Sauer WP5000 Series Manuel utilisateur
●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
WP5000 Basic WA 41013675 en GB 20190916 | 3
4 | WP5000 Basic WA 41013675 en GB 20190916
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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6 | WP5000 Basic WA 41013675 en GB 20190916
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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//RJRJ&&DQRDQRH&LUFH&LUFOHOH
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TeTelleepphhoonene LLQWQWHUQHUQDWDWLRLRQQDODO
410-410-604-3142604-3142
E-E-maimaill::seservrviicece@@sasaueruuerussa.ca.coomm
WeWebb::wwwww.sauerusw.sauerusaa..ccomom
8 | WP5000 Basic WA 41013675 en GB 20190916
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
WP5000 Basic WA 41013675 en GB 20190916 | 9
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
10 | WP5000 Basic WA 41013675 en GB 20190916
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