Maintenance schedule

Sauer compressor

WP200

WP200_WA_03, 2009-07
Titel_WP200_1.fm

Titel_WP200_1.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 sup-
ply.
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 sched-
ule must be observed. Shortening the maintenance intervals is
of no advantage with regard to the operating performance or
service 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 op-
erating 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 check-
boxes. 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 sched-
ule following commissioning or following the last mainte-
nance routine.
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 Maintenance

Maintenance Schedule No. Compressor type: WP200

Beginning of this maintenance schedule: Type series 2W

❑ after commissioning Compressor number:

❑ after last maintenance routine Factory no.:

Date: Year of construction:

Hours of operation: Date of commissioning:

Interval

last maintenance routine

[hours of operation]

At least annually
commissioning

at < 1000 h
50 h after

50 h after

or repair

2000 h
1000 h

3000 h

4000 h
Maintenance work

069229

069230

069229

069231
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 valves, section 1.9 ❏ ❏
Replace 1st-stage valves, section 1.10 ❏ ❏
Replace 2nd-stage valves, section 1.10 ❏ ❏ ❏ ❏
Replace 1st-stage piston rings, gudgeon pins and ❏
gudgeon pin bearings, section 1.12
Replace 2nd-stage piston rings, gudgeon pins and ❏
gudgeon pin bearings, section 1.12
Check piston and cylinder, section 1.13 ❏
Renew flexible gear rim, section 1.16 ❏
Check condensate separator, section 1.17 ❏
Overhaul drain valves (as per order), section 1.18 ❏
Clean particle trap, section 1.19 ❏ ❏ ❏ ❏
Replace zinc protection ❏
(freshwater operation), section 1.20
Replace bursting disc, section 1.21 ❏ ❏ ❏ ❏
Check cooling water pump, section 1.22 ❏
Hours of operation
Date
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Signature (initials)

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1.4 Table of tightening torques

Screw(s) Tightening torque

Connecting rod screws 115 Nm

Flywheel fastening screw 550 Nm

Cylinder head-screws (1st/2nd stage) 82 Nm

Bursting plate flange 54 Nm

Retaining screw of the 2nd stage valve on the 15 Nm

valve cover

Screws at the cylinder cover, 30 Nm (screw M8)

Mounting of the 1st stage cooler insert 60 Nm (screw M10)

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.
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 Maintenance

1.6 Replacing the air filter cartridge

Air filter cap

1. Open clips and take the air filter cap off.

2. Remove used cartridge.
3. Clean filter housing with a suitable solvent and wipe out with
a lint-free cloth.
4. Insert new cartridge into air filter.
5. Put on cap and close clips.
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1.7 Changing the oil
Note!
Use oil according to the lubricant table (see Sauer oil recommen-
dation or operating manual section 10).

Oil filler cap

Dipstick

Oil drain valve cap

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1. Run compressor for approx. 15 minutes until operating tem-

perature is reached.

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 Maintenance

2. Place drip tray (of a capacity sufficient to hold the complete

oil filling quantity, 11.5 l) below the oil drain valve.
3. Unscrew oil filler cap and oil drain valve cap, open oil drain
valve and pull out dipstick.
4. Wait until all oil is drained.
5. Close oil drain valve and screw on cap.
6. Top up oil and check level with the dipstick.
✓ The level should be between the upper and lower marks on
the dipstick.
7. Put dipstick back in and screw oil filler cap back on.

1.8 Cleaning the oil strainer

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 gas-
ket.
8. Tightly refasten oil strainer.
9. Tighten nuts on inspection hole cover.

1.9 Checking the valves

Removing valves 1. Loosen clamp on air filter and take out air filter.
2. Loosen unions and hose lines at the valve covers.
3. Undo valve cover screws and take off valve covers. Prise off
using the screws if necessary.
4. Carefully take out 1st-stage valve.
5. Undo valve retaining screw and take out 2nd-stage valve.

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

Checking valves 1. Check valves externally for:

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damage,
carbonisation,

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

Removing 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.

1. Install valves and valve covers. Insert new O-rings (see illus-
trations).

Note!
Never reuse old rings. This may lead to leaks.

1st stage O-ring

Gasket

2. Attach 1st-stage valve cover. Fasten all screwed connections

hand-tight.
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 Maintenance

2nd stage Valve retaining screw

O-ring
3. Fasten valve to valve cover using valve retaining screw.
4. Attach 2nd-stage valve cover. Fasten all screwed connec-
tions hand-tight.
5. Fasten valve cover nuts tightly. Observe tightening torques
(see section 1.4).
6. Attach unions and hose lines to the valve covers.
7. Mount air filter and tighten clamp.

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.
Due to material fatigue, we recommend that used valves not be
repaired.
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1.11 Draining the cooling water

Drain plugs

1. Block the cooling water inlet and outlet.

2. Remove the hoses for the cooling water inlet and outlet from
the cylinders.
3. Unscrew the drain plugs and drain the cooling water.

1.12 Replacing piston rings, gudgeon pins and gudgeon pin bear-
ings
1. Remove valve covers and valves as described in section 1.9,
'Checking the valves'.
2. Remove cylinder base nuts.
3. Remove cylinder. Grab and hold the piston before you have
completely removed the cylinder.

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

1st stage 4. Remove valve covers and valves as described in section 1.9,
'Checking valves'.
5. Dismantle the inspection hole cover from the crankcase.
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6. Remove connecting rod bolts and remove connecting rod

bearing cover with bearing bush.
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 Maintenance

7. Push piston together with connecting rod upper part out of the
cylinder.
8. Remove all piston rings from the pistons and clean pistons.

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.
9. Fit piston rings in the respective piston.

Note!
Use an assembly sleeve for pushing the piston into the liner from
above (see operating manual section 11, 'Spare parts and ac-
cessories').
10. Put connecting rod back with sufficient oil and screw on the
bottom part by hand.

Note!
Figures are hammered into the upper and lower sections of the
connecting rods. They must match. See illustration.

2
2

✓ It must be possible for the connecting rod bolts to be fully

screwed in by hand. This is the only way of ensuring that they
are seated correctly on the crankshaft. The connecting rod
must be able to rotate easily on the crankshaft once tight-
ened.
11. Tighten connecting rod bolts; see tightening torque in section
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1.4.

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2nd stage 1. Loosen the flange connections and dismantle compressed air
manifold.
2. Loosen both unions and dismantle the compressed air line
from the cylinder of the 2nd stage to the final separator.
3. Block the cooling water inlet, remove the drain plug located
below on the cylinder of the 2nd stage and drain the cooling
water.
4. Loosen screwed pipe connections on the cylinder and dis-
mantle cooling water inlet pipe. The screw connection nipple
remains on the cylinder.
5. Unscrew the cooling water hose line between the 1st and the
2nd stage and remove.
6. Dismantle both the inspection hole covers from the crank-
case.
7. Loosen the connecting rod bolts and remove them from the
crankcase together with bearing cover. Push the connecting
rod upper part with the piston up in the cylinder.
8. Loosen the four nuts at the base of the cylinder of the 2nd
stage.
9. On both sides of the cylinder unscrew the two M10 × 25 up-
per retaining screws on the cooler cover and replace with
M10 × 100 screws. Attach a suitable hoist to the screws and
pull the cylinder sideways out of the crankcase (weight: ap-
prox. 100 kg).
10. Pull cylinder further up along with connecting rod with piston.
Pull connecting rod towards front from the crankcase open-
ing.
11. Put cylinder down at the side and pull connecting rod with pis-
ton down from the cylinder.
12. Remove all piston rings from the pistons.

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.
13. Sequence of assembly is exactly opposite to that of disman-
tling. Replace the screws on the cooler covers on both sides
of the cylinder with the M10 × 25 retaining screws.
14. Put connecting rod back with sufficient oil and screw on the
bottom part by hand.
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 Maintenance

Note!
Figures are hammered into the upper and lower sections of the
connecting rods. These must match in any case (see illustra-
tion).

2
2

✓ It must be possible for the connecting rod bolts to be fully

screwed in by hand. This is the only way of ensuring that they
are seated correctly on the crankshaft. The connecting rod
must be able to rotate easily on the crankshaft once tight-
ened.
15. Tighten connecting rod bolts; see tightening torque in section
1.4.
16. Install new piston rings in the respective pistons. Make sure
they are in the correct positions: piston rings with asymmetri-
cal cross sections are marked on one of the surfaces with
'TOP'. During installation this face must face upwards (see il-
lustration).

1st stage 2nd stage

TOP TOP
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1.13 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 1.12,
'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 1.14, 'Wear limits

for cylinder diameters'.
5. Install cylinders and pistons as described in section 1.12, 'Re-
placing piston rings, gudgeon pins and gudgeon pin bear-
ings'.
6. Install valves and cylinder heads as described in section 1.9,
'Checking valves'.

1.14 Wear limits for cylinder diameters

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

Cylinders Wear limit of diameter

1st stage 195.15 mm

2nd stage 88.10 mm

1.15 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 1.16, 'Renewing flexible gear rim'.
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2. Check the coupling parts for damage.

✓ The teeth of the coupling parts must not be deformed.

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 Maintenance

3. Replace flexible gear rim as described in section 1.16, 'Re-

newing flexible gear rim'.

1.16 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 op-
erating 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
tighten the motor mounting screws.
7. Remove support from under the coupling bell housing.

Flexible gear rim

Compressor Motor

8. Reinstall separated connecting lines and pipes.

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1.17 Inspecting the condensate separator

1. Remove pipes and check separator for obstructions.

1.18 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.
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6. Replace following parts:

conical spring, diaphragm and two O-rings.
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 Maintenance

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.

1.19 Cleaning particle trap

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

1.20 Replacing the zinc protection

The zinc protection for the 1st-stage cylinder is situated laterally
on the cylinder cover at the top.
The zinc protection for the 2nd-stage cylinder is situated laterally
on the cylinder cover at the bottom beside the bursting disc
flange.
1. Drain the cooling water.
1. Unscrew the zinc protection.
2. Clean the sealing surface and thread.
3. Insert new zinc protection with new ring.

1.21 Replacing the bursting disc

1. Drain the cooling water.
2. Undo the screws and remove the pressure flange on the cyl-
inder of the 2nd stage.
3. Remove the bursting disc and ring.
4. Clean the sealing surfaces.
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 5. Install a new ring and new bursting disc. Check that the gas-
ket is correctly installed. Fit first the gasket and then the burst-
ing disc into the cylinder.
6. Screw on the pressure flange; see tightening torque in sec-
tion 1.4.

1.22 Checking the cooling water pump

Note!
The cooling water pump is an optional component and is not
supplied as a standard component.

The cooling water pump should be checked as follows in case of

abnormal running sound or leaks:

Removing the 1. Block the cooling water inlet and outlet.

pump 2. Disconnect electrical connection.
3. Remove the drain plug located below on the cylinder of the
2nd stage and drain the cooling water of the compressor.
4. Loosen the flange connections on the cooling water inlet and
outlet of the pump. Remove rings and clean sealing surfaces.
5. Loosen the bolted fastening of the pump at the foot and re-
move pump from the console.

Replacing the The floating ring seals are maintainance-free. In case heavy leak-
floating ring seals ages are noticed after a long running time, the floating ring seal
is to be replaced as a complete unit.

Note!
Note the diagram of the pump in the Spare Parts Catalogue.
Please refer to the operating instructions provided by the pump
manufacturer.

6. Remove impeller and shaft retaining ring.

7. Pull the entire floating ring seal with the cap out from the
shaft.

Note!
The floating ring seals are delicate elastomers and must not
come into contact with grease or oil.
Avoid touching them with your fingers (use clean gloves or
cloth).
Do not soil or damage floating ring seals.
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Moisten the gaskets with low surface tension water to facilitate

assembly.

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 Maintenance

8. Carefully slide new floating ring seal on to shaft with a rotating

motion.

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

Mounting the 1. Assemble the pump back in the reverse sequence. Insert
pump new flange gaskets.
2. Fill pump and suction pipe completely with cooling water.
3. Connect electrical connection.

Checking the di- Briefly switch on pump motor. The motor must not reach its oper-
rection of rotation ating speed during this. The direction of rotation must be the
same as the one indicated by the arrow on the pump housing.
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