m6 2 compressor

8/8/2019 M6 2 Compressor

1/115

J.ESAUER&SOHN

M A S C H I N E N B A U G M B H

O^

lloölBJ

Type: WP 45 L

Operating Instructions


2/115

Edited by: ZINDEL AG -Tec hn ical Documentation, www.zindel.de

Version 1-1

>

<

o

>

http://www.zindel.de/http://www.zindel.de/


3/115

Sauer compressor type approvals

(DtrmamsdKr Xlopb

* r & 5a m MuctHnsnt isu GrnOH

Sehr f }»tvte 0HT 4n ur>d H«fnn

' W^l*./

Ri£g1^El' '^

E N C L S T E R I N C S E R V I C E S

1 Pnt Dnlx ^pfrmvl Dimmml It mliil utilll 1

„ » . ̂ .„«^„-V ̂. v .. ^.. „ ... „ .™.

Hiiln JHä Hq i t l s f i n » / « r I fc e C lu i i y i n H ' i n u f . ' i f t l^.

L M t h l l K T l

Ci:nir>n'«Bf Typ*«

»pn^i .-;

N B I Æ « p ^ C v t o i b m . v ™ » n u l r , i l c ) l I ' l i i n j - n Nr

I 'Slai^dirf iveiy promTv. bar

V3

" ' S M I P '

jiä wry jH**nirp.

hm T «

^ » « I r p t n

i*™^

, « ,

-

DET NORSKE VERITAS

TYP E APPROVAL CERTIFICATE

r i l t » C cr t i f i cW c c M u m i i - ( = r a g e

1] S lum/ 111 ii>«c /i

1

rrfc

n ei

>4ciBst;f VsnirAS' Ri^Jis J OB CL AS S I F H. tniiN

m

«Sk : VERTTAS'RULESFOK

C L A S S I F K * rirj l

Iff

MOBÜ.el

M A I U S E D I M S I O H

MalailurM

CERTIFICATE OF TYPE APPROVAL

AIR COM PRESSOR SETS

J.P. S A I t K Ä M J H N MAM H I > t > B A l

(^.obll

« ( t>.

i

EC declaration of conformity

M d a l l n M J b y m a c h in a r y d ln c t t v a SOr SSa / EEC

Cu Bt o m o f

P

O d n S i '

SSM - Or t l e r No 4

BKLna.

a DrucWiumBClt"il>

I h a l • u p p l i « « m o d a l o f

c o t n p l iM w t t h I f w M t o w ln g p r o v 4 » io iM a p p t y t n g

D iTHCtwo BB^ BZ ' EE C ( I F D i r e c t i v » 9 3 . 4 4 , ' E t C

t on

A)> p l> M l h a r m o n iz a d t t a n d a n la I n p a r t i c u la r

E N 2 9 2- 2 . E M 0 5 2

E^50^ •a.

EN 5 0 0 B1 - I . EN M 0 a 2 - 2

V B Q 1 6

I P. SAl'HR

r

,R , JPSAUnRa.SOHN,R

^ - ^ \ \M MIM MM ' IMin i ' - ^ - ' '

^

F a Q f u c i h i m B c n n *

S S M - O m w - N o •

SAUERHPCo m p T BSs o ' Un F l

•i

•

• • • i n « « > d a d t o b a I n c o r p o r a t e d k i t e m a c h in e r y

CH-

a i M i n b i M w l I H

m a c h ln a r y l o c o o M Hu W m a c h in a r y c o v a r a i l b y t h i s d i r a c t tv » a n d m

n a l b * p u l I n t o » r v t e a u n t i l l lw m a c t i l n a r y ( o lo w t Hc b l lwy t r a I D b i

Incorpor ilKj ha i btan daclarad I n conformity

HIFM

ttie pr

t h * d a r K t i > * u * n w n < t e d b y e 9 ' 3 a 2 E E C I . <

~

I d a u n d a n t t I n p u l t c u l a i

e N 2 S 2 - 2 , E N 1 0 1 ? , E N 6 Ü 2 M E N S O O B I - l I

• n i j a t d a u n d t p a c l f l c i

I.P.SAITR & SOflN

<

<

O

>

I M O N U M B E R : S 3 3 2 7 5

Note

On this page only a few examples are show n. Further type ap

provals are available

on

request.

Version 1-1


4/115

Genuine Sauer spare par ts -

certified safety

C e r t i f i c a t e o f C o n f o r m i t y a n d A u t h e n t i c i t y

Kiel,

Serial Number; 2 1 1 7 8 9 - ^ 8 ^ ^ ^ ^

With this Certificate of Confomiity and Authenticity we the

J.R SAUER SOHN


2 4 1 5 7 K i e l - G e r m a n y

certify- that the items , total no. and only these item s

which have been dehvered with attached shipping note

number are

Genuine Sauer

with proven, guanirugi^

writteii (y 'ÉJ^^^MlA '-' rB r rc viÄ pJ rr any way on the

a t t ac l i c^m njm ^ioM or j I i i ^W fi r i c a te i ts el f wil l m ake th is

ce rt i f ic ^ ^ \ , JW . In this case there are jus t i f ied evidences

that grey market spares of inferior quality have been

delivered.

If you want to be informed about your advantages when

using Genuine Sauer Spare Parts or in case of doubts, plea se

contact our Service Department:

Int. -49-431-39 40 -86/87 (Fax -89).

e-mail: service(«;sauersohn.de

or visit our website http/zwww.sauersohn.de.

Version 1-1

http://www.sauersohn.de/http://www.sauersohn.de/http://www.sauersohn.de/


5/115

Contents

<

CG

5

1 .

G eneral 8

1.1 At the outset 8

1.2 General information 8

1.3 Warranty and Liability 8

1.4 Type approval and genuine Sauer spare

parts 9

1.5 J.P . SAUER & SOH N customer service 10

1.6 How these instructions are organized 11

2. Safety 12

2.1 Specified cond itions of use 12

2.2 P rohibition of unauthorized conversion 12

2.3 Safety information 12

2.4 Safety markings on the machine 13

2.5 Safety devices 14

2.6 Noise protection 14

2.7 Waste disposal 15

2.8 Staff requirements 15

2.9 P ersonal protection gear 15

3. Design and Function 1 6

3.1 Overview 16

3.2 Mode of Operation 20

3.3 Indicators on the Sauer Com pressor 22

3.4 Displays and control elements on the

com pressor control 23

4. Tech nical Specifications 24

4.1 Specification data 24

4.2 Com pressed air system plan 26

Version 1 -1


6/115

9

5. Transport and Installation 27

5.1 Transport 27

5.2 Storage before installation 28

5.3 Installation 28

5.4 Connecting the com pressor 31

5.5 Filling in oil 37

5.6 Setting the ultimate pressure switch 38

5.7 Checks after installation and before the first

start 38

6. Operation 39

6.1 Safe opera tion 39

6.2 Ope rating mode 40

6.3 Com missioning 40

6.4 Routine operation 42

7. Troubleshooting 44

8. Maintenance 47

8.1 Ma intenance serv ice by J.P. SAUER & SOHN 47

8.2 Maintenance safety 47

8.3 Maintenance schedu le 48

8.4 Table of tightening torques 50

8.5 Oil change 50

8.6 Check screwed connections 51

8.7 Air filter cartridge replacement 51

8.8 Checking valves 52

8.9 Checking the piston rings 54

8.10 Replacing gudgeon pins/gudgeon pin

bearings 55

8.11 Replacing valves 56

8.12 Checking pistons and cylinders 56

8.13 Checking the drive bearings 56

8.14 Checking the coup ling 58

^>

Version 1 - 1


7/115

9. Placing out of Service 59

9.1 Safety when placing out of service and

dismounting 59

9.2 Shutting down the compressor temp orarily. . 59

9.3 Dismantling 60

1 0.

Lubricant Table 61

10.1 Lubricating oils 62

10.2 Slushing oils 63

1 1 .

Spare Parts and Acce ssories 64

1 2.

Annex 65

<

CD

Version 1-1


8/115

^ —

1.

General

1.1 At the outset

The following main specifications of your Sauer compressor are

found on the type label affixed to the crankc ase:

- compressor type

- factory num ber

- year of construction

We recommend you write down this information in chapter

11 . "Spare P arts and Acces sories".

1.2 General information

Condit ions

We presuppose that only authorized persons will operate and

service the Sauer compressor. These persons must have read

and understood the operating instructions.

Avai labi l i ty These instructions shall always be kept available at the site of op

eration.

Copyr ight The copyright for these instructions remains with

J.P. SAUER &

SOHN.

The se instructions, or parts thereof, shall

not be cop ied, distributed or made ava ilable to third pa rties. Con

travention will be prosecuted.

1.3 Warranty and Liab ility

We exonerate the contractually a greed wa rranty claims and liabil

ity claims, if they can be attributed to at least one of the following:

- use of the machine not as spec ified;

- use of spare parts that are not genu ine Sauer spare parts;

- operation of the machine with faulty or not properly installed

safety devices and protection devices;

- disregard of the opera ting instructions;

- unauthorized m odifications of the machine or its control sys

tem;

- inadequate monitoring of mach ine parts subject to wear;

- inexpert repa irs;

- force ma jeure.

i

<

Version 1 - 1


9/115

General

1.4 Type approval and genuine Sauer spare parts

• The type approval for the Sauer compressor is valid under the

cond ition that parts and compone nts specified and qualified by

J.P. SAUER & SO HN are used. The type approval is made by

the Classification Society and the EC Declaration of Conform

ity or EC Manufacturer's Declaration. Disregard of the specifi

cations may cause the type approval to expire.

• Only the use of genu ine Sauer spare parts ensure s com pli

ance with these specfications and thus the perfect and safe

operation of the Sauer compressor.

• If genuine Sauer spare parts are not used we reserve the right

of exclusion of liability for personal injury and m aterial dam age.

• genuine Sauer spare parts are supplied with a Certificate of

Conform ity and a Certificate of Authenticity. A specimen of this

document is shown before the table of contents of these in

structions. If spare parts are received without this certificate,

there is a risk that thes e are not gen uine S auer spare parts. In

such case please contact our customer service.

Do not use parts from

the „grey ma rket". . .

\ I

. . . but only genuine Sauer

spare parts with certificate

<

<

Version 1-1


10/115

1.5 J.R SAUER & SOHN customer service

In case of technica l quest ions perta in ing to m ainten ance or repair

p lease contact our customer serv ice:

J .R SAUER & SOHN Masch inenbau GmbH

Customer Serv ice

P.O. Box 92 13

D-24157Kie l

Teleph one ( in ternat ional ) :

Technical in format ion +4 9 431 39 40 -87

Spare parts order ing +4 9 431 39 40 -86/886

Telefax ( internat ional ) :

+ 49

431 39 40 -89

Em ergency serv ice ( in ternat ional ) : + 49 172 4 14 63 94

E-Mail: se rv i ce@sauersohn .de

W e b : www.saue rsohn .de

Note

I f you have quest ions regarding your Sauer compressor p lease

state compressor type and factory number (see chapter

11. "Spare P ar ts and Accessor ies " o r type labe l on the c rank-

case).

i

<

10 Version 1 - 1

mailto:[email protected]://www.sauersohn.de/http://www.sauersohn.de/mailto:[email protected]


11/115

E

<

o

o

i

General

1.6 H ow these instruc tions are organ ized

Listings Gene ral listings are den oted by horizontal bars.

Example:

The cooling consists of

- fan wh eel,

- fan wheel cage, and

- cooler assem bly.

Act ion

Individual instructions or multiple instructions, whe re the se

quence is of no importance are normally denoted by bullets.

Example:

• Check oil level.

Instructions to be carried out in a certain sequence are num

bered.

Example:

1. Turn the main switch O N .

2.

Choose the operating mod e.

3. Turn the control ON .

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

Example:

/ The control light is on .

Safety instructions Safety instructions are em phasized by pictographs and signal

words. The safety instructions are described in detail in chapter

2. "Sa fety".

Version 1 -1 11


12/115

2. Safety

2.1 Specified conditions of use

This Sauer compressor must be used for the compressing of air

only. The Sauer compresso r m ust not be used at ambient temp er

atures of below +5 °C. Any other use is not as specified and re

quires the explicit consent in writing by J.P. SAU ER & SO HN .

Observance of these operating instructions, the installation re

quirements detailed in the instructions, and the keeping of main

tenance rates are part of the spec ified cond itions of use as

well.

2.2 Prohibition of unauthorized conversion

Unauthorized conversion and modification of the Sauer compres

sor is not permitted, since they could endange r humans and m ay

lead to machine dama ge.

Contact J.P. SAUER & SOH N when planning conversions or mo

difications to obtain a written permission.

2.3 Safety information

A

The safety information in these instructions is divided in two clas

ses.

The following pictographs and signal words are used:

Danger

High risk.

Disregard of this safety information may cause personal injury

and substantial material damage .

Note

Average risk.

Disregard of this safety information may cause damage to the

machine.

8

12 Version 1- 1


13/115

Safety

2.4 Safety markings on the machine

A

Danger

Safety markings a ffixed to the machine must not be altered or re

moved. Replace damaged or lost safety markings immediately,

true to the origina l.

Sauer compressor models with an EC Manufacturer's Declarati

on or EC D eclaration of Con formity are ma rked with the following

safety markings:

Safety marking

A

A

A

Meaning

Danger High voltage

(Only on Sauer compres

sor with electric motor)

Compressor starts auto

matically without warning

Hot surface

Safety marking

@

(D

- -

IVIeanlng

Read instructions

Wear hearing protection

Rotational direction of

Crankshaft

Location of safety markings (top view)

Version 1 - 1 13


14/115

2.5 Safety devices

A

Danger

Safety devices must not be adjusted, disabled or removed.

The safety devices must be tested and checked on a regular ba

sis.

Safety valves must be

- installed sealed and

- should only be replaced, adjusted and sealed by authorised

personnel.

Safety valves

Fusible p lug / tem

perature control

Every pressure compa rtment of a stage of the Sauer compressor

is equipped with a safety valve, which will blow off when the blo-

wing-off pressure is reached.

Safety valves are installed at the following locations:

-

1^*

compression stage: on the cylinder head of

cylinder of 2" ^ stage;

- 2"*^ com pression stage: in the conde nsate separator behind

the stage;

A fusible plug is fitted in the cond ensate separator of the 2nd sta

ge to m onitor cooling . It melts at 120 °C an d allows the com

pressed air to escape, when its temperature exceeds the

threshold value. This protects the compressor against overhea

ting.

The fusible plug can only be use d once. If it blows, it need s to be

replaced with a new one.

As an alternative to the fusible

plug,

the Sau er compressor can

be fitted with a temperature con trol. This will turn the co mp ressor

off if the temperature of the compressed air exceeds the limit.

2.6 Noise protection

A

Sou nd p ressure level details a re found in the Technical Spec ifica

tions (see chapter 4).

If necessary the Sa uer com presso r can be equipped with a noise

protection hood, which is available as optional accessory from

J.P. SAUER & SOHN.

Danger

When the compressor is operated without noise protection hood,

hearing protection should be worn near the compressor.

§

CO

14 Version 1 - 1


15/115

Safety

2.7 Waste disposal

Note

Under the laws and reg ulations in force, the following materials

arising from the operation of the compressor need to be dis

posed of ecologically safe:

- conde nsate (oil and water saturated) arising from recooling in

the compression process;

- used oil and grease and rags soiled by it;

- cleaning ma terial and rags soiled by it.

2.8 S taff requirements

Only authorised persons are permitted to service the Sauer Co m

pressor Before com mencing work they must have read and un

derstand the operating manual and must be familiar with the

safety devices and safety regulations.

In addition to the instructions in this operating ma nua l and manuf

acturer documentation, accepted technical standards must be

observed as well as all regional laws, standards a nd regulations

such as the

- Equipmen t and P roduct Safety Act (Geräte- und P roduktsi

cherheitsgesetz),

- Ordinan ce on Industrial Safety and Health (Betriebssicher

heitsverordnung),

- Regu lations for acciden t prevention pertaining to com pres

sors,

- VDE regulations and

- Regu lations on environm ental protection.

In addition, where appropriate, regulations of the responsible

classification society as well as operational regulations must be

observed.

Persons authorised to operate the compressor are the attending

specialists introduced to the job and trained by the operator.

Persons authorised to service the compressor are the trained

specialists of the operator and of the manufacturer.

2.9 Personal protection gear

The operator has to provide the persona l protection gear (he aring

protection, safety boots, etc.) for the pe rsonnel carrying out any

work on the Sauer compressor.

Version 1 -1 15


16/115

^

3.

Design and Function

3.1 Overview

10

1 2

11

9 6 8

7 8

u..

16

Version 1 -1


17/115

Des ign and Fnnr t inn

Item

1

2

3

4

5

6

7

8

9

10

11

Name

Cylinder 1®* stage

Cylinder 2""^ stage

Cooler

Safety valve 1®' stage

Safety valve 2 ^ stage

Condensate separator 1^' stage

Condensate separator 2"^ stage (final separator)

Drain valve

Oil dip stick

Air filter

Drive (electric motor or diesel engine)

Version 1 - 1 17


18/115

^

Longitudinal sec

tion

Item

1

2

3

4

5

6

7

8

9

Name

Cooler

1^'stage

Cooler 2"^^ stage

Fan wheel

Connecting rod

Coupling (flexible coupling for electric motor drives; centrifugal

clutch for diesel engine drive)

Flywheel

Transmission bell housing

Crankshaft

Bearing bracket

18

Version 1-1


19/115

Design

and

Function

Cross section

6

7

Note

Details

of

parts and spare parts

are

found

in the

spare p arts

ca

talogue.

Item

1

2

3

4

5

6

7

Name

1^*

stage: cylinder with head and valve

Piston

1 ^

stage

2 '^

stage : cylinder with head and valve

Piston 2 ̂ stage

Crankcase

Connecting rod

Dipper

Version

1-1

19


20/115

3.2 M ode of Operation

Drive

Compressor cont

rol

The Sauer compres sor is driven by an electric m otor directly flan

ged to the transm ission be ll housing of the crankcase , where the

power is transmitted by means of a flexible coupling.

Alternatively a diesel engine can be used to drive the compres

sor. This is attached by means of a special flang e. It transm its po

wer by means of a centrifugal clutch.

The Sauer compressor with electric drive is electrically controlled

and monitored by a com pressor control system. This control sys

tem must comply with the lega l provisions. Optionally,

J.P. SAUER & SO HN supply a suitable compressor con trol sys

tem.

Compression

Cooling

Condensate sepa

rat ion

The compressor takes in ambient air through a sheet filter with

tube silencer and compresses it in two single-stage cylinders to

the ultimate pres sure. Each cylinder is a com pression stag e, after

which the air is after-cooled.

The final compression temperatures are below the flash point of

standard motor oils (mineral oils).

The cylinders arranged in shape of the letter V are fitted with

easy-to-service lamellar valves w ith long service life. Due to the

low compression end temperatures the susceptibility of the

val

ves to carbon isation is extreme ly low.

An axial fan located on the cranksha ft draw s cool air in from the

surroun ding and blows it over the cylinder, cooler, valves and oil

sump.

The after-cooling takes place after every stage in externally

gal

van ised gilled pipe radiator.

Condensate containing oil and water, that is formed during com

pression and after-cooling, accum ulates in the condensate sepa

rator behind every stage.

I

20 Version 1- 1


21/115

Design and Function

Condensate drai - The condensate is drained through drain lines. Solenoid valves

ning/Pressure reli- s""® f'̂ ^®*̂ '"^ ^h® ^''^ ''^ ''"^^^ o^ ^h® Sauer com pressor w ith elec tric

o motor

drive.

Thes e solenoid valves must be open when the Sauer

compressor is unpressurized. The drain valves should close a

few seconds after starting and the Sauer compressor should ac

celerate against pressure. The solenoid valves should d rain the

machine at predetermined intervals during operation. The sole

noids valves are controlled by the compressor control system.

Han d valves are fitted in the drain lines of the Sauer compressor

with diesel engine drive. Solenoid valves can be fitted optionally.

Lubr icat ion The drive is lubricated by the splash oil in the crankcase. A dipper

on the conn ecting rod of the 1®* stage dips in the oil sump and

splashes lubricating oil on lubricating points.

I

Version 1 -1 21


22/115

9

3.3 Indicators on the Sauer Com pressor

Item

1

2

Name

P ressure gauge 1^*

stage

P ressure g auge 2"̂ ^

stage

Indication

Compressed air pressure after the 1®'

stage

Ultimate pressure

I

22 Version 1 - 1


23/115

Design and Rinction

3.4 D isplays and control elements on the com pressor control

Note

The standard version of Sauer compressor with diesel engine

does not have a compressor control.

If the compressor control is supplied by J.P. SAUER & SOHN,

refer the docum entation in addition.

The following display and control elements should be present on

the front side of the compressor control:

Display/

control element

"Operation" signal

lamp

"Oil level" fault

indi

cator lamp (optio

nal)

"Air temperature "

fault indicator lamp

(optional)

"Overcurrent" fault

indicator lamp

Operating hour

meter

Operating m ode

selector

Main switch

Explanation

Glows when the compressor is running.

Glows if the compressor is cut-off due to oil

defi

ciency.

Glows if the com pressor is cut-off due to too high a

compressed air outlet temperature.

Glows if the com pressor is cut-off due to too high a

motor current.

Displays the hours of operation of the compressor.

• Switch position "Manual":

To switch on the compressor manually. Compres

sor starts and continues to operate until it is manu

ally switched off.

• Switch position "0"

To switch off the com pressor manually. Fault

indi

cators, if any, are reset.

• Switch position "Auto":

Com pressor is started and stopped due to the ope

ning and closing of an external make-and-break

contact (e.g. pressure switch of the comp ressed air

receiver).

Disconnects the power supply from the com pressor

control to the compressor.

A main switch should be provided, if required by the

legal or regulatory provisions.

Version 1 -1 23


24/115

9

4. Technical Specifications

4.1 Specification data

Name

Compressor type

Data

W P 4 5 L

Number of cylinders

Number of compression stages

Cylinder diameter 1^ ' stage

Cylinde r diameter 2""^ stage

Piston stroke

Maximum pump speed

Direction of rotation (as seen on flywheel)

2

2

136 mm

60 mm

60 mm

1800 rpm

clockwise

Maximum working pressure

Set pressures of safety valves:

1

®*

stage

2"^^

stage

40 bar

8 bar

5 % higher than the ultimate pressure

Oil filling quan tity

Oil quantity between dip stick markings

Oil type

5.2

1

1.6

1

see chapter 10. "Lubricant table"

Oil level switch (optional)

Holding capacity

Operating current

Setting

10 VA

0.5 A

Opens when oil level is falling

I

i

24

Version 1 -1


25/115

Technical Specifications

Name

Solenoid valves (standard for operation with elec

tric motor; optional for operation with diesel

engine):

Pick-up and holding power

Setting

Ultimate pressure switch (standard for operation

with electric motor; optional for operation with die

sel engine):

Maximum switching current

Setting

Switch function

Data

1 8 V A / 1 4 W

normally open; starting

relief:

approx.

15 seconds;

intermediate draining: 15 seconds every 15 minu

tes.

6A /22 0 V

to customer's specifications

change-over contact

Temperature switch (optional):

Maximum switching current

Setting

Switch function

1 6 A / 4 4 0 V

opens at 80 °C rising

change-over contact

Non-return valve:

Response pressure

approx.

1

bar

Sound pressure level (in free sound field at 1 m

distance)

maximum 88 dB(A)

Weight and dimensions

see Installation Plan

Note

Please refer to the order-specific documentation of your com

pressor for specific data, such as ultimate pressure, speed, po

wer requirements, etc.

Version 1 - 1

25


26/115

9

4.2 Com pressed air system plan

1 3 4 5 2 3 4 5

10 2

Outlet

Item

1

2

3

4

5

6

7

8

9

1 0

Name

Drive motor

Safety valve

Compressor stage

Intercooler and aftercooler

Pressure gauge

Oil level switch (optional)

Condensate separator

Drain valve (for operation w ith electric moto r: solenoid valve; for

operation with diesel engine: hand valve)

Intake filter

Temperature switch (optional)

<

o'

CM

S

26 Version

1

- 1


27/115

Transport and Installation

5. Transport and Installation

5.1 Transport

Shipping The machine is packed suitable for shipping.

• Immediately on receipt of the Sauer com pressor it should be

checked for completeness and dam age.

• The transport company and J.P. SAU ER & SOH N must be im

mediately notified of any dam age to the packing or the mach i

ne.

Transpor ta t ion

The Sauer compressor must be transported by a forklift truck or

hoisted by crane.

Danger

Suspended load when transported.

The forklift truck/crane must have sufficient load bearing capaci

ty-

• Ensure that no persons stay within the dange r area of the sus

pended load and the forklift truck/crane.

• Sling the unpacked comp ressor at the two lifting eyes on the

crankcase and electric motor or diesel engine as the case

may be (see illustration).

• Lift, move, and set dow n carefully.

Lifting eyes on the

Sauer compressor

with electric motor

^;»AAAA


28/115

Lifting eyes on the

Sauer compressor

with diesel engine

5.2 Storage before installation

If the Sauer com presso r has to be stored before installation, do

not unpack and store at the following conditions:

- temp erature: +5 to +40 °C;

- relative hum idity 30 ... 95% , not con den sating ;

- dry, under a roof and protected against dew ;

- protected against soiling;

- protected against vibrations and shoc ks.

Note

The standard factory conservation is sufficient for a maximum

storage period of 12 months.

5.3 Installation

Note

When in doubt if the intended place of installation and room are

suitable, contact J.P. SAUER & SOHN in time before the instal

lation. There you w ill also get help w ith the design of a ventilating

system,

if required at the place of installation.

For installation observe the installation instructions and the folio- |

wing cond itions. ^i

28 Version 1 - 1


29/115


Installation condi

tions

max 55°C

min 5°C

The place of installation must be dry and free of dust.

The place of installation must be vented in such way that the

heat generated during operation is dissipated.

Room temperature while the Sauer compressor is running:

+5 ... +55 °C

(deviating temperatures only if confirmed in writing by

J.P. SAUER & SOHN)

Note

The air temperature at the cooling air intake of the compressor

must not excee d +55

°C

when the com pressor is running. Room

conditions and the heat, generated by the com pressor a nd other

machines installed in the room, must be taken into considerati

on.

• If necessary, install a ventilation or exhaust system at the

place of installation.

• Install any ventilation system in such way that the fresh air

stream is not directly directed against the compressor. Other

wise there is a risk of condensation of water inside the machi

ne and subsequent damage.

Version 1-1

29


30/115

This way is correct

Do not install fresh

air feed this way

Installation condi

tions (cont 'd)

- At a room temp erature of below +5 °C the room needs to be

heated or the Sau er comp ressor must be equipped with a he

ating system.

- Choose the location so that the Sauer com pressor is acces sib

le and has sufficient clearance to walls and other machinery

(see installation documents).

- Do not position the m otor side in a room niche, so the Saue r

compressor will not take in the warmed-up cooling air again.

- Do not position severa l com pressors one after the other, to

prevent one compressor from taking in the warmed-up cooling

air of another compressor.

Note

J.P. SAUER & S O HN is glad to advise you on the installation of

the compressors.

o

8

s.

30 Version 1 -1


31/115


Foundat ion

Note

The standard delivery resilient-mount bedding has a resonant

frequency of approx. 10 Hz.

Gen eration of oscillations of the intended foundation by other ne

arby m achinery must not be at 10 Hz. Othenwise there is a risk

that the standard delivery resilient-mount bedding is destroyed

by sympathetic vibration.

1.

Check early enou gh if there are foundation vibrations in the

10 Hz range.

2. If in doubt, check with J.P. SAU ER & SO HN to see if a mo di

fied resilient-mount bedding can be used.

5.4 Connecting the com pressor

Danger

The compressor should only be connected by qualified technici

ans.

Any work on the electrical installation must be carried out

by qualified electricians only.

Note

The o il filler tube is insulated using a section of hose. Do not re

move the insulating material.

Pipel ines

The com press ed air outlet and the d rain outlet of the Sauer com

pressor must be connected to the perma nently fitted pipelines

using hose lines (see illustration).

KWXVXWXVXVXVXyXV> >KV.v.VXW..AWWWW.WW.WXVXV.^^^^^^^ t f l f f i

Hose lines on the Sauer compres

sor with electric motor

8

Version 1 -1

31


32/115

9

Hose lines on the Sauer com

pressor with diesel engine

A

Danger

Com pressed air escapes from the drain outlets when the com

pressor starts and when the condensate is drained. Do not ope

rate compressor without the hose lines connected.

I

32 Version 1 -1


33/115


Hose lines have to be installed free of tension and untw isted.

\ I '

|BI h*

*.*ij--__

_ - ^

a t

\ \ Th is way is correct

1

iB^] 1

T - . X

Not this wa y

Drain

Note

Condensa te build-up is oil-saturated. It may only be disposed of

in compliance with applicable legal regulations.

J.P. SAUER & SO HN can supply condensa te collecting pots for

separating condensate, as well as condensate treatment units

for separating the oil from the condensate.

I

Note

We recomm end con necting the compressor's drainage separa

tely.

When the d rain lines of several com pressors are to be connec

ted to a com mon pipe, observe the following:

- Choose a sufficient nominal diameter for the common drain

line.

- Connect drain lines of the individual compres sors at a sharp

angle to the common drain line, so no pressure can build up

in the drain line of a stopped compressor.

Version 1 -1 33


34/115

»

\ ' ' . ^ x \

\ ' ' . i s : \ \ '

I .é;>. \

' '

This way is correct

Not this way

å

<

34 Version 1 -1


35/115


Connections

The illustrations show the connections and fittings for the opera

tion of the standa rd version Sauer compressor.

r g = - Note

k t ^ For technical specifications of the individual items please refer to

Chapter 4

All toggle switches are factory set.

As an option , the subsystems can be prewired in a terminal box.

E

O

O

o

_ i

Item

1

2

3

4

5

6

Name

Drain valve

Drive motor

Ultimate pressure

switch

Oil level switch (opti

onal)

Temperature control

(optional)

Non-return valve

Type

Soleno id valve

3-phase

motor

Toggle switch

Toggle switch

Toggle switch

Plug valve

Function

Starting relief and draining

Drive of the com pressor

Stops/starts the compressor

Stops compressor in case of low oil level

Stops com pressor in case of excess tempera

ture

Prevent air backflow

Version 1-1

35


36/115

9

Item

1

2

3

4

5

6

7

Name

Drain valve

Drive motor

Ultimate pressure

switch (optional):

Oil level switch (opti

onal)

Temperature control

(optional)

Non-return v alve

Drain valve (optional)

Type

Hand valve

Diesel engine

Toggle switch

Toggle switch

Toggle switch

P lug valve

Solenoid valve

Function


Drive of the compressor

Stops/starts the compressor

Stops compressor in case of low oil level

Stops compressor in case of excess tempera

ture

Prevent air backflow


36

Version 1-1


37/115


5.5 Filling in oil

The Sauer compressor is supplied without oil.

Danger

Oil must be filled into the compressor's crankcase before initial

operation

Use lubricating oil (see chapter 10. "Lubricant table").

Observe filling amount (see chapter 4. "Technical Specificati

ons").

I

Oil filler plug

Dipstick

1.

Unscrew oil filler plug (red).

2. Fill in oil and check level with the dipstick.

Note

Fill only to the upper marking on the dipstick. Otherwise the oil

consum ption of the com pressor will increase.

3. P ut dipstick back in and replace the oil filler plug.

Version 1 -1 37


38/115

5.6 Setting the ultimate pressure switch

Note

The ultimate pressure switch must be connected directly to the

compressed air receiver to ensure a quiet and uniform compres

sor operation.

The pressure loss between the compressor an d compressed air

receiver must be taken into account for selecting the maximum

set pres sure. Too high a set pressure can caus e the safety valve

of the final stage to blow off.

5.7 Checks after installation and before the first start

- Electrical connection corresponds with the type label data?

- Are all connections between compressor and the pressurized

air unit supplied correctly installed? Pay special attention to

the compressed air outlet.

- Are drain lines properly connected? See section "Drainage"

- Oil filled into crankcase?

- Hav e all tools and foreign objects been remov ed from the com

pressor?

- Air filter turned from transport position to operating position?

- Entire unit clean?

I

38 Version 1 -1


39/115

Operation

6. Operation

6.1 Safe operation

Danger

| \ Only authorized persons are permitted to comm ission and ope

rate the Sauer compressor

A

Danger

f \ Turn on and start the com pressor only if

- it has been che cked for proper working con dition;

- all tools and foreign objects are removed from the machine.

Danger

f \ Turn compressor immediately OFF when persons or objects are

endan gered. Start compressor only when the danger is over.

A

Danger

1 ^

In Automa tic mode the com presso r starts autom atically without

warning

Danger

f \ Risk of burns by hot surfaces of the com presso r when it is run

ning. Wear gloves.

A

Danger

f

\ Risk of hearing dam age due to the sound pressure level when

the compressor is running Wear hearing protection near the

compressor.

Note

Turn compressor OFF in the case of faults, abnormal ratings or

irregularities. Refer to chapter 7. "Trouble S hoo ting" to remove

cause.

Version 1 -1 39


40/115

9

6.2 Operating mode

Note

Applicable to S auer comp ressor with compressor control.

After switching on the power supply to Sauer compressor it can

be started in one of the following two operating modes using the

operating mode selector:

-

"Manual"

operating m ode:

Compressor starts and keeps on operating until it is stopped

or switched off using the operating mode selector or the main

switch respectively.

-

"Automatic"

operating m ode:

The starting and stopping of the compressor is controlled ex

ternally (e.g. by the pressure switch of the compressed air re

ceiver).

When the Sauer compressor starts, it does so without any load

with the drain valves open. The valves close after a few seconds

and the compressor accelerates against pressure.

6.3 Commissioning

Checking the di

rection of rotation

( ^

Note

Applicable to Sauer com pressor with compressor control.

At first, let the Sauer com presso r run only for a few seco nds to

check the direction of rotation.

1. Turn power supply ON .

2.

Set the operating mode selector to "M anua l" to start the com

pressor in Manual mode.

3. Imm ediately check the com presso r's direction of rotation. It

must rotate in the direction indicated by the arrow on the

crankcase.

4. Set the operating mode selector to "0 " to stop the compres

sor.

5. Turn the power supply OFF.

6. If the direction of rotation is incorrect, have polarity of the

electric motor changed by a qualified electrician.

E

J

UJ

40 Version 1 -1


41/115

Operation

Test run for Sauer

compressor with

electric motor

Test run for Sa uer

compressor with

A

1.

2.

/

3.

4.

6.

7.

Turn power sup ply ON .

Set the operating mode selector to "M anual" to start the com

pressor in Manual mode.

If correctly set the drain valves will close after approx. 15 se

conds and the co mpressor a ccelerates against pressure.

Check pressure gauges of the stages and compare w ith no

minal values (for nominal values see chapter 6.4 "Routine

Operation").

Check the functioning of the automatic intermediate draining.

It must drain every 15 minutes for approx. 15 seconds. This is

recognizable by the pressure drop at the pressure gauges.

Set the operating mode selector to " 0" to stop the compres

sor.

Turn the power supply OFF.

If necessary, remove causes for deviations and faults. Also

see Chapter 7. "Trouble-shooting" for this purpose.

Danger

The S auer com presso r is fitted with a cen trifuga l clutch for star

ting relief. The sw itch-on speed of the clutch is approx.

1000 rpm.

The speed setting m ust not be changed. Otherwise power trans

mission starting with about 1400 rpm cannot be guaranteed.

Note

For Sauer com pressor with compressor co ntrol see section

"Test-run for Sauer Compressor with Electric Motor".

diesel engine

1.

Ope n the drain valves on the condensate separators of the 1 ^

and 2 "^ stage.

2.

Start the diese l engine.

3. Close both the drain valves.

/ The compressor accelerates against pressure.

4. Check pressure gauges of the stages and compare with no

minal values (for nominal values see chapter 6.4 "Routine

Operation").

5. Open both the drain valves every

15..

.20 m in., drain the

con

densate and close them again.

6. Open both the drain valves.

7. Stop the diese l engine .

8. If necessary, remove causes for deviations and faults. Also

Version 1 - 1

41


42/115

see C hapter 7. "Trouble-shooting" for this purpose.

6.4 Routine operation

Cleaning

Checks

Operat ion with

compressor cont

rol

Operat ion without

compressor cont

rol

Observat ion

• Keep com presso r site clean.

• Keep indicators and control elements clean .

• Inspect conn ections, pipelines and electric cables for dam age.

• Check the oil level once a week before starting, top up if ne

cessary. Do not fill oil beyond the ma ximum mark.

1.

Turn power supply ON .

2.

Set operating m ode selector to "Auto" to operate the com

pressor in Automatic Mode.

1.

2.

3.

4.

Open the drain valves on the con densate separators of the 1 ^

and 2"^ stage.

Start the diesel engine.

Close both the drain valves.

Open both the drain valves every 15 ...20 min., drain the con

densate and close them ag ain.

Pay attention to abnormal operating s ound s.

Pay attention to leakages (compressed air, oil, condensate).

During operation the pressure reading of the pressure gauge

shou ld be within the shaded region of the stage pressure cha rt

(see below).

In case of deviations see C hapter 7. "Trouble-shooting".

m

42 Version 1 - 1


43/115

Operation

i

f

ro

0

O )

ro

^ — »

(/3

•O

c

CN

Stage pressure chart 1 ^ stage

40 -

30 -

20 "

10 -

0 -

1 2 3 4

/

/

/

/

/

-^^

5 6

1^* stage [bar] ^

Note

Dependent on the desired ultimate pressu re of the 2"'̂ stage the

permissible pressure for the 1®* stage can be taken from the

chart.

Version 1 -1 43


44/115

9

7. Troubleshooting

Note

• In case of malfunctions, first check the indicators on the com

pressor control and the compressor.

• Try to remedy the fault by following the information given in

the table below.

• If the cause for the fault can no t be eliminated , contact

J.P. SAUER & SO HN custom er service.

Fault

Operation with compressor

control:

compressor does

not start or is cut-off.


control:

compressor was

cut-off, " Oil leve l" fault indi

cator lamp" (optional) is

glowing.


control: compressor was

cut-off, "Overcurrent" fault

indicator lamp" is glowing.

Safety valve of

1 ®

stage

blows off:

P ressure exceeds blow-

ing-off pressure (8 bar)

Pressure below blow-

ing-off pressure (8 bar)

2""^

stage safety valve blows

off:

Pressure exceeds blow-

ing-off pressure (ulti

mate pressure + 5%)

Pressure below blow-

ing-off pressure (ulti

mate pressure + 5%)

Maximum pressure is

exceed in the 1®' stage.

Likely cause

No supply voltage / no control

voltage.

The oil level is too low.

The motor is overheated.

Excessive current drawn.

Piston seizure

Remedy

Check fuses. Replace blown fuses.

Check the oil level, add oil as required.

Determine the cause of the fault and

remedy. The compressor can be

started again after being allowed to

cool off.

Check cylinder and piston for striation,

replace if necessary.

2" ^

stage valve is not working

properly.

Safety valve is faulty.

Check 2 ' ̂ stage valve, replace if nec

essary.

Replace the safety valve.

Valve in air line to co mpress ed

air receiver closed.

P ressure sw itch set too high.

Safety valve set too low or

faulty.

P ressure loss in the com

pressed air line to the air

receiver too high.

Valve of 2"^^ stage leaky.

Open the valve.

Reduce set pressure.

Increase set pressure or replace safety

valve.

Reduce pressure losses.

Check valve

for

damage, replace if

necessary.

44

Version 1 -1


45/115

Troubleshooting

Fault

P ressure gauges of 1®' and

2"*^

stage displaying insuffi

cient pressure.

No pressure indicated in 1^'

and 2"'^ stage pressure

gauges.

Air escaping from com

pressed air lines

Air escaping from the over

flow opening of the final

separator's fusible plug.


control: compressor was

cut-off, "Air temperature"

fault indicator lamp"

(optional) is glowing.


control: solenoid valve does

not close.

Compressor makes loud

noises.

Oil leaking from crankcase.

Likely cause

Valve of 1^ ' stage leaky.

Air filter very dirty.

Sauer comp ressor with elec

tric motor: no voltage at sole

noid valve.

Sauer comp ressor with elec

tric motor: solenoid valve

defective.

Sauer compressor with diesel

engine: hand valve open.

Gaskets of connections leak

ing.

Comp ression ring connections

leaking.

Temperature of compressed

air too h igh at outlet; insuffi

cient cooling by faulty fan.

Very dirty cooler; insufficient

ventilation.

Temperature of compressed

air too high at outlet; insuffi

cient cooling by faulty fan.

Very dirty cooler; insufficient

ventilation.

No supply vo ltage.

Solenoid faulty.

Foreign matter in solenoid

valve.

Connecting rod bearing faulty.

Gudgeon pin bearing faulty.

Crank shaft bearing faulty.

Gasket or shaft seal faulty.

Screws not tight.

Remedy

Check 1^ ' stage valve, replace if nec

essary.

Replace air filter cartridge.

Check power supply of the solenoid

valve.

Check solenoid valves, replace if nec

essary.

Close hand valves.

Replace relevant gasket.

Turn co mpressor OFF. Wait until all

parts are relieved of pressure (check

pressure gauges). Then tighten unions .

Replace fan . Replace fusible plug.

Clean the cooler. Check room ventila

tion. Replace fusible plug.

Replace fan.

Clean the cooler. Check the room

ven

tilation.

Check fuse s, replace blown fuses.

Replace solenoid.

Clean solenoid va lve.

Check connecting rod bearing, replace

if necessary. Check oil supply.

Check gudgeon pin bearing, replace if

necessary.

Check crank shaft bearing, replace if

necessary.

Tighten screws.

If there is heavy leaking, check to see

which gasket is faulty, then replace it.

Minor traces of oil on the crankcase

or oil drops below the compressor are

harmless. Wipe off with a rag.

Version 1 -1 45


46/115

Fault

Water in oil

P remature breaking of valve

plates, valve springs or

valve disks.

Likely cause

Incorrect ventilation (compres

sor is undercooled).

Insufficient drainag e.

Insulating sleeve of crank-

case vent m issing or dam

aged.

Insufficient drainag e.

Remedy

Change the room ventilation.

Check drain lines and drain intervals.

Replace insulating sleeve.

Extend com pressor running time.

Check drain lines and drain intervals.

Note:

Indentation marks appearing on

the valve plate due to valve impact are

normal.

I

46 Version 1 - 1


47/115

Maintenance

8. Maintenance

8.1 Maintenance service by J.R SAUER & SOHN

The J.R SAUER & SOHN customer service offers different

maintenance se rvices - e.g. full maintenance or valve replace

ment service.

8.2 Maintenance safety

Before se rv ic in g 1. Disconnect the power supply to the compressor.

2. P ost danger sign "Caution Maintenance Work " at the power

supply.

o

<

A

Danger

Only authorised p ersons are perm itted to service and make ad

justments to the Sauer compressor

Danger

f \ Risk of injury from hot surfaces

• \ Let comp ressor cool off after turning OFF.

Danger

Risk of injury from pressurised compressor components

Check the pressure gauges before servicing to ensure the com

pressor is com pletely relieved of pressure.

Danger

Danger High voltage

- Never assume that a circuit is de-energised - always check

for your own safety

- The main switch is ene rgised, even when it is turned OFF .

- Com pone nts being worked on shou ld only be energised if this

is explicitly spe cified.

Danger

Danger of death from missing safety devices and missing isola

ting protection devices

Reinstall all safety devices and isolating pro tection devices after

servicing.

This also applies to electrical protection devices (e.g.

earth wires).

Version 1 -1 47


48/115

9

8.3 M aintenance schedu le

Danger

For all maintenance work chapter 8.4 "Table of tightening tor

ques"

must be observed for specific screws.

Note

The m aintenanc e intervals specified in the maintenance schedu

le must be adhered to. Shortening the maintenance intervals is

of no advantage with regard to operating performance or service

life of the Sauer compressor.

Note

After a major overhaul (=8,000 operating hours) the mainte

nance schedule begins all over again.

Instructions for

the maintenance

scliedule

Use the m aintenance schedule as mas ter template or copy the

respective page from the digital docume nt and save it as a se

parate file under a suitable name. Use the maintenance sche

dule as guide and evidence.

Regularly check the m aintenance schedule to see which main

tenance intervals, subject to the number of operating hours,

are due. The intervals are shown in the table's colum n hea

ders.

Check the column of each maintenance interval to see which

ma intenance work is to be carried out at the end of each m ain

tenance interval.The required tasks are indicated by check bo

xes.

Description and chap ter num ber of the tasks are shown in

the first column.

Carry out all maintenance work of a maintenance interval and

tick the appropriate check boxes of the maintenance schedu

le.

Then enter ope rating hours count, date and your signature.

When b eginning a new maintenance schedule

- enter: main specifications, date of commissioning, number

of maintenance schedule, current date and operating hours

count

- tick: beginning after commissioning/after major overhaul

I

48 Version 1 - 1


49/115

Maintenance

M ain ten an ce Sch ed u le N o .

Beg in n in g o f th is m ain ten an ce

sch ed u le

ü a f t e r c o m m i s s i o n i n g

ü af te r m ajo r o ver h au l

Date:

Oper a t in g h o u r s co u n t :

Co m pr esso r type

Type ser ies

Co m pr esso r n u m b er

Factory no . :

Year o f construct ion:

Date o f co m m iss io n in g :

2 L

\ ^ I nt e rv a

\ , (o per a t in g h ou r«

M a i n t e n a n c e w o r k \ ^

Check screwed connect ions 8 .6

Oi l change 8.5

Air f i l ter car tr idge replacement

8.7

Checking valves 8.8

Checking the p iston r ings 8.9

Rep lac ing gudgeon p ins/gud

geon p in bear ings 8.10

Replacing valves 8.11

Check ing p is tons and cy l inders

8.12

Checking dr ive bear ings 8.13

Check ing coup l ing 8 .14

Opera t ing hours coun t :

Da te

Signa tu re

(init ials)

c

'E

.2

« Ö

(A

E

E

o

u

*^

•^

(0

o

in

•

•

i

1

s

•

•

(0

0>

>.

o

o

q

V

»^

><

ns

> .

(/)

(0

<

•

•

•

o

o

q

•

•

•

o

o

q

c«i

•

•

•

•

o

o

q

•

•

•

o

o

q

•

•

•

•

•

•

•

o

o

o

tri

•

•

•

o

o

o

(O

•

•

•

•

o

o

o

•

•

•

3

(C

0)

>

o

^

o

"if

E

II

o

o

o

oo

•

•

•

•

•

•

•

•

•

Note

Check compressor 50 hours after every m aintenance work is

carried out. Check all screws affected by the maintenance work

to see if they are tight.

Version 1 - 1

49


50/115

9

8.4 Table of tightening torques

Screw(s)

Flywheel fastening screw

Cylinder head nut 1®' stage

Cylinder head nut 2"^^ stage

Tightening torque

175

Nm

42 Nm

75 Nm

8.5 Oil change

Note

Use oil as per Lub ricant Table (see chapter 10).

Oil filler plug

Dipstick

Oil drain plug

1. P lace oil sum p (of sufficient capacity to hold the com plete oil

filling, see chapter 4 "T echnical data") u nder the oil drain plug.

2. Remove the oil drain plug.

3. Wait until all oil is dra ined.

4. Replace the oil drain plug.

I

50 Version 1 -1


51/115

Maintenance

5. Unscrew oil filler plug (red).

6. Fill in oil and check level with the dipstick.

/ The level shall be between the uppe r and lower mark on the

dipstick.

7. P ut dipstick back in and screw the oil filler plug back on .

8.6 Check screwed connections

Check all unions for tightne ss and tighten if necessary. It

con

cerns:

- Cooler an d air lines;

- Unions of pipe and hose lines;

- Cylinder head ;

- Cylinder;

- Drive mo tor, coupling and intermediate flange;

- Measuring equipment and switchgear;

- bearings;

- accessories and equipment accessories.

8.7 Air filter cartridge replacement

Wing nut

1.

Loosen w ing nut and take off air filter cap.

2.

Take out used air filter cartridge.

3. Insert new air filter cartridge .

4.

Insert cap and tighten wing nut.

Version 1-1

51


52/115

9

8.8 Checking valves

Note

While reinstalling valves use only new gask ets and rings everyti-

me. Use only genuine Sauer spare parts. They are precision

parts with defined and tested dimensions and material characte

ristics, specially designed for use in Sauer compressors. Instal

lation of other gaskets may lead to leakage and could cause

substantial damage to the compressor.

Valve removal

Checking the la

mellar valves

(1^*

and 2""* stage)

- i

1.

Loosen un ions and hose line of the crankcase vent at the cy

linder heads.

2. Remove cylinder head nuts and remove the cylinder heads.

3. Remove the valves with care.

4. Check valves. If lame llar valve is heavily carbon ised or dam a

ged,

replace complete valve.

Note

Lamellar valves require very little maintenance and function

even in presence of sm all quantities of dirt in contrast to plate

valves. Norm ally the plates have the same service life as the

val

ve body

which,

due to its geom etry, can not be refaced or lapped.

Therefore a replacement of individual plates is not recommen

ded.

Should a plate be broken prem aturely nevertheless

(e.g.

through

the influence of foreign objects), contact our service.

I

52 Version 1 - 1


53/115

Main tenance

Valve installation

Low tolerance gasket

Cylinder head gasket

5. Fit lame llar valve an d cylinde r head of the

1 ^

stage. Use new

cylinder head gasket as well as new low tolerance gaskets

while doing so (see Illustration above). Observe the tighte

ning torque (see section 8.4).

Note

Do not reuse the used low tolerance gasket under any circum

stances. Doing so leads to leakage within a short time.

Cyl inderhead

gasket

0-r ing

6. Fit lamellar valve and cylinder head of the 2" ^ stage. Use new

cylinder head gasket as well as new o-ring while doing so

(see Illustration above). Observe the tightening torque (see

section 8.4).

7. Attach unions and hose line to the cylinder heads.

<

5

Version 1-1

53


54/115

9

Note

Particularly lamellar valves are those parts of a reciprocating

compressor, that are subject to the m ost stress. In order to achie

ve the gua ranteed maintenance intervals, these valve are

high-

quality precision parts, specially ma tched to the individual com

pression stages and their functioning carefully checked before

delivery. Repair by the m aintenance and operating personnel re

quires special knowledge, which may not be available every time.

For such cases J.P. SAUE R & SO HN offer a valve replacement

service. In case it should be necessary please contact the Sauer

service department.

8.9 C heck ing the pisto n rings

1. Remove cylinder heads and valves as described in chapter

8.8 "Checking the valves".

2. P ull cylinder off. Hold the piston before the cylinder comes off.

Note

If the piston is not held when pulling the cylinder off, it will fall

against the crankcase.

3. Unscrew the rear cylinder head bolts of the

1^*

stage.

4.

Rem ove circlips of gudgeo n pins, push gudgeon pin out and

take piston off.

5. Rem ove all piston rings from the pistons.

6. P lace piston rings in their respective cylinders and m easure

the gap clearance with a feeler gauge.

7. Replace piston rings if the gap clearance exceeds the follo

wing limits.

1®*

stage

2" ^

stage

1.4 mm

1.2 mm

Note

Always replace all pistons rings of a piston when o ne of the pis

ton rings exceeds the limit.

54 Version 1 -1


55/115

Maintenanrp

t s t

1 ̂ ^ stage

2"^* stage

8

TOP

Install piston rings on the respective p iston. Make sure they

are in the correct p osition: piston rings having an asym metric

cross section are m arked on one of the surfaces with "TOP ".

This surface must be above while mounting (see the illustra

tion above).

9. Fit a new cylinde r base gasket for each cylinder.

10.

Fix the rear cylinder head b olts of the

1^*

stage back.

11 .

P ush the piston into the respective cylinder up to the gud geon

pin bore and mount the cylinder along with the piston.

12.

Fix pistons on the conn ecting rods. For this purpose, press

the gudgeon pin in and fit the circlip of the gudgeon p in.

13 . Fit cylinder heads and valves as described in chapter 8.8,

"Checking the valves".

8.10 Rep lacing gud geon pins/gudg eon pin bearings

1. Remove cylinder heads and valves as described in chapter


2.

Remove cylinders and pistons as desc ribed in chapter 8.9,

"Checking the piston rings".

3. P ress gudgeon pin bearing out of the conn ecting rod's sma ll

end.

4. Replace gudge on pin and gudgeon pin bearing.

5. P ress gudgeon pin bearing into the conn ecting rod's sm all

end.

6. Fit cylinders and pistons as described in chapter 8.9, "C he

cking the piston rings".

7. Fit cylinder hea ds and valves as described in chapter 8.8,


Version 1-1

55


56/115

8.11 Replacing valves

Remove and install valves as detailed in section 8.8 "Checking

valves". Replace complete valve.

8.12 Checking pistons and cylinders

1. Remove cylinde r heads and valves as described in chapter


2.

Remove cylinde rs and pistons as des cribed in chapter 8.9,


3. Check cylinders and pistons for scouring and excessive wea

ring marks. Replace relevant parts.

4.

Measure cylinde r and replace if the following wear limits are

exceeded:

Cyl inder

1®'stage

2 " ^

s tage

Wear l imit of diameter

136.15 mm

60.10 mm

5. Fit cylinders and pistons as described in chapter 8.9, "Che


6. Fit cylinder heads and valves as desc ribed in chap ter 8.8,


8.13 Check ing the drive bearings

1.

Remove cylinder heads and valves as described in chapter


2.

Remove cylinders and pistons as described in chapter 8.9,


3. Remove fan cover, fan wheel and the entire cooler unit.

4. Remove the motor with intermediate flange , coupling and fly

wheel.

Remove bearing bracket.

.

6.

7.

8.

St

Unscrew the dipper on the connecting rod of the

1^^

stage.

Turn the cranksh aft in such a way that the crankpin is at the

bottom dead centre (DC) of the 2'^'^ stage.

P ull the crankshaft along with the conn ecting rod through the

motor-side guide of the crankshaft bearing.

9. Swing and turn the crankshaft in such a way that it lies free

inside the crankcase along with the connecting rod.

10.

Lift the crankshaft ou t.

11.

Remove the circlip on the crankshaft.

12 . Rem ove the thrust bearing.

56

Version 1 -1


57/115

Maintenance

<

13.

Take off the connecting rod.

14. Inspect the connecting rod bearing for score marks and ex

cessive wear marks and replace in case of heavy wear.

Note

The shaft seals of the crank shaft bearing should only be re

placed after the bearing brackets have been removed

15. Check crankshaft bearings, replace if substantially worn . If

necessary use new shaft

seal.

16.

M ount the conne cting rod.

17. Check the thrust bearing, replace if necessary and mount it.

18.

Fix circlip.

19.

Place the crankshaft in the crankcase and push it in the mo

tor-side guide of the crankshaft bearing by swinging and tur

ning

it.

While doing so, take care that the connecting rods are

inside the respective stages.

20. Fit the dipper on the connecting rod of the 1 ̂ stage back. Pay

attention to the location of the dipper (see illustration in cha p

te r 3.1 "O verview"). Tighten the locknut of the dipper.

21. Fit bearing bracket. Use new gasket.

22.

Install motor with intermediate flange, coupling and flywheel.

Observe the tightening torque (see section 8.4).

23.

Fit cooler unit, fan wheel and fan cover.

24. Fit cylinders and pistons as described in chapter 8.9, "Che


25. Fit cylinder heads and valves as described in chapter 8.8,


Version 1 -1 57


58/115

9

8.14 Checking the coupling

Note

[\y^^~^

Applicable to Saue r com pressor with electric motor.

Checking r ing gear

1.

Support com pressor under the transm ission bell hou sing.

2. Remove the electric motor mounting screws.

3. Carefully lift the electric motor using the lifting eyes (see

chapter 5.1: "Transport").

4.

P ull electric motor carefully away from the intermediate

flan

ge.

5. Check the flexible gear rim of the coupling for dam age . The

teeth of the flexible gear rim must not be deform ed.

6. If required , replace flexible gear rim.

7. Slide electric motor gently against the intermediate flange

and tighten the m otor mounting screws.

8. Remove support from under the transmission bell hous ing.

Tooth of flexible gear rim

I

58

Version 1-1


59/115

Placing out of Service

9. Placing out of Service

9.1 Safety when placing out of service and dismounting

A

Danger

The compressor shall only be placed out of service and dis

mounted by instructed and trained specialists of the operator.

The specialists must be familar with the protection devices and

regulations before starting the work. Any work on the electrical

installation m ust be carried out by qualified elec tricians only.

In addition, information contained in the documentation of out

side vendors is to be observed .

9.2 Shutting down the com pressor temporarily

Every 4 weeks p erform a test run for at least 30 minutes. Then ad

ditional corrosion prevention measures are not required.

When the Sauer compressor is to be shut down for more than

12 weeks,

conse rvation with slushing o il is recom me nded. In this

case periodic test runs are not necessary.

Note

Use one of the slushing oils recommended in Chapter 10 "Lub

ricant Table" for corrosion protection.

The slushing oil has satisfactory running properties. In case of

emergency the machine can be started for a short duration with

slushing oil filling.

1.

Run compressor for approx. 5 minutes with drain valves and

pressure line ope n.

/ Any existing cond ensa te is blown off.

2.

Open the oil drain plug (see illustration in chap ter 8.5 "O il

change"), drain compressor oil and dispose it off in an

envi

ronmentally friendly manner. Close the oil drain plug again.

3. Fill abou t 3 litres of slush ing oil.

4. Start compressor and run for approx. 5 minutes with drain val

ves and pressure line opened.

5. Stop compressor.

6. Rem ove the air filter on the cylinder head of the 1 ^̂ stage (see

illustration in section 3.1 "Overview"). For this purpose, loo

sen the clamp and lift off the air filter.

7. Unscrew the safety valve of the

1 ̂

stage on the cylinder he ad

of the 2'^'^ stage (see illustration in section 3.1 "Overview").

8. Start compresso r and slowly inject approx. 15 cc slushing oil

Version 1 -1 59


60/115

Placing back into

service

into the intake port of the 1^̂ stage.

9. Slowly inject approx. 10 cc slushing oil in the opening in the

cylinder head of the 2"^ stage.

10 .

Wait until oil mist com es out of the pressure line.

11. Stop compressor.

12 .

Fit air filter and safety valve back. Use new gasket for the

safety v alve.

13 .

If necessary, post a sign that the compressor has been trea

ted with anticorrosion agents and is shut down.

14.

Disconnect power lines from the mains supply if necessary.

1.

Connect to power supply, if necessary.

2.

Drain slush ing oil and fill with com presso r oil. P roceed as de

scribed in chapter 6.3 " Com missioning".

9.3 Dismantling

Dismantl ing

Disposal

1.

2.

3.

4.

5.

Turn comp ressor O FF a nd disconnect from power supply.

Make sure by reading the pressure gauges before servicing

that the compressor is completely relieved of pressure.

Disconnect power lines from the mains supply.

Remove oil and lubricants and dispose of in an environmen

tally friendly manner.

Drain any remaining condensate and dispose of in an envi

ronmentally friendly manner.

Material/component

Lubricants

Steel/iron

Electric cables

Electronic compon ents

Plastics

How to dispose

as hazardous waste

as metal scrap

as hazardous waste

as electronic waste

as hazardous waste

g

60 Version 1 -1


61/115

Lubr i can t Tab le

10.

Lubricant Table

( ^

Note

Lubricants not me ntioned in the lubricant table may only be used

after approval by J.P. SAU ER & SO HN . Otherwise the warranty

will expire. Contact customer service in case of need.

Take note of all informa tion about the lubricants give n in this

chapter.

Area of validity

General recom

mendat ion

The lubricant table applies to all Sauer com pressors intended for

the compression of air.

The lubricant table does

not

apply to

- Sauer compresso rs for the com pression of neutral gase s;

- temp erature ranges outside of 5 ... 55 °C.

The follow ing recomm enda tions ap ply to the 5 ... 55 °C tem per

ature range:

- Use mineral oils of viscosity class ISO VG 1 00 or SAE 30.

- Lubricating oils should conform to group V CL according to

DIN 51506.

Note

In the case of

2-stage 30 bar compressors

the use of

synthet

ic lubricating oils may be beneficial. Please contact us for

more information about synthetic lubricating oils approved by us.

o

<

Version 1-1 61


62/115

9

10.1 Lubricating oils

Brand

Agip

ARAL

AVIA

BP

Castrol

Chevron

DEA

Esso

Mobil

Shell

Name

Diesel Gamma

30

Dicrea 100

Acer 100

Motor

Oil HD 30

Cladium

50

Motanol HE 100

Kowal M 30

Disola

M 30

Avilub Compressor Oil VDL-100

Avilub Compressor

Oil

VDL-100

Motor oil HDC 30

Motor

oil HD 30

Energol

RC 100

Energol IC-DG 30

Energol DL-MP 30

Energol OE-HT

30

Vanellus

C3 SAE 30

Aircol PD 100

Marine CDX 30

HD

Compressor

Oil 100

Delo 1000 Marine 30

Veritas 8 00 Marine 30

RP M Heavy Duty Motor 30

ActroEP VDL-100

TrionEP VDL-100

Regis SAE 30

Exxcolub 77

Exxcolub

100

Compressor

Oil 3021 N

Exxmar 12 TP 30

Exxmar XA

Essolube

HDX

Plus

+30

Rarus 427

DTE Oil

Heavy

Mobilgard

300

CorenaOil P 100

RimulaX30

Melina

S Oil 30

Melina Oil 30

Gadinia Oil 30

Group

VCL-100

VDL-100

VCL-100

SAE 30

SAE 30

VDL-100

VCL-100

SAE 30

VDL-100

VCL-100

SAE 30

SAE 30

VDL-100

VCL-100

SAE 30

SAE 30

SAE 30

VDL-100

SAE 30

VDL-100

SAE 30

SAE 30

SAE 30

VDL-100

VDL-100

SAE 30

VDL

VDL-100

VDL-100

SAE 30

SAE 30

SAE 30

VDL-100

VDL

SAE 30

VDL-100

SAE 30

SAE 30

SAE 30

SAE 30

62 Version 1 -1


63/115

Brand

TEXACO

TOTAL

10.2 Slushing oil

<

o

o

1 -

Lubricant

T^^»

Name

Compressor

Oil EP VDL 100

Regal R&O 100

Ursatex

30

DOROAR30

Dacnis P 100

Carprano

TD 30

MilcanoTCSO

Disola M3015

Group

VDL-100

VOL-100

SAE 30

SAE 30

VDL-100

SAE 30

SAE 30

SAE 30

S

Brand

Agip

ARAL

AVIA

BP

Castrol

DBA

ELF

Esse

FINA

Mobil

Shell

TEXACO

Name

Rustica C SAE 30

Konit Motor Oil SAE 30

MK1540S

Avilub MK 3000

MEK 20 W-20

Running-in and Preservation Oil

Deamot

EKM 642 SAE 30

Stockage

30

MZK

Motor

Oil HD 30

Antirust

MZ 110

Rusan

NF

Motor

Oil SAE 30

Mobilarma

524

Ensis Motor

Oil 30

Engine

Oil EKM 146 SAE 30

Version 1 - 1

63

P


64/115

11.

Spare Parts and Accessories

Spare parts cata

logue

Note

Please note the information in chapter

1.

"Ge neral" regading our

genuine Sauer spare parts.

J.P. SAUER & SO HN garantee the complete spare parts supply

over the entire service life of the Sauer compressor.

Our genuine Sauer spare parts are subject to constant quality

control and further development. They conform to the latest

tech

nical developments.

In addition to the genuine Sauer spare parts, our delivery pro

gram comprises a large number of accessories for your Sauer

compressor and special components to complete your air sys

tem,

such as:

- fully automatic controls;

- adsorption drye rs;

- refrigerated air dryers;

- filters;

- silencing cabin ets;

- com presse d air receivers;

- fittings.

We supply instructions and a ma intenance manual for each ac

cessory.

The spare parts catalogue is found in the annex to these instruc

tions.

- W ith the help of overviews, illustrations an d lists the required

parts is quickly found.

- Th e spare parts catalogue, including the operating instructions

is also available on C D-R OM . Here, an order form can be filled

in , printed out and send immediately.

For doing so , you need the

m ain specifications

of you r Sauer

com pressor from the table below . If they have not yet been en

tered there, they can be found on the type label affixed to the

crankcase.

Compressor type

Factory no.:

Year of construc

tion:

Furthermore, the number of operating hours should be stat- <

ed,

if possible. 5

N

64 Version 1 -1


65/115

Annex

12. Annex

This Annex to the operating instructions contains

- docum entation supplied by outside vendors;

- data sheets.

<

<

Version 1- 1 65


66/115

A

§

z

<

66 Version 1 -1


67/115

IE SAUER SOHN


«

Ein Mitglied d er

SAUER-Gruppe

mpressor

Type: WP 45 L

Spare Part List

Vers ion 1 -1


68/115

E - 2 Version 1 -1


69/115

Spare Part List

H f r • - - •

WP 45L Sauer com pressor

Reference No. Subassemblies Page

WP 45L Sauer compressor 4

064 478 crankrcase 6

064 076 crankshaft 10

064 059 connectig rod

1

st stage 12

064 060 connectig rod 2nd stage 14

031 881 piston

1

st stage 16

064 061 piston 2nd stage 18

064 062 cylinder with head and valve

1

st stage 20

064 063 cylinder with head and valve 2nd stage 22

065 910 cooler compi 24

065 909 air lines 28

064 072 crankcase venting 30

064 071 measuring dev ice 32

037 219 flexible coupling f. motor 160L / M 34

037 331 centrifugal clutch f. Diesel engine 36

064 070 resilient mou nts f.E-Motor 38

064 778 resilient mou nts f. Diesel engine 40

060 354 automatic draina ge 42

Note: Exp lanation of the sub assem blies in chapter 3 "Design and Fun ction'

of the operating instructions

Version 1 - 1 E - 3


70/115

9

W P 45L Sauer compressor

E - 4

Version 1 -1


71/115

Spare Part List

WP 45L Sauer compressor

Item

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

Reference No .

064 478

064 076

064 059

064 060

031 881

064 061

064 062

064 063

065 910

065 909

064 072

064 071

037 219

037 331

064 070

064 778

060 354

Designation

crankrcase

crankshaft

connectig rod 1st stage

connectig rod 2nd stage

piston 1st stage

piston 2nd stage

cylinder with head and valve 1st stage

cylinder with head and valve 2nd stage

cooler compl.

air lines

crankcase venting

measuring device

flexible coupling f. motor 160L / M

centrifugal clutch f. Diesel engine

resilient mounts f.E-Motor

resilient mounts f. Diesel engine

automatic drainage

Qty.

Version 1 - 1

E- 5


72/115

»

064 478 crank rcase

1 2 ,

16, 17

6 , 7

21

E - 6

Version 1 -1


73/115

spare Part List

064 478 crankrcase

1 4 , 16

1 0 , 13

8 , 3 0

1 5 ,

19

Version

1

-1

E- 7


74/115

E - 8 Version 1 -1


75/115

spare Part List

064 478 c ran krca se

Item

1

2

5

6

7

8

10

11

12

13

14

15

16

17

19

20

21

30

Reference No.

064 268

064 122

064 047

005 029

000 979

064 064

001 620

000 269

005 930

037 152

037 153

030 744

002 031

002 156

005 009

001 886

030 831

035 520

Designation

crankcase

bearing bracket

packing for bearing bracket

gasket

plug

dipstick

hexagon nut

eye bolt

stud

cylinder head stud 2nd stage

cylinder head stud 1st stage

plug

hexagon nut

washer

gasket

shaft seal

shaft seal

o-ring

Qty.

4

1

7

4

6

1

13

7

1

1

1

2

Version 1-1

E -

9


76/115

9

064 076 crankshaft

E- 10

Version 1 -1


77/115

spare Part List

064 076 crankshaft

Item

1

2

3

4

5

7

9

10

12

13

14

15

16

17

Reference No.

064 053

064 382

064 054

056 887

064 642

033 502

000 119

000 188

001 667

002 439

004 458

001 982

002 266

037 154

Designation

crankshaft

f lywheel

pressure washer f lywheel

pressure washer fan wheel

washer

fan wheel

hexagon head screw

hexagon head screw

locking plate

circlip

tension bushing

fitting key

cylinder roller bearing

cylinder roller bearing

Qty.

2

Version 1-1

E - 1 1


78/115

9

064 059 connectig rod 1st stage

E - 1 2

Version 1 -1


79/115

Spare Part List

064 059 connectig rod 1st stage

Item

1

2

4

5

6

Reference No.

066 719

064 126

002 094

037 155

036 107

Designation

pin

connect ing rod Iststage

hexagon nut

connecting rod bearing

piston pin bearing

Qty.

1

1

1

1

2

Version 1 -

m6 2 compressor

Documents