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Sauer WP400 Maintenance Schedules

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Maintenance schedule
Sauer compressor
WP400
WP400_WA_03, 2009-07

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Summary of Contents for Sauer WP400

  • Page 1 Maintenance schedule Sauer compressor WP400 WP400_WA_03, 2009-07...
  • Page 2 Titel_WP400_1.fm Edited by: ZINDEL AG – Technical Documentation, www.zindel.de...

  • Page 3: Safety During Maintenance

    Maintenance 1. Maintenance J.P. SAUER & SOHN maintenance service customer service offers various mainte- J.P. SAUER & SOHN nance services: inspections, maintenance, major overhauls, re- conditioned compressors and service contracts. Safety during maintenance 1. Interrupt power supply to the compressor.

  • Page 4: Maintenance Schedule

    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.
  • Page 5 Maintenance Maintenance Schedule No. Compressor type WP400 Beginning of this maintenance schedule Type series ❑ Compressor number: after commissioning ❑ Factory no.: after last maintenance routine Date: Year of construction: Hours of operation: Date of commissioning: Interval [hours of operation] Maintenance work Maintenance set item no.
  • Page 6 Table of torques Screw(s) Torque Connecting rod screws 115 Nm Flywheel fastening screw 550 Nm Valve cover nuts (1st/2nd stage) 82 Nm Bursting disc flange 54 Nm Valve retaining screw 9 Nm Checking screwed connections Check all unions and screwed connections for tightness and re- tighten if necessary.

  • Page 7: Changing The Oil

    4. Insert new cartridge into air filter. 5. Put on cap and close clips. Changing the 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 valve cap 1.

  • Page 8: Checking The Valves

    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.
  • Page 9 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).

  • Page 10: Replacing Valves

    Valve retaining screw 2nd stage 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.

  • Page 11: Draining The Cooling Water

    Maintenance 1.11 Draining the cooling water Drain plug 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 bea- rings 1.
  • Page 12 4. Remove valve covers and valves as described in section 1.9, 1st stage 'Checking valves'. 5. Dismantle the inspection hole cover from the crankcase. 6. Remove connecting rod bolts and remove connecting rod be- aring cover with bearing bush. 7. Push piston together with connecting rod upper part out of the cylinder.
  • Page 13 Maintenance must be able to rotate easily on the crankshaft once tigh- tened. 11. Tighten connecting rod bolts; see tightening torque in section 1.4. 1. Loosen the flange connections and dismantle compressed air 2nd stage manifold. 2. Loosen both unions and dismantle the compressed air line from the cylinder of the 2nd stage to the final separator.
  • Page 14 14. 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. These must match in any case (see illustrati- on). ✓ It must be possible for the connecting rod bolts to be fully screwed in by hand.
  • Page 15 110,15 mm 2nd stage 1.15 Checking coupling Note! This applies to Sauer compressors with electric motors. 1. Remove the electric motor from the copmressor as described Visual inspection in section 1.16, 'Renewing flexible gear rim'. 2. Check the coupling parts for damage.
  • Page 16 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. 1. Support compressor under the coupling bell housing. Renewing flexible 2. Remove the electric motor mounting screws.
  • Page 17 Maintenance 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.
  • Page 18 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.

  • Page 19: Removing The Pump

    Maintenance 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: 1.

  • Page 20: Mounting The Pump

    Note! The motor bearing should be replaced if the shaft has noticeable play. A possibly damaged pump impeller must likewise be re- placed. 1. Assemble the pump back in the reverse sequence. Insert Mounting the new flange gaskets. pump 2. Fill pump and suction pipe completely with cooling water. 3.

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