WP81L BA1 ET1 en 1402

S a u e r
C o m p r e s s o r
Type: WP 81 L
Operating Instructions
High-pressure compressor
3-stage
Air-cooled
WP81L_BA_Titel_en_1402.fm
Translation of the original operating manual

Issue: 02 / 2014
Edited by: J.P. Sauer & Sohn Maschinenbau GmbH – Technical Documentation
Zertifikate_en_01.fm
Type approvals for Sauer compressors

Zertifikate_en_01.fm
Note!
This page shows only a few examples. Further type approvals
are available upon request.
Genuine Sauer spare parts -
Certified safety
PL E
S AM Zertifikate_en_01.fm
Table of Contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Type approval and genuine Sauer spare parts . . . . . . . . . . . . . . . . . . . . . 10
1.5 J.P. SAUER & SOHN customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6 Text conventions used in this Operator Manual . . . . . . . . . . . . . . . . . . . . . 12
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Unauthorised modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Safety information – Warning and caution . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Safety markings on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 Safety and protection equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.6 Noise protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7 Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.8 Safety requirements for personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.9 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3 Displays on the Sauer compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.4 Displays and controls on the compressor control . . . . . . . . . . . . . . . . . . . . 31
4 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.1 Specification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.2 P&I diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5 Transport and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2 Storage before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.4 Connecting the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.5 Adjusting the final pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.6 Filling with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.7 Checks to be carried out after installation and before initial start-up . . . . . 47
WP81L_BA1_IVZ_en_1402.fm
5
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.1 Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.3 Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.4 Routine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.1 J.P. SAUER & SOHN maintenance service . . . . . . . . . . . . . . . . . . . . . . . . 60
8.2 Maintenance safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.4 Sauer Easy Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.5 Table of tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.6 Changing the air filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.7 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.8 Cleaning the oil intake screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.9 Checking the valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.10 Replacing the valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.11 Replacing the piston rings, piston pins and piston pin bearings . . . . . . . . . 77
8.12 Replacing the flexible gear rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.13 Overhauling the drain valves (order-specific) . . . . . . . . . . . . . . . . . . . . . . . 83
8.14 Checking the safety valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
9.1 Safety when decommissioning and disassembling . . . . . . . . . . . . . . . . . . 88
9.2 Temporary preservation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10 Lubricants for Sauer compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
11 Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
12 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6
7
1 General
1.1 Foreword
This Operator Manual contains instructions concerning the
installation, safe operation, maintenance and repair of the Sauer
compressor as well as an illustrated parts list.
The following unique specification for the Sauer compressor can
be found on the nameplate affixed to the compressor:
– Compressor type
– Serial number
– Year of construction:
We recommend that you record this information in Chapter 11

and always provide this data when requesting parts and any
repair instructions.
1.2 Precautions
Specific We recommend that only authorised and trained personnel
precautions operate and service the Sauer compressor. These responsible
personnel should be thoroughly familiar with, and frequently
review, the Operator Manual.
This Operator Manual must always be readily available at the
compressor installation.
Copyright The copyright for this Operator Manual remains with

J.P. SAUER & SOHN. The Operator Manual, or parts thereof,
shall not be copied, distributed or made available to third parties.
Contravention will result in prosecution.
WP81L_BA1_en_1402.fm
8
General
1.3 Warranty and liability
Sauer will no longer cover warranty or be liable for any claims if

a failure is attributed to any of the following:
– Use of the machine in a manner or for a purpose other than

that specified;
– Replacement with parts not manufactured or approved by
Sauer;
– Use of spare parts that are not genuine Sauer spare parts;
– Operation of the machine with faulty or improperly installed
safety and/or protective devices;
– Failure to observe the Operator Manual;
– Unauthorised modifications to the machine or its control
system;
– Inadequate monitoring of machine parts subject to wear;
– Failure to maintain/repair in accordance with Sauer
instructions;
– Force majeure.
9
1.4 Type approval and genuine Sauer spare parts
• Type approval for the Sauer compressor is valid on condition
that only parts and components specified and quality-tested by
J.P. SAUER & SOHN are used. Type approval is provided by
the classification 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 thus also the
reliable, safe operation of the Sauer compressor.
• If spare parts other than genuine Sauer spare parts are used,
we reserve the right of exclusion from liability for personal
injury and material damage.
• Genuine Sauer spare parts are supplied with a Certificate of
Conformity and Authenticity. An example of this document is
shown before the Table of Contents in this Operator Manual. If
spare parts are received without this certificate, there is a risk
that these are not genuine Sauer spare parts. In such an
instance please contact our customer service department.
Note!
This is a high pressure compressor. For your own safety and for
reliable compressor operation, use genuine Sauer spare parts
only.
Correct Incorrect
Only use genuine Sauer spare parts Do not use parts

that are certified! obtained on the
"grey market"!
10
General
1.5 J.P. SAUER & SOHN customer service
Should you have any technical questions relating to maintenance

or repair, please contact the Sauer Service department:
J.P. SAUER & SOHN Maschinenbau GmbH

Sauer Service
P.O. Box 92 13
D-24157 Kiel
Telephone (international):
Technical information +49 431 39 40 87
Spare parts orders +49 431 39 40 86/886
Fax (international): +49 431 39 40 89
Emergency service
(international): +49 172 4 14 63 94
E-mail: service@sauercompressors.de
Web: www.sauercompressors.com
Note!
For all questions regarding your Sauer compressor, please
specify the compressor type and serial number (see Chapter 11
or nameplate on the compressor).
11
1.6 Text conventions used in this Operator Manual
Lists General lists are marked using a dash.
e. g.:
Compressor cooling consists of
– fan,
– fan cage, 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.
e. g.:
• Check oil level.
Instructions to be carried out in a certain sequence are

numbered.
e. g.:
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.

e. g.:
The control light lights up.
Safety Safety and warning instructions are presented pictorially with

instructions clear instructions. The safety instructions are described in detail
in Chapter 2.
12
13
General
2 Safety
2.1 Proper use
This Sauer compressor system must only be used to compress

the specified gas/medium (see factory test). The Sauer
compressor must not be used at ambient temperatures below
+5 °C or over +55 °C. Any other unauthorised use requires the
express written approval of J.P. SAUER & SOHN.
In addition, proper conditions of use also include compliance with
this Operator Manual and the installation requirements and
maintenance intervals described in these.
Most accidents that occur during operation and maintenance of
machinery result from failure to observe basic safety rules or
precautions.
When handling, operating or carrying out maintenance,
personnel must observe safe engineering working practices and
local regulations.
2.2 Unauthorised modifications

Unauthorised modifications to the Sauer compressor are not
permitted. Modifications may lead to life-threatening injuries,
endanger personnel and damage the equipment.
When planning any modifications, contact J.P. SAUER & SOHN
to obtain written approval.
14
Safety
2.3 Safety information – Warning and caution
The safety information in this Operator Manual is presented as

‘high’ risk and ‘lower’ risk, as follows:
Warning – Danger!
High risk.
Ignoring these safety instructions can cause personal injury, or
death, and significant equipment damage.
Caution – Note!
Lower risk.
Failure to observe these safety instructions may cause damage
to the equipment.
15
2.4 Safety markings on the machine
Danger!
Safety markings affixed to the machine must not be altered or
removed. Replace damaged or lost safety markings immediately
with an approved replacement.
The Sauer compressor with an EC Manufacturer's Declaration or
EC Declaration of Conformity is provided with the following safety
markings:
Safety marking Meaning Safety marking Meaning
High voltage! Read Operator

Danger to life! Manual!
Compressor starts Wear hearing

automatically protection.
without warning.
Hot surface! Rotational direction

of crankshaft
Location of safety markings
16
Safety
2.5 Safety and protection equipment
Danger!
Safety equipment must not be adjusted, disabled or removed.
The safety devices must be tested and checked periodically.
Safety valves must be
– installed sealed and
– replaced, adjusted and re-sealed by authorised personnel
only.
Safety valves Each compression stage of the Sauer compressor is equipped

with a safety valve, which will fully discharge air when the blow-
off pressure is reached.
The safety valves are installed at the following locations:
– 1st compression stage: at the cooler;
– 2nd compression stage: on the cylinder head of the 3rd
compression stage;
– 3rd compression stage: at the final separator behind the 3rd
compression stage.
Temperature The Sauer compressor is equipped with a fusible plug in the final
monitoring separator to protect the unit in case the compressor cooling fails.
The fusible plug melts at 121 °C and releases an exhaust port for
the compressed air if the temperature limit is exceeded.
As an alternative to the fusible plug, the Sauer compressor can
be fitted with a temperature switch. The temperature switch
transmits a signal to the compressor control if the temperature
limit is exceeded so that the compressor is switched off.
A temperature sensor can also be used as an optional
alternative.
17
Oil pressure The Sauer compressor is equipped with an oil pressure switch.
monitoring The oil pressure switch transmits a signal to the compressor
control if the oil pressure falls below p < 1 bar so that the
compressor is switched off.
An oil pressure sensor can also be used as an optional
alternative.
Final pressure A final pressure switch is included with the Sauer compressor,
monitoring which is installed by the operator depending on the operation
task. The final pressure switch transmits a signal to the
compressor control if the lower or upper limit value is reached so
that the compressor is stopped or started automatically.
A final pressure sensor can also be used as an optional
alternative.
2.6 Noise protection
Sound pressure level details are included in the technical

specifications (see Chapter 4).
The Sauer compressor can be equipped with a sound-proof
canopy to reduce noise, which is available as an accessory from
J.P. SAUER & SOHN.
Danger!
If the compressor is operated without the sound-proof canopy,
hearing protection must be worn in the area around the
compressor.
Note!
A mandatory instruction to this effect is attached to the
compressor (see Chapter 2.4).
Note!
The operator must also affix a corresponding mandatory
instruction in clear view in the vicinity of the machine or on the
entry door to the compressor room.
18
Safety
2.7 Waste disposal
Note!
While recyclable materials are used as far as possible, local
environmental regulations, or laws, dictate that the following are
disposed of to avoid polluting the environment:
– Condensate (containing oil and water) arising from after-
cooling in the compression process;
– Used oils and greases, and cloths soiled by these lubricants;
– Cleaning agents and cloths soiled by these agents.
2.8 Safety requirements for personnel
Only personnel authorised by J.P. SAUER & SOHN are

permitted to work on 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, recognised engineering standards must
be observed as well as all local laws, standards and regulations
such as:
– the Equipment and Product Safety Act,

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

regulations must be observed.
Only personnel trained and thoroughly familiar with the
compressor operation should be authorised to operate the
compressor.
Personnel authorised to service the compressor must be trained

technical specialists employed by the operator and the
manufacturer.
19
2.9 Personal protective equipment
The operator must provide personal protective equipment for

personnel carrying out any work on the compressor. This
includes:
– Hearing protection
– Safety boots
– Safety goggles
– Protective gloves
20
21
Safety
3 Design and function
3.1 Overview
Note!
Details of parts and spare parts can be found in the spare parts
catalogue.
WP81L with expansion vessel
19 18 6 20
15 8 16 10 9 17
5
22
Design and function
WP81L without expansion vessel
14
12
11
13
Item Designation
1 Cylinder 1st compression stage
2 Cylinder 2nd compression stage
3 Cylinder 3rd compression stage
4 Safety valve 1st compression stage
5 Safety valve 2nd compression stage
6 Safety valve 3rd compression stage
7 Cooler 1st compression stage
8 Condensate separator 2nd compression stage
9 Condensate separator 3rd compression stage
10 Condensate collection container (option)
11 Condensate discharge 1st compression stage
12 Condensate discharge 2nd compression stage
13 Condensate discharge 3rd compression stage
14 Compressed air line
15 Solenoid drain valve 1st compression stage
16 Solenoid drain valve 2nd compression stage
17 Solenoid drain valve 3rd compression stage
18 Oil pressure switch

19 Oil dipstick
20 Electric motor
23
Vertical
sectional view
6 4 5 7
13
8
3
12 1 11 2 10
24
Design and function
Item Designation
1 Crankcase
2 Crankshaft
4 Cooler 2nd compression stage
5 Cooler 3rd compression stage
6 Fan
7 Connecting rod
8 Flexible coupling
9 Bell housing
10 Flywheel
11 Oil intake screen
12 Lubricating oil pump
13 Bearing bracket
25
Horizontal
sectional view
6 5 4 9 8 7
26
Design and function
Item Designation
1 Cylinder with head and valve 1st compression stage
2 Piston 1st compression stage
3 Connecting rod 1st compression stage
4 Cylinder with head and valve 2nd compression stage
5 Piston 2nd compression stage
6 Connecting rod 2nd compression stage
7 Cylinder with head and valve 3rd compression stage
8 Piston 3rd compression stage
9 Connecting rod 3rd compression stage
10 Crankcase
27
3.2 Functional description
Drive The Sauer compressor is driven by an electric motor, which is
bolted to the coupling housing and transmits torque via a flexible
coupling.
As an alternative, a diesel engine can be used. In this case, it is
attached using a special flange and torque is transmitted by a
centrifugal clutch.
Compressor The Sauer compressor is controlled and monitored by an electric

control 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 ambient air through a suction filter, with
silencer, and compresses the air to the final system pressure in
three single-stage cylinders. Each cylinder is a compression
stage, and the air is cooled after each of them.
Dividing the entire pressure ratio into three compression stages
results in lower compression temperatures.
The cylinders are arranged in a W-configuration and are
equipped with lamellar valves that are easy to maintain and have
a long service life. The susceptibility of the valves to coking or
carbon build-up is extremely low due to the low compression
temperatures.
Cooling An axial fan mounted on the crankshaft draws cooling air from the
ambient air and blows it across the cylinders, cooler, valves and
oil pan. Optimal cooling of the respective compressor
components is achieved due to the placement of the fan.
28
Design and function
Condensate Condensate containing oil and water that is created during

separation compression and inter-cooling is collected in the condensate
separator behind each compression stage.
Condensate Condensate is drained via drain lines. Solenoid valves are

discharge/ installed as solenoid drain valves in the drain lines for each
separator. The drain valves must be open when the Sauer
Pressure relief
compressor is not in operation. A few seconds after starting, the
drain valves should close and the Sauer compressor should
power up against system pressure. The drain valves should drain
the system at preset intervals during operation. The solenoid
drain valves are controlled by the compressor control.
Lubrication/Oil A gearwheel oil pump, driven by the crankshaft, draws the

pressure lubricating oil from the crankcase, and then pumps it to the
connecting-rod bearings. Crankshaft bearings, piston pin bearing
and pistons are lubricated by the splash oil in the crankcase. The
oil pressure is monitored by an oil pressure sensor.
The compressor control stops the compressor if the oil pressure
falls below the lower limit value.
29
3.3 Displays on the Sauer compressor
4 6 1 2 5 7 3
Item Designation Display

1 Pressure gauge 1st Compressed air pressure after 1st compression
compression stage stage
2 Pressure gauge 2nd Compressed air pressure after 2nd compression
3 Pressure gauge 3rd Compressed air pressure after 3rd compression
compression stage stage (final pressure)
4 Thermometer 1st Compressed air temperature after 1st compression
5 Thermometer 2nd Compressed air temperature after 2nd
compression stage compression stage
6 Thermometer 3rd Compressed air temperature after 3rd compression
7 Oil pressure gauge Oil pressure display
(optional)
30
Design and function
3.4 Displays and controls on the

compressor control
Note!
If the compressor control has been supplied by
J.P. SAUER & SOHN, read the accompanying documentation.
The following displays and controls can be found on the front of
the compressor control:
Display/
Description
Control element
“Operation” signal Lights up when the compressor is running.
lamp
“Oil pressure” fault Lights up if the compressor has shut down because of low oil
indicator lamp pressure.
“Overcurrent” fault Lights up if the compressor has shut down because of excessive
indicator lamp motor current.
Run time counter Indicates the hours the compressor has run.
Operation mode • “Manual” mode:
selector 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 on the compressed air re-
ceiver).
Main switch Disconnects the power supply from the compressor control to the
compressor.
A main switch should be installed if required by local law and
regulations.
Optional:
“Air temperature” Lights up if the compressor has shut down because the
fault indicator lamp compressed air temperature is too high.
31
4 Technical specifications
4.1 Specification data
Designation Data
Compressor type WP 81 L
Number of cylinders 3
Number of compression stages 3
Cylinder diameter 1st compression stage 136 mm
Cylinder diameter 2nd compression stage 70 mm
Cylinder diameter 3rd compression stage 46 mm
Piston stroke 81 mm
Maximum speed 1800 rpm
Direction of rotation (looking towards Clockwise
flywheel)
Maximum working pressure 40 bar

Permitted intake pressure Maximum 1200 mbar(a)
Minimum 900 mbar(a)
Set pressures for safety valves:

1st compression stage 4 bar
2nd compression stage 12 bar
3rd compression stage 5 % above final pressure
Oil sump capacity 10.5 l

Oil quantity between dipstick markings 2l
Oil type see Chapter 10
Oil pressure monitoring (optional):

Low oil pressure switch 6 A / 220 V
32
Technical specifications
Designation Data
Setting Opens at 1 bar falling
approx. 15 s delay on start instruction
Switch function Change-over contact
Oil pressure sensor 4 - 20 mA / 0 - 16 bar
(optional / alternative to switch)
Temperature monitoring (optional):

Opens at 80 °C rising (industrial application)
90 °C rising (shipbuilding application)
Temperature switch 6 A / 220 V
Temperature sensor 4 - 20 mA / PT 1000 / -50 °C to +250 °C
Final pressure monitoring (optional):

Final pressure switch 6 A / 220 V
Final pressure sensor 4 - 20 mA / 0 - 160 bar
Solenoid drain valve:

Pickup and holding power Order-specific
Setting Currentless open
Starting relief approx. 15 s
Periodic drainage, every 15 min for 15 s (industrial application)
5 min for 3 s (shipbuilding application)
Sound pressure level (free field at 1 m) max. 90 dB(A)

Weight and dimensions See installation drawing
33
Note!
Please refer to the order-specific documentation of your
compressor for data such as final pressure, speed, power
requirements, etc.
4.2 P&I diagram
29 8 5 2 11 6 9 7 10 13 4 22 27 30
21
M 1 2 3 3 12 17
14
15
23 18 16 19 20
24 25 26 28 31
Item Designation
1 Electric motor
2 Safety valve 1st compression stage
3 Safety valve 2nd compression stage
4 Safety valve 3rd compression stage
5 1st compression stage

6 2nd compression stage
34
Technical specifications
Item Designation
7 3rd compression stage
9 Cooler 2nd compression stage
10 Cooler 3rd compression stage
11 Pressure gauge 1st compression stage
12 Pressure gauge 2nd compression stage
13 Pressure gauge 3rd compression stage
14 Oil pressure gauge
15 Oil pressure switch (optional: oil pressure sensor)
16 Condensate separator 2nd compression stage
17 Condensate separator 3rd compression stage
18 Solenoid drain valve 1st compression stage
19 Solenoid drain valve 2nd compression stage
20 Solenoid drain valve 3rd compression stage
21 Suction filter
22 Temperature switch (optional: temperature sensor)
23 Oil pump
24 Pressure relief valve
25 Drive lubrication
26 Oil filter
27 Non-return valve
28 Condensate collection container
29 Air inlet
30 Compressed air outlet
31 Condensate outlet
35
5 Transport and installation
5.1 Transport
Shipping The machine is packed ready for shipping.
• Upon receipt of the Sauer compressor, the goods must be
checked immediately for completeness and damage.
• Damage to the packaging or the machine must be reported 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 load rings (1).
• Raise, move into position and set down with care.
1 1
36
Transport and installation
5.2 Storage before installation
If the Sauer compressor has to be placed in storage before it is

set up, leave it in the packaging and store in the following
conditions:
– Temperature: +5 °C to +40 °C;

– Relative humidity 30% … 95%, non-condensing;
– In a dry area, under a roof and protected from dew formation;
– Protected from soiling;
– Protected from vibration and shock.
Note!
The standard factory protective packing is sufficient for a
maximum storage period of 12 months.
Note!
High pressure hoses can be stored for up to five years after
delivery.
37
5.3 Installation
Note!
If in doubt regarding the suitability of the intended installation
area, please contact J.P. SAUER & SOHN. Sauer can provide
help with the design of a ventilation system, if this is required for
the installation area.
For proper installation, follow the installation instructions and
observe the following conditions.
Correct ventilation Incorrect ventilation
Installation – The installation area must be dry and free from dust.
conditions – Ensure that the installation area is ventilated in such a way that
the heat generated during operation can be extracted.
– Room temperature for Sauer compressor operation:
Max. 55 °C +5 °C … +55 °C
(If it is intended to operate the compressor outside this
temperature range, written approval must be obtained from
Min. 5 °C J.P. SAUER & SOHN).
38
Note!
The air temperature at the cooling air inlet to the compressor
must not exceed +55 °C when the compressor is running. Take
into account the conditions in the area of installation as well as
the heat generated by the compressor and any other machines
installed in the same area.
• If necessary, install a ventilation and/or air extraction system
in the area.
• Install the fresh air feed in such way that the cooling air stream
is never directed at the compressor. Otherwise, there is a
danger that condensation will form inside the machine, with
corresponding consequential damage.
– If the room temperature is below +5 °C, the room must be

heated, or a heater must be provided for the Sauer
compressor.
– The installation location must be selected in such a way that
the Sauer compressor is easily accessible and the servicing
intervals (see installation documentation) are maintained.
– Install the compressor so that the cooling fan cannot
recirculate the warm cooling air.
– Avoid positioning several compressors behind each other so
that one 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 compressors.
39
Foundation
Note!
The resilient mount that is supplied as standard has a resonant
frequency of about 10 Hz.
The compressor foundation provided must not be exposed to
vibrations at a frequency of 10 Hz from neighbouring machines.
Otherwise, there is a risk that the standard resilient mount
supplied may be destroyed by resonance vibration.
1. Check beforehand whether there are vibrations of the
machine foundation in the 10 Hz range.
2. If in doubt, contact J.P. SAUER & SOHN to determine
whether an adapted resilient mount can be used.
40
5.4 Connecting the compressor
Danger!
The compressor may only be connected by qualified
technicians. All electrical installation work must be carried out
exclusively by trained and qualified electrical technicians.
Note!
The oil filler tube is protected with an insulating hose. The
insulation material must not be removed.
Pipelines The compressed air outlet (1) and drainage connections (2) on
the compressor must be connected to the system operator's
permanent pipelines via hose lines.
1
Danger!
When the compressor starts up and drains, compressed air
escapes from the drainage connections. Consequently, do not
operate the compressor without hose lines connected.
41
The hose lines must be installed free of tension and not twisted.
Correct installation Incorrect installation
Drainage system
Note!
Accumulated condensate contains oil. It may only be disposed
of in compliance with applicable legal regulations.
J.P. SAUER & SOHN offers condensate collection containers for
separating air from condensate as well as condensate
processing systems for separating oil from condensate.
42
Note!
We recommend connecting the compressor's drainage system
separately.
When the drain lines of several compressors are to be
connected to a common pipe, observe the following:
– Choose a sufficiently large diameter for the common drain
line.
– Connect drain lines of the individual compressors at a sweep
angle to the common drain line, so no pressure can build up
in the drain line.
Correct connection Incorrect connection

43
Connections The illustration shows the connections and fittings for operating
the Sauer compressor in its basic configuration.
7 8 6
2 3 5 4 1
Item Designation Type Function

1 Drive motor Electric motor Compressor drive
Drain valve 1st com- Solenoid valve Start relief and drainage
2
pression stage system
Drain valve 2nd com- Solenoid valve Start relief and drainage
3
Drain valve 3rd com- Solenoid valve Start relief and drainage
4
Oil pressure switch Change-over Shut down the compressor if
5 (optional: alternative oil switch the oil pressure is too low
pressure sensor)
Final pressure switch Change-over Start/Stop control for the
6 (optional: alternative final switch compressor
pressure sensor)
Temperature switch Change-over Switch off compressor if
7 (optional: alternative tem- switch temperature is too high
perature sensor)
8 Non-return valve Plug valve Prevent air back-flow
44
Note!
For technical specifications of the individual items, see Chapter
4.
All optional change-over switches are factory set.
If desired, the components are supplied pre-wired to a terminal
box.
5.5 Adjusting the final pressure switch
Note!
The final pressure switch must be connected directly at the
compressed air receiver to ensure smooth, even compressor
operation.
Pay attention to the pressure loss between the compressor and

compressed air receiver when selecting the maximum pressure
setting. If the set pressure is too high, the safety valve for the final
stage blows off.
45
5.6 Filling with oil
Danger!
• It is imperative to fill the crankcase of the compressor with oil
before initial operation.
• Use only lubricating oil that is approved for use by
J.P. SAUER & SOHN (see Chapter 10).
• Note the amount of oil needed (see Chapter 4).
1 2
1. Remove the oil filler cap (1).

2. Pour in oil and check the oil level (3) with the dipstick (2).
Note!
Only fill the oil to the upper mark on the dipstick. Overfilling
increases the oil consumption of the compressor.
3. Replace the dipstick (2) and screw the oil filler cap (1) back in.
46
5.7 Checks to be carried out after installation and be-

fore initial start-up
Before starting the compressor for the first time, ensure that:
– The electrical connection matches the data on the nameplate.

– All connections between the compressor and the compressed
air system are properly installed. Pay particular attention to the
compressed air connection.
– The amount of oil indicated for operation is present in the
crankcase.
– All tools and foreign objects have been removed from the
compressor.
– The required cooling air supply is ensured.
– The suction line is not clogged.
– The entire system is clean.
47
6 Operation
6.1 Safe operation
Danger!
The Sauer compressor must be started up and operated by
authorised personnel only.
Danger!
Only turn on and start the compressor when
– checks have been carried out to ensure that it is in good order
and
– all tools and foreign objects have been removed from the
machine.
Danger!
Turn the compressor off immediately if personnel and property
are at risk. Only restart the compressor if the risk no longer
persists.
Danger!
In automatic mode the compressor starts automatically without
warning.
Danger!
Risk of burns from touching hot surfaces of the compressor
during operation. Wear protective gloves.
Danger!
Risk of hearing damage due to the sound pressure level when
the compressor is in operation. Wear hearing protection near the
compressor.
Note!
Turn off the compressor in the event of any abnormal/fault
conditions or unexpected events. Correct the causes by
referring to Chapter 7.
48
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 when you press the START button and
continues to run until it is stopped either by pressing the STOP
button or when the final pressure is reached.
To restart the compressor, the START button must be pressed
again.
– “Automatic” operating mode:
Once the compressor has been started initially by pressing the
START button, it is started and stopped automatically via the
start and final pressure settings.
You can stop the compressor at any time by pressing the
STOP button. After stopping the compressor manually, press
the START button to restart it.
When the Sauer compressor starts, it starts without load with the
solenoid drain valves open. After a few seconds, the solenoid
drain valves close and the compressor powers up against system
pressure.
49
6.3 Initial operation
Checking the First allow the Sauer compressor to run for just a few seconds in
direction of order to check the direction in which it rotates.
rotation 1. Turn on the power supply.
2. Set the mode selector switch to “Manual” to start the
compressor in manual mode.
3. Immediately check the compressor’s direction of rotation. It
must rotate in the direction indicated by the arrow on the
crankcase.
4. Set the mode selector switch to “0” to stop the compressor.
5. Turn off the power supply.
6. If it is rotating in the wrong direction, the polarity of the electric
motor must be reversed by a qualified electrician.
Danger!
If the direction of rotation is incorrect, no oil pressure builds up.
Thus, there is a risk of subsequent damage.
Test run 1. Turn on the power supply.

2. Set the mode selector switch to “Manual” to start the
compressor in manual mode.
If correctly set, the solenoid drain valves close after about 15
seconds and the compressor should power up against
system pressure.
3. Check the pressure gauges of each compression stage as
well as the oil pressure gauge, and compare readings with
the nominal values (for nominal values see the stage
pressure diagram).
4. Check that periodic automatic drainage is functioning
correctly.
It must drain for about 15 seconds every 15 minutes. This is
indicated by a drop in pressure on the pressure gauge.
5. Set the mode selector switch to “0” to stop the compressor.
6. Turn off the power supply.
7. If necessary, eliminate the cause of variations from nominal
values and malfunctions. See also Chapter 7.
8. Fill out the commissioning certificate and send it to the Sauer
Service department. The commissioning certificate can be
found in the Appendix.
50
Operation
6.4 Routine operation

Cleaning • Keep the area around the system clean.
• Keep the display and control elements clean.
Inspection • Inspect connections, pipelines and electrical cables for

damage.
• Check the oil level once a week before starting and top up, if
necessary. Do not overfill with oil beyond
the maximum mark.
Operation 1. Turn on the power supply.

2. Set operating mode to “Auto” to operate the compressor in
automatic mode.
Monitoring • Watch out for abnormal operating noise.

• Pay attention to leaks (compressed air, oil, condensate).
• During operation the air pressure indicated on the display of
the optional pressure gauges should be within the shaded
region in the stage pressure chart (see below).
• The oil pressure should be between 1.8 bar and 4 bar.
In the event of variations, see Chapter 7.
Note!
It is permissible to start compressors a maximum of five to six
times within one hour.
The minimum operating time for each start should be 10
minutes. Repeatedly using the system for shorter operating
periods leads to reduced gas quality and/or damage to the
compressor.
51
Stage pressure diagram for 1st and 2nd compression stage
3rd stage [bar]
40
30
20
10
0
1 2 3 7 8 9 10 11
1st stage [bar] 2nd stage [bar]
Note!
Depending on the desired final pressure at the 3rd compression
stage, the allowable pressure for the 1st and 2nd stages can be
read from the above diagram.
52
53
Operation
7 Troubleshooting
Note!
• If a malfunction occurs, first check the displays on the
compressor control panel and on the compressor.
• Try to correct the fault with the help of the table below.
If the fault cannot be corrected, please contact the Sauer
Service department.
The damage report log is included as an appendix to this
Operator Manual.
Possible
Fault Remedy
cause
Compressor does not No input power supply/no Check fuses. Replace blown
start or turns off. control voltage. fuses.
Oil pressure monitor Oil level too low. Check oil level and top up, if
switched compressor necessary. Check for leaks.
off:
Oil too viscous. Fill with recommended oil.
Check that room temperature >
+5 °C.
Oil filter blocked. Clean oil filter.
Oil line blocked. Clean oil line.
Oil pump faulty or Check oil pump. If necessary,
leaking. eliminate leak and/or replace oil
pump.
54
Troubleshooting
Possible
Fault Remedy
cause
Compressor was Excessive current drawn. Check supply voltage and
switched off by electrical connections. The
overcurrent relay. compressor can be started again
after a cooling down period.
Check whether the crankshaft
can easily be turned by hand. If
not, disconnect and ascertain
whether the problem has to do
with the motor or the
compressor.
Piston seizure. Check cylinders and pistons for
any score marks and replace, if
necessary.
Safety valve of 1st
stage blows off:
Pressure exceeds Valve of 2nd stage not Check valve of 2nd stage and
blow-off pressure (4 working properly. replace, if necessary.
bar)
Gasket between suction Replace gasket.
and pressure side of 2nd
stage faulty.
Pressure below Safety valve faulty. Replace safety valve.
blow-off pressure (4
bar)
Safety valve of 2nd
stage blows off:
Pressure exceeds 3rd stage valve is not Check valve of 3rd stage and
blow-off pressure working properly. replace, if necessary.
(12 bar)
Gasket between suction Replace gasket.
and pressure side of 3rd
stage is faulty.
Pressure below Safety valve faulty. Replace safety valve.
blow-off pressure
(12 bar)
55
Possible
Fault Remedy
cause
Safety valve of 3rd
stage blows off:
Pressure exceeds Valve in air line to Open valve.
blow-off pressure compressed air receiver
(final pressure closed.
+5 %)
Pressure switch set too Lower the pressure setting.
high.
Pressure below Safety valve set too low Replace safety valve.
blow-off pressure or is faulty.
(final pressure
Excessively high Reduce pressure losses.
+5 %)
pressure losses in air line
to compressed air
receiver.
Pressure gauge for 1st Valve of 2nd stage Check valve of 2nd stage and
stage is showing leaking. replace, if necessary.
excessive pressure.
Pressure gauge of 2nd Valve of 3rd stage Check valve of 3rd stage and
stage showing leaking. replace, if necessary.
excessive pressure.
The pressure gauges Valve of 1st stage Check valve of 1st stage and
for all stages show leaking. replace, if necessary.
insufficient pressure.
Air filter very dirty. Clean or replace air filter insert.
Pressure gauges of all No power at solenoid Check solenoid valve power
stages showing no drainage valve. supply.
pressure.
Solenoid valve of the Check the solenoid valve and
drainage is faulty. replace, if necessary.
Air escaping from Gaskets at connections Replace faulty gasket.
compressed air lines. leaking.
Cutting ring joints Switch compressor off. Wait until
leaking. all parts are no longer under
pressure; check the pressure
gauge for this. Tighten all
unions.
56
Troubleshooting
Possible
Fault Remedy
cause
Air escaping from Compressed air Replace fan.
overflow opening of temperature at the outlet Replace fusible plug.
final separator's fusible too high; insufficient
plug. cooling due to faulty fan.
Cooler heavily soiled; Clean cooler.
inadequate air supply/ Check room ventilation.
extraction. Replace fusible plug.
Compressor was Compressed air Check whether the fan can be
switched off, temperature at outlet too turned, test the fan and replace,
temperature monitoring high; insufficient cooling if necessary.
has tripped. due to faulty fan. Check whether ambient
temperature is < +55 °C.
Check cooling air intake is not
restricted.
Cooler soiled or feed line Clean cooler. Check room
blocked; inadequate air ventilation/
supply/extraction. air extraction.
Solenoid drain valve No power supply. Check fuses, replace blown
does not close. fuses.
Solenoid faulty. Replace solenoid.
Foreign matter in Clean solenoid drain valve.
solenoid drain valve.
Abnormal compressor Connecting rod bearing Check connecting rod bearing
noise. faulty. and replace, if necessary.
Check oil supply.
Piston pin bearing faulty. Check piston pin bearing and
replace, if necessary.
Crankshaft bearing faulty. Check crankshaft bearing and
Motor bearing faulty. Check motor bearing and
57
Possible
Fault Remedy
cause
Oil leaking from Gasket or shaft Tighten all screws.
crankcase. seal faulty. Screws not If there is significant leakage,
tight. check to see which gasket is
faulty, then replace it.
Minor traces of oil on the
housing or oil drops below the
compressor are harmless. Wipe
off with a lint-free cloth.
Oil escaping at the Gasket between cylinder Replace gasket.
cylinder base. and crankcase faulty.
Water in the oil. Poor ventilation Correct the room ventilation.
(compressor is
overcooled).
Poor drainage. Check drain lines and drainage
intervals.
Insulation tube at Replace insulation tube.
crankcase vent missing
or damaged.
Very short compressor Extend compressor running
running time. time.
Premature failure of Poor drainage. Check drain lines and drainage
valve plates, valve intervals.
springs or valve discs.
Note: Impact impressions in the
valve plate from the sealing seat
are normal.
58
59
Troubleshooting
8 Maintenance
8.1 J.P. SAUER & SOHN maintenance service
Sauer Service offers various maintenance services: inspection,

maintenance, major overhaul, replacement compressors, and
service contracts.
If you have any questions, please contact our customer service

department:
J.P. SAUER & SOHN Maschinenbau GmbH

Sauer Service
P.O. Box 92 13
D-24157 Kiel
Telephone (international):
Technical information +49 431 39 40 87
Spare parts orders +49 431 39 40 86/886
Fax (international): +49 431 39 40 89
Emergency service
(international): +49 172 4 14 63 94
E-mail: service@sauercompressors.de
Web: www.sauercompressors.com
or contact an authorised J.P. SAUER & SOHN service partner in

your area.
60
Maintenance
8.2 Maintenance safety

Before 1. Disconnect the power supply to the compressor.
maintenance 2. Put up “Attention! Maintenance work!” sign on the power
work supply.
3. Shut down the compressor and secure it against restarting.
4. Put on personal protective equipment (see Chapter 2.9).
Danger!
The Sauer compressor must not be serviced or adjusted except
by authorised personnel!
Danger!
Risk of injury from hot surfaces!
Allow compressor to cool down after shutting off.
Danger!
Risk of injury from pressurised compressor components!
Check the pressure gauges before servicing to ensure the
compressor is completely depressurised.
61
Danger!
High voltage! Danger to life!
– Never assume that a circuit is de-energised – Always check
to be sure.
– The main switch is energised, even when it is turned off.
– Components being worked on should only be energised if this
is explicitly specified.
Danger!
Danger of death from missing safety devices and missing
isolating protective devices!
Reinstall all safety devices and isolating protective devices after
servicing. This also applies to electrical protective devices.
62
Maintenance
8.3 Maintenance schedule
Danger!
During all maintenance work, follow the instructions in Chapter
8.5 regarding specified screws.
Note!
The maintenance intervals specified in the maintenance
schedule must be adhered to. Shorter maintenance intervals do
not afford any advantage in respect of the operating behaviour
or the service life of the Sauer compressor.
Note!
After the last maintenance stage the maintenance schedule
begins again.
Note!
J.P. SAUER & SOHN recommends having an inspection
(function test) carried out by qualified personnel at least once a
year.
63
Instructions for • Use the maintenance schedule as a master template or copy
the maintenance the respective page from the document and save it as a
separate file under a suitable name. Use the maintenance
schedule
schedule as a guide and as a record of work completed.
• Regularly check the maintenance schedule to see which
maintenance intervals must be observed depending upon the
number of operating hours. The intervals are shown in the
table’s column headers.
• Check the column for each maintenance interval to see what
maintenance work is to be carried out at the end of each
maintenance interval. The required tasks are indicated by
check boxes. The description for the tasks is shown in the first
column.
• Carry out all maintenance work for an interval and tick the
appropriate check boxes in the maintenance schedule. Then
enter the number of operating hours completed, the date and
your signature.
• When beginning a new maintenance schedule
– enter the following: Main specifications, date of
commissioning, maintenance schedule number, date and
number of operating hours completed.
– mark with an “X”: Start of current maintenance schedule
after commissioning or after last maintenance stage.
64
Maintenance
8.4 Sauer Easy Care
Maximum operational reliability at lowest cost
Simple The Sauer Easy Care maintenance concept makes maintenance

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

(maintenance kit contains all important parts)
– Clearly defined maintenance routines
(preventative maintenance)
– Maximum operating reliability
(replacement before failure)
– Exceptionally low maintenance costs
(repairs hardly ever necessary)
– Guaranteed storage life of maintenance parts
(no failures within maintenance intervals)
65
The part number for the respective maintenance kit is listed in the
maintenance chart at the following position:
Example of Easy Care Maintenance Chart
Note!
In the following maintenance chart, the intervals and
maintenance tasks to be carried out have been adapted to the
respective compressor type.
Note!
If you have questions about the Sauer Easy Care maintenance
concept, the Sauer Service department will be glad to help you.
66
Maintenance
Maintenance schedule number: Compressor type: WP81L

Start of this maintenance Type series Passat
schedule:
 After commissioning Compressor number:
 After last maintenance stage Serial number:
Date: Year of construction:
Operating hours: Date of commissioning:
Interval
last maintenance stage

[operating hours]
At least once a year

commissioning
or repair work
if < 1000 h
50 h after
50 h after
1,000 h
2,000 h
3,000 h
4,000 h
Maintenance task
069 157
069 160
069 157
069 161
Sauer Easy Care part number
Changing the air filter insert, see 8.6     

Changing the oil, see 8.7       
Cleaning the oil strainer, see 8.8 
Checking the 1st stage valve, see 8.9 
Checking the 2nd stage valve, see 8.9 
Replacing the 1st stage valve, see 8.10 
Replacing the 2nd stage valve, see 8.10 
Replacing the 3rd stage valve, see 8.10  
Replacing the piston rings, piston pins and

piston pin bearings of all stages, see 8.11
Replacing the flexible coupling, see 8.12 
Overhauling the solenoid drain valves

(order-specific), see 8.13
(according to operator
Checking the safety valves, see 8.14
specifications)
Operating hours
Date
Signature
(initials)
67
Note!
Always check the compressor after 50 hours following any
maintenance work. Check all screws and nuts affected by
maintenance to see if they are tight.
8.5 Table of tightening torques
Screw(s) Tightening torque

Connecting rod bolt 70 Nm
Flywheel fixing screw 175 Nm
Cylinder head screws 1st 42 Nm
compression stage
Cylinder head screws 2nd and 3rd 75 Nm
compression stages
68
Maintenance
8.6 Changing the air filter insert
1 2
4 3
1. Loosen clamps (1) and remove the cap (2) on the air filter.
2. Take out the used air filter insert (3).
3. Clean the housing (4) with a suitable solvent and wipe it out
with a lint-free cloth.
4. Insert a new air filter insert (3).
5. Refit the cap (2) and secure with clamps (1).
69
8.7 Changing the oil
Note!
Only use oil as recommended in the lubricant table (see Chapter
10).
2 3
5
6
1. Place an oil pan (of a size sufficient for the oil sump capacity,
see Chapter 4) below the oil drain cock (1).
2. Open the oil drain cock (1).
3. Wait until all the oil has drained out.
4. Close the oil drain cock (1).
5. Unscrew the oil filler cap (2).
6. Pour in oil and check the oil level with the dipstick (3).
The filling level must be between the upper (5) and
lower (6) gauge mark on the dipstick.
7. Replace the dipstick (3) and screw the oil filler cap (2) back in.
70
Maintenance
8.8 Cleaning the oil strainer
1 2 3 4
1. Loosen the nuts (1) for the crankcase inspection cover (2).
2. Remove the crankcase inspection cover (2).
3. Loosen the union (3) on the oil strainer (4).
4. Take out the oil strainer (4).
5. Wash out the oil strainer (4)
with a suitable solvent.
6. Carefully clean the sealing surface of the crankcase
inspection cover (2).
7. Refit the oil strainer (4).
8. Screw on the crankcase inspection cover (2) with a new
gasket.
71
8.9 Checking the valves
Removing valves 1. Loosen the clamp on the air filter and replace the air filter.
2. Disconnect the pipe unions and hose lines at the cylinder
heads.
3. Remove cylinder head nuts and remove the cylinder heads.
4. Carefully remove the valves.
Testing valves 5. Check the exterior of the valves for:
– damage,
– coking,
– oiling,
– corrosion, and
– moisture.
Note!
Valves that are damaged, heavily coked or corroded must be
replaced.
Determine the cause (see Chapter 7 of Operator Manual).
6. Clean all sealing surfaces.
72
Maintenance
Installing valves
Note!
Install all valves with new gaskets and ring gaskets. Only use
genuine Sauer spare parts. Installation of different gaskets may
lead to leakages and may cause substantial damage to the
compressor.
Valve 1st stage 7. Fit the valve (1) and cylinder head (2) of the 1st compression
stage. Use new cylinder head gaskets (3) as well as a new
low tolerance o-ring (4) when doing so (see illustration).
4 3
Note!
Do not reuse used low tolerance o-rings under any
circumstances. Doing this will lead to leakages within a short
period of time.
8. Tighten the cylinder head nuts by hand.

73
Valve 2nd stage 9. Remove the strips (1) of the cylinder head gasket of the 2nd
compression stage to separate the inner and outer ring of the
cylinder head gasket from one another.
1 1
10. Place the inner ring between the pins (2) and place the outer
ring around the plates on the sealing surfaces (3).
2 3
11. Fit the cylinder head of the 2nd compression stage (4) on the
cylinder head gasket (5). Tighten the cylinder head nuts by
hand.
4
74
Maintenance
Valve 3rd stage 12. Install the valve and cylinder head of the 3rd compression
stage (6).
In doing so, insert a new o-ring (7) into the groove in the
cylinder below the valve.
13. Insert a new cylinder head gasket (8) between the valve and
the cylinder head (see illustration).
14. Fit the cylinder head of the 3rd compression stage (6).
Tighten the cylinder head nuts by hand.
15. Tighten the pipe unions and hose lines by hand.
16. Securely tighten the cylinder head nuts. Observe the
tightening torques (see Chapter 8.5).
17. Securely tighten the pipe unions and hose lines.
75
8.10 Replacing the valves
Remove and reinstall valves as described in Chapter 8.9. Make

sure you replace all valves completely when doing this.
Note!
Valves that have reached the end of their service life must be
replaced and disposed of.
J.P. SAUER & SOHN does not recommend repairing used
valves due to the effects of material fatigue.
76
Maintenance
8.11 Replacing the piston rings, piston pins and

piston pin bearings
1. Remove the cylinder heads and valves as described in

Chapter 8.9.
2. Loosen the cylinder head nuts of the 3rd compression stage.
3. Remove the cylinder. Hold the piston while the cylinder
comes off.
Note!
If the piston is not held while pulling the cylinder off, it will strike
against the crankcase.
4. Remove the circlips of the piston pin, push out the piston pin
and remove the piston.
5. Remove all piston rings from the respective pistons and clean
the pistons.
Checking 6. Check cylinders and pistons for excessively deep scoring

pistons and marks. Replace parts as required.
cylinders
Note!
If the piston running surface in the cylinder has edges that can
be felt, remove the edges with a Flexhone brush or a Scotch-
Brite non-woven abrasive. Otherwise the edges may damage
the new piston rings when installing the piston.
77
Measuring
cylinder wear
2 1
Note!
This measurement can be made with used and new piston rings.
1. 1st measurement:
Insert the piston ring about 5 mm (1) below the top edge of
the cylinder (above the level of the highest piston ring), and
measure the gap clearance with the feeler gauge in the area
(3) not occupied by the piston rings.
2. 2nd measurement:
Push the piston ring down about 50 mm (2) (below the level
of the lowest piston ring), and measure the gap clearance
again in the wearing area (4).
78
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 Gap clearance difference WP81L

1 0.45 mm
2 0.3 mm
3 0.3 mm
Note!
Contact the Sauer Service department if the difference between
the two gap clearances is greater than indicated in the table
above.
Replacing the 4. Press the piston pin bearings out of the connecting rod eyes
piston pins/ using a suitable tool and replace them with new piston pin
bearings.
piston
5. Mount the piston on the connecting rod. To do this, press the
pin bearings
new piston pin in and insert the piston pin circlips.
Note!
Check that the circlips fit securely in the grooves.
79
Installing piston 6. Install new piston rings in the respective piston. Make sure
rings they are in the correct position: piston rings with an
asymmetric cross section are marked with “TOP” on one of
the surfaces. The marked face must be at the top when the
piston ring is installed (see illustration).
1 2 3
TOP
TOP TOP TOP
TOP TOP TOP
Item Designation
1 Piston 1st compression stage
2 Piston 2nd compression stage
3 Piston 3rd compression stage
80
Maintenance
Note!
Replace all piston rings with new ones. The following damage
may occur when removing the piston rings:
• The piston rings edges are damaged on the wearing edges in
the cylinder.
• If the piston rings are bent multiple times fine cracks appear,
which may cause the material to break.
Note!
Arrange the piston ring gaps so that they are staggered.
Installing 7. Fit a new cylinder base gasket for each cylinder.

cylinder and 8. The cylinders are installed in reverse order to their
valves disassembly.
9. Install valves and cylinder heads as described in Chapter 8.9.
81
8.12 Replacing the flexible coupling
2 1 5 4 5 3
1. Shut down the compressor (2) and secure it against

restarting.
2. Support the compressor (2) under the bell housing.
3. Loosen the fixing screws (4) of the electric motor (3).
4. Lift the electric motor (3) carefully at the lifting eye bolts (5)
(see Chapter 5.1).
5. Pull the electric motor (3) carefully away from the compressor
(2).
6. Replace the coupling flexible insert (1).
7. Carefully slide the electric motor (3) onto the compressor (2)
and tighten the fixing screws (4).
8. Remove the support under the bell housing.
9. Reinstall the disconnected connecting lines and pipes.
82
Maintenance
8.13 Overhauling the solenoid drain valves

(order-specific)
1
2
6 4
7
10
8
1. Shut down the compressor and secure it against restarting.

2. Unscrew the hexagon nut (1).
3. Carefully prise off the plastic threaded part (2) with the
screwdriver.
4. Detach the coil (3) from the solenoid armature (4).
5. Loosen the four inner hexagon cap screws (5).
6. Remove the valve upper part (6).
7. Replace the following parts:
Spring (7), membrane (8) and two O-rings (9).
8. In the event of heavy soiling: clean the nozzle (10).
9. Refit the valve upper part (6).
10. Tighten the four inner hexagon cap screws (5).
11. Attach the coil (3) to the solenoid armature (4).
83
Note!
The coil and the solenoid armature must be dry at all times.
12. Position the plastic threaded part (2) correctly and press onto
the brace (4).
13. Carefully place the hexagon nut (1) in position and tighten by
hand.
14. Tighten the hexagon nut (1) gently with a spanner.
84
Maintenance
8.14 Checking the safety valves
Danger!
The safety valve is a part of the safety device. Safety equipment
must not be adjusted, disabled or removed. Safety equipment
must be checked regularly and replaced as necessary.
The safety valves are sealed by the manufacturer to prevent

tampering. The construction of the safety valves means that they
cannot be tested for function.
The operator must check the safety valves in accordance with
country-specific guidelines and laws, and replace them as
necessary.
Note!
Safety valves must not be replaced except by personnel
specially trained for this task.
At J.P. SAUER & SOHN, training courses are conducted in

seminars by experienced personnel in workshops or by
independent study of training material such as videos,
catalogues and assembly instructions provided by
J.P. SAUER & SOHN.
85
Note!
The Sauer Service department offers a professional and
qualified safety valve replacement service.
For more information, contact the Sauer Service department.
Checking safety valves

Carry out the following checks to detect any damage to safety
valves as early as possible:
• Inspect external pipelines for damage.
• Test threaded connections for proper seating.
• Inspect attached parts for damage.
• Inspect valve seals for damage.
This completes the safety valve inspection procedure.
Danger!
Faulty safety valve.
Damage to the safety valves and external pipelines must be
corrected immediately by trained and qualified technicians.
86
87
Maintenance
9 Decommissioning
9.1 Safety when decommissioning
and disassembling
Danger!
The compressor must only be decommissioned and
disassembled by trained technicians employed by the operator.
These specialists must be familiar with the protection devices
and regulations before starting the work. All electrical installation
work must be carried out exclusively by trained and qualified
electrical technicians.
In addition, information contained in suppliers’ documentation
must be observed.
88
Decommissioning
9.2 Temporary preservation and storage
A test run for at least 30 minutes should be carried out every four
weeks. Additional corrosion prevention measures are not
required.
If the Sauer compressor is to be laid up for more than 12 weeks,
preservation with a preservation oil is recommended. If this
preservation is carried out, periodic test runs are not needed.
Note!
Use one of the preservation oils recommended in Chapter 10 for
corrosion protection.
Note!
The preservation is sufficient for 12 months. After this period has
expired, the compressor must be preserved again.
1. Run the compressor for approx. 5 minutes with the solenoid

drain valves and pressure line open.
Any existing condensate is blown out.
2. Drain the compressor oil and dispose of it in an
environmentally safe manner.
3. Fill with about 6 litres of preservation oil.
4. Start the compressor and run for approx. 5 minutes with
solenoid drain valves and pressure line open.
5. Stop the compressor.
6. Unscrew the air filter.
89
7. Unscrew the plug (1) on the cylinder head of the 2nd
compression stage (2).
3
2 1
8. Inject approx. 10 cm3 of preservation oil (3)

into the suction chamber of the 2nd compression stage.
9. Tighten the plug (1) on the cylinder head of the 2nd
compression stage (2).
10. Unscrew the safety valve for the 2nd compression stage (5)
on the 3rd compression stage cylinder head (4).
4 5
11. Inject approx. 10 cm3 of preservation oil (6)

into the suction chamber of the 3rd compression stage.
12. Tighten the safety valve (5) again.
90
Decommissioning
13. Inject approx. 15 cm3 of preservation oil into the intake fitting
of the 1st compression stage.
14. Refit the air filter.
15. Start the compressor.
16. Wait until oil mist escapes from the discharge line.
17. Stop the compressor.
18. Drain the preservation oil and dispose of it in an
19. Put up a sign indicating that the compressor was preserved
and taken out of service.
20. Disconnect the mains supply cables.
Restarting 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.
91
9.3 Disassembly
Follow these 1. Turn the compressor off and disconnect from the power
steps for supply.
disassembly: 2. Read the pressure gauge or pressure display to ensure that
the compressor is completely depressurised.
3. Disconnect the mains supply cables.
4. Remove oil and lubricants and dispose of them in an
5. Drain any remaining condensate and dispose of it in an
Disposal
Material / Component Safe disposal

Lubricants As hazardous waste
Steel/iron As metal scrap
Electrical cables As hazardous waste
Electronic components As scrap electronic waste
Plastics As hazardous waste
92
93
Decommissioning
10 Lubricants for
Sauer compressors
The "Recommended oils for Sauer compressors" applies to all
Sauer compressors that are designed to compress air.
Note!
The oil types mentioned in "Recommended oils for Sauer
compressors" represent a complete list of the oils that have
yielded entirely positive operating results.
High product quality and long service life can only be guaranteed
if the oils listed are used with due consideration for the
conditions of the specific application.
Product names may vary by country.
Note!
If an oil is used that is not included in this list, contrary to the
recommendations of J.P. SAUER & SOHN, the warranty
coverage for the Sauer compressor will automatically become
null and void.
Use of an oil not included in this list can result in failure and
irreparable damage to the compressor.
If you need help in selecting the correct oil, please contact the
Sauer Service department.
94
Lubricants for Sauer compressors
95
11 Spare parts and accessories
Note!
Please take careful note of the instructions in Chapter 1
regarding our genuine Sauer spare parts.
J.P. SAUER & SOHN guarantees the complete spare parts

supply over the entire service life of the Sauer compressor.
Our genuine Sauer spare parts are subject to continuous quality
control and further development. They conform to the latest
technical developments.
Besides the genuine Sauer spare parts, our supply programme
also includes a wide range of accessories for your Sauer
compressor and special equipment for your compressed air
system, such as:
– Fully automatic controls

– Adsorption dryers
– Refrigerated air dryers
– Filters
– Sound-proof canopies
– Compressed air receivers and
– Fittings
We supply instructions and a maintenance manual for each

accessory. WP81L_BA1_en_1402.fm
96
Spare parts and accessories
Spare parts The spare parts catalogue can be found in the Appendix to this
catalogue Operator Manual.
– The required parts can be quickly found with the help of

diagrams, figures 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 this, you will need the main specifications of your
Sauer compressor from the table below. If you have not
entered this here, you will find it on the nameplate, which is
attached to the crankcase.
Compressor type:
Serial number:
Year of
construction:
Furthermore, the number of operating hours should be

stated, if possible.
97
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
98
Appendix
J.P. SAUER & SOHN

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

Purchaser Operator Authorised Sauer Service Partner
99
J.P. SAUER & SOHN
 Return of goods Maschinenbau GmbH
 Notification of claim Brauner Berg 15 - 24159 Kiel
Phone: +49 - 431- 39 40 - 0
Date: Fax: +49 - 431- 39 40 - 89
E-mail: service@sauersohn.de
Applicant: Please always complete.
Company Compressor type:
Street
Postcode/City
Customer no. Serial no.:
Location
End customer: Operating hours:
Company
Street Date of fault:
Postcode/City
Customer no. Ambient temperature:
Location
Spare parts Reason for return
Designation Quantity Part no. Report on fault 
Repair 
Checking as customer service 
Goods taken back against credit 
note
To be completed by manufacturer
Brief description of damage:
Report
by manufacturer only
To be completed
100
101
Appendix
S a u e r
C o m p r e s s o r
Type: WP 81L
Spare parts catalogue
WP81L_ET_Titel_ en_1402.fm
WP81L_ET_Titel_ en_1402.fm
Translation of the original operator manual

Issue: 02 / 2014
Edited by: J.P. Sauer & Sohn Maschinenbau GmbH – Technical Documentation
065 203 / 064 285 Compressor unit WP 81L- 100
Page
Part No. Assembly Rev.
E-
065 203 Compressor unit WP 81L-100 ............................................... 6 5315-a
064 081 Compressor WP 81L ............................................................. 8 5450-b
064 106 Crankcase ............................................................................. 10 6640-f
064 064 Dipstick ................................................................................. 12 5294-_
064 284 Crankshaft ............................................................................. 14 5327-a
063 102 Connecting rod 1st compression stage ................................. 16 5599-b
063 103 Connecting rod 2nd compression stage ............................... 18 5599-b
062 981 Connecting rod 3rd compression stage ................................ 20 5599-c
031 881 Piston 1st compression stage ............................................... 22 6420-d
062 525 Piston 2nd compression stage .............................................. 24 5348-b
064 108 Piston 3rd compression stage ............................................... 26 5337-a
064 109 Cylinder with head and valve 1st compression stage ........... 28 6384-b
064 110 Cylinder with head and valve 2nd compression stage .......... 30 5390-a
064 111 Cylinder with head and valve 3rd compression stage ........... 32 5390-b
064 112 Cooler and air lines ................................................................ 34 6275-h
064 302 Crankcase vent ..................................................................... 38 6537-c
064 105 Separator assembly 3rd compression stage ......................... 40 5309-a
063 121 Separator 3rd compression stage ......................................... 42 _-f
064 118 Measuring device .................................................................. 44 6209-c
064 119 Oil pump drive ....................................................................... 46 5754-c
057 916 Pressure relief valve ............................................................. 48 5549-a
062 909 Gearwheel oil pump .............................................................. 50 6665-a
064 458 Automatic drainage system ................................................... 52 5845-b
065 248 Resilient mounts ................................................................... 54 5765-c
065 478 Drain hose ............................................................................. 56 6039-a

WP81L_ET1_en_1402.fm
065 188 Terminal box with wiring ........................................................ 58 6497-c
066 364 Temperature monitoring ........................................................ 60 6575-
Flexible coupling ................................................................... 62 _-_
E-3
Page
Part No. Assembly Rev.
E-
Optional assemblies
064 285 Compressor unit WP 81L-100 ............................................... 66 5729-c
Without condensate collection container

064 269 Automatic drainage system ................................................... 68 6145-c

064 283 Resilient mounts .................................................................... 70 5729-c
065 641 oil pressure test valve ........................................................... 72 6482-c
Optional loose accessories

Final pressure switch / Final pressure sensor ........................ 76 _-_
Note:
For explanations of the assemblies, refer to Chapter 3 "Design
and Function" in this operating manual.
E-4
E-5
065 203 Compressor unit WP 81L-100
13 12
1 4 3 8 14 5 9 10 11
E-6
Item No. Part No. Designation Quantity

1 064 081 Compressor WP 81 L 1
3 064 458 Automatic drainage system 1
4 065 248 Resilient mounts 1
5 064 097 Channel section 1
8 000 184 Hexagon cap screw 4
10 001 620 Hexagon nut 2
11 002 161 Washer 4
12 037 321 Standard hub, motor side 1
13 033 494 Flexible gear rim 1
14 1) Electric motor 1
1)
The part number for the electric motor varies according to the order.
E-7
064 081 Compressor WP 81L
11 10 12 9
17
19
19 21
7
13
3 6
15
4
14
2 16 1 21 5 8
E-8
064 081 Compressor WP 81 L

1 064 106 Crankcase 1
2 064 284 Crankshaft 1
3 063 102 Connecting rod 1st compression stage 1
4 063 103 Connecting rod 2nd compression stage 1
5 062 981 Connecting rod 3rd compression stage 1
6 031 881 Piston 1st compression stage 1
7 062 525 Piston 2nd compression stage 1
8 064 108 Piston 3rd compression stage 1
9 064 109 Cylinder with head and valve 1st compression stage 1
10 064 110 Cylinder with head and valve 2nd compression 1
stage
11 064 111 Cylinder with head and valve 3rd compression stage 1
12 064 112 Cooler and air lines 1
13 064 302 Crankcase vent 1
14 064 105 Separator assembly 3rd compression stage 1
15 064 118 Measuring device 1
16 064 119 Oil pump drive 1
17 064 137 Flange 1
19 000 499 Cap screw 14
20 004 408 Grooved pin with head 4
21 036.345 Flange hub, compressor side 1
E-9
064 106 Crankcase
13 14 20 23 10
1
19
29
6
12 26
3
2
19 11
5
30
18 28
16 21 24
11 19
17 27 8 25 7
E - 10
064 106 Crankcase

1 064 303 Crankcase 1
2 064 064 Dipstick 1
3 064 079 Bearing bracket 1
5 051 883 Inspection cover 2
6 064 095 Gasket 1
7 063 748 Gasket 2
8 036 896 Oil intake screen 1
10 000 270 Load ring 1
11 001 411 Stud 24
12 033 717 Stud 4
131 037 217 Stud 6
141) 037 218 Stud 4
16 001 459 Stud 4

17 001 009 Plug 1
18 038 919 Oil drain cock 1
23 001 021 Plug 1
24 002 146 Washer 4
25 004 635 Union 1
27 005 001 Ring gasket 1
29 007 123 Shaft seal 1
30 030 831 Shaft seal 1
1) Inserted with Loctite 542.
E - 11
064 064 Dipstick
E - 12
064 064 Dipstick

1 037 076 Dipstick 1
3 035 520 O-ring 2
E - 13
064 284 Crankshaft
6 14 1 14 2 3 9
13 13
11
12
E - 14
064 284 Crankshaft

1 064 323 Crankshaft 1
2 064 138 Flywheel 1
3 064 054 Washer 1
4 056 887 Washer 1
6 033 502 Fan 1
11 001 667 Locking plate 1
12 004 458 Dowel pin 1
13 001 982 Fitted key 1
14 033 215 Cylindrical roller bearing 2
E - 15
063 102 Connecting rod 1st compression stage
4
E - 16
063 102 Connecting rod 1st compression stage

1 063 100 Connecting rod 1st compression stage 1
2 036 107 Needle roller bearing 2
3 056 590 Connecting rod bearing 1
41) 053 713 Connecting rod bolt 2
52) 031 883 Piston pin 1st compression stage 1
1) Item
4, 053 713 Connecting rod bolt is part of assembly 063 100.
2) Item
5, 031 883 Piston pin is part of assembly 031 881
E - 17
063 103 Connecting rod 2nd compression stage
4
E - 18
063 103 Connecting rod 2nd compression stage

1 063 101 Connecting rod 2nd compression stage 1
52) 062 524 Piston pin 2nd compression stage 1
1) Item
2) Item
E - 19
062 981 Connecting rod 3rd compression stage
4
E - 20
062 981 Connecting rod 3rd compression stage

1 062 982 Connecting rod 3rd compression stage 1
52) 062 469 Piston pin 3rd compression stage 1
1) Item
2) Item
E - 21
031 881 Piston 1st compression stage
E - 22
031 881 Piston 1st compression stage

1 090 650 Piston 1st compression stage 1
2 031 883 Piston pin 1st compression stage 1
3 012 512 Taper faced compression ring 1
4 031 901 Nose ring 1
5 031 902 Double bevelled oil control ring 1
6 002 976 Circlip 2
71) 036 107 Needle roller bearing 2
1)
Item 7, Needle roller bearing 036 107 is part of assembly 063 102.
E - 23
062 525 Piston 2nd compression stage
E - 24
062 525 Piston 2nd compression stage

1 062 404 Piston 2nd compression stage 1
2 062 524 Piston pin 2nd compression stage 1
3 002 748 Rectangular ring 1
4 002 552 Nose ring 2
5 002 585 Slotted oil control ring 1
6 036 112 Circlip 2
1)
Item 7, Needle roller bearing 036 108 is part of assembly 063 103
E - 25
064 108 Piston 3rd compression stage
4
E - 26
064 108 Piston 3rd compression stage

1 064 093 Piston 3rd compression stage 1
2 062 469 Piston pin 3rd compression stage 1
4 036 112 Circlip 2
5 002 662 Rectangular ring 1
6 002 543 Nose ring 2
1)
Item 7, Needle roller bearing 036 108 is part of assembly 062 981
E - 27
064 109 Cylinder with head and valve 1st compression stage
6 8
E - 28
064 109 Cylinder with head and valve 1st compression stage

1 064 087 Cylinder 1st compression stage 1
2 064 134 Cylinder head 1st compression stage 1
3 064 048 Gasket 1
4 063 059 Gasket 1
5 056 235 Gasket 1
6 039 547 Air filter 1
7 037 157 Valve 1st compression stage 1
81) 039 548 Filter element for air filter 1
1)
Item 8, 039 548 Filter element for air filter is part of assembly 039 547.
E - 29
064 110 Cylinder with head and valve 2nd compression stage
4
E - 30
064 110 Cylinder with head and valve 2nd compression stage

1 064 082 Cylinder 2nd compression stage 1
2 064 085 Cylinder head 2nd compression stage 1
3 060 266 Gasket 1
4 064 094 Gasket 1
5 034 983 Valve 2nd compression stage 1
8 000 972 Plug 1
E - 31
064 111 Cylinder with head and valve 3rd compression stage
11
12
10 9
E - 32
064 111 Cylinder with head and valve 3rd compression stage

1 064 084 Cylinder 3rd compression stage 1
2 064 135 Cylinder head 3rd compression stage 1
3 064 051 Gasket 1
4 062 936 Gasket 2
6 001 517 Stud 4
9 033 714 Safety valve 2nd compression stage 1
11 040 889 Valve 3rd compression stage 1
12 037 526 O-ring 1
E - 33
064 112 Cooler and air lines
10 8 11 38 31 26 43 13 26 7 9 23
24 20 16
24 20
21
42 12
37 40
36 28
36 33 14 41
36 29
37 34
30 37
26
53 5 2
17
25 24 22
32
4 19 24 1 50 51 18 32 35 27 6
E - 34
064 112 Cooler and air lines

1 064 113 Cooler 2nd compression stage 1
2 064 114 Cooler 3rd compression stage 1
3 064 524 Distributor 1
4 064 102 Fan cover 1
5 064 115 Pipe 1
6 064 116 Pipe 1
7 064 091 Flange 1
8 064 092 Attachment rail 3
9 064 050 Gasket 1
10 064 042 Clamp 3
11 064 075 Clamp 3
12 064 117 Pipe 1
13 064 618 Pipe 1
14 064 619 Pipe 1
16 064 342 Pipe 4
17 037 211 Cooler 1st compression stage 1
18 037 221 Separator 2nd compression stage 1
201) 033 532 Hexagon cap screw 9
211) 000 123 Hexagon cap screw 6
22 000 452 Cap screw 4

23 000 497 Cap screw 4
24 003 114 Lock washer 16
25 037 609 Washer 4
26 004 666 Union 3
27 004 652 Union 1
282) 004 647 Union 1
29 006 219 Union 1
E - 35
30 006 221 Union 1
31 006 228 Union 1
323) 006 187 Union 2
332) 006 452 Stub 1
34 033 224 Safety valve 1st compression stage 1

35 030 340 O-ring 1
40 006 190 Union 1
414) 038 096 Cutting ring 2
507) 006 002 Union 1
517) 006 221 Union 1
528) 004 647 Union 1
538) 006 000 Union 1
1) Insert with Loctite 542.

2) Screw union in the galvanised block using molybdenum paste.
3)
Remove union edge sealing ring.
4) Replace union cutting ring with item 41 during assembly.
5) Replace union cutting ring with item 42 during assembly.
6)
Replace union cutting ring with item 43 during assembly.
7) Item 50, 006 002 and item 51, 006 221 Union belong to assembly 064 113
8) Item 52, 004 647 and item 53, 006 000 Union belong to assembly 064 114
E - 36
E - 37
064 302 Crankcase vent
5 4 11 9
6
11
10
4
7
1
E - 38
064 302 Crankcase vent

1 035 824 Oil filler cap 1
2 006 380 Reducing union 1
4 038 920 Stub 2
51) 037 138 Reducer 1

6 037 137 Y-joint 1
71) 064 523 Pipe adaptor 1

9 034 612 Low pressure hose 1
10 033 952 Hose 1
11 040 300 Single ear clamp 2
1)
Inserted with sealing tape.
E - 39
064 105 Separator assembly 3rd compression stage
8 12
5 6
4
E - 40
064 105 Separator assembly 3rd compression stage

1 063 121 Separator 1
3 031 905 Union 1
4 006 187 Union 1
5 030 752 Safety valve 3rd compression stage 1
E - 41
063 121 Separator 3rd compression stage
10
12
11
6
E - 42
063 121 Separator 3rd compression stage

1 063 228 Separator housing 1
2 063 229 Separator insert 1
3 062 328 Baffle cone 1
41) 060 342 Fusible plug 1

9 036 171 O-ring 1
11 001 007 Plug 1
1)
121 °C / 250 °F
E - 43
064 118 Measuring device
4 19 13 16 20 4 19 23 15 20
19 4
20 14
21
3
20 16
10 17
11
10 17 1 5 6 7 12 18 9 2 25
E - 44
064 118 Measuring device

1 008 633 Pipe 1
2 008 633 Pipe 1
3 064 326 Double ended stud end 1
4 033 223 Thermometer 3
5 030 082 Oil pressure switch1) 1

7 002 144 Washer 2
9 033 704 Union 1
10 030 510 Union 2
11 034 132 Union 1
13 038 280 Pressure gauge 1st compression stage 1
14 038 281 Pressure gauge 2nd compression stage 1
15 038 282 Pressure gauge 3rd compression stage 1
162) 037 160 Adapter 2

21 038 264 Pressure gauge angle 1
23 038 279 Oil pressure gauge 1
25 039 316 Pressure sensor1) 1
1) As an option, item 5, Oil pressure switch can be replaced by item 25, Pressure sensor.
2
) Insert item 16 with seal tape.
E - 45
064 119 Oil pump drive
2 6 5 4
1 7 9 10
E - 46
064 119 Oil pump drive

1 057 916 Pressure relief valve 1
2 062 909 Gearwheel oil pump 1
3 064 098 Gearwheel 1
5 056 318 Gasket 1
6 030 545 Gasket 1
7 000 970 Plug 1
8 001 942 Fitted key 1
E - 47
057 916 Pressure relief valve
3 5
E - 48
057 916 Pressure relief valve

3 054 164 Spring 1
5 002 962 Circlip 1
E - 49
062 909 Gearwheel oil pump
6 8 2 11 1 10 9
E - 50
062 909 Gearwheel oil pump

1 062 908 Oil pump gearwheel 1
2 036 360 Oil pump housing 1
6 033 212 Oil pump cover 1
8 040 795 O-ring 1
10 001 672 Locking plate 1
11 001 925 Fitted key 1
E - 51
064 458 Automatic drainage system
11
10
14
11
10
12 8 9 15 9 7 1 5 10 2 11 4 6 13
E - 52

1 063 120 Expansion vessel 1
2 066 888 Throttle 1
5 030 744 Plug 1
6 003 115 Lock washer 4
7 004 641 Union 2
8 004 998 Union 1
9 006 216 Union 3
10 006 455 Stub 3
1)
11 Solenoid valve 3
12 008 663 Pipe 1
13 008 663 Pipe 1
14 008 663 Pipe 1
15 008 663 Pipe 1
1) The order number for the solenoid valve varies according to the order.
E - 53
065 248 Resilient mounts
8 9
3 5 6 7 4 5 6 7 2
E - 54

2 061 002 Drain hose 3
5 002 166 Washer 2
6 031 149 Buffer 4
7 037 172 Mounting plate 4
8 033 222 High pressure hose 1
9 033 489 Non-return valve 1
E - 55
065 478 Drain hose
2 1 2
E - 56
065 478 Drain hose

1 037 941 Compressed air hose 1
2 037 942 Hinge bolt clamp 2
E - 57
065 188 Terminal box with wiring
2 4
E - 58
065 188 Terminal box with wiring

2 091 029 Terminal box 1
4 000 891 Cap screw 4
E - 59
066 364 Temperature monitoring
2 1
3
E - 60
066 364 Temperature monitoring

1 037 883 Temperature switch 1
2 000 410 Cap screw 2
E - 61
Flexible coupling
1 3 2
E - 62
Flexible coupling
11) 036 345 Flange hub, compressor side 1
22) 037 321 Standard hub, motor side 1
33) 033 494 Flexible gear rim 1
1) Item 1, 036 345 Compressor flange hub is part of assembly 064 081.
2) Item 2, 037 321 Standard hub, motor side is part of assembly 065 203.
3) Item 3, 033 494 Flexible gear rim is part of assembly 065 203.
E - 63
Optional assemblies:
E - 64
E - 65
13 12
1 4 3 8 14 5 9 10 11
E - 66


1 064 081 Compressor WP 81L 1
3 064 269 Automatic drainage system 1
4 064 283 Resilient mounts 1
5 064 097 Channel section 1
11 002 161 Washer 4
12 037 321 Standard hub, motor side 1
13 033 494 Flexible gear rim 1
14 1) Electric motor 1
1)
The part number for the electric motor varies according to the order.
E - 67
3 1 2 3 1 2 3 1 4
E - 68


1)
1 Solenoid valve 3
2 004 641 Union 2
3 006 455 Stub 3
4 066 888 Throttle 1
1) The order number for the solenoid valve varies according to the order.
E - 69
8 9
20 2 3 5 6 20 7 20 2 20 20 4 6 7 2 20
E - 70

2 061 002 Hose line 3
5 002 166 Washer 2
6 031 149 Buffer 4
7 037 172 Mounting plate 4
8 033 222 High pressure hose 1
9 033 489 Non-return valve 1
201) 004 689 Union 6
1)
Item 20, 004 689 Union is part of assembly 061 002.
E - 71
065 641 oil pressure test valve
4 7
11 3 9 3
E - 72
065 641 oil pressure test valve

2 065 648 Stub 1
3 004 598 Union 2
4 030 532 Union 1
5 036 052 Test cock 1
6 035 906 Adapter 1
9 037 036 Ball valve 1
11 008 633 Pipe 1
E - 73
Optional loose accessories:
E - 74
E - 75
Final pressure switch / Final pressure sensor
1 2
E - 76
Final pressure switch / Final pressure sensor
1 1.1) Final pressure switch 2) 3) 1

2 1.2) Final pressure sensor 1
1.1)
The part number varies according to the order / see "Final pressure switch" table
1.2)The part number varies according to the order / see "Final pressure sensor" table
2) The final pressure switch is supplied loose and assembled by the customer.
3)
As an option, the final pressure switch can be replaced by a final pressure sensor.
Final pressure switch

Part No. Designation
035 221 Pressure range 1 - 16 bar
Final pressure sensor

Part No. Designation
E - 77
E - 78
Index
Parts List by Part No.
Page
Part No. Designation Assembly Item
E-
1) Final pressure switch ............................. 76 1
1) Final pressure sensor ............................ 76 2
1) Solenoid valve ........................................ 064 269 68 1
1) Electric motor ......................................... 064 285 66 14
1) Solenoid valve ........................................ 064 458 52 11
1) Electric motor ......................................... 065 203 6 14
000 009 Hexagon cap screw ............................... 064 118 44 6
000 270 Load ring ................................................ 064 106 10 10
000 410 Cap screw .............................................. 066 364 60 2
000 452 Cap screw .............................................. 064 112 34 22
000 497 Cap screw .............................................. 064 112 34 23
000 499 Cap screw .............................................. 064 081 8 19
WP81L_ET1_Index_en_1402.fm
000 891 Cap screw .............................................. 065 188 58 4

000 970 Plug ........................................................ 064 119 46 7
000 972 Plug ........................................................ 064 110 30 8
001 007 Plug ........................................................ 063 121 42 11
E - 79
Page
E-
001 009 Plug ........................................................ 064 106 10 17
001 021 Plug ........................................................ 064 106 10 23
001 064 Hexagon nut ........................................... 062 909 50 9
001 411 Stud ........................................................ 064 106 10 11
001 459 Stud ........................................................ 064 106 10 16
001 517 Stud ........................................................ 064 111 32 6
001 620 Hexagon nut ........................................... 064 106 10 20
001 620 Hexagon nut ........................................... 064 111 32 7
001 620 Hexagon nut ........................................... 064 285 66 10
001 620 Hexagon nut ........................................... 065 203 6 10
001 667 Locking plate .......................................... 064 284 14 11
001 672 Locking plate .......................................... 062 909 50 10
001 925 Fitted key ................................................ 062 909 50 11
001 942 Fitted key ................................................ 064 119 46 8
001 982 Fitted key ................................................ 064 284 14 13
002 031 Hexagon nut ........................................... 064 106 10 19
002 094 Hexagon nut ........................................... 064 106 10 21
002 098 Hexagon nut ........................................... 064 106 10 26
002 144 Washer ................................................... 064 118 44 7
002 146 Washer ................................................... 064 106 10 24
002 161 Washer ................................................... 064 285 66 11
002 161 Washer ................................................... 065 203 6 11
002 166 Washer ................................................... 064 283 70 5
002 166 Washer ................................................... 065 248 54 5
002 543 Nose ring ................................................ 064 108 26 6
002 552 Nose ring ................................................ 062 525 24 4
002 585 Slotted oil control ring ............................. 062 525 24 5

002 662 Rectangular ring ..................................... 064 108 26 5
002 748 Rectangular ring ..................................... 062 525 24 3
E - 80
Index
Page
E-
002 962 Circlip ..................................................... 057 916 48 5
002 976 Circlip ..................................................... 031 881 22 6
003 114 Lock washer ........................................... 064 112 34 24
003 115 Lock washer ........................................... 064 458 52 6
003 438 Ring gasket ............................................ 064 119 46 10
003 496 Ring gasket ............................................ 063 121 42 12
003 496 Ring gasket ............................................ 064 119 46 9
004 408 Grooved pin with head ........................... 064 081 8 20
004 458 Dowel pin ............................................... 064 284 14 12
004 598 Union ...................................................... 065 641 72 3
004 635 Union ...................................................... 064 106 10 25
004 641 Union ...................................................... 064 269 68 2
004 641 Union ...................................................... 064 458 52 7
004 647 Union ...................................................... 064 112 34 28
004 647 Union ...................................................... 064 114 36 52
004 652 Union ...................................................... 064 112 34 27
004 666 Union ...................................................... 064 112 34 26
004 689 Union ...................................................... 064 283 70 20
004 998 Union ...................................................... 064 458 52 8
005 001 Ring gasket ............................................ 064 106 10 27
005 001 Ring gasket ............................................ 064 118 44 17
005 006 Ring gasket ............................................ 064 118 44 18
005 009 Ring gasket ............................................ 063 121 42 8
005 009 Ring gasket ............................................ 064 105 40 6
005 009 Ring gasket ............................................ 064 106 10 28
005 009 Ring gasket ............................................ 064 110 30 7
005 009 Ring gasket ............................................ 064 112 34 36

005 009 Ring gasket ............................................ 064 118 44 19
005 009 Ring gasket ............................................ 064 302 38 8
E - 81
Page
E-
005 009 Ring gasket ............................................ 066 364 60 3
005 016 Ring gasket ............................................ 064 105 40 11
005 016 Ring gasket ............................................ 064 111 32 10
005 016 Ring gasket ............................................ 064 112 34 37
005 023 Ring gasket ............................................ 064 105 40 12
005 027 Ring gasket ............................................ 064 112 34 38
005 029 Ring gasket ............................................ 063 121 42 7
005 247 Hexagon cap screw ................................ 064 112 34 19
006 000 Union ...................................................... 064 114 36 53
006 002 Union ...................................................... 064 113 36 50
006 187 Union ...................................................... 064 105 40 4
006 187 Union ...................................................... 064 112 34 32
006 190 Union ...................................................... 064 112 34 40
006 216 Union ...................................................... 064 458 52 9
006 219 Union ...................................................... 064 112 34 29
006 221 Union ...................................................... 064 112 34 30
006 221 Union ...................................................... 064 113 36 51
006 228 Union ...................................................... 064 112 34 31
006 380 Reducing union ...................................... 064 302 38 2
006 385 Reducing union ...................................... 064 105 40 9
006 387 Reducing union ...................................... 064 105 40 8
006 390 Reducing union ...................................... 063 121 42 6
006 452 Stub ........................................................ 064 112 34 33
006 455 Stub ........................................................ 064 269 68 3
006 455 Stub ........................................................ 064 458 52 10

007 123 Shaft seal ............................................... 064 106 10 29
008 633 Pipe ........................................................ 064 118 44 1
E - 82
Index
Page
E-
008 633 Pipe ........................................................ 064 118 44 2
008 633 Pipe ........................................................ 065 641 72 11
008 663 Pipe ........................................................ 064 458 52 12
008 663 Pipe ........................................................ 064 458 52 13
008 663 Pipe ........................................................ 064 458 52 14
008 663 Pipe ........................................................ 064 458 52 15
012 512 Taper faced compression ring ................ 031 881 22 3
030 082 Oil pressure switch ................................. 064 118 44 5
030 340 O-ring ..................................................... 064 112 34 35
030 510 Union ...................................................... 064 118 44 10
030 532 Union ...................................................... 065 641 72 4
030 545 Gasket .................................................... 064 119 46 6
030 744 Plug ........................................................ 064 458 52 5
030 752 Safety valve 3rd compression stage ..... 064 105 40 5
030 831 Shaft seal ............................................... 064 106 10 30
031 149 Buffer ...................................................... 064 283 70 6
031 149 Buffer ...................................................... 065 248 54 6
031 881 Piston 1st compression stage ............... 064 081 8 6
031 883 Piston pin 1st compression stage .......... 031 881 22 2
031 883 Piston pin 1st compression stage .......... 031 881 16 5
031 901 Nose ring ................................................ 031 881 22 4
031 902 Double bevelled oil control ring .............. 031 881 22 5
031 905 Union ...................................................... 064 105 40 3
033 017 Reducing union ...................................... 064 118 44 12
033 212 Oil pump cover ....................................... 062 909 50 6
033 215 Cylindrical roller bearing ........................ 064 284 14 14
033 222 High pressure hose ................................ 064 283 70 8

033 222 High pressure hose ................................ 065 248 54 8
033 223 Thermometer ......................................... 064 118 44 4
E - 83
Page
E-
033 224 Safety valve 1st compression stage ...... 064 112 34 34
033 489 Non-return valve ..................................... 064 283 70 9
033 489 Non-return valve ..................................... 065 248 54 9
033 494 Flexible gear rim ..................................... 065 203 62 3
033 502 Fan ......................................................... 064 284 14 6
033 704 Union ...................................................... 064 118 44 9
033 714 Safety valve 2nd compression stage ..... 064 111 32 9
033 717 Stud ........................................................ 064 106 10 12
033 952 Hose ....................................................... 064 302 38 10
034 132 Union ...................................................... 064 118 44 11
034 612 Low pressure hose ................................. 064 302 38 9
034 791 Ring gasket ............................................ 065 641 72 7
034 983 Valve 2nd compression stage ............... 064 110 30 5
035 061 Ring gasket ............................................ 064 118 44 20
035 520 O-ring ..................................................... 064 064 12 3
035 824 Oil filler cap ............................................. 064 302 38 1
035 906 Adapter ................................................... 065 641 72 6
036 052 Test cock ................................................ 065 641 72 5
036 107 Needle roller bearing .............................. 063 102 16 2

036 112 Circlip ..................................................... 062 525 24 6
E - 84
Index
Page
E-
036 112 Circlip ..................................................... 064 108 26 4
036 171 O-ring ..................................................... 063 121 42 9
036 345 Flange hub, compressor side ................. 064 081 62 1
036 345 Flange hub, compressor side ................. 064 081 8 21
036 359 Gearwheel .............................................. 062 909 50 5
036 360 Oil pump housing ................................... 062 909 50 2
036 896 Oil intake screen ..................................... 064 106 10 8
037 036 Ball valve ................................................ 065 641 72 9
037 076 Dipstick .................................................. 064 064 12 1
037 137 Y-joint ..................................................... 064 302 38 6
037 138 Reducer ................................................. 064 302 38 5
037 157 Valve 1st compression stage ................. 064 109 28 7
037 160 Adapter .................................................. 064 118 44 16
037 172 Mounting plate ....................................... 064 283 70 7
037 172 Mounting plate ....................................... 065 248 54 7
037 211 Cooler 1st compression stage ............... 064 112 34 17
037 217 Stud ........................................................ 064 106 10 13
037 218 Stud ........................................................ 064 106 10 14
037 221 Separator 2nd compression stage ........ 064 112 34 18
037 321 Standard hub, motor side ....................... 065 203 62 2
037 526 O-ring ..................................................... 064 111 32 12
037 609 Washer ................................................... 064 112 34 25
037 883 Temperature switch ................................ 066 364 60 1
037 941 Compressed air hose ............................. 065 478 56 1
037 942 Hinge bolt clamp .................................... 065 478 56 2

037 966 Cutting ring ............................................. 064 112 34 42
038 096 Cutting ring ............................................. 064 112 34 41
E - 85
Page
E-
038 264 Pressure gauge angle ............................ 064 118 44 21
038 279 Oil pressure gauge ................................. 064 118 44 23
038 280 Pressure gauge 1st compression stage 064 118 44 13
038 281 Pressure gauge 2nd compression stage 064 118 44 14
038 282 Pressure gauge 3rd compression stage 064 118 44 15
038 401 Cutting ring ............................................. 064 112 36 43
038 919 Oil drain cock .......................................... 064 106 10 18
038 920 Stub ........................................................ 064 302 38 4
039 316 Pressure sensor ..................................... 064 118 44 25
039 547 Air filter ................................................... 064 109 28 6
039 548 Filter element for air filter ........................ 039 547 28 8
040 300 Single ear clamp ..................................... 064 302 38 11
040 795 Gasket .................................................... 062 909 50 8
040 889 Valve 3rd compression stage ................ 064 111 32 11
051 883 Inspection cover ..................................... 064 106 10 5
053 713 Connecting rod bolt ................................ 062 982 20 4
054 164 Spring ..................................................... 057 916 48 3
056 235 Gasket .................................................... 064 109 28 5
056 318 Gasket .................................................... 064 119 46 5
056 590 Connecting rod bearing .......................... 062 981 20 3
056 730 Gearwheel .............................................. 064 119 46 4
056 887 Washer ................................................... 064 284 14 4
057 916 Pressure relief valve ............................... 064 119 46 1

060 266 Gasket .................................................... 064 110 30 3
060 342 Fusible plug ............................................ 063 121 42 4
E - 86
Index
Page
E-
061 002 Hose line ................................................ 064 283 70 2
061 002 Drain hose .............................................. 065 248 54 2
062 328 Baffle cone ............................................. 063 121 42 3
062 404 Piston 2nd compression stage ............... 062 525 24 1
062 469 Piston pin 3rd compression stage .......... 064 108 26 2
062 469 Piston pin 3rd compression stage .......... 064 108 20 5
062 524 Piston pin 2nd compression stage ......... 062 525 24 2
062 524 Piston pin 2nd compression stage ......... 063 525 18 5
062 525 Piston 2nd compression stage .............. 064 081 8 7
062 908 Oil pump gearwheel ............................... 062 909 50 1
062 909 Gearwheel oil pump ............................... 064 119 46 2
062 936 Gasket .................................................... 064 111 32 4
062 981 Connecting rod 3rd compression stage 064 081 8 5
062 982 Connecting rod 3rd compression stage . 062 981 20 1
063 059 Gasket .................................................... 064 109 28 4
063 100 Connecting rod 1st compression stage .. 063 102 16 1
063 101 Connecting rod 2nd compression stage . 063 103 18 1
063 102 Connecting rod 1st compression stage . 064 081 8 3
063 103 Connecting rod 2nd compression stage 064 081 8 4
063 120 Expansion vessel ................................... 064 458 52 1
063 121 Separator 3rd compression stage .......... 064 105 40 1
063 228 Separator housing .................................. 063 121 42 1
063 229 Separator insert ..................................... 063 121 42 2
063 748 Gasket .................................................... 064 106 10 7
064 042 Clamp ..................................................... 064 112 34 10
064 048 Gasket .................................................... 064 109 28 3
064 050 Gasket .................................................... 064 112 34 9

064 051 Gasket .................................................... 064 111 32 3
064 054 Washer ................................................... 064 284 14 3
E - 87
Page
E-
064 064 Dipstick ................................................... 064 106 10 2
064 075 Clamp ..................................................... 064 112 34 11
064 079 Bearing bracket ....................................... 064 106 10 3
064 081 Compressor WP 81L .............................. 064 285 66 1
064 081 Compressor WP 81L .............................. 065 203 6 1
064 082 Cylinder 2nd compression stage ............ 064 110 30 1
064 084 Cylinder 3rd compression stage ............. 064 111 32 1
064 085 Cylinder head 2nd compression stage ... 064 110 30 2
064 087 Cylinder 1st compression stage ............. 064 109 28 1
064 091 Flange .................................................... 064 112 34 7
064 092 Attachment rail ....................................... 064 112 34 8
064 093 Piston 3rd compression stage ................ 064 108 26 1
064 094 Gasket .................................................... 064 110 30 4
064 095 Gasket .................................................... 064 106 10 6
064 097 Channel section ...................................... 065203 6 5
064 097 Channel section ...................................... 064 285 66 5
064 098 Gearwheel .............................................. 064 119 46 3
064 102 Fan cover ............................................... 064 112 34 4
064 105 Separator 3rd compression stage, ......... 064 081 8 14
complete
064 106 Crankcase .............................................. 064 081 8 1
064 108 Piston 3rd compression stage ................ 064 081 8 8
064 109 Cylinder with head and valve .................
064 081 8 9
1st compression stage
064 110 Cylinder with head and valve ................. 064 081 10
8
2nd compression stage
064 111 Cylinder with head and valve ................. 064 081 11
8
3rd compression stage
064 112 Cooler assembly ..................................... 064 081 8 12
064 113 Cooler 2nd compression stage .............. 064 112 34 1
064 114 Cooler 3rd compression stage .............. 064 112 34 2
E - 88
Index
Page
E-
064 115 Pipe ........................................................ 064 112 34 5
064 116 Pipe ........................................................ 064 112 34 6
064 117 Pipe ........................................................ 064 112 34 12
064 118 Measuring device ................................... 064 081 8 15
064 119 Lubricating oil pump drive ...................... 064 081 8 16
064 134 Cylinder head 1st compression stage .... 064 109 28 2
064 135 Cylinder head 3rd compression stage .... 064 111 32 2
064 137 Flange .................................................... 064 081 8 17
064 138 Flywheel ................................................. 064 284 14 2
064 269 Automatic drainage system .................... 064 285 66 3
064 283 Resilient mounts ..................................... 064 285 66 4
064 284 Crankshaft .............................................. 064 081 8 2
064 302 Crankcase vent ...................................... 064 081 8 13
064 303 Crankcase .............................................. 064 106 10 1
064 323 Crankshaft .............................................. 064 284 14 1
064 326 Double ended stud end .......................... 064 118 44 3
064 342 Pipe ........................................................ 064 112 34 16
064 458 Automatic drainage system .................... 065 203 6 3
064 523 Pipe adaptor ........................................... 064 302 38 7
064 524 Distributor ............................................... 064 112 34 3
064 618 Pipe ........................................................ 064 112 34 13
064 619 Pipe ........................................................ 064 112 34 14
065 248 Resilient mounts ..................................... 065203 6 4
065 648 Stub ........................................................ 065 641 72 2
066 888 Throttle ................................................... 064 269 68 4
066 888 Throttle ................................................... 064 458 52 2
090 650 Piston 1st compression stage ................ 031 881 22 1

091 029 Terminal box ........................................... 065 188 58 2
1)
The order number varies according to the order.
E - 89
E - 90

WP81L BA1 ET1 en 1402

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S a u e r

Translation of the original operating manual

Type approvals for Sauer compressors

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

5 Transport and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

10 Lubricants for Sauer compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

11 Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

We recommend that you record this information in Chapter 11

Copyright The copyright for this Operator Manual remains with

1.3 Warranty and liability

Sauer will no longer cover warranty or be liable for any claims if

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

Only use genuine Sauer spare parts Do not use parts

1.5 J.P. SAUER & SOHN customer service

Should you have any technical questions relating to maintenance

J.P. SAUER & SOHN Maschinenbau GmbH

Instructions Individual instructions or multiple instructions requiring action but

Instructions to be carried out in a certain sequence are

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

The control light lights up.

Safety Safety and warning instructions are presented pictorially with

This Sauer compressor system must only be used to compress

2.2 Unauthorised modifications

2.3 Safety information – Warning and caution

The safety information in this Operator Manual is presented as

Safety marking Meaning Safety marking Meaning

High voltage! Read Operator

Compressor starts Wear hearing

Hot surface! Rotational direction

Location of safety markings

2.5 Safety and protection equipment

Safety valves Each compression stage of the Sauer compressor is equipped

2.6 Noise protection

Sound pressure level details are included in the technical

2.7 Waste disposal

2.8 Safety requirements for personnel

Only personnel authorised by J.P. SAUER & SOHN are

– the Equipment and Product Safety Act,

In addition, all applicable classification society and operational

Personnel authorised to service the compressor must be trained

The operator must provide personal protective equipment for

WP81L with expansion vessel

WP81L without expansion vessel

18 Oil pressure switch

Compressor The Sauer compressor is controlled and monitored by an electric

Condensate Condensate containing oil and water that is created during

Condensate Condensate is drained via drain lines. Solenoid valves are

Lubrication/Oil A gearwheel oil pump, driven by the crankshaft, draws the

Item Designation Display

3.4 Displays and controls on the

Maximum working pressure 40 bar

Set pressures for safety valves:

Oil sump capacity 10.5 l

Oil pressure monitoring (optional):

Temperature monitoring (optional):

Final pressure monitoring (optional):

Solenoid drain valve:

Sound pressure level (free field at 1 m) max. 90 dB(A)

Weight and dimensions See installation drawing

4.2 P&I diagram

5 1st compression stage

Transport The Sauer compressor must be transported using a forklift truck

5.2 Storage before installation