Air Compressor WP400

S a u e r C o m p r e s s o r Type ype:: WP 400 Operating Instructions

Version 1 - 1

•

High-pressure Compressor

•

2 Stages

•

water-cooled

VO001AK1.fm

Edited by: ZINDEL – Technical Documentation, www.zindel.de Version 1 - 1

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Sauer compressor type approv approvals als

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Note! On this page only a few examples are shown. Further type approvals are available on request. Version 1 - 1

Genuine Sauer spare parts – certified safety

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Inhaltsverzeichnis

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1. 1.1 1.2 1.3 1.4 1.5 1.6

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 At the outset . . . . . . . . . . . . . . . . . . . . . . . . . . 8 General information. . . . . . . . . . . . . . . . . . . . . 8 Warranty and Liability . . . . . . . . . . . . . . . . . . . 8 Type approval and genuine Sauer spare parts 9 Customer service of J.P. SAUER & SOHN . . 10 Organisation of these instructions . . . . . . . . . 11

2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specified conditions of use . . . . . . . . . . . . . . Prohibition of unauthorized conversion . . . . . Safety information . . . . . . . . . . . . . . . . . . . . . Safety markings on the machine . . . . . . . . . . Safety devices . . . . . . . . . . . . . . . . . . . . . . . . Noise protection . . . . . . . . . . . . . . . . . . . . . . Waste disposal . . . . . . . . . . . . . . . . . . . . . . . Staff requirements . . . . . . . . . . . . . . . . . . . . . Personal protection gear . . . . . . . . . . . . . . . .

3. 3.1 3.2 3.3 3.4

Design and Function. . . . . . . . . . . . . . . . . . 16 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Mode of Operation. . . . . . . . . . . . . . . . . . . . . 20 Indicators on the Sauer Compressor. . . . . . . 22 Indicators and controls of the compressor control system . . . . . . . . . . . . . . . . . . . . . . . . 23

4. 4.1 4.2

Technical Specifications . . . . . . . . . . . . . . 24 Specification data . . . . . . . . . . . . . . . . . . . . . 24 Compressed air system plan and cooling water plan . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5. 5.1 5.2 5.3 5.4

Transport and Installation . . . . . . . . . . . . . Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage before installation. . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the compressor . . . . . . . . . . . . . Version 1 - 1

12 12 12 12 13 14 14 14 15 15

28 28 29 29 32 5

5.5 5.6

Filling in oil . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Checks after installation and before the first start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6. 6.1 6.2 6.3 6.4

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe operation. . . . . . . . . . . . . . . . . . . . . . . . Operating modes. . . . . . . . . . . . . . . . . . . . . . First Commissioning . . . . . . . . . . . . . . . . . . . Routine operation . . . . . . . . . . . . . . . . . . . . .

7.

Trouble-shooting. . . . . . . . . . . . . . . . . . . . . 42

8. 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . Maintenance service by J.P. SAUER & SOHN Maintenance safety . . . . . . . . . . . . . . . . . . . . Maintenance schedule . . . . . . . . . . . . . . . . . Table of tightening torques . . . . . . . . . . . . . . Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking screwed connections. . . . . . . . . . . Air filter cartridge replacement . . . . . . . . . . . Checking valves . . . . . . . . . . . . . . . . . . . . . . Checking the piston rings . . . . . . . . . . . . . . . Replacing gudgeon pins/gudgeon pin bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing valves . . . . . . . . . . . . . . . . . . . . . . Checking pistons and cylinders. . . . . . . . . . . Checking the drive bearings . . . . . . . . . . . . . Checking the coupling. . . . . . . . . . . . . . . . . . Cleaning particle trap . . . . . . . . . . . . . . . . . . Checking zinc protection . . . . . . . . . . . . . . . . Burst disc . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking cooling water pump (optional) . . . .

46 46 46 47 49 49 51 51 52 55

Placing out of Service. . . . . . . . . . . . . . . . . Safety when placing out of service and dismounting. . . . . . . . . . . . . . . . . . . . . . . . . . Shutting down the compressor temporarily. . Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . .

64

8.11 8.12 8.13 8.14 8.15 8.16 8.17 8.18 9. 9.1 9.2 9.3

38 38 39 39 40

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10. 10.1 10.2

Lubricant Table . . . . . . . . . . . . . . . . . . . . . . 66 Lubricating oils . . . . . . . . . . . . . . . . . . . . . . . 67 Slushing oils . . . . . . . . . . . . . . . . . . . . . . . . . 68

11.

Spare Parts and Accessories. . . . . . . . . . . 69

12.

Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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AL001AB1.fm

1.

General

1.1

At the outset The following main specifications of your Sauer compressor are found on the type label affixed to the crankcase: – Compressor type – Factory number – Year of construction Please enter this data in Chapter 11, "Spare Parts and Accessories" as soon as possible.

1.2

General information

Conditions

We presuppose that only authorised persons will operate and service the Sauer compressor. These persons must have read and understood the operating instructions.

Availability

These instructions shall always be kept available at the site of operation.

Copyright

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

1.3

Warranty and Liability We exonerate the contractually agreed warranty claims and liability claims, if they can be attributed to at least one of the following: – use of the machine for non-intended purposes; – use of spare parts that are not genuine Sauer spare parts; – operation of the machine with faulty or not properly installed safety devices and protection devices; – disregard of the operating instructions; – unauthorised modifications to the machine or its control system; – inadequate monitoring of machine parts subject to wear; – improperly carried out repairs; – force majeure.

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General 1.4

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

Do not use parts from the "grey market"…

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1.5

Customer service of J.P. SAUER & SOHN In case of technical questions pertaining to maintenance or repair please contact our customer service: SAUER & SOHN Maschinenbau GmbH Customer Service P.O. Box 92 13 D-24157 Kiel Telephone (international): Technical information +49 431 39 40 -87 Spare parts ordering +49 431 39 40 -86/886 Telefax (international): +49 431 39 40 -89 Emergency service (international): +49 172 4 14 63 94 [email protected] E-Mail: www.sauersohn.de Web: Note! In case of queries regarding your Sauer compressor please indicate the compressor-type and the factory number (see Chapter 11. "Spare parts and Accessories” or type label on the crankcase).

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General 1.6

Organisation of these instructions

Lists

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

Actions

Individual instructions or multiple instructions, where the sequence is of no importance are normally given as bulleted lists. Example: • Check 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

Results of actions carried out are denoted by a check mark. Example: ✓ The control light lights up.

Safety instructions

Safety instructions are distinguished by pictographs and signal words. Safety instructions are described in Chapter 2. "Safety" in detail.

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2.

Safety

2.1

Specified conditions of use This Sauer compressor must be used for the compressing of air only. The Sauer compressor must not be used at ambient temperatures of below +5 °C. Any other use is not as specified and requires the explicit consent in writing by J.P. SAUER & SOHN . Observance of these operating instructions, the installation requirements detailed in the instructions, and the keeping of maintenance rates are part of the specified conditions of use as well.

2.2

Prohibition of unauthorized conversion Unauthorized conversion and modification of the Sauer compressor is not permitted, since they could endanger humans and may lead to machine damage. Contact J.P. SAUER & SOHN when planning conversions or modifications to obtain a written permission.

2.3

Safety information The safety information in these instructions is divided in two classes. The following pictographs and signal words are used: Danger! High risk. Disregard of this safety information may cause personal injury and substantial material damage. Note! Average risk. Disregard of this safety information may cause damage to the machine.

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Safety 2.4

Safety markings on the machine Caution! Safety markings affixed to the machine must not be altered or removed. Replace damaged or lost safety markings immediately, true to the original.

Sauer compressor models with an EC Manufacturer's Declaration or EC Declaration of Conformity are marked with the following safety markings: Safety marking

Meaning

Safety marking

Meaning

Danger! High voltage!

Read instructions!

Compressor starts automatically without warning!

Wear hearing protection!

Hot surface!

Rotational direction of Crankshaft

Location of safety markings (top view)

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2.5

Safety devices Danger! Safety devices must not be adjusted, disabled or removed. The safety devices must be periodically tested and checked. Safety valves must be – installed sealed and – replaced, adjusted and sealed by authorised personnel only.

Safety valves

Every pressure compartment of a stage of the Sauer compressor is equipped with a safety valve, which will blow off when the blowing-off pressure is reached. Safety valves are installed at these locations: – 1st compression stage: in the back cooler cover of the 2nd intercooler; – 2nd compression stage: in the final separator behind the stage;

Temperature switch

The Sauer compressor is fitted with a temperature switch for monitoring the compressor cooling. This will turn the compressor off if the temperature of the compressed air exceeds the limit.

2.6

Noise protection Sound pressure level details are found in the Technical Specifications (see chapter 4). If necessary the Sauer compressor can be equipped with a noise protection hood, which is available as optional accessory from J.P. SAUER & SOHN . Danger! When the compressor is operated without noise protection hood, hearing protection should be worn near the compressor.

2.7

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

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Safety 2.8

Staff requirements Only authorised persons are permitted to service the Sauer Compressor! Before commencing work they must have read and understand the operating manual and must be familiar with the safety devices and safety regulations. In addition to the instructions in this operating manual and manufacturer documentation, accepted technical standards must be observed as well as all regional laws, standards and regulations such as the – Equipment and Product Safety Act (Geräte- und Produktsicherheitsgesetz), – Ordinance on Industrial Safety and Health (Betriebssicherheitsverordnung), – Regulations for accident prevention pertaining to compressors, – VDE regulations and – Regulations on environmental protection. In addition, where appropriate, regulations of the responsible classification society as well as operational regulations must be observed. Persons authorised to operate the compressor are the attending specialists introduced to the job and trained by the operator. Persons authorised to service the compressor are the trained specialists of the operator and of the manufacturer.

2.9

Personal protection gear The operator has to provide the personal protection gear (hearing protection, safety boots, etc.) for the personnel carrying out any work on the Sauer compressor.

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3.

Design and Function

3.1

Overview 5 13 1 7

6

13 3

5

2

8

1 20 19

17 4 16

9 18 15

14

12

11

Item

16

10

Name

1

Cylinder 1st stage

2

Cylinder 2nd stage

3

Safety valve 1st stage (not visible)

4

Safety valve 2nd stage

5

Air filter

6

Oil filler

7

Cooling water outlet (not visible)

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Design and Function Item

Name

8

Compressed air outlet

9

Drain valve 1st stage (not visible)

10

Drain valve of 2nd stage:

11

Compressed air temperature switch

12

Burst disc

13

Zinc protection 1st stage

14

Zinc protection 2nd stage

15

Oil dip stick

16

Cooling water inlet

17

Particle trap

18

Oil drain valve

19

Oil pressure switch

20

Cooling water stop valve

Note! Details of parts and spare parts are found in the spare parts catalogue.

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Longitudinal section

3 4

5

2 1

Item

Name

1

Crankcase

2

Crankshaft

3

Connecting rod 1st stage

4

Connecting rod 2nd stage

5

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Design and Function Cross section

5

1

7

6 2

8 5 9 6 1 4 2

3

Item

Name

1

1st stage: cylinder with head and valve

2

Piston 1st stage

3

2nd stage: cylinder with head and valve

4

Piston 2nd stage

5

Valve cover 1st stage

6

Plate valve

7

Air lines

8

Valve cover 2nd stage

9

Lamellar valve

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3.2

Mode of Operation

Compressor

The Sauer compressor is a two stage water-cooled air compressor with three cylinders. The 1 st stage and the 2nd stage are respectively fitted with two and one single acting trunk pistons each. The connecting rods of all the pistons sit on a common crankpin of the double bearing crankshaft.

Drive

The Sauer compressor is driven by an electric motor directly flanged to the transmission bell housing of the crankcase, where the power is transmitted by means of a flexible coupling.

Compressor control

The Sauer compressor with electric drive is electrically controlled and monitored by a compressor control system. This control system must comply with the legal provisions. Optionally, J.P. SAUER & SOHN supply a suitable compressor control system.

Compression

The compressor takes in ambient air through a sheet filter with tube silencer and compresses it in the two cylinders of the 1st stage. The air is led to the cylinder of the 2 nd stage and compressed to the ultimate pressure. The air is after-cooled after each cylinder. A replaceable wet liner with double O-ring sealing is fitted in each cylinder. The cylinders in W-shape configuration are equipped with platevalves or lamellar valves, which have a long service life and are easy to service.

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Design and Function Cooling

The compressor is cooled with fresh water. Sea water cooling is possible optionally. The air compressed in the 1 st and 2nd stage is recooled in straight cooler pipes, which are expanded into the cylinders. The cooling water flows directly past the cooler pipes and the replaceable liners in the cylinder. The cooling water cavities are protected against corrosion with zinc electrodes. Optionally, the compressor can be fitted with an inbuilt cooling water pump. This pump is not self-priming and is driven by an electric motor. When the compressor is not fitted with a cooling water pump, the cooling water supply is cut off when the compressor is shutdown using a solenoid valve at the cooling water inlet. The functioning of the compressor cooling is monitored by the compressed air-temperature control. The compressor is stopped immediately if the compressed air temperature exceeds the upper limit.

Condensate separation

Condensate accumulating in the 1 st stage is collected in collecting tanks of the back cooler covers of 1 st stage. The 2nd stage has a separate condensate separator for the oil and water containing condensate arising from compression and recooling.

Condensate draining/Pressure relief 

The condensate is drained through drain lines. Drain lines are fitted with solenoid valves. These must be open when the Sauer compressor is unpressurized. The drain valves should close a few seconds after starting and the Sauer compressor should accelerate against pressure. The solenoid valves should drain the machine at predetermined intervals during operation. The solenoids valves are controlled by the compressor control system.

Lubrication/oil pressure

An oil gear pump driven by the crankshaft sucks the lubrication oil from the crankcase and supplies it to the friction bearings of the connecting rods. Crankshaft bearing, gudgeon pin bearing and piston are lubricated by the splash oil present in the crankcase. The oil pressure is monitored with an oil pressure switch. The compressor control system stops the compressor immediately if the oil pressure falls to the lower limit.

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3.3

Indicators on the Sauer Compressor

6

3 4

1

2

5

Item

Name

Indication

1

Pressure gauge 1st stage

Compressed air pressure after the 1st stage

2

Pressure gauge 2nd stage

Compressed air pressure after the 2nd stage

3

Thermometer 1st stage (not visible)

Compressed air temperature after the

Thermometer 2nd stage (not visible)

Compressed air temperature after the

5

Oil pressure gauge

Oil pressure of the oil pump

6

Cooling water thermometer (not visible)

Temperature of the cooling water at the cooling water outlet

4

1st stage 2nd stage

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Design and Function

3.4

Indicators and controls of the compressor control system Note! If the compressor control system is supplied by J.P. SAUER & SOHN take notice of the documentation supplied.

At the front of the compressor control the following indicators and control elements are found: Indicator/  Control element

Description

Signal lamp “Operation”

Lights when the compressor is running.

Fault indicator lamp “Oil pressure”

Lights if the compressor has been shut off because of low oil pressure.

Fault indicator lamp “Air temperature”

Lights if the compressor has been shut off because of excessive outlet air temperature.

Fault indicator lamp “Overcurrent”

Lights if the compressor has been shut off because of excess motor current.

Working hour meter

Indicates the working hours of the compressor.

Operating mode selector

• Selector position “Manual”: Starting the compressor manually. The compressor starts up and continues to run until it is manually turned off. • Selector position “0”: Turns compressor manually OFF. Any pending fault messages are reset. • Selector position “Auto”: The compressor is started and stopped by the opening and closing of an external switching contact (e.g. pressure switch of the compressed air receiver).

Main switch

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

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4.

Technical Specifications

4.1

Specification data Description

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 (as seen on flywheel)

clockwise

Maximum operating pressure

30 bar

Set pressures of safety valves: 1st stage

8 bar

2nd stage

5 % higher than the ultimate pressure

Oil filling quantity

13.5 l

Oil quantity between dip stick markings

5l

Oil type

see chapter 10. “Lubricant table”

Oil pressure switch: Maximum switching current

6A / 220 V

Setting

opens at 1 bar falling approx. 15 seconds starting bypass

Switch function

change-over contact

Drain valves: Pick-up and holding power

18 VA / 14 W

Setting

normally open; starting relief: approx. 15 seconds; intermediate draining: 15 seconds every 15 minutes.

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Technical Specifications Description

Data

Ultimate pressure switch (optional): Maximum switching current

6A / 220 V

Setting

to customer's specifications

Switch function

change-over contact

Temperature switch: Maximum switching current

16A / 440 V

Setting

opens at 80 °C rising

Switch function

change-over contact

Max. allowable primary pressure at cooling water inlet:

5 bar in absence of cooling water pump 2.5 bar with cooling water pump

Bursting pressure of the burst disc in the cooling water system:

> 6 bar

Temperature of cooling water at the outlet.

optimal 30 °C…45 °C, max. 50 °C

Cooling water stop valve

Holding capacity: 36 W Setting: Closed when compressor is shutdown; Valve is closed dead

Cooling water pump (optional) Electrical connection

440 V/60 Hz 1.1 kW or 400 V/50 Hz 1 kW

Setting

non-self-priming, should start and stop in synchronisation with the compressor

Sound pressure level (in free sound field at 1 m distance)

maximum 92 dB(A)

Weight and dimensions

see installations plan

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

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4.2

Compressed air system plan and cooling water plan 21

5

4

3 4

5 22 2

5

4

17

1

3

3

19 14 6 17 20 11 3 12 13

10

8 10

9

8

7

Item

26

9 18

2

15 16

Name

1

Drive motor

2

Safety valve

3

Compressor stage

4

Intercooler and aftercooler

5

Compressed air pressure gauge

6

Oil pressure switch

7

Condensate separator

8

Drain

9

Solenoid drain valve

10

Air filter/silencer

11

Oil pump

12

Pressure relief valve

13

Oil filter

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Technical Specifications Item

Name

14

Oil pressure gauge

15

Non-return valve

16

Ultimate pressure switch

17

Compressed air thermometer

18

Compressed air temperature switch

19

Cooling water hand valve

20

Cooling water pump (optional)

21

Cooling water thermometer

22

Cooling water stop valve

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5.

Transport and Installation

5.1

Transport

Shipping

The machine is packed suitable for shipping. • Immediately on receipt of the Sauer compressor it should be checked for completeness and damage. • The transport company and J.P. SAUER & SOHN must be immediately notified of any damage to the packing or the machine.

Transportation

The Sauer compressor must be transported by a forklift truck or hoisted by crane. Danger! Suspended load when transported. The forklift truck/crane must have sufficient load bearing capacity. • Ensure that no persons stay within the danger area of the suspended load and the forklift truck/crane. • Sling the unpacked compressor at the lifting eyes on the crankcase and the motor (see illustration). • Lift, move, and set down carefully.

Lifting eyes

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Transport and Installation 5.2

Storage before installation If the Sauer compressor has to be stored before installation, do not unpack and store at the following conditions: – temperature: +5 to +40 °C; – relative humidity 30 … 95%, not condensating; – dry, under a roof and protected against dew; – protected against soiling; – protected against vibrations and shocks. Note! The standard factory conservation is sufficient for a maximum storage period of 12 months.

5.3

Installation Note! In case of doubts regarding the suitability of the installation room and place or in case of queries regarding compressor cooling contact J.P. SAUER & SOHN in time. There you will also get help with the design of a ventilating system, if it is required at the place of installation.

Follow the installation instructions and the following conditions during installation.

Installation conditions

– The place of installation must be dry and free of dust. – The place of installation must be ventilated in such way that the heat generated during operation is dissipated. – Room temperature while the Sauer compressor is running: +5 … +55 °C (deviating temperatures only if confirmed in writing by J.P. SAUER & SOHN )

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Note! The air temperature at the installation place of the compressor must not exceed +55 °C. Room conditions and the heat generated by the compressor and other machines installed in the room must be taken into consideration. • If necessary, install a ventilation or exhaust system at the place of installation. • Install the fresh air feed in such way that the fresh air stream is not directed straight at the compressor. Otherwise there is a risk of condensation of water inside the machine and subsequent damage.

This way is correct!

Do not install fresh air feed this way!

– At a room temperature of below +5 °C the room needs to be 30

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Transport and Installation heated or the Sauer compressor must be equipped with a heating system. – Choose the location such that the Sauer compressor is accessible and has sufficient clearance to walls and other machinery (see installation documents). Note! The Sauer-Compressor is cooled with fresh water. Sea water cooling is also possible optionally; however, depending upon the temperature and composition the sea water can have corrosive effect. The cooling water quantity must be so adjusted that the maximum cooling water outlet temperatures specified in section 4.1 are not exceeded. By aligning the cooling water inlet and outlet, the cooling water cavities are automatically deaerated. Note! J.P. SAUER & SOHN would be glad to advise you on the installation of the compressors.

Foundation Note! The resilient-mount bedding delivered as standard has a resonant frequency of approx. 10 Hz. The excitation of the intended compressor-foundation by vibrations from the machines installed in the vicinity must not be in the 10 Hz range. Otherwise there is a risk that the standard delivery resilient-mount bedding is destroyed by sympathetic vibration.

1. Check early enough if there are foundation vibrations in the 10 Hz range. 2. If in doubt, check with J.P. SAUER & SOHN to see if a modified resilient-mount bedding can be used.

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5.4

Connecting the compressor Danger! The compressor should only be connected by qualified technicians. Any work on the electrical installation must be carried out by qualified electricians only.

Pipelines

The compressed air outlet, coiling water inlet and outlet as well as the and the drain outlets of the Sauer compressor must be connected to the stationary pipelines by hose lines.

Hose lines

Danger! Compressed air escapes from the drain outlets when the compressor starts and when the condensate is drained. Do not operate compressor without the hose lines connected.

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

This way is correct!

Not this way!

Draining Note! Condensate that is formed contains oil. It may only be disposed of in compliance with applicable legal provisions. J.P. SAUER & SOHN can supply condensate collecting pots for separating air from the condensate, as well as condensate treatment units for separating the oil from the condensate.

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Note! We recommend connecting the compressor's drain separately. When the drain lines of several compressors are to be connected to a common pipe, observe the following: – Choose a sufficient nominal diameter for the common drain line. – Connect drain lines of the individual compressors at an acute angle to the common drain line, so no pressure can build up in the drain line of a stopped compressor.

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This way is correct!

Not this way!

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Transport and Installation Connections

The illustration below shows the connections and fittings for the operation of the standard version Sauer compressor. 1

2

7 6 5

4

3

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

Item

Name

Type

Function

1

Non-return valve

Plate valve

Prevent air back-flow

2

Ultimate pressure switch

Toggle switch

Stops/starts the compressor

3

Drain

Solenoid valve

Starting relief and draining

4

Compressed air temperature switch

Toggle switch

Stops compressor in case of excess temperature

5

Cooling water pump (optional)

Centrifugal pump non-self-priming

Pumps cooling water

6

Oil pressure switch

Toggle switch

Stops compressor when oil level is low

7

Cooling water stop valve

Solenoid valve

Cuts off cooling water flow when machine is shutdown

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5.5

Filling in oil The Sauer compressor is supplied without oil. Danger! Oil must be filled into the compressor's crankcase before initial operation! Use lubricating oil (see chapter 10. “Lubricant table”). Note filling amount (see chapter 4. “Technical Specifications”).

Oil filler plug

Dipstick

1. Unscrew oil filler plug (red). 2. Fill in oil and check level with the dipstick. Note! Fill only to the upper marking on the dipstick. Otherwise the oil consumption of the compressor will increase.

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

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Transport and Installation 5.6

Checks after installation and before the first start – Does electrical connection correspond to the type label data? – Are all connections between compressor and the surrounding compressed air unit correctly installed? Pay special attention to the compressed air outlet. – Are drain lines properly connected? (See Section "Draining”.) – Are cooling water lines opened? – Is oil filled in the crankcase? – Have all tools and foreign objects been removed from the compressor? – Has the air filter been turned to operating position from transport position (see overprint on the filter housing)? – Is the entire unit clean?

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6.

Operation

6.1

Safe operation Danger! Only authorized persons are permitted to commission and operate the Sauer compressor! Danger! Turn on and start the compressor only if – it has been checked for proper working condition; – all tools and foreign objects are removed from the machine. Caution! Turn compressor immediately OFF when persons or objects are endangered. Start compressor only when the danger is over. Danger! In Automatic mode the compressor starts automatically without warning! Danger! Risk of burns by hot surfaces of the compressor when it is running. Wear gloves. Danger! Risk of hearing damage due to the sound pressure level when the compressor is running! Wear hearing protection near the compressor. Note! Turn compressor OFF in the case of faults, abnormal ratings or irregularities. Refer to chapter 7. “Trouble Shooting” to remove cause.

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Operation 6.2

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

6.3

First Commissioning

Checking the direction of rotation

At first, let the Sauer compressor run only for a few seconds to check the direction of rotation. 1. Turn the power supply ON. 2. Set the operating mode selector to “Manual” 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 operating mode selector to “0” to stop the compressor. 5. Turn the power supply OFF. 6. If the direction of rotation is incorrect, have polarity of the electric motor changed by a qualified electrician. 7. Checking the direction of rotation of the optional cooling water pump: Switch the pump motor ON for a short duration. The motor must not reach its operating speed during this. The direction of rotation must be the same as the one indicated by the arrow on the pump. Otherwise, see Point 6. Pump and suction pipe must be filled with cooling water. Danger! The cooling water pump must never run dry.

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Danger! No oil pressure if the direction of rotation of the compressor is wrong. Risk of subsequent damage.

Test run

6.4

1. Turn the power supply ON. 2. Set the operating mode selector to “Manual” to start the compressor in manual mode. ✓ If correctly set the drain valves will close after approx. 15 seconds and the compressor accelerates against pressure. 3. Check pressure gauges of the stages as well as the oil pressure guage and compare with nominal values (for nominal values see stage pressure chart in section 6.4 "Routine Operation”). 4. Check the functioning of the automatic intermediate draining. ✓ It must drain every 15 minutes for approx. 15 seconds. This is recognisable by the pressure drop at the pressure gauges. 5. Check the cooling water flow-rate. ✓ The temperature of the cooling water at the outlet should be as indicated in section 4.1 "Specification Data“. The temperature can be read with the cooling water thermometer at the cooling water outlet. If these temperatures are exceeded or fallen short of, the cooling water flow-rate must be increased or decreased accordingly. In case of aggregates with built in cooling water pump the flow rate can be regulated with the gate valve on the pump. 6. Set the operating mode selector to “0” to stop the compressor. 7. Turn the power supply OFF. 8. If necessary, remedy the causes for deviations from nominal values and faults. Also see Chapter 7. "Trouble-shooting” for this purpose.

Routine operation

Cleaning

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

Checks

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Operation Operation

1. Turn power supply ON. 2. Open cooling water lines. 3. Set operating mode selector to “Auto” to operate the compressor in Automatic Mode.

Observation

• Pay attention to abnormal operating sounds. • Pay attention to leakages (compressed air, oil, condensate). The temperature of the cooling water at the outlet should be as indicated in section 4.1 "Specification Data“. • During operation the pressure indicated by the pressure gauge of the first stage should be within the shaded region of the stage pressure chart (see below). • The oil pressure should be between 1.8 bar and 4 bar. In case of deviations see Chapter 7. "Trouble-shooting”. Stage pressure chart 1st stage

   ]   r   a    b    [   e   r   u   s   s   e   r   p   e    t   a   m    i    t    l    U

1st stage [bar] Note! Depending on the desired ultimate pressure of the 2 nd stage the permissible pressure for the 1st stage can be read from the chart.

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HI001AC1.fm

7.

Trouble-shooting F

Note! • In case case of malfun malfunctio ctions, ns, first first chec check k the indicat indicators ors on the comcompressor control and the compressor . • Try to remedy remedy the fault fault by by followi following ng the informat information ion given given in the table below. • If the the cause cause for for the fault fault canno cannott be elimin eliminated ated,, contact contact J.P. SAUER & SOHN customer service.

Fault

Likely cause

Remedy

The compressor does not start or does not switch OFF.

No supply voltage / no control voltage.

Check fuses. Replace blown fuses.

Compressor was switched off, fault indicator lamp "Oil Pressure" glowing.

The oi oil le level is is to too lo low.

Check th the oi oil le level, ad add oi oil as as re required.

The oil pump is faulty or leaking.

Check the oil pump. Fix the leak or replace the oil pump, as required.

Compressor was switched off, Fault indicator lamp "Overcurrent“ glowing.

The motor is overheated. Excessive current drawn.

Determine the cause of the fault and correct it. The compressor can be started again after being allowed to cool off.

Piston seizure

Check liner and piston for score marks, replace if necessar y.

2nd stage valve is not working properly.

Check 2nd stage valve, replace if necessary.

Sealing between inlet and out-

Replace gasket.

Safety valve of 1st stage blows off: Pressure exceeds blowing-off pressure (8 bar)

let side of the 2nd stage is faulty. Pressure below blowing-off pressure (8 bar) Pressure in the 1st stage excessively high.

Safety valve is faulty.

Replace the safety valve.

Valve of 1st stage leaky.

Check the valve for damage and replace if necessary; replace gaskets.

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Trouble-shooting Fault

Likely cause

Remedy

2nd stage safety valve blows off: Pressure exceeds blowing-off pressure (ultimate pressure + 5%)

Valve in air line to the comValve pressed air receiver closed.

Open the valve.

Pres Pr essu sure re swi switc tch h set set too too high high..

Redu Re duce ce set set pre press ssur ure. e.

Pressure below blowing-off pressure (ultimate pressure + 5%)

Safety valve set too low or is faulty.

Replace the safety valve.

Pressure in the 2nd stage inadmissibly high.

Valve of 2nd stage leaky.

Check the valve for damage and replace if necessary; replace gaskets.

Pressure gauge of the 1st stage indicates too low a pressure.

Valve of 1st stage leaky.

Check 1st stage valve, replace if necessary.

Air filter ver y dir ty.

Replace air filter car tridge.

Drain valve of 1st stage leaky.

Clean drain valve and rebuild the valve seat if necessary.

No pressure indicated in 1st

No power at drain valve.

Check drain val alv ve power supply.

and 2nd stage pressure gauges.

Drain valve faulty.

Check drain valve, replace if necessary.

Air escaping from compressed air lines

Gaskets of connections leaking.

Replace relevant gasket.

Compression ring connections leaking.

Turn compressor OFF. Wait until all parts are relieved of pressure (check pressure gauges). Then tighten unions.

Compressed air temperature at outlet too high due to cooling water deficiency deficiency..

Increase cooling water flow-rate (only in case of the version with cooling water pump: open the gate valve behind the pump further), check the functioning of the cooling water stop valve; clean particle trap.

Compressed air-temperature at the outlet too high due to too high cooling water water inlet temperature.

Check cooling water-inlet temperature (max. 40 °C).

Compressed air-temperature at the outlet too high due to poor heat transfer in the cooler as a result of boiler scale formation.

Clean cooling water cavities with boiler cleaning compound.

No supply voltage.

Check fuses, replace blown fuses.

Solenoid faulty.

Replace solenoid.

Fore oreig ign n mat matter ter in dr drai ain n val valve ve..

Clea Cl ean n dra drain in va valv lve. e.

Compressor was switched off, fault indicator lamp "Air Temperature" glowing.

Drain valve does not close.

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Fault

Likely cause

Remedy

Intermediate drainage is not functioning.

Timer not set or not set correctly.

Set timer to 15 s drainage and 15 min closing interval.

Cooling water stop valve does not open.

No supply voltage.

Check fuses, replace blown fuses.

Solenoid faulty.

Replace solenoid.

Foreign bodies in the cooling water stop valve.

Clean cooling water-stop valve.

Connec Con nectin ting g rod bearin bearing g fault faulty y.

Check conne Check connecti cting ng rod rod bearing bearing,, replac replace e if necessary. Check oil supply.

Gudg Gu dgeo eon n pin pin be beari aring ng fa faul ulty ty..

Check Chec k gud gudgeo geon n pin pin bea bearin ring, g, rep repla lace ce if necessary.

Cran Cr anks ksha haft ft be bear arin ing g fau faullty ty..

Che hec ck cr cran ank k sha shaft ft be bear arin ing, g, re repl plac ace e ifif necessary.

Oil lea leakin king g from from cra crankc nkcase ase..

Gasket Gas ket or sha shaft ft seal seal fa fault ulty y. Screws not tight.

Tighten screws. If there is heavy leakage, leakage, check to see which gasket is faulty, faulty, then replace it. Minor traces of oil on the crankcase or oil drops below the compressor are harmless. Wipe off with a rag.

Water is leaking at the relief groove of the cylinder flange surface.

Liner O-ring above the relief groove is faulty.

Replace the O-ring.

Oil is leaking at the relief groove of the cylinder flange surface.

Liner O-ring below the relief groove is faulty.

Replace the O-ring.

Water in oil

Compressor is overcooled because of – too high cooling cooling water water flowflowrate – improp improper er room ventilat ventilation ion – very short short compressor compressor running time.

Reduce cooling water flow-rate. Change the room ventilation in such a way that it does not blow directly at the compressor; increase the compressor running time

Insufficient drainage.

Check drain lines and drain inter va vals.

Compressor makes loud noises.

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Trouble-shooting Fault Burst disc in the cooling water circuit responds.

Premature breaking of valve plates, valve springs or valve disks.

Likely cause

Remedy

Leakages in the cooler.

Re-expansion of the cooler pipes in the cylinder housing. For this purpose, separate working instructions and tool under the article code 066367 are available on request.

Pressure peaks in the cooling water circuit, which lead to the overstepping of the bursting pressure of the burst disc.

Identify the causes for pressure peaks and eliminate or reduce them (starting of additional stronger pumps, actuation of electromagnetic stop valve or alternating check valves or similar.)

Insufficient drainage.

Check drain lines and drain intervals. Note: Indentation marks appearing on the valve plate due to valve impact are normal.

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8.

Maintenance

8.1

Maintenance service by J.P. SAUER & SOHN The J.P. SAUER & SOHN customer service offers different maintenance services – e.g. full maintenance or valve replacement service.

8.2

Maintenance safety

Before servicing

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

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Maintenance 8.3

Maintenance schedule Danger! Section 8.4 “Table of tightening torques” must be followed for specific screws during all maintenance work. Note! The maintenance intervals specified in the maintenance schedule must be adhered to. Shortening the maintenance intervals is of no advantage with regard to operating performance or service life of the Sauer compressor. Note! After a major overhaul (=12,000 operating hours) the maintenance schedule begins all over again.

Instructions for the maintenance schedule

• Use the maintenance schedule as master template or copy the respective page from the digital document and save it as a separate file under a suitable name. Use the maintenance schedule as guide and for documentation. • Regularly check the maintenance schedule to see which maintenance intervals, subject to the number of operating hours, are due. The intervals are shown in the table's column headers. • Check the column of each maintenance interval to see which maintenance work is to be carried out at the end of each maintenance interval. The required tasks are indicated by check boxes. Description and chapter number of the tasks are shown in the first column. • Carry out all maintenance work of a maintenance interval and tick the appropriate check boxes of the maintenance schedule. Then enter operating hours count, date and your signature. • When beginning a new maintenance schedule – enter: main specifications, date of commissioning, number of maintenance schedule, current date and operating hours count – tick : beginning after commissioning/after major overhaul

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Maintenance Schedule No.

Compressor type

Beginning of this maintenance schedule

Type series

❏after commissioning

Compressor number

❏after major overhaul

Factory no.:

Date:

Year of construction:

Operating hours count:

Date of commissioning:

Interval (operating hours)

  n   o    i    t   a   r   e   p   o    l   a    i    t    i   n    i   r   e    t    f   a    0    5

  r   a    l   e   y   u    /   a    0    h   r    0   e    0  ,   v    1   o   r   <   o    f    i    j   a    l   y   m   r   r   a   e   e   y    t    f    t   a   s    0   a   e    5    l    t    A

❏

❏

❏

❏

Maintenance work  Checking screwed connections 8.6 Oil change 8.5 Air filter cartridge replacement 8.7 Checking valves 8.8 Checking piston rings 8.9 Replacing gudgeon pins/gudgeon pin bearings 8.10 Replacing valves 8.11 Checking pistons and cylinders 8.12 Checking drive bearings 8.13 Checking coupling 8.14 Cleaning particle trap 8.15 Checking zinc protection 8.16 Burst disc 8.17 Checking cooling water pump (optional) 8.18

2W

   0    0    0  ,    1

   0    0    0  ,    2

   0    0    0  ,    3

   0    0    0  ,    4

   0    0    0  ,    5

   0    0    0  ,    6

   0    0    0  ,    7

   0    0    0  ,    8

   0    0    0  ,    9

   0    0    0  ,    0    1

   0    0    0  ,    1    1

   l   u   a    h   r   e   v    d   o   e   r   r    i   o    j   u   a   q   e   m   r   =   s   a    0    0    0  ,    2    1

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏ ❏ ❏

❏ ❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏

❏ ❏

Operating hours count:

Date

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Signature (initials)

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Maintenance Note! Check compressor 50 hours after every maintenance work is carried out. Check all screws affected by the maintenance work to see if they are tight.

8.4

Table of tightening torques Screw(s)

8.5

Tightening torque

Connecting rod screws

115 Nm

Flywheel fastening screw

550 Nm

Valve cover screws (1st/2nd stage)

160 Nm

Bursting plate flange

54 Nm

Retaining screw of the 2nd stage valve on the valve cover

9 Nm

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

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Oil filler plug

Dipstick

Oil drain plug

1. Place oil sump (of sufficient capacity to hold the complete oil filling, see chapter 4) under the oil drain plug. 2. Remove the oil drain plug. 3. Wait until all oil is drained. 4. Replace the oil drain plug. 5. Unscrew oil filler plug (red). 6. Fill in oil and check level with the dipstick. ✓ The level shall be between the upper and lower mark on the dipstick. 7. Put dipstick back in and screw the oil filler plug back on.   m    f  .    1 _    5    0    0    A    W    I_

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Maintenance 8.6

Checking screwed connections Check all unions and screwed connections for tightness, retighten if necessary. This concerns – cooler and air lines; – unions of pipe lines and hose lines; – cylinder heads; – cylinders; – electric motor and intermediate flange; – measuring and switching devices; – bedding; – accessories and equipment parts.

8.7

Air filter cartridge replacement Air filter cap

1. 2. 3. 4.

Open clips and take the air filter cap off. Remove the used air filter cartridge. Put new air filter cartridge in. Put cap back on and close the clips.

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8.8

Checking valves Note! Plate valves and particularly lamellar valves are those pats of a reciprocating compressor, that are subject to the most stress. In order to achieve the guaranteed maintenance intervals, these valve are specially matched to the individual compression stages as high-quality precision parts, and their functioning carefully checked before delivery. Repair by the maintenance and operating personnel requires special knowledge, which may not be available every time. For such cases J.P. SAUER & SOHN offer a valve replacement service. In case it should be necessary please contact the Sauer service department. In case of two stage water-cooled compressors, the high final compression temperature can lead to untimely soiling of valves if ambient conditions are unfavourable or poor varieties oil are used. In such cases, some other oil is to be used or the maintenance intervals are to be shortened. Note! While reinstalling valves use only new gaskets and rings everytime. Do not reuse the used rings under any circumstances. Doing so leads to leakage within a short time. Use only genuine Sauer spare parts. They are precision parts with defined and tested dimensions and material characteristics, specially designed for use in Sauer compressors. Installation of other gaskets may lead to leakage and could cause substantial damage to the compressor.

Checking the plate valve (1st stage)

1. Loosen the clamp and remove air filter. 2. Loosen the hose of the crankcase vent at the union and remove with nipple. 3. Loosen the valve cover nuts and pull the valve cover uniformly with the two M12 screws. 4. Take out valve carefully. Note! When removing, cleaning and installing the plate valve, take care that no valve parts are damaged. This applies particularly to the sealing surfaces and the valve springs. Slight damage to the raised faces of the valve seats can be removed by refacing on a lapping plate.

5. Unscrew nut. For this purpose, clamp the valve in "soft jaws" is such a way that the the valve mating surfaces do not get damaged. 52

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Maintenance 6. Disassemble valve. 7. Clean all valve parts. For this purpose soak them in an oil dissolving fluid (e.g. petroleum or benzene). 8. Check valve parts for damage. Replace damaged valve parts.

9. Carefully reassemble valve (see illustration), tighten nut. 10. Use a pin with round tip to check the valve plate's smoothness of action against the spring pressure. 11. Fit plate valve and valve cover. Use new sealing rings in the valve cover while doing so (see illustration). Observe the tightening torque (see section 8.4). 12. Fit the hose of the crankcase vent and fix with clamp. 13. Mount air filter and fix with clamp.

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O-ring

Checking lamellar valve (2nd stage)

1. Loosen the for flange screws of the compressed air manifold on the valve cover of the 2nd stage. Loosen flange connection on the two cylinders of the 2nd stage. 2. Loosen the valve cover nuts and pull the valve cover uniformly with the two M12 screws. 3. Remove the retaining screw on the valve cover and take out valve carefully. 4. Examine the valve. If lamellar valve is heavily carbonised or damaged, replace complete valve. Note! Lamellar valves require very little maintenance and function even in presence of small quantities of dirt in contrast to plate valves. Normally the plates have the same service life as the valve body which, due to its geometry, can not be refaced or lapped. Therefore a replacement of individual plates is not recommended. Should a plate be broken prematurely nevertheless (e.g. through impact of foreign objects), contact our service.

5. Fix the lamellar valve on the valve cover with the retaining screw. Observe the tightening torque (see section 8.4). 6. Fit lamellar valve and valve cover. Use new sealing rings while doing so (see illustration). Observe the tightening torque (see section 8.4).

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Maintenance

O-ring

O-ring

8.9

Checking the piston rings

1st stage

1. Remove valve cover and valves as described in section 8.8, “Checking valves”. 2. Dismantle inspection hole cover on the crankcase. 3. Remove connecting rod bolts and remove connecting rod bearing cover with bearing bush. Push piston together with connecting rod upper part out of the cylinder. 4. Remove all piston rings from the pistons. 5. Place piston rings in their respective cylinders and measure the gap clearance with a feeler gauge. 6. Replace piston rings if the gap clearance exceeds the following limits. Compression ring

1.80 mm

Oil scraper ring

1.80 mm

Note! Always replace all pistons rings of a piston when one of the piston rings exceeds the limit.

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55

Note! Use an assembly sleeve for pushing the piston into the liner from above (see Chapter 11 "Spare parts and Accessories“).

8. Put connecting rod back with sufficient oil and screw on the bottom part with hand. Note! Numbers are punched on the upper and lower parts of the connecting rod. These must match in any case . See illustration.

7 7

✓

2nd stage

56

It should be possible to screw in the connecting rod bolts completely with hand. Only then the correct seat on the crankshaft can be guaranteed. After tightening, the connecting rod should rotate easily on the crankshaft.

1. Loosen the flange connection and dismantle compressed air manifold. 2. Loosen screwed pipe connections 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, dismantle cooling water inlet pipe. The screw connection nipple remains on the cylinder. 5. Remove the union nut of the cooling water hose between the cylinders of the 1st and 2nd stage and remove the cooling water hose. The bend remains on the cylinder of the 2nd stage. 6. Dismantle both the inspection hole covers from the crankcase. 7. Loosen the connecting rod bolts and remove them from the Version 1 - 1

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Maintenance 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 foot of the cylinder of the 2nd stage. 9. Turn the two M16 lifting eye nuts (see Chapter 11 "Spare parts and Accessories“) on both the upper studs of the valve cover and pull the cylinder out of the crankcase with a suitable lifting device (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. 13. Place piston rings in their respective cylinders and measure the gap clearance with a feeler gauge. 14. Replace piston rings if the gap clearance exceeds the following limits. Compression ring

0.75 mm

Oil scraper ring

0.65 mm

15. Fit piston rings. Fit N-ring in the third groove from above. Make sure they are in the correct position: piston rings having an asymmetric cross section are marked on one of the surfaces with “TOP”. The marked face must be at the top when the piston ring is installed. See illustration.

TOP

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16. Sequence of assembly is exactly opposite to that of dismantling. 17. Put connecting rod back with sufficient oil and screw on the bottom part with hand (see section 8.4 for tightening torque).

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Note! Numbers are punched on the upper and lower parts of the connecting rod. These must match in any case . See illustration.

7 7

✓

It should be possible to screw in the connecting rod bolts completely with hand. Only then the correct seat on the crankshaft can be guaranteed. After tightening, the connecting rod should rotate easily on the crankshaft.

8.10 Replacing gudgeon pins/gudgeon pin bearings 1. Remove valve covers and valves as described in section 8.8, “Checking valves”. 2. Remove cylinder and piston with connecting rod as described in Section 8.9 "Checking piston rings”. 3. Remove circlip of the gudgeon pin and push the gudgeon pin out. 4. Press gudgeon pin bearing out of the connecting rod's small end. 5. Replace gudgeon pin and gudgeon pin bearing. 6. Press gudgeon pin bearing into the connecting rod's small end. 7. Assemble piston with connecting rod and cylinder as described in Section 8.9 "Checking piston rings". 8. Assemble valves and valve covers as described in Section 8.8 "Checking valves”.

8.11 Replacing valves Remove and install valves as detailed in section 8.8 “Checking valves”. Replace complete valve. 58

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Maintenance 8.12 Checking pistons and cylinders 1. Remove valve cover and valves as described in section 8.8, “Checking valves”. 2. Remove cylinders and pistons as described in section 8.9, “Checking the piston rings”. 3. Check liner and pistons for scouring and excessive wearing marks. Replace relevant parts. 4. Measure liner and replace if the following wear limits are exceeded: Cylinder

Wear limit of diameter

1st stage

195.15 mm

2nd stage

110.15 mm

5. If the liners were to be pulled out, fit them back with new sealing rings. 6. Fit cylinders and pistons as described in section 8.9, “Checking the piston rings”. 7. Assemble valve cover and valve as described in section 8.8, “Checking valves”.

8.13 Checking the drive bearings

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1. Remove valve cover and valves as described in section 8.8 “Checking the valves”. 2. Remove cylinder and piston with connecting rod as described in Section 8.9 "Checking piston rings”. 3. Inspect the connecting rod bearing for score marks and excessive wear marks and replace in case of heavy wear. 4. Dismantle electric motor with intermediate flange, coupling and flywheel as described in Section 8.14 "Checking coupling“. 5. Remove bearing bracket. 6. Pull crankshaft out. 7. Inspect the crankshaft bearing for score marks and excessive wear marks and replace in case of heavy wear. If required, use new shaft seal. 8. Fit crankshaft. 9. Install bearing bracket. If necessary use new gasket. 10. Fit electric motor with intermediate flange, coupling and flywheel. Observe the tightening torque (see section 8.4). 11. Assemble piston with connecting rod and cylinder as described in Section 8.9 "Checking piston rings". 12. Assemble valves and valve covers as described in Section Version 1 - 1

59

8.8 "Checking valves”.

8.14 Checking the coupling Visual check

1. Remove protection cover on the transmission bell housing on the first stage. Through the inspection port check the coupling's flexible gear rim for damage. The teeth of the flexible gear rim must not be deformed. 2. Fix protection cover back. 3. If necessary, replace the flexible gear rim as described below. Protection cover

Removing the gear rim

4. Support compressor under the transmission bell housing. 5. Remove the electric motor mounting screws. 6. Lift the electric motor carefully using the lifting eye (see section 5.1 "Transport”). 7. Pull electric motor carefully away from the intermediate flange. 8. Replace flexible gear rim.

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Maintenance

Tooth of flexible gear rim

9. Slide electric motor gently against the intermediate flange and tighten the motor mounting screws. 10. Remove support from under the transmission bell housing.

8.15 Cleaning particle trap 1. Block cooling water inlet. 2. Loosen the cap of the particle trap (in front of the cooling water-control valve) and remove the strainer. 3. Clean the strainer. 4. Fit the strainer back, screw on the cap.

8.16 Checking zinc protection The zinc protections for the cylinders of the 1st stage are located laterally on the cylinder. The zinc protection for the cylinder of the 2nd stage is located laterlly on the cylinder beside the burst disc flange. 1. Unscrew the zinc protection and remove loose parts. 2. Check the zinc protection. Minimum diameter is 24 mm. Regenerate the zinc protection if the consumption is too high. 3. Fit the zinc protection back with a new sealing ring.

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8.17 Burst disc 1. Remove screw and dismantle pressure flange on the cylinder of the 2nd stage. 2. Remove burst disc and sealing ring. 3. Clean sealing surface. 4. Insert new gasket and new burst disc. Pay attention to the correct position of the gasket. Fit first the gasket and then the burst disc into the cylinder. 5. Bolt the pressure flange back.

8.18 Checking cooling water pump (optional) The pump should be checked as follows in case of abnormal running sound or leakages from the pump:

Disassembling the pump

1. Block the cooling water inlet and outlet. 2. Disconnect electrical connection. 3. Remove the drain plug located below on the cylinder of the 2nd stage and drain the cooling water of the compressor. 4. Loosen the flange connections on the cooling water inlet and outlet of the pump. 5. Loosen the bolted fastening of the pump at the foot and remove pump from the console.

Replacing the floating ring seals

The floating ring seals are maintainance-free. In case heavy leakages are noticed after long running time, the floating ring seal is to be replaced as a complete unit. 6. Remove impeller and shaft retaining ring. 7. 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. Caution: A great deal of care and cleanliness is essential required during the assembly of new floating ring seal. The gliding surfaces must never be touched with fingers. Any damage must in any case be avoided. Moisten the elastomers with low surface tension water to facilitate easier assembly. Caution: Floating ring seals must never come in contact with grease or oil! The shape of spare floating ring seals can be different from that of the built in floating ring seals. The spare floating ring seal however has the same assembly dimensions and is interchangeab-

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Maintenance le. The floating ring seal must be carefully slid onto the shaft with rotating motion.

Note! The motor bearing should be replaced if the shaft has noticeable play. A possibly damaged pump impeller must likewise be replaced.

Assembling the pump

8. Assemble the pump back in the reverse sequence. 9. Checking the direction of rotation of the optional cooling water pump: Switch the pump motor ON for a short duration. The motor must not reach its operating speed during this. The direction of rotation must be the same as the one indicated by the arrow on the pump. The pump and the suction pipe must be completely filled with cooling water.

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9.

Placing out of Service

9.1

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

9.2

Shutting down the compressor temporarily Every 4 weeks perform a test run for at least 30 minutes. Then additional corrosion prevention measures are not required. When the Sauer compressor is to be shut down for more than 12 weeks , conservation with slushing oil is recommended. In this case periodic test runs are not necessary. Note! Use one of the slushing oils recommended in Chapter 10 "Lubricant Table" for corrosion protection. The slushing oil has satisfactory running properties. In case of emergency the machine can be started for a short time with a slushing oil filling.

1. Run compressor for approx. 5 minutes with drain valves and pressure line open. ✓ Any existing condensate is blown off. 2. Drain compressor oil and dispose it of in an environmentally friendly manner. 3. Fill about 10 litres of slushing oil. 4. Start compressor and run for approx. 5 minutes with drain valves and pressure line opened. 5. Stop compressor. 6. Unscrew both the air filters. 7. Start compressor and slowly inject approx. 100 cc slushing oil into the intake ports. 8. Wait until oil mist comes out of the pressure line. 9. Stop compressor. 10. Fit both air filters back. 11. If necessary, post a sign that the compressor has been trea64

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Placing out of Service ted with anticorrosion measures and is placed out of service. 12. If necessary disconnect mains supply.

Restarting

9.3

1. Connect power supply, if necessary. 2. Drain slushing oil and fill with compressor oil. 3. Proceed as described in section 6.3 "Commissioning”.

Dismantling

Dismantling

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

Disposal Material/component

How to dispose

Lubricants

as hazardous waste

Steel/iron

as metal scrap

Electric cables

as hazardous waste

Electronic components

as electronic waste

Plastics

as hazardous waste

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ST001AD1.fm

10. Lubricant Table Scope

The lubricant table applies to all Sauer compressors intended for the compression of air. The lubricant table does not apply to – Sauer compressors for the compression of neutral gases; – temperature ranges outside of 5 … 55 °C.

General recommendation

We recommend mineral oils of the viscosity class in accordance with ISO VG 100 for the temperature range 5 … 55 °C. The lubricating oils should at least conform to the group VCL in accordance with DIN 51506. Note! The recommended oil types bring down the carbonisation in the compressor valves and the connected pipes and fittings to a minimum. Lubricants not mentioned in the lubricant table may only be used after approval by J.P. SAUER & SOHN . Otherwise the warranty will lapse. Please contact our customer service when selecting oils not listed here or in case of deviating operating conditions.

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Lubricant Table 10.1 Lubricating oils Brand Agip

ARAL

AVIA

BP

Castrol Chevron

DEA

Esso

Mobil

Shell

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Name

Group

Diesel Gamma 30

VCL-100

Dicrea 100

VDL-100

Acer 100

VCL-100

Motor Oil HD 30

SAE 30

Cladium 50

SAE 30

Motanol HE 100

VDL-100

Kowal M 30

VCL-100

Disola M 30

SAE 30

Avilub Compressor Oil VDL-100

VDL-100

Avilub Compressor Oil VDL-100

VCL-100

Motor oil HDC 30

SAE 30

Motor oil HD 30

SAE 30

Energol RC 100

VDL-100

Energol IC-DG 30

VCL-100

Energol DL-MP 30

SAE 30

Energol OE-HT 30

SAE 30

Vanellus C3 SAE 30

SAE 30

Aircol PD 100

VDL-100

Marine CDX 30

SAE 30

HD Compressor Oil 100

VDL-100

Delo 1000 Marine 30

SAE 30

Veritas 800 Marine 30

SAE 30

RPM Heavy Duty Motor 30

SAE 30

Actro EP VDL-100

VDL-100

Trion EP VDL-100

VDL-100

Regis SAE 30

SAE 30

Exxcolub 77

VDL

Exxcolub 100

VDL-100

Compressor Oil 3021 N

VDL-100

Exxmar 12 TP 30

SAE 30

Exxmar XA

SAE 30

Essolube HDX Plus +30

SAE 30

Rarus 427

VDL-100

DTE Oil Heavy

VDL

Mobilgard 300

SAE 30

Corena Oil P 100

VDL-100

Rimula X 30

SAE 30

Melina S Oil 30

SAE 30

Melina Oil 30

SAE 30

Gadinia Oil 30

SAE 30 Version 1 - 1

67

Brand TEXACO

TOTAL

Name

Group

Compressor Oil EP VDL 100

VDL-100

Regal R&O 100

VCL-100

Ursatex 30

SAE 30

DORO AR 30

SAE 30

Dacnis P 100

VDL-100

Carprano TD 30

SAE 30

Milcano TC 30

SAE 30

Disola M 3015

SAE 30

10.2 Slushing oils Brand

Name

Agip

Rustica C SAE 30

ARAL

Konit Motor Oil SAE 30

AVIA

MK 1540 S Avilub MK 3000

BP

MEK 20 W-20

Castrol

Running-in and Preservation Oil

DEA

Deamot EKM 642 SAE 30

ELF

Stockage 30

Esso

MZK Motor Oil HD 30 Antirust MZ 110

FINA

Rusan NF Motor Oil SAE 30

Mobil

Mobilarma 524

Shell

Ensis Motor Oil 30

TEXACO

Engine Oil EKM 146 SAE 30

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Spare Parts and Accessories 11. Spare Parts and Accessories Note! Please note the information in chapter 1. “General” regading our genuine Sauer spare parts.

J.P. SAUER & SOHN garantee the complete spare parts supply over the entire service life of the Sauer compressor. Our genuine Sauer spare parts are subject to constant quality control and further development. They conform to the latest technical developments. In addition to the genuine Sauer spare parts, our delivery program comprises a large number of accessories for your Sauer compressor and special components to complete your air system, such as: – fully automatic controls; – adsorption dryers; – refrigerated air dryers; – filters; – silencing cabinets; – compressed air receivers; – fittings. We supply instructions and a maintenance manual for each accessory.

Spare parts catalogue

The spare parts catalogue is found in the annex to these instructions. – With the help of overviews, illustrations and lists the required parts is quickly found. – The spare parts catalogue, including the operating instructions is also available on CD-ROM. Here, an order form can be filled in, printed out and send immediately. For doing so, you need the main specifications of your Sauer compressor from the table below. If they have not yet been entered there, they can be found on the type label affixed to the crankcase. Compressor type Factory no.: Year of construction:

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

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Annex

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S a u e r C o m p r e s s o r Type: WP 400

Spare Part List

Version 1 - 1

-2

Version 1 - 1

Spare Part List WP 400 Sauer compressor

Reference No.

Subassemblies

WP 400

Sauer compressor . . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..................... 4

064 140

crankcase . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . ..................... 6

064 448

protection device. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..................... 8

064 142

crankshaft . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . ................... 10

063 864

connecting rod 1st stage . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . .................. 12

064 144

connecting rod 2nd stage . . . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .................. 14

064 261

piston 1st stage . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . .................. 16

064 145

piston 2nd stage . . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ................... 18

063 866

cylinder 1st stage . . . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ................... 20

063 915

cylinder 2nd stage . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . .................. 22

063 868

valve cover 1st stage . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . .................. 24

063 869

valve cover 2nd stage . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . .................. 26

037 134

concentric valve 1st stage . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . ................... 28

036 959

lamellar valve 2nd stage . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . .. . . .................. 30

064 146

air pipes. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. ................... 32

064 147

cooling water pipes compr. . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .................. 34

064 366

cooling water lines unit without pump ..................................... 36

066 143

cooling water lines unit with pump ...................... ................... 38

038 238

cooling water pump. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . .................. 41

064 148

crankcase venting . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . .................. 46

063 985

lubricating oil supply . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . .................. 48

064 038

measuring device . . . .. . . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . . .. . . ................... 50

064 308

auxiliary tools, compl. . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . .................. 52

064 151

resilient mounts f. motor 280 S/M....................... ................... 54

064 039

automatic drainage . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . .................. 56

063 950

compressor monitor . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . ................... 58

Note:

Page

Explanation of the subassemblies in chapter 3 "Design and Function" of the operating instructions

Version 1 - 1

E-3

WP 400 Sauer compressor

-4

Version 1 - 1

Spare Part List WP 400 Sauer compressor

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25

Reference No. Designation

Qty.

064 140 064 142 063 864 064 144 064 261 064 145 063 866 063 915 063 868 063 869 037 134 036 959 064 146 064 147 064 366 066 143 064 148 063 985 064 038 033 423 064 308 064 151 063 950 064 039

1 1

crankcase crankshaft connecting rod 1st stage connecting rod 2nd stage piston 1st stage piston 2nd stage cylinder 1st stage cylinder 2nd stage valve cover 1st stage valve cover 2nd stage concentric valve 1st stage lamellar valve 2nd stage air pipes cooling water pipes compr. cooling water lines unit without pump cooling water lines unit with pump crankcase venting lubricating oil supply measuring device flex.coupling f. motor 280 S/M auxiliary tools, compl. resilient mounts f. motor 280 S/M compressor monitor  automatic drainage

Version 1 - 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

E- 5

064 140 crankcase

-6

Version 1 - 1

Spare Part List 064 140 crankcase

Item 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 27 28 29 30 31

Reference No. Designation

Qty.

063 786 064 394 051 883 036 897 064 257 063 748 063 749 030 743 004 635 000 971 005 001 035 984 005 009 038 102 001 620 036 960 001 621 001 408 002 031 064 331 064 332 000 494 064 448 030 556

1 1

crankcase housing cover   inspection hole cover  oil sieve dipstick inspecting hole cover packing housing cover packing shaft seal union plug gasket cock Ring stud hexagon nut stud hexagon head nut stud hexagon nut blind flange blind flange packing Socket Head Cap Screw protection device o-ring

Version 1 - 1

2 1 1 2 1 1 1 2 2 1 1 6 6 12 12 16 16 1 1 4 1 1

E- 7

064 448 protection device

-8

Version 1 - 1

Spare Part List 064 448 protection device

Item 1 3 4 5

Reference No. Designation

Qty.

064 449 001 408 002 031 002 156

1 2

protection cover  stud hexagon nut washer  

Version 1 - 1

2 2

E- 9

064 142 crankshaft

- 10

Version 1 - 1

Spare Part List 064 142 crankshaft

Item 1 2 3 4 6 7 8 9

Reference No. Designation

Qty.

064 143 063 544 063 732 063 811 005 297 033 994 036 961 000 542

1 1

crankshaft driving plate washer   flywheel hexagon head screw cylinder head screw cylinder roller bearing cylinder head screw

Version 1 - 1

1 1 1 2 2 10

E -11

063 864 connecting rod 1st stage

- 12

Version 1 - 1

Spare Part List 063 864 connecting rod 1st stage

Item 1 2 3 4

Reference No. Designation

Qty.

063 712 061 857 035 823 061 676

1 1

connecting rod connecting rod bearing needle roller bearing connecting rod screw

Version 1 - 1

1 2

E -13

064 144 connecting rod 2nd stage

- 14

Version 1 - 1

Spare Part List 064 144 connecting rod 2nd stage

Item 1 2 3 4

Reference No. Designation

Qty.

063 826 061 857 037 058 061 676

1 1

connecting rod connecting rod bearing needle roller bearing connecting rod screw

Version 1 - 1

1 2

E -15

064 261 piston 1st stage

- 16

Version 1 - 1

Spare Part List 064 261 piston 1st stage

Item 1 2 3 4 5

Reference No. Designation

Qty.

036 983 036 078 002 716 035 962 002 985

1 1

piston piston pin R-ring G-ring circlip

2 1 2

Version 1 - 1

E -17

064 145 piston 2nd stage

- 18

Version 1 - 1

Spare Part List 064 145 piston 2nd stage

Item 1 2 3 4 5 6

Reference No. Designation

Qty.

063 815 064 150 033 571 002 634 002 605 012 682

1 1

piston piston pin R-ring N-ring S-ring circlip

2 1 1 2

Version 1 - 1

E -19

063 866 cylinder 1st stage

- 20

Version 1 - 1

Spare Part List 063 866 cylinder 1st stage

Item 1 2 4 5 6 7 8 9 10 12 14 15 16 17 18 19 22 23 24 26

Reference No. Designation

Qty.

063 779 061 822 063 660 063 656 063 652 063 776 063 747 063 797 063 796 000 497 001 533 000 507 000 523 000 977 001 016 035 390 001 621 005 023 005 009 036 962

1 1

cylinder housing 1st stage zinc protection cylinder cover   cooler cover, rear  cooler cover, front finished bushing cylinder cover packing cooler cover packing, rear  cooler cover packing, front cylinder head screw stud cylinder head screw cylinder head screw plug plug plug hexagon head nut gasket Ring o-ring

Version 1 - 1

1 1 1 1 1 1 1 6 6 19 2 1 3 1 6 3 3 4

E -21

063 915 cylinder 2nd stage

- 22

Version 1 - 1

Spare Part List 063 915 cylinder 2nd stage

Item 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25

Reference No. Designation

Qty.

064 442 061 822 054 883 063 662 064 395 063 654 063 808 063 747 063 751 063 750 051 530 061 942 000 505 000 551 000 497 001 533 001 621 001 016 000 977 035 390 005 023 005 009 030 131

1 1

cylinder housing 2nd stage zinc protection protection cover  cylinder cover   cooler cover, rear  cooler cover, front finished bushing cylinder cover packing cooler cover packing, rear  cooler cover packing, front protection cover packing bursting plate cylinder head screw cylinder head screw cylinder head screw stud hexagon head nut plug plug plug gasket Ring o-ring

Version 1 - 1

1 1 1 1 1 1 1 1 1 1 4 21 6 4 4 1 1 1 3 1 4

E -23

063 868 valve cover 1st stage

- 24

Version 1 - 1

Spare Part List 063 868 valve cover 1st stage

Item 1 2 3 4 5

Reference No. Designation

Qty.

064 236 036 394 037 151 030 912 036 395

1 1

valve cover  dry air filter   o-ring o-ring Filter insert for air filter 

Version 1 - 1

1 1 1

E -25

063 869 valve cover 2nd stage

- 26

Version 1 - 1

Spare Part List 063 869 valve cover 2nd stage

Item 1 2 3 4 5

Reference No. Designation

Qty.

063 743 036 964 003 493 036 963 035 970

1 1

valve cover  hexagon head screw gasket o-ring o-ring

Version 1 - 1

1 1 1

E -27

037 134 concentric valve 1st stage

- 28

Version 1 - 1

Spare Part List 037 134 concentric valve 1st stage

Item 1 2 3 4 5 6

Reference No. Designation

Qty.

037 187 037 188 037 189 037 190 037 191 037 192

1 1

suction valve plate delivery valve plate delivery valve plate delivery valve spring delivery valve spring suction valve spring

Version 1 - 1

1 2 2 2

E -29

036 959 lamellar valve 2nd stage

- 30

Version 1 - 1

Spare Part List 036 959 lamellar valve 2nd stage

Item 1 2 3

Reference No. Designation

Qty.

037 186 037 236 037 237

1 8

suction plate DIA 124 delivery plate delivery spring plate

Version 1 - 1

8

E -31

064 146 air pipes

- 32

Version 1 - 1

Spare Part List 064 146 air pipes

Item 1 2 4 6 7 8 9 10 11 12 13 14 15 16

Reference No. Designation

Qty.

063 812 063 121 056 335 000 054 000 137 002 151 036 157 006 193 005 946 030 751 030 752 005 009 005 016 005 023

1 1

collecting tube separator   packing hexagon head screw hexagon head screw washer  union union stud adaptor  safety valve safety valve Ring safety valve gasket gasket

Version 1 - 1

2 12 2 2 1 1 1 1 1 1 2 2

E -33

064 147 cooling water pipes compr.

- 34

Version 1 - 1

Spare Part List 064 147 cooling water pipes compr.

Item 1 2 4 6 9 10 11 12

Reference No. Designation

Qty.

037 144 037 265 037 194 038 390 004 661 036 967 034 875 037 305

4 1

angle angle union hose union union adaptor  reducer 

3 2 4 1 1 1

Version 1 - 1

E -35

064 366 cooling water lines unit without pump

- 36

Version 1 - 1

Spare Part List 064 366 cooling water lines unit without pump

Item 1 2 3 4 5 6 7 8

Reference No. Designation

Qty.

037 142 032 679 032 725 037 930 037 265 037 266 036 967 037 267

1 1

soleniod valve dirt trap connector   connector   angle connector  union reducer 

Version 1 - 1

2 1 1 1 1 1

E -37

066 143 cooling water lines unit with pump

- 38

Version 1 - 1

Spare Part List 066 143 cooling water lines unit with pump

Item 1 2 3 4 5 6 7 8 9 10 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 35 36

Reference No. Designation

Qty.

066 442 066 145 066 144 005 265 012 851 000 155 000 594 001 620 002 051 038 201 032 725 002 161 037 267 037 144 037 265 002 166 036 967 032 679 037 150 064 396 038 238 038 386 037 493 037 293 036 614 030 658 037 441 037 930 037 305 000 119 000 048 002 153 002 156

1 2

holder  ledge L-profil hexagon head screw hexagon head screw hexagon head screw cylinder head screw hexagon nut hexagon nut reducer  connector   washer  reducer   angle angle washer   union dirt trap solenoid valve gate valve cooling water pump hose clamp flange flange packing packing connector   reducer   hexagon head screw hexagon head screw washer  washer 

Version 1 - 1

1 8 4 2 2 2 8 1 1 4 1 1 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 4 8

E -39

066 143 cooling water lines unit with pump

Item 37 38 40 41

- 40

Reference No. Designation

Qty.

002 025 002 031 037 851 004 666

2 6

hexagon nut hexagon nut union union

1 1

Version 1 - 1

Spare Part List

Version 1 - 1

E - 41

038 238 cooling water pump

- 42

Version 1 - 1

Spare Part List 038 238 cooling water pump

Version 1 - 1

E -43

- 44

Version 1 - 1

Spare Part List 038 238 cooling water pump

Item 1

Reference No. Designation

Qty.

038 290

1

packing kit

Version 1 - 1

E -45

064 148 crankcase venting

- 46

Version 1 - 1

Spare Part List 064 148 crankcase venting

Item 1 2 3 4 5 6 7 8 9 10 11 12 14

Reference No. Designation

Qty.

038 407 038 268 033 087 034 612 035 254 037 139 037 140 037 185 037 144 037 194 035 824 037 264 033 952

1 1

pipe adaptor  distribution piece reducer   LP-hose hose clamp hose union bend connector  angle union filling cover   LP-hose hose

Version 1 - 1

1 1 4 4 2 1 1 1 1 1 1

E -47

063 985 lubricating oil supply

- 48

Version 1 - 1

Spare Part List 063 985 lubricating oil supply

Item 1 2 7 8 10 11 12

Reference No. Designation

Qty.

063 543 057 916 003 438 000 452 056 318 036 363 030 544

1 1

oil pump overpressure valve oil pump gasket cylinder head screw packing lubricating oil supply packing packing

Version 1 - 1

1 4 1 1 1

E -49

064 038 measuring device

- 50

Version 1 - 1

Spare Part List 064 038 measuring device

Item 1 2 3 6 7 8 9 10 12

Reference No. Designation

Qty.

035 009 035 010 035 061 038 073 005 009 005 016 035 906 030 182 030 509

3 1

Pressure gauge Pressure gauge Gasket ring angle thermometer 0-250°C Ring safety valve gasket adaptor  angle thermometer  plug

Version 1 - 1

4 3 3 1 1 1 1

E -51

064 308 auxiliary tools, compl.

- 52

Version 1 - 1

Spare Part List 064 308 auxiliary tools, compl.

Item 1 2 3

Reference No. Designation

Qty.

037 225 064 306 064 309

2 1

lifting eye nut assembly bushing turning rod

Version 1 - 1

1

E -53

064 151 resilient mounts f. motor 280 S/M

- 54

Version 1 - 1

Spare Part List 064 151 resilient mounts f. motor 280 S/M

Item 1 2 3 4 5 6 8 9 10

Reference No. Designation

Qty.

066 595 033 531 000 589 046 837 034 763 035 942 004 701 065 664 063 947

2 8

cooling water hose lines countersunk screw cylinder head screw resilient mount HP - hose HP - hose union non-return valve rail

Version 1 - 1

8 8 1 2 2 1 2

E -55

064 039 automatic drainage

- 56

Version 1 - 1

Spare Part List 064 039 automatic drainage

Item 1 2 3 4 5 6 7 8 9 10 11 12 13

Reference No. Designation

Qty.

049 129 033 961 006 187 004 647 005 964 004 973 035 555 000 434 005 009 006 000 006 455 008 663 008 672

1 1

tube clamp stud adaptor   union union union union solenoid valve Socket Head Cap Screw Ring union stud adaptor   pipe pipe

Version 1 - 1

1 2 1 1 2 2 2 1 1 1 1

E -57

063 950 compressor monitor

- 58

Version 1 - 1

Spare Part List 063 950 compressor monitor

Item 1 3 4 5 6 8

Reference No. Designation

Qty.

064 018 030 082 000 409 004 596 033 017 008 633

1 1

temperature monitor  oil pressure switch socket head cap screw union reducer   pipe

Version 1 - 1

2 2 1 1

E -59

- 60

Version 1 - 1

Index Reference No.

Designation

000 048 000 054 000 119 000 137 000 155 000 409 000 434 000 452 000 494 000 497 000 497 000 505 000 507 000 523 000 542 000 551 000 589 000 594 000 971 000 977 000 977 001 016 001 016 001 408 001 408 001 533 001 533 001 620 001 620 001 621 001 621 001 621 002 025 002 031 002 031 002 031 002 051 002 151 002 153 002 156 002 156 002 161 002 166 002 605 002 634 002 716 002 985 003 438 003 493 004 596 004 635 004 647

hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . socket head cap screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Socket Head Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Socket Head Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . oil pump gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Version 1 - 1

Page

Pos.

39 33 39 33 39 59 57 49 7 21 23 23 21 21 11 23 55 39 7 21 23 21 23 7 9 21 23 7 39 7 21 23 40 7 9 40 39 33 39 9 39 39 39 19 19 17 17 49 27 59 7 57

34 6 33 7 6 4 8 8 29 12 16 14 15 16 9 15 3 7 11 17 21 18 20 19 3 14 17 16 8 18 22 19 37 20 4 38 9 8 35 5 36 14 18 5 4 3 5 7 3 5 10 4

E -61

Reference No.

Designation

004 661 004 666 004 701 004 973 005 001 005 009 005 009 005 009 005 009 005 009 005 009 005 016 005 016 005 023 005 023 005 023 005 265 005 297 005 946 005 964 006 000 006 187 006 193 006 455 008 633 008 663 008 672 012 682 012 851 030 082 030 131 030 182 030 509 030 544 030 556 030 658 030 743 030 751 030 752 030 912 032 679 032 679 032 725 032 725 033 017 033 087 033 423 033 531 033 571 033 952 033 961 033 994

union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . safety valve gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . safety valve gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . hexagon head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . angle thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dirt trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dirt trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . flex.coupling f. motor 280 S/M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . countersunk screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- 62

Version 1 - 1

Page

Pos.

35 40 55 57 7 7 21 23 33 51 57 33 51 21 23 33 39 11 33 57 57 57 33 57 59 57 57 19 39 59 23 51 51 49 7 39 7 33 33 25 37 39 37 39 59 47 5 55 19 47 57 11

9 41 8 6 12 14 24 24 14 7 9 15 8 23 23 16 4 6 11 5 10 3 10 11 8 12 13 6 5 3 25 10 12 12 31 29 9 12 13 4 2 20 3 13 6 3 20 2 3 14 2 7

Index Reference No.

Designation

034 612 034 763 034 875 035 009 035 010 035 061 035 254 035 390 035 390 035 555 035 823 035 824 035 906 035 942 035 962 035 970 035 984 036 078 036 157 036 363 036 394 036 395 036 614 036 897 036 959 036 960 036 961 036 962 036 963 036 964 036 967 036 967 036 967 036 983 037 058 037 134 037 139 037 140 037 142 037 144 037 144 037 144 037 150 037 151 037 185 037 186 037 187 037 188 037 189 037 190 037 191 037 192

LP-hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HP - hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasket ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hose clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . needle roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . filling cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . HP - hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricating oil supply packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dry air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter insert for air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . oil sieve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . lamellar valve 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hexagon head screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . needle roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . concentric valve 1st stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hose union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . soleniod valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . suction plate DIA 124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . suction valve plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . delivery valve plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . delivery valve plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . delivery valve spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . delivery valve spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . suction valve spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Version 1 - 1

Page

Pos.

47 55 35 51 51 51 47 21 23 57 13 47 51 55 17 27 7 17 33 49 25 25 39 7 5 7 11 21 27 27 35 37 39 17 15 5 47 47 37 35 39 47 39 25 47 31 29 29 29 29 29 29

4 5 11 1 2 3 5 19 22 7 3 11 9 6 4 5 13 2 9 11 2 5 28 4 12 17 8 26 4 2 10 7 19 1 3 11 6 7 1 1 16 9 21 3 8 1 1 2 3 4 5 6

E -63

Reference No.

Designation

037 194 037 194 037 225 037 236 037 237 037 264 037 265 037 265 037 265 037 266 037 267 037 267 037 293 037 305 037 305 037 441 037 493 037 851 037 930 037 930 038 386 038 073 038 102 038 201 038 238 038 268 038 290 038 390 038 407 046 837 049 129 051 530 051 883 054 883 056 318 056 335 057 916 061 676 061 676 061 822 061 822 061 857 061 857 061 942 063 121 063 543 063 544 063 652 063 654 063 656 063 660 063 662

union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lifting eye nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . delivery plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . delivery spring plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LP-hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . angle thermometer 0-250°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . cooling water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . distribution piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . packing kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pipe adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . resilient mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tube clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . protection cover packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inspection hole cover  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . protection cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . overpressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connecting rod screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connecting rod screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . zinc protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . zinc protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connecting rod bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connecting rod bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bursting plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driving plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooler cover, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooler cover, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooler cover, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .

- 64

Version 1 - 1

Page

Pos.

35 47 53 31 31 47 35 37 39 37 37 39 39 35 39 39 39 40 37 39 39 51 7 39 39 47 45 35 47 55 57 23 7 23 49 33 49 13 15 21 23 13 15 23 33 49 11 21 23 21 21 23

4 10 1 2 3 12 2 5 17 6 8 15 27 12 32 30 26 40 4 31 25 6 15 10 23 2 1 6 1 4 1 12 3 3 10 4 2 4 4 2 2 2 2 13 2 1 2 6 7 5 4 5

Index Reference No.

Designation

063 712 063 732 063 743 063 747 063 747 063 748 063 749 063 750 063 751 063 776 063 779 063 786 063 796 063 797 063 808 063 811 063 812 063 815 063 826 063 864 063 866 063 868 063 869 063 915 063 947 063 950 063 985 064 018 064 038 064 039 064 140 064 142 064 143 064 144 064 145 064 146 064 147 064 148 064 150 064 151 064 236 064 257 064 261 064 306 064 308 064 309 064 331 064 332 064 366 064 394 064 395 064 396

connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . valve cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder cover packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder cover packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inspecting hole cover packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . housing cover packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooler cover packing, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooler cover packing, rear  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . finished bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder housing 1st stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooler cover packing, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooler cover packing, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . finished bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . collecting tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connecting rod 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . valve cover 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . valve cover 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cylinder 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . compressor monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricating oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . temperature monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . measuring device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . automatic drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connecting rod 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . piston 2nd stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . air pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooling water pipes compr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . crankcase venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . resilient mounts f. motor 280 S/M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . valve cover .  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . piston 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . assembly bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . auxiliary tools, compl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . turning rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . blind flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . blind flange packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cooling water lines unit without pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . cooler cover, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gate valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Version 1 - 1

Page

Pos.

13 11 27 21 23 7 7 23 23 21 21 7 21 21 23 11 33 19 15 5 5 5 5 5 55 5 5 59 5 5 5 5 11 5 5 5 5 5 19 5 25 7 5 53 5 53 7 7 5 7 23 39

1 3 1 8 9 6 7 11 10 7 1 1 10 9 8 4 1 1 1 3 7 9 10 8 10 24 18 1 19 25 1 2 1 4 6 13 14 17 2 23 1 5 5 2 22 3 27 28 15 2 6 22

E -65