Applicable Systems
Electra Saver
Symptoms
Oil level in the sump has dropped below the minimum safe operating level visible in the sight glass. The low oil level switch opens and triggers a shutdown.
Possible Causes
- External oil leak from drain plug, filter housing, or separator gasket
- Oil separator element failed, causing excessive oil carryover to the plant air system
- Oil consumption elevated due to worn piston rings or excessive blow-by in the airend
- Compressor was overfilled previously and the apparent low level is actually the correct level
Troubleshooting Steps
- Step 1: Inspect the compressor base and floor for oil puddles or drips
Tighten drain plugs, replace gaskets, and repair any visible leak points - Step 2: Check downstream air receivers and filters for oil accumulation
If oil is present downstream, replace the separator element and inspect the scavenge line for blockage - Step 3: Perform a blow-by test: remove the oil fill cap and feel for excessive pressure pulses with the compressor running
Strong pulses indicate airend ring wear. Schedule an airend rebuild if blow-by is severe - Step 4: Verify the oil level with the compressor stopped and cooled, on level ground
Fill to the center of the sight glass. Overfilling causes foaming and separator failure
How to Reset
Reset: Add oil to the correct level or repair the leak, then press Reset on the controller. The unit runs a 30-second pre-lube cycle before loading.
Common Replacement Parts
- GD-1010: AEON 9000 SP oil, 20L pail (Synthetic PAO, ISO VG 46, 8000-hour life)
- GD-1011: Oil separator element, Electra Saver 30-50 (Flanged, 190 mm OD x 380 mm height)
- GD-1012: Sump drain plug with magnet (Magnetic plug catches wear particles for inspection)
Frequently Asked Questions
- Q: How much oil does an Electra Saver 37 hold?
Approximately 30 liters. Always fill to the center of the sight glass while stopped. The level will appear lower when running due to oil circulation.
- Q: Why is oil in my air lines?
Usually a failed separator or overfilled sump. Check the separator differential pressure and oil level first before suspecting the airend.
Source: Gardner Denver Electra Saver II Operation and Maintenance Manual, GD-ESA-II-OM
Category: Compressor