PAS WP121L-WP151L Marine WAs - en - GB - 1804

● High pressure com-
pressor
● 3-stage
● Air-cooled
MAINTENANCE INSTRUCTIONS
Sauer-Compressors
Type: WP121L / WP151L Marine
Series: Passat
EN 04 | 2018 www.sauercompressors.com
Translation of the original maintenance instructions
Edition: 04 / 2018
Edited by: J.P. Sauer & Sohn Maschinenbau GmbH – Technical Documentation
TABLE OF CONTENTS
Table of contents
1 General................................................................................................ 5
1.1 Foreword........................................................................... 5
1.2 Target group...................................................................... 5
1.3 Sauer-Service................................................................... 5
2 Preparing for maintenance................................................................ 7
2.1 Installation conditions....................................................... 7
2.2 Requirements for maintenance work................................ 7
2.3 Ordering spare parts......................................................... 8
2.4 Basic activities.................................................................. 9
3 Maintenance..................................................................................... 13
3.1 Maintenance schedule.................................................... 13
3.1.1 Replacing the air filter insert........................................... 16
3.1.2 Changing the oil.............................................................. 17
3.1.3 Cleaning the oil strainer.................................................. 19
3.1.4 Checking and replacing valves....................................... 20
3.1.5 Replacing the piston rings, gudgeon pins and gudgeon
pin bearings.................................................................... 24
3.1.6 Replacing the flexible coupling element......................... 31
3.1.7 Servicing the solenoid drain valve.................................. 32
3.1.8 Checking the safety valves............................................. 34
4 Preservation..................................................................................... 35
4.1 Preservation for decommissioning of longer than 12
weeks.............................................................................. 35
4.2 Commissioning after storage.......................................... 37
5 Index.................................................................................................. 39
PASSAT Master Wartungsanleitung en GB 1804 | 3

4 | PASSAT Master Wartungsanleitung en GB 1804
GENERAL
1 General
1.1 Foreword
These maintenance instructions describe how to maintain the Sauer-Com-
pressor WP121L / WP151L Marine and provide maintenance personnel with
the following essential information:
n Performing maintenance
n Checking components
n Replacing components
These maintenance instructions and the associated oper-

ating instructions cover proper use and maintenance. Any
other work must be carried out by specialist personnel
authorised by J.P. Sauer & Sohn Maschinenbau GmbH.
More detailed information about the technical documentation

and safety-related information can be found in the operating
instructions for the WP121L / WP151L Marine.
1.2 Target group

These maintenance instructions are aimed at all personnel who perform
work with or on the Sauer-Compressor, e.g.:
n Servicing work
n Inspection
n Maintenance
n Care
Personnel who carry out this work must have read and understood the main-
tenance instructions first.
Actions or activities that are not described in this documen-

tation may only be carried out by Sauer-Service or by spe-
cialist personnel authorised by J.P. Sauer & Sohn Maschi-
nenbau GmbH.
1.3 Sauer-Service
In case of technical questions and any queries regarding spare parts orders,
maintenance and repairs, contact Sauer-Service.

For any enquiries to Sauer-Service, have the following specifications for the
Sauer-Compressor to hand:
n Compressor type
n Serial number
n Year of construction
The specifications can be found on the nameplate of the Sauer-Compressor.
Contact
Postal address: J.P. SAUER & SOHN

Maschinenbau GmbH
Sauer-Service
Postfach 92 13
24157 Kiel, Germany
Telephone (international):
Technical information: +49 431 39 40 -87
Spare parts orders: +49 431 39 40 -86/886
Telefax (international): +49 431 39 40 -89
Emergency service 24/7 (interna- +49 172 4 14 63 94
tional):
E-mail: service@sauercompressors.de
Web: www.sauercompressors.com

PREPARING FOR MAINTENANCE
2 Preparing for maintenance

This chapter summarises the general preparations that are necessary before
any maintenance work.
2.1 Installation conditions

The following conditions must be met:
n The installation location must be dry and free from dust.
n Ensure that the installation location is ventilated in such a way that the
heat generated during operation can be extracted.
n The room temperature must be within the range defined in the technical
data. Ä Operating Instructions, "Technical data" chapter
n The Sauer-Compressor must be easily accessible at all times.
2.2 Requirements for maintenance work
Personnel qualification
Service personnel
Personnel authorised to service the compressor must be trained technical
specialists employed by the operator and the manufacturer.
Required personal pro-

tective equipment
Hearing protection
Wear protective equipment to protect the hearing against damage, predomi-
nantly caused by excessively loud noises.
Protective gloves
Wear protective gloves.
Safety boots
Wear safety boots.
Safety goggles
Wear protective equipment to protect the eyes against harmful influences.

Work clothing
Wear clothing to prevent against harmful influences.
Required tools
Crane and lifting gear
Crane and appropriate lifting gear (e. g. chains, cross beam) with sufficient
load bearing capacity.
Measuring beaker
Measuring beaker for measuring out operating materials, e.g. oil.
Oil injector
Oil injector for feeding in small quantities of operating materials, e.g. preser-
vation oil.
Required materials
"Staburags N12" grease
Preservation oil
In line with the specifications in the oil recommendations for Sauer-Compres-
sors.
Table of tightening tor- Data Value Unit

ques
Connecting rod bolts 70 Nm
Flywheel fixing screw 350 Nm
Cylinder head nuts for compression stages 75 Nm
Cable socket knurled screw 1.7 Nm
2.3 Ordering spare parts

Order the Sauer spare parts or Sauer maintenance kits required for the
maintenance work from Sauer-Service. Specify the following information in
the order:
n Part number
The part number for Sauer spare parts can be found in the spare parts
catalogue.
The part numbers for maintenance kits can be found in the maintenance
schedule in the maintenance instructions.
n Main specifications of the Sauer‑Compressor
The main specifications for the Sauer‑Compressor are shown on the
nameplate.
n Number of operating hours

The spare parts catalogue and operating instructions are

also available on CD. To save time, you can fill out the order
form contained therein, print it and send it off.
Compressor type:
Serial number:
Year of construction:
Only genuine Sauer spare parts

– are subject to continuous quality assurance and ongoing
development. conform to the latest technical develop-
ments.
– guarantee the long service life of your Sauer-Com-
pressor.
– meet the conditions of warranty by J.P. Sauer & Sohn
Maschinenbau GmbH.
2.4 Basic activities
WARNING!
Risk of injury when working on the Sauer-Compressor
If the Sauer-Compressor is not shut down, depressurised
and secured against being restarted, there is a significant
risk of injury when working on it.
– Before starting any work, shut down the Sauer-Com-
pressor and secure it against being restarted.
– Make sure that the system is depressurised.
WARNING!
Danger when working on live parts
There is a significant risk of injury when working on electrical
connections and the live parts of the Sauer-Compressor.
– Only carry out work on live parts of the Sauer-Com-
pressor when the power supply is disconnected and
secured against being reconnected.
– All work on the electrical system may only be carried out
by specialist electricians.
– Secure live cables against direct contact.
– Install live cables in line with the applicable standards
and directives.

WARNING!
Risk of injury due to electric fault currents
Electrical faults such as short-circuits can result in significant
injuries.
– Make sure that safety equipment to detect short circuits
and disconnect all connection phases are properly
installed.
– Ensure that the operator network has the required level
of protection.
WARNING!
Hazard due to missing or incorrectly assembled safety
equipment
Missing or incorrectly assembled safety equipment can
result in serious injuries.
– During maintenance work, safety equipment may only be
removed and re-assembled by trained and authorised
personnel.
– Before recommissioning after maintenance, assemble all
covers, unions and safety equipment in line with the
specifications.
– After assembly, check the function of covers, unions and
safety equipment.
Before starting any maintenance work:

n Turn off the Sauer-Compressor power supply and secure against being
turned on again.
n Put up “Attention! Maintenance work!” sign on the power supply.
n Mark the cylinders and cylinder heads to ensure they are in the same
installation position when assembled.
During maintenance work:
n All gaskets and sealing rings that are touched, exposed or removed
during maintenance work must be replaced and disposed of in an envi-
ronmentally friendly manner.
n Clean all exposed sealing surfaces.
n For unions, lubricate the threads with EO-Niromont assembly paste.
n Tighten unions with no specified tightening torques as follows:
– Tighten the union until there is a perceptible increase in force, then
mark the position of the union.
– Securely tighten the union by a further 30° (use the marking as a
guide).

The following further applies for cutting ring unions:

A visible gap must remain between the union nut and the
adaptor straight tube to boss after the cutting ring union has
been tightened. This gap becomes smaller every time the
cutting ring union is loosened and tightened again. If a gap is
no longer visible during tightening of the cutting ring union,
the union can no longer be sufficiently tightened and will
leak. The cutting ring union and the pipeline must then be
replaced.
After completion of all maintenance work:

n Remove "Attention! Maintenance work!" sign.
n Turn on the power supply to the Sauer-Compressor.
n Perform an inspection 50 operating hours after all maintenance work.
Check all screws affected by maintenance work to see if they are tight.

MAINTENANCE
3 Maintenance
These maintenance instructions describe the necessary maintenance work
involved in preventive servicing of the Sauer-Compressor.
The maintenance schedule provides you with an overview of the successive
maintenance intervals, the maintenance work to be carried out and the
required Sauer Easy Care maintenance kits.
The maintenance work is explained step by step in the following sections of
the maintenance instructions.
3.1 Maintenance schedule

The maintenance schedule is used as a guideline and to document the
maintenance work carried out.
1. Use the maintenance schedule as a template to be copied, or save it
as a digital document in an appropriate format.
2. Compare the regular operating hours of the Sauer-Compressor with
the maintenance intervals. The maintenance intervals can be found in
the left-hand column of the maintenance schedule.
3. Determine the maintenance work (scheduled maintenance work at the
maintenance interval). The maintenance work appears in the left-hand
column.
4. Carry out the maintenance work and document this in the maintenance
schedule by entering the number of operating hours, date and signa-
ture.
When beginning a new maintenance schedule

n enter:
– Main specifications
– Date of commissioning
– Maintenance schedule number
– Date
– Number of operating hours completed
n tick: Start after initial commissioning/major overhaul

Maintenance schedule number: Compressor type: WP121L / WP151L Marine
Start of this maintenance schedule Type series: Passat
c After initial commissioning Compressor serial number:
c After major overhaul Serial number:
Date of maintenance: Year of construction:
Number of operating hours completed: Date of commissioning:
Order number: I
Maintenance interval by operating

hours
Maintenance work ⇨ 50 h after commissioning
⇨ 50 h after Maintenance interval I4

or repair
Maintenance intervals
I1: 1000 h or after one year of operation at the latest
I2: 2000 h or after two years of operation at the latest

I1 I2 I3 I4
I3: 3000 h or after three years of operation at the latest
*)
I4: 4000 h or after four years of operation at the latest
*)
Note! After the last interval, the maintenance routine begins again with I1. 069269A
069177A
069269A
069178A
Sauer Easy Care maintenance kits:
Ä Chapter 3.1.1 „Replacing the air filter insert“ on page 16 c c c c c

Ä Chapter 3.1.2 „Changing the oil“ on page 17 c c c c c c
Ä Chapter 3.1.3 „Cleaning the oil strainer“ on page 19 c
Checking the valves for compression stages 1 and 2
c
Ä Chapter 3.1.4 „Checking and replacing valves“ on page 20
Replacing the valves for compression stages 1 and 2
c
Replacing the valves for compression stage 3
c c
Ä Chapter 3.1.5 „Replacing the piston rings, gudgeon pins and
c
gudgeon pin bearings“ on page 24
Ä Chapter 3.1.6 „Replacing the flexible coupling ele-
c
ment“ on page 31
Ä Chapter 3.1.7 „Servicing the solenoid drain
c
valve“ on page 32

MAINTENANCE
Maintenance interval by operating

hours
Maintenance work ⇨ 50 h after commissioning
⇨ 50 h after Maintenance interval I4

or repair
Maintenance intervals
I1: 1000 h or after one year of operation at the latest
I2: 2000 h or after two years of operation at the latest

I1 I2 I3 I4
I3: 3000 h or after three years of operation at the latest
*)
I4: 4000 h or after four years of operation at the latest
*)
Note! After the last interval, the maintenance routine begins again with I1.
069269A
069177A
069269A
069178A
Sauer Easy Care maintenance kits:
Check in accordance with country-

specific regulations / recommended
Ä Chapter 3.1.8 „Checking the safety valves“ on page 34
after 4000 operating hours at the
latest
Observe manufacturer's operating
Servicing electric motor
instructions
Signature
(initials)
NOTICE!
Maintenance of the solenoid drain valve
The spare parts required for maintenance of the solenoid
drain valve are not included as part of the maintenance kit. If
required, please contact the Sauer-Service department.

3.1.1 Replacing the air filter insert
Personnel: n Service personnel
Protective equipment: n Protective gloves
n Work clothing
n Safety boots
1 2
1 3
1
4
1
Fig. 1: Air filter

1 Clamp
2 Air filter cap
3 Air filter insert
4 Air filter housing
1. Loosen clamps and remove the air filter cover.
2. Remove the air filter insert from the air filter housing.
3. Clean the air filter housing with a lint-free cloth.
4. Fit a new air filter insert in the air filter housing.
5. Attach the air filter cap and close the clamps.

MAINTENANCE
3.1.2 Changing the oil

Protective equipment: n Safety goggles
n Protective gloves
n Work clothing
n Safety boots
Fig. 2: Oil change

1 Oil filler cap
2 Oil dipstick
3 Oil drain valve
1. Unscrew the oil filler cap and remove it.
2. Place an oil spill pan with sufficient capacity underneath the oil drain
valve. Oil quantity: Ä Operating instructions, chapter "Technical data".
3. Open the oil drain valve.
4. Drain the oil completely.
5. Close the oil drain valve.
6. Pour in oil and check the oil level on the dipstick. The oil must be
between the upper and lower marks on the dipstick.
7. Screw on the oil filler cap.

3.1.2.1 Flushing process for switching from mineral oil to syn-
thetic oil
When switching from mineral oil to synthetic oil, the com-

pressor crankcase must be flushed with synthetic oil three
times.
Draining the mineral oil 1. Allow the compressor to run for approximately 15 minutes to warm up.
2. Switch the compressor off and secure it against being switched on
again.
3. Drain all of the mineral oil.
Flushing the com- 1. Fill the compressor with synthetic oil up to 3/4 of the regular oil sump
pressor capacity.
2. Switch the compressor on and allow it to run for about 15 min.
3. Switch the compressor off and secure it against being switched on
again.
4. Drain all of the synthetic oil.
5. Repeat this process two more times.
6. Fill the compressor with synthetic oil up to the regular oil sump
capacity.
ð The compressor is filled with synthetic oil and ready for operation.

MAINTENANCE
3.1.3 Cleaning the oil strainer

n Protective gloves
n Work clothing
n Safety boots
1 2 3 4 5 6 5 4
Fig. 3: Cleaning the oil strainer (Example: WP311L)

1 Union
2 Oil strainer
3 Crankcase (side sectional view)
4 Nut
5 Crankcase inspection cover
6 Crankcase (frontal sectional view)
1. Unscrew the nuts from one of the two crankcase inspection covers.
2. Remove crankcase inspection cover.
3. Loosen the union on the oil strainer.
4. Remove the oil strainer.
5. Clean the oil strainer with oil-dissolving fluid (petroleum) and blow out
with compressed air.
6. Remove the old inspection cover joint and carefully clean the sealing
surface.
7. Assemble the oil strainer using the union.
8. Place the new inspection cover joint on the crankcase sealing surface.
9. Fit the crankcase inspection cover.
10. Screw the nuts in and tighten them.

3.1.4 Checking and replacing valves
3.1.4.1 Preparatory work
n Protective gloves
n Work clothing
n Safety boots
NOTICE!
Damage due to faulty gaskets
Do not continue using used gaskets. Doing this will lead to
leakages within a short period of time.
– Only re-install valves, cylinder heads and cylinders with
new gaskets.
NOTICE!
Damage due to low quality spare parts
Installation of low quality spare parts may lead to leakages
and may cause substantial damage to the compressor.
– Use only genuine Sauer spare parts. They are precision
parts specially designed for these installation situations
with defined and tested dimensions and material charac-
teristics.
NOTICE!
Damage due to faulty valves
Do not repair used valves. Valves that have reached the end
of their service life must be replaced and disposed of.
– Use only genuine Sauer spare parts.
Valves are exposed to the greatest loads of all the parts of a

piston compressor. In order to achieve the guaranteed main-
tenance intervals, these valves are high-quality precision
parts, specially adapted to the individual compression units,
and their function is carefully checked before delivery.
If necessary, contact Sauer-Service.
1. Loosen the screw on the air filter flange and remove the air filter.
2. Unscrew and remove the pipe unions and hose lines at the cylinder
heads.

MAINTENANCE
3.1.4.2 Checking and replacing valves

Removing the compres-
sion stage 1 valve
1
2
3
Fig. 4: Removing the compression stage 1 valve

1 Studs
2 Hexagon nut with washer
3 Cylinder head
4 Valve
5 Ring gasket
6 Gasket
7 Cylinder
1. Unscrew the hexagon nut and remove the cylinder head.
2. Remove the valve from the cylinder.
3. Remove the ring gasket and gaskets and clean the sealing surfaces.
Checking the compres- Check the exterior of the valve for:

sion stage 1 valve
n damage
n coking
n oiling
n corrosion
n moisture
If necessary, establish the cause of the fault.
Installing the compres- 1. Place the new gasket centrally on the cylinder.
sion stage 1 valve
2. Place the valve on the gasket.
3. Place another gasket centrally on the valve.
4. Fit the ring gasket centrally on the valve.
5. Carefully slide the cylinder head over the studs and onto the cylinder.
6. Screw on the hexagon nuts with washers and tighten by hand.

sion stage 2 valve
1
2
4
5

1 Stud
2 Hexagon nut
3 Cylinder head
4 Valve
5 Gasket
6 Cylinder
1. Unscrew the hexagon nuts and remove the cylinder head.
3. Remove both gaskets and clean the sealing surfaces.

sion stage 2 valve
n damage
n coking
n oiling
n corrosion
n moisture
Installing the compres- 1. Slide a gasket over the studs and onto the cylinder.
sion stage 2 valve
2. Fit the valve inside the cylinder.
3. Fit a gasket over the studs onto the valve.
4. Place the other gasket centrally on the compression stage 2 valve.
6. Screw on the cylinder head nuts and finger-tighten.

MAINTENANCE

sion stage 3 valve

1 Stud
2 Hexagon nut
3 Cylinder head
4 Gasket
5 Valve
6 Ring gasket
7 Cylinder
1. Unscrew the hexagon nuts and remove the cylinder head.
3. Remove the gasket and the ring gasket and clean the sealing surfaces.

sion stage 3 valve
n damage
n coking
n oiling
n corrosion
n moisture
Installing the compres- 1. Insert a new ring gasket in the cylinder.

sion stage 3 valve
2. Place the valve on the cylinder.
3. Fit a gasket over the studs onto the valve.
5. Screw on the hexagon nuts and finger-tighten.

3.1.4.3 Final tasks
Final tasks 1. Screw the pipe unions and hose line back on the cylinder heads, but
do not tighten.
2. Tighten all the hexagon head screws on the cylinder head. Observe
the tightening torque.
Ä Chapter 2.2 „Requirements for maintenance work“ on page 7
3. Securely tighten the pipe unions and hose lines.
4. Place the air filter on the air filter flange and secure on the air filter
flange with the screw.
3.1.5 Replacing the piston rings, gudgeon pins and

gudgeon pin bearings
The instructions for replacing the piston rings, gudgeon pins

and gudgeon pin bearings are described as an example and
apply equally to all compression stages.

n Protective gloves
n Work clothing
n Safety boots
Special tool: n Crane and lifting gear
Materials: n "Staburags N12" grease
Removing cylinders Requirement: Cylinder head and valves have already been removed.
1. Loosen and unscrew the cylinder foot nuts.
2. Carefully pull the cylinders off the crankcase over the studs.
NOTICE!
Damage to the piston
The piston may be damaged if it strikes against the
crankcase while work is carried out on the cylinder or
connecting rod.
– Always support or hold the piston while work is car-
ried out.
3. Take off the cylinder foot gasket and dispose of it in an environmentally

sound manner.
4. Clean the sealing surfaces on the cylinder foot and crankcase.

MAINTENANCE
Replacing the gudgeon

pins and gudgeon pin 1
bearings
Fig. 7: Connecting rod with piston (example)

1 Piston
2 Gudgeon pin bearing
3 Gudgeon pin
4 Circlip
5 Connecting rod
Requirement: Cylinder heads, valves and cylinders have already been
removed.
1. Remove the circlips on the gudgeon pin.
2. Press the gudgeon pin out of the gudgeon pin bearing.
3. Remove the piston.
4. Press the gudgeon pin bearing out of the connecting rod eye using a
bearing press.
5. Clean and lubricate the connecting rod eye.
Use the oil used for operation of the Sauer-Com-

pressor to lubricate all affected components.
6. Clean the hole for the gudgeon pin in the piston.

7. Lubricate the hole for the gudgeon pin in the piston and the gudgeon
pin itself.
8. Press the new gudgeon pin bearing into the connecting rod eye.
9. Lubricate the gudgeon pin bearing.

Replacing the piston 1. Remove piston rings from the piston using piston ring pliers.
rings
NOTICE!
Damage due to faulty piston rings
Do not continue using used piston rings. Doing so will
lead to damage to the piston and cylinder liner within a
short period of time.
– Only re-install pistons with new piston rings.
2. Clean the pistons using an oil-dissolving fluid (e.g., kerosene).

3. Measure the cylinder wear as described in Ä Chapter 3.1.5.1
„Checking pistons and cylinders“ on page 28.
4. Insert new piston rings into the grooves on the piston using piston ring
pliers.
Note the correct position of the piston rings. Piston

rings with an asymmetrical cross section have a
marking on one of the surfaces. This marking must
point to the cylinder head during installation. Ensure
that the different piston rings are in the correct
sequence. The correct sequence can be found in the
spare parts catalogue.
5. Repeat steps 1 to 5 for all pistons.
Assembly 1. Fit a new circlip in the piston.

2. Slide the new gudgeon pin into the piston until the gudgeon pin eye is
not blocked when inserting.
3. Slide the connecting rod into the piston.
4. Press the gudgeon pin through the gudgeon pin bearing as far as the
circlip.
5. Fit the second new circlip.
6. Lubricate the pistons and cylinders.
7. Fit a new cylinder foot gasket for each cylinder.
8. Check that the joint gaps of the piston rings are offset.
The piston rings can be secured in position using lubri-

cating grease.
9. Hold together the piston rings with the tension band or using special
pliers.

MAINTENANCE
10.
NOTICE!
Damage due to tilting of the piston and the piston
rings
Tilted pistons and piston rings lead to damage to the
compressor.
– If there is too much resistance when assembling
the cylinder, check the position of the piston rings.
Slide the cylinder carefully over the pistons.

11. Lower the cylinder onto the cylinder flange surface on the crankcase.
12. Screw in and tighten the cylinder foot nuts.
13. Install the cylinder head and valve as described in Ä Chapter 3.1.4
„Checking and replacing valves“ on page 20.
Final tasks
1. Screw the pipe unions and hose lines back on the cylinder heads and
tighten by hand.
2. Securely tighten the cylinder head nuts. Observe the tightening torque.
Ä Chapter 2.2 „Requirements for maintenance work“ on page 7
3. Securely tighten the pipe unions and hose lines.

3.1.5.1 Checking pistons and cylinders
n Work clothing
n Safety boots
The term cylinder as used here also includes cylinder liners.
Compression unit has already been removed. Piston has already been dis-
assembled. Ä see "Replacing the piston rings, gudgeon pins and gudgeon
pin bearings"
1. Check the piston and cylinder for scoring marks and excessive wear.
2. If there is excessive wear, replace the parts.
Fig. 8: Cylinder surface in unused condition
Contact the Sauer-Service department of J.P. Sauer & Sohn

Maschinenbau GmbH if cylinders or pistons need to be
replaced.

MAINTENANCE
Measuring cylinder wear

This measurement can be made with used or new piston
rings.
1. 1st measurement:
Push the piston ring into the cylinder about 5 mm below the upper
edge of the cylinder and above the visible running surface of the piston
rings. Measure the end gap with a feeler gauge.
2. 2nd measurement:
Push the piston ring into the cylinder about 50 mm below the upper
edge of the cylinder and within the visible running surface of the piston
rings. Measure the end gap with a feeler gauge.
3. Calculate the difference between the gap clearances from the 1st and
2nd measurements, and compare this with the values in the permitted
gap clearance differences table.
Fig. 9: Cylinder wear measurement

1 approx. 5 mm below the upper edge of the cylinder
2 approx. 50 mm below the upper edge of the cylinder
1 2
Fig. 10: End gap

1 Piston ring
2 End gap
Piston diameter Permissible gap clearance differ-

ence
≥ 100 mm 0.45 mm
< 100 mm 0.30 mm
If the permissible gap clearance difference is exceeded, con-

tact Sauer-Service.

MAINTENANCE
3.1.6 Replacing the flexible coupling element

n Work clothing
n Safety boots
Fig. 11: Flexible coupling element

1 Crankcase
2 Hub, compressor side
3 Flexible coupling element
4 Hub, motor side
5 Spacer block
6 Electric motor
1. Support the compressor under the crankcase.
2. Unscrew the fixing screws for the electric motor.
3. Attach the motor at the lifting eyes using appropriate lifting gear.
ÄMotor weight: See rating plate on motor.
4. Carefully lift the electric motor using the lifting eyes.
5. Pull the electric motor carefully away from the crankcase.
6. Replace the flexible coupling element.
7. Carefully slide the electric motor onto the crankcase and screw in and
tighten the fixing screws on the electric motor.
8. Remove the support under the crankcase.

3.1.7 Servicing the solenoid drain valve
WARNING!
Risk of injury due to high pressure
Components are pressurised and can lead to significant inju-
ries (e. g. valves, pipes, hoses, pressure reducing valves,
strainers).
– Local health and safety laws, standards and regulations,
e. g., BGR 500, must be observed.
– Wear the specified personal protective equipment to
minimise the risk of injury.
WARNING!
Danger when working on live parts
There is a significant risk of injury when working on electrical
connections and the live parts of the Sauer-Compressor.
– Only carry out work on live parts of the Sauer-Com-
pressor when the power supply is disconnected and
secured against being reconnected.
– All work on the electrical system may only be carried out
by specialist electricians.
– Secure live cables against direct contact.
– Install live cables in line with the applicable standards
and directives.

n Work clothing
n Safety boots
An order-specific gasket set is required for this maintenance

work. Please contact the Sauer-Service department.

MAINTENANCE
4
4
8
9
9
10
Fig. 12: Solenoid drain valve (exploded drawing)

1 Hexagon nut
2 Threaded element
3 Coil
4 Inner hexagon socket head screws
5 Solenoid armature
6 Nozzle
7 Spring
8 Diaphragm
9 O-rings
10 Lower valve section
1. Unscrew the hexagon nut.
2. Carefully lift the threaded element with the screw-driver.
3. Remove the coil from the solenoid armature.
4. Loosen the four hexagon socket head screws.
5. Remove the upper section of the valve.
6. Replace the following parts:
n Spring
n Diaphragm
n O-rings
7. Unscrew the nozzle.
8. Clean the nozzle with compressed air.
9. Screw in the nozzle.
10. Attach the upper section of the valve. Screw in and tighten the four
hexagon socket head screws. Attach the coil to the solenoid armature.
11. Position the threaded element correctly and press it onto the solenoid
armature.

12. Carefully screw on the hexagon nuts by hand.
13. Slightly tighten the hexagon nuts.
3.1.8 Checking the safety valves
DANGER!
Risk of excess pressure build-up
Faulty or manipulated safety valves may lead to excess
pressure build-up. Excess pressure build-up may destroy the
system. In this case, there is a serious risk of death in the
vicinity of the system due to flying parts and escaping hot
gas, hot air or hot cooling water.
– Check the safety valves regularly and replace if faulty.
– Do not adjust, disable or remove safety valves.
The safety valves are sealed by the manufacturer to prevent tampering. The
construction of the safety valves means that they cannot be tested for func-
tion.
The operator must check the safety valves in accordance with country-spe-
cific guidelines and laws, and replace them as necessary.
J.P. Sauer & Sohn Maschinenbau GmbH offers a profes-

sional and qualified safety valve replacement service and
corresponding training for maintenance personnel. Please
contact Sauer-Service.
Carry out the following checks to detect any damage to safety valves:
n Check the safety valve and seal for signs of external damage.
n Check threaded connections for proper seating.
n Inspect attached parts and lines for damage.
Have damage to safety valves, attached parts and lines repaired immedi-
ately by the Sauer-Service department.

PRESERVATION
4 Preservation
This chapter describes the preservation work that is required before and
after storing the Sauer-Compressor for a long period.
4.1 Preservation for decommissioning of

longer than 12 weeks
If the Sauer-Compressor is scheduled to be decommissioned for longer than
12 weeks, J.P. Sauer & Sohn Maschinenbau GmbH recommends preserva-
tion with a preservation oil. If this preservation is carried out, periodic test
runs are not needed.
Use one of the preservation oils specified in the "Oil recom-

mendation for Sauer-Compressors".

Protective equipment: n Hearing protection
n Safety goggles
n Protective gloves
n Work clothing
n Safety boots
Special tool: n Measuring beaker
n Oil injector
Materials: n Preservation oil
1. Disconnect the power supply for the solenoid drain valves from the
compressor control.
ð The solenoid drain valves remain open.
2. Run the compressor for around 5 minutes with the solenoid drain
valves and pressure line open.
ð Any existing condensate is blown out.
3. Stop the compressor.
4. Drain the oil and dispose of in an environmentally sound manner.
5. Fill the compressor with preservation oil up to 3/4 of the regular oil
sump capacity.
6. Run the compressor for around 5 minutes with the solenoid drain
ð The preservation oil disperses in the oil circuit.
7. Stop the compressor.
8. Make sure that the Sauer-Compressor is depressurised. To do this,
check the pressure displays for the compression stages.
If there is any residual pressure, check whether all solenoid drain
valves are open.

9. Inject approx. 150 ml of preservation oil into the suction chamber of
compression stage 1.
10. Unscrew the pressure gauge on the cylinder head of compression
stage 2.
12. Disassemble the pressure gauge on the suction side flange from the
cylinder head of compression stage 3.
14. Re-assemble the pressure gauge.
15. Run the compressor for around 15 seconds with the solenoid drain
ð The preservation oil disperses in the oil circuit.
16. Turn off the Sauer-Compressor and secure against being turned on
again.
If fitted, turn off the main switch to disconnect the power to the Sauer-
Compressor and the compressor control.
17. Reconnect the power supply for the solenoid drain valves to the com-
pressor control.
18. Drain the preservation oil.
Dispose of oil in an environmentally sound manner.
19. Attach a warning sign to prevent the preserved compressor from being
started accidentally.

PRESERVATION
4.2 Commissioning after storage

If the maximum storage time is exceeded, the Sauer-Compressor must be
inspected for possible damage before commissioning.
NOTICE!
Damage to the Sauer-Compressor
The following work should be carried out independently with
the authorisation ofJ.P. Sauer & Sohn Maschinenbau GmbH.
Otherwise, contact the Sauer-Service department.

Protective equipment: n Hearing protection
n Work clothing
n Protective gloves
n Safety boots
Requirement: The Sauer-Compressor has been properly preserved and

stored.
1. Connect the power supply.
2. Fill the compressor with a specified oil.ÄOil recommendation
3. Perform commissioning according to the operating instructions.
4. Watch out for abnormal operating noise.
5. Compare the values displayed on the pressure gauges for each com-
pression stage with the specified setpoints in the technical data: Ä
Operating Instructions

INDEX
5 Index
M
Maintenance
air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
cylinder wear measurement . . . . . . . . . . . . 29
flexible coupling element . . . . . . . . . . . . . . 31
gudgeon pin bearings . . . . . . . . . . . . . . . . 24
gudgeon pins . . . . . . . . . . . . . . . . . . . . . . . 24
maintenance schedule . . . . . . . . . . . . . . . . 13
material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
oil change . . . . . . . . . . . . . . . . . . . . . . . . . 17
oil strainer . . . . . . . . . . . . . . . . . . . . . . . . . 19
personal protective equipment . . . . . . . . . . . 7
personnel qualification . . . . . . . . . . . . . . . . . 7
piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
piston rings . . . . . . . . . . . . . . . . . . . . . . . . 24
preparation . . . . . . . . . . . . . . . . . . . . . . . . . 7
safety valves . . . . . . . . . . . . . . . . . . . . . . . 34
solenoid drain valve . . . . . . . . . . . . . . . . . . 32
spare parts . . . . . . . . . . . . . . . . . . . . . . . . . 8
special tools . . . . . . . . . . . . . . . . . . . . . . . . . 8
tightening torque . . . . . . . . . . . . . . . . . . . . . 8
valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Maintenance schedule . . . . . . . . . . . . . . . . . . 13
P
Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . 35
decommissioning . . . . . . . . . . . . . . . . . . . . 35
recommissioning . . . . . . . . . . . . . . . . . . . . 37
S
Sauer-Service . . . . . . . . . . . . . . . . . . . . . . . . . . 5

PAS WP121L-WP151L Marine WAs - en - GB - 1804

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● High pressure com-

PASSAT Master Wartungsanleitung en GB 1804 | 3

These maintenance instructions and the associated oper-

More detailed information about the technical documentation

1.2 Target group

Actions or activities that are not described in this documen-

PASSAT Master Wartungsanleitung en GB 1804 | 5

Postal address: J.P. SAUER & SOHN

6 | PASSAT Master Wartungsanleitung en GB 1804

2 Preparing for maintenance

2.1 Installation conditions

2.2 Requirements for maintenance work

Required personal pro-

PASSAT Master Wartungsanleitung en GB 1804 | 7

Table of tightening tor- Data Value Unit

2.3 Ordering spare parts

8 | PASSAT Master Wartungsanleitung en GB 1804

The spare parts catalogue and operating instructions are

Only genuine Sauer spare parts

2.4 Basic activities

PASSAT Master Wartungsanleitung en GB 1804 | 9

Before starting any maintenance work:

10 | PASSAT Master Wartungsanleitung en GB 1804

The following further applies for cutting ring unions:

After completion of all maintenance work:

PASSAT Master Wartungsanleitung en GB 1804 | 11

3.1 Maintenance schedule

When beginning a new maintenance schedule

PASSAT Master Wartungsanleitung en GB 1804 | 13

Maintenance interval by operating

⇨ 50 h after Maintenance interval I4

I2: 2000 h or after two years of operation at the latest

Ä Chapter 3.1.1 „Replacing the air filter insert“ on page 16 c c c c c

14 | PASSAT Master Wartungsanleitung en GB 1804

Maintenance interval by operating

⇨ 50 h after Maintenance interval I4

I2: 2000 h or after two years of operation at the latest

Check in accordance with country-

PASSAT Master Wartungsanleitung en GB 1804 | 15

Fig. 1: Air filter

16 | PASSAT Master Wartungsanleitung en GB 1804

3.1.2 Changing the oil

Fig. 2: Oil change

PASSAT Master Wartungsanleitung en GB 1804 | 17

When switching from mineral oil to synthetic oil, the com-

18 | PASSAT Master Wartungsanleitung en GB 1804

3.1.3 Cleaning the oil strainer

Fig. 3: Cleaning the oil strainer (Example: WP311L)

PASSAT Master Wartungsanleitung en GB 1804 | 19

Valves are exposed to the greatest loads of all the parts of a

20 | PASSAT Master Wartungsanleitung en GB 1804

3.1.4.2 Checking and replacing valves

Fig. 4: Removing the compression stage 1 valve

Checking the compres- Check the exterior of the valve for:

PASSAT Master Wartungsanleitung en GB 1804 | 21

Fig. 5: Removing the compression stage 2 valve

Checking the compres- Check the exterior of the valve for:

22 | PASSAT Master Wartungsanleitung en GB 1804

Removing the compres-

Fig. 6: Removing the compression stage 3 valve

Checking the compres- Check the exterior of the valve for:

Installing the compres- 1. Insert a new ring gasket in the cylinder.

PASSAT Master Wartungsanleitung en GB 1804 | 23