Sauer WP5000 Series User manual

●High pressure com‐
pressor
●Sea-water-cooled
M A I N T E N A N C E I N S T R U C T I O N S
Sauer-Compressors
Type: WP5000N
Order no. 41013675 | Series: WP5000
EN 09 | 2019 www.sauerusa.com

Original maintenance instructions
Edition: 16 / 09 / 2019
Edited by: Sauer USA – Technical Documentation

Table of contents
1 General................................................................................................ 5
1.1 Foreword........................................................................... 5
1.2 Target group...................................................................... 5
2 Sauer-Service..................................................................................... 7
3 Preparing for maintenance................................................................ 9
3.1 Installation conditions....................................................... 9
3.2 Requirements for maintenance work................................ 9
3.3 Ordering spare parts....................................................... 10
3.4 Basic activities................................................................ 11
3.5 Draining and refilling cooling water................................. 13
4 Maintenance..................................................................................... 17
4.1 Maintenance schedule.................................................... 17
4.1.1 Changing the oil and cleaning the oil strainer................. 19
4.1.2 Replacing air filter inserts............................................... 22
4.1.3 Checking the valves of compression stages 1 and 2...... 24
4.1.4 Replacing the valves for compression stages 1 and 2... 29
4.1.5 Replacing the valves for compression stages 3 and 4... 30
4.1.6 Replacing the piston rings, gudgeon pins and gudgeon
pin bearings.................................................................... 33
4.1.7 Servicing the solenoid drain valve compression
stage 1............................................................................ 43
4.1.8 Servicing the solenoid drain valve compression
stage 2............................................................................ 45
4.1.9 Servicing pneumatic drain valves................................... 47
4.1.10 Servicing the cooling water solenoid valve..................... 49
4.1.11 Cleaning the cooler inserts............................................. 52
4.1.12 Replacing the sacrificial zinc anode................................ 55
4.1.13 Replacing the bursting discs........................................... 57
4.1.14 Checking the safety valves............................................. 59
5 Preservation..................................................................................... 61
5.1 Preservation for decommissioning of longer than
12 weeks......................................................................... 61
5.2 Commissioning after storage.......................................... 63
6 Index.................................................................................................. 65
TABLE OF CONTENTS
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1 General
1.1 Foreword
These maintenance instructions describe how to maintain the Sauer-Com-
pressor WP5000 and provide maintenance personnel with the following
essential information:
nPerforming maintenance
nChecking components
nReplacing 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
authorized by Sauer USA.
More detailed information about the technical documentation
and safety-related information can be found in the operating
instructions for the WP5000.
1.2 Target group
These maintenance instructions are aimed at all personnel who perform
work with or on the Sauer-Compressor, e. g.:
nServicing work
nInspection
nMaintenance
nCare
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 authorized by Sauer USA.
GENERAL
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2 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:
nCompressor type
nSerial number
nYear of construction
These specifications can be found on the nameplate on the crankcase of the
Sauer-Compressor.
SAUER-SERVICE
WP5000 Basic WA 41013675 en GB 20190916 | 7
ContactContact
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TeTelleepphhoonene LLQWQWHUQHUQDWDWLRLRQQDODO
410-410-604-3142604-3142
E-E-maimaill::seservrviicece@@sasaueruuerussa.ca.coomm
WeWebb::wwwww.sauerusw.sauerusaa..ccomom

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3 Preparing for maintenance
This chapter summarises the general preparations that are necessary before
any maintenance work.
3.1 Installation conditions
The following conditions must be met:
nThe installation location must be dry and free from dust.
nEnsure that the installation location is ventilated in such a way that the
heat generated during operation can be extracted.
nThe room temperature must be within the range defined in the technical
data. ÄOperating Instructions, "Technical data" chapter
nThe Sauer-Compressor must be easily accessible at all times.
3.2 Requirements for maintenance work
Service personnel
Personnel authorised to service the compressor must be trained technical
specialists employed by the operator and the manufacturer.
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.
Personnel qualification:
Required personal pro-
tective equipment
PREPARING FOR MAINTENANCE
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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.
Preservation oil
In line with the specifications in the oil recommendations for Sauer-Compres-
sors.
Specification Tightening torque
Connecting rod bolts 90 Nm
Cylinder foot nuts 175 Nm
Hexagon head screws for valve
cover of compression
stages 1, 2 and 3
115 Nm
Hexagon head screws for valve
cover of compression stage 4
250 Nm
Socket head cap screws on the
cooler
110 Nm
Safety valve for compression
stage 1, 2 , 3 and 4
160 Nm
Bursting disc flange screws 75 Nm
Sacrificial zinc anodes 150 Nm
3.3 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:
nPart number
The part number for Sauer spare parts can be found in the spare parts
catalogue.
nMain specifications of the Sauer‑Compressor
The main specifications for the Sauer‑Compressor are shown on the
nameplate.
nNumber of operating hours
Required tools:
Required material:
Table of tightening tor-
ques
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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 Sauer USA.
3.4 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.
PREPARING FOR MAINTENANCE
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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:
nTurn off the Sauer-Compressor power supply and secure against being
turned on again.
nPut up “Attention! Maintenance work!” sign on the power supply.
nMark the cylinders and cylinder heads to ensure they are in the same
installation position when assembled.
During maintenance work:
nAll 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.
nClean all exposed sealing surfaces.
nFor unions, lubricate the threads with Innotec Ceramic Grease assembly
paste.
nTighten 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).
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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:
nRemove "Attention! Maintenance work!" sign.
nTurn on the power supply to the Sauer-Compressor.
nPerform an inspection 50 operating hours after all maintenance work.
Check all screws affected by maintenance work to see if they are tight.
3.5 Draining and refilling cooling water
Some maintenance measures require the cooling water to
be drained. This process and the refilling will be described in
the following section.
PREPARING FOR MAINTENANCE
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Fig. 1: Cooling water piping compression stage 1
1 Plug
2 Ring gasket
3 Cooling water piping
The cooling system for the compressor consists of 4 sets of cooling water
piping, which connect the cylinders and the cooler. An angle flange is
located on both ends of each cooling water piping. Two sets of cooling water
piping are fitted with a plug at both ends, and two are fitted with a plug at
one end only. To drain the cooling water, it is sufficient to unscrew the bottom
plug in each cooling water piping.
1. Provide collection containers with sufficient capacity or a suitable outlet
for the cooling water (up to 50 litres).
2. Close cooling water inlet and outlet and secure against being opened
again.
3. Use the pressure gauge to make sure that the cooling system is dep-
ressurised.
4. Unscrew the lower plugs on all four sets of cooling water piping and
allow the cooling water to drain into the containers provided or the
outlet.
5. Remove old ring gaskets and dispose of in an environmentally sound
manner
6. Clean all sealing surfaces.
7. Screw all plugs in again with new ring gaskets.
Draining the cooling
water
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1. Open the cooling water supply.
ðThe cooling circuit fills up with cooling water.
2. Open the cooling water outlet.
3. Unscrew the upper plugs in the cooling water piping and allow the
water to flow until no bubbles are in the escaping water.
4. Screw the upper plugs back in using new ring gaskets.
Fill with cooling water
PREPARING FOR MAINTENANCE
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MAINTENANCE
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4
4.1
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 SauerEasyCare maintenance kits.
The maintenance work is explained step by step in the following sections of
the maintenance instructions.
Maintenance schedule
The maintenance schedule is used as a guideline and to document the
maintenance work. Please refer to maintenance schedule provided with
package from Sauer USA.
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 header of the maintenance schedule.
3. Determine the maintenance routine (scheduled maintenance work at
the maintenance interval). The maintenance work appears in the
header column.
4. Carry out the maintenance routine and document this in the mainte-
nance schedule by entering the number of operating hours, date and
signature.
When beginning a new maintenance schedule
nenter:
– Main specifications
– Date of commissioning
– Maintenance schedule number
– Date
– Number of operating hours completed
ntick: Start after initial commissioning/major overhaul
NOTICE!
Always check the compressor after 50 hours following any
maintenance work. Check all screws and nuts affected by
maintenance to see if they are tight.
NOTICE!
Sauer offers maintenance kits that include all of the necessary
equipment needed for each overhaul. For more information,
please contact [email protected].

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4.1.1 Changing the oil and cleaning the oil strainer
Personnel: nService personnel
Protective equipment: nSafety goggles
nProtective gloves
nWork clothing
nSafety boots
MAINTENANCE
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Fig. 2: oil change
1 Oil filler
2 Crankcase inspection cover
3 Hexagon head screw
4 Gasket
5 Pressure test threading
6 Tube
7 Tube o-ring
8 Oil pipe
9 Thread fitting
10 Oil strainer
11 Oil dipstick
12 Oil drain valve
1. Place an oil spill pan with sufficient capacity (Ä Technical data in the
operating instructions) under the oil drain valve in the crankcase.
2. Unscrew the oil filler cap to ventilate.
3. Loosen the union nut and remove the locking cone.
4. Open the oil drain valve.
ðOil drains into the oil spill pan provided
5. Drain the oil completely.
6. Close the oil drain valve.
Draining the oil
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