WP45L BA1 ET1 en 1104

S a u e r
C o m p r e s s o r
Type: WP 45 L
Operator Manual
High-pressure Compressor
2-stage
Air-cooled
WP45L_BA1_Titel_en_1104.fm
Translation of the original operator manual

Edition: 04 / 2011
Edited by: J.P. Sauer & Sohn Maschinenbau Technical Documentation
Zertifikate_en_0.fm
Sauer compressor Type Approvals
Note!
On this page only a few examples are shown. FurtherType Approvals are available on request.
Genuine Sauer spare parts

certified safety
Zertifikate_en_0.fm
N
E
M
I
C
SPE
Table of Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Type approval and genuine Sauer- spare parts . . . . . . . . . . . . . . . . . . . . . .10
J.P. SAUER & SOHN Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Text conventions used in this Operator Manual . . . . . . . . . . . . . . . . . . . . . .12
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Conditions of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Unauthorised modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Safety information - warning and caution . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Safety warnings on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Safety and protection devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Noise protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Safety requirements for personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3
3.1
3.2
3.3
3.4
Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Displays on the Sauer- compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Indicators and operating elements on the compressor control . . . . . . . . . . .27
4
4.1
4.2
Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Specification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
P&I flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
Transport and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Storage before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Connecting the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Adjusting the final pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Filling with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Checks to be carried out after installation and before first start-up . . . . . . .43
WP45L_BA1_IVZ_ en_1104.fm
1
1.1
1.2
1.3
1.4
1.5
1.6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Routine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
8
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.13
8.14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
J.P. SAUER & SOHN Maintenance Service . . . . . . . . . . . . . . . . . . . . . . . . .56
Maintenance safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Table of tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Checking the screw connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Changing the air filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Replacing the valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Replace the piston rings, gudgeon pins and gudgeon pin rings . . . . . . . . . 67
Replacing the coupling flexible insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Checking the condensate separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Overhauling drain valves (order-related) . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Checking the safety valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9
9.1
9.2
9.3
Storage, Preservation Lay-up Procedure . . . . . . . . . . . . . . . . . . . . .78

Safety when storing and removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Temporary preservation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
10
10.1
10.2
Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Preservation oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
11
Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
12
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
6
6.1
6.2
6.3
6.4
WP45L_BA1_en_1104.fm
General information
1.1 Foreword
This Operator Manual provides installation guidance, safe
operation, maintenance and repair instructions with illustrated
parts list.
The following unique specification for the Sauer compressor can
be found on the nameplate affixed to the compressor:
Compressor type
Works number
Year of construction
We recommend you enter this information in Chapter 11 and
always provide this data when requesting parts and any repair
instructions.
1.2 Precautionary measures

We recommend that only authorised and trained personnel
operate and service the Sauer compressor. Such responsible
personnel must have read and understood the Operator Manual.
These instructions should always be available where the
compressor is installed.
Copyright
The copyright for this Operator Manual remains with

J.P. SAUER & SOHN. These instructions, or parts thereof, shall
not be copied, distributed or made available to third parties.
Contravention will result in prosecution.
Specific
precautionary
measures
General information
1.3 Warranty and liability
Sauer can no longer provide warranty coverage or be held liable

for any claims if a failure is attributed to any of the following:
Use of the machine not as specified
Substitution of parts not manufactured or approved by Sauer
Use of spare parts that are not genuine Sauer spare parts
Operation of the machine with faulty or improperly installed
safety and/or protection devices
Failure to observe the Operator Manual
Unauthorised modification to the machine or its control system
Inadequate monitoring of machine parts subject to wear
Failure to carry out maintenance/repairs in accordance with
Sauer instructions
Force majeure
1.4 Type approval and genuine Sauer-spare parts

Type approval for the Sauer compressor is valid under the
condition that parts and components specified and qualified by
J.P. SAUER & SOHN are used. Type approval is provided by
the Classification Society and the EC Declaration of
Conformity or EC Manufacturer's Declaration. Failure to
observe these requirements may void type approval.
Only the use of genuine Sauer spare parts will ensure
compliance with these specifications and, therefore, reliable
and safe operation of the Sauer compressor.
If non-genuine Sauer spare parts are used, we reserve the
right of exclusion from liability for personal injury and
equipment damage.
Genuine Sauer spare parts are supplied with a Certificate of
Conformity and a Certificate of Authenticity. An example of this
document is shown just before the Table of Contents in these
instructions. If spare parts are delivered to you without this
certificate, there is a risk that these are not genuine Sauer
spare parts. In such an instance please contact our Customer
Service.
Note!
This is a high-pressure compressor. For your own safety and for
reliable compressor operation, use genuine Sauer parts only.
Correct
Do not use parts from the

grey market!
Only use genuine Sauer spare parts

supplied with a certificate!
Incorrect
10
General information
1.5 J.P. SAUER & SOHN Customer Service
Should you have any technical questions or questions related to
maintenance or repair, please contact our Customer Service:
J.P. SAUER & SOHN Maschinenbau GmbH
Customer Service
P.O. Box 92 13
24157 Kiel, Germany
Phone (international):
Technical information
Spare parts orders
Fax (international):
Emergency service
(international):
E-mail:
Web:
+49 431 39 40 -87

+49 431 39 40 -86/886
+49 431 39 40 -89
+49 172 4 14 63 94
service@sauersohn.de
www.sauercompressors.com
Note!
If you have questions regarding your Sauercompressor, please
specify the compressor model and serial number (see Chapter
11 or nameplate on the compressor).
11
1.6 Specific instructions

Lists
General lists are marked using a dash.

Example:
The compressor cooling system consists of
Fan wheel
Fan wheel housing and
Cooler assembly
Instructions
Individual instructions or multiple instructions requiring action but

where the sequence is of no importance are normally denoted by
a bullet point.
Example:
Check oil level.
Instructions which must be followed in a certain sequence are
numbered.
Example:
1. Turn the main switch ON.
2. Choose the operating mode.
3. Turn the control ON.
Results of actions carried out are denoted by a tick mark.
Example:
The control light is on.
Safety and warning instructions are presented using icons with
clear instructions. The safety instructions are described in detail
in Chapter 2.
Safety
instructions
12
General information
13
Safety
2.1 Conditions of Use

This compressor system must only be used for the compression
of the specified gas/media (see factory test). The Sauer
compressor must not be used at ambient temperatures below
+5 C. Any other unauthorised use requires the express written
approval of J.P. SAUER & SOHN.
In addition, specified conditions of use also include observing the
Operator Manual and the installation requirements and
maintenance intervals described there.
Most accidents which occur during operation and maintenance of
machinery result from failure to observe basic safety rules or
precautions.
When handling, operating or carrying out maintenance,
personnel must observe safe engineering working practices and
local regulations.
2.2 Unauthorised modification
Unauthorised modification of the Sauer compressor is not

permitted. Modifications may lead to an accident that can be lifethreatening, cause personal injury or result in damage to the
equipment.
Contact J.P. SAUER & SOHN and request written approval of
any planned modifications.
14
Safety
2.3 Safety Information - Warning and Caution
The safety information in these instructions is presented as high
risk and lower risk, as follows:
Warning - Danger!
High risk.
Ignoring these safety instructions can cause personal injury, or
death, and significant equipment damage.
Caution - Note!
Lower risk.
Disregarding this safety note may result in damage to the
equipment.
15
2.4 Safety Warnings on the Machine

Danger!
Safety labelling affixed to the machine must not be altered or
removed. Replace damaged or lost safety labels immediately
with an exact replica.
The Sauer compressor with an EC Manufacturer's Declaration or
EC Declaration of Conformity is marked with the following safety
labelling:
Safety marking
Meaning
Safety marking
Meaning
High voltage! Danger

to life!
Read Operator
Manual!
Compressor starts
automatically without
warning!
Wear hearing
protection!
Hot surface!
Rotational direction of
crankshaft
Location of safety markings
16
Safety
2.5 Safety and protection devices
Danger!
Safety devices must not be adjusted, tampered with or removed.
The safety devices must be periodically tested and checked:
Safety valves must only be
installed with a lock-seal and
replaced, adjusted and re-sealed by authorised personnel.
Each compression stage of the Sauer compressor is equipped
with a safety valve, which will fully discharge air when the blowoff pressure is reached.
Safety valves are installed at the following locations:
1st compression stage: in 2nd stage cylinder head;
2nd compression stage: in the condensate separator after the
2nd stage.
Temperature
monitoring
The Sauer compressor is equipped with a safety fuse in the final

separator to protect the unit in case the compressor cooling fails.
The safety fuse melts at 121 C and releases an exhaust port for
the compressed air if the temperature limit is exceeded.
The safety fuse can only be used once. The safety fuse must be
replaced by a new one if it has tripped.
As an alternative to the safety fuse, the Sauer compressor can be
equipped with a high air temperature switch which replaces the
safety fuse. The high air temperature switch shuts down the
compressor if the compressed air temperature exceeds the limit
value.
Oil monitoring
Optionally, an oil level switch can be installed which sends a

signal to the compressor control if the oil level is too low and
stops the compressor.
Final pressure
monitoring
A final pressure switch is included with the Sauer compressor

which is installed by the owner depending on the operation task.
The final pressure switch triggers as soon as the factory-adjusted
values are reached.
Safety valves
17
2.6 Noise protection

Sound pressure level details are found in the Technical
Specification (see Chapter 4).
The Sauer compressor can be equipped with a sounddampening enclosure to reduce noise, available as an accessory
from J.P. SAUER & SOHN.
Danger!
With a free field of 1m the sound pressure level is greater than
85 dB(A) if the compressor is operated without sounddampening enclosure. Consequently, each person must wear
hearing protection when working in the same room where the
compressor is operated.
Note!
A corresponding mandatory sign is affixed to the compressor
(see Chapter 2.4).
Note!
The owner must affix an additional corresponding mandatory
sign in a clearly visible manner near the machine or at the
entrance door.
2.7 Waste disposal
Note!
The following materials which accumulate during operation of
the compressor must be disposed of in an environmentally
sound manner in accordance with applicable laws:
Condensate (oil/water) arising from inter-cooling in the
compression process
Used oil and grease, and rags soiled by oil and grease
Cleaning agents and rags soiled by such agents
18
Safety
2.8 Safety requirements for personnel
Only personnel authorised by J.P. SAUER & SOHN are
permitted to service the Sauer compressor! Before commencing
work they must have read and understood the instructions in the
Operator Manual, and must be familiar with all safety devices and
safety regulations.
In addition to the instructions in this Operator Manual and
supplier documentation, accepted engineering standards must
be observed as well as all local laws, standards and regulations
such as the
Equipment and Product Safety Act
Industrial Health and Safety Regulations
Regulations for accident prevention pertaining to compressors
VDE (Association of German Electricians) regulations and
Regulations on environmental protection.
Additionally, where appropriate classification society regulations
and operational regulations must be observed.
Only persons who are trained and thoroughly familiar with
compressor operation should be authorised to operate the
compressor.
Persons authorised to perform maintenance work are trained
specialists of the operator and of the manufacturer.
2.9 Personal protective equipment
The owner must provide personal protective equipment such as

Hearing protection
Safety boots
Protective goggles
Protective gloves
for personnel carrying out any work on the Sauer compressor.
19
Design and function
3.1 Overview
Note!
Details of parts and spare parts can be found in the spare parts
catalogue.
11
10
20
Design and function
Item
Designation
Cylinder 1st stage
Cylinder 2nd stage
Cooler
Safety valve 1st stage
Safety valve 2nd stage
Condensate separator 1st stage
Condensate separator 2nd stage
Drain valve 1st stage
Drain valve 2nd stage
10
Oil dipstick
11
Electric motor
21
Vertical
sectional view
7
8
10
22
Designation
Cooler 1st stage
Cooler 2nd stage
Fan wheel
Connecting rod 1st stage
Connecting rod 2nd stage
Flexible coupling
Flywheel
Bell housing
Crankshaft
10
Bearing housing
Item
Design and function

Cross
section view
2
5
Item
Designation
Cylinder with head and valve 1st stage
Piston 1st stage
Cylinder with head and valve 2nd stage
Piston 2nd stage
Crankcase
Lubricating pin
23
3.2 Functional description

The Sauer compressor is driven by an electric motor which is
screw-connected to the clutch housing. The torque is transmitted
by means of a flexible coupling.
As an alternative, a diesel motor can be used which is then
installed via a special flange. The torque is transmitted by means
of a centrifugal clutch.
Compressor
control
Driven by an electric motor, the Sauer compressor is controlled

and monitored by an electrical compressor control. This control
system must comply with legal regulations. Optionally,
J.P. SAUER & SOHN supplies a suitable compressor control.
Compression
The compressor takes in the ambient air via a layered filter with
a tube silencer and compresses it in two compression stages with
a total of two single-stage cylinders to the final pressure. Each
cylinder is a compression stage, after which the air is intercooled.
The compression temperatures are below the flash point of
standard mineral-based motor oils.
The cylinders arranged in a V-configuration are equipped with
valves which are easy to maintain and have a long service life.
Due to the low compression temperatures, there is virtually no
coking on the valves.
Cooling
An axial fan mounted on the crankshaft sucks cooling air from

ambient air and blows it across the cylinders, coolers, valves and
oil pan. Inter-cooling takes place after each stage in zinc-coated
finned tube coolers.
Condensate
separation
Oil/water condensate that collects during compression and intercooling is collected in the condensate separators after each
stage.
Drive
24
Design and function

Condensate is drained via drain lines. For each separator there
are solenoid valves installed as drain valves in the drain lines.
The drain valves must be open when the Sauer compressor is
depressurised. A few seconds after starting, the drain valves
should close and the compressor should power up against
system pressure. The drain valves should drain the system
during operation at preset intervals. The control of the drain
valves (solenoid valves) is carried out by the compressor control.
Lubrication/oil
pressure
The crankshaft bearing and piston are lubricated by oil splash in

the crankcase. The lubricating pin located at the connecting rod
of the 1st stage dips into the oil at the bottom of the crankcase and
flings the oil against the lubricating points.
Optionally, the oil level can be monitored using an oil level
monitoring device. The compressor is stopped by the control if
there is not enough oil.
Oil/water
draining and
pressure relief
25
3.3 Displays on the Sauer-compressor

1
Item
Designation
Indicator
Pressure gauge
1st stage
Compressed air pressure after 1st stage
Pressure gauge
2nd stage
Final pressure of the compressed air after the

2nd stage
26
Design and function

3.4 Indicators and operating elements on the
compressor control
Note!
If the compressor control is supplied by J.P. SAUER & SOHN,
read the documentation supplied.
On the front of the compressor control, the following indicators
and operating elements can be found:
Display/operating
element
Signal lamp
Operation
Explanation
Illuminates when the compressor is running.
Fault indicator lamp Illuminates if the compressor has shut down because of excess
Overcurrent
motor current.
Mode time counter
Indicates the hours the compressor has run.
Mode selector
switch
Manual mode:
Starts the compressor manually. The compressor starts up and
continues to run until it is manually turned off again.
Selector position 0:
Turns the compressor off manually. Any pending fault messages
are reset.
Auto mode:
The compressor starts and stops with the opening and closing of
a remote contact (e.g. pressure switch at a compressed air
vessel).
Main switch
Disconnects the power supply from the compressor control to the

compressor.
A main isolator switch should be installed if required by local law
and regulations.
Optional:
Fault indicator lamp Illuminates if the compressor has shut down because of excess
Air temperature
compressed air temperature.
Fault indicator lamp Illuminates if the compressor has shut down because the oil level
Oil level
is too low.
27
Technical Specification
4.1 Specification data

Designation
Data
Compressor type
WP 45 L
Number of cylinders
Number of compression stages
Cylinder diameter 1st stage
136 mm
Cylinder diameter 2nd stage
60 mm
Piston stroke
60 mm
Maximum speed
1800 rpm
Direction of rotation (when looking toward

flywheel)
Clockwise
Maximum working pressure
40 bar
Permissible suction pressure
Maximum 1300 mbar (a)

Minimum 900 mbar (a)
Set pressures for safety valves:

1. stage
8 bar
2. stage
5 % above final pressure
Oil sump capacity
5.2 l
Oil refill quantity dipstick MAX/MIN
1.4 l
Oil type
see Chapter 10
Pickup and holding power
18 VA/14 W (order-specific)
Setting
Currentless open;
Relief starting: approx.15 s;
Periodic automatic drainage: every
15 min for 15 s
28
Solenoid valves:
Designation
Data
Final pressure switch (option):

Maximum switching current
6 A/220 V
Setting
As required by customer
Switch function
Change-over contact
Temperature monitoring (optional):

16 A / at 440 V the maximum
Oil monitoring (optional):

1 A / at 250 V the maximum
Switch function
Normally open
sound pressure level

(free field at 1 m)
max. 87 dB(A)
Weight and dimensions
See installation drawing
Note!
Please refer to the order-specific documentation of your
compressor for data such as final pressure, speed, power
requirements, etc.
29
4.2 P&I Flow Diagram

1
11 7
19
12
10
20
14 15
16
13
18
17
30
Item
Designation
Electric motor
1st compression stage
2nd compression stage
Cooler 1st stage
Cooler 2nd stage
Condensate separator 1st stage
Condensate separator 2nd stage
Pressure gauge 1st stage
Pressure gauge 2nd stage
10
11
12
Solenoid valve (drainage) 1st stage
13
Solenoid valve (drainage) 2nd stage
14
High pressure hose
15
Non-return valve
16
Compressed air outlet
17
Suction filter
18
Air intake
19
Condensate outlet 1st stage
20
Condensate outlet 2nd stage
31
Transport and Installation
5.1 Transport
Shipping
The machine is packed ready for shipping.

The Sauer compressor must be checked for completeness
and any damage immediately upon receipt.
Damage to the packaging or the machine must be reported to
the transport firm and J.P. SAUER & SOHN immediately.
Transport
The Sauer compressor must be transported using a forklift truck

or be hoisted by a crane.
Danger!
Suspended load during transport.
The forklift truck/crane must have sufficient load-bearing
capacity.
Ensure that no personnel are within the danger area of the
suspended load and the forklift truck/crane.
Sling the unpacked compressor onto the lifting eye bolt (see
illustration, position 1).
Raise, move into position and set down with care.
32

5.2 Storage before Installation
If the Sauer compressor has to be stored before installation, do
not unpack, and store under the following conditions:
Temperature: +5 C to +40 C;
Relative humidity 30 % 95 %, non-condensing
In a dry area, under a roof, with dew protection
Protected from being soiled
Protected against vibration and shock
Note!
The standard factory protective packing is sufficient for a
maximum storage period of 12 months.
Note!
High pressure hoses can be stored for up to five years after
delivery.
33
5.3 Installation
Note!
If in doubt regarding the suitability of the intended installation
area, please contact J.P. SAUER & SOHN. If required for the
installation area, Sauer can provide help with the design of a
ventilation system.
For proper installation, follow the installation instructions and
observe the following conditions.
Installation
requirements
max. 55 C
The installation area must be dry and free from dust.

Ensure that the installation is ventilated in such a way that the
heat generated during operation is removed.
Room temperature during operation of the Sauercompressor:
+5 C +55 C
(Please contact J.P. SAUER & SOHNfor operation outside
this temperature range).
min. 5 C
Note!
The air temperature at the cooling air inlet of the compressor
must not exceed +55 during operation. Conditions in the area of
installation as well as the heat generated by the compressor and
any other machines installed in the same area must be kept in
mind.
If necessary, install a ventilation or air extraction system in the
area.
Install the fresh air feed in such a way that the cooling air
stream is never directed at the compressor. Otherwise, there
is a danger that condensation will occur within the machine,
with corresponding consequential damage.
34

Correct
Incorrect
At room temperatures below +5 the room must be heated or

a heater must be installed on the Sauer compressor.
The installation location must be selected in such a way that
the Sauer compressor is easily accessible and the servicing
intervals (see installation documentation) are maintained.
Position so that the fan does not suck in heated air again.
Do not position several compressors behind each other so that
a compressor does not suck in the heated cooling air of
another compressor.
Note!
J.P. SAUER & SOHN would be pleased to advise you on
installation of the compressors.
35
Foundation
Note!
The standard delivery anti-vibration resilient mount has a
resonant frequency of approx. 10 Hz.
Excitation of the compressor foundation by vibrations from other
machines installed in the vicinity must not be in the 10 Hz range.
Otherwise there is a danger that the standard anti-vibration
resilient mount could be destroyed by resonating vibration.
1. Check whether there are vibrations of the machine

foundation in the 10 Hz range.
2. If in doubt, contact J.P. SAUER & SOHN in order to clarify
whether a different anti-vibration resilient mount can be used.
36

5.4 Connecting the compressor
Danger!
The compressor must only be connected by a qualified
technician. Any work on the electrical installation must be carried
out by qualified electricians only.
Note!
The oil filler tube is protected with an insulating hose. The
insulation material (position 1) must not be removed.
Pipelines
The hose line for the compressed air outlet (1) and the hose lines
for the drainage connections (2) of the Sauer compressor must
be connected to the system owner's piping.
1
Danger!
At the compressor start-up and during drainage compressed air
escapes from the drainage connections. Consequently, do not
operate the compressor without hose lines connected.
37
Hose lines
The hose lines must be installed free of tension and not twisted.
Correct
Incorrect
Drainage system
Note!
Accumulated condensate contains oil. It may only be disposed
of in compliance with applicable legal regulations.
J.P. SAUER & SOHN offers condensate collection containers
for separating air from condensate as well as condensate
processing systems for separating oil from condensate.
Note!
We recommend connecting up the compressor drainage
separately.
If you wish to combine the drainage of several compressors,
please observe the following:
Choose a sufficient nominal diameter for the common drain
line;
Connect the drain lines of the individual compressors at a
sharp angle to the common drain line, so that no pressure can
build up in the drain line of a compressor that is not in
operation.
38
Incorrect connection
Correct connection
39
Connections
The illustration below shows the connections and the fittings for
the operation of a typical Sauer compressor.
Item
1
Designation
Type
Function
Drive motor
Electric motor
Compressor drive
Non-return valve
Plug valve
Prevent compressed air flowing

back
Drain hose
Low-pressure
hose
Guides the condensate away from

the compressor
Drain valve 2nd stage
Solenoid valve
Start relief and drainage
Drain valve 1st stage
Solenoid valve
Start relief and drainage
2
3
Note!
For technical specifications of the individual items, please refer
to Chapter 4. All change-over switches are factory adjusted. If
desired, the components are supplied pre-wired to a terminal
box.
40

5.5 Adjusting the final pressure switch
Note!
The final pressure switch must be connected directly at the
compressed air vessel to ensure smooth, even compressor
operation.
Pay attention to the pressure loss between the compressor and

compressed air vessel when selecting the maximum pressure
setting at the final pressure switch. If the final pressure selected
is too high, the safety valve of the final stage blows off.
As an alternative, a sensor can also be used. No setting is
required on the sensor because the value setting is carried out
via the compressor control.
41
5.6 Filling with oil

Note!
Unless otherwise ordered, Sauer compressors are delivered
without oil filling.
Danger!
Make sure to fill the crankcase of the compressor with oil before
initial operation!
Only use lubricating oil approved by J.P. SAUER & SOHN (see
Chapter 10).
Note the amount of oil needed (see Chapter 4).
1. Unscrew the oil fill cap (position 1).

2. Pour in oil and check the oil level with the dipstick (position 2).
Note!
Only fill with oil up to the upper mark on the oil level indicator.
Overfilling increases the oil consumption of the compressor.
3. Replace the dipstick and screw the oil fill cap back in.
42

5.7 Checks to be carried out after installation and
before the first start-up.
Before starting the compressor for the first time, ensure that:
The electricity connection matches the data on the nameplate.

All connections between the compressor and the compressed
air equipment are properly installed.
The amount of oil indicated for operation is located in the
crankcase.
All tools and foreign objects have been removed from the
compressor.
The required cooling air supply is ensured.
The air filter is not clogged.
The entire system is clean.
43
Operation
6.1 Safe operation

Danger!
Only authorised persons are permitted to put the Sauer
compressor into operation and operate it!
Danger!
Only switch on and start the compressor when
it has been checked that it is in perfect condition;
all tools and foreign objects have been removed from the
machine.
Danger!
Immediately turn compressor off if personnel and property are
endangered. Only re-start compressor when there is no more
danger or possible damage.
Danger!
In Automatic mode the compressor starts automatically without
warning.
Danger!
Risk of burns from touching hot surfaces of the compressor
during operation. Wear protective gloves!
Danger!
Risk of hearing damage because of the sound pressure level
while the compressor is running! Wear hearing protection!
Note!
Switch compressor off in the event of any abnormal/fault
conditions or unexpected events. Eliminate the cause of
problem with the help of Chapter 7.
44
Operation
6.2 Operating modes
After you have turned on the power supply to the Sauer

compressor, it can be started with one of the following two
operating modes using the mode selector setting:
Manual operating mode:
The compressor starts and continues to run until it is stopped
or turned off either by using the mode selector switch or the
main switch.
Automatic operating mode:
Starting and stopping the compressor is controlled by external
devices (for example using the pressure switch of the pressure
vessel).
When the Sauer compressor starts, it starts without load with the
drain valves open. After a few seconds the valves close and the
compressor powers up against system pressure.
A compressor control - whether provided by Sauer or the
customer - must always be equipped with this function.
45
6.3 Initial operation

Check the
direction of
rotation
Allow the Sauer compressor to run only for a few seconds to

check the direction of rotation.
1. Switch the power supply on.
2. Set the mode selector switch to Manual to start the
compressor in manual mode.
3. Immediately check the compressors direction of rotation. It
must rotate in the direction indicated by the arrow on the
crankcase.
4. Set the mode selector switch to 0 to stop the compressor.
5. Switch off the power supply.
6. If the direction of rotation is incorrect, the polarity of the
electric motor should be changed by a qualified electrician.
Test run
46

2. Set the mode selector switch to Manual to start the
compressor in manual mode.
If correctly adjusted, the drain valves close after about 15
seconds and the compressor should power up against
system pressure.
3. Check the pressure gauges of each stage and compare
readings with the nominal values (see Chapter 6.4 for
nominal values).
4. Check the function of the periodic automatic drainage.
It must drain for about 15 seconds every 15 minutes. This is
indicated by a drop in pressure on the pressure gauges.
5. Set the mode selector switch to 0 to stop the compressor.
6. Switch off the power supply.
7. If necessary eliminate the cause of deviations from nominal
values and malfunctions. See also Chapter 7.
8. Complete the commissioning certificate and send it to
J.P. SAUER & SOHN Customer Service. The commissioning
certificate is in the Appendix.
Danger!
There is no oil pressure if the direction of rotation is incorrect.
Risk of subsequent damage!
Operation
6.4 Routine operation
Cleaning
Keep compressor area clean.

Keep indicators and operating elements clean.
Checks
Inspect connections, pipes and electric cables for damage.

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

2. Set mode selector switch to Auto to operate the compressor
in Automatic mode.
Watch out for
Abnormal operating noise.

Pay attention to leaks (compressed air, oil, condensate).
The pressure indicated on the pressure gauges must remain
within the grey zone in the stage pressure diagram (see
below).
The oil pressure should be between 1.8 and 4 bar for
compressors with oil pressure display.
In the event of deviations, see Chapter 7.
Note!
Compressors may be started no more than five to six times
within one hour.
The minimum period of operation must be 10 minutes per start.
Repeatedly using the system for shorter operating periods leads
to reduced gas quality and/or damage to the compressor.
47
2nd stage [bar]
Stage pressure diagram 1st and 2nd stage
40
30
20
10
0
1
1st stage [bar]
Note!
Depending on the desired final pressure in the 2nd stage, the
allowable pressure for the 1st stage can be read from the above
diagram.
48
Operation
49
Troubleshooting guide
Note!
Should a malfunction occur, first check the indicators on the
compressor control panel and on the compressor.
Try to correct the fault with the help of the table below.
If the fault cannot be corrected, please contact
J.P. SAUER & SOHNCustomer Service. The fault description
journal is in the Appendix of this Operator Manual.
Probable cause
Remedy
Compressor does not

start or switches off.
No input power supply/no

control voltage.
Check the fuses. Replace blown

fuses.
Compressor was
switched off, fault
indicator lamp Oil
monitoring (option)
lights up.
Oil level too low.
Check oil level and top up if

necessary. Check for leaks.
Oil too viscous.
Fill with recommended oil.

Check that room temperature is
> + 5 C.
Compressor was
switched off by
overcurrent delay, fault
indicator lamp
Overcurrent lights up.
Motor is overheated.
Excessive current drawn.
Check supply voltage and

electrical connections. The
compressor can be started again
after a cooling down period.
Check whether the crankshaft
can easily be turned by hand. If
not, disconnect and ascertain
whether the problem has to do
with the motor or the
compressor.
Piston seizure
50
Check cylinders and pistons for

any score marks, replace as
necessary.
Fault
Fault
Probable cause
Remedy
Safety valve of
1st stage blows off:
Pressure exceeds
blow-off pressure
(8 bar)
2nd stage valve is not

working properly.
Check the valve of the 2nd stage

and replace if necessary.
Gasket between suction

and pressure side of the
2nd stage is faulty.
Replace gasket.
Safety valve is faulty.
Replace safety valve.
Pressure above
blow-off pressure
(final pressure
+ 5 %)
Valve in the air line to the

compressed air vessel is
closed.
Open valve.
Pressure switch is set too

high.
Lower the pressure setting.
Pressure below
blow-off pressure
(final pressure
+ 5 %)
Safety valve is set too

low or is faulty.
Replace safety valve.
Excessively high
pressure losses in the air
line to the compressed
air vessel.
Reduce the pressure losses.
Pressure gauge of the

1st stage is showing
excessive pressure.
Valve of the 2nd stage is

leaking.
Check the valve of the 2nd stage

The pressure gauges

of all stages show
insufficient pressure.
Valve of the 1st stage is

leaking.
Check the valve of the 1st stage

Air filter very dirty.
Clean the air filter insert or

replace it.
The pressure gauges

of all stages show no
pressure.
No power at a solenoid
drainage valve.
Check solenoid valve power

supply.
A solenoid valve of the

drainage is faulty.
Check the solenoid valves and

replace them if necessary.
Pressure below
blow-off pressure
(8 bar)
Safety valve of
2nd stage blows off:
51
Air escaping from the

compressed air lines.
Air escaping from the

overflow opening of the
final separator's safety
fuse.
Compressor was
switched off, high air
temperature monitoring
(option) has tripped.
Solenoid valve
(drainage) does not
close.
Abnormal compressor
noise.
Probable cause
Remedy
Connection gaskets or
seals leaking.
Replace faulty gasket or seal.
Cutting rings leaking.
Switch compressor off. Wait until

all parts are no longer under
pressure; check the pressure
gauge for this. Tighten all
fittings.
Compressed air
temperature at the outlet
too high; insufficient
cooling due to faulty fan.
Replace fan.
Replace safety fuse.
Compressed air
too high;
cooler very dirty;
insufficient ventilation.
Clean cooler.
Check ventilation.
Replace safety fuse.
Compressed air
too high; insufficient
cooling due to faulty fan.
Check whether fan wheel can be

turned, check fan wheel and
replace if necessary.
Check if the ambient
temperature is < 55 C.
Check that the cooling air inlet is
not blocked.
Cooler dirty or supply line

blocked; insufficient
ventilation.
Clean cooler. Check room

ventilation.
No power supply.
Check fuses, replace blown

fuses.
Solenoid faulty.
Replace solenoid.
Foreign matter in
solenoid valve.
Replace solenoid valve.
Connecting rod bearing

faulty.
Check connecting rod bearing,

Check oil supply.
Gudgeon pin bearing

faulty.
Check gudgeon pin bearing,

Crankshaft bearing faulty. Check crankshaft bearing,

Motor bearing faulty.
52
Check motor bearing, replace if

necessary.
Fault
Fault
Probable cause
Remedy
Oil leaking to the

outside.
Gasket or
shaft seal faulty. Screws
not tight.
Tighten all screws.

If there is significant leakage
check to see which gasket is
faulty, then replace it.
Minor traces of oil on the
crankcase or oil drops below the
compressor are harmless. Wipe
off with a lint-free rag.
Air escaping between

the cylinder and
cylinder head.
Gasket between cylinder

head and valve or
between valve and
cylinder faulty. Cylinder
head nut is not tightened
correctly.
Replace gasket or both gaskets.

Tighten cylinder head nuts with
correct tightening torque (see
Chapter 8.4).
Oil escaping at the

cylinder base.
Gasket between
crankcase and cylinder
faulty. Cylinder head nut
is not tightened correctly.
Replace gasket.
Tighten cylinder head nuts with
correct tightening torque (see
Chapter 8.4).
Water in oil
Incorrect ventilation
(excessive cooling of
compressor).
Change room ventilation.
Poor drainage.
Check drain lines and drainage

intervals.
Insulation tube at the

crankcase vent is
missing or damaged.
Replace insulation tube.
Very short compressor

running time.
Extend compressor running

time.
Poor drainage.
Check and optimise drain lines

and drainage intervals. Replace
valve.
Premature fracture of
valve plates, valve
springs, or valve reeds.
Note: Indentations in the gasket

contact surface of the valve
plate are normal.
53
54
55
Maintenance
8.1 J.P. SAUER & SOHN Maintenance Service

J.P. SAUER & SOHN Customer Service offers various
maintenance services:
inspection, maintenance, major overhaul, replacement
compressors, and service contracts.
Please contact our Customer Service:
J.P. SAUER & SOHN Maschinenbau GmbH
Customer Service
P.O. Box 92 13
24157 Kiel, Germany
Phone (international):
Technical information
Spare parts orders
Fax (international):
Emergency service
(international):
E-mail:
Web:
+49 431 39 40 -87

+49 431 39 40 -86/886
+49 431 39 40 -89
+49 172 4 14 63 94
service@sauersohn.de
www.sauercompressors.com
or contact an authorised J.P. SAUER & SOHN service partner in

your area.
56
Maintenance
8.2 Maintenance safety
Before maintenance work
1. Disconnect the power supply to the compressor.

2. Put up Attention! Maintenance work! sign on the power
supply.
3. Shut down the compressor and secure it against restarting.
Danger!
Risk of injury due to improper operation!
Only authorised persons are permitted to service and make
adjustments to the Sauer compressor!
Danger!
Risk of injury from hot surfaces!
Allow compressor to cool down after shutting 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!
High voltage! Danger to life!
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 must only be energised if this
is explicitly specified.
Danger!
Danger of death from missing protective equipment and missing
guards!
Reinstall all protective equipment and guards after servicing.
This also applies to electrical protection devices (e.g. earth
wires).
57
8.3 Maintenance schedule

Danger!
For all maintenance work Chapter 8.4 must be observed for
certain screws/bolts.
Note!
The maintenance intervals specified in the maintenance
schedule must be adhered to. Shortening maintenance intervals
is of no advantage with regard to operating performance or
service life of the Sauer compressor.
Note!
After the last maintenance stage the maintenance schedule
begins all over again.
Instructions for
the maintenance
schedule
58
Use the maintenance schedule as a master template or copy

the respective page from the document and save it as a
separate file under a suitable name. Use the maintenance
schedule as a guide and as a record of work completed.
Regularly check the maintenance schedule to see which
maintenance intervals, must be kept, depending upon the
number of operation hours. The intervals are shown in the
tables column headers.
Check the column of each maintenance interval to see what
maintenance work is to be carried out at the end of each
maintenance interval. The required tasks are indicated by
check boxes. The description for tasks are shown in the first
column.
Carry out all maintenance work for an interval and tick the
appropriate check boxes of the maintenance schedule. Then
enter operation hours, date and your signature.
When beginning a new maintenance schedule
Enter: main specifications, date of commissioning, number
of maintenance schedule, current date and operation hours
count.
Mark with an X: Maintenance schedule beginning after
commissioning or after the last maintenance stage.
Note!
J.P. SAUER & SOHN recommends to have an inspection
(function test) carried out by qualified personnel at least once a
year.
Maintenance
Compressor type:
Type series
Compressor number:
Factory No.:
Year of construction:
Date of commissioning:
2,000 h
3,000 h
4,000 h
069 147
069 146
069 148
1,000 h
50 h after last maintenance stage or repair
For checking the
stage valve, see. 8.8
1st
For checking the
2nd
stage valve, see 8.8.
Maintenance work
Maintenance kit Part number
For checking screw connections, see 8.5
For changing the air filter insert, see 8.6
For changing oil, see 8.7
WP45L
Mistral
069 146
50 h after
Commissioning
Interval
[Operation hours]
At least annually
if < 1,000 h
Maintenance schedule No.:

Maintenance schedule beginning:
After commissioning
After last maintenance stage
Date:
Operation hours:
For replacing the 1st stage valve, see 8.9.
For replacing the 2nd stage valve, see 8.9.

For replace the piston rings, gudgeon pins and
1st stage gudgeon pin bearings, see 8.10
For replace the piston rings, gudgeon pins and
2nd stage gudgeon pin bearings, see 8.10
For replacing the coupling flexible insert, see
8.11
For checking the condensate separator, see
8.12
For overhauling drain valves (order-related),
see 8.13
For checking safety valves, see 8.14
(according to the owner's

instructions)
Operating hours
Date
Signature (initials)
59
Note!
Carry out a check 50 h after completing a maintenance
routine. Check all screws and nuts affected by maintenance to
see if they are tight.
8.4 Table of tightening torques

Bolts/screws
Tightening torque
Flywheel fixing screw
175 Nm
Cylinder head screws 1st stage
55 Nm
Cylinder head screws 2nd stage
75 Nm
8.5 Checking the screw connection
Check all fittings and screw connections for tightness, re-tighten

as necessary. This includes:
Coolers and air lines
Fittings for pipe lines and flexible hose lines
Cylinder heads
Cylinders
Motor, coupling and flange;
Monitoring systems and switchgear
Base frame/foundation
Accessories and ancillary equipment
60
Maintenance
8.6 Changing the air filter insert
1
1. Open fasteners (position 1) and remove cover (position 2) of

the air filter.
2. Remove used air filter insert (position 3).
3. Clean housing (position 4) using a suitable solvent (e.g.
kerosene) and wipe out with a lint-free rag.
4. Insert new air filter insert.
5. Insert cover and close fasteners.
61
8.7 Change oil

Note!
Use oil according to lubricant table (see Chapter 10) or
according to oil recommendation for Sauer compressors.
1. Allow the compressor to run for about 5 minutes to warm up.

2. Place oil catchpan (of a size sufficient for the oil sump
capacity, see Chapter 4) beneath the oil drain cock (3).
3. Unscrew the oil fill cap (1).
4. Open oil drain cock (3).
5. Wait until all oil has drained.
6. Close oil drain cock (3).
7. Pour in new oil and check the oil level with the dipstick (2).
The filling level must be between the upper and lower gauge
mark on the dipstick.
8. If the oil level is reached, replace the dipstick (2) and screw
the oil fill cap (1) shut.
62
Maintenance
8.8 Checking valves
Removing valves
1. Loosen the clamp on the air filter and replace the air filter.
2. Disconnect the pipe fittings and hose lines on the cylinder
heads.
3. Unscrew the cylinder head nuts and remove the cylinder
heads.
4. Carefully remove the valves.
Checking valves
5.
Check valves for visible:

Damage
Oiling
Coking
Corrosion and
Humidity
If there is damage, heavy coking or corrosion, replace
valves.
Determine the cause (see Chapter 7).
6. Clean all mating surfaces.
Note!
Install all valves with new gaskets and washers. Do not reuse old
gaskets and washers.
Only use genuine Sauer spare parts.
Installation of old or other gaskets and washers may lead to
leakage and may cause substantial damage to the compressor.
Installing the 1st

stage valve
2
4
1
63
7. Place new cylinder head gasket (3) within the stud bolts onto
the cylinder (5). Insert the new low-tolerance gasket ring (4)
into the groove of the valve (1) Now insert the valve (1) into
the cylinder head (2) from below.
(Caution: The low-tolerance gasket ring may not shift while
doing so).
8. Hold the cylinder head and valve. Now carefully slide both
parts together over the stud bolts and place them onto the
cylinder head gasket.
9. Tighten the cylinder head screws by hand.
64
Maintenance
Installing the 2nd
stage valve
1
10. Insert new O-ring (3) into the groove between cylinder (5) and
valve (4). Insert new cylinder head gasket (2) between valve
(4) and cylinder head (1).
11. Tighten the cylinder head screws by hand.
12. Screw pipe fittings and hose line onto the cylinder heads and
tighten by hand.
13. Securely tighten the cylinder head screws. Observe the
tightening torque (see Chapter 8.4).
14. Securely tightening pipe fittings and hose line
65
8.9 Replacing valves

Remove and install valves as described in Chapter 8.8. Make
sure to completely replace the valves when doing this.
Note!
Valves which have reached their service life must be replaced
and disposed of.
We do not recommend repairing used valves due to material
fatigue.
66
Maintenance
8.10 Replacing piston rings, gudgeon pins and
gudgeon pin rings
1. Remove cylinder heads and valves as described in Chapter
8.8.
2. Carefully remove the cylinder. Hold the piston while the
cylinder comes off.
Note!
If the piston is not held while the cylinder is being pulled off, it will
strike the crankcase.
3. Remove the gudgeon pin circlips, push out the gudgeon pin
and remove the piston.
4. Remove all piston rings from the respective pistons and clean
the pistons.
Note!
Always replace all piston rings by new ones.
Checking
pistons and
cylinders
5. Check cylinders and pistons for scoring marks and excessive

wear. Replace parts as required.
Note!
If edges can be felt on the piston running surface in the cylinder,
these edges must be broken using a Flexhon brush or a ScotchBrite abrasive pad. As otherwise the edges may damage the
new piston rings when installing the piston.
67
Measuring
piston wear
Note!
It is possible to measure used and new piston rings.
1
3
1. 1. measurement:
Insert the piston ring into the cylinder approx. 5 mm (1)
beneath the upper edge (above the turning point of the top
piston ring) and measure the gap clearance using a feeler
gauge in the area (3) where the piston rings are not running.
2. 2. measurement:
Slide the piston ring down by approx. 50 mm (2) (beneath the
turning point of the lowest piston ring) and measure the gap
clearance in the wear area (4) again.
68
Maintenance
3. Calculate the difference between the two gap clearances (1)

of
measurement 1 and measurement 2 and compare it with the
gap clearance difference values in the table.
stage
WP45L gap clearance difference
0.45 mm
0.30 mm
Note!
J. P. SAUER & SOHN'S Customer Service is to be consulted if
the difference between the two gap clearances is greater than
indicated in the table above.
Replacing the
gudgeon pins/
gudgeon pin
bearings (smallend bearing)
1. Press gudgeon pin bearing into the connecting rod's small

end with a suitable tool and replace it by a new gudgeon pin
bearing.
2. Install the pistons to the connecting rods. To do this, press the
new gudgeon pin in and insert the circlips.
Note!
Check circlips for secure fit in the grooves.
69
Installing piston
rings
3. Install piston rings in the respective piston. Make sure they

are in the correct position: piston rings having an asymmetric
cross section are marked with TOP on one of the surfaces.
The marked face must be at the top when the piston ring is
installed (see illustration).
2
TOP
TOP
TOP
Item
TOP
Designation
Piston 1st stage
Piston 2nd stage
4. The piston ring locks should be staggered around the piston

circumference.
5. Insert a new cylinder foot gasket for each cylinder.

6. The cylinders are installed in reverse order to their
disassembly.
7. Install valves and cylinder heads as described in Chapter 8.8.
Installing
cylinder and
valves
70
Maintenance
8.11 Replacing the coupling flexible insert
Note!
Applies to Sauer compressors with electric motor.
1.
2.
3.
4.
Shut down the compressor and secure it against restarting.

Support the compressor (1) under the bell housing.
Unscrew fixing screws (2) of the electric motor (3).
Lift the electric motor (3) carefully at the lifting eye bolts (4)
(see Chapter 5.1).
5. Pull the electric motor (3) carefully away from compressor (1).
6. Replace coupling flexible insert (5).
1
7. Carefully slide the electric motor (3) onto the compressor (1)
and tighten the fixing screws (2).
8. Remove the support under the bell housing.
9. Reinstall the disconnected connecting lines and pipes.
71
8.12 Checking the condensate separator

3
Item
72
Designation
Separator 1st stage
Separator 2nd stage
Separator head 1st stage
Separator head 2nd stage
1.
2.
3.
4.
5.
6.
7.

Disconnect installed air lines and hoses.
Remove the 2nd stage safety valve.
Remove the separator housing from the crankcase.
Remove the separator cover.
Check the separator for damage.
Clean the separator housing using a suitable solvent (e.g.
kerosene).
8. Blow out solvent (e.g. kerosene) with air.
9. Assembly follows the steps in reverse order.
Separator
Maintenance
8.13 Overhauling drain valves (order-related)
1
2
3
5
6
10
4
7
8
9

Unscrew the hex nut (1).
Carefully lift the threaded portion (2) with the screwdriver.
Remove coil (3) from armature (4).
Loosen the four Allen screws (5).
Remove valve top (6).
Replace the following parts:
spring (7), membrane (8) and two O-rings (9).
8. If heavily soiled: clean nozzle (10).
9. Attach valve top (6).
10. Tighten the four Allen screws (5).
1.
2.
3.
4.
5.
6.
7.
73
11. Attach coil (3) onto the armature (4).

Note!
The coil and the armature must always be dry.
12. Position the plastic threaded portion (2) correctly and

press it onto the armature (4).
13. Carefully attach the hexagon nut (1) by hand and screw on.
14. Slightly tighten the hexagon nut (1) with a spanner.
74
Maintenance
8.14 Check safety valves
A safety valve blows off by releasing air to assure the functioning
of the safety valve.
Danger!
Dirt particles may be flung out by the escaping air.
Wear protective glasses and gloves!
Keep your head away from the safety valve.
Danger!
High buildup of noise during blowing off.
Wear hearing protection!
Danger!
Safety valve may reach high temperatures due to operation.
Wear protective gloves!
Note!
Depending on the installation location of the compressor, the
owner of the compressor system must determine the
maintenance intervals in compliance with the valid, countryspecific regulations, standards and laws.
Note!
The safety valves may only be checked by personnel especially
trained for this purpose.
Note!
The J.P. SAUER & SOHN Customer Service offers proper
safety valve inspections within the framework of inspection
agreements.
Please contact our Customer Service.
75
1. Turn on the system and start up the compressor until it has

reached test pressure.
The actual design of safety valve may differ from the illustration.
2. Turn the lifting device (1) on the safety valve (2) to the left until
the safety valve blows.
3. After the safety valve (2) actuates, turn the lifting device (1)
back to the right as far as possible. The valve must close
tightly after doing this.
Note!
The pressure setting must only be changed at the
manufacturer's factory. The safety valve is sealed.
Danger!
The safety valve is a part of the safety device.
Safety devices must not be adjusted, tampered with or removed.
The safety devices must be periodically tested and checked:
76
Maintenance
77
Storage, Preservation Lay-up

Procedure
9.1 Safety when storing and removing
Danger!
The compressor is only to decommissioned and disassembled
by the owner's trained specialists. These specialists must be
familiar with the protection devices and regulations before
starting the work. Any work on the electrical installation must be
carried out by qualified electricians only.
In addition, information contained in suppliers documentation
must be observed.
78
Storage, Preservation Lay-up Procedure

9.2 Temporary decommissioning
Perform a test run for at least 30 minutes every four weeks.
Additional corrosion prevention measures are not required.
When the Sauer compressor is to be laid up for more than 12
weeks, preservation with a preservation oil is recommended.
When preservation is completed, periodic test runs are not
needed.
Note!
Use one of the preservation oils recommended in Chapter 10 for
corrosion protection.
The preservation oil has satisfactory running properties. In an
emergency the machine can be started for a short duration when
filled with preservation oil.
Note!
The preservation is sufficient for 12 months. After expiry of this
period the compressor must be preserved again.
1. Run compressor for approx. 10 minutes with drain valves and

final pressure line open.
Any existing oil/water is removed.
2. Open oil drain cock, drain compressor oil and dispose of in an
environmentally safe manner.
Close the oil drain cock again.
3. Fill with about 3 litres of preservation oil.
4. Start compressor and run for approx. 5 minutes with drain
valves and final pressure line open.
5. Stop the compressor.
79
2
3
6. Remove air filter (1) on the cylinder head of the 1st stage (2)
by loosening the clamp (3) and removing the air filter (1).
7. Unscrew the 1st stage safety valve (5) on the 2nd stage (6)
cylinder head.
8. Start compressor and slowly inject approx. 15 cm3 of
preservation oil into the 1st stage intake fittings (4).
9. Slowly inject about 10 cm3 of preservation oil into the
2nd stage (6) cylinder head opening (7).
80

10. The oil amounts indicated must not be exceeded.
11. Start the compressor and allow to run for about 15 s.
12. Wait until oil mist comes out of the final pressure line.
13. Stop the compressor.
14. Reinstall air filter and safety valve. Use a new gasket for the
safety valve.
15. Put up a sign that the compressor was preserved and taken
out of service.
16. Disconnect the mains supply cables.
1. Connect the mains supply cables.

2. Pour in compressor oil as described in Chapter 5.6.
3. Follow the instructions given in Chapter 6.3.
Putting back into

service
81
9.3 Disassembly
Follow these
steps for
disassembly:
1. Turn compressor off and disconnect it from power supply.

2. Read the pressure gauge to ensure that the compressor is
completely depressurised.
3. Disconnect the mains supply cables.
4. Remove oil and lubricants and dispose of in an
5. Drain any remaining condensate and dispose of in an
Disposal
Material/system component
Disposal method
As hazardous waste
Steel/iron
As metal scrap
Electric cables
As hazardous waste
Electronic components
As scrap electronic waste
Plastics
As hazardous waste
Lubricants
82
83
10 Lubricant table
Scope
The lubricant table applies to all Sauer compressors which are

designed to compress air.
The lubricant table does not apply to
Sauer compressors designed to compress neutral gasses
for temperatures outside the 5 C ... 55 C range.
General
recommendation
For temperatures lying within the 5 C 55 C range we

recommend mineral oils meeting the ISO VG 100 viscosity
grade. At minimum, the lubricating oil should correspond to the
group VCL as per DIN 51506 .
For the following reasons, we do not approve the use of synthetic
lubricating oils for 2-stage air-cooled compressors:
The good water repelling characteristics of synthetic
lubricating oils cause condensation of moisture in the
crankcase and may lead to corrosion damage and damage to
the drive.
2-stage air-cooled compressors are designed to run at low
compression temperatures so that the high temperature
stability of synthetic oils is not required.
Note!
The recommended types of oil reduce the level of coking in the
compressor valves and the upstream pipe lines and fittings to a
minimum.
Lubricants which are not listed in the lubricant table may only be
used after approval has been given by J.P. SAUER & SOHN.
Otherwise the guarantee is made void.
Please contact our Customer Service when selecting oils not
listed, or if operating conditions differ from those recommended.
10.1 Lubricating oils

The following mineral oils may be used in Sauer compressors;
Shell Corena P 100 mineral oil is the standard type used to fill
and operate the unit.
84
Note!
Unless otherwise ordered, Sauer compressors
are delivered without oil.
Lubricant table
Brand
Agip
ARAL
AVIA
BP
CHEVRON
ESSO
Shell
TEXACO
Group
VCL-100
VDL-100
VCL-100
SAE 30
SAE 30
VCL-100
VDL-100
VDL-100
VCL-100
SAE 30
VDL-100
VDL-100
SAE 30
SAE 30
VDL-100
VDL-100
SAE 30
SAE 30
SAE 30
VDL-100
SAE 30
SAE 30
SAE 30
SAE 30
VDL-100
VCL-100
SAE 30
SAE 30
VDL-100
SAE 30
TOTAL
Product name
Diesel Gamma 30
Dicrea 100
Acer 100
Motor Oil HD 30
Cladium 50
Kowal M30
Avilub Verdichterl VDL-100
Energol RC 100
Energol IC-DG 30
Vanellus C3 SAE 30
Aircol PD 100
HD Compressor Oil 100
Delo 1000 Marine 30
Veritas 800 Marine 30
Rarus 426
Rarus 427
Mobilgard 300
Mobilgard 312
Delvac 1230
Corena P 100
Rimula X 30
Melina S Oil 30
Melina Oil 30
Gadinia Oil 30
Compressor Oil EP VDL 100
Regal EP 100
Ursatex 30
Veritas 800 Marine 30
Dacnis P 100
Disola M 3015
85
The following mineral oils may alternatively be used without

restriction in marine applications:
Brand
NATO classified
NATO classified
Product name
O - 278
OMD 113
Group
VDL-120
VDL-100
10.2 Preservation oils

The standard oil used by Sauer for compressor preservation is
Mobilarma 524.
Alternatively, the following preservation oils can be used:
Brand
Product name
Agip
Rustica C SAE 30
ARAL
Konit Motorl SAE 30
AVIA
MK 1540 S
BP
MEK 20 W-20
DEA
Deamot EKM 642 SAE 30
Esso
MZK Motorenl HD 30
Rostschutz MZ 110
Mobil
Mobilarma 524
Shell
Ensis Motor Oil 30
Note!
Further oils for various applications for Sauer compressors can
be found in the "Oil recommendations for Sauer compressors"
document.
86
Note!
The product name may vary by country.
Lubricant table
87
11 Spare Parts and Accessories

Note!
Please note the information in Chapter 1 regarding our genuine
Sauer spare parts.
J.P. SAUER & SOHN guarantee the complete spare parts supply
over the entire service life of the Sauer compressor.
Our genuine Sauer spare parts are subject to constant quality
control and further development. They conform to the latest
technical developments.
In addition to genuine Sauer spare parts, our range of supply
includes many accessories for your Sauer compressor as well as
special equipment for your entire compressed air system,
including:
Fully automatic controls
Adsorption dryers
Refrigerant type dryers
Filters
Sound-dampening enclosures
Compressed air vessels and
Fittings
We supply instructions and a maintenance manual for each

accessory.
88
Spare Parts and Accessories

Spare parts
catalogue
The spare parts catalogue is in the Appendix to this Operator

Manual.
The required parts can be quickly found with the help of
diagrams, illustrations and lists.
The spare parts catalogue and Operator Manual are also
available on CD-ROM. This makes it easy to fill out an order
form, print it out and send it in immediately.
To do so, you need themain specificationsof your Sauer
compressor from the table below. If the data has not yet been
entered, it can be found on the nameplate affixed to the
crankcase.
Compressor type:
Factory No.:
Year of construction:
You should additionally indicate the number of operating

hours.
89
12 Appendix
This Appendix to the Operator Manual contains

Form for commissioning certificate
Form for Return of Goods/Notification of Claim
Supplier documentation
Data sheets
90
Appendix
Commissioning certificate for compressors
J.P. SAUER & SOHN

Maschinenbau GmbH
Brauner Berg 15 - 24159 Kiel
Phone: +49 - 431- 39 40 - 0
Fax: +49 - 431- 39 40 - 89
E-mail: service@sauersohn.de
Purchaser
Company
Street
Postcode
Contact
Phone number
Customer number
Order number
Compressor type
Delivery date
Date commissioned
Sauer service engineer
Owner
Company
Street
Postcode
Contact
Phone number
Serial No.
Operating hours
Company/name
Company/name
Company/name
Company/name
Installation of compressor/complete system
Good
Faults
Check of rotational
direction
Compression
temperature
Suction temperature
Start/stop pressure
Faults
Oil level check

Control system check
Faults
Ventilation
Good
Ambient conditions
Good
Voltage?
Good
Installation site
C
C
Test run
Faults
Vibration behaviour of compressor
Good
Faults
Accessories
Compressed air vessel
Refrigerant type dryer
Adsorption dryer
Installation of complete system carried out by:
Good
Faults
Filter
Condensate removal
Operating personnel have received instruction and are familiar with the safety and maintenance requirements.
The maintenance instructions are available to the owner.
The operating company has been advised to use only genuine SAUER & SOHN spare parts.
Notes/faults:
The system has been accepted by the owner.
City:
Purchaser
Authorised Sauer- Service Partner
Owner
Date:
91
J.P. SAUER & SOHN
Return of goods
Notification of claim
Maschinenbau GmbH
Brauner Berg 15 - 24159 Kiel, Germany
Phone: +49 - 431- 39 40 - 0
Date:
Fax: +49 - 431- 39 40 - 89

E-mail: service@sauersohn.de
Manufacturer
Please always complete.
Company
Street
Postcode/City
Customer No.
Location
Compressor type:
Serial No.:
To be completed by manufacturer
End customer
Operation hours:
Company
Street
Postcode/City
Customer No.
Location
Spare parts
Designation
Date of fault:
Ambient temperature:
Reason for return

Quantity
Part No.
Report on fault
Repair
Checking as customer
service
Goods taken back against
credit note
92
Report
To be completed
by manufacturer only
Short description of fault
S a u e r
C o m p r e s s o r
Type: WP 45 L
Spare parts catalogue
WP45L_ET1_Titel_en_1104.fm
Translation of the original operator manual

Edition: 04 / 2011
Edited by: J.P. Sauer & Sohn Maschinenbau Technical Documentation
WP45L_ET1_en_1104.fm
065 864 Compressor unit WP 45 L

Page
E-
Rev.
Compressor unit WP45 L .....................................................
5796-a
065 866
Compressor WP45 L ............................................................
5796-b
064 478
Crankcase.............................................................................
12
6229-b
064 064
Dipstick .................................................................................
14
5294-
064 076
Crankshaft.............................................................................
16
5813-d
064 059
Connecting rod 1st stage.......................................................
18
5815-b
064 060
Connecting rod 2nd stage......................................................
20
5568-a
031 881
Piston 1st stage .....................................................................
22
6420-d
064 061
Piston 2nd stage ....................................................................
24
064 062
Cylinder with head and valve 1st stage ................................
26
6384-b
064 063
Cylinder with head and valve 2nd stage ...............................
28
5682-b
065 910
Cooler, complete ..................................................................
30
5793-b
065 905
Cooler 1st stage ....................................................................
32
064 068
Cooler 2nd stage ...................................................................
34
5241-a
064 072
Crankcase vent .....................................................................
36
6415-b
065 909
Air lines .................................................................................
38
6265-b
063 121
Separator 2nd stage ..............................................................
40
-f
064 071
Compressor monitoring and control......................................
42
5730-c
062 407
Compressor monitoring and control 2nd stage......................
44
6209-a
060 354
Automatic drainage system...................................................
46
5488-c
064 070
Anti-vibration resilient mount ................................................
48
5708-d
061 001
Hose line ..............................................................................
50
Flexible coupling ...................................................................
52
064 018
Temperature monitoring (option) ..........................................
54
5784-g
060 445
Oil level monitoring device (optional) ...................................
56
6047-h
Ref. No.
Assembly
065 864
E-3
Note:
Explanation of the assemblies in Chapter 3 of the operator
manual.
E-4
E-5
065 864 Compressor unit WP45 L

1
8, 10, 11, 13
9, 14, 15
16
17
18
8, 10, 11, 12, 13
E-6

065 864 Compressor unit WP45 L
Item No.
Ref. No.
065 866
Compressor WP 45L
060 354
Automatic drainage system
064 070
Anti-vibration resilient mount
064 043
Motor support
064 044
Motor support
002 161
Washer
000 184
Hexagon head screw
10
000 155
Hexagon head screw
11
001 620
Hexagon nut
12
001 636
Washer
13
012 597
Lock washer
14
037 220
Motor half coupling
15
033 494
Coupling flexible insert
16
1)
Electric motor
17
064 137
Flange
18
000 499
Cap screw
Quantity
The order number for the electric motor is order-specific.
1)
Designation
E-7
065 866 Compressor WP45 L

9
10
1, 15
16
14
E-8

7
12
11
E-9
E - 10

Ref. No.
Designation
Quantity
064 478
Crankcase
064 076
Crankshaft
064 059
064 060
064 061
Piston 2nd stage
031 881
Piston 1st stage
064 062
Cylinder with head and valve 1st stage
064 063
Cylinder with head and valve 2nd stage
065 910
Cooler, complete
10
064 072
Crankcase vent
11
065 909
Air lines
12
064 071
Compressor monitoring and control
14
000 499
Cap screw
15
004 408
Locking pin
16
036 345
Compressor half coupling
Item No.
E - 11
064 478 Crankcase

1
11
2
21
20
12, 16, 17
5
6, 7
14, 16
55 Nm
10, 13
75 Nm
15, 19
E - 12

064 478 Crankcase
Item No.
Ref. No.
064 268
Crankcase
064 122
Bearing housing
064 047
Gasket
005 029
Washer
000 979
Plug
064 064
Dipstick
10
001 620
Hexagon nut
11
000 269
Lifting eye bolt
12
005 930
Stud screw
131)
037 152
Stud screw, cylinder head 2nd stage
141)
037 153
Stud screw, cylinder head 1st stage
15
038 919
Oil drain cock
16
002 031
Hexagon nut
13
17
002 156
Washer
19
005 009
Washer
20
001 886
Shaft seal
21
030 831
Shaft seal
Quantity
Item 13 and item 14 inserted with Loctite 542.
1)
Designation
E - 13
064 064 Dipstick
E - 14

064 064 Dipstick
Ref. No.
Designation
Quantity
037 076
Dipstick
035 520
O-ring
Item No.
E - 15
064 076 Crankshaft

7
17
16
6
11
75 Nm
15
3
10
175 Nm
Z
Y
18
12
15
9
4
13
E - 16
14

064 076 Crankshaft
Item No.
Ref. No.
064 053
Crankshaft
064 382
Flywheel
064 054
Washer
056 887
Washer
064 642
Thrust washer
064 335
Liner
033 502
Fan wheel
000 119
Hexagon head screw
10
000 188
Hexagon head screw
11
000 158
Hexagon head screw
12
001 667
Lock plate
13
002 439
Circlip
14
004 458
Adapter sleeve
15
001 982
Feather key
16
002 266
Cylindrical roller bearing
17
037 154
Cylindrical roller bearing
181)
004 472
Dowel pin
Quantity
Item 18, 004 472 Dowel pin is part of assembly 064 642.
1)
Designation
E - 17
064 059 Connecting rod 1st stage
E - 18

064 059 Connecting rod 1st stage
Item No.
Ref. No.
066 719
Lubricating pin
064 126
Connecting rod
002 094
Hexagon nut
037 155
Small-end bearing
036 107
Small-end bearing
71)
031 883
Gudgeon pin
Quantity
Item 7, 031 883 Gudgeon pin is part of assembly 031 881.
1)
Designation
E - 19
064 060 Connecting rod 2nd stage
E - 20

064 060 Connecting rod 2nd stage
Item No.
Ref. No.
064 128
Connecting rod
037 155
Small-end bearing
037 156
Small-end bearing
71)
064 074
Gudgeon pin
Quantity
Item 7, 064 074 Gudgeon pin is part of assembly 064 061.
1)
Designation
E - 21
031 881 Piston 1st stage
3
4
5
2
E - 22

031 881 Piston 1st stage
Item No.
Ref. No.
090 650
Piston
031 883
Gudgeon pin
012 512
Taper face ring
031 901
Nose ring
031 902
Oil scraper ring
002 976
Circlip
71)
036 107
Small-end bearing
Quantity
Item 7, 036 107 Small-end bearing is part of assembly 064 059.
1)
Designation
E - 23
064 061 Piston 2nd stage
3
4
5
1
6
2
E - 24

064 061 Piston 2nd stage
Item No.
Ref. No.
064 129
Piston
064 074
Gudgeon pin
031 541
Plain ring
002 548
Nose ring
031 542
Oil scraper ring
002 980
Circlip
71)
037 156
Small-end bearing
Quantity
Item 7, 037 156 Small-end bearing is part of assembly 064 060.
1)
Designation
E - 25
064 062 Cylinder with head and valve 1st stage

7, 9
5
8
4
1
E - 26

064 062 Cylinder with head and valve 1st stage
Item No.
Ref. No.
064 130
Cylinder
064 134
Cylinder head
064 048
Gasket
063 059
Gasket
056 235
Washer
039 547
Silencer filter
037 157
Valve
91)
039 548
filter element
Quantity
Item 9, 039 548 Filter element is part of assembly 039 547.
1)
Designation
E - 27
064 063 Cylinder with head and valve 2nd stage
4
6
9
E - 28

064 063 Cylinder with head and valve 2nd stage
Ref. No.
Designation
Quantity
064 132
Cylinder
064 135
Cylinder head
064 049
Gasket
064 051
Gasket
006 385
Reducing union
037 158
Valve
030 915
005 016
Washer
037 526
O-ring
Item No.
E - 29
065 910 Cooler, complete
14
11, 15
10, 17
16
2
3
Y
4, 12, 15
12, 15
9
12, 15
8
8
13
E - 30

065 910 Cooler, complete
Item No.
Ref. No.
065 905
Cooler 1st stage
064 068
Cooler 2nd stage
056 914
Fan cover
064 341
Pipe
064 139
Flange
064 041
Attachment rail
064 050
Gasket
064 042
Clamp
064 075
Clamp
10
064 643
Pipe
11
005 247
Hexagon head screw
121)
033 532
Hexagon head screw
131)
000 123
Hexagon head screw
14
000 493
Cap screw
15
003 114
Lock washer
12
16
006 186
Fitting
17
012 862
Cutting ring
Quantity
Item 12 and item 13 inserted with Loctite 542.
1)
Designation
E - 31
065 905 Cooler 1st stage

A-A
B
A
B
B-B
E - 32

065 905 Cooler 1st stage
Ref. No.
Designation
Quantity
065 904
Cooler
004 652
Fitting
006 190
Fitting
Item No.
E - 33
064 068 Cooler 2nd stage
E - 34

064 068 Cooler 2nd stage
Ref. No.
Designation
Quantity
064 046
Cooler
004 641
Fitting
004 998
Fitting
005 009
Washer
Item No.
E - 35
064 072 Crankcase vent

12
11
11
10
2, 3, 8
E - 36

064 072 Crankcase vent
Item No.
Ref. No.
035 824
Filling cover
006 380
Reducing union
006 205
Fitting
038 920
Stub
51)
037 138
Reducer
037 137
Y-joint
71)
064 522
Pipe nipple joint
005 009
Washer
034 612
Low-pressure hose
10
033 952
Insulation tube
11
040 300
Single-eye clamp
12
012 766
Pipe
Quantity
Items 5 and item 7 inserted with seal tape.
1)
Designation
E - 37
065 909 Air lines

10, 18
9
11, 19
12, 18
15, 17
10
1
6
8
8, 20
14
E - 38

065 909 Air lines
Ref. No.
Designation
Quantity
063 121
Separator 2nd stage
064 567
Clamp
066 170
Pipe
000 147
Hexagon head screw
005 671
Cap screw
006 187
Fitting
006 186
Fitting
10
006 225
Fitting
11
006 386
Reducing union
12
006 385
Reducing union
13
006 217
Fitting
14
037 221
Separator 1st stage
15
030 752
17
005 009
Washer
18
005 016
Washer
19
005 023
Washer
20
030 340
O-ring
Item No.
E - 39
063 121 Separator 2nd stage
11, 12
9
1
4
8
10
3
E - 40

063 121 Separator 2nd stage
Item No.
Ref. No.
063 228
Separator housing
063 229
Separator head
062 328
Baffle cone
41)
060 342
Fusible plug
006 390
Reducing union
005 029
Washer
005 009
Washer
036 171
O-ring
10
036 041
Hexagon head screw
11
001 007
Plug
12
003 496
Washer
Quantity
121 C / 250 F
1)
Designation
E - 41
064 071 Compressor monitoring and control

3, 6
4, 5
1, 3
E - 42

064 071 Compressor monitoring and control
Ref. No.
Designation
Quantity
066 370
Pressure gauge 1st stage
062 407
Compressor monitoring and control 2nd stage
035 061
Washer
037 160
Socket fitting
003 500
Washer
038 264
Pressure gauge angle piece
Item No.
E - 43
062 407 Compressor monitoring and control 2nd stage
E - 44

062 407 Compressor monitoring and control 2nd stage
Ref. No.
Designation
Quantity
038 282
Pressure gauge 2nd stage
062 408
Double ended stud end
035 061
Washer
Item No.
E - 45
060 354 Automatic drainage system
E - 46

060 354 Automatic drainage system
Item No.
Ref. No.
11)
2)
1)
Quantity
Solenoid valve
006 455
Stub
006 381
Reducing union
004 635
Fitting
Specify voltage and frequency for order!

The order number for the solenoid valve is order-specific.
2)
Designation
E - 47
064 070 Anti-vibration resilient mount

9
7, 8
3, 4
10
E - 48

064 070 Anti-vibration resilient mount
Ref. No.
Designation
Quantity
061 001
Hose line
000 068
Hexagon head screw
001 637
Washer
031 149
Anti-vibration resilient mount
037 172
Mounting plate
000 066
Hexagon head screw
002 166
Washer
037 746
High pressure hose
10
033 488
Non-return valve
Item No.
E - 49
061 001 Hose line

2
E - 50

061 001 Hose line
Ref. No.
Designation
Quantity
038 309
High pressure hose
004 694
Fitting
Item No.
E - 51
Flexible coupling
3
E - 52

Flexible coupling
Item No.
Ref. No.
Designation
Quantity
11)
036 345
Compressor half coupling
22)
037 220
Motor half coupling
33)
033 494
Coupling flexible insert
1)
Item 1, 036 345 Compressor half coupling is part of assembly 065 866.
Item 2, 037 220 Motor half coupling is part of assembly 065 864.
3) Item 3, 033 494 Coupling flexible insert is part of assembly 065 864.
2)
E - 53
064 018 Temperature monitoring

1
2, 4
E - 54

064 018 Temperature monitoring
Ref. No.
Designation
Quantity
035 468
High air temperature switch
000 410
Cap screw
002 144
Washer
Item No.
E - 55
060 445 Oil level monitoring device
E - 56

060 445 Oil level monitoring device
Item No.
Ref. No.
11)
060 445
Oil level monitoring device
Quantity
1
Item 1, Oil level monitoring device is only available as a complete assembly.
1)
Designation
E - 57
E - 58
Index
Parts List by Ref. No.
Assembly
Page
E-
Item
Solenoid valve ........................................
060 354
46
Electric motor .........................................
065 864
16
000 066
Hexagon head screw .............................
064 070
48
000 068
064 070
48
000 119
064 076
16
000 123
065 910
30
13
000 147
065 909
38
000 155
065 864
10
000 158
064 076
16
11
000 184
065 864
000 188
064 076
16
10
000 269
Lifting eye bolt ........................................
064 478
12
11
000 410
Cap screw ..............................................
064 018
54
000 493
Cap screw ..............................................
065 910
30
14
000 499
Cap screw ..............................................
065 864
18
000 499
Cap screw ..............................................
065 866
14
000 979
Plug ........................................................
064 478
12
001 007
Plug ........................................................
063 121
40
11
001 620
Hexagon nut ...........................................
064 478
12
10
001 620
Hexagon nut ...........................................
065 864
11
001 636
Washer ...................................................
065 864
12
001 637
Washer ...................................................
064 070
48
001 667
Lock plate ...............................................
064 076
16
12
001 886
Shaft seal ...............................................
064 478
12
20
001 982
Feather key ............................................
064 076
16
15
002 031
Hexagon nut ...........................................
064 478
12
16
002 094
Hexagon nut ...........................................
064 059
18
WP45L_ET1_Index_en_1104.fm
Ref. No.
Designation
E - 59
Page
E-
Item
Washer ...................................................
064 018
54
002 156
Washer ...................................................
064 478
12
17
002 161
Washer ...................................................
065 864
002 166
Washer ...................................................
064 070
48
002 266
Cylindrical roller bearing .........................
064 076
16
16
002 439
Circlip .....................................................
064 076
16
13
002 548
Nose ring ................................................
064 061
24
002 976
Circlip .....................................................
031 881
22
002 980
Circlip .....................................................
064 061
24
003 114
Lock washer ...........................................
065 910
30
15
003 496
Washer ...................................................
063 121
40
12
003 500
Washer ...................................................
064 071
42
004 408
Locking pin .............................................
065 866
15
004 458
Adapter sleeve .......................................
064 076
16
14
004 472
Dowel pin ................................................
064 076
16
18
004 635
Fitting .....................................................
060 354
46
004 641
Fitting .....................................................
064 068
34
004 652
Fitting .....................................................
065 905
32
004 694
Fitting .....................................................
061 001
50
004 998
Fitting .....................................................
064 068
34
005 009
Washer ...................................................
063 121
40
005 009
Washer ...................................................
064 068
34
005 009
Washer ...................................................
064 072
36
005 009
Washer ...................................................
064 478
12
19
005 009
Washer ...................................................
065 909
38
17
005 016
Washer ...................................................
064 063
28
005 016
Washer ...................................................
065 909
38
18
005 023
Washer ...................................................
065 909
38
19
005 029
Washer ...................................................
063 121
40
Designation
002 144
E - 60
Assembly
Ref. No.
Index
Assembly
Page
E-
Item
Washer ...................................................
064 478
12
005 247
065 910
30
11
005 671
Cap screw ..............................................
065 909
38
005 930
Stud screw .............................................
064 478
12
12
006 186
Fitting .....................................................
065 909
38
006 186
Fitting .....................................................
065 910
30
16
006 187
Fitting .....................................................
065 909
38
006 190
Fitting .....................................................
065 905
32
006 205
Fitting .....................................................
064 072
36
006 217
Fitting .....................................................
065 909
38
13
006 225
Fitting .....................................................
065 909
38
10
006 380
Reducing union ......................................
064 072
36
006 381
Reducing union ......................................
060 354
46
006 385
Reducing union ......................................
064 063
28
006 385
Reducing union ......................................
065 909
38
12
006 386
Reducing union ......................................
065 909
38
11
006 390
Reducing union ......................................
063 121
40
006 455
Stub ........................................................
060 354
46
012 512
Plain ring ................................................
031 881
22
012 597
Lock washer ...........................................
065 864
13
012 766
Pipe ........................................................
064 072
36
12
012 862
Cutting ring .............................................
065 910
30
17
030 340
O-ring .....................................................
065 909
38
20
030 752
Safety valve 2nd stage ...........................
065 909
38
15
030 831
Shaft seal ...............................................
064 478
12
21
030 915
Safety valve 1st stage ............................
064 063
28
031 149
Anti-vibration resilient mount ..................
064 070
48
031 541
Plain ring ................................................
064 061
24
031 542
Oil scraper ring .......................................
064 061
24
Ref. No.
Designation
005 029
E - 61
Page
E-
Item
Piston 1st stage ......................................
065 866
031 883
Gudgeon pin ...........................................
031 881
22
031 883
Gudgeon pin ...........................................
064 059
18
031 901
Nose ring ................................................
031 881
22
031 902
Oil scraper ring .......................................
031 881
22
033 488
Non-return valve .....................................
064 070
48
10
033 494
Coupling flexible insert ...........................
52
033 494
Coupling flexible insert ...........................
065 864
15
033 502
Fan wheel ...............................................
064 076
16
033 532
Hexagon head screw ..............................
065 910
30
12
033 952
Insulation tube ........................................
064 072
36
10
034 612
Low-pressure hose .................................
064 072
36
035 061
Washer ...................................................
062 407
44
035 061
Washer ...................................................
064 071
42
035 468
High air temperature switch ....................
064 018
54
035 520
O-ring .....................................................
064 064
14
035 824
Filling cover ............................................
064 072
36
036 041
Hexagon head screw ..............................
063 121
40
10
036 107
Small-end bearing ..................................
031 881
22
036 107
064 059
18
036 171
O-ring .....................................................
063 121
40
036 345
Compressor half coupling .......................
52
036 345
Compressor half coupling .......................
065 866
16
037 076
Dipstick ...................................................
064 064
14
037 137
Y-joint .....................................................
064 072
36
037 138
Reducer ..................................................
064 072
36
037 152
Stud screw, cylinder head 2nd stage .......
064 478
12
13
037 153
Stud screw, cylinder head 1st stage .......
064 478
12
14
037 154
Cylindrical roller bearing .........................
064 076
16
17
Designation
031 881
E - 62
Assembly
Ref. No.
Index
Assembly
Page
E-
Item
064 059
18
037 155
064 060
20
037 156
064 060
20
037 156
064 061
24
037 157
Valve ......................................................
064 062
26
037 158
Valve ......................................................
064 063
28
037 160
Socket fitting ..........................................
064 071
42
037 172
Mounting plate .......................................
064 070
48
037 220
Motor half coupling .................................
52
037 220
Motor half coupling .................................
065 864
14
037 221
Separator 1st stage ................................
065 909
38
14
037 526
O-ring .....................................................
064 063
28
037 746
High pressure hose ................................
064 070
48
038 264
Pressure gauge angle piece ..................
064 071
42
038 282
Pressure gauge 2nd stage ......................
062407
44
038 309
High pressure hose ................................
061 001
50
038 919
Oil drain cock .........................................
064 478
12
15
038 920
Stub ........................................................
064 072
36
039 547
Silencer filter ..........................................
064 062
26
039 548
filter element ..........................................
064 062
26
040 300
Single-eye clamp ...................................
064 072
36
11
056 235
Washer ...................................................
064 062
26
056 887
Washer ...................................................
064 076
16
056 914
Fan cover ...............................................
065 910
30
060 342
Fusible plug ............................................
063 121
40
060 354
Automatic drainage system ....................
065 864
060 445
Oil level monitoring device .....................
060 455
56
061 001
Hose line ................................................
064 070
48
062 328
Baffle cone .............................................
063 121
40
Ref. No.
Designation
037 155
E - 63
Page
E-
Item
Compressor monitoring and control 2nd

stage .......................................................
064 071
42
062 408
Double ended stud end ..........................
062 407
44
063 059
Gasket ....................................................
064 062
26
063 121
Separator 2nd stage ................................
065 909
38
063 228
Separator housing ..................................
063 121
40
063 229
Separator head .......................................
063 121
40
064 041
Attachment rail .......................................
065 910
30
064 042
Clamp .....................................................
065 910
30
064 043
Motor support .........................................
065 864
064 044
Motor support .........................................
065 864
064 046
Cooler .....................................................
064 068
34
064 047
Gasket ....................................................
064 478
12
064 048
Gasket ....................................................
064 062
26
064 049
Gasket ....................................................
064 063
28
064 050
Gasket ....................................................
065 910
30
064 051
Gasket ....................................................
064 063
28
064 053
Crankshaft ..............................................
064 076
16
064 054
Washer ...................................................
064 076
16
064 059
Connecting rod 1st stage ........................
065 866
064 060
Connecting rod 2nd stage .......................
065 866
064 061
Piston 2nd stage .....................................
065 866
064 062
Cylinder with head and valve 1st stage ..
065 866
064 063
Cylinder with head and valve 2nd stage .
065 866
064 064
Dipstick ...................................................
064 478
12
064 068
Cooler 2nd stage .....................................
065 910
30
064 070
Anti-vibration resilient mount ..................
065 864
064 071
Compressor monitoring and control .......
065 866
12
064 072
Crankcase vent ......................................
065 866
10
Designation
062 407
E - 64
Assembly
Ref. No.
Index
Assembly
Page
E-
Item
Gudgeon pin ..........................................
064 060
20
064 074
Gudgeon pin ..........................................
064 061
24
064 075
Clamp .....................................................
065 910
30
064 076
Crankshaft ..............................................
065 866
064 122
Bearing housing .....................................
064 478
12
064 126
Connecting rod .......................................
064 059
18
064 128
Connecting rod .......................................
064 060
20
064 129
Piston .....................................................
064 061
24
064 130
Cylinder ..................................................
064 062
26
064 132
Cylinder ..................................................
064 063
28
064 134
Cylinder head .........................................
064 062
26
064 135
Cylinder head .........................................
064 063
28
064 137
Flange ....................................................
065 864
17
064 139
Flange ....................................................
065 910
30
064 268
Crankcase...............................................
064 478
12
064 335
Liner .......................................................
064 076
16
064 341
Pipe ........................................................
065 910
30
064 382
Flywheel .................................................
064 076
16
064 478
Crankcase...............................................
065 866
064 522
Pipe nipple joint ......................................
064 072
36
064 567
Clamp .....................................................
065 909
38
064 642
Thrust washer ........................................
064 076
16
064 643
Pipe ........................................................
065 910
30
10
065 866
Compressor WP 45L ..............................
065 864
065 904
Cooler ....................................................
065 905
32
065 905
Cooler 1st stage .....................................
065 910
30
065 909
Air lines ..................................................
065 866
11
065 910
Cooler, complete ....................................
065 866
066 170
Pipe ........................................................
065 909
38
Ref. No.
Designation
064 074
E - 65
Assembly
Page
E-
Item
Pressure gauge 1st stage .......................
064 071
42
066 719
Lubricating pin ........................................
064 059
18
090 650
Piston .....................................................
031 881
22
Designation
066 370
Ref. No.
E - 66

WP45L BA1 ET1 en 1104

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WP45L BA1 ET1 en 1104

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S a u e r

Translation of the original operator manual

Sauer compressor Type Approvals

Genuine Sauer spare parts

Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Transport and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Storage, Preservation Lay-up Procedure . . . . . . . . . . . . . . . . . . . . .78

Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

1.2 Precautionary measures

The copyright for this Operator Manual remains with

Sauer can no longer provide warranty coverage or be held liable

1.4 Type approval and genuine Sauer-spare parts

Do not use parts from the

Only use genuine Sauer spare parts

+49 431 39 40 -87

1.6 Specific instructions

General lists are marked using a dash.

Individual instructions or multiple instructions requiring action but

2.1 Conditions of Use

2.2 Unauthorised modification

Unauthorised modification of the Sauer compressor is not

2.4 Safety Warnings on the Machine

High voltage! Danger

Location of safety markings

The Sauer compressor is equipped with a safety fuse in the final

Optionally, an oil level switch can be installed which sends a

A final pressure switch is included with the Sauer compressor

2.6 Noise protection

2.7 Waste disposal

2.9 Personal protective equipment

The owner must provide personal protective equipment such as

Design and function

Design and function

Cylinder 2nd stage

Safety valve 1st stage

Safety valve 2nd stage

Condensate separator 1st stage

Condensate separator 2nd stage

Drain valve 1st stage

Drain valve 2nd stage

Cooler 1st stage

Cooler 2nd stage

Connecting rod 1st stage

Connecting rod 2nd stage

Design and function

Piston 1st stage

Connecting rod 1st stage

Cylinder with head and valve 2nd stage

Piston 2nd stage

Connecting rod 2nd stage

3.2 Functional description

Driven by an electric motor, the Sauer compressor is controlled

An axial fan mounted on the crankshaft sucks cooling air from

Design and function

The crankshaft bearing and piston are lubricated by oil splash in

3.3 Displays on the Sauer-compressor

Compressed air pressure after 1st stage

Final pressure of the compressed air after the

Design and function

Indicates the hours the compressor has run.