WABCO 1200E Maintenance Manual
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WABCO 1200E Maintenance Manual

WABCO 1200E Maintenance Manual

System saver series single cartridge air dryers
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Maintenance Manual 34
System Saver Series Single Cartridge Air
Dryers
System Saver Series
•1200E, P, U
•1800E, P, U
•1200 Plus, MCP
Revised 03-16

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  • Page 1 Maintenance Manual 34 System Saver Series Single Cartridge Air Dryers System Saver Series •1200E, P, U •1800E, P, U •1200 Plus, MCP Revised 03-16...
  • Page 2 Information contained in this publication was 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 to discontinue the production of parts described at any time.

  • Page 3: Table Of Contents

    Section 2: Component Removal and Combo Tank Installation for Regeneration-Style Air Dryers Installation Combo Tank Installation for Regeneration-Style Air Dryers Component Replacement Meritor WABCO System Saver Series Single Cartridge Air Requirements Dryer Component Replacement Guide — Dedicated Component Removal and Installation Purge...
  • Page 4 Notes...

  • Page 5: Section 1: Introduction

    TP-92116, Installing the Meritor WABCO System Saver Series Air Dryer, provides complete installation instructions. System Saver 1200E: Tubing and banjo fitting at front of dryer PB-8857AS contains a complete listing of air dryer replacement System Saver 1200P/1800P: Uses dedicated purge tank. Port 22 parts.

  • Page 6: How The Air Dryer Works

    NOTE: For further information about System Saver E air dryers and components, refer to Section 4 and Section 5. For special applications, refer to Section 6. 4007638a SYSTEM SAVER 1200 PLUS Figure 1.3 Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 7: Air Dryer Cycle

    The governor turns the compressor off when system reaches CONTROL cut-out pressure, between 120 psi and 130 psi (827-896 kPa) “WET” AIR “DRY” AIR depending on governor settings. CONTROL/DRY LINES ENGINE TURBO BOOST PRESSURE 1002145a Meritor WABCO Maintenance Manual 34 (Revised 03-16)
  • Page 8 When the compressor unloads, the purge valve opens: 1200E, P , U 1200 PLUS On 1200E, P, U, 1800E, P, U, the dryer purges the desiccant 1800E, P , U cartridge and expels any water collected in the dryer base.
  • Page 9 1 Introduction Typical System A typical Meritor WABCO System Saver 1200 or 1800 Series air dryer installation is illustrated in Figure 1.5. A System Saver 1200 Plus system is shown in Figure 1.6. Illustrations for Combo Tank installations appear in Section 6.
  • Page 10 UNLOADER LINE SYSTEM SAVER 1200 PLUS AIR DRYER COMPRESSOR DRYER SYSTEM INLET PORT RESERVOIRS ONE-WAY CONTROL CHECK (PURGE) VALVE PORT COMPRESSOR DISCHARGE LINE PURGE VALVE (EXHAUST) SUPPLY SUPPLY LINE TANK 4012522a Figure 1.6 Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 11: Air Dryer Components

    1 Introduction Air Dryer Components Meritor WABCO single cartridge air dryers contain replaceable component parts. Standard air dryer components are illustrated in Figure 1.7. For 1200 Plus Series air dryers, refer to Figure 1.8. Refer to Figure 1.9 for 1200 Plus Series air dryers with Multi Circuit Protection.
  • Page 12 1 Introduction Figure 1.8 SYSTEM SAVER 1200 PLUS SERIES AIR DRYER DESICCANT PRESSURE CARTRIDGE RELIEF VALVE O-RING OUTLET CHECK VALVE ASSEMBLY GOVERNOR HEATER ASSEMBLY TURBO CUT-OFF VALVE PURGE VALVE ASSEMBLY ASSEMBLY 4007692a Figure 1.8 Meritor WABCO Maintenance Manual 34 (Revised 03-16)
  • Page 13 SYSTEM SAVER 1200 PLUS SERIES AIR DRYER WITH MULTI CIRCUIT PROTECTION DESICCANT CARTRIDGE DRAIN O-RING VALVE TURBO CUT-OFF VALVE ASSEMBLY PURGE VALVE ASSEMBLY HEATER ASSEMBLY GOVERNOR PRESSURE RELIEF VALVE OUTLET CHECK 4011774a VALVE ASSEMBLY Figure 1.9 Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 14: Dryer Identification

    Spin-on/spin-off design allows quick and easy maintenance. The System Saver 1800 Series cartridge is 3.2-inches (81 mm) taller than the 1200 Series cartridge [6.4-inches (164 mm) tall]. Figure 1.11. Always replace cartridges with authentic Meritor WABCO brand cartridges. 1002148b Figure 1.11...
  • Page 15 It allows air to flow into the dryer and go directly to the Figure 1.15 outlet port, bypassing the desiccant cartridge. The 1200 and 1200E Series with date codes later than 0894 do not use a bypass valve.
  • Page 16 ECON Valve Replacement Part: This valve is used on System that remains open during a compressor unload cycle. It allows Saver Series 1200E single cartridge air dryers used with Holset collected moisture, condensation, and contamination to be expelled E-type compressors. Figure 1.19.
  • Page 17 Figure 1.23 1002157a 4011899a Figure 1.23 Figure 1.25 Purge Silencer: Optional part for all Meritor WABCO air dryers. It is used to reduce the noise level of an air dryer purge. Figure 1.24. Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 18: Section 2: Component Removal And Installation

    Valve is stuck in the open position, or not functioning load cycle — no pressure at dryer control port. properly. Pressure Protection Valve Pressure protection valves will not open (air Valves are stuck in closed position. dryer must be replaced). Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 19: Component Removal And Installation

    NOTE: Replacement cartridges are marked “System Saver Series.” Replacement kit contains one cartridge and one O-ring. Figure 2.1. 1002163b Figure 2.1 Loosen and remove the old cartridge. Use strap wrench if necessary. Remove and discard O-ring from dryer base. Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 20: Outlet Check Valve Assembly

    O-ring seal. Figure 2.5 RECEPTACLE Figure 2.3 O-RING THERMOSTAT GREASE VALVE BODY SPRING HEATER ELEMENT O-RING 1002167a WASHER Figure 2.5 SNAP RING 1002165a Disconnect the plug. Figure 2.3 Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 21: Turbo Cut-Off Valve Assembly

    Review Figure 2.7 to ensure you have all of the parts required NOTE: Kits made after 12-1-09 use an O-ring in place of a lip to replace the turbo cut-off valve. seal. Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 22: System Saver 1200 Plus Governor

    Install the new spring, cover and snap ring to hold the Use only the Meritor WABCO governor specified for use with the components in place. System Saver 1200 Plus air dryer.

  • Page 23: Purge Valve Assembly

    O-ring and Remove the piston assembly from the base. Figure 2.14. filter over the orifice. Install the new mounting bolts and tighten to 53 in-lb (6 N m). Figure 2.12. Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 24: Pressure-Controlled Check Valve (Pccv)

    NOTE: New style valves have the hex nipple pipe fitting installed. Before replacing, look at the arrow on this valve. You must install the valve so that the arrow faces the tank on which it is installed. Figure 2.17. 1002175b Figure 2.15 Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 25: Bypass Valve

    Figure 2.20 Review Figure 2.19 to ensure you have all of the parts required Install the new spring so it fits around the “Y”-shaped fins on to replace the bypass valve. the valve body. Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 26: Pressure Relief Valve

    SILENCER damage can result. NOTE: The threads on the replacement pressure relief valve provided by Meritor WABCO are coated with sealant. They do not require any additional sealant. Screw the replacement valve into the Street-Tee fitting or the 1002183a dryer base, depending on the date code of the air dryer.

  • Page 27: Air Dryer Assembly

    22-30 ft-lb (30-40 N m). Figure 2.26 and Figure 2.27. instructions on an initial installation, refer to TP-92116, Installing the Meritor WABCO System Saver Air Dryer. To obtain this Figure 2.26 publication, refer to the Service Notes page on the front inside cover of this manual.

  • Page 28: Section 3: Troubleshooting And Testing

    System Saver 1200 Plus with MCP. The entire air dryer needs to be replaced if these parts are not operating effectively. Maintenance To keep your Meritor WABCO air dryer operating efficiently, the routine maintenance in Table C is recommended. Table C...

  • Page 29: Maintenance Tips

    Check the line from the governor to port 4 of the dryer for oil and/or water. Keep this line clean to help prevent freezing. 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.

  • Page 30: Troubleshooting

    Inspect and replace outlet check valve too long (more than as needed. 30 seconds), Regeneration valve not shutting Replace regeneration valve. accompanied by loss off regeneration airflow. of pressure in the supply tank. Meritor WABCO Maintenance Manual 34 (Revised 03-16)
  • Page 31 Inspect air governor. Repair/replace per properly. manufacturer’s instructions. Cut-out pressure never achieved Check for air leaks in system and repair by air compressor. as needed. If no leaks in system, check compressor output. Repair/replace per manufacturer’s instructions. Meritor WABCO Maintenance Manual 34 (Revised 03-16)
  • Page 32 Frequency varies unloading when cut-out manufacturer’s instructions. with engine speed. pressure is reached. NOTE: With U Series air dryers, the compressor unloads through the dryer, so a steady flow of air is normal. Meritor WABCO Maintenance Manual 34 (Revised 03-16)
  • Page 33 Heater assembly not working. Replace heater assembly. Wrong voltage air dryer used; Replace with correct voltage air dryer. i.e., 12-volt air dryer used in a 24-volt system. Meritor WABCO Maintenance Manual 34 (Revised 03-16)
  • Page 34 Water in system Dryer not suitable for Review the application guidelines. Refer tanks, everything application. to TP-9672. For assistance, call the else checks out Meritor OnTrac™ Customer Call Center okay. at 866-OnTrac1 (668-7221). Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 35: Tests

    (7 kPa), in the secondary air tank to determine if air pressure is within the required ranges. To avoid damaging components, Meritor WABCO recommends performing this resistance check with the heater in place. Operational Test for System Saver Series Air Dryers —...

  • Page 36: Pressure-Controlled Check Valve Test - Regeneration Style Only

    NOTE: A 10 psi (69 kPa) drop in pressure in the secondary air compressor has unloaded. system is normal for Meritor WABCO System Saver Series regeneration style air dryers. Drain the supply tank down to 80 psi (552 kPa) or lower.
  • Page 37 Secondary air gauge not plumbed to the secondary air system. Use a calibrated air gauge in the secondary tank to check air pressure. Make the necessary installation changes or repairs and repeat the operational test. Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 38: Section 4: Appendix I - Glossary

    10 to 25 seconds. This backflow of air from the air system and through the air dryer removes moisture from the desiccant cartridge and readies the air dryer for the next compressor load cycle. Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 39: Section 5: Appendix Ii - Application Info

    Operating Parameter Requirement −40°F to 175°F (−40°C to Temperature (ambient operating range) 80°C) Electrical Power (for heater 12 or 24 volts available and solenoid/timer power) Thermostat Range (On/Off 45°F, 86°F (7°C, 30°C) temp) Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 40: System Saver Series Installation Criteria

    (2.75 m) in length, a minimum of three feet (0.91 m) of 1/2-inch (127 mm) thick closed-cell polyethylene pipe insulation be used at the connection to the air dryer. Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 41: Section 6: Appendix Iii - Special Applications

    VALVE TANK CONTROLLED LINE CHECK VALVE CHECK VALVE (FLOW DIRECTION) BACKFEED LINE 4003880a Figure 6.1 On the 1200E Series, an integral Econ valve eliminates the need for the external Econ valve. Figure 6.2. Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 42: Econ Valve

    Econ valve, and your application requires one, Meritor WABCO recommends installing the System Saver 1200E. ECON Valve 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.
  • Page 43 Reconnect the lines to the Econ valve at air dryer inlet port (Port 1). WASHER ECON Valve Replacement on System Saver 1200E Air Dryers To replace the Econ valve assembly on Meritor WABCO System TUBE Saver 1200E air dryers, follow these instructions. 4003882a Remove the Econ valve assembly.

  • Page 44: Alcohol Evaporator

    If an alcohol evaporator is installed in the air system, check for a bypass line connected to the evaporator. Figure 6.6. Figure 6.6 LINE TO SUPPLY TANK LINE FROM AIR DRYER ALCOHOL EVAPORATOR 1002188a Figure 6.6 Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 45: Combo Tank Installation For Regeneration-Style Air Dryers

    CHECK VALVE LINE PORT DRYER OUTLET PORT PURGE SYSTEM VALVE RESERVOIR (EXHAUST) SUPPLY INTERNAL LINE CHECK VALVE SYSTEM RESERVOIR SUPPLY TANK CHECK (WET) VALVE ALTERNATE PCCV LOCATION WITH COMBO RESERVOIR 4003883a Figure 6.7 Meritor WABCO Maintenance Manual 34 (Revised 03-16)
  • Page 46 INLET RESERVOIR SUPPLY LINE PORT LINE DRYER INTERNAL OUTLET CHECK PORT VALVE PURGE VALVE (EXHAUST) SUPPLY TANK SYSTEM (WET) RESERVOIR ALTERNATE PCCV LOCATION WITH COMBO RESERVOIR PRESSURE- CONTROLLED CHECK VALVE 4003884a Figure 6.8 Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 47: Meritor Wabco System Saver Series Single Cartridge Air Dryer Component Replacement Guide - Dedicated Purge

    6 Appendix III — Special Applications Meritor WABCO System Saver Series Single Cartridge Air Dryer Component Replacement Guide — Dedicated Purge Figure 6.9 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 48: Meritor Wabco System Saver Series Single Cartridge Air Dryer Component Replacement Guide

    6 Appendix III — Special Applications Meritor WABCO System Saver Series Single Cartridge Air Dryer Component Replacement Guide NOTE: Whenever an assembly is replaced due to seal damage from oil contamination, it is recommended that you find and correct the source of the oil contamination and replace the desiccant cartridge.

  • Page 49: Section 7: Appendix Iv - Exploded View Of System Saver 1200 Plus Series Air Dryer

    7 Appendix IV — Exploded View of System Saver 1200 Plus Series Air Dryer Figure 7.1 SYSTEM SAVER 1200 PLUS SERIES AIR DRYER DESICCANT PRESSURE CARTRIDGE RELIEF VALVE O-RING OUTLET CHECK VALVE ASSEMBLY GOVERNOR HEATER ASSEMBLY TURBO CUT-OFF VALVE PURGE VALVE ASSEMBLY ASSEMBLY 4007692a Figure 7.1 Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 50: Section 8: Appendix V - Temporary Air Dryer Bypass

    Leave the valves open to the atmosphere for several hours if possible. When repairs are completed, be sure to check that all reservoirs (including the air dryer) are emptied of all contaminants. Meritor WABCO Maintenance Manual 34 (Revised 03-16)

  • Page 51: Section 9: Appendix Vi - Exploded View Of

    SYSTEM SAVER 1200 PLUS SERIES AIR DRYER WITH MULTI CIRCUIT PROTECTION DESICCANT CARTRIDGE DRAIN O-RING VALVE TURBO CUT-OFF VALVE ASSEMBLY PURGE VALVE ASSEMBLY HEATER ASSEMBLY GOVERNOR PRESSURE RELIEF VALVE OUTLET CHECK 4011774a VALVE ASSEMBLY Figure 9.1 Meritor WABCO Maintenance Manual 34 (Revised 03-16)
  • Page 52 Meritor WABCO Vehicle Control Systems 2135 West Maple Road Printed in USA Troy, MI 48084-7121 866-OnTrac1 (668-7221) Copyright 2016 Revised 03-16 meritorwabco.com Meritor, Inc. Maintenance Manual 34 (16579)

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