Main Air Compressor WP 200

● High pressure com‐
pressor
● Water-cooled
MAINTENANCE INSTRUCTIONS
Sauer-Compressors
Type: WP200 Marine
Series: Typhoon
EN 12 | 2020 www.sauercompressors.com
Original maintenance instructions
Edition: 10 / 12 / 2020
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................................................................... 6
2 Preparing for maintenance................................................................ 7
2.1 Installation conditions....................................................... 7
2.2 Requirements for maintenance work................................ 7
2.3 Ordering spare parts......................................................... 9
2.4 Basic activities.................................................................. 9
3 Maintenance..................................................................................... 13
3.1 Replacing the air filter insert........................................... 17
3.2 Changing the oil.............................................................. 18
3.2.1 Flushing process when changing the oil type................. 19
3.3 Cleaning the oil strainer.................................................. 20
3.4 Checking and replacing valves....................................... 21
3.4.1 Preparatory work............................................................ 21
3.4.2 WP200 and WP240........................................................ 22
3.4.3 Final tasks....................................................................... 24
3.5 Replacing the piston rings, gudgeon pins and gudgeon
pin bearings.................................................................... 24
3.5.1 Checking pistons and cylinders...................................... 35
3.6 Replacing the flexible coupling element......................... 38
3.7 Servicing the solenoid drain valves................................ 39
3.8 Servicing the cooling water solenoid valve..................... 42
3.9 Cleaning the particle trap................................................ 43
3.10 Replacing the sacrificial zinc anode................................ 44
3.11 Checking the safety valves............................................. 45
3.12 Checking the cooling water safety valve......................... 46
4 Preservation..................................................................................... 49
4.1 Preservation for decommissioning of longer than 12
weeks.............................................................................. 49
4.2 Commissioning after storage.......................................... 51
5 Index.................................................................................................. 53
Typhoon Master Wartungsanleitung en GB 20201210 | 3

4 | Typhoon Master Wartungsanleitung en GB 20201210
GENERAL
1 General
1.1 Foreword
These maintenance instructions describe how to maintain the Sauer-Com-
pressor WP200 Marine and provide maintenance personnel with the fol-
lowing essential information:
n Performing maintenance
n Checking components
n Replacing components
These maintenance instructions and the associated opera-

ting 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 WP200 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 operating hours and the fol-
lowing 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
Brauner Berg 15
24159 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. ÄOperating 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
Assembly paste
Separating agent for connecting points and sliding surfaces that are exposed
to very tough environmental conditions.
Preservation oil
In line with the specifications in the oil recommendations for Sauer-Compres-
sors.
Table of tightening tor-

ques All specifications relate to factory lubricated screws and nuts
relevant for maintenance.
Specification Tightening torque

Connecting rod bolts 115 Nm
Flywheel fixing screw 550 Nm
Compression stage 1 / compression 82 Nm
stage 2 valve cover nuts
Compression stage 2 valve cover 7.5 Nm
locking screw
Compression stage 1 cooler cover 30 Nm
screws (M8)
screws (M8)
screws (M8)
screws (M12)
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 number 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
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.
NOTICE!
Make sure that the system is depressurised.
Check the pressure on the pressure gauges. Only start
maintenance work once no further pressure is indicated.

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 fitted safety equip-
ment
Missing or incorrectly fitted safety equipment can result in
serious injuries.
– During maintenance work, safety equipment may only be
removed and re-refitted by trained and authorised per-
sonnel.
– Before recommissioning after maintenance, fit all contact
protection, unions and safety equipment in line with the
specifications.
– After fitting, check the function of contact protection,
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 Innotec Ceramic Grease 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).
In addition, for cutting ring unions:

After tightening the cutting ring union, a visible gap must
remain between the union nut and the adaptor fitting. 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 ensure 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.
The maintenance schedule is used as a guideline and to document the

maintenance work.
1. Use the maintenance schedule as a template to be copied, or save it
as a digital document in an appropriate format.
2. Regularly compare the operating hours of the Sauer-Compressor with
the maintenance intervals. The maintenance intervals can be found in
the header of the maintenance schedule.
3. Determine the maintenance work scheduled for the given maintenance
interval. The maintenance work appears in the header 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 initial commissioning
– Maintenance schedule number
– Date
– Number of operating hours completed
n Tick off: Starting after initial commissioning/major overhaul

Maintenance schedule number: Compressor type: WP200 Marine
Start of this maintenance schedule Series: Typhoon
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 initial commissioning:
Order number: I
Maintenance interval by operating

hours
Maintenance work ⇨ 50 h after initial 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 work begins again with I1. 069229A
069230A
069229A
069231A
Sauer Easy Care maintenance kit
Ä Chapter 3.1 ‘Replacing the air filter insert’ on page 17 c c c c

Ä Chapter 3.2 ‘Changing the oil’ on page 18 c c c c c c
Ä Chapter 3.3 ‘Cleaning the oil strainer’ on page 20 c
Checking the valve compression stage 1
c c
Ä Chapter 3.4 ‘Checking and replacing valves’ on page 21
Replacing compression stage 1 valve
c c
Replacing compression stage 2 valve
c c c c
Ä Chapter 3.5 ‘Replacing the piston rings, gudgeon pins and
c
gudgeon pin bearings’ on page 24
Ä Chapter 3.6 ‘Replacing the flexible coupling element’
c
on page 38
Ä Chapter 3.7 ‘Servicing the solenoid drain valves’ on page 39 c
Ä Chapter 3.8 ‘Servicing the cooling water solenoid valve’
c
on page 42
Ä Chapter 3.9 ‘Cleaning the particle trap’ on page 43 c c c c

MAINTENANCE
Maintenance interval by operating

hours
Maintenance work ⇨ 50 h after initial 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 work begins again with I1.
069229A
069230A
069229A
069231A
Sauer Easy Care maintenance kit
Ä Chapter 3.10 ‘Replacing the sacrificial zinc anode’

c
on page 44
Check in accordance with country-
specific regulations or after 4000
Ä Chapter 3.11 ‘Checking the safety valves’ on page 45
operating hours at the latest recom-
mended
Ä Chapter 3.12 ‘Checking the cooling water safety valve’
on page 46 (Fresh-water cooling)
c
(Optional: Replace bursting disc if fitted. See information directly
below this table for details.)
Observe manufacturer's operating
Service electric motor
instructions
Signature
(initials)
NOTICE!
Replace bursting disc if fitted
Irrespective of the maintenance interval for the cooling water
safety valve, the bursting disc must be replaced at every
maintenance interval.
The maintenance kits for compressors with a bursting disc
differ from the maintenance kits with a cooling water safety
valve.
If required, please contact the Sauer-Service department.

Recommendation
J.P. Sauer & Sohn Maschinenbau GmbH recommends that
you have your compressor inspected by Sauer-Service or by
personnel specially trained by J.P. Sauer & Sohn Maschi-
nenbau GmbH after 5000 operating hours or after five years
of operation at the latest.
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.
NOTICE!
Maintenance of the cooling water solenoid valve
The spare parts required for maintenance of the cooling
water solenoid valve are not included as part of the mainte-
nance kit. If required, please contact the Sauer-Service
department.
NOTICE!
Maintenance of the cooling water safety valve
The spare parts required for maintenance of the cooling
water safety valve are not included as part of the mainte-
nance kit. If required, please contact the Sauer-Service
department.

MAINTENANCE
3.1 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.

3.2 Changing the oil
CAUTION!
Hazard due to contact with lubricant, oils and conden-
sate containing oil
Contact with lubricants and oils can result in injury when
working on the Sauer-Compressor.
– Wear the specified personal protective equipment to
minimise the risk of injury.
– Wash affected areas of skin immediately with suitable
cleaning agent and running water.
– In case of contact with the eyes or mucous membranes,
immediately wash the affected areas under running
water.

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

1 Oil filler cap
2 Dipstick
3 Oil drain valve
1. Place an oil container with sufficient capacity underneath the oil drain
valve.
Oil quantity: Ä Operating instructions, chapter "Technical data"
2. Unscrew the oil filler cap.

MAINTENANCE
3. Open the oil drain valve.

4. Drain oil completely into the oil spill pan.
5. Close the oil drain valve.
6. Pour in new oil and check the oil level with the dipstick. The oil level
must be between the upper and lower marks.
7. Insert the dipstick and screw the oil filler cap back in.
3.2.1 Flushing process when changing the oil type
NOTICE!
Damage due to mixing mineral oil and synthetic oil
types
Mixtures of mineral oil and synthetic oil types must not be
used for compressor operation.
– When changing the oil type, the compressor’s crankcase
must be flushed three times with the new oil type.
Draining the compressor 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. Place an oil container with sufficient capacity underneath the oil drain
valve.
4. Drain off all the oil and dispose of in an environmentally sound manner.
Flushing the com- 1. Fill the compressor with the new oil type up to 3/4 of the regular oil
pressor filling quantity.
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 oil.
5. Repeat the "Flushing the compressor" process twice more.
Filling the compressor 1. Fill the compressor with the new oil type up to the regular oil filling
quantity.
2. Switch on the compressor.
ð The compressor is ready for operation.

3.3 Cleaning the oil strainer
n Protective gloves
n Work clothing
n Safety boots
Material: n Assembly paste
1 2 3 4 5 6 7 5 4 6
Fig. 3: Cleaning the oil strainer

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

MAINTENANCE
3.4 Checking and replacing valves

3.4.1 Preparatory work
n Protective gloves
n Work clothing
n Safety boots
Material: n Assembly paste
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.
The replaced O-rings can be secured in position using

grease.
1. On versions with air filter: Loosen the clamp on the air filter flanges
and remove the air filter.
2. Disconnect hoses and pipelines at the valve covers.

3.4.2 WP200 and WP240
Removing the valve
compression stage 1
Fig. 4: Valve compression stage 1

1 Valve cover nut
2 Stud
3 Forcing screw M10
4 O-ring
5 Gasket
6 Valve cover
7 Valve
1. Unscrew the valve cover nuts.
2. Screw M10 screws into both forcing threads and press the valve cover
off.
3. Remove the valve cover.
4. Take out the o-ring and gasket and dispose of in an environmentally
sound manner.
5. Carefully remove the valve.
Checking compression Check the exterior of the valves for:

stage 1 valves
n damage
n coking
n oiling
n corrosion
n moisture
Replace valves that are damaged, heavily coked or corroded. Do not
open the valves.
If necessary, establish the cause of the fault.

MAINTENANCE
Installing the valves on 1. Clean all sealing surfaces.

compression stage 1
2. Replace valves according to the instructions in the maintenance
schedule.
3. Carefully insert the new valve in the cylinder.
4. Insert a new o-ring and a new gasket.
5. Fit the valve cover on the cylinder and screw on the valve cover nuts
hand tight.
Removing the valve

compression stage 2
Fig. 5: Valve compression stage 2

1 Stud
2 Valve cover nut
3 Forcing screw M10
4 Hexagon head screw
5 O-ring
6 Valve cover
7 O-ring
8 Valve
1. Unscrew the valve cover nuts.
2. Screw M10 screws into both forcing threads and press the valve cover
off.
3. Remove the valve cover.
4. Take out the o-ring and gasket and dispose of in an environmentally
sound manner.
5. Loosen the hexagon head screw and carefully remove the valve.

Checking the valve com- Check the exterior of the valve for:
pression stage 2
n damage
n coking
n oiling
n corrosion
n moisture
Replace valves that are damaged, heavily coked or corroded.
If necessary, establish the cause of the fault.
Installing the valve com- 1. Clean all sealing surfaces.

pression stage 2
2. Replace valve according to the instructions in the maintenance
schedule.
3. Carefully insert the new valve in the cylinder.
4. Insert a new o-ring and gasket.
5. Fit the valve cover on the cylinder and screw on the valve cover nuts
hand tight.
3.4.3 Final tasks

1. Fit the hoses and pipelines on the valve covers, but do not tighten
them.
2. Fully tighten the valve cover nuts crosswise. Observe the tightening
torque. Ä Chapter 2.2 ‘Requirements for maintenance work’ on page 7
3. Securely tighten the hoses and pipelines.
4. Fit the air filters on the compression stage 1 cylinders.
3.5 Replacing the piston rings, gudgeon

pins and gudgeon pin bearings
n Protective gloves
n Work clothing
n Safety boots
Tool: n Crane and lifting gear

MAINTENANCE
Draining the cooling

water
1. Provide a container with sufficient capacity or a suitable outlet for the
cooling water (at least 30 litres).
Fig. 6: Draining the cooling water

1 Plug compression stage 2
2 Plug compression stage 1
2. Close the cooling water inlet and outlet.
3. Unscrew the plug on the underside of the cylinder, allow the cooling
water to drain into the container or outlet provided and dispose of in an
environmentally sound manner.
4. Remove the ring gasket from the plug and dispose of in an environ-
mentally sound manner.
5. Securely tighten the plug with new ring gasket.
Removing cylinders Requirement: Valve cover and valves have already been removed, cooling
water has been drained. Ä Chapter 3.4 ‘Checking and replacing valves’
on page 21
1. Disconnect hose lines and pipelines from all cylinder units.
2. Unscrew the nuts from the studs on the two crankcase inspection
covers.
3. Remove the two crankcase inspection covers.

4. Remove the old seals on the crankcase inspection covers and flanges
and carefully clean the sealing surfaces.
5.
NOTICE!
Note the position and alignment of the connecting rods
on the crankshaft (e.g., with markings on the upper
sections of the connecting rods).
The connecting rods must be reinstalled in the same
position and alignment to ensure optimal lubrication
during operation.
Unscrew the connecting rod bolts and, together with the lower con-
necting rod bearings, remove the lower connecting rod sections from
the crankcase (Ä Fig. 9).
6. Screw two lifting eye nuts (thread size M16) onto the grub screws on
the valve cover fastening.
Sling and secure the cylinder unit to suitable lifting gear (min. load
bearing capacity 100 kg) by the lifting eye nuts.
7. When removing the relevant compression stage, turn the crankshaft so
that the associated piston extends as far as possible upwards into the
cylinder.
8. Unscrew the hexagon nuts for securing the cylinder units on the crank-
case.

MAINTENANCE
9.
DANGER!
Risk of injury due to suspended load
The heavy weight of the load means that there is a sig-
nificant risk of injury during transportation.
– Ensure that no personnel are within the danger
area of the suspended load and the transport
equipment.
– Only use appropriate transport and lifting equip-
ment for the load.
– Only lift the load at the lifting eyes provided.
J.P. Sauer & Sohn Maschinenbau GmbH recommends

that the following work steps are performed by 2 per-
sons.
Secure the piston with connecting rod on the associated cylinder unit
and carefully lift the cylinder unit along with the piston and connecting
rod carefully using appropriate lifting gear (load bearing capacity min.
100 kg).
NOTICE!
Hold the connecting rods in such a way that they do
not strike against the crankcase or cylinder wall and do
not slide with the piston from the cylinder.
The upper connecting rod bearings may fall during
lifting. In this case, remove the connecting rod bear-
ings from the crankcase and check for damage. Com-
pletely replace any damaged connecting rod bearings.
When lifting the cylinder unit, do not damage the studs.
10. Carefully set down the cylinder unit with piston and connecting rod on
its side on a soft surface.
11. Carefully pull the piston and connecting rod for the compression stages
out of the cylinder liner. Do not tilt the piston.
12. Remove the cylinder foot gasket and o-rings and clean the sealing sur-
faces.

Removing gudgeon pins
Fig. 7: Piston compression stage 1

1 Piston
2 Gudgeon pin bearing
3 Gudgeon pin
4 Circlip
5 Connecting rod

MAINTENANCE
Fig. 8: Piston compression stage 2

1 Piston
2 Gudgeon pin bearing
3 Gudgeon pin
4 Circlip
5 Connecting rod
Requirement: Piston and connecting rods have already been removed.

1. Remove the gudgeon pin circlips with circlip pliers and press the
gudgeon pin out of the gudgeon pin bearing. Do not strike out the
gudgeon pin under any circumstances.
2. Remove the piston.
Removing the piston Requirement: Piston and connecting rods have already been separated.
rings and cleaning the
1. Remove all piston rings from the piston using piston ring pliers.
piston
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. Measure the cylinder liner wear as described in Ä Chapter 3.5.1

‘Checking pistons and cylinders’ on page 35.
3. Clean the piston ring grooves and the gudgeon pin bore.

Replacing piston rings, Requirement: Piston and connecting rods have already been separated.
gudgeon pins and
gudgeon pin bearings 1. Press the gudgeon pin bearing out of the connecting rod eye using a
for compression stages bearing press.
2. Clean the connecting rod eye and lubricate it with the oil used for ope-
rating the Sauer-Compressor.
3. Lubricate the hole for the gudgeon pin in the piston and the new
gudgeon pin with the oil used for operating the Sauer–Compressor.
4. Press a new gudgeon pin bearing into the connecting rod eye and
lubricate the gudgeon pin bearing with the oil used for operating the
Sauer–Compressor.
5. Fit a new circlip in the piston with circlip pliers.
It must be possible to turn the circlip in the groove. If

the circlip is not seated correctly in the groove, there is
a risk of consequential damage.
6. Insert new piston rings into the grooves on the piston using piston ring
pliers.
Observe the position of the piston rings. Piston rings

with an asymmetrical cross section have a marking on
one of the surfaces. This marking must face towards
the valve cover when the piston ring is installed.
7. Position the piston rings so that the joint gaps are offset evenly. The
joint gaps must not be arranged one above the other.
It must be possible for the piston rings to turn in the

piston ring groove.
The piston rings can be secured in position using

grease.
8. Press the gudgeon pin into the piston so that the connecting rod can
still be pushed into the piston.
9. Position the hole for the gudgeon pin in the piston and gudgeon pin
bearing flush in the connecting rod eye and press the gudgeon pin
through it as far as the circlip.
10. Fit a second new circlip in the piston with circlip pliers.
11. Repeat the steps for all pistons.
12. The subsequent steps are only performed when assembling the cyl-
inder unit and crankcase.

MAINTENANCE
Assembly
1. Clean the crankshaft and lubricate it with the oil used for operating the
Sauer-Compressor.
2. Lubricate the piston and cylinder liner with the oil used for Sauer-Com-
pressor operation.
3. Check that the joint gaps for the piston rings are evenly offset.
4. Hold together the piston rings with the tension band or using special
pliers.
5. Carefully insert the piston into the cylinder liner in the cylinder unit. Do
not tilt the piston.
If there is too much resistance on insertion, check the

position of the piston rings.
6. Repeat steps 2 to 5 for all pistons.

7. Slide the piston with connecting rod into the relevant cylinder liner until
the piston is completely in the cylinder liner.
8. Fit the o-ring on the associated cylinder liner.
9. Secure the pistons and connecting rods.
10. Screw two lifting eye nuts (thread size M16) onto the grub screws on
the valve cover fastening of a cylinder unit.
11. Sling and secure the cylinder unit to suitable lifting gear (min. load
bearing capacity 100 kg) by the lifting eye nuts.

12.
DANGER!
Risk of injury due to suspended load during trans-
portation.
The heavy weight of the system component means
that there is a significant risk of injury during transpor-
tation.
– Ensure that no personnel are within the danger
area of the suspended load and the transport
equipment.
– Only use appropriate transport and lifting equip-
ment to transport the system component.
– Only lift the system component at the eye bolts
provided.
– Secure the system component against slipping and
tilting, particularly when driving on slopes and
ramps.
– Observe the specific details of the weight and
centre of gravity of the system component in the
installation drawing.
NOTICE!
Damage caused by incorrect position and align-
ment of the connecting rods
Take note of the position and alignment of the con-
necting rods on the crankshaft (e.g., with prior mark-
ings on the upper sections of the connecting rods).
The connecting rods must be installed in the same
position and alignment as they were in before they
were removed. Otherwise, optimal lubrication during
operation cannot be guaranteed.
NOTICE!
Damage caused by loose components
Secure the connecting rods in such a way that they do
not strike against the cylinder wall and do not slide with
the piston from the cylinder.
The upper connecting rod bearings may fall. Insert the
upper connecting rod bearings only when the respec-
tive connecting rod is guided towards the crankshaft.
Do not damage the studs when fitting the cylinder units
onto the bare compressor.
J.P. Sauer & Sohn Maschinenbau GmbH recommends

that the following work steps are performed by 2 per-
sons.
13. Carefully lift the cylinder unit and then carefully guide the upper section
of the connecting rod and the upper connecting rod bearing onto the
crankshaft.

MAINTENANCE
14. Carefully fit the upper section of the connecting rod with the upper con-
necting rod bearing on the crankshaft.
15. Carefully place the cylinder unit on the bare compressor.
16. Screw the retaining nuts onto the studs and tighten by hand.
17. Repeat the steps with the other cylinder unit.
Fig. 9: Numerical marking on connecting rod

1 Numerical marking
2 Connecting rod bolt
3 Lower connecting rod bearing
4 Connecting rod (lower half)
18. Mount the lower connecting rod section and lower connecting rod
bearing on the connecting rod in such a way that the numerical
marking on the upper and lower section lie on top of one another in
each case.

19. Carefully and evenly screw in the connecting rod bolts by hand and
then tighten by hand.
NOTICE!
Damage caused by incorrect positioning of the
connecting rod
The only way to ensure that the connecting rods are
positioned correctly on the crankshaft is to fit them as
specified and carefully screw them in by hand.
After tightening, all connecting rods should rotate
easily on the crankshaft.
20. Turn the crankshaft through a complete revolution by turning the fly-
wheel and check that the connecting rod rotates easily on the crank-
shaft.
21. If the connecting rod does not rotate easily on the crankshaft, loosen
the connecting rod bolts again and repeat steps 13 to 16.
22. Tighten the connecting rod bolts using the specified tightening torque
Ä Chapter 2.2 ‘Requirements for maintenance work’ on page 7.
23. Tighten the retaining nuts for the cylinder unit crosswise using the
specified tightening torque Ä Chapter 2.2 ‘Requirements for mainte-
nance work’ on page 7.
24. Remove the lifting gear from the cylinder unit.
25. Turn the flywheel so that the crankshaft completes one full revolution
to ensure that nothing is jammed.
26. Fit the crankcase inspection cover with a new gasket.
27. Insert the new gasket and o-ring for the valve cover, slightly greasing
the o-ring.
28. Install the valve cover, screwing the valve cover nuts hand tight.
Final tasks 1. Attach the hoses and pipelines at the cylinder heads and tighten by
hand.
2. Securely tighten the fixing nuts on the valve cover crosswise. Observe
the tightening torque: Ä Chapter 2.2 ‘Requirements for maintenance
work’ on page 7.
3. Securely tighten the hoses and pipelines.
4. Open the cooling water inlet and cooling water outlet.
5. Open the cooling water solenoid valve for filling.

MAINTENANCE
3.5.1 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
removed Ä Chapter 3.5 ‘Replacing the piston rings, gudgeon pins and
gudgeon pin bearings’ on page 24.
1. Check the piston and cylinder for scoring marks and excessive wear.
2. If there are excessive scoring marks, replace the parts.
Fig. 10: Cylinder surface in unused condition
Contact the Sauer-Service department at J.P. Sauer & Sohn

Maschinenbau GmbH if cylinders or pistons need to be
replaced.
During the measurement make sure that the piston rings are
parallel with one another. To do this, use the piston
belonging to the cylinder without piston rings as a depth
stop.

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 end gaps from the 1st and
2nd measurements, and compare this with the values in the permitted
end gap differences table.
Fig. 11: Cylinder wear measurement

MAINTENANCE
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. 12: 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
Contact the Sauer-Service of J.P. Sauer & Sohn Maschi-

nenbau GmbH if the mechanical seal needs to be replaced.

3.6 Replacing the flexible coupling element
WARNING!
Risk of burns from hot surfaces.
The cylinders, motor, pressure lines and cooling water piping
have hot surfaces. Contact with hot surfaces can cause
serious injuries.
– Keep a safe distance away from the Sauer-Compressor.
– Allow the Sauer-Compressor to cool down before begin-
ning maintenance work.

n Work clothing
n Safety boots
Fig. 13: Flexible coupling element

1 Electric motor
2 Hub
3 Flexible coupling element
4 Crankcase
1. Shut down the compressor and secure it against restarting.
2. Support the compressor under the bell housing.
3. Unscrew the fixing screws for the electric motor.
4. Attach the motor to appropriate lifting gear at the eye bolts. ÄMotor
weight: See nameplate on motor.

MAINTENANCE
DANGER!
Risk of injury due to suspended load
The weight of the motor means that there is a significant risk
of injury when lifting and transporting the motor.
– Ensure that no personnel are within the danger area of
the suspended load and the transport equipment.
– Only use appropriate transport and lifting equipment to
lift and transport the motor.
– Only lift the motor at the eye bolts provided.
– Observe the motor's centre of gravity.
5. Carefully lift the electric motor using the eye bolts.

6. Pull the electric motor carefully away from the crankcase.
7. Replace the flexible coupling element.
8. Carefully slide the motor against the crankcase.
9. Screw in and tighten the motor fixing screws.
10. Remove the support under the bell housing.
3.7 Servicing the solenoid drain valves

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.
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.
4
4
6 7
9
10
10
11
Fig. 14: Solenoid drain valve (exploded drawing)

1 Knurled screw
2 Threaded element
3 Coil
4 Inner hexagon socket head screw
5 Solenoid armature
6 Nozzle
7 Upper valve section
8 Spring
9 Diaphragm
10 O-ring
11 Lower valve section
1. Drain the cooling water as described in Ä ‘Draining the cooling water’
on page 25.
2. Unscrew the knurled screw.
3. Remove the threaded element.
4. Remove the coil from the solenoid armature.
5. Loosen the four hexagon head screws.

MAINTENANCE
6. Remove the upper section of the valve.

7. Replace the following parts:
n Spring
n Diaphragm
n O-rings
8. Unscrew the nozzle.
9. Clean the nozzle with compressed air.
10. Screw in the nozzle.
11. Fit the upper section of the valve and check that the direction of flow is
correct. Observe the arrows on the upper and lower section of the
valve.
12. Screw in and tighten the four hexagon head screws. Attach the coil to
the solenoid armature.
13. Fit the threaded element.
14. Screw on the knurled screw.

3.8 Servicing the cooling water solenoid
valve
n Work clothing
n Safety boots
An order-specific gasket set is required for this maintenance

work. Please contact the Sauer-Service department.
4
4
6 7
9
10
10
11
Fig. 15: Cooling water solenoid valve exploded drawing

1 Knurled screw
2 Threaded element
3 Coil
4 Inner hexagon socket head screw
5 Solenoid armature
6 Nozzle
7 Upper valve section
8 Spring

MAINTENANCE
9 Diaphragm
10 O-ring
11 Lower valve section
1. Drain the cooling water as described in Ä ‘Draining the cooling water’
on page 25.
2. Drain the cooling water out through the plugs underneath compression
unit 1.1 and compression stage 2.
3. Unscrew the knurled screw.
4. Remove the threaded element.
5. Remove the coil from the solenoid armature.
6. Loosen the four hexagon head screws.
7. Remove the upper section of the valve.
8. Replace the following parts:
n Spring
n Diaphragm
n O-rings
9. Unscrew the nozzle.
10. Clean the nozzle with compressed air.
11. Screw in the nozzle.
12. Fit the upper section of the valve and check that the direction of flow is
correct. Observe the arrows on the upper and lower section of the
valve.
13. Screw in and tighten the four hexagon head screws. Attach the coil to
the solenoid armature.
14. Fit the threaded element.
15. Screw on the knurled screw.
3.9 Cleaning the particle trap

n Protective gloves
n Work clothing
n Safety boots
Cleaning the particle 1. Provide a container with sufficient capacity or a suitable outlet for the
trap cooling water (at least 30 litres).
3. Unscrew the cap on the particle trap, allow the cooling water to drain
into a container or outlet provided for this purpose, and dispose of in
an environmentally sound manner.
4. Take the strainer out of the particle trap.

5. Clean the strainer.
6. Fit the strainer in place and screw the cap on.
3.10 Replacing the sacrificial zinc anode

n Work clothing
n Safety boots
Replacing the sacrificial 1. Provide a container with sufficient capacity or a suitable outlet for the
zinc anode cooling water (up to 30 litres).
3. Unscrew and replace sacrificial zinc anodes.
4. Screw in the plugs with new ring gaskets.

MAINTENANCE
3.11 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. There is then 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 in the case of water-cooled compres-
sors.
– Check the safety valves regularly and replace if faulty.
– Do not adjust, disable or remove safety valves.
CAUTION!
Risk of injury from safety equipment
Direct contact with safety valves can result in injury. When
blowing off a safety valve, hot air or hot gas escapes at high
pressure.
– Avoid direct contact with the safety valves and maintain
a safe distance from them.
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 Check attached parts and lines for damage.
Have damage to safety valves, attached parts and lines repaired immedi-
ately by the Sauer-Service department.

3.12 Checking the cooling water safety
valve
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. There is then 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 in the case of water-cooled compres-
sors.
– 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 and replace the safety valves in accordance with
country-specific guidelines and laws.

sional and qualified safety valve replacement service and
NOTICE!
Replace bursting disc if fitted
Irrespective of the maintenance interval for the cooling water
safety valve, the bursting disc must be replaced at every
maintenance interval.
The maintenance kits for compressors with a bursting disc
differ from the maintenance kits with a cooling water safety
valve.
If required, please contact the Sauer-Service department.

n Protective gloves
n Work clothing
n Safety boots
Removing the cooling

water safety valve for
external inspection

MAINTENANCE
1. Provide a container with sufficient capacity or a suitable outlet for the

cooling water (up to 30 litres).
4. Screw the plug back in with a new ring gasket.
5. Loosen and unscrew the socket head cap screws on the cooling water
safety valve.
6. Remove the cooling water safety valve from the cooler housing.
7. Remove the old gasket.
8. Clean the sealing surface.
9. Check the exterior of the cooling water safety valve for:
n calcification
n contamination
Replace heavily calcified or contaminated cooling water safety valve.
10. Fit a new gasket.
11. Fit a cooling water safety valve on the cooler housing, screw in the
socket head cap screws and tighten.
Optional:
Replacing the cooling water
bursting disc

sional and qualified bursting disc replacement service and

3. Screw the plug back in with a new ring gasket.
4. Loosen and unscrew the socket head cap screws on the bursting disc
cover.
5. Remove the cover and bursting disc from the cooler housing.
6. Remove the old gasket.
7. Clean the sealing surface.
8. Fit a new gasket.
9. Fit a new bursting disc.
10. Fit the cover on the cooler housing, screw in the socket head cap
screws and tighten.

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
Tool: n Measuring beaker
n Oil injector
Material: n Preservation oil
1. Disconnect the power supply for the solenoid drain valve from the com-
pressor control.
ð The solenoid drain valve will remain open.
2. Run the compressor for around 5 minutes with the solenoid drain valve
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. Ä Chapter 3.2 ‘Changing the oil’ on page 18
6. Run the compressor for around 5 minutes with the solenoid drain valve
and pressure line open.
ð The preservation oil disperses in the compressed air 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 the solenoid drain
valve is open.

9. Remove the air filter
10. Spray approx. 150 ml of preservation oil into the compression unit 1
suction connector.
11. Unscrew the valve locking screw on the compression stage 2 valve
cover.
12. Spray approx. 70 ml of preservation oil into the compression stage 2
intake opening.
13. Screw the valve locking screw back in with a new ring gasket.
Ä Chapter 2.2 ‘Requirements for maintenance work’ on page 7
14. Fit the air filter.
15. Run the compressor for around 15 seconds with the solenoid drain
valve and pressure line open.
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.
Ensure that the oil is disposed of or treated 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 of J.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
A T
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Tightening torques . . . . . . . . . . . . . . . . . . . . . . 8
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
C
Cooling water safety valve . . . . . . . . . . . . . . . 46 V
Cooling water solenoid valve . . . . . . . . . . . . . 42 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
cylinder wear measurement . . . . . . . . . . . . . . 36
F
Flexible coupling element . . . . . . . . . . . . . . . . 38
G
Gudgeon pin . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Gudgeon pin bearing . . . . . . . . . . . . . . . . . . . 24
M
Maintenance
maintenance schedule . . . . . . . . . . . . . . . . 13
Maintenance schedule . . . . . . . . . . . . . . . . . . 13
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
O
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Oil strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
P
Particle trap . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Personal protective equipment . . . . . . . . . . . . . 7
Personnel qualification . . . . . . . . . . . . . . . . . . . 7
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . 49
decommissioning . . . . . . . . . . . . . . . . . . . . 49
recommissioning . . . . . . . . . . . . . . . . . . . . 51
S
Sacrificial zinc anode . . . . . . . . . . . . . . . . . . . 44
Safety valves . . . . . . . . . . . . . . . . . . . . . . . . . 45
Solenoid drain valve . . . . . . . . . . . . . . . . . . . . 39
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Main Air Compressor WP 200

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● High pressure com‐

Typhoon Master Wartungsanleitung en GB 20201210 | 3

These maintenance instructions and the associated opera-

More detailed information about the technical documentation

1.2 Target group

Actions or activities that are not described in this documen-

Typhoon Master Wartungsanleitung en GB 20201210 | 5

Postal address: J.P. SAUER & SOHN

6 | Typhoon Master Wartungsanleitung en GB 20201210

2 Preparing for maintenance

2.1 Installation conditions

2.2 Requirements for maintenance work

Required personal pro-

Typhoon Master Wartungsanleitung en GB 20201210 | 7

Table of tightening tor-

Specification Tightening torque

8 | Typhoon Master Wartungsanleitung en GB 20201210

2.3 Ordering spare parts

Only genuine Sauer spare parts

2.4 Basic activities

Typhoon Master Wartungsanleitung en GB 20201210 | 9

Before starting any maintenance work:

10 | Typhoon Master Wartungsanleitung en GB 20201210

In addition, for cutting ring unions:

After completion of all maintenance work:

Typhoon Master Wartungsanleitung en GB 20201210 | 11

The maintenance schedule is used as a guideline and to document the

When beginning a new maintenance schedule

Typhoon Master Wartungsanleitung en GB 20201210 | 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 ‘Replacing the air filter insert’ on page 17 c c c c

14 | Typhoon Master Wartungsanleitung en GB 20201210

Maintenance interval by operating

⇨ 50 h after Maintenance interval I4

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

Ä Chapter 3.10 ‘Replacing the sacrificial zinc anode’

Typhoon Master Wartungsanleitung en GB 20201210 | 15

16 | Typhoon Master Wartungsanleitung en GB 20201210

3.1 Replacing the air filter insert

Fig. 1: Air filter

Typhoon Master Wartungsanleitung en GB 20201210 | 17

Personnel: n Service personnel

Fig. 2: Oil change

18 | Typhoon Master Wartungsanleitung en GB 20201210

3. Open the oil drain valve.

3.2.1 Flushing process when changing the oil type

Typhoon Master Wartungsanleitung en GB 20201210 | 19

Fig. 3: Cleaning the oil strainer

20 | Typhoon Master Wartungsanleitung en GB 20201210

3.4 Checking and replacing valves

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

The replaced O-rings can be secured in position using

Typhoon Master Wartungsanleitung en GB 20201210 | 21

Fig. 4: Valve compression stage 1

Checking compression Check the exterior of the valves for:

22 | Typhoon Master Wartungsanleitung en GB 20201210

Installing the valves on 1. Clean all sealing surfaces.

Removing the valve

Fig. 5: Valve compression stage 2

Typhoon Master Wartungsanleitung en GB 20201210 | 23

Installing the valve com- 1. Clean all sealing surfaces.