Air Dryer, Meritor WABCO System Saver 1200 Ok
Air Dryer, Meritor WABCO System Saver 1200 Ok
Air Dryer, Meritor WABCO System Saver 1200 Ok
El secador de aire consta de un cuerpo ligero de aluminio y acero. El cartucho desecante está contenido en un recipiente
giratorio en la parte superior del secador de aire.
Los siguientes componentes se conectan al cuerpo del secador de aire:
• Válvula de alivio de presión: esta válvula protege el secador de aire contra la sobrepresurización. La válvula está
conectada directamente al secador de aire.
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• Recipiente desecante: una carcasa cilíndrica de acero que contiene los elementos filtrantes y el desecante necesarios
para filtrar y secar el aire que pasa a través de ella.
• Conjunto de calentador/termostato: ubicado en la base del secador de aire, este conjunto está diseñado para evitar que
la humedad acumulada se congele.
• Válvula de retención de salida: esta válvula evita que el aire del sistema regrese a través del secador de aire y escape
por la válvula de purga durante el ciclo de descarga del compresor.
• Válvula de retención controlada por presión: esta válvula está separada del secador de aire y está instalada en el
tanque de aire del sistema. La válvula permite que el aire regrese desde el tanque del sistema al tanque de suministro
siempre que la presión del sistema de aire permanezca entre el rango normal de activación y desactivación del
regulador de aire.
• Válvula de purga: esta válvula permite que la humedad y los contaminantes acumulados se expulsen del secador de
aire durante el ciclo de purga.
• Válvula de regeneración: esta válvula permite que el aire de los tanques de suministro y del sistema pase por alto la
válvula de retención de salida y fluya hacia la válvula de regeneración. Luego, el aire fluye a través de un orificio donde
se expande y elimina la humedad del desecante. Luego, el aire sale a través de la válvula de purga.
• Silenciador (Silenciador): un componente opcional que se conecta a la válvula de purga y se utiliza para eliminar la
mayor parte del ruido durante el ciclo de purga del secador de aire.
• Válvula de corte del turbocompresor: esta válvula cierra el camino entre el compresor de aire y la válvula de purga del
secador de aire para ayudar a mantener la presión de sobrealimentación para obtener la máxima potencia del motor
durante el ciclo de descarga del compresor.
Principios de Operación
Hot, compressed air enters the air dryer through the inlet port. As the hot air is forced into the desiccant cartridge, the
temperature of the compressed air falls to nearly ambient. Oil and water vapor condense and initially settle into the base of the
dryer. The moisture-laden air also passes through the desiccant bed, where any remaining moisture is retained by the desiccant.
The clean air then passes through the air dryer outlet port to the supply reservoir. See Fig. 2.
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1. Heater/Thermostat Assembly
2. Desiccant Canister
3. Filter
4. Regeneration Valve Assembly
5. Exhaust Port (Purge Valve Assembly)
6. Pressure Relief Valve
When the compressor reaches about 125 psi (862 kPa), the purge valve opens, allowing the initial decompression of the dryer,
and expelling the water and contaminants collected in the base of the dryer. The regeneration valve, along with the pressure-
controlled check valve, allows the system air to flow back through the dryer. This back flow dries the desiccant for the next cycle.
WARNING
When draining the air system, do not look into the air jets or direct them toward another person, as dirt or sludge
particles may be in the airstream. Do not disconnect pressurized hoses because they may whip as air escapes from
the line. Failure to take all necessary precautions during service operations of the air brake system can cause
personal injury.
When working on or around air brake systems and components, observe the following precautions.
1. Apply the parking brake, chock the tires, and stop the engine when working under the vehicle. Draining the air system may
cause the vehicle to roll. Keep hands away from the brake chamber push rods and slack adjusters, which may apply as air
system pressure drops.
2. Wear safety goggles.
3. Never connect or disconnect a hose or line containing air under pressure; it may whip as air escapes. Never remove a
component or pipe plug unless you are sure all system pressure has been depleted.
4. Don't disassemble a component before reading and understanding recommended procedures. Use only the correct tools
and follow basic tool safety.
5. Replacement hardware, tubing, hose, fittings, etc. should be the same size, type, length, and strength as the original
equipment. When replacing tubing or hose, be sure that all of the original supports, clamps, or suspending devices are
installed or replaced.
6. Replace any components that have stripped threads or damaged parts. Don't attempt to repair parts by machining.
7. Never exceed recommended air pressure.
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WARNING
Before starting the procedures below, read the information in Safety Precautions, 100. Failure to follow the safety
precautions during service operations on the air brake system can cause personal injury.
Removal
1. Drain the air system.
2. Disconnect the wiring harness from the air dryer.
3. Mark the air lines for later reference, then disconnect them from the air dryer.
4. Remove the capscrews, washers, and spacers that attach the air dryer to the mounting bracket.
5. Remove the air dryer. See Fig. 1 .
1. Desiccant Canister
2. 1/2" Capscrew, Washer, and Spacer
Installation
1. Position the air dryer on the mounting bracket. Install the spacers, washers, and capscrews. Tighten them 22 to 30 lbf·ft (30
to 41 N·m). See Fig. 1 .
2. Make sure the air lines are clean. Replace any line or fitting that is crimped or damaged.
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3. Connect the remaining air lines to the air dryer as previously marked. Tighten the nut on each fitting finger-tight. Then, using
two wrenches to prevent twisting the hose, further tighten the nut until there is firm resistance.
4. Connect the air dryer wiring harness.
5. Pressurize the air system and check for leaks. Repair as necessary.
WARNING
Before starting the procedures below, read the information in Safety Precautions, 100. Failure to follow the safety
precautions during service operations on the air brake system can cause personal injury.
Fig. 1, Push the Piston, Spring, and Cover out of the Valve
Cavity
3. Using a strap wrench, turn the desiccant cartridge counterclockwise and remove it.
4. Using a wooden stick, push the piston, spring, and the cover out of the valve cavity.
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IMPORTANT: If the valve cavity is damaged, preventing a tight seal, replace the air dryer.
9. Install the new spring, cover, and snap ring to hold the components in place.
10. Thread the desiccant cartridge onto the dryer base (turn clockwise). When the seal contacts the base, tighten the cartridge
one complete turn more. Do not over-tighten.
WARNING
Before starting the procedures below, read the information in Safety Precautions, 100. Failure to follow the safety
precautions during service operations on the air brake system can cause personal injury.
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IMPORTANT: If the valve cavity is damaged, preventing a tight seal, replace the air dryer.
8. Install the spring in the valve head, and position them in the valve cavity.
9. Install the snap ring to secure the valve head in position.
WARNING
Before starting the procedures below, read the information in Safety Precautions, 100. Failure to follow the safety
precautions during service operations on the air brake system can cause personal injury.
1. O-Ring 4. Washer
2. Valve Body 5. Snap Ring
3. Spring
3. Remove the snap ring, washer, valve body, and the O-ring.
4. Clean the cavity area with a commercial cleaning solvent.
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IMPORTANT: If the valve cavity is damaged, preventing a tight seal, replace the air dryer.
9. Install a new washer and snap ring to secure the assembly in the valve cavity.
10. Connect the air line to the outlet port. Tighten the nut on the fitting finger-tight. Then, using two wrenches to prevent twisting
the hose, further tighten the nut until there is firm resistance. Tighten the nut one-sixth turn more.
WARNING
Before starting the procedures below, read the information in Safety Precautions, 100. Failure to follow the safety
precautions during service operations on the air brake system can cause personal injury.
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1. Seal
2. O-Ring
3. Air Dryer Base
IMPORTANT: If the air dryer base is damaged, preventing a tight seal, replace the air dryer.
WARNING
Before starting the procedures below, read the information in Safety Precautions, 100. Failure to follow the safety
precautions during service operations on the air brake system can cause personal injury.
1. Thermostat 3. O-Ring
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WARNING
Before starting the procedures below, read the information in Safety Precautions, 100. Failure to follow the safety
precautions during service operations on the air brake system can cause personal injury.
NOTE: When the valve housing is removed, the spring and the retainer will fall out of the housing. See Fig. 1 .
2. Remove the four mounting bolts and remove the valve housing assembly.
3. Remove the rubber diaphragm.
4. Using a commercial cleaning solvent, clean the groove where the diaphragm lip fits.
5. Install a new diaphragm with its lip in the groove.
IMPORTANT: If the groove is damaged, preventing a tight seal, replace the air dryer.
6. Install the new spring and retainer (with the retainer lip facing out).
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1. Diaphragm 3. Spring
2. Retainer 4. Valve Housing Assembly
WARNING
Before starting the procedures below, read the information in Safety Precautions, 100. Failure to follow the safety
precautions during service operations on the air brake system can cause personal injury.
1. Using snap ring pliers, expand the snap ring and pull the silencer off of the purge valve head. See Fig. 1 .
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3. Silencer
WARNING
Before starting the procedures below, read the information in Safety Precautions, 100. Failure to follow the safety
precautions during service operations on the air brake system can cause personal injury.
3. Screw the replacement valve into the dryer base. Do not exceed a torque of 30 lbf·ft (41 N·m) for a 3/8-inch thread, or 65
lbf·ft (88 N·m) for a 1/2-inch thread.
NOTE: The threads on the replacement pressure relief valve provided by Meritor WABCO are coated with sealant.
They do not require any additional sealant.
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WARNING
Before starting the procedures below, read the information in Safety Precautions, 100. Failure to follow the safety
precautions during service operations on the air brake system can cause personal injury.
1. Air Line
2. Nylon Tube Connector
3. Pressure-Controlled Check Valve
4. Hex Nipple Pipe Fitting
5. Air Tank
NOTE: Apply liquid Loctite® Hydraulic Sealant (brown), or an equivalent, to the threads of all fittings before
installing them. Always apply sealant to the external threads so that any excess will be scraped off externally rather
than internally to the joint.
5. Install the pipe fittings on the new valve. Make sure that the arrow on the valve will be pointing towards the tank when
installed.
6. Install the new valve on the air tank.
7. Connect the air line to the air-line fitting on the valve. Tighten the air line securely.
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22/5/24, 17:18 Air Dryer, Meritor WABCO System Saver 1200
WARNING
Before starting the procedures below, read the information in Safety Precautions, 100. Failure to follow the safety
precautions during service operations on the air brake system can cause personal injury.
If the gauge reading is less that 90 psi (621 kPa), either the pressure-control check valve is installed backwards, it is
damaged, or there are air leaks in the secondary air system.
If the secondary gauge reading does not change, or the reading does not fall below 100 psi (689 kPa):
• There is no pressure-controlled check valve installed, or it is installed in the wrong tank.
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• The pressure-controlled check valve is installed into a one-way check valve, rather than in place of a one-way check
valve.
• There is another check valve located between the air dryer and the secondary air tank.
• The secondary air gauge is not plumbed to the secondary air system.
42.28.300 Troubleshooting
Troubleshooting Table
Meritor WABCO System Saver 1200 Troubleshooting
Dryer leaks from purge valve during Purge valve frozen open (cold weather Check heater. Repair/replace if
compressor-loaded cycle. The leak may operation). necessary. Make sure governor to dryer
cause excessive compressor cycling or port 4 line is free of water/oil.
prevent the system from building air Remove and inspect purge valve and
pressure. clean water/oil from top of piston.
Debris under purge valve seat, such as Disassemble and clean purge valve.
particles from fittings or air inlet line.
Purge valve washer installed upside- Remove cartridge and clean dryer sump
down. area. Ensure lip on aluminum washer
faces DOWN, away from dryer.
Wrong air-line connected to dryer port 4 Verify correct air-line installation and
(unloader port). correct as needed.
Purge valve snap-ring not fully seated in Seat snap-ring fully into groove.
groove.
Slight leak from purge valve. After Outlet check valve not seating or Remove, inspect, and clean outlet check
several hours, the supply tank may be regeneration valve not shutting off valve and regeneration valve
empty. regeneration airflow. diaphragms. Replace if worn or
damaged.
Regeneration cycle too long (more than Outlet check valve not seating. Inspect and replace outlet check valve
30 seconds), accompanied by loss of as needed.
pressure in the supply tank.
Regeneration valve not shutting off Replace regeneration valve.
regeneration airflow.
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Regeneration cycle too short (less than High air system demands during Increase air system capacity or reduce
10 seconds). compressor unloaded cycle. air demands.
One-way check valve installed in system Remove one-way check valve. Make
reservoir instead of, or with, pressure- sure pressure-controlled check valve is
controlled check valve. installed correctly.
No regeneration cycle. No airflow from Air dryer not connected to supply tank or Verify proper dryer installation per
purge valve after initial purge blast connections reversed at dryer. system diagram.
(dryer decompression).
Regeneration valve not working. Replace regeneration valve.
Air dryer does not purge when Air line between governor and air dryer Repair air line.
compressor unloads (no blast of air from port 4 kinked or plugged.
purge valve).
Purge valve stuck closed. Replace purge valve.
Air governor not working properly. Inspect air governor. Repair/replace per
manufacturer's instructions.
Cut-out pressure never achieved by air Check for air leaks in system and repair
compressor. as needed. If no leaks in system, check
compressor output. Repair/replace per
manufacturer's instructions.
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Air dryer purges too often, perhaps as Leak in line between governor and dryer Repair air line.
frequently as every 15 seconds, port 4.
accompanied by excessive cycling of the
compressor. Leak in line between supply tank and Repair air line.
governor.
Outlet check valve not seating. Inspect and replace outlet check valve
as needed.
Air governor has less than 16 psi range. Replace air governor.
Air flows out of purge valve entire time Turbo cut-off valve not sealing. Replace turbo cut-off valve.
compressor is unloaded. NOTE: With U Series air dryers the
compressor unloads through the dryer,
so a steady flow of air is normal.
Rapid "spitting" of air from purge valve in Holset E-type compressor used, but no Install Econ valve to provide make-up air
small amounts. Frequency varies with Econ valve installed. to compressor.
engine speed.
Compressor not completely unloading Inspect compressor. Repair/replace per
when cut-out pressure is reached. manufacturer's instructions.
Air leak at turbo cut-off valve vent. Hole Temperature of air coming into dryer is Move dryer farther from compressor.
burned in piston. too high—not enough cooling takes Add additional compressor discharge
place before dryer inlet. line before air dryer. Add cooling coil or
heat exchanger before air dryer.
NOTE: Inlet air temperature must not
exceed 175°F (80°C).
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Air leak at turbo cut-off valve vent. Lip seal installed upside-down on piston. Install lip seal correctly.
Lip must face UP (towards dryer).
Valve bore worn excessively. Inspect valve bore for wear. If a new
turbo cut-off valve does not seal in a
clean, lubricated bore, replace the air
dryer.
Air dryer frozen (water collecting in base No electrical power to heater connector. Check for a blown fuse. Repair heater
of dryer is freezing). circuit.
NOTE: There must be power to the
heater connector the entire time the
vehicle's ignition is ON.
Wrong voltage air dryer used; i.e., 12- Replace with correct voltage air dryer.
volt air dryer used in a 24-volt system.
No air pressure build-up in system. Air dryer not plumbed correctly Ensure compressor discharge line is
(connections reversed). plumbed to air dryer port 1, and air dryer
port 21 is connected to vehicle's supply
tank.
Wrong air line connected to dryer port 4. Ensure dryer port 4 line is connected to
the "UNL" port of the air governor.
Air dryer leaks from purge valve. Refer to purge valve conditions listed in
this chart.
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Water in tanks; often following Pressure-controlled check valve not Install pressure-controlled check valve in
aftermarket installation or when dryer is installed in correct tank or not installed secondary tank.
a replacement for a competitive brand. at all.
Water, oil, or sludge in air system tanks. Desiccant contaminated with oil. Replace desiccant. Inspect compressor
per manufacturer's instructions.
Water in system tanks, everything else Dryer not suitable for application. Review application guidelines.
checks out okay. For assistance, call Arvin Meritor's
Customer Service Center at 800-535-
5560.
42.28.400 Specifications
See Fig. 1 for the plumbing diagram.
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