Sauer WP 33 L User manual

Sauer
Compressor
Type: WP 33 L
Operator Manual
High-pressure Compressor
2 Stages
Air-cooled

WP33L_BA_Titel_en_08.fm
Edition: 11 / 2008
Edited by: J.P. Sauer & Sohn Maschinenbau – Technical Documentation
WP33L_BA_Titel_en_08.fm

Zertifikate_en_0.fm
Sauer compressor Type Approvals
Note!
On this page only a few examples are shown. FurtherType Ap-
provals are available on request.

Zertifikate_en_0.fm
Genuine Sauer spare parts –
certified safety
SPECIMEN

WP33L_BA_en_08_IVZ.fm
5
Table of Contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Warrenty and Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Type Approval and genuine Sauer spare parts . . . . . . . . . . . . . . . . . . . . . 10
1.5 J.P. SAUER & SOHN customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6 Specific instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Conditions of use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Unauthorised moditifaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Safety information - Warning & Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Safety warnings on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5 Safety and protection devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6 Noise protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.7 Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.8 Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.9 Personal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Indicators for the Sauer compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4 Compressor Control System - Indicators and Control . . . . . . . . . . . . . . . . . 27
4 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 Specification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2 P&I Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6
WP33L_BA_en_08_IVZ.fm
5 Transport and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2 Storage before Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.4 Connecting the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.5 Stop/Start pressure switch setting(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.6 Filling with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.7 Installation checks and before the initial start . . . . . . . . . . . . . . . . . . . . . . . 42
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.1 Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2 Operation modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.3 Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.4 Routine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7 Troubleshouting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.1 Maintenance and Service by J.P. SAUER & SOHN . . . . . . . . . . . . . . . . . . 50
8.2 Maintenance safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.4 Table of tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.5 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.6 Checking screw connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.7 Air Intake filter cartridge cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.8 Checking valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.9 Checking the piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.10 Replacing gudgeon pins / bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.11 Replacing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.12 Checking pistons and cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.13 Checking the drive bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.14 Replacing the connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.15 Checking the coupling and replacing the coupling insert . . . . . . . . . . . . . . 70
8.16 Checking the oil / water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.17 Checking the safety valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

WP33L_BA_en_08_IVZ.fm
7
9 Storage, Preservation - “lay-up“ procedure . . . . . . . . . . . . . . . . . . . . . . 73
9.1 Safety when storing and removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.2 Temporary preservation & storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9.3 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10 Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10.1 Lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10.2 Preservation oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11 Spare Parts and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
12 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

8
WP33L_BA_K1_12_en_08.fm
1 General
1.1 Foreword
This Operator Manual provides installation guidance, safe oper-
ation, maintenance and repair instructions with illustrated parts
breakdown.
The following unique specification for the Sauer Compressor can
be found on the nameplate affixed to the compressor:
– compressor type
– serial number
– year of construction
We recommend you record this information in Chapter 11, “Spare
Parts and Accessories”, and always provide this data when re-
questing parts and any repair instructions.
1.2 Precautions
Specific
precautions
We recommend that only authorised and trained personnel Op-
erate and Service the Sauer Compressor. Such responsible per-
sonnel should be thoroughly familar with, and frequently review,
the Operator Manual.
These instructions should always be readily available at the com-
pressor installation.
Copyright The copyright for these instructions remains with J.P. SAUER &
SOHN. These instructions, or parts thereof, shall not be copied,
distributed or made available to third parties. Contravention will
result in prosecution.
WP33L_BA_K1_12_en_08.fm

General
WP33L_BA_K1_12_en_08.fm
9
1.3 Warranty and Liability
Sauer can no longer cover warranty, be liable for any claims, if a
failure is attributed to any of the following:
– use of the machine not as specified;
– substitution of parts not manufactured or approved by Sauer;
– use of spare parts that are not genuine Sauer spare parts;
– operation of the machine with faulty or improperly installed
safety and/or protection devices;
– disregard of the operating instructions;
– unauthorised modification to the machine or its control system;
– inadequate monitoring of machine parts subject to wear;
– failure to maintain/repair in accordance with Sauer instruc-
tions;
– force majeure.

10
WP33L_BA_K1_12_en_08.fm
1.4 Type Approval and genuine Sauer spare parts
• The Type Approval for the Sauer Compressor is valid under
the condition that parts and components specified and quali-
fied by J.P. SAUER & SOHN are used. The Type Approval is
provided by the Classification Society and the EC Declaration
of Conformity or EC Manufacturer's Declaration. Disregard for
the “specifications“ may cause the Type Approval to expire.
• Only the use of genuine Sauer spare parts will ensure compli-
ance with these ’specfications’ and, therefore, reliable and
safe operation of the Sauer Compressors.
• If non-genuine Sauer spare parts are used, we reserve the
right of exclusion from liability for personal injury and material
damage.
• Genuine Sauer spare parts are supplied with a Certificate of
Conformity and a Certificate of Authenticity. An example of this
document is shown just before the Table of Contents in these
instructions. If spare parts are received without this certificate,
there is a risk that these are not genuine Sauer spare parts. In
such an istance please contact our Customer Service.
Note!
Be aware this is a high-pressure compressor, for your own safe-
ty and for reliable compressor operation, only unse genuine
Sauer parts.
Do not use parts from the
“grey market“!
Only use genuine Sauer spare parts
supplied with a Certificate!
Correct Incorrect