WABCO 1200E User manual
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
Service Notes
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.
Meritor WABCO Maintenance Manual 34 (Revised 03-16)
About This Manual
This manual contains maintenance procedures for Meritor WABCO’s
System Saver Series single cartridge air dryers.
Before You Begin
1. Read and understand all instructions and procedures before
you begin to service components.
2. Read and observe all Warning and Caution hazard alert
messages in this publication. They provide information that can
help prevent serious personal injury, damage to components,
or both.
3. Follow your company’s maintenance and service, installation,
and diagnostics guidelines.
4. Use special tools when required to help avoid serious personal
injury and damage to components.
Hazard Alert Messages and Torque
Symbols
WARNING
Warnings are included to alert the user that possible hazards
are associated with the processes/procedures described.
These may cause death or injury in any form, if the
instructions in the operational or procedural task are not
followed precisely. Warnings describe the potential hazards
and possible impact that could occur if the warnings are not
observed.
CAUTION
Cautions are included to alert the user than damage to the
equipment is possible if the instructions in the operational or
procedural task are not followed precisely. Cautions describe
the hazards and possible impact that could occur if the
cautions are not observed.
@This symbol alerts you to tighten fasteners to a specified torque
value.
NOTE: Notes are included to provide the user with supplemental
information, which is helpful but does not necessarily belong in the
core text. Many operational and procedural tasks are easier with the
addition of notes.
How to Obtain Additional Maintenance,
Service and Product Information
Visit Literature on Demand at meritor.com to access and order
additional information.
Contact the Meritor OnTrac™ Customer Call Center at
866-668-7221 (United States and Canada); 001-800-889-1834
(Mexico); or email OnTrac@meritor.com.
If Tools and Supplies are Specified in
This Manual
Contact Meritor’s Commercial Vehicle Aftermarket at
888-725-9355.
Contents
pg. pg.1Section 1: Introduction
Overview
Other Publications Related to Meritor WABCO System
Saver Series Single Cartridge Air Dryers
Air Dryer Identification
2 How the Air Dryer Works
3 Air Dryer Cycle
7 Air Dryer Components
10 Dryer Identification
Description of Components
14 Section 2: Component Removal and
Installation
Component Replacement
Requirements
15 Component Removal and Installation
Desiccant Cartridge
16 Outlet Check Valve Assembly
Heater Assembly
17 Turbo Cut-Off Valve Assembly
18 System Saver 1200 Plus Governor
Regeneration Valve Assembly
19 Purge Valve Assembly
20 Pressure-Controlled Check Valve (PCCV)
21 Bypass Valve
22 Pressure Relief Valve
Purge Silencer (Muffler)
23 Air Dryer Assembly
24 Section 3: Troubleshooting and Testing
Maintenance
25 Maintenance Tips
26 Troubleshooting
31 Tests
Heater Resistance
Electric Power to Dryer
Leak Test
Air Pressure Checks
Operational Test for System Saver Series Air Dryers —
Regeneration and Purge Style
32 Pressure-Controlled Check Valve Test — Regeneration
Style Only
34 Section 4: Appendix I — Glossary
Definitions
Basic Air System/Air Dryer Terms
35 Section 5: Appendix II — Application Info
Requirements
Operating Environment
36 System Saver Series Installation Criteria
37 Section 6: Appendix III — Special
Applications
Description
Holset E-Type Compressor Systems
38 ECON Valve
40 Alcohol Evaporator
41 Combo Tank Installation for Regeneration-Style Air Dryers
42 Combo Tank Installation for Regeneration-Style Air Dryers
43 Meritor WABCO System Saver Series Single Cartridge Air
Dryer Component Replacement Guide — Dedicated
Purge
44 Meritor WABCO System Saver Series Single Cartridge Air
Dryer Component Replacement Guide
45 Section 7: Appendix IV — Exploded View of
System Saver 1200 Plus Series Air Dryer
46 Section 8: Appendix V — Temporary Air
Dryer Bypass
Bypass Procedure
47 Section 9: Appendix VI — Exploded View of
System Saver 1200 Plus Series with Multi
Circuit Protection
Notes
1 Introduction
1
Meritor WABCO Maintenance Manual 34 (Revised 03-16)
1 Introduction
Overview
Maintenance Manual 34 contains troubleshooting steps and service
information for the Meritor WABCO System Saver Series (1200 and
1800) single cartridge air dryers.
NOTE: If you have a System Saver TWIN air dryer, use Maintenance
Manual 35, Meritor WABCO System Saver TWIN Air Dryer. To obtain
this publication, refer to the Service Notes page on the front inside
cover of this manual.
Other Publications Related to Meritor WABCO
System Saver Series Single Cartridge Air
Dryers
TP-92116, Installing the Meritor WABCO System Saver Series Air
Dryer, provides complete installation instructions.
PB-8857AS contains a complete listing of air dryer replacement
parts.
TP-97101 is a troubleshooting guide. There is also a poster-sized
troubleshooting guide, TP-9772, available.
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.
TP-1033, System Saver 1200 Plus Series Air Dryers, provides
installation instructions.
TP-1343, Troubleshooting and Repairing System Saver 1200 Plus
Air Dryers with Turbo Cut-off Valves on Vehicles with Cummins
Engines, provides service instructions.
TP-09133, Replacing a Bendix AD9 Air Dryer with a System Saver
1200 Plus Air Dryer, provides replacement instructions.
TP-0579, Installation Instructions for Meritor WABCO’s Dessicant
Cartridge Replacement Kit, provides installation instructions.
TP-9610, Using an Alcohol Evaporator with Meritor WABCO System
Saver 1000, 1200, and 1200 E Series Single Cartridge, provides air
dryer instructions.
TP-9557, Pressure Relief Valve Installation Instructions for Meritor
WABCO System Saver 1000, 1200 and 1200E Series and System
Saver TWIN Air Dryers, and Modification Instructions for Units
Equipped with Alcohol Evaporators, provides installation
instructions.
To order literature, visit our website at meritorwabco.com.
Air Dryer Identification
Alphabetical designations of the System Saver Series family of air
dryers have specific meanings:
P Indicates an external purge tank is used for 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 line — unloaded compressor (with external
purge tank)
System Saver 1200/1800: System regeneration valve assembly on
side of dryer
System Saver 1200E: Tubing and banjo fitting at front of dryer
System Saver 1200P/1800P: Uses dedicated purge tank. Port 22
drilled and tapped
System Saver 1200U/1800U: Small regeneration hole visible in
back of Port 1 when fitting is removed. No spring in turbo cut-off
valve assembly.
System Saver 1200UP/1800UP: Port 22 drilled and tapped. Small
regeneration hole visible at back of Port 1 when fitting is removed.
No spring in turbo cut-off valve assembly. Dedicated purge tank.
The air dryer base is the same for both the 1200 and 1800 Series
air dryers, however the 1800 Series canister is 3.2 inches taller
than the 1200. This larger canister contains 50% more desiccant,
which makes the 1800 ideal for applications calling for frequent
starts, stops and long compressor cycles. System Saver 1200 and
System Saver 1800 Series air dryers are illustrated in Figure 1.1.
System Saver 1200P and System Saver 1800P, which are used with
a dedicated purge tank, are illustrated in Figure 1.2.
System Saver 1200 Plus: Has the governor integrated into the
body of the air dryer and also has an integrated purge tank.
Figure 1.3.
System Saver 1200 Plus MCP: Has the governor and pressure
protection elements integrated into the body of the air dryer. Also
has an integrated purge tank. Figure 1.4.
1 Introduction
2Meritor WABCO Maintenance Manual 34 (Revised 03-16)
Figure 1.1
Figure 1.2
Figure 1.3
Figure 1.4
How the Air Dryer Works
During system pressure build-up, compressed air passes into the air
dryer where the filter system removes contaminants and passes the
air into the drying stage.
Moisture-laden air passes through the desiccant bed in the air dryer
cartridge and moisture is retained by the desiccant. Moisture that
condenses out also collects in the base of the dryer. When the
compressor unloads, the water is expelled and dried air flows back
through the dryer, drying the desiccant for the next cycle.
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.
Figure 1.1
SYSTEM SAVER 1200 AND 1800 SERIES
Figure 1.2
SYSTEM SAVER 1200P AND 1800P
Figure 1.3
SYSTEM SAVER 1200 PLUS
4003875a
4003876a
4007638a
Figure 1.4
SYSTEM SAVER 1200 PLUS MCP
4011898a
1 Introduction
3
Meritor WABCO Maintenance Manual 34 (Revised 03-16)
Air Dryer Cycle
A single cartridge air dryer cycle is illustrated in Table A.
Table A
The governor turns the compressor on when supply tank pressure
drops below cut-in pressure, between 100 psi and 110 psi
(689-758 kPa) depending on governor settings.
Compressed air passes into the air dryer at the inlet port:
앫Moisture-laden air and contaminants pass through the
desiccant.
앫Moisture is retained by desiccant; moisture also collects in the
base of the dryer.
앫Contaminants are removed as air passes through the desiccant
bed.
The governor turns the compressor off when system reaches
cut-out pressure, between 120 psi and 130 psi (827-896 kPa)
depending on governor settings.
1002142a
CONTROL
“WET” AIR
“DRY” AIR
CONTROL/DRY
LINES
ENGINE TURBO
BOOST PRESSURE
1002143a
1002145a
CONTROL
“WET” AIR
“DRY” AIR
CONTROL/DRY
LINES
ENGINE TURBO
BOOST PRESSURE
1 Introduction
4Meritor WABCO Maintenance Manual 34 (Revised 03-16)
When the compressor unloads, the purge valve opens:
앫On 1200E, P, U, 1800E, P, U, the dryer purges the desiccant
cartridge and expels any water collected in the dryer base.
— Regeneration valve opens.
앫On 1200 regeneration models, when the regeneration valve
opens.
— Dry system air flows back through the dryer, 10 psi (69 kPa)
is taken from the supply and secondary tanks for the
regeneration.
— Back flow dries desiccant, preparing it for the next cycle.
앫On 1200 P, UP, 1800 P and UP:
— Dry air flows from the separate purge tank back through the
air dryer.
앫On 1200 Plus:
— Dry air flows from the integrated purge tank back through
the air dryer. Air can be felt and heard flowing from the
purge valve for an extended period of time.
— Dry system air flows back through the air dryer to
regenerate the desiccant.
1002144b
1200E, P, U
1800E, P, U
1200 PLUS
TO
CANISTER
FROM
CANISTER
IN
OUT TO TANKS
1 Introduction
5
Meritor WABCO Maintenance Manual 34 (Revised 03-16)
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.
Figure 1.5
Figure 1.5
1002141c
PURGE
VALVE
(EXHAUST)
COMPRESSOR
DISCHARGE
LINE
COMPRESSOR
CONTROL
(PURGE) PORT
COMPRESSOR
INTAKE LINE
PRESSURE-
CONTROLLED
CHECK VALVE
SUPPLY
TANK
SYSTEM
RESERVOIRS
ONE-WAY
CHECK
VALVE
DRYER
OUTLET
PORT
SYSTEM SAVER SERIES
REGENERATION
STYLE AIR DRYER
DRYER
INLET
PORT
UNLOADER
LINE
RESERVOIR-
TO-GOVERNOR
LINE
1800
1200
SUPPLY
LINE
PURGE
TANK
PURGE
VALVE
(EXHAUST)
P SERIES WITH DEDICATED
PURGE TANK
BOTTOM VIEW
OF AIR DRYER
REGENERATION
VALVE
GOVERNOR
UNLOADER
PORT
1 Introduction
6Meritor WABCO Maintenance Manual 34 (Revised 03-16)
Figure 1.6
Figure 1.6
4012522a
COMPRESSOR
DISCHARGE
LINE PURGE VALVE
(EXHAUST)
COMPRESSOR
CONTROL
(PURGE)
PORT
DRYER
INLET PORT
COMPRESSOR
INTAKE LINE
SUPPLY
TANK
SYSTEM
RESERVOIRS
ONE-WAY
CHECK
VALVE
SYSTEM SAVER
1200 PLUS
AIR DRYER
UNLOADER
LINE
SUPPLY
LINE
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7
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