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Meritor Wabco System Saver Series Maintenance Manual

Single cartridge air dryers
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System Saver Series
Single Cartridge
Air Dryers
Maintenance Manual 34
Revised 11-02
System Saver Series
• 1000
• 1200E, P, U
• 1800E, P, U

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Summary of Contents for Meritor Wabco System Saver Series

  • Page 1 System Saver Series Single Cartridge Air Dryers Maintenance Manual 34 Revised 11-02 System Saver Series • 1000 • 1200E, P, U • 1800E, P, U...
  • Page 2 Service Notes Information on our Web Site This manual provides instructions for Meritor WABCO’s System Saver Series single cartridge air Enter meritorwabco.com in your browser’s dryers. Before you begin procedures: address box for quick access to our web site. At our home page, click on literature to access our 1.

  • Page 3: Table Of Contents

    Testing the Meritor WABCO System Saver Series Air Dryer ....... .
  • Page 4 Notes...

  • Page 5: Section 1: Introduction

    TP-9772, available. Figure 1.1 TP-9672, Air Dryer Application Guide, provides an in-depth look at System Saver Series air dryer applications. T-20102V, Air System Troubleshooting video Stopping With Air and T-97105V, System Saver 1200 videotapes are also available.

  • Page 6: How The Air Dryer Works

    Section 1 Introduction How the Air Dryer Works A typical Meritor WABCO System Saver 1200 or 1800 Series air dryer installation is illustrated in During system pressure build-up, compressed air Figure 1.3 . Illustrations for Combo Tank passes into the air dryer where the filter system...

  • Page 7: Air Dryer Cycle

    Section 1 Introduction Air Dryer Cycle A single cartridge air dryer cycle is illustrated below. The governor turns the compressor on when CONTROL supply tank pressure drops below cut-in pressure “WET” AIR (approximately 100 psi). “DRY” AIR CONTROL/DRY LINES ENGINE TURBO BOOST PRESSURE 1002142a Compressed air passes into the air dryer at the...

  • Page 8: Air Dryer Components

    NOTE: For information about System Saver E air dryers and components, refer to Appendix I and Appendix II. For special applications, refer to Meritor WABCO single cartridge air dryers contain Appendix III. replaceable component parts. Air dryer components are illustrated in Figure 1.4 . Refer to Section 3 for instructions.

  • Page 9: Dryer Identification

    Section 1 Introduction Dryer Identification The identification tag on the face of the dryer provides important information about the air dryer — information you will need when servicing or replacing components. Figure 1.5 . Figure 1.5 SYSTEM SAVER 1800/1800U SYSTEM SYSTEM SAVER SAVER...
  • Page 10 1002151a Figure 1.10 Pressure-Controlled Check Valve (PCCV): Used with System Saver Series regeneration style air dryers. The PCCV is usually mounted on the secondary air tank in place of an inlet check valve. It lets air backflow from the secondary...
  • Page 11 Figure 1.13 . Not used with “P” style dryers. 1002155a Figure 1.14 ECON Valve Replacement Part: This valve is used on System Saver Series 1200E single cartridge air dryers used with Holset E-type compressors. MM-34 Revised 11-02...
  • Page 12 Section 1 Introduction Figure 1.15 ECON Valve: This valve must be installed if System Saver 1000 or 1200 Series air dryers NOT DESIGNATED E are used with Holset E-type compressors. This valve is not required on System Saver 1200 E air dryers. Turbo Cut-off Valve: A valve located in the inlet port of the air dryer.

  • Page 13: Section 2: Troubleshooting & Testing

    1002159a Meritor WABCO air dryer components are installed in the air dryer at the factory and are designed to last for the life of the dryer. Under some operating conditions, however, a replacement may be required. Refer to Section 3 for replacement guide instructions.

  • Page 14: Troubleshooting

    Section 2 Troubleshooting & Testing Troubleshooting NOTE: The exploded view of the System Saver single canister air dryer in Section 1 illustrates the location of components in the dryer. Conditions you may experience, and suggested solutions, appear in the following System Saver Series Air Dryer Troubleshooting table.
  • Page 15 Section 2 Troubleshooting & Testing Conditions May Occur In: Regeneration Dedicated Style Air Purge Tank Condition Possible Cause Dryers Air Dryers Solution No regeneration Air dryer not connected to supply Verify proper dryer installation per cycle. No airflow tank or connections reversed at system diagram.
  • Page 16 Section 2 Troubleshooting & Testing Conditions May Occur In: Regeneration Dedicated Style Air Purge Tank Condition Possible Cause Dryers Air Dryers Solution Air leak at turbo Lip seal installed upside-down on Install lip seal correctly. cut-off valve vent. piston. Lip must face UP (towards dryer).

  • Page 17: System Tests

    Check the connections to see if soap solution bubbles. Heater Resistance No Soap Bubbles: Connections are sealed To avoid damaging components, Meritor WABCO properly. recommends performing this resistance check Soap Bubbles Appear: Connections are NOT with the heater in place.

  • Page 18: Pressure-Controlled Check Valve Test - Regeneration Style Only

    NOTE: A drop from 120 to 95 ± 5 psi during this test is normal for vehicles equipped with NOTE: A 10 psi drop in pressure in the the System Saver Series air dryer and a secondary air system is normal for Meritor pressure-controlled check valve.

  • Page 19: Section 3: Installing Replacement Parts

    Section 3 Installing Replacement Parts Replacement Requirements Section 3 Installing Replacement Parts WARNING Before replacing any air dryer component, make To prevent serious eye injury, always wear safe sure the air compressor and air governor are eye protection when you perform vehicle working properly.

  • Page 20: Component Replacement

    Installing Replacement Parts NOTE: When replacing air dryer components, use 2. Loosen and remove the old cartridge. Use only Meritor WABCO replacement parts. strap wrench if necessary. 3. Remove and discard O-ring from dryer base. The exploded view of the air dryer in Section 1 shows the location of the various air dryer 4.

  • Page 21: Outlet Check Valve Assembly

    Section 3 Installing Replacement Parts Outlet Check Valve Assembly 7. Install the new spring with its small end around the “Y”-shaped fins on the valve body. 1. Review Figure 3.3 to make sure you have all of 8. Install the new washer and the new snap ring the parts required to replace the outlet check to hold the components in place.

  • Page 22: Turbo Cut-Off Valve Assembly

    Section 3 Installing Replacement Parts NOTE: For dryers with date codes of 0894 or Figure 3.7 earlier, follow the special instructions in the replacement kit to complete the installation. Spring not used in 6. Install the new retainer and screw to hold the U Series air dryers.

  • Page 23: Regeneration Valve Assembly

    Section 3 Installing Replacement Parts Regeneration Valve Assembly 4. Clean and inspect the diaphragm lip groove. If the groove is damaged so that a tight seal The regeneration valve assembly kit contains two cannot be maintained, replace the air dryer. different diaphragms to service the regeneration 5.

  • Page 24: Purge Valve Assembly

    Section 3 Installing Replacement Parts Purge Valve Assembly 4. Remove washer and O-rings from the base. 5. Clean and inspect the valve bore. If the bore is 1. Review Figure 3.11 to make sure you have all damaged so that a tight seal cannot be of the parts required to replace the purge valve.

  • Page 25: Pressure-Controlled Check Valve (Pccv)

    PC check valve. 5. Test the installation for proper operation. 11. Install snap ring to hold the valve head in (Refer to Testing the Meritor WABCO System place. Saver Series Air Dryer in this section.)

  • Page 26: Pressure Relief Valve

    TP-9557, Pressure Relief Valve Installation, pressure relief valve provided by Meritor for instructions. This publication is available from WABCO are coated with sealant. They do not Meritor WABCO, 800-535-5560. require any additional sealant. 1. Remove the old valve from the dryer. Figure 3.19...

  • Page 27: Purge Silencer (Muffler)

    6. Reconnect all system air lines. 3. Remove the three mounting bolts. Remove the 7. Test the installation for proper operation. air dryer from its mounting location. (Refer to Testing the Meritor WABCO System Figure 3.21. Saver Series Air Dryer which follows.) MM-34...

  • Page 28: Testing The Meritor Wabco System Saver Series Air Dryer

    Section 3 Installing Replacement Parts Testing the Meritor WABCO System Saver Series Air Dryer 1. Turn off the engine after the air system reaches cut-out pressure (approximately 120 psi) and the air compressor has unloaded. 2. Drain the primary air tank(s) down to 80 psi or lower.

  • Page 29: Appendix I Glossary

    Appendix I Glossary Basic Air System/Air Dryer Terms Appendix I Glossary Air Compressor A device that pumps air to and builds air pressure in an air system. Air Dryer A device that cools, filters, and dries the air delivered by an air compressor.

  • Page 30: Appendix Ii: Application Information

    Appendix II Application Information Discharge Line: Appendix II Application Information WARNING Diameter from compressor to air dryer To prevent serious eye injury, always wear safe 1/2-inch i.d. minimum eye protection when you perform vehicle maintenance or service. Length from compressor to air dryer Determined by temperature of air at the inlet General Requirements port of the air dryer.

  • Page 31: System Saver Series Installation Criteria

    Appendix II Application Information System Saver Series Installation Criteria Operating Parameters Requirements Pressure requirements Maximum pressure 140 psi Minimum governor cut-out 115 psi pressure Governor range 15 to 25 psi (cut-out — cut-in) Flow capacity Compressor rating 25 cfm maximum...

  • Page 32: Appendix Iii: Special Applications

    Holset E-Type Compressor Appendix III Special Applications Systems When a System Saver Series air dryer is used with a Holset E-type compressor system, an external Econ valve is used. Figure A.1. On the 1200E Series, an integral Econ function eliminates the need for the external Econ valve.

  • Page 33: Econ Valve

    CONTROLLED CHECK VALVE 1002187b ECON Valve Figure A.3 Meritor WABCO recommends the ECON valve be mounted in the air system away from the dryer. This helps prevent dryer freeze-up. Refer to the vehicle manufacturer’s manual for installation instructions. To replace an ECON valve that is mounted directly to the air dryer, follow these instructions.
  • Page 34 Appendix III Special Applications 2. Unscrew and remove the Econ valve from the Figure A.5 air dryer inlet port No. 1. Save fitting for reinstallation. ECON VALVE 3. Install the replacement Econ valve. Apply a good quality teflon paste pipe ®...

  • Page 35: Alcohol Evaporator

    Appendix III Special Applications Alcohol Evaporator Check the vehicle’s air system for an alcohol evaporator. NOTE: Typically, an alcohol evaporator will be installed in the line between the air dryer and the supply (wet) tank. Common installations are on the truck’s firewall, on a frame rail and behind the cab.

  • Page 36: Combo Tank Installation For Regeneration-Style Air Dryers

    Appendix III Special Applications Combo Tank Installation for Regeneration-Style Air Dryers GOVERNOR COMPRESSOR INTAKE LINE RESERVOIR TO GOVERNOR UNLOADER LINE PORT UNLOADER LINE SYSTEM SAVER SERIES 1800 REGENERATION STYLE AIR DRYER 1200 COMPRESSOR REGENERATION CONTROL VALVE (PURGE) PORT PRESSURE- COMPRESSOR DRYER...

  • Page 37: Combo Tank Installation For Regeneration-Style Air Dryers

    Appendix III Special Applications Combo Tank Installation for Regeneration-Style Air Dryers GOVERNOR COMPRESSOR RESERVOIR INTAKE LINE TO GOVERNOR LINE UNLOADER PORT UNLOADER LINE SYSTEM SAVER SERIES 1800 REGENERATION STYLE AIR DRYER 1200 COMPRESSOR REGENERATION CONTROL VALVE (PURGE) PORT COMPRESSOR DRYER SYSTEM...

  • Page 38: Meritor Wabco System Saver Series Single Cartridge Air Dryer Component Replacement Guide - Dedicated Purge

    Appendix III Special Applications Meritor WABCO System Saver Series Single Cartridge Air Dryer Component Replacement Guide — Dedicated Purge 1800 1200 DESICCANT CARTRIDGE HEATER ASSEMBLY O-RING PRESSURE RELIEF VALVE TURBO CUT-OFF VALVE ASSEMBLY OUTLET CHECK VALVE ASSEMBLY Spring not used with U Series dryers.

  • Page 39: Meritor Wabco System Saver Series Single Cartridge Air Dryer Component Replacement Guide

    Appendix III Special Applications Meritor WABCO System Saver Series Single Cartridge Air Dryer Component Replacement Guide 1800 HEATER ASSEMBLY • Disconnect plug. 1200 • Remove old assembly. • Install replacement element and DESICCANT CARTRIDGE thermostat. • Remove old cartridge. — Install retainer and screw to secure.
  • Page 40 Notes...
  • Page 41 Notes...
  • Page 42 Notes...
  • Page 44 Information contained in this publication was in effect at the time the publication was approved for Vehicle Control Systems printing and is subject to change without notice or liability. Meritor WABCO reserves the right to revise 3331 West Big Beaver Road, Suite 300 the information presented or discontinue the production of parts described at any time.

This manual is also suitable for:

System saver 1000System saver 1200eSystem saver 1200pSystem saver 1200uSystem saver 1800eSystem saver 1800p ... Show all

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