Maintenance schedule

Sauer compressor

WP151L

WP151L_WA_02, 2009-02
Titel_151L_2.fm

Titel_151L_2.fm

Edited by: ZINDEL AG – Technical Documentation, www.zindel.de

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Maintenance

1. Maintenance
1.1 J.P. SAUER & SOHN maintenance service
J.P. SAUER & SOHN customer service offers various mainte-
nance services: inspections, maintenance, major overhauls, re-
conditioned compressors and service contracts.

1.2 Safety during maintenance

Before mainte- 1. Interrupt power supply to the compressor.
nance work 2. Fit 'Warning: maintenance work' warning sign to power supp-
ly.
3. Shut off the compressor and secure to prevent restarting.

Danger!
Risk of injury due to incorrect operation!
Only authorised personnel are permitted to service and adjust
the Sauer compressor!

Danger!
Risk of injury from hot surfaces!
Let compressor cool down after turning OFF.

Danger!
Risk of injury due to pressurised components!
Before undertaking any maintenance work, use pressure gauge
to ensure that there is no more pressure in the compressor.

Danger!
Danger! High voltage!
– Never assume that a circuit is de-energised – always check
for your own safety!
– The mains isolator remains energised, even when it is turned
OFF.
– Components being worked on should only be energised if this
is explicitly specified.
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 Danger!
Danger of death if there are no safety devices or no isolating pro-
tection devices!
After undertaking servicing work, always refit all safety devices
and isolating protection devices. This also applies to electrical
protection devices.

1.3 Maintenance schedule

Danger!
Whenever undertaking maintenance work, observe section 1.4,
'Table of tightening torques', for particular bolts.
Note!
The maintenance intervals specified in the maintenance sche-
dule must be observed. Shortening the maintenance intervals is
of no advantage with regard to the operating performance or ser-
vice life of the Sauer compressor.
Note!
After the final maintenance routine, the maintenance schedule
starts from the beginning.

Use of the mainte- • Use the maintenance schedule as a master template or copy
nance schedule the relevant page from the digital document and save it as a
separate file under a suitable name. Use the maintenance
schedule as a guide and for verification.
• Regularly check the maintenance schedule to see which main-
tenance intervals are due depending upon the number of ope-
rating hours. The intervals are shown in the table's column
headers.
• Check the column for each maintenance interval to see which
maintenance work is to be carried out at the end of the main-
tenance interval. The required tasks are indicated by checkbo-
xes. A description and the section number of the tasks are
shown in the first column.
• Carry out all maintenance tasks for a maintenance interval
and tick the appropriate check boxes of the maintenance
schedule. Then enter hours of operation, date and signature.
• When beginning a new maintenance schedule:
– enter: maintenance schedule number, date and hours of
operation, main specifications and date of commissioning;
– mark with a cross: beginning of this maintenance schedu-
le following commissioning or following the last mainte-
nance routine.
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 Maintenance

Maintenance Schedule No. Compressor type: WP151L

Beginning of this maintenance sche- Type series
3L
dule:
❑ after commissioning Compressor number:

❑ after last maintenance routine Factory no.:

Date: Year of construction:

Hours of operation: Date of commissioning:

Interval
[hours of operation]

At least annually
commissioning

last major overhaul

at < 1000 h
50 h after

50 h after

or repair

2000 h
1000 h

3000 h

4000 h
Maintenance task

069269

069177

069269

069178
Maintenance set item no.

Check screwed connections, section 1.5 ❏ ❏

Replace air filter cartridge, section 1.6 ❏ ❏ ❏ ❏ ❏ ❏
Carry out oil change, section 1.7 ❏ ❏ ❏ ❏ ❏ ❏ ❏
Clean oil strainer, section 1.8 ❏
Check 1st-stage valve, section 1.9 ❏
Check 2nd-stage valve, section 1.9 ❏
Replace 1st-stage valve, section 1.10 ❏
Replace 2nd-stage valve, section 1.10 ❏
Replace 3rd-stage valve, section 1.10 ❏ ❏
Replace 1st-stage piston rings, gudgeon pins and ❏
gudgeon pin bearings, section 1.11
Replace 2nd-stage piston rings, gudgeon pins and ❏
gudgeon pin bearings, section 1.11
Replace 3rd-stage piston rings, gudgeon pins and ❏
gudgeon pin bearings, section 1.11
Check piston and cylinder, section 1.12 ❏
Renew flexible gear rim, section 1.15 ❏
Check condensate separator, section 1.16 ❏
Overhaul drain valves ❏
(as per order), section 1.17
Hours of operation

Date
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Signature (initials)

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1.4 Table of torques

Bolt(s) Torque

Connecting rod bolts 70 Nm

Flywheel bolt 350 Nm

Cylinder head nuts 75 Nm

1.5 Checking screwed connections

Check all unions and screwed connections for tightness and re-
tighten if necessary. This relates to:
– cooler and air lines;
– unions on pipe and hose lines;
– cylinder heads;
– cylinders;
– electric motor;
– measuring and switching devices;
– bearing; and
– accessories and equipment parts.

1.6 Replacing air filter cartridge

Air filter cap

1. Open clips and take air filter cap off.

2. Remove used cartridge.
3. Clean filter housing with a suitable solvent and wipe out with
a lint-free cloth.
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4. Insert new cartridge into air filter.

5. Put on cap and close clips.

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 Maintenance

1.7 Changing oil

Note!
Use oil according to the lubricant table (see Sauer oil recom-
mendation or operating manual section 10).

Oil filler cap

Dipstick

Oil drain plug

1. Run compressor for approx. 5 minutes until operating tempe-

rature is reached.
2. Place drip tray (of a capacity sufficient to hold the complete
oil filling quantity, 20,0 l) below the oil drain plug.
3. Unscrew oil filler cap (red), unscrew oil drain plug and pull out
dipstick.
4. Wait until all oil is drained.
5. Screw on oil drain plug with a new ring.
6. Top up oil and check level with the dipstick.
✓ The level should be between the upper and lower marks on
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the dipstick.
7. Put dipstick back in and screw oil filler cap back on.

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1.8 Cleaning oil strainers
Nuts for inspection hole cover

Oil strainer
Union

1. Unscrew nuts on inspection hole cover.

2. Take off inspection hole cover.
3. Unscrew union on oil strainer.
4. Take out oil strainer.
5. Wash out oil strainer in a suitable solvent.
6. Carefully clean sealing surface for inspection hole cover gas-
ket.
7. Position inspection hole cover with new original Sauer gasket.
8. Tightly refasten oil strainer.
9. Tighten nuts on inspection hole cover.

1.9 Checking valves

Removing valves 1. Unscrew unions and hose line at the cylinder heads.
2. Remove cylinder head nuts and remove cylinder heads.
3. Carefully remove valves.

Note!
When removing and installing a valve, take care that no valve
parts are damaged. This particularly applies to the sealing sur-
faces.
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 Maintenance

Checking valves 4. Check valves externally for:

damage,
carbonisation,
oiling,
corrosion and
moisture.
Replace damaged, severely carbonised or corroded valves.
Determine cause (see operating manual section 7, 'Trouble-
shooting').
5. Clean all sealing surfaces.

Installing valves
Note!
Refit all valves with new gaskets and rings only. Only use original
Sauer spare parts. Installing other gaskets may lead to compres-
sor leaks and damage.

6. Install valves and cylinder heads. Insert new cylinder head

gaskets and new low tolerance gaskets (see illustrations).

Note!
Never reuse or turn over and reuse an old low tolerance gasket.
This may lead to leaks.
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 1st stage
Low tolerance gasket

Cylinder head gaskets

7. Attach 1st-stage cylinder head. Fasten all screwed connec-

tions hand-tight.
8. Remove bridging elements between the inner and outer rings
on 2nd-stage cylinder head gasket.
2nd stage

Cylinder head gaskets

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 Maintenance

2nd sta-
stage

Bridging element Bridging element

9. Lay inner ring between the pins. Lay outer ring around lamel-
lae.
2nd stage
Sealing surfaces

Pins

10. Attach 2nd-stage cylinder head. Fasten all screwed connec-

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tions hand-tight.

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 11. Insert new O-ring into groove under valve in 3rd-stage cylin-
der.
3rd stage

O-ring Cylinder head gaskets

12. Attach 3rd-stage cylinder head. Fasten all screwed connec-

tions hand-tight.

13. Screw on cylinder head nuts tightly. Observe tightening tor-

ques (see section 1.4).
14. Screw unions and hose line to the cylinder heads.

Note!
Valves are those parts of a reciprocating compressor that are
subject to the most stress. In order to achieve the guaranteed
maintenance routines, these valves are high-quality precision
parts which have been co-ordinated especially to the individual
compression stages and checked carefully for proper functioning
before delivery.

1.10 Replacing valves

Remove and install valves as described in section 1.9, 'Checking
valves'. Replace complete valve.

Note!
Valves whose service life has expired must be replaced and dis-
posed of.
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Due to material fatigue, we recommend that used valves not be

repaired.

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 Maintenance

1.11 Replacing piston rings, gudgeon pins and gudgeon pin bea-
rings
1. Remove cylinder heads and valves as described in section
1.9, 'Checking valves'.
2. Remove cylinder base nuts.
3. Remove cylinders. Grab and hold the piston before you have
completely removed the cylinder.

Note!
If you do not hold the piston while you remove the cylinder, it will
collide with the crankcase.

4. Remove the safety rings of the piston pins, press the piston
pins out and remove the pistons.
5. Remove all piston rings from the pistons and clean pistons.
6. Install new piston rings in the respective pistons. Make sure
they are in the correct positions: piston rings with asymmet-
rical cross sections are marked on one of the surfaces with
'TOP'. During installation this face must face upwards (see il-
lustration).

Note!
Replace all piston rings with new ones! The following damage
may occur on removal of the piston rings:
• the edges of the piston rings may be damaged on the wearing
edges in the cylinder;
• fine cracks which can lead to material fracture may appear if
the piston rings are bent up repeatedly.

1st stage 2nd stage 3rd stage

TOP
TOP
TOP
TOP
TOP

Note!
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Stagger the piston ring gaps.

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 7. Press the gudgeon pin bearing out from the connecting rod
eye using suitable tools and renew.
8. Install piston with the new, halfway-inserted gudgeon pin in
the cylinder.
9. Insert new Sauer cylinder base gasket.
10. Assemble piston together with cylinder by pressing the gud-
geon pin in at the connecting rod. Observe tightening torque
(see section 1.4).
11. Insert circlips precisely into grooves.
12. Screw on cylinder base nuts.
13. Install cylinder heads and valves as described in section 1.9,
'Checking valves'.

1.12 Checking pistons and cylinders

1. Remove cylinder heads and valves as described in section
1.9, 'Checking valves'.
2. Remove cylinders and pistons as described in section 1.11,
'Replacing piston rings'.
3. Check cylinders and pistons for scoring and heavy wear and
tear marks. Replace relevant parts.

Note!
If the piston running surface in the cylinder reveals perceptible
wearing edges, the edges must be broken up with a honing
brush or Scotch-Brite abrasive cloth.
Otherwise the edges will damage the new piston rings on instal-
lation of the pistons.

4. Check wear limits as described in section 1.13, 'Wear limits

for cylinder diameters'.
5. Install cylinders and pistons as described in section 1.11, 'Re-
placing piston rings, gudgeon pins and gudgeon pin bea-
rings'.
6. Install valves and cylinder heads as described in section 1.9,
'Checking valves'.
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 Maintenance

1.13 Wear limits for cylinder diameters

1. Measure cylinder and replace if the following wear limits are
exceeded:

Cylinders Wear limit of diameter

1st stage 160.15 mm

2nd stage 88.10 mm

Top part: 50.10 mm

3rd stage
Guide part: 88.10 mm

1.14 Checking coupling

Note!
This applies to Sauer compressors with electric motors.

Visual inspection 1. Remove the electric motor from the copmressor as described
in section 1.15, 'Renewing flexible gear rim'.
2. Check the coupling parts for damage.
✓ The teeth of the coupling parts must not be deformed.
3. Replace flexible gear rim as described in section 1.15, 'Re-
newing flexible gear rim'.

1.15 Renewing flexible gear rim

Note!
This applies to Sauer compressors with electric motors.

Renewing flexible 1. Support compressor under the coupling bell housing.

gear rim 2. Remove the electric motor mounting screws.
3. Carefully lift the electric motor using the lifting eyes (see ope-
rating manual section 5.1, 'Transport').
4. Carefully pull the electric motor away from the compressor.
5. Replace flexible gear rim.
6. Carefully slide electric motor against the compressor and tig-
hten the motor mounting screws.
7. Remove support from under the coupling bell housing.
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 Flexible gear rim

Compressor Motor

8. Reinstall separated connecting lines and pipes.

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 Maintenance

1.16 Checking and cleaning condensate separators

1 2 3

5 4

Item Name

1 Cylinder, 3rd stage

2 Cylinder, 2nd stage

3 Safety valve, 3rd stage

4 Condensate separator, 3rd stage (final separator)

5 Condensate separator, 2nd stage

1. Remove attached air lines and hoses.

2. Remove 3rd-stage safety valve.
3. Remove separator housing from crankcase.
4. Take off separator cap.
5. Inspect separator for damage and soiling.
6. Remove dirt with a suitable solvent.
7. Blow out solvent with air.
8. Assemble condensate separator, safety valve, air lines and
hoses in reverse order.
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1.17 Overhauling water drain valves
Hexagon nut

1. Unscrew hexagon nut.

2. Carefully lift up plastic threaded part with the screwdriver.
3. Remove coil from armature.
4. Unscrew the four Allen screws.
5. Remove upper section of valve.
6. Replace following parts:
conical spring, diaphragm and two O-rings.
7. In case of severe soiling: clean nozzle.
8. Position upper section of valve.
9. Tighten the four Allen screws.
10. Place the coil on the armature.

Note!
The coil and the armature must always be dry.

11. Correctly position the plastic threaded part and press onto the
armature.
12. Carefully position hexagon nut by hand and screw on.
13. Lightly tighten hexagon nut using a spanner.
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