Meritor Wabco System Saver 1000, Maintenance Manual

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: ...vice Information on our Web Site Enter meritorwabco com in your browser s address box for quick access to our web site At our home page click on literature to access our publications meritorwabco com...

Page 3: ...o Cut Off Valve Assembly 18 Regeneration Valve Assembly 19 Purge Valve Assembly 20 Pressure Controlled Check Valve PCCV 21 Bypass Valve Pressure Relief Valve 22 Purge Silencer Muffler 23 Air Dryer Ass...

Page 4: ...Notes...

Page 5: ...desiccant regeneration U Indicates discharge line unloaded compressor E Indicates a Holset style compressor function G Indicates integral governor for air compressor control UP Indicates discharge lin...

Page 6: ...siccant for the next cycle A typical Meritor WABCO System Saver 1200 or 1800 Series air dryer installation is illustrated in Figure 1 3 Illustrations for Combo Tank installations appear in Appendix II...

Page 7: ...oisture also collects in the base of the dryer The governor turns the compressor off when system reaches cut out pressure approximately 120 psi When the compressor unloads the purge valve opens O Drye...

Page 8: ...pendix II For special applications refer to Appendix III Figure 1 4 1002146b SYSTEM SAVER 1200 OR 1800 DESICCANT CARTRIDGE PRESSURE RELIEF VALVE PURGE VALVE ASSEMBLY REGENERATION VALVE ASSEMBLY FOR RE...

Page 9: ...1 5 1696 1002147b SYSTEM SAVER 1000 1200 1200U DATE CODE FIRST 2 DIGITS BUILD WEEK LAST 2 DIGITS BUILD YEAR MANUFACTURING LOCATION CODE SYSTEM SAVER 1800 1800U SYSTEM SAVER 1200E PART NUMBER SYSTEM S...

Page 10: ...Series and 1000 Series with date codes later than 0894 do not use a bypass valve Figure 1 8 1002150a Figure 1 9 Outlet Check Valve A valve located in the outlet port port 21 of the air dryer It preven...

Page 11: ...r base that remains open during a compressor unload cycle It allows collected moisture condensation and contamination to be expelled from the air dryer during a purge cycle Figure 1 12 1002154a Figure...

Page 12: ...harger boost pressure during a compressor unload cycle thereby maintaining boost pressure for maximum engine horsepower Figure 1 14 There is no spring in the turbo cut off valve assemblies used on U S...

Page 13: ...instructions Interval Required Action Weekly Ensure dryer purges when compressor unloads Weekly or as recommended by the manufacturer Drain purge tank dedicated purge tank dryers Weekly or as recommen...

Page 14: ...ring fully into groove Slight leak from purge valve After several hours the supply tank may be empty Outlet check valve not seating or regeneration valve not shutting off regeneration airflow Yes No R...

Page 15: ...e air system leaks Excessive air system demands Outlet check valve not seating Regeneration valve not shutting off properly Air governor has less than 16 psi range Leaking air compressor unloader s Ye...

Page 16: ...n valves etc Air dryer leaks from purge valve Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Ensure compressor discharge line is plumbed to air dryer port 1 and air dryer port 21 is connected to vehicle s su...

Page 17: ...nnection that contains pressurized air Check the connections to see if soap solution bubbles No Soap Bubbles Connections are sealed properly Soap Bubbles Appear Connections are NOT sealed properly To...

Page 18: ...and air system problems Clean the Regeneration and Outlet Check valves Disconnect the compressor line from the air dryer Dryer Port 4 Check the compressor and governor per the manufacturer s recommend...

Page 19: ...ly not working internal short or open circuit Outlet Check Valve Air continues to flow from purge valve after purge cycle but stops flowing when the compressor load cycle begins Valve is stuck in the...

Page 20: ...the vehicle with safety stands Do not work under a vehicle supported only by jacks Jacks can slip and fall over Serious personal injury can result Desiccant Cartridge 1 Replacement kit contains one ca...

Page 21: ...ayer of grease to the valve bore and the O ring 6 Install the new valve body with its long end in the bore 7 Install the new spring with its small end around the Y shaped fins on the valve body 8 Inst...

Page 22: ...rings and seals 2 Remove the snap ring The cover and spring may fall out of the bore when the snap ring is removed 3 Remove the desiccant cartridge as described above Use a wooden stick to push the pi...

Page 23: ...lts and the valve housing assembly When you remove the housing the spring and cap will fall out 3 Remove the rubber diaphragm 4 Clean and inspect the diaphragm lip groove If the groove is damaged so t...

Page 24: ...2 4 Remove washer and O rings from the base 5 Clean and inspect the valve bore If the bore is damaged so that a tight seal cannot be maintained replace the air dryer 6 Apply a thin layer of grease to...

Page 25: ...ve and remove the valve from the tank and hex nipple pipe fitting 3 Install the new valve O Whatever orientation up or down the valve is in when it is tight is acceptable as long as the arrow is point...

Page 26: ...t the front Port 1 of the dryer On dryers with date codes later than 2295 the pressure relief valve is located at the side of the dryer Port 31 Figure 3 18 2 Unscrew and remove the old pressure relief...

Page 27: ...System Saver Air Dryer 1 Drain all pressure from the air system Disconnect all air lines Use markers to label the lines for proper reinstallation 2 Disconnect the heater electrical plug from the heat...

Page 28: ...k to see if the pressure controlled check valve is installed backwards If so install correctly and re test If not check for air leaks in the secondary air system If no significant air leaks are found...

Page 29: ...ystem supply tank which triggers the compressor unload cycle Dedicated Purge Tank A separate air tank used exclusively for holding air used in an air drying cycle This tank eliminates the need for a r...

Page 30: ...flow of air back from the supply tank to the air dryer O Feed purge valve by a direct line from the air governor Operating Environment Requirements Discharge Line O Diameter from compressor to air dr...

Page 31: ...ing 2 minutes maximum Occasional three times per day maximum 7 minutes Compressor unloaded time Minimum for purge cycle 20 seconds Maximum duty cycle Compressor on time total running time 30 Discharge...

Page 32: ...Series air dryer WITHOUT an Econ valve and your application requires one Meritor WABCO recommends installing the System Saver 1200E Figure A 1 PURGE VALVE EXHAUST COMPRESSOR DISCHARGE LINE COMPRESSOR...

Page 33: ...w and remove all of the lines from the Econ valve at the air dryer inlet port Figure A 3 Figure A 2 1002187b PURGE VALVE EXHAUST COMPRESSOR DISCHARGE LINE COMPRESSOR CONTROL PURGE PORT COMPRESSOR INTA...

Page 34: ...r D Using a wrench loosen and remove the Econ valve from the banjo fitting E Remove the banjo fitting and metal washer F Clean the valve surface area thoroughly before replacement 2 Install the replac...

Page 35: ...found at other locations 1 Check the vehicle s air system to determine if an alcohol evaporator is installed 2 If an alcohol evaporator is installed in the air system check for a bypass line connecte...

Page 36: ...SOR INTAKE LINE PRESSURE CONTROLLED CHECK VALVE SUPPLY TANK WET SYSTEM RESERVOIR INTERNAL CHECK VALVE DRYER INLET PORT UNLOADER LINE RESERVOIR TO GOVERNOR LINE 1800 1200 SYSTEM RESERVOIR CHECK VALVE S...

Page 37: ...OMPRESSOR INTAKE LINE PRESSURE CONTROLLED CHECK VALVE SUPPLY TANK WET SYSTEM RESERVOIR INTERNAL CHECK VALVE DRYER INLET PORT UNLOADER LINE 1800 1200 SYSTEM RESERVOIR SUPPLY LINE DRYER OUTLET PORT ALTE...

Page 38: ...stem Saver Series Single Cartridge Air Dryer Component Replacement Guide Dedicated Purge O RING HEATER ASSEMBLY DESICCANT CARTRIDGE PRESSURE RELIEF VALVE PURGE VALVE ASSEMBLY OUTLET CHECK VALVE ASSEMB...

Page 39: ...commended torque See Pressure Relief Valve in Section 3 REGENERATION VALVE ASSEMBLY REGENERATION STYLE DRYERS ONLY Remove old assembly and diaphragm Clean diaphragm lip groove Install replacement diap...

Page 40: ...Notes...

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Page 44: ...in effect at the time the publication was approved for printing and is subject to change without notice or liability Meritor WABCO reserves the right to revise the information presented or discontinu...