S a u e r

C o m p r e s s o r
Type: WP 400

Operating instructions
• High pressure compressor
• 2-stage
• Water-cooled
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Translation of the original Operating Instructions

Edition: 04 / 2014
Edited by: J.P. Sauer & Sohn Maschinenbau GmbH – Technical Documentation
 Zertifikate_en_01.fm

Type approvals for Sauer compressors

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Note!
This page shows only a few examples. Further type approvals
are available upon request.
Genuine Sauer spare parts -
Certified safety

PL E
S AM Zertifikate_en_01.fm
 Table of Contents

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Type approval and genuine Sauer Spare Parts . . . . . . . . . . . . . . . . . . . . . 10
1.5 J.P. SAUER & SOHN Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6 Text conventions used in these Operating Instructions . . . . . . . . . . . . . . . 12

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Unauthorised modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Safety information – Warning and caution . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Safety markings on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 Safety and protection equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.6 Noise protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7 Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.8 Safety requirements for personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.9 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3 Displays on the Sauer-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.4 Displays and controls on the compressor control . . . . . . . . . . . . . . . . . . . . 30
4 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
4.1 Specification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.2 P&I diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5 Transport and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

5.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2 Storage before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.4 Connecting the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.5 Adjusting the final pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.6 Filling with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.7 Checks to be carried out after installation and before initial start-up . . . . . 50
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6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
6.1 Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.3 Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.4 Routine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
8.1 J.P. SAUER & SOHN maintenance service . . . . . . . . . . . . . . . . . . . . . . . . 64
8.2 Maintenance safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.4 Sauer Easy Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.5 Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.6 Table of tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.7 Changing the air filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.8 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.9 Cleaning the oil strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.10 Checking the valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.11 Replacing the valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
8.12 Replacing the piston rings, gudgeon pins and gudgeon pin bearings . . . . 81
8.13 Replacing the elastomeric spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.14 Checking the safety valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.15 Overhauling the solenoid drain valves (order-specific) . . . . . . . . . . . . . . . . 90
8.16 Cleaning the particle trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.17 Replacing the sacrificial zinc anode (fresh-water mode) . . . . . . . . . . . . . . 92
8.18 Checking the cooling water pump (option) . . . . . . . . . . . . . . . . . . . . . . . . . 93

9 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
9.1 Safety when decommissioning and disassembling . . . . . . . . . . . . . . . . . . 96
9.2 Temporary preservation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

10 Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

11 Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

12 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
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1 General
1.1 Foreword
These Operating Instructions contain instructions concerning the
installation, safe operation, maintenance and repair of the Sauer-
Compressor as well as an illustrated parts list.
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 that you record this information in chapter 11 and

always provide this data when ordering parts and for any repair
instructions.

1.2 Precautions
Specific It is essential that only authorised and trained personnel operate
precautions and service the Sauer-Compressor. These responsible
personnel should be thoroughly familiar with, and frequently
review, the Operating Instructions.
These operating instructions must always be readily available at
the compressor installation.

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

1.3 Warranty and liability

Sauer will no longer cover warranty or be liable for any claims if
a failure is attributed to any of the following:

– Use of the machine in a manner or for a purpose other than

that specified;
– Replacement with parts not manufactured or approved by
Sauer;
– Use of spare parts that are not genuine Sauer Spare Parts
– Operation of the machine with faulty or improperly installed
safety and/or protective devices;
– Failure to observe the Operating Instructions;
– Unauthorised modifications to the machine or its control
system;
– Inadequate monitoring of machine parts subject to wear;
– Failure to maintain/repair in accordance with Sauer
instructions;
– Force majeure.
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1.4 Type approval and genuine Sauer Spare Parts

• Type approval for the Sauer-Compressor is valid on condition

that only parts and components specified and quality-tested by
J.P. SAUER & SOHN are used. Type approval is provided by
the classification body and the EC Declaration of Conformity or
EC Manufacturer's Declaration. Failure to observe these
requirements may void type approval.
• Only the use of genuine Sauer Spare Parts will ensure
compliance with these specifications and, therefore, reliable
and safe operation of the Sauer-Compressor.
• If parts other than genuine Sauer Spare Parts are used, we
reserve the right to refuse liability for personal injury and
material damage.
• Genuine Sauer Spare Parts are supplied with a Certificate of
Conformity and a Certificate of Authenticity. An example of this
document is shown before the Table of Contents in these
Operating Instructions. If spare parts are received without this
certificate, there is a risk that these are not genuine Sauer
Spare Parts. In such an instance, please contact Sauer-
Service.

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

Correct Incorrect

Use only genuine Sauer Spare Parts Do not use parts

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that are certified! obtained on the

"grey market".

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 General

1.5 J.P. SAUER & SOHN Service

Should you have any technical questions relating to maintenance
or repair, please contact the Sauer-Service department:

J.P. SAUER & SOHN Maschinenbau GmbH

Sauer-Service
Postfach 92 13
D-24157 Kiel

Telephone (international):
Technical information +49 431 39 40 87
Spare parts orders +49 431 39 40 86/886
Fax (international): +49 431 39 40 - 89
Emergency service
(international): +49 172 4 14 63 94
E-mail: service@sauercompressors.de
Web: www.sauercompressors.com

Note!
If you have questions regarding your Sauer-Compressor, please
specify the compressor model and serial number (see chapter
11 or nameplate on the compressor).
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1.6 Text conventions used in these Operating
Instructions
Lists General lists are marked using a dash.
Example:
Compressor cooling system consists of

– Cooler assembly
– Cooling water lines

Instructions Individual instructions or multiple instructions requiring action but

where the sequence is of no importance are normally denoted by
a bullet point.
Example:

• Check the oil level.

Instructions to be carried out in a certain sequence are

numbered.
Example:

1. Turn the main switch ON.

2. Choose the operating mode.
3. Turn the control ON.

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

Example:

The control light is on.

Safety in- Safety and warning instructions are presented pictorially with
structions clear instructions. The safety instructions are described in detail
in chapter 2.
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General
2 Safety
2.1 Proper use
This Sauer-Compressor must only be used to compress the
specified gas/medium (see factory test). The Sauer-Compressor
must not be used at ambient temperatures below +5 °C or over
+55 °C. Any other unauthorised use requires the express written
approval of J.P. SAUER & SOHN.
In addition, proper conditions of use also include compliance with
these Operating Instructions and the installation requirements
and maintenance intervals described in these.
Most accidents that occur during operation and maintenance of
machinery result from failure to observe basic safety rules or
precautions.
When handling, operating or carrying out maintenance,
personnel must observe safe engineering working practices and
local regulations.

2.2 Unauthorised modifications

Unauthorised modifications to the Sauer-Compressor are not
permitted. Modifications may lead to life-threatening injuries,
endanger personnel and damage the equipment.
When planning any modifications, contact J.P. SAUER & SOHN
to obtain written approval.
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 Safety

2.3 Safety information – Warning and caution

The safety information in these Operating Instructions is
presented as ‘high’ risk and ‘lower’ risk, as follows:

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

Caution – Note!
Lower risk.
Failure to observe these safety instructions may cause damage
to the equipment.
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2.4 Safety markings on the machine
Danger!
Safety markings affixed to the machine must not be altered or
removed. Replace damaged or lost safety markings immediately
with an approved replacement.

The Sauer-Compressor with an EC Manufacturer's Declaration

or EC Declaration of Conformity is provided with the following
safety markings:

Safety marking Meaning Safety marking Meaning

High voltage! Read Operating
Danger to life! Instructions!

Compressor starts Wear hearing

automatically protection.
without warning.

Hot surface! Direction of rotation

of crankshaft

Location of safety markings

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 Safety

2.5 Safety and protection equipment

Danger!
Safety equipment must not be adjusted, disabled or removed.
Safety equipment must be tested and checked periodically.
Safety valves must only be installed with a lock-seal and
replaced, adjusted and re-sealed by authorised personnel.

Safety Each compression stage of the Sauer-Compressor is equipped

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

There is a safety valve on the cylinder housing of the 2nd stage

in the cooling water circuit of the compressor, which opens if the
blow-off pressure is exceeded.

Temperature The Sauer-Compressor is equipped with a temperature switch. If

monitoring the temperature rises above a predefined limit value, the
temperature switch sends a signal to the control, which then
switches the compressor off.
A temperature sensor can also be used as an optional
alternative.

Oil pressure The Sauer-Compressor is equipped with an oil pressure

monitoring controller that trips if the pressure drops below p < 1 bar.
An oil pressure controller can also be used as an optional
alternative.

Final pressure A final pressure switch is included with the Sauer-Compressor,

monitoring which is installed by the operator depending on the operation
task. The final pressure switch transmits a signal to the
compressor control if the lower or upper limit value is reached so
that the compressor is stopped or started automatically.
A final pressure sensor can also be used as an optional
alternative.
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2.6 Noise protection
Sound pressure level details are included in the technical
specifications (see chapter 4).
The Sauer-Compressor can be equipped with a sound-proof
canopy to reduce noise,
available as an accessory from J.P. SAUER & SOHN.

Danger!
If the equipment is operated without a sound-proof canopy,
hearing protection must be worn.

Note!
A mandatory instruction to this effect is attached to the
compressor (see chapter 4.2).

Note!
The operator must also affix a corresponding mandatory
instruction in clear view in the vicinity of the machine or on the
entry door to the compressor room.

2.7 Waste disposal

Note!
While recyclable materials are used as far as possible, local
environmental regulations, or laws, dictate that the following are
disposed of to avoid polluting the environment:
– Condensate (containing oil and water) arising from after-
cooling in the compression process;
– Used oils and greases, and cloths soiled by these lubricants;
– Cleaning agents and cloths soiled by these agents.
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 Safety

2.8 Safety requirements for personnel

Only personnel authorised by J.P. SAUER & SOHN are
permitted to service the Sauer-Compressor! Before commencing
work they must have read and understood the instructions in the
Operating Instructions and must be familiar with all safety
devices and safety regulations.
In addition to the instructions in these Operating Instructions and
supplier documentation, recognised engineering standards must
be observed as well as all local laws, standards and regulations
such as:

– the Equipment and Product Safety Act,

– the German Ordinance on Industrial Safety and Health,
– the rules for the prevention of compressor-related accidents,
– the provisions of the Verband Deutscher Elektrotechniker
(VDE/German electrical engineering industry association),
– the regulations on environmental protection.

In addition, all applicable classification society and operational

regulations must be observed.
Only personnel trained and thoroughly familiar with the
compressor operation should be authorised to operate the
compressor.
Personnel authorised to service the compressor must be trained
technical specialists employed by the operator and the
manufacturer.
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2.9 Personal protective equipment
The operator must provide personal protective equipment for
personnel carrying out any work on the Sauer-Compressor. This
includes:

– hearing protection,
– safety boots,
– safety goggles,
– Protective gloves.

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Safety
 3 Design and function
3.1 Overview

Note!
Details of parts and spare parts can be found in the Spare Parts
Catalogue.

7 4 11 5 15

9 16 13 12
17
2

6 14

1
3

8
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 Design and function

Item Designation
1 Cylinder stage 1.1
2 Cylinder stage 1.2
3 Cylinder 2nd stage
4 Safety valve 1st stage
5 Safety valve 2nd stage
6 Air filter
7 Oil filler
8 Oil dipstick
9 Oil drain valve
10 Oil pressure controller
11 Drain valve 1st stage
12 Drain valve 2nd stage
13 Compressed air temperature monitor
14 Cooling water stop valve
15 Electric motor
16 Cooling water safety valve
17 Crankcase vent
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Vertical
sectional view
7

5
1
3
2
9 4

Item Designation
1 Crankcase
2 Crankshaft
3 Flywheel
4 Flexible coupling
5 Connecting rod stage 1.1
6 Connecting rod stage 1.2
7 Connecting rod 2nd stage
8 Lubricating oil supply
9 Compressor monitoring and protection
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 Design and function

Horizontal
sectional view

17 8 11
14

7
9
10
12
13
6
4
15
1
3
16 18

Item Designation
1 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
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9 Valve cover 2nd stage

10 Valve stage 1.1
11 Valve stage 1.2

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 Item Designation
12 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

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 Design and function

3.2 Functional description

Drive Drive for the Sauer-Compressor is provided by an electric motor,
which is bolted onto the crankcase. The torque is transmitted via
a flexible coupling.
Alternatively, a diesel engine can be used. In this case, torque is
transmitted via a centrifugal clutch.

Compressor The Sauer-Compressor with an electric motor drive is controlled

control and monitored by an electrical compressor control. For details
about the compressor control, refer to the accompanying
Operating Instructions for the electronic compressor control.

Compression The compressor takes in ambient air via an air filter and
compresses it in two compression stages with a total of three
single-acting cylinders to the final pressure, with the 1st stage
consisting of two cylinders of the same design connected in
parallel. The air is cooled in each cylinder with cooling water. The
cylinders are arranged in a W-configuration and are equipped
with valves that 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.
The air that is compressed in the 1st and 2nd stages is
intercooled in U-shaped cooler tubes that are pressed on one
side via a cartridge version between the cylinder housing and the
cylinder cover.

1
2

Item Designation
1 Cooler tube
2 Cylinder cover
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3 Cylinder housing

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 Cooling water flows around the cooler tubes and the replaceable
cylinder liners inside the cylinder. The cooling water spaces are
protected by sacrificial 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 system is monitored by a temperature
controller. The compressor is stopped immediately if the
compressed air temperature exceeds the upper limit value.
Optionally, the compressor can be equipped with a cooling water
pump, which is driven by its own electric motor.

Condensate Any condensate that forms in the 1st stage is collected in the
separation collection box of the 1st stage cooler cover. The 2nd stage has a
separate condensate separator for condensate containing oil and
water that forms during compression and inter-cooling.

Condensate Condensate is drained via drain lines. Solenoid drain valves are
draining and installed in the drain lines for each separator. The solenoid drain
valves must be open when the Sauer-Compressor is
pressure relief
depressurised. A few seconds after starting, the solenoid drain
valves should close and the Sauer-Compressor should power up
against system pressure. The solenoid drain valves should drain
the system during operation at preset intervals. The solenoid
drain valves are controlled by the compressor control.

Lubrication / Oil An oil pump, driven by the crankshaft, draws the lubricating oil
pressure from the crankcase, and then pumps it to the connecting rod
bearings. Crankshaft bearings, gudgeon pin bearings and
pistons are lubricated by the splash oil in the crankcase. The oil
pressure is monitored by a low oil pressure switch.
The compressor is stopped by the control if the oil pressure falls
below the limit value.
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 Design and function

3.3 Displays on the Sauer-Compressor

4
6

Item Designation Display

1 Pressure gauge 1st stage Compressed air pressure after 1st stage
2 Pressure gauge 2nd stage Compressed air pressure after 2nd stage
3 Temperature gauge stage Compressed air temperature after stage 1.1
1.1
4 Temperature gauge stage Compressed air temperature after stage 1.2
1.2
5 Temperature gauge 2nd Compressed air temperature after 2nd stage
stage
6 Oil pressure gauge Oil pressure of oil pump
7 Cooling water temperature Cooling water temperature
gauge
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3.4 Displays and controls on the compressor control

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

The following displays and controls can be found on the front of

the compressor control:

Display/ Description
Control element
“Operation” signal Lights up when the compressor is running.
lamp
“Oil pressure” fault Lights up if the compressor has shut down because of low oil
indicator lamp pressure.
“Overcurrent” fault Lights up if the compressor has shut down because of excessive
indicator lamp motor current.
Operating Indicates the hours the compressor has run.
hours counter
Operating “Manual” mode:
mode selector Start 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 on the compressed air
receiver).
Main switch Disconnects the power supply from the compressor control to the
compressor.
A main switch should be installed if required by local law and
regulations.
Optional:
“Air temperature” Lights up if the compressor has shut down because of high outlet
fault indicator lamp gas temperature.
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30
WP400_BA1_en_1404.fm
Design and function

31
4 Technical specifications
4.1 Specification data

Designation Data
Compressor type WP 400

Number of cylinders 3
Number of compression stages 2
Cylinder diameter 1st stage 195 mm
Cylinder diameter 2nd stage 110 mm
Piston stroke 90 mm
Maximum speed 1800 rpm
Direction of rotation (looking towards Clockwise
flywheel)

Maximum working pressure 30 bar

Permitted intake pressure Maximum 1300 mbar (a)
Minimum 900 mbar (a)
Set pressures for safety valves:
1st stage 8 bar
2nd stage 10 % above final pressure

Oil sump capacity 13.5 l

Oil quantity between dipstick markings 5l
Oil type see chapter 10

Oil pressure monitoring:

Low oil pressure switch 6 A/220 V
WP400_BA1_en_1404.fm

Setting Opens at 1 bar falling

approx. 15 s delay on start instruction
Switch function Change-over contact

32
 Technical specifications

Designation Data

Oil pressure controller 4 - 20 mA / 0 - 16 bar

(optional / alternative to switch)

Temperature monitoring (optional)

Opens at 80 °C rising (for industrial use)
90 °C rising (shipbuilding application)
Temperature switch 6 A/220 V
Switch function Change-over contact
Temperature sensor 4 - 20 mA / PT 1000 / -50°C to + 250°C
(optional / alternative to switch)

Final pressure monitoring (optional):

Final pressure switch 6 A/220 V
Switch function Change-over contact
Final pressure sensor 4 - 20 mA / 0 - 160 bar
(optional / alternative to switch)

Solenoid drain valve:

Pickup and holding power Order-specific
Setting Currentless open
Periodic drainage every 15 min for 15 s (industrial
application)
every 5 min for 3 s (shipbuilding
application)

Cooling water:
Maximum permissible entry pressure at 5 bar without cooling water pump
the cooling water inlet 3 bar with cooling water pump
WP400_BA1_en_1404.fm

Set pressure of the cooling water safety 7.2 bar

valve
Cooling water temperature at the outlet 40 to 50 °C

33
Designation Data
Cooling water stop valve Holding power: 36 W
Valve is closed when currentless

Cooling water pump (optional):

Electrical connection 440 V / 60 Hz 1.1 kW or 400 V / 50 Hz 1
kW
Setting Not self-priming,
should start and stop in synchronisation
with the compressor

Sound pressure level max. 92 dB(A)

(free field at 1 m)

Weight and dimensions See installation drawing

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

WP400_BA1_en_1404.fm

34
 Technical specifications

4.2 P&I diagram

41 31 12 10

36

5 6
4
30 29 34
32 33
14 15
M 40
1 3 28
2 16
1.1 1.2 2 M
11 13 35
26 7
27 21 38
25 9
8
19
24 17 18
23 20

22

37 39

Item Designation
1 Compression stage 1.1
2 Compression stage 1.2
3 2nd compression stage
4 Cooler stage 1.1
5 Cooler stage 1.2
6 Cooler 2nd stage
7 Condensate separator stage 1.1
8 Condensate separator stage 1.2
9 Condensate separator 2nd stage
WP400_BA1_en_1404.fm

10 Safety valve 1st stage

11 Safety valve 2nd stage
12 Pressure gauge 1st stage

35
 Item Designation
13 Pressure gauge 2nd stage
14 Temperature gauge stage 1.1
15 Temperature gauge stage 1.2
16 Temperature gauge 2nd stage
17 Solenoid drain valve 1st stage
18 Solenoid drain valve 2nd stage
19 Air filter stage 1.1
20 Air filter stage 1.2
21 Non-return valve
22 Pressure relief valve
23 Drive lubrication
24 Oil strainer
25 Oil pump
26 Oil pressure gauge
27 Oil pressure monitoring
28 Electric motor
29 Cooling water particle trap
30 Cooling water stop valve
31 Cooling water temperature gauge
32 Cooling water pump (option)
33 Cooling water pump motor (option)
34 Manual valve (with cooling water pump only)
35 Temperature switch
36 Cooling water safety valve
37 Air inlet
38 Compressed air outlet
39 Condensate
WP400_BA1_en_1404.fm

40 Cooling water inlet

41 Cooling water outlet

36
WP400_BA1_en_1404.fm
Technical specifications

37
5 Transport and installation
5.1 Transport
Shipping The machine is packed ready for shipping.
• Upon receipt of the Sauer-Compressor, the goods must be
checked immediately for completeness and damage.
• Damage to the packaging or the machine must be reported
immediately to the shipping company and J.P. SAUER &
SOHN.

Transport The Sauer-Compressor must be transported using a forklift truck

or be hoisted by a crane.

Danger!
Suspended load during transport.
The forklift truck/crane must have sufficient load
bearing capacity.
Ensure that no personnel are within the danger area of the
suspended load and the forklift truck/crane.
Sling the unpacked compressor at the four lifting eyes (1) (see
figure).
Raise, move into position and set down with care.

1
1
WP400_BA1_en_1404.fm

38
 Transport and installation

5.2 Storage before installation

If the Sauer-Compressor has to be placed in storage before it is
set up, leave it in the packaging and store in the following
conditions:

– Temperature: +5 to +40 °C;

– Relative humidity 30 to 95%, non-condensing;
– In a dry area, under a roof and protected from dew formation;
– Protected from contamination;
– Protected from vibration and shock

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

Note!
High pressure hoses can be stored for up to five years after
delivery.
WP400_BA1_en_1404.fm

39
5.3 Installation

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

For proper installation, follow the installation documents and

observe the following conditions.

Correct ventilation Incorrect ventilation

Installation – The installation area must be dry and free from dust.
conditions – Ensure that the installation area is ventilated in such a way that
the heat generated during operation can be extracted.
– Room temperature for Sauer-Compressor operation:
Max. 55 °C
+5 °C to +55 °C
(operation outside this temperature range only with written
approval from J.P. SAUER & SOHN).
– For proper installation, follow the installation documents and
Min. 5 °C observe the following conditions.
WP400_BA1_en_1404.fm

40
 Transport and installation

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

– If the room temperature is below +5 °C, the room must be

heated, or a heater must be provided for the Sauer-
Compressor.
– The installation location must be selected to ensure that the
Sauer-Compressor is easily accessible.

The cooling water chambers are automatically vented by the

positioning of the cooling water inlet and outlet.
The quantity of cooling water must be set so 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.

50 °C
40 °C
WP400_BA1_en_1404.fm

41
 Note!
The Sauer-Compressor is cooled with fresh-water.
While sea water cooling is optionally also possible, it can have
an extremely corrosive effect depending on its temperature and
composition.

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

Foundation
Note!
The standard delivery anti-vibration resilient mount has a
resonant frequency of approx. 10 Hz.
The compressor foundation provided must not be exposed to
vibrations at a frequency of 10 Hz from neighbouring machines.
Otherwise, there is a risk that the standard anti-vibration resilient
mount may be destroyed by resonance vibration.
1. Check beforehand whether there are vibrations of the
machine foundation in the 10 Hz range.
2. If in doubt, contact J.P. SAUER & SOHN to clarify whether a
different anti-vibration resilient mount can be used.

WP400_BA1_en_1404.fm

42
 Transport and installation

5.4 Connecting the compressor

Danger!
The compressor may only be connected by qualified
technicians. All electrical installation work must be carried out
exclusively by trained and qualified electrical technicians.

Pipelines The compressed air outlet, cooling water inlet and outlet, and the
drainage connections on the Sauer-Compressor must be
connected to the system operator's fixed water pipelines via hose
lines.

1 2

Item Designation
1 Cooling water hose lines
2 Compressed air outlet
3 Drain lines
4 Cooling water inlet
WP400_BA1_en_1404.fm

43
 Danger!
When the compressor starts up and drains, compressed air
escapes from the drainage connections. Consequently, do not
operate the compressor without hose lines connected.

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

Drainage system
Note!
Accumulated condensate contains oil. It may only be disposed
of in compliance with applicable legal regulations.
J.P. SAUER & SOHN offers condensate collection containers for
separating air from condensate as well as condensate
processing systems for separating oil from condensate.
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44
 Transport and installation

Note!
We recommend connecting the compressor's drainage system
separately.
When the drain lines of several compressors are to be
connected to a common pipe, observe the following:
Choose a sufficiently large diameter for the common drain line.
Connect drain lines of the individual compressors at a sweep
angle piece to the common drain line, so no pressure can build
up in the drain line.

Correct connection Incorrect connection

WP400_BA1_en_1404.fm

45
Connections The illustration shows the connections and couplings for
operating the Sauer-Compressor in its basic configuration.

8 1 2 3 4

9 7 6 5

Item Designation Type Function

1 Drive motor Electric motor Compressor drive
2 Non-return valve Plate valve Prevents air from flowing back.
3 Final pressure Change-over Start/Stop control for the compressor
switch switch
4 Safety valve Spring-loaded Prevent overpressure of parts
safety valve containing pressure
5 Drain valve Solenoid valve Start relief and drainage system
6 Temperature con- Change-over Switches off the compressor if the
troller switch temperature is too high
7 Low oil pressure Change-over Switch off the compressor if the oil
switch switch pressure is too low
8 Cooling water Solenoid valve Prevent flow of cooling water when the
stop valve machine is stopped.
9 Cooling water Centrifugal pump Pumps cooling water
WP400_BA1_en_1404.fm

pump (option) not self-priming

46
 Transport and installation

Note!
For technical specifications of the individual items, see chapter
4.
All change-over switches are factory set.
If desired, the components are supplied pre-wired to a terminal
box.
WP400_BA1_en_1404.fm

47
5.5 Adjusting the final pressure switch

Note!
The final pressure switch must be connected directly at the
compressed air receiver to ensure smooth, even compressor
operation.

Pay attention to the pressure loss between the compressor and

compressed air receiver when selecting the maximum pressure
setting. If the set pressure is too high, the safety valve for the final
stage blows off.

WP400_BA1_en_1404.fm

48
 Transport and installation

5.6 Filling with oil

Note!
Unless otherwise ordered, Sauer-Compressors are delivered
without oil filling.

Danger!
• It is imperative to fill the crankcase of the compressor with oil
before initial operation.
• Use only oil that is approved for use by J.P. SAUER & SOHN
(see chapter 10).
• Note the amount of oil needed (see chapter 4).

1. Unscrew the oil filler cap (1).

2. Pour in oil and check the oil level with the dipstick (2).

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

3. Replace the dipstick (2) and screw the oil filler cap (1) back in.
WP400_BA1_en_1404.fm

49
5.7 Checks to be carried out after installation and
before initial start-up
Before starting the compressor, ensure that:

– The electrical connection matches the data on the nameplate.

– All connections between the compressor and the compressed
air system are properly installed.
– The amount of oil indicated for operation is present in the
crankcase.
– The cooling water line is open.
– All tools and foreign objects have been removed from the
compressor.
– The entire system is clean.

WP400_BA1_en_1404.fm

50
WP400_BA1_en_1404.fm
Transport and installation

51
6 Operation
6.1 Safe operation

Danger!
The Sauer-Compressor must be started up and operated by
authorised personnel only.

Danger!
Only turn on and start the compressor when
checks have been carried out to ensure that it is in good order
and
all tools and foreign objects have been removed from the
machine.

Danger!
Turn the compressor off immediately if personnel and property
are at risk. Only restart the compressor if the risk no longer
persists.

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

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

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

Note!
Turn off the compressor in the event of any abnormal/fault
conditions or unexpected events. Correct the causes by
referring to chapter 7.
WP400_BA1_en_1404.fm

52
 Operation

6.2 Operating modes

After you have turned on the power supply to the Sauer-

Compressor, it can be started with one of the following two
operating modes using the mode selector switch:

– "Manual" operating mode:

The compressor starts when you press the START button and
continues to run until it is stopped either by pressing the STOP
button or when the final pressure is reached.
To restart the compressor, the START button must be pressed
again.
– "Automatic" operating mode:
Once the compressor has been started initially by pressing the
START button, it is started and stopped automatically by the
start and final pressure settings.
You can stop the compressor at any time by pressing the
STOP button. After stopping the compressor manually, press
the START button to restart it.

When the Sauer-Compressor starts, it starts without load with the

solenoid drain valves open. After a few seconds, the solenoid
drain valves close and the compressor powers up against system
pressure.
WP400_BA1_en_1404.fm

53
6.3 Initial operation
Checking the First allow the Sauer-Compressor to run for just a few seconds in
direction of order to check the direction in which it rotates.
rotation
1. Turn on the power supply.
2. Set the mode selector switch to “Local” to start the
compressor in manual mode.
3. Immediately check the compressor’s direction of rotation. It
must rotate in the direction indicated by the arrow on the
crankcase.
4. Set the mode selector switch to “0” to stop the compressor.
5. Turn off the power supply.
6. If it is rotating in the wrong direction, the polarity of the electric
motor must be reversed by a qualified electrician.

Danger!
If the crankshaft rotates in the wrong direction, no oil pressure
builds up. Thus, there is a risk of subsequent damage.

7. Check the direction of rotation of the cooling water pump

(option):
Switch on the pump motor.
The motor must not reach its operating speed.
The direction of rotation must agree with the rotation direction
arrow on the pump. If it is rotating in the wrong direction, the
polarity of the electric motor must be reversed by a qualified
electrician.
The pump and suction pipe must be completely filled with
cooling water.

Danger!
The cooling water pump must not be allowed to run dry.
WP400_BA1_en_1404.fm

54
 Operation

Test run 1. Turn on the power supply.

2. Set the mode selector switch to “Manual” to start the
compressor in manual mode.
If correctly set, the solenoid drain valves close after about 15
seconds and the compressor should power up against
system pressure.
3. Check the pressure gauges for each stage as well as the oil
pressure gauge and compare readings with the nominal
values (for nominal values see chapter 6.4).
4. Check that automatic periodic drainage is functioning
correctly.
It operates at different intervals depending on the application
area (see chapter 4.1). This is indicated by a drop in pressure
on the pressure gauges.
5. Check that cooling water is flowing.
The temperature of the cooling water at the outlet should be
within the range indicated in chapter 4.1. The temperature
can be read on the cooling water thermometer at the cooling
water outlet. If these temperatures are exceeded or not
reached, the flow of cooling water must be increased or
decreased accordingly.
For compressor units with an integrated cooling water pump,
the flow can be controlled using the slider on the pump.
6. Set the mode selector switch to “0” to stop the compressor.
7. Turn off the power supply.
8. If necessary, eliminate the cause of variations from nominal
values and malfunctions. See also chapter 7.
9. Fill out the commissioning certificate and send it to the Sauer-
Service department. The commissioning certificate can be
found in the Appendix.
WP400_BA1_en_1404.fm

55
6.4 Routine operation
Cleaning • Keep the area around the system clean.
• Keep the display and control elements clean.

Inspection • Inspect connections, pipelines and electrical cables for

damage.
• Check the oil level once a week before starting and top up, if
necessary. Do not overfill with oil beyond the maximum mark.

Operation 1. Turn on the power supply.

2. Open the cooling water lines.
3. Set the mode selector switch to “Auto“ to operate the
compressor in Automatic mode.

Monitoring • Watch out for abnormal operating noise.

• Pay attention to leaks (compressed air, oil, condensate). The
temperature of the cooling water at the outlet should be within
the range indicated in chapter 4.1.
• The air pressure indicated on the display of the pressure
gauge should be within the grey zone in the stage pressure
diagram (see below):
• The oil pressure should be between 1.8 bar and 4 bar.

In the event of variations, see chapter 7.

Note!
It is permissible to start compressors five to six times within a
period of one hour.
The minimum operating time for each start should be 10
minutes. Repeatedly using the system for shorter operating
periods damages the compressor.
WP400_BA1_en_1404.fm

56
 Operation

Stage pressure diagram 1st stage

2nd stage [bar]

30

20

10

1 2 3 4 5 6
1st stage [bar]

Note!
Depending on the final pressure of the last compression stage,
the pressure of the individual compression stages can be read
from the diagram.
WP400_BA1_en_1404.fm

57
7 Troubleshooting
Note!
If a malfunction occurs, first check the displays on the
compressor control panel and on the compressor.
Try to correct the fault with the help of the table below.
If the fault cannot be corrected, please contact the Sauer-
Service department.
The damage report log is included as an appendix to these
Operating Instructions.

Fault Possible Remedy

cause
Compressor does not No input power supply/no Check fuses. Replace blown
start or turns off. control voltage. fuses.
Oil pressure monitor Oil level too low. Check oil level and top up, if
switched compressor necessary. Check for leaks.
off.
Oil too viscous. Fill with recommended oil.
Check that room temperature is
> + 5°C.
Oil strainer blocked. Clean oil strainer.
Oil line blocked. Clean oil line.
Oil pump faulty or Check oil pump. If necessary,
leaking. eliminate leak and/or replace oil
pump.
WP400_BA1_en_1404.fm

58
 Troubleshooting

Fault Possible Remedy

cause
Compressor was Excessive current drawn. Check supply voltage and
switched off by electrical connections. The
overcurrent relay. compressor can be started
again after a cooling down
period.
Check whether the crankshaft
can easily be turned by hand. If
not, disconnect and ascertain
whether the problem has to do
with the motor or the
compressor.
Piston seizure Check cylinders and pistons for
any score marks and replace, if
necessary.
Safety valve of 1st
stage blows off:
Pressure exceeds Valve of 2nd stage not Check valve of 2nd stage and
blow-off pressure (8 working properly. replace, if necessary.
bar)
Gasket between suction Replace gasket.
and pressure side of 2nd
stage faulty.
Pressure below Safety valve faulty. Replace safety valve.
blow-off pressure
(8 bar)
Safety valve of 2nd
stage blows off:
Pressure above Valve in air piping to Open valve.
blow-off pressure compressed air receiver
(final pressure + closed.
10%)
Pressure switch set too Lower the pressure setting.
high.
Excessively high Reduce pressure losses.
pressure losses in air
piping to compressed air
receiver.
WP400_BA1_en_1404.fm

Pressure below Safety valve set too low Replace safety valve.
blow-off pressure or is faulty.
(final pressure
10%).

59
Fault Possible Remedy
cause
Pressure gauge of 1st Valve of 2nd stage Check valve of 2nd stage and
stage is showing leaking. replace, if necessary. Replace
excessive pressure. gaskets.
Pressure gauge of 1st Valve of 1st stage Check valve of 1st stage and
stage showing leaking. replace, if necessary.
insufficient pressure.
Air filter very dirty. Replace air filter insert.
Pressure gauges of all No power at solenoid Check solenoid valve power
stages showing no drainage valve. supply.
pressure.
Solenoid valve of the Check the solenoid valve and
drainage system is faulty. replace, if necessary.
Air escaping at the Gaskets at connections Replace faulty gasket.
pressure lines. leaking.
Cutting ring joints Switch compressor off. Wait until
leaking. all parts are no longer under
pressure; check the pressure
gauge for this. Tighten all
unions.
Compressor was Compressed air Increase the flow of the cooling
switched off, temperature at outlet too water
temperature monitoring high due to low cooling (for compressors with a cooling
has tripped. water. water pump only: Open the
slider at the rear of the pump
further);
Check the temperature of the
cooling water at the outlet and
the functioning of the cooling
water stop valve;
Clean the particle trap.
Compressed air Clean cooling water chambers
temperature at outlet too with a descaling agent.
high because of poor
thermal transition in the
cooler as a result of
scaling in the chamber.
Solenoid valve No power supply. Check fuses, replace blown
(drainage) does not fuses.
WP400_BA1_en_1404.fm

close.
Solenoid faulty. Replace solenoid.
Foreign matter in Replace solenoid valve.
solenoid valve.

60
 Troubleshooting

Fault Possible Remedy

cause
Cooling water stop No power supply. Check fuses, replace blown
valve does not open. fuses.
Solenoid faulty. Replace solenoid.
Foreign matter in Replace solenoid valve.
solenoid valve.
Abnormal compressor Connecting rod bearing Check connecting rod bearing
noise. faulty. and replace, if necessary.
Check oil supply.
Gudgeon pin bearing Check gudgeon pin bearing and
faulty. replace, if necessary.
Crankshaft bearing faulty. Check crankshaft bearing and
replace, if necessary.
Motor bearing faulty. Check motor bearing and
replace, if necessary.
Oil leaking from Gasket or shaft Tighten all screws.
crankcase. seal faulty. Screws not If there is significant leakage,
tight. check to see which gasket is
faulty, then replace it.
Minor traces of oil on the
housing or oil drops below the
compressor are harmless. Wipe
off with a lint-free cloth.
Water escaping at the O-ring of cylinder liner Replace o-ring.
relief groove of the faulty above relief
cylinder flange surface. groove.
Oil escaping at relief O-ring of cylinder liner Replace o-ring.
groove of cylinder faulty below relief groove.
flange surface.
Water in the oil. Excessive cooling of Reduce flow of cooling water.
compressor due to Change room ventilation so that
- flow of cooling water too air stream is not blown directly
high against compressor.
- unfavourable room Extend compressor running
ventilation hours
- very short compressor
running hours
WP400_BA1_en_1404.fm

Inadequate drainage. Check drain lines and drainage

intervals.

61
Fault Possible Remedy
cause
The cooling water Leaks in cooler. Replace cooler insert.
safety valve is
Pressure peaks in the Determine the cause of the
actuated.
cooling water circuit pressure peaks and eliminate
cause the set pressure of these causes (start-up of
the safety valve to be additional pumps, actuation of
exceeded. electromagnetic stop valves or
shuttle valves, or similar causes)
Premature fracture of Inadequate drainage. Check drain lines and drainage
valve plates, valve intervals.
springs or
plates. Note: Impact impressions in the
valve plate from the sealing seat
are normal.

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62
 WP400_BA1_en_1404.fm

63
Troubleshooting
8 Maintenance
8.1 J.P. SAUER & SOHN maintenance service
Sauer-Service offers various maintenance services: inspection,
maintenance, major overhaul, replacement compressors, and
service contracts.

Please contact Sauer-Service:

J.P. SAUER & SOHN Maschinenbau GmbH

Sauer-Service
Postfach 92 13
D-24157 Kiel

Telephone (international):
Technical information +49 431 39 40 87
Spare parts orders +49 431 39 40 86/886
Fax (international): +49 431 39 40 89
Emergency service
(international): +49 172 4 14 63 94
E-mail: service@sauercompressors.de
Web: www.sauercompressors.com

or contact an authorised J.P. SAUER&SOHN service partner in

your area.

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64
 Maintenance

8.2 Maintenance safety

Before main- 1. Disconnect the power supply to the compressor.
tenance work 2. Put up “Attention! Maintenance work!” sign on the power
supply.
3. Shut down the compressor and secure it against restarting.
4. Put on personal protective equipment (see chapter 2.9).

Danger!
Risk of injury if operated incorrectly!
The Sauer-Compressor must not be serviced or adjusted except
by authorised personnel!

Danger!
Risk of injury from hot surfaces!
Allow compressor to cool down after shutting off.

Danger!
Risk of injury from pressurised components!
Check the pressure gauges before servicing to ensure the
compressor is completely depressurised.
WP400_BA1_en_1404.fm

65
 Danger!
High voltage! Danger to life!
Never assume that a circuit is de-energised – Always check to
be sure.
– The main switch is energised, even when it is turned off.
– Components being worked on should only be energised if this
is explicitly specified.

Danger!
Danger of death from missing safety devices and missing
isolating protective devices!
Reinstall all safety devices and isolating protective devices after
servicing. This also applies to electrical protection devices (e.g.
earth cables).

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66
 Maintenance

8.3 Maintenance schedule

Danger!
During all maintenance work, follow the instructions in chapter
8.6 regarding specified screws and nuts.

Note!
The maintenance intervals specified in the maintenance
schedule must be adhered to. Shorter maintenance intervals do
not provide any advantages with regard to the operating
behaviour or service life of the Sauer-Compressor.

Note!
After the last maintenance stage the maintenance schedule
begins again.

Note!
J.P. SAUER & SOHN recommends having an inspection
(function test) carried out by qualified personnel at least once a
year.
WP400_BA1_en_1404.fm

67
Maintenance • Use the maintenance schedule as a master template or copy
schedule the respective page from the document and save it as a
separate file under a suitable name. Use the maintenance
instructions
schedule as a guide and as a record of work completed.
• Regularly check the maintenance schedule to see which
maintenance intervals must be observed depending upon the
number of operating hours. The intervals are shown in the
table’s column headers.
• Check the column for each maintenance interval to see what
maintenance work is to be carried out at the end of each
maintenance interval. The required tasks are indicated by
check boxes. The description and chapter number for tasks
are shown in the first column.
• Carry out all maintenance work for an interval and tick the
appropriate check boxes in the maintenance schedule. Enter
the number of operating hours completed, the date and add
your signature.
• When beginning a new maintenance schedule
– enter the following: Main characteristic data, date of
commissioning, maintenance schedule number, date and
number of operating hours.
– mark with an “X”: Start of current maintenance schedule
after commissioning or after last maintenance stage.

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 Maintenance

8.4 Sauer Easy Care

Maximum operational reliability at lowest cost

Simple The Sauer Easy Care maintenance concept makes maintenance

maintenance easier (one maintenance routine=one maintenance kit=one order
number) and guarantees that your Sauer-Compressor will have
concept
a long, reliable service life through the regular replacement of
important components. It also ensures that labour costs are
clearly defined and service times can be planned.
The Sauer Easy Care maintenance kits include all components
that are required for the currently pending maintenance routine.

The advantages of Sauer Easy Care are:

– Simple preparation and performance of maintenance work

(maintenance kit contains all important parts)
– Clearly defined maintenance routines
(preventative maintenance)
– Maximum operating reliability
(replacement before failure)
– Exceptionally low maintenance costs
(repairs hardly ever necessary)
– Guaranteed storage life of maintenance parts
(no failures within maintenance intervals)
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 The part number for the respective maintenance kit is listed in the
maintenance chart at the following item:

Example of Easy Care Maintenance Chart

Note!
In the following maintenance chart, the intervals and
maintenance tasks to be carried out have been adapted to the
respective compressor type.

Note!
If you have questions about the Sauer Easy Care maintenance
concept, the Sauer-Service department will be glad to help you.
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 Maintenance

8.5 Maintenance chart

Maintenance schedule number: Compressor type: WP400
Start of this maintenance Type series Typhoon
schedule:
 After commissioning Compressor serial number:
 After last maintenance stage Serial number:
Date: Year of construction:
Operating hours: Date of commissioning:

Interval

last maintenance stage

[operating hours]

if < 1,000 h per year

At least annually
commissioning

or repair work
50 h after

50 h after

1,000 h
2,000 h
3,000 h
4,000 h
Maintenance task

069 234
069 235
069 234
069 236
Sauer Easy Care part number

Changing the air filter insert, see 8.7     

Changing the oil, see 8.8       
Cleaning the oil strainer, see 8.9 
Checking the 1st stage valves, see 8.10  
Replacing the 1st stage valves, see 8.11  
Replacing the 2nd stage valve, see 8.11    
Replacing the piston rings, gudgeon pins and
piston gudgeon pin bearings of all stages, see 
8.12
Replacing the elastomeric spider, see 8.13 
Checking the safety valves, see 8.14 (according to operator
specifications)
Overhauling the solenoid drain valves (order-

specific), see 8.15
Cleaning the particle trap, see 8.16.    
Replacing the sacrificial zinc anode (fresh-water

mode), see 8.17
Checking the cooling water pump (option), see
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
8.18

71
Operating hours
Date
Signature (initials)

Note!
Always check the compressor after 50 hours following any
maintenance work.
Check all screws and nuts affected by maintenance to see if they
are tight.

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 Maintenance

8.6 Table of tightening torques

Screw(s) Tightening torque

Connecting rod screws/bolts 115 Nm
Flywheel fixing screw 550 Nm
Cylinder head screws 82 Nm
1st and 2nd stage
Locking screw of the 2nd stage valve 7.5 Nm
on the valve cover
Screws on the cylinder cover,
(installation of 1st stage cooler insert)
M8 screw 30 Nm
M10 screw 60 Nm
Screws on the cylinder cover,
(installation of 2nd stage cooler
insert) M10 screw 60 Nm
M12 screw 105 Nm
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8.7 Changing the air filter insert

1. Open the clips and take off the air filter cap (1).
2. Take out the used air filter insert.
3. Wipe the housing with a lint-free cloth, if necessary.
4. Insert a new air filter insert.
5. Fit the cap (1) and secure the clips.

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 Maintenance

8.8 Changing the oil

Note!
Only use oil as recommended in the lubricant table (see chapter
10).

1. Place an oil pan (of a size sufficient for the oil sump capacity,
see chapter 4) below the oil drain valve (3).
2. Unscrew the oil filler cap (1).
3. Open the oil drain valve (3).
4. Wait until all the oil has drained out.
5. Close the oil drain valve (3).
6. Pour in oil, and while doing so check the oil level with the
dipstick (2).
The level should be between the upper and lower marks on
the dipstick.
7. Insert the dipstick (2) and screw the oil filler cap (1) back in.
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8.9 Cleaning the oil strainer

3 4 1 2

1. Loosen the nuts (1) and remove the crankcase inspection

cover (2).
2. Loosen the union (3) on the oil strainer (4).
3. Remove the oil strainer (4) from the crankcase.
4. Wash out the oil strainer (4) with a suitable solvent (e.g.
petrol).
5. Carefully clean the sealing surface of the crankcase
inspection cover (2).
6. Refit the oil strainer (4).
7. Screw on the crankcase inspection cover (2) with a new
gasket.

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 Maintenance

8.10 Checking the valves

Removing valves 1. Loosen the clamp on the air filter and replace the air filter.
2. Loosen the pipe unions and hose lines at the valve covers.
3. Loosen the valve cover nuts and remove the valve cover.
4. Carefully remove the 1st stage valve.
5. Separate the 2nd stage valve from the valve cover by
loosening the valve locking screw.

Checking the 6. Check the exterior of the valves for:

valves
– damage,
– coking,
– oiling,
– corrosion, and
– moisture.

Note!
Valves that are damaged, heavily coked or corroded must be
replaced.
Determine the cause (see chapter 7).

7. Clean all sealing surfaces.

Note!
Install all valves with new gaskets and ring gaskets. Do not reuse
old gaskets and ring gaskets.
Only use genuine Sauer Spare Parts.
Installation of old or other gaskets and ring gaskets may lead to
leakage and may cause substantial damage to the compressor.
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77
Installing valves
Note!
Do not reuse used ring gaskets under any circumstances. Doing
this will lead to leakages within a short period of time.

1st stage 1. Install the 1st stage valve and valve cover.
Use new ring gaskets in the valve cover when doing this.

Item Designation
1 O-ring
2 Valve cover
3 Valve 1st stage

2. Tighten the valve cover screws and all screw connections by

hand.
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 Maintenance

2nd stage 3. Fasten the valve to the valve cover with the locking screw; for
the correct tightening torque, see chapter 8.6.
4. Fit the valve with the valve cover using new ring gaskets.
5. Tighten the valve cover and all screw connections by hand.

1 2

Item Designation
1 Locking screw
2 O-ring
3 Valve cover
4 Valve 2nd stage

6. Tighten the screw connections; for the correct tightening

torques, see chapter 8.6.
7. Refit the air filter.
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8.11 Replacing the valves

Remove and reinstall valves as described in chapter 8.10. Make

sure you replace the valves completely.

Note!
Valves that have reached the end of their service life must be
replaced and disposed of.
J.P. SAUER & SOHN does not recommend repairing used
valves due to the effects of material fatigue.

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 Maintenance

8.12 Replacing the piston rings, gudgeon pins and

gudgeon pin bearings

1. Close the cooling water inlet and outlet.

2. Unscrew the drain screws and drain the cooling water.
3. Disconnect the cooling water inlet and outlet hoses from the
cylinders.
4. Remove the valve covers and valves as described in chapter
8.10.
5. Loosen the flange connections and remove the compressed
air manifold.

Removing the 6. Loosen the cylinder foot nuts.

1st stage 7. Remove the cylinder. Hold the piston while the cylinder
cylinder comes off.

Note!
If the piston is not held while pulling the cylinder off, it will strike
against the crankcase.

Removing the 8. Loosen the pipe unions and loosen the pressure line between
2nd stage the 2nd stage cylinder and the final separator.
cylinder 9. Loosen the pipe union on the cylinder.
Remove the hose line for the cooling water inlet. The union
fitting must be left on the cylinder.
10. Remove the cooling water hose line between the 1st and 2nd
stage cylinders.
11. Loosen the four nuts on the foot of the 2nd stage cylinder.
12. Screw two lifting eye nuts onto the two uppermost studs in the
cover, fasten the cylinder to suitable lifting gear by the
screws, and pull the cylinder sideways out of the crankcase.
13. Remove the cylinder. Hold the piston as the cylinder comes
off
WP400_BA1_en_1404.fm

81
 .

Note!
If the piston is not held while pulling the cylinder off, it will strike
against the crankcase.

14. Remove the gudgeon pin circlips, push out the gudgeon pins
and remove the piston.
15. Remove all piston rings from the piston and clean the piston.

Checking 1. Check cylinders and pistons for excessively deep scoring

pistons and marks. Replace parts as required.
cylinders

Note!
If the piston running surface in the cylinder has edges that can
be felt, remove the edges with a Flexhon brush or a Scotch-Brite
non-woven abrasive. Otherwise the edges may damage the new
piston rings when installing the piston.

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 Maintenance

Measuring
cylinder wear

2 1

Note!
This measurement can be made with used and new piston rings.

1. 1st measurement:
Insert the piston ring about 5 mm (1) below the top edge of
the cylinder (above the level of the highest piston ring), and
measure the gap clearance with the feeler gauge in the area
(3) not occupied by the piston rings.
2. 2nd measurement:
Push the piston ring down about 50 mm (2) (below the lowest
level of the lowest piston ring), and measure the gap
clearance in the wearing area (4) again.
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 1

3. Calculate the difference between the two gap clearances (1)

of measurement 1 and measurement 2 and compare it with
the gap clearance difference values in the table.

Stage End gap difference WP 400

1 0.45 mm
2 0.30 mm

Note!
Contact the Sauer-Service department if the difference between
the two gap clearances is greater than indicated in the table
above. WP400_BA1_en_1404.fm

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 Maintenance

Replacing 1. Use a suitable tool to press the gudgeon pin bearings out of
gudgeon pin the connecting rod eye and replace them.
bearings

Installing piston 2. Install the piston rings in the piston. Make sure they are in the
rings correct position: piston rings with an asymmetric cross
section are marked with “TOP” on one of the surfaces. The
marked face must be at the top when the piston ring is
installed (see figure).

1 2

TOP

TOP

Stage Designation
1 1st compression stage piston
2 2nd compression stage piston

Note!
Replace all piston rings with new ones. The following damage
may occur when removing the piston rings:
• The piston ring edges are damaged on the wearing edges in
the cylinder.
• If the piston rings are bent multiple times fine cracks appear,
which may cause the material to break.
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85
 Note!
Arrange the piston ring locks so that they are staggered.

Replacing the 3. Mount the piston on the connecting rod. To do this, press the
gudgeon pin new gudgeon pin in and insert the gudgeon pin circlips.
4. To assemble cylinders, valves and valve covers, reverse the
steps for disassembly.

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 Maintenance

8.13 Replacing the elastomeric spider

1 2 3

Item Designation
1 Coupling hub compressor side
2 Elastomeric spider
3 Coupling hub motor side

1. Shut down the compressor and secure it against restarting.

2. Support the compressor under the bell-housing.
3. Unscrew the fixing screws for the electric motor.
4. Lift the electric motor carefully at the lifting eyes (see chapter
5.1).
5. Pull the electric motor carefully away from the compressor.
6. Replace the elastomeric spider.
7. Carefully slide the electric motor onto the flange and finger-
tighten the fixing screws.
8. Remove the support under the bell-housing.
9. Tighten the fixing screws with a screw-driver.
10. Reinstall the disconnected connecting lines and pipes.
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8.14 Checking the safety valves

Danger!
The safety valve is a part of the safety device. Safety equipment
must not be adjusted, disabled or removed. Safety equipment
must be checked regularly and replaced as necessary.

Note!
Testing must be carried out quickly and must not be repeated.

The safety valves are sealed by the manufacturer to prevent

tampering. The construction of the safety valves means that
they cannot be tested for function.
The operator must check the safety valves in accordance with
country-specific guidelines and laws, and replace them as
necessary.

Note!
Safety valves must not be replaced except by personnel
specially trained for this task.

At J.P. SAUER & SOHN, training courses are conducted in

seminars by experienced personnel in workshops or by
independent study of training material such as videos,
catalogues and assembly instructions provided by
J.P. SAUER & SOHN. WP400_BA1_en_1404.fm

88
 Maintenance

Note!
SAUER-Service offers a professional and qualified safety valve
replacement service.

For further information, please contact J.P. SAUER & SOHN

Customer Service.

Checking the safety valve

Carry out the following checks to detect any damage to safety
valves as early as possible:
• Inspect external pipelines for damage.
• Test threaded connections for proper seating.
• Inspect attached parts for damage.
• Inspect valve seals for damage.
This completes the safety valve inspection procedure.

Danger!
Faulty safety valve.
Damage to the safety valves and external pipelines must be
corrected immediately by trained and qualified technicians.
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8.15 Overhauling the solenoid drain valves (order-
specific)

1
2

6 4

7
10
8

1. Shut down the compressor and secure it against restarting.

2. Unscrew the hexagon nut (1).
3. Carefully prise off the plastic threaded part (2) with the
wrench.
4. Detach the coil (3) from the solenoid armature (4).
5. Loosen the four inner hexagon head screws (5).
6. Remove the valve upper part (6).
7. Replace the following parts:
Spring (7), membrane (8) and two o-rings (9).
8. Clean the nozzle (10).
9. Refit the valve upper part (6).
10. Tighten the four inner hexagon head screws (5).
11. Attach the coil (3) to the solenoid armature (4).
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 Maintenance

8.16 Cleaning the particle trap

1 2 1

3 4

Item Designation
1 Particle trap
2 Cooling water stop valve
3 Compressor with cooling water pump
4 Compressor without cooling water pump

1. Shut off the cooling water supply.

2. Unscrew the cap on the particle trap in front of the cooling
water stop valve and take out the strainer.
3. Clean the strainer.
4. Insert the strainer, screw the cap back on.
5. Turn the cooling water supply back on.
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8.17 Replacing the sacrificial zinc anode (fresh-water
mode)

Item Designation
1 Sacrificial zinc anode

The sacrificial zinc anode for the 1st and 2nd stage cylinders is
located along the long side in the top of the cylinder cover.

1. Unscrew the sacrificial zinc anode.

2. Check the zinc cartridge.
The minimum diameter is 24 mm.
If consumption is too high, replace the sacrificial zinc anode.
3. Install the sacrificial zinc anode using a new ring gasket.
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 Maintenance

8.18 Checking the cooling water pump (option)

If unusual running noises or leaks are noticed, the cooling water
pump should be checked as follows:

Disassembling 1. Close off the cooling water inlet and outlet.

the pump 2. Disconnect the electrical connection.
3. Loosen the drain screw at the bottom of the 2nd stage
cylinder and drain the cooling water from the compressor.
4. Loosen the flange connections at the cooling water inlet and
outlet on the pump.
5. Loosen the screw connections on the pump foot and remove
the pump from the bracket.

Replacing the The mechanical seals are maintenance-free. If heavier leaks

mechanical occur after a prolonged period of operation, the mechanical seal
must be replaced as a complete unit.
seals

Note!
Refer to the illustration of the pump in the spare parts catalogue.
Observe the pump manufacturer's operating instructions.

6. Remove the flywheel and shaft seal.

7. Remove the entire mechanical seal and the cover from the
shaft.

Note!
The new mechanical seal must be fitted extremely carefully and
in conditions of complete cleanliness.
Do not touch the seal with fingers (wear clean gloves or use a
cloth).
Take particular care not to damage or soil the mechanical seal.
To make installation easier, moisten the elastomeric spider with
depressurised water.

8. For installation, the new mechanical seal must be slid

carefully onto the shaft with a twisting motion.
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93
 Note!
If the shaft exhibits noticeable play, the motor bearing should be
replaced. If the pump flywheel is damaged, it should be replaced
as well.

Assembling the 9. Replace the pump in reverse order of its removal. Use a new
pump flange seal.
10. Completely fill the pump and suction line with cooling water.
11. Connect the electrical connection.

Checking the 12. Switch on the pump motor briefly.

direction of The motor must not reach its operating speed. The direction
of rotation must agree with the rotation direction arrow on the
rotation
pump.

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 WP400_BA1_en_1404.fm

95
Maintenance
9 Decommissioning
9.1 Safety when decommissioning and disassembling
Danger!
The compressor must only be decommissioned and
disassembled by trained technicians employed by the operator.
These specialists must be familiar with the protection devices
and regulations before starting the work. Any work on the
electrical installation must be carried out by qualified electricians
only.
In addition, information contained in suppliers’ documentation
must be observed.

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96
 Decommissioning

9.2 Temporary preservation and storage

A test run for at least 30 minutes should be carried out every four
weeks. Additional corrosion prevention measures are not
required.
If the Sauer-Compressor is to be laid up for more than 12 weeks,
preservation with a preservation oil is recommended. If this
preservation is carried out, periodic test runs are not needed.

Note!
Use one of the preservation oils recommended in chapter 10 for
corrosion protection.

1. Run the compressor for approx. 5 minutes with the solenoid

drain valves and pressure line open.
Any existing condensate is blown out.
2. Drain the compressor lubricating oil and dispose of it in an
environmentally safe manner.
3. Fill with about 10 litre of preservation oil.
4. Start the compressor and run for approx. 5 minutes with the
drain valves and pressure line open.
5. Stop the compressor.
6. Unscrew both air filters on the 1st stage cylinder head.
7. Spray approx. 150 ml of preservation oil slowly into each
intake fitting of the 1st stage.
8. Refit the air filter.
WP400_BA1_en_1404.fm

97
 1

Item Designation
1 Intake fitting
2 Hexagon head screw

9. Unscrew the hexagon head screw on the 2nd stage valve

cover.
10. Spray approx. 125 ml of preservation oil into the opening.
11. Screw the hexagon head screw back in.
12. Start the compressor.
13. Wait until oil mist escapes from the pressure line.
14. Stop the compressor.
15. Drain the preservation oil and dispose of it in an
environmentally safe manner.
16. Attach a notice indicating that the compressor has been
preserved and taken out of service.
17. Disconnect the mains supply cables.
WP400_BA1_en_1404.fm

Restarting 1. Connect the mains supply cables.

2. Pour in compressor lubricating oil as described in chapter
5.6.
3. Follow the instructions given in chapter 6.3.

98
 Decommissioning

9.3 Disassembly
Disassembly 1. Turn the compressor off and disconnect from the power
supply.
2. Read the pressure gauge or pressure display to ensure that
the compressor is completely depressurised.
3. Disconnect the mains supply cables.
4. Remove oil and lubricants and dispose of them in an
environmentally safe manner.
5. Drain any remaining condensate and dispose of it in an
environmentally safe manner.

Disposal

Material / Component Safe disposal

Lubricants As hazardous waste
Steel/iron As scrap metal
Electrical cables As hazardous waste
Electronic components As scrap electronic waste
Plastics As hazardous waste
WP400_BA1_en_1404.fm

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10 Lubricant table
Note!
The oil types mentioned in "Recommended oils for Sauer-
Compressors" represent a complete list of the oils that have
yielded entirely positive operating results.
High product quality and long service life can only be guaranteed
if the oils listed are used with due consideration for the
conditions of the specific application.
Product names may vary by country.

Note!
If an oil is used that is not included in this list, contrary to the
recommendations of J.P. SAUER & SOHN, the warranty
coverage for the Sauer-Compressor will automatically become
null and void.
Use of an oil not included in this list can result in failure and
irreparable damage to the compressor.
If you need help in selecting the correct oil, please contact the
Sauer-Service department.

WP400_BA1_en_1404.fm

100
 WP400_BA1_en_1404.fm

101
Lubricant table
11 Spare parts and accessories
Note!
Please take careful note of the instructions in chapter 1
regarding our genuine Sauer Spare Parts.

J.P. SAUER & SOHN guarantee the complete spare parts supply
over the entire service life of the Sauer-Compressor.
Our genuine Sauer Spare Parts are subject to constant quality
control and further development. They conform to the latest
technical developments.
In addition to genuine Sauer Spare Parts, our range of supply
includes many accessories for your Sauer-Compressor as well
as special equipment for your entire compressed air system,
including:

– Fully automatic controls;

– Adsorption dryers;
– Refrigeration dryers;
– Filters;
– Sound-proof canopies;
– Compressed air receivers;
– Couplings.

We supply instructions and a maintenance manual for each

accessory.
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 Spare parts and accessories
Spare Parts The Spare Parts Catalogue can be found in the Appendix to these
Catalogue Operating Instructions.

– The required parts can be quickly found with the help of

diagrams, figures and lists.
– The spare parts catalogue, including operating instructions, is
also available on CD. This makes it easy to fill out an order
form, print it out and send it in immediately.
To do this, you will need the main specifications of your
Sauer-Compressor from the table below. If you have not
entered this here, you will find it on the nameplate, which is
attached to the crankcase.

Compressor type:
Serial number:
Year of
construction:

Furthermore, the number of operating hours should be stated,

if possible.
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103
12 Appendix
This Appendix to the Operating Instructions contains:

– Form for commissioning certificate

– Form for Return of Goods/Notification of Claim
– Supplier documentation
– Data sheets

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 Appendix

J.P. SAUER & SOHN

Commissioning certificate for compressors Maschinenbau GmbH
Brauner Berg 15 - 24159 Kiel
Phone: +49 - 431- 39 40 - 0
Fax: +49 - 431- 39 40 - 89
E-mail: service@sauer-
sohn.de
Purchaser Operator Installation site
Company Company
Street Street
Postcode Postcode
Contact Contact
Phone number Phone number
Customer number
Order number
Compressor type Serial no.
Delivery date Operating hours
Date commissioned
Sauer-Service engineer Company/name
Company/name
Company/name
Company/name
Installation of compressor/complete system Direction of rotation check
 good  defective Compression temperature °C
Ventilation Intake temperature °C
 good  defective Start/stop pressure
Ambient conditions Oil level check
 good  defective Control system check
Voltage? Test run
 good  defective
Vibration behaviour of compressor
 good  defective
Accessories Installation of complete system carried out by:
Compressed air receiver
Refrigeration dryer
Adsorption dryer  good  defective
Filter
Condensate removal
Operating personnel have received instructions and are familiar with the safety and maintenance requirements.
The maintenance instructions are available to the operator.
The operating company has been advised to use only genuine SAUER & SOHN Spare Parts.
Notes/faults:

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

WP400_BA1_en_1404.fm

Purchaser Operator Authorised Sauer-Service Partner

105
 J.P. SAUER & SOHN
 Return of goods Maschinenbau GmbH
 Notification of claim Brauner Berg 15 - 24159 Kiel
Phone: +49 - 431- 39 40 - 0
Date: Fax: +49 - 431- 39 40 - 89
E-mail: service@sauersohn.de
Applicant: Please always complete.
Company Compressor type:
Street
Postcode/City
Customer no. Serial no.:
Location
End customer: Operating hours:
Company
Street Date of fault:
Postcode/City
Customer no. Ambient temperature:
Location
To be completed by manufacturer

Spare parts Reason for return

Designation Quantity Part no. Report on fault 
Repair 
Checking as customer 
service
Goods taken back against 
credit note

Brief description of damage:

Report
by manufacturer only
To be completed

WP400_BA1_en_1404.fm

106
S a u e r
C o m p r e s s o r
Type: WP 400
Spare Parts Catalogue
 WP400_ET_Titel_en_1404.fm

Translation of the original Operating Instructions

Edition: 04 / 2014
Edited by: J.P. Sauer & Sohn Maschinenbau GmbH – Technical Documentation
 Spare Parts Catalogue

064 344 Compressor unit WP 400

Page
Part no. Assembly Rev.
E-
064 344 Compressor unit WP 400 .................................................... 6 5993-i

064 035 Compressor WP 400 ........................................................... 8 6562-k

064 140 Crankcase ........................................................................... 10 6229-b

064 142 Crankshaft ........................................................................... 12 5698-a

063 864 1st compression stage connecting rod ............................... 14 _-a

064 144 2nd compression stage connecting rod .............................. 16 _-a

064 261 1st compression stage piston ............................................. 18 5376-b

064 145 2nd compression stage piston ............................................ 20 5282-a

067 735 Cylinder 1st compression stage .......................................... 22 _-_

067 737 Cylinder 2nd compression stage ......................................... 24 6651-a

063 868 Valve cover 1st compression stage ..................................... 26 6384-c

063 869 Valve cover 2nd compression stage ................................... 28 _-a

064 146 Air pipings ........................................................................... 30 5997-b

063 121 Separator ............................................................................ 32 _-f

064 147 Cooling water lines (compressor) ....................................... 34 6103-e

063 985 Lubricating oil supply .......................................................... 36 5447-c

063 543 Gearwheel oil pump ............................................................ 38 6665-d

057 916 Pressure relief valve ........................................................... 40 5549-a

064 148 Crankcase vent ................................................................... 42 6415-c

064 038 Compressor monitoring and protection ............................... 44 6103-e

064 448 Protective device ................................................................. 46 5765-b

063 950 Unit monitoring .................................................................... 48 5236-c

064 018 Temperature monitoring ...................................................... 50 5784-g

064 039 Automatic drainage system ................................................. 52 5646-c

064 366 Cooling water line ............................................................... 54 6137-d

WP400_ET1_en_1404.fm

064 151 Anti-vibration resilient mount ............................................... 56 6523-f

065 664 Non-return valve ................................................................. 58 _-_

064 447 Terminal box with wiring ...................................................... 60 6497-e

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 Page
Part no. Assembly Rev.
E-
Flexible coupling ................................................................ 62 _-_

Optional assemblies
066 143 Cooling water lines with cooling water pump ..................... 66 6776-k

038 238 Cooling water pump ........................................................... 70 6832-f

037 159 Flow rate display ................................................................ 72 5396-b

066 596 Oil pressure test valve ........................................................ 74 6614-d

Optional loose accessories

Final pressure switch / Final pressure sensor ........................ 78 _-_

Note:
For explanations of the assemblies, refer to chapter 3 "Design
and Function" in these Operating Instructions.
WP400_ET1_en_1404.fm

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WP400_ET1_en_1404.fm
Spare Parts Catalogue

E-5
064 344 Compressor unit WP 400

4 1 2 12 11 3 17 18 9 8 15 16 14

WP400_ET1_en_1404.fm

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 Spare Parts Catalogue

064 344 Compressor unit WP 400

Item no. Part no. Designation Quantity

1 064 035 Compressor WP 400 1
2 063 950 Unit monitoring 1
3 064 039 Automatic drainage system 1
4 064 366 Cooling water line 1
8 063 800 Motor rail 2
9 064 370 Spacer ring 1
11 037 057 Standard-hub, motor side 1
12 033 423 Elastomeric spider 1
14 1) Electric motor 1
15 002 170 Washer 4
16 000 216 Hexagon head screw 4
17 036 960 Stud 8
18 001 621 Hexagon nut 8

30 064 151 Anti-vibration resilient mount 1

1) The part number for the electric motor varies according to the order.
WP400_ET1_en_1404.fm

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064 035 Compressor WP 400

9 14

26 30

12

11

27

22

17

15

23
8

5
10

3
24

13
6

1 31 2 3 4
WP400_ET1_en_1404.fm

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 Spare Parts Catalogue

064 035 Compressor WP 400

Item no. Part no. Designation Quantity

1 064 140 Crankcase 1
2 064 142 Crankshaft 1
3 063 864 1st compression stage connecting rod 2
4 064 144 2nd compression stage connecting rod 1
5 064 261 1st compression stage piston 2
6 064 145 2nd compression stage piston 1
7 067 735 Cylinder 1st compression stage 2
8 067 737 Cylinder 2nd compression stage 1
9 063 868 Valve cover 1st compression stage 2
10 063 869 Valve cover 2nd compression stage 1
11 064 146 Air pipings 1
12 064 147 Cooling water lines (compressor) 1
13 063 985 Lubricating oil supply 1
14 064 148 Crankcase vent 1
15 064 038 Compressor monitoring and protection 1
17 064 448 Protective device 1
22 036 333 Flange hub 1
23 037 134 Valve 1st compression stage 2
24 036 959 Valve 2nd compression stage 1
26 005 546 Stud 2
27 000 543 Socket head cap screw 10
30 037 225 Lifting eye 2
31 004 411 Grooved pin with head 8
WP400_ET1_en_1404.fm

E-9
064 140 Crankcase

17 18
9

17 18
11 12

15 16

19 20

11 12 13 14 4 10 5 22 3 6
WP400_ET1_en_1404.fm

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 Spare Parts Catalogue

064 140 Crankcase

Item no. Part no. Designation Quantity

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 Union 1

11 000 971 Plug 2
12 005 001 Ring gasket 2
13 038 919 Oil drain valve 1
14 005 009 Ring gasket 1
15 038 102 Stud 6
16 001 620 Hexagon nut 6
17 036 960 Stud 12
18 001 621 Hexagon nut 12
19 001 408 Stud 16
20 002 031 Hexagon nut 16

222) 030 556 O-ring 2

1) Item 10, 004 635, insert union with Loctite 542.

2) Item 22, 030 556 O-Ring is part of assembly 064 257.
WP400_ET1_en_1404.fm

E - 11
064 142 Crankshaft

2 7 8 1 8
WP400_ET1_en_1404.fm

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 Spare Parts Catalogue

064 142 Crankshaft

Item no. Part 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 Socket head cap screw 2
8 036 961 Cylindrical roller bearing 2
WP400_ET1_en_1404.fm

E - 13
063 864 Connecting rod 1st compression stage

4
WP400_ET1_en_1404.fm

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 Spare Parts Catalogue

063 864 Connecting rod 1st compression stage

Item no. Part no. Designation Quantity

1 063 712 Connecting rod 1
2 061 857 Connecting rod bearing 1
3 035 823 Small-end needle roller bearing 1

41) 061 676 Connecting rod bolt 2

52) 036 078 Gudgeon pin 1

1)
Item 4, 056 316 Connecting rod bolt is part of assembly 063 712.
2)
Item 5, 036 078 Gudgeon pin is part of assembly 064 261.
WP400_ET1_en_1404.fm

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064 144 Connecting rod 2nd compression stage

4
WP400_ET1_en_1404.fm

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 Spare Parts Catalogue

064 144 Connecting rod 2nd compression stage

Item no. Part no. Designation Quantity

1 063 826 Connecting rod 1
2 037 058 Small-end needle roller bearing 1
3 061 857 Connecting rod bearing 1

41) 061 676 Connecting rod bolt 2

52) 064 150 Gudgeon pin 1

1)
Item 4, 061 676 Connecting rod bolt is part of assembly 063 826.
2)
Item 5, 064 150 Gudgeon pin is part of assembly 064 145.
WP400_ET1_en_1404.fm

E - 17
064 261 Piston 1st compression stage

7 2 5
WP400_ET1_en_1404.fm

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 Spare Parts Catalogue

064 261 Piston 1st compression stage

Item no. Part no. Designation Quantity

1 036 983 Piston 1
2 036 078 Gudgeon pin 1
3 002 716 Rectangular ring 2
4 035 962 Double bevelled oil control ring 1
5 002 985 Circlip 2

71) 035 823 Small-end needle roller bearing 1

1)
Item 7, Small-end needle roller bearing 035 823 is part of assembly 063 864.
WP400_ET1_en_1404.fm

E - 19