WP320L WP460L

● High pressure com-
pressor
● 3-stage
● Air-cooled
MAINTENANCE INSTRUCTIONS
Sauer-Compressors
Type: WP320L / WP460L Marine
Series: Levante
EN 07 | 2018 www.sauercompressors.com
Translation of the original maintenance instructions
Edition: 07 / 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
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....................................................... 11
3.4 Basic activities................................................................ 12
3.5 Assembling and disassembling the guard grating.......... 15
4 Maintenance..................................................................................... 21
4.1 Maintenance schedule.................................................... 21
4.1.1 Replacing the air filter insert........................................... 24
4.1.2 Changing the oil.............................................................. 25
4.1.3 Replacing the oil filter..................................................... 26
4.1.4 Replacing the oil strainer................................................ 27
4.1.5 Replacing valves............................................................. 28
4.1.6 Replacing the piston rings, gudgeon pins and gudgeon
pin bearings.................................................................... 33
4.1.7 Replacing the flexible coupling element......................... 40
4.1.8 Servicing the solenoid drain valve.................................. 41
4.1.9 Replacing the safety valves............................................ 43
4.1.10 Replacing sensors.......................................................... 46
4.1.11 Replacing pressure gauge hoses................................... 51
4.1.12 Replacing the drain hose................................................ 53
4.1.13 Replacing the high pressure hose.................................. 54
5 Preservation..................................................................................... 55
5.1 Preservation for decommissioning of longer than 12
weeks.............................................................................. 55
5.2 Commissioning after storage.......................................... 57
6 Index.................................................................................................. 59
LEV_BRE_CYC Master WA en GB 1807 | 3

4 | LEV_BRE_CYC Master WA en GB 1807
GENERAL
1 General
1.1 Foreword
These maintenance instructions describe how to maintain the Sauer-Com-
pressor WP320L / WP460L 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 WP320L / WP460L 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.

SAUER-SERVICE
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:
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
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:
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.
3.2 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.
Strap spanner
Required materials
EO-Niromont assembly paste
Lubricating grease
High-temperature lubricating grease, e.g., Staburags N12.
Preservation oil
In line with the specifications in the oil recommendations for Sauer-Compres-
sors.

Table of tightening tor- Data Value Unit

ques
G3/4 safety valve 160 Nm
Flywheel fixing screws1) 75 Nm
Cylinder head nuts for compression stages 75 Nm
1 and 2
Cylinder head nuts for compression stage 3 90 Nm
Connecting rod bolts 70 Nm
Cable socket knurled screw 1.7 Nm
Cylinder foot nuts for compression stages 75 Nm
Oil strainer 125 Nm
Flange screws for electric motor 130 Nm
Fixing screws of the flexible coupling ele- 49 Nm
ment.
Fastening for solenoid drain valve coil 25 Nm
Temperature sensor union 35 Nm
Oil pressure sensor and final pressure 25 Nm
sensor union
1) Retighten each flywheel fixing screw 3x.
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).
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:
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 it contains, 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 J.P. Sauer & Sohn Maschinenbau GmbH war-
ranty conditions.
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.

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.

3.5 Assembling and disassembling the

guard grating
For maintenance work on the compressor unit, the guard grating can be par-
tially removed.
Disassembling the side Personnel: n Service personnel
section of the guard gra-
Protective equipment: n Safety goggles
ting (option)
n Protective gloves
n Work clothing
n Safety boots
Fig. 1: Opening the quick release locks (example of WP460L Marine)

1 Side section
2 Quick release locks
1. Open the side section of the guard grating:
Open the quick release locks in the direction indicated by the arrow.

Fig. 2: Removing the side section of the guard grating (example of WP460L
Marine)

1 Side section
2. Open the side section of the guard grating out and remove it upwards.
The smaller side sections of the guard grating can be

disassembled in the same way.
ð The compressor unit is accessible for maintenance work.

3. Close the side section of the guard grating:
Insert the lower clip on the side section in the guard grating.
4. Push the side section of guard grating upwards and engage the quick
release locks.
Disassembling the front

cover
Fig. 3: Disassembling the front cover (example of WP460L Marine)

2 Front cover
1. Open the quick release locks.

2.
The front cover is held in place by clips at the top.
Swing the front cover out at the bottom unclip it at the top.
ð The compressor unit is accessible from the front.
Re-assemble the front cover in the reverse order.
Opening the top section

of the guard grating
Fig. 4: Opening the top section of the guard grating (example of WP460L
Marine)
2 Top section of the guard grating
1. Open the quick release locks.
2. Open the top section of the guard grating.
ð The compressor unit is accessible from above.

The top section is closed in the reverse order.

MAINTENANCE
4 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 kit.
The maintenance work is explained step by step in the following sections of
the maintenance instructions.
4.1 Maintenance schedule

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. 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: WP320L / WP460L Marine
Start of this maintenance schedule Type series: Levante
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 work Maintenance interval

by operating hours
⇨ 50 h after commissioning
Maintenance intervals I1 I2 I3 I4
I1: 1000 h or after one year of operation at the latest
I2: 2000 h or after two years of operation at the latest
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.
Sauer Easy Care maintenance kits: WP320L
(069637*) (069632*)
069630
069631
069630
069677
069635
069636
069635
069681
Ä Chapter 4.1.1 „Replacing the air filter insert“ on page 24 c c c c c

Ä Chapter 4.1.2 „Changing the oil“ on page 25 c c c c
Ä Chapter 4.1.3 „Replacing the oil filter“ on page 26 c c c c c
Ä Chapter 4.1.4 „Replacing the oil strainer“ on page 27 c c
Ä Chapter 4.1.5 „Replacing valves“ on page 28 c c
Ä Chapter 4.1.6 „Replacing the piston rings, gudgeon pins and gudgeon pin c
bearings“ on page 33
Ä Chapter 4.1.7 „Replacing the flexible coupling element“ on page 40 c
Ä Chapter 4.1.8 „Servicing the solenoid drain valve“ on page 41 c c
Ä Chapter 4.1.9 „Replacing the safety valves“ on page 43 c
Ä Chapter 4.1.10 „Replacing sensors“ on page 46 1) c
Ä Chapter 4.1.11 „Replacing pressure gauge hoses“ on page 51 c
Ä Chapter 4.1.12 „Replacing the drain hose“ on page 53 c
Ä Chapter 4.1.13 „Replacing the high pressure hose“ on page 54 c

MAINTENANCE
Maintenance work Maintenance interval

by operating hours
⇨ 50 h after commissioning
Maintenance intervals I1 I2 I3 I4
I1: 1000 h or after one year of operation at the latest
I2: 2000 h or after two years of operation at the latest
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.
(069637*) (069632*)
069630
069631
069630
069677
069635
069636
069635
069681
*) Optional maintenance kit for compressors with switches
1) Sensors are installed as standard. If the compressor is shipped with switches according to the
optional configuration, no maintenance work is required in this respect.
Signature
(initials)

4.1.1 Replacing the air filter insert
Personnel: n Service personnel
Protective equipment: n Protective gloves
n Work clothing
n Safety boots
Fig. 5: Air filter

1 Clamp
2 Air filter cap with air filter insert
3 Air filter housing
1. Loosen the clips and remove the air filter cap with air filter insert.
2. Clean the air filter housing with a lint-free cloth.
3. Fit a new air filter cap with air filter insert in the air filter housing.
4. Fasten the clips.

MAINTENANCE
4.1.2 Changing the oil

n Protective gloves
n Work clothing
n Safety boots
Fig. 6: Changing the oil (example of WP460L Marine)

1 Oil drain valve
2 Oil level indicator
3 Oil filler cap
Requirement: Disassemble the front cover Ächapter "Disassembling and
assembling the guard grating".
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. Fill the oil and check the level on the oil level indicator.

The oil must be level with the middle of the oil level
indicator and must remain below the upper mark on
the oil level indicator.
7. Assemble the oil filler cap.
4.1.3 Replacing the oil filter

n Protective gloves
n Work clothing
n Safety boots
Special tool: n Strap spanner
Fig. 7: Replacing the oil filter (example of WP460L Marine)

1 Oil strainer

MAINTENANCE
Requirement: Disassemble the side service flaps Ächapter "Disassembling

and assembling the guard grating".
1. Unscrew the oil filter with a strap spanner and dispose of in an environ-
mentally sound manner.
2. Fit the new oil filter and hand-tighten it.
4.1.4 Replacing the oil strainer

n Protective gloves
n Work clothing
n Safety boots
Fig. 8: Replacing the oil strainer (example of WP460L Marine)

1 Oil strainer
1. Loosen the oil strainer union.
2. Take out the oil strainer together with the seal ring and dispose of in an
environmentally sound manner.

3. Fit and tighten a new oil strainer with new seal ring.
4.1.5 Replacing valves

4.1.5.1 Preparatory work
n Protective gloves
n Work clothing
n Safety boots
Materials: n EO-Niromont 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.
Unscrew and remove the pipe unions and hose lines at the cylinder
heads.

MAINTENANCE
4.1.5.2 Replacing valves

Removing the compres-
sion stage 1 valve on the
WP320L
Fig. 9: Compression stage 1 valve (WP320L)

1 Cylinder head
2 Studs
3 Cylinder head nut
4 Low tolerance o-ring
5 Compression stage 1 valve
6 Cylinder head gasket
7 Cylinder
8 Socket head cap screw
1. Unscrew the cylinder head nuts.
2. Remove the cylinder head with valve
3. Remove the socket head cap screws.
4. Detach the compression stage 1 valve from the cylinder and dispose of
in an environmentally sound manner.
5. Remove all gaskets.
6. Clean the sealing surfaces carefully, taking care not to scratch or
damage them.

sion stage 1 valve on the
WP460L
Fig. 10: Compression stage 1 valve (WP460L)

1 Cylinder head
2 Studs
3 Cylinder head nut
7 Cylinder
2. Remove the cylinder head with valve
3. Detach the compression stage 1 valve from the cylinder and dispose of
in an environmentally sound manner.
damage them.
Installing the compres- 1. Fit a new cylinder head gasket over the studs and onto the cylinder.
sion stage 1 valve
2. Insert a new low-tolerance o-ring in the new valve for compression
stage 1.
3. For the WP320L only: Assemble a new compression stage 1 valve on
the cylinder head with socket head cap screws.
4. Carefully slide the cylinder head over the studs and onto the cylinder.
5. Screw on the cylinder head nuts with washers and tighten by hand.

MAINTENANCE

sion stage 2 valve
Fig. 11: Compression stage 2 valve

1 Distribution flange
2 Screw
4 Studs
5 Cylinder head nut
8 Cylinder head
10 Cylinder
1. Undo the screws and remove the distribution flange.
3. Remove the cylinder head. While doing so, hold the valve firmly in
place.
4. Remove the valve from the cylinder head and dispose of in an environ-
damage them.
Installing the compres- 1. Slide a new cylinder head gasket over the studs and onto the cylinder.
sion stage 2 valve
stage 2.
3. Insert the new valve for compression stage 2 in the cylinder head.
4. Hold the valve firmly in place inside the cylinder head and carefully
slide both over the studs and onto the cylinder.
5. Screw on the cylinder head nuts and finger-tighten.
6. Insert a new low-tolerance o-ring for the distribution flange.

7. Place the distribution flange on the cylinder head and tighten it.

sion stage 3 valve
Fig. 12: Compression stage 3 valve

1 Studs
2 Cylinder head nut
5 Cylinder head
7 Cylinder
2. Remove the cylinder head. While doing so, hold the valve firmly in
place.
3. Remove the valve from the cylinder head and dispose of in an environ-
damage them.
Installing the compres- 1. Slide a new cylinder head gasket over the studs and onto the cylinder.
sion stage 3 valve
stage 3.
3. Insert the new valve for compression stage 3 in the cylinder head.
4. Hold the valve firmly in place inside the cylinder head and carefully
slide both over the studs and onto the cylinder.
5. Screw on the cylinder head nuts and finger-tighten.

MAINTENANCE
4.1.5.3 Final tasks

Final tasks 1. Smear the pipe threads and sealing surfaces with assembly paste.
2. Screw the pipe unions and hose line back on the cylinder heads, but
do not tighten.
3. Securely tighten the cylinder head nuts. Observe the tightening torque.
Ä Chapter 3.2 „Requirements for maintenance work“ on page 9
4. Securely tighten the pipe unions and hose lines.
4.1.6 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 Lubricating grease
Removing cylinders Requirement: The cylinder head and valve that are to be serviced have
already been removed.
1. Remove the cover for the fan flywheel in the intermediate housing.
2. Turn the fan flywheel until the piston is in the top dead centre position.
3. Loosen and unscrew the cylinder foot nuts.
4. 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.
5. Take off the cylinder foot gasket and dispose of it in an environmentally

sound manner.
6. Clean the sealing surfaces of the cylinder foot and crankcase carefully,
taking care not to scratch or damage them.

Replacing the gudgeon
pins and gudgeon pin 1
bearings
Fig. 13: Connecting rod with piston (example)

1 Piston
2 Gudgeon pin bearing
3 Gudgeon pin
4 Circlip
5 Connecting rod
Requirement: The cylinder head and valve that are to be serviced and the
cylinder 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.

MAINTENANCE
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 4.1.6.1
„Checking pistons and cylinders“ on page 37.
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 connecting rod is
not blocked in the next step.
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.

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 4.1.5
„Replacing valves“ on page 28.
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 3.2 „Requirements for maintenance work“ on page 9
3. Securely tighten the pipe unions and hose lines.

MAINTENANCE
4.1.6.1 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. 14: 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.

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. 15: 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. 16: 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.

4.1.7 Replacing the flexible coupling element
n Work clothing
n Safety boots
Fig. 17: Flexible coupling element (example of WP460L Marine)

1 Fan flywheel
2 Intermediate housing
3 Flexible coupling element
4 Hub, motor side
5 Electric motor
Requirement: If necessary, disconnect cable connections and pipelines.
1. Unscrew the fixing screws for the electric motor.
2. Carefully lift the electric motor using the lifting eyes.
3. Carefully pull the electric motor away from the intermediate housing.
4. Unscrew the fixing screws of the flexible coupling element.
5. Replace the flexible coupling element.
6. Screw in and tighten the fixing screws of the flexible coupling element.
7. Carefully push the electric motor against the intermediate housing.
8. Screw in and tighten the electric motor fixing screws.

MAINTENANCE
4.1.8 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!
and directives.

n Work clothing
n Safety boots
4
4
8
9
9
10
Fig. 18: 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.

MAINTENANCE
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.
4.1.9 Replacing 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.
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.
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.

Replacing the safety
valve
n Protective gloves
n Work clothing
n Safety boots
Fig. 19: Replacing the safety valve (1/2) (example of WP460L Marine)
1 Safety valve compression stage 2

MAINTENANCE
Fig. 20: Replacing the safety valve (2/2) (example of WP460L Marine)
1. Unscrew the safety valves.
2. Dispose of the ring gaskets.
3. Fit new ring gaskets.
4. Screw in and tighten the new safety valves. Ä Chapter 3.2 „Require-
ments for maintenance work“ on page 9

4.1.10 Replacing sensors
WARNING!
and directives.
Replacing the tempera- Personnel: n Service personnel

ture sensor
n Work clothing
n Safety boots

MAINTENANCE
Fig. 21: Replacing the temperature sensor (example of WP460L Marine)

1 Cable
2 Temperature sensor
3 Union

WARNING!
The sensors must only be connected and disconnected by a
qualified electrician.
1. Disconnect the cable to the temperature sensor in the compressor ter-

minal box.
2. Loosen the union.
3. Dispose of the temperature sensor and cable.
4. Assemble a new temperature sensor with cable.
5. Connect the temperature sensor cable in the compressor terminal box.

Replacing the oil pres- Personnel: n Service personnel
sure sensor
n Work clothing
n Safety boots
The Sauer-Compressor must be completely depressurised

before the oil pressure sensor is replaced. This can be done
for example by opening the manual drainage system. Read
off the values of the pressure gauges for the compression
stages to check whether the Sauer-Compressor is com-
pletely depressurised.
Fig. 22: Replacing the oil pressure sensor (example of WP460L Marine)
1 Union
2 Oil pressure sensor
3 Cable socket
4 Cable
Requirement: The oil has been drained Ächapter "Changing the oil".

MAINTENANCE

WARNING!
1. Loosen the knurled screw on the cable socket.

2. Pull the cable out.
4. Dispose of the oil pressure sensor in an environmentally sound
manner.
5. Assemble a new oil pressure sensor with union.
6. Install the cable.
7. Tighten the cable socket knurled screw. Ä Chapter 3.2 „Requirements
for maintenance work“ on page 9
Replacing the final pres- Personnel: n Service personnel

sure sensor
n Work clothing
n Safety boots
WARNING!
Risk of injury when working on the final pressure
sensor
If work is to be carried out on the final pressure sensor of the
Sauer-Compressor and the lines are not shut off and dep-
ressurised by the operator, there is a significant risk of injury
while working in this area.
– The pressure lines between the pressure reservoir and
the compressor must be shut off and secured against
opening by the operator before work is started on the
final pressure sensor.
– The corresponding pressure lines must be completely
depressurised.

Fig. 23: Replacing the final pressure sensor (example of WP460L Marine)
1 Union
2 Cable socket
3 Cable
4 Final pressure sensor
WARNING!
1. Loosen the knurled screw on the cable socket.

2. Pull the cable out.
4. Dispose of the final pressure sensor in an environmentally sound
manner.
5. Assemble a new final pressure sensor with union.
6. Install the cable.
7. Tighten the cable socket knurled screw. Ä Chapter 3.2 „Requirements
for maintenance work“ on page 9

MAINTENANCE
4.1.11 Replacing pressure gauge hoses

n Protective gloves
n Work clothing
n Safety boots
Fig. 24: Pressure gauge hoses (1/2) (example of WP460L Marine)

1 Pressure gauge hose union compression stage 3
2 Pressure gauge stop valve compression stage 2
3 Pressure gauge hose compression stage 2
8 Oil for pressure gauge hose

9 Oil pressure gauge hose union
Fig. 25: Pressure gauge hoses (2/2) (example of WP460L Marine)

2 Oil stop valve
1. Close pressure gauge stop valves and oil stop valve.
2. Disconnect the unions at both ends of the pressure gauge hoses.
3. Dispose of the pressure gauge hoses in an environmentally sound
manner.
4. Assemble new pressure gauge hoses.
5. Securely tighten the union.
6. Open pressure gauge stop valves and oil stop valve.

MAINTENANCE
4.1.12 Replacing the drain hose

n Protective gloves
n Work clothing
n Safety boots
Fig. 26: Drain hose (example of WP460L Marine)

1 Clamp
2 Drain hose
3 Clamp
1. Loosen clamps.
2. Disassemble the drain hose.
3. Dispose of the drain hose in an environmentally sound manner.
4. Install a new drain hose.
5. Securely tighten the clamps.

4.1.13 Replacing the high pressure hose

n Protective gloves
n Work clothing
n Safety boots
Fig. 27: High pressure hose (example of WP460L Marine)

1 Union
2 High pressure hose
3 Union
2. Disassemble the high pressure hose.
3. Dispose of the high pressure hose in an environmentally sound
manner.
4. Install a new high pressure hose.
5. Securely tighten the union.

PRESERVATION
5 Preservation
This chapter describes the preservation work that is required before and
after storing the Sauer-Compressor for a long period.
5.1 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 it 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 sol-

enoid drain valves are open.
9. Unscrew the air filter.

10. Spray approx. 150 ml preservation oil into the suction compartment of
compression stage 1.
11. Remove the plug on the distribution flange of compression stage 2.
13. Remove the plug on the suction flange of compression stage 3.
15. Replace the copper ring gaskets and reinsert the plugs.
16. Mount the air filter.
17. Run the compressor for around 15 seconds with the solenoid drain
ð The preservation oil disperses in the oil circuit.
18. 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.
19. Reconnect the power supply for the solenoid drain valves to the com-
pressor control.
20. Drain the preservation oil.
21. Dispose of oil in an environmentally sound manner.
22. Attach a warning sign to prevent the preserved compressor from being
started accidentally.

PRESERVATION
5.2 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
6 Index
M
Maintenance
air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
cylinder wear measurement . . . . . . . . . . . . 38
drain hose . . . . . . . . . . . . . . . . . . . . . . . . . 53
flexible coupling element . . . . . . . . . . . . . . 40
guard grating . . . . . . . . . . . . . . . . . . . . . . . 15
gudgeon pin bearings . . . . . . . . . . . . . . . . 33
gudgeon pins . . . . . . . . . . . . . . . . . . . . . . . 33
high pressure hose . . . . . . . . . . . . . . . . . . 54
maintenance schedule . . . . . . . . . . . . . . . . 21
material . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
oil change . . . . . . . . . . . . . . . . . . . . . . . . . 25
oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
oil strainer . . . . . . . . . . . . . . . . . . . . . . . . . 27
personal protective equipment . . . . . . . . . . . 9
personnel qualification . . . . . . . . . . . . . . . . . 9
piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
piston rings . . . . . . . . . . . . . . . . . . . . . . . . 33
preparation . . . . . . . . . . . . . . . . . . . . . . . . . 9
pressure gauge hoses . . . . . . . . . . . . . . . . 51
safety valves . . . . . . . . . . . . . . . . . . . . . . . 43
sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
solenoid drain valve . . . . . . . . . . . . . . . . . . 41
spare parts . . . . . . . . . . . . . . . . . . . . . . . . . 11
special tools . . . . . . . . . . . . . . . . . . . . . . . . 10
tightening torque . . . . . . . . . . . . . . . . . . . . 11
valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Maintenance schedule . . . . . . . . . . . . . . . . . . 21
P
Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . 55
decommissioning . . . . . . . . . . . . . . . . . . . . 55
recommissioning . . . . . . . . . . . . . . . . . . . . 57
S
Sauer-Service . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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● High pressure com-

LEV_BRE_CYC Master WA en GB 1807 | 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-

LEV_BRE_CYC Master WA en GB 1807 | 5

Postal address: J.P. SAUER & SOHN

LEV_BRE_CYC Master WA en GB 1807 | 7

3 Preparing for maintenance

3.1 Installation conditions

3.2 Requirements for maintenance work

Required personal pro-

LEV_BRE_CYC Master WA en GB 1807 | 9

10 | LEV_BRE_CYC Master WA en GB 1807

Table of tightening tor- Data Value Unit

3.3 Ordering spare parts

The spare parts catalogue and operating instructions are

LEV_BRE_CYC Master WA en GB 1807 | 11

Only genuine Sauer spare parts

3.4 Basic activities

12 | LEV_BRE_CYC Master WA en GB 1807

Before starting any maintenance work:

LEV_BRE_CYC Master WA en GB 1807 | 13

After completion of all maintenance work:

14 | LEV_BRE_CYC Master WA en GB 1807

3.5 Assembling and disassembling the

Fig. 1: Opening the quick release locks (example of WP460L Marine)

LEV_BRE_CYC Master WA en GB 1807 | 15

16 | LEV_BRE_CYC Master WA en GB 1807

The smaller side sections of the guard grating can be

ð The compressor unit is accessible for maintenance work.

Disassembling the front

Fig. 3: Disassembling the front cover (example of WP460L Marine)

LEV_BRE_CYC Master WA en GB 1807 | 17

Re-assemble the front cover in the reverse order.

Opening the top section

18 | LEV_BRE_CYC Master WA en GB 1807

The top section is closed in the reverse order.

LEV_BRE_CYC Master WA en GB 1807 | 19

4.1 Maintenance schedule

When beginning a new maintenance schedule

LEV_BRE_CYC Master WA en GB 1807 | 21

Maintenance work Maintenance interval

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

I3: 3000 h or after three years of operation at the latest

Sauer Easy Care maintenance kits: WP320L

Ä Chapter 4.1.1 „Replacing the air filter insert“ on page 24 c c c c c

22 | LEV_BRE_CYC Master WA en GB 1807

Maintenance work Maintenance interval

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

I3: 3000 h or after three years of operation at the latest

Sauer Easy Care maintenance kits: WP320L

optional configuration, no maintenance work is required in this respect.

LEV_BRE_CYC Master WA en GB 1807 | 23

Fig. 5: Air filter

24 | LEV_BRE_CYC Master WA en GB 1807