... 067 737 40 10 E .......................................... 064 140 19 2 064 396 Sliding socket ..... 066 143 75 22 064 448 Protective device ......... 064 035 16 14 064 150 Gudgeon pin . 066 143 75 3 066 145 Attachment rail ......fm Index Assembly Page E- Ref................. 064 035 16 20 064 370 Spacer ring .................... 064 140 19 5 064 261 Piston stage 1........... 067 737 40 4 067 716 Gasket .......1 and 1...................... 066 148 6 9 064 394 Housing cover ............................................................................................. 066 148 7 4 066 144 Angle steel bar ............ 064 035 15 5 064 331 Blind flange ........................................ 066 143 75 2 066 442 Support plate ............... 064 035 16 19 064 332 Gasket ............ 067 735 34 5 067 710 Cooler cover 2nd stage ...................................................................................................... 064 035 16 12 064 148 Crankcase vent .......... 064 035 16 11 064 147 Cooler water lines ....... No.......................... 067 737 40 6 067 715 Cooler insert 2nd stage ............... 064 151 82 1 067 708 Cooler cover ................................................................ 064 257 22 1 064 257 Dipstick ..................... 064 344 10 9 064 370 Spacer ring .......................... 064 151 82 9 066 143 Cooling water lines with pump ........ 064 035 15 4 064 145 Piston .....................2 .............................. Designation Item 064 144 Connecting rod 2nd stage .................................................... 064 035 15 6 064 146 Air lines .......................... 064 145 32 2 064 236 Valve cover ............................................................................................... 064 038 62 14 065 664 Non-return valve .............................................................................................. 064 035 15 17 064 449 Guard plate ........................................... 063 868 44 1 064 256 Dipstick ........................................... 064 448 64 1 065 352 Double ended stud end ...................101 ...................................WP400_ET_Index_en_08.................................... .............fm Assembly Page E- Ref...... 064 146 48 1 067 734 Cylinder housing .............. 038 238 78 1 WP400_ET_Index_en_08......................... 067 735 34 1 067 735 Cylinder stage 1..................... 067 735 34 9 067 741 Gasket ............ 064 035 15 7 067 737 Cylinder 2nd stage .... E ....................... 067 737 40 1 067 729 Compressed air manifold .................102 ...................... 067 737 40 11 067 718 Cylinder housing 2nd stage ............................................................................... 064 035 15 8 067 738 Cooler insert .... No..2 ..............Designation Item 067 717 Gasket .......1 and 1................................... 067 735 34 10 Cooler water pump ........................................................ 067 735 34 3 067 739 Gasket ................... ............. 064 018 70 2 000 434 Cap screw ............. 066 148 6 14 064 146 Air lines ......... 064 035 16 25 000 497 Cap screw ...............................................Index WP400_ET_Index_en_08.. No.................................................................... 064 344 10 14 037 067 AC motor ...................... 067 737 40 14 000 509 Cap screw .............103 .................................................. 064 035 16 11 037 140 Angle piece ...... Assembly Page E- Ref................................. 067 735 34 15 000 509 Cap screw .............fm Parts List by Ref............................................ 063 985 54 8 000 475 Cap screw .............................................................................. 067 737 40 13 000 409 Cap screw ....... 064 151 82 4 066 145 Attachment rail ........................... 064 147 52 1 037 144 Angle piece .. 063 121 50 3 064 331 Blind flange ..... 063 950 68 4 000 410 Cap screw .... 064 148 60 7 037 144 Angle piece ............................................................ 064 148 60 9 037 265 Angle piece ......................... 067 735 35 12 000 497 Cap screw .......... 067 735 34 13 000 494 Cap screw ................................................ 066 143 75 2 064 039 Automatic drainage system .. 066 143 75 3 046 837 Anti-vibration resilient mount . 067 737 40 18 000 519 Cap screw ................................... 064 147 52 2 066 144 Angle steel bar ................................................................................... Designation Item 037 067 AC motor ........... 064 035 16 19 051 531 Burst disc ................................................................................................... 064 344 10 3 064 039 Automatic drainage system ......................................................... No.................... 067 737 40 16 000 505 Cap screw ....................................................... 067 735 34 16 E ...................................................................................................................................................................... 066 148 6 3 062 328 Baffle cone ........................ 064 039 72 8 000 456 Cap screw . ...................................1.....................1 and 1............................................................. 066 143 74 26 067 729 Compressed air manifold ......................... 064 035 15 23 063 712 Connecting rod .........fm Designation E ............................................................................ 066 143 75 7 033 994 Cap screw .................................... 067 737 40 15 000 589 Cap screw ...................................................... 057 916 58 5 002 985 Circlip ........................ 064 035 15 27 000 554 Cap screw ............... 064 344 11 2 063 950 Compressor monitoring ................................................ 066 148 6 1 037 134 Concentric valve stage 1......................... 064 344 10 1 064 035 Compressor WP 400-100 .... 063 864 26 1 063 826 Connecting rod ................................... 064 144 28 1 064 144 Connecting rod 2nd stage ........104 Assembly Page E- Ref..... 067 737 40 4 064 147 Cooler water lines ......... 064 035 16 12 WP400_ET_Index_en_08....... and 1.........Item 000 543 Cap screw ................ 064 151 82 3 000 594 Cap screw ................................2 ............. 066 148 7 2 064 038 Compressor monitoring and control ..... 067 737 40 6 067 738 Cooler insert ............................. 064 035 15 15 064 035 Compressor WP 400-100 ............................. 063 864 26 2 061 857 Connecting rod bearing ......... 064 144 28 3 063 864 Connecting rod stage 1................... 064 035 15 3 067 708 Cooler cover ............................ 064 142 24 7 002 962 Circlip ............... two-part ..................... 067 735 34 3 067 715 Cooler insert 2nd stage ............... 067 735 34 5 067 710 Cooler cover 2nd stage ........................... 064 261 30 5 012 982 Circlip ............ 064 035 88 1 063 950 Compressor monitoring ............................. No.................... 064 146 48 1 036 333 Compressor half coupling . ............. 064 035 15 22 036 333 Compressor half coupling ........ 064 035 15 4 061 857 Connecting rod bearing ..........................................................2 .................... 064 145 32 6 037 493 Clamp............................. ...................... 064 151 82 2 033 423 Coupling flexible insert ....................... 037 134 66 2 037 189 Delivery valve plate ........................... 066 148 88 3 033 423 Coupling flexible insert / elastic coupling insert ............................................................... Designation Item 038 238 Cooler water pump ................................. 064 035 15 1 051 883 Crankcase inspection cover .... 064 142 24 8 037 188 Delivery valve plate ............. 064 140 19 1 064 140 Crankcase ......................................................... 064 035 15 7 036 961 Cylindrical roller bearing ..... 067 735 34 1 067 718 Cylinder housing 2nd stage .... 066 143 75 23 066 143 Cooling water lines with pump ..... 037 134 66 3 037 190 Delivery valve spring ........................................................................................... 064 140 19 3 064 148 Crankcase vent .........................................WP400_ET_Index_en_08........................................................... 067 737 40 1 067 735 Cylinder stage 1.........................1 and 1......................... 064 035 15 2 064 143 Crankshaft ................................... 066 148 6 12 063 786 Crankcase .......................................... 067 737 40 5 067 734 Cylinder housing ....................... 037 134 66 5 064 256 Dipstick .......... 064 038 62 10 033 531 Countersunk screw ................... 064 140 19 5 065 352 Double ended stud end ..................................... 064 035 16 14 064 142 Crankshaft . 067 735 35 4 063 662 Cylinder cover 2nd stage ....... 064 344 10 12 033 423 Coupling flexible insert / elastic coupling insert ......105 ........................... 064 344 11 4 030 182 Cooling water thermometer ........................................ 037 134 66 4 037 191 Delivery valve spring ............................ 064 035 15 8 063 660 Cylinder cover ...................fm Index Assembly Page E- Ref............. 064 142 24 1 067 737 Cylinder 2nd stage ..........................................2 .... 064 038 62 14 E ..................................................................... No... 064 257 22 1 064 257 Dipstick ............. 066 148 7 4 064 366 Cooling water lines without pump ..... .................................................................................. 063 869 46 3 003 496 Gasket .......................................................... 066 143 74 27 063 811 Flywheel .... 067 737 41 26 005 009 Gasket ...................... 063 121 50 4 003 438 Gasket .............................................................. 063 121 50 12 005 001 Gasket ...................... 067 735 34....................................................................................................Item 035 984 Drain cock ........... 063 543 56 8 WP400_ET_Index_en_08........................ 064 140 18 14 005 009 Gasket ............................. 064 038 62 8 005 016 Gasket .................................. 064 146 48 16 005 023 Gasket ........................... 064 038 62 7 005 009 Gasket ............................................ 064 146 48 15 005 023 Gasket .............................................. ..... 064 142 24 2 036 394 Dry air filter ........................................ 064 148 60 11 036 395 Filter insert .............................................................. 067 737 41 24 005 016 Gasket ................................................................................................................................... 064 146 48 14 005 009 Gasket ... 063 985 54 7 003 493 Gasket ........................ 064 140 18 13 063 544 Driving disc ..................................................................... 064 147 52 4 037 194 Extension piece ................................................. 064 142 24 4 060 34 2 Fusible plug ...................... 067 735 34......................................... 35 24 005 009 Gasket .................. 063 121 50 7 030 544 Gasket .......................................................... 35 23 005 023 Gasket .......... 064 039 72 9 005 009 Gasket .......................................................... 063 121 50 8 005 009 Gasket ......................................... 063 868 44 2 037 194 Extension piece ....................... No.............................................................. 064 148 60 10 035 824 Filling cover ..................................................... 064 140 18 12 005 001 Gasket .......fm Designation E ......... 036 394 44 5 037 293 Flange ..........................................................................106 Assembly Page E- Ref.. 067 737 40 23 005 029 Gasket ................ .................... 064 140 19 6 063 749 Gasket .. 064 140 18 7 064 332 Gasket ......... 067 735 34 9 067 741 Gasket ......................................... 067 737 40 12 056 318 Gasket .............................. 066 143 74 33 000 137 Hexagon head screw ..................... 063 543 56 5 064 449 Guard plate ...................... 064 145 32 2 000 048 Hexagon head screw ....... 063 543 56 7 037 441 Gasket ......................... 064 448 64 1 036 078 Gudgeon pin .......... 067 735 34 10 038 290 Gasket kit ..................................................................... 064 146 48 6 000 119 Hexagon head screw ........................................................ 038 238 78 2 063 543 Gear oil pump .................... 066 143 74 34 000 054 Hexagon head screw .................. 067 735 35 8 063 747 Gasket ............ 067 737 40 11 067 739 Gasket ............................................................................................................................................... 066 148 6 16 005 265 Hexagon head screw ................... 064 261 30 2 064 150 Gudgeon pin .................................................... 066 143 74 4 E ................................................................................................. 066 143 74 30 051 530 Gasket ............................... 064 035 16 20 067 716 Gasket ............................................................................................................................................................................................................ 067 737 40 10 067 717 Gasket ....................... 063 543 56 3 056 335 Gasket .............................................. 064 038 62 3 036 363 Gasket ............................................................fm Index Assembly Page E- Ref.............. 064 146 48 4 063 747 Gasket .......................................... 067 737 40 9 063 748 Gasket .....................107 ...................WP400_ET_Index_en_08....................................................... No.............. 066 143 74 29 035 061 Gasket .. 063 985 54 1 036 359 Gear wheel ................... 064 146 48 7 000 216 Hexagon head screw ................. Designation Item 030 658 Gasket ................................................... 064 344 10 16 000 216 Hexagon head screw ......... ........................ 064 147 52 6 066 595 Hose line .................................................fm Designation E .... 064 140 19 18 001 621 Hexagon nut ......................................................... 066 148 6 18 001 621 Hexagon nut ........ 066 143 74 8 001 621 Hexagon nut ......... 066 143 74 37 002 031 Hexagon nut ................. 064 151 82 5 035 942 High pressure hose ................................................................ 064 018 70 1 034 763 High pressure hose ..... 063 869 46 2 001 620 Hexagon nut ................................................................................................................................................108 Assembly Page E- Ref.......................... 066 143 74 38 002 051 Hexagon nut .......................... 064 142 24 6 036 041 Hexagon head screw .. 066 143 74 6 005 297 Hexagon head screw ........................................ 064 140 18 16 001 620 Hexagon nut ....................................... 064 148 60 14 036 959 Lamellar valve 2nd stage ........... 064 151 82 1 037 139 Hose sleeve ................................................................................................. 064 151 82 6 038 386 High pressure hose .............. 064 344 10 18 001 621 Hexagon nut ................ 064 035 15 24 037 225 Lifting eye bolt nut .................................................................................... 063 121 50 10 036 964 Hexagon head screw ........................ 067 735 35 22 001 621 Hexagon nut ....................... 067 737 40 19 002 025 Hexagon nut ......... 064 140 19 20 002 031 Hexagon nut ...Item 005 265 Hexagon head screw ........ 064 448 64 3 002 031 Hexagon nut ......................... 064 140 19 2 033 952 Insulation hose ............ .................... 066 143 75 5 005 265 Hexagon head screw .............................................. 066 595 84 1 038 390 High pressure hose ........................... 066 143 76 9 035 468 High air temperature switch ........................ 064 035 16 30 WP400_ET_Index_en_08......... No...... 066 143 75 25 038 389 High pressure hose ............................... 064 148 60 6 064 394 Housing cover ............................................................................ .................................. 067 735 34 26 036 963 O-ring .......................................109 ..............fm Index Assembly Page E- Ref.... 063 869 46 5 036 171 O-ring ....................................................................................... 067 737 40 25 030 556 O-ring ............. Designation Item 063 776 Liner ....................................... 064 261 30 4 036 897 Oil strainer .......... 063 543 56 6 036 767 Oil pump gear wheel ................................................................................ 064 140 18 4 030 131 O-ring .......................... 067 737 40 8 004 411 Locking pin ..................... 064 257 22 2 030 912 O-ring .................................................................... 066 148 6 8 037 057 Motor half coupling .................................................................................... 065 664 86 1 065 664 Non-return valve .............................................. 064 035 16 31 030 08 2 Low oil pressure switch ...................................... 064 145 32 4 033 212 Oil pump cover .......... 064 145 32 5 035 962 Oil scraper ring ............. 063 868 44 3 E ............. 066 148 6 11 037 883 Non-return valve ............ 063 121 50 9 036 962 O-ring ................................ 064 035 15 13 063 800 Motor attachment rail ............................................... 067 735 34 7 063 808 Liner .............................................................. 064 344 10 8 063 800 Motor attachment rail ......................................... 064 344 10 11 037 057 Motor half coupling ................... 063 868 44 4 035 970 O-ring .... 063 543 56 2 002 605 Oil scraper ring ............................ No..... 063 543 56 1 036 360 Oil pump housing .......................... 064 151 82 9 002 634 Nose ring ......... 064 035 88 2 037 057 Motor half coupling ................................................................................................. 063 950 68 3 034 612 Low-pressure hose ... 064 148 60 12 063 985 Lubricating oil supply ...........................................................................WP400_ET_Index_en_08............... 063 869 46 4 037 151 O-ring ....................................... 064 148 60 4 037 264 Low-pressure hose ....................................................... Item 032 679 Particle trap ....................................................................................................... 064 039 72 13 032 725 Pipe adaptor .................. ... 064 366 80 3 032 725 Pipe adaptor ............................................... 064 035 15 6 064 261 Piston stage 1.......................................................... 066 143 74 31 037 144 Pipe bend .......................................................................................... 063 950 68 8 008 663 Pipe .................... 064 145 32 1 064 145 Piston ...... 066 143 75 20 008 633 Pipe . 064 366 80 5 037 265 Pipe bend ........................................................... No............................................................... 064 366 80 7 036 967 Pipe fitting ......................................................................... 066 143 75 13 037 930 Pipe adaptor ............... 067 735 34 17 000 977 Plug . 064 366 80 4 037 930 Pipe adaptor ....... 064 261 30 1 063 815 Piston .........................................................1 and 1............................................................................ 064 145 32 3 000 971 Plug ............................. 064 039 72 1 036 967 Pipe fitting ................................................................... 064 035 15 5 002 716 Plain ring .............. 064 147 52 12 037 305 Pipe reducing adaptor ..................................................................... 064 261 30 3 033 571 Plain ring ................................... 75 17 049129 Pipe clamp ........ 064 366 80 2 032 679 Particle trap ..................... 067 737 40 21 WP400_ET_Index_en_08..... 066 143 75 32 036 983 Piston .. 064 148 60 1 037 305 Pipe reducing adaptor ........................................... 066 143 74 19 038 407 Pipe nipple joint ...................................................................................................................... 064 140 18 11 000 971 Plug ................................................2 .......................110 Assembly Page E- Ref................................. 066 143 74....................................................... 067 737 41 27 000 977 Plug ..............................fm Designation E ....... 064 147 52 10 036 967 Pipe fitting ........................ 066 143 75 16 037 265 Pipe bend .......... 064 039 72 12 008 672 Pipe ..................... .................... 067 737 41 20 004 596 Plug ........................................................................ 067 735 34.............................................. 066 595 84 2 004 701 Plug ................ 064 039 72 6 005 964 Plug ..................................... 063 985 54 2 054 883 Protecting cap .......................................... 064 151 82 8 004 973 Plug ........... 064 038 62 13 030 66 4 Pressure gauge 2nd stage ............................................................................................................................................... 064 039 72 5 006 000 Plug ................................................. 066 143 75 40 061 820 Plug ................. 064 035 15 17 E ...................111 .................. 065 664 86 2 004 661 Plug ........... 065 664 86 3 037 851 Plug .................................... 064 038 62 2 035 009 Pressure gauge oil ................................................................................. Designation Item 001 007 Plug ............ 064 038 62 12 035 390 Plug ....................... 064 146 48 9 037 851 Plug .......... 064 039 72 3 006 193 Plug ........................................ 35 18 001 016 Plug ..................................................................fm Index Assembly Page E- Ref... 063 950 68 5 004 635 Plug .................................................................................................... 064 039 72 10 006 187 Plug ................................. 061 822 38 1 038 288 Pressure gauge 1st stage .................................................................... 067 737 40 3 064 448 Protective device ............WP400_ET_Index_en_08........................................................................................ 063 121 50 11 001 016 Plug .................. 064 147 52 9 004 666 Plug ................... No....... 064 039 72 4 004 661 Plug ..... 067 737 40 22 036 157 Plug ........................................................ 064 146 48 10 030 509 Plug ......................... 067 735 34 19 035 390 Plug ....................................................................................... 066 143 75 41 004 666 Plug ......................................................................... 064 038 62 1 057 916 Pressure relief valve ........................................................ 064 140 18 10 004 647 Plug ......................................................... ..................................................... 064 146 48 2 063 229 Separator head .............................. 038 238 78 3 030 752 Safety valve 2nd stage .................................. 064 146 48 13 030 751 Safety valve stage 1................... No....................................... 064 151 82 10 037 267 Reducing nipple ... 064 038 62 9 036 654 Solenoid valve ...................... .............................................................fm Designation E ........................... 066 143 75 22 035 823 Small-end bearing ......................................................................................................................................................................... 063 121 50 1 030 743 Shaft seal ........................ 064 144 28 2 037 058 Small-end bearing ....... 064 366 80 6 035 906 Socket fitting .......... 066 143 74 15 006 390 Reducing union ............................................................................ 063 864 30 7 035 823 Small-end bearing ............................. 064 039 72 7 037 142 Solenoid valve ...... 064 144 32 7 037 266 Socket ........................................................... 064 146 48 11 006 455 Stub ........................................ 064 344 10 9 064 370 Spacer ring .......... 063 121 50 6 033 017 Reducing union ................................2 ............................................................................ 066 148 6 9 054 164 Spring .....................Item 063 947 Rail ...... 064 140 18 9 064 396 Sliding socket ................................................. 057 916 58 3 005 946 Stub ............................................................................. 064 146 48 12 063 121 Separator .............. 063 864 26 3 037 058 Small-end bearing ................................ 066 143 74 10 038 257 Repair kit ................................. 066 143 74 21 064 370 Spacer ring ...................... 063 950 68 6 033 087 Reducing union ..............................................112 Assembly Page E- Ref................. 064 366 80 8 037 267 Reducing nipple ........... 064 039 72 11 WP400_ET_Index_en_08............................. 063 121 50 2 063 228 Separator housing ..... 064 366 80 1 037 150 Solenoid valve ............ 064 148 60 3 038 201 Reducing union ......... 064 035 15 9 002 144 Washer ................ 066 143 74 28 034 875 T-joint .................................................. 066 143 74 35 002 156 Washer ............... Designation Item 033 961 Stub ......................................................................fm Index Assembly Page E- Ref..........................1 and 1.... 064 035 15 10 063 868 Valve cover stage 1.......................... 066 148 6 17 038 102 Stud screw ............................................ 064 146 48 8 002 153 Washer .. 064 148 60 8 063 743 Valve cover ........................................................................................... 064 448 64 6 002 156 Washer ................ 066 143 74 36 E .......... No.. 067 735 35 14 001 533 Stud screw ......... 064 140 19 17 036 960 Stud screw ........................................................ 063 950 68 1 038 941 Thermometer compressed air .................. 067 737 40 17 005 546 Stud screw .. 064 035 16 26 036 960 Stud screw . 064 448 64 2 001 463 Stud screw ...............................113 ................................................................ 064 039 72 2 001 408 Stud screw ............2 ........... 063 869 46 1 064 236 Valve cover ........................................................................... 064 018 70 4 002 151 Washer ............................ 037 134 66 1 037 192 Suction valve spring ...... 064 147 52 11 037 185 T-joint ............. 064 344 10 17 036 960 Stud screw ............. 063 868 44 1 063 869 Valve cover 2nd stage ........................ 037 134 66 6 066 442 Support plate .. 064 140 18 15 037 187 Suction valve plate ........................................................... 064 148 60 2 064 018 Temperature monitoring ........................................................................................................................... 064 140 19 19 001 408 Stud screw ................ 066 143 74 1 038 268 T reducer ......................................................................................................................... 064 038 62 6 036 614 Threaded flange ...........................................WP400_ET_Index_en_08..................... 061 822 38 3 001 533 Stud screw ........................................................................................................................ ................................................. 064 148 60 5 061 821 Zinc cartridge ...............fm Assembly Page E- Ref......................... E . 064 142 24 3 035 254 Worm drive hose clip .............................Designation Item 002 161 Washer ................... No.......... 066 143 74 18 002 170 Washer .............. 067 735 35 2 061 822 Zinc protection ..............114 ............... 064 344 10 15 002 170 Washer ........................................ 066 143 74 14 002 166 Washer ................ 067 737 40 2 Cooler water pump ............... 061 822 38 2 061 822 Zinc protection ...................................... 038 238 78 1 WP400_ET_Index_en_08......................................................................... 066 148 6 15 063 732 Washer ........................................................................
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