WABCO SYSTEM SAVER HP MM1736 User manual

SYSTEM SAVER HP
AIR DRYER
MAINTENANCE MANUAL
MM1736

Table of Contents

3
Table of Contents
EN
Table of Contents
1 General Information ......................................................................................................................................... 4
2 Safety Information............................................................................................................................................ 6
3 Introduction ...................................................................................................................................................... 7
3.1 Overview .........................................................................7
3.2 AirDryerIdentication ...............................................................7
3.3 HowtheAirDryerWorks .............................................................7
3.3.1 Air Dryer Cycle .......................................................................................................................... 8
3.3.2 System Saver HP Air Dryer System .......................................................................................... 9
3.4 AirDryerComponents ..............................................................10
3.4.1 DryerIdenticationTag ........................................................................................................... 11
3.4.2 DescriptionofComponents..................................................................................................... 11
4 Component Removal and Installation.......................................................................................................... 14
4.1 ComponentReplacement ...........................................................14
4.1.1 Requirements.......................................................................................................................... 14
4.2 ComponentRemovalandInstallationProcedures ........................................16
4.2.1 DesiccantCartridge................................................................................................................. 16
4.2.2 Outlet Check Valve Assembly ................................................................................................. 18
4.2.3 Heater Assembly ..................................................................................................................... 19
4.2.4 TurboCut-OValveAssembly ................................................................................................ 20
4.2.5 Governor ................................................................................................................................. 20
4.2.6 PurgeValveAssembly ............................................................................................................ 21
4.2.7 Air Dryer Assembly.................................................................................................................. 21
5 Troubleshooting and Testing ........................................................................................................................ 23
5.1 Maintenance .....................................................................23
5.1.1 MaintenanceTips .................................................................................................................... 24
5.2 Troubleshooting ...................................................................24
5.2.1 Tests........................................................................................................................................ 27
5.2.2 Air Pressure Checks................................................................................................................ 28
6 Glossary.......................................................................................................................................................... 30
7 Application Information................................................................................................................................. 31
7.1 Recommendations.................................................................31
7.1.1 OperatingEnvironment ........................................................................................................... 31
7.1.2 DischargeLine ........................................................................................................................ 31
7.2 SystemSaverInstallationCriteria .....................................................32
Edition 2
10.2019
MM1736 1 (en)
This publication is not subject to any update service. 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. WABCO reserves the right to revise the
information presented or to discontinue the production of parts described at any time.

4
General Information General Information
EN 1 General Information
Symbols used in this document
DANGER
Descriptionofanimmediatesituationwhichwillresultinirreversibleinjuryordeathifthewarningis
ignored.
WARNING
Descriptionofapossiblesituationwhichmayresultinirreversibleinjuryordeathifthewarningis
ignored.
CAUTION
Descriptionofapossiblesituationwhichmayresultinirreversibleinjuryifthewarningisignored.
NOTICE
Descriptionofapossiblesituationwhichmayresultinmaterialdamageifthewarningisignored.
i
i
Importantinformation,notesand/ortips
www www
@
@ @@
Referencetoinformationontheinternet
1. Actionstep
- Actionstep
ÖConsequenceofanaction
List
• List
Note on the use of a tool/WABCO tool
How to Obtain Additional Maintenance, Service and Product Information
Ifyouhaveanyquestionsaboutthematerialcoveredinthispublication,orformoreinformationabout
theWABCOproductline,pleasecontactWABCOCustomerCareCenterat855-228-3203,byemailat
[email protected],orvisitourwebsite:www.wabco-na.com.

5
General Information
EN
WABCO Academy
www www
@
@ @@
https://www.wabco-academy.com/home/
WABCO online product catalog
www www
@
@ @@
http://inform.wabco-auto.com/
Your direct contact to WABCO
WABCO North America
WABCO USA LLC
1220 Pacic Drive
Auburn Hills, MI 48326
Customer Care Center: [phone]
www.wabco-na.com

6
Safety Information Introduction
EN 2 Safety Information
Provisions for a safe work environment
Onlytrainedandqualiedautotechniciansandautomechanicsmaycarryoutworkonthevehicle.
Readthispublicationcarefully.
Followallwarnings,noticesandinstructionstoavoidpersonalinjuryandpropertydamage.
Alwaysabidebythevehiclemanufacturer'sspecicationsandinstructions.
Observeallaccidentregulationsoftherespectivecompanyaswellasregionalandnational
regulations.
Theworkplaceshouldbedry,su󰀩cientlylitandventilated.
Usepersonalprotectiveequipmentifrequired(safetyshoes,protectivegoggles,respiratory
protectionandearprotectors).
ReadandobserveallDanger,WarningandCautionhazardalertmessagesinthispublication.They
provideinformationthatcanhelppreventseriouspersonalinjury,damagetocomponents,orboth.
WARNING
Topreventseriouseyeinjury,alwayswearsafeeyeprotectionwhenyouperformvehicle
maintenanceorservice.
WARNING
Parkthevehicleonalevelsurface.Blockthewheelstopreventthevehiclefrommoving.Supportthe
vehiclewithsafetystands.Donotworkunderavehiclesupportedonlybyjacks.Jackscansliporfall
over.Seriouspersonalinjuryanddamagetocomponentscanresult.
WARNING
Removeallairpressurefromtheairsystembeforeyoudisconnectanycomponent,includingthe
desiccantcartridge.Pressurizedaircancauseseriouspersonalinjury.

7
Introduction
EN
3 Introduction
3.1 Overview
MaintenanceManualMM1736containstroubleshootingstepsandserviceinformationfortheWABCO
SystemSaverHPsinglecartridgeairdryers.
IfyouhaveaWABCOSystemSaver(1200or1800)singlecartridgeairdryer,useMM34,WABCO
SystemSaverSeries(1200and1800)SingleCartridgeAirDryers.IfyouhaveaWABCOSystemSaver
Twinairdryer,useMM35,WABCOSystemSaverTwinAirDryer.Todownloadthesepublications,goto
wabco-na.com.
3.2 Air Dryer Identication
TheSystemSaverHPairdryerhasthegovernorintegratedintothebodyoftheairdryerandalsohasan
integratedpurgetank.Figure1.
Fig.1
4013285a
PURGE
TANK
GOVERNOR
3.3 How the Air Dryer Works
Duringsystempressurebuild-up,compressedairpassesintotheairdryerwherethelter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owsbackthroughthedryer,dryingthedesiccantforthenext
cycle.

8
Introduction Introduction
EN 3.3.1 Air Dryer Cycle
AsinglecartridgeairdryercycleisillustratedinTableA.
Table A: Air Dryer Cycle
Cycle Stage Air Flow
Thegovernorturnsthecompressorloading
onwhensupplytankpressuredropsbelow
cut-inpressure,between105-115psi
(724-792kPa)dependingonthegovernor
settings.
4013565c
CONTROL
“WET” AIR
“DRY” AIR
COMPRESSOR
INTAKE LINE
Compressedairpassesintotheairdryerat
theinletport:
Moisture-ladenairandcontaminants
enterthedesiccant.
Moistureisretainedbydesiccant;
moisturealsocollectsinthebaseofthe
dryer.
Contaminantsareremovedasair
passesthroughthedesiccantbed.
4013286a
INLET
PORT 1
CARTRIDGE
OUTLET
PORT 2.1/2.2
Thegovernorunloadsthecompressor
whenthesystemreachescut-outlevel132
psi(910kPa)+/-3psi,dependingonthe
governorsettings.
4013566c
CONTROL
“WET” AIR
“DRY” AIR
COMPRESSOR
INTAKE LINE

9
Introduction
EN
Cycle Stage Air Flow
Whenthecompressorunloads,thepurge
valveopens.OntheSystemSaverHP:
Dryairowsfromtheintegratedpurge
tankbackthroughtheairdryer.Aircan
befeltandheardowingfromthepurge
valveforanextendedperiodoftime.
Drysystemairowsbackthroughthe
airdryertoregeneratedesiccant.
4013569a
PURGE PORT
3.2
CARTRIDGE
PURGE
TANK
3.3.2 System Saver HP Air Dryer System
Fig.2
4013288a
COMPRESSOR
DISCHARGE
LINE
COMPRESSOR
CONTROL
(PURGE)
PORT
DRYER
INLET PORT
COMPRESSOR
INTAKE LINE
SUPPLY
TANK
SYSTEM
RESERVOIRS
ONE-WAY
CHECK
VALV E
SYSTEM SAVER
IP AIR DRYER
UNLOADER
LINE
SUPPLY
LINE
PURGE VALV E
(EXHAUST)
ONE-WAY
CHECK
VALV E

10
Introduction Introduction
EN 3.4 Air Dryer Components
WABCOSystemSaverHPsinglecartridgeairdryerscontainreplaceablecomponentpartsshownin
Figure3.RefertoSection4forinstructionsforremovalofoldpartsandinstallationofnewparts.
Fig.3
4013289a
GOVERNOR
PORT 3.3
PRESSURE
RELIEF VALV E
PORT 3.1
DESICCANT
OR COALESCING
CARTRIDGE
O-RING
HEATER
ASSEMBLY
PORT 6
PURGE VALV E
ASSEMBLY
PORT 3.2
TURBO CUT-OFF
VALVE ASSEMBLY
PORT 3.4
OUTLET
CHECK VALV E
ASSEMBLY
PORT 2.1

11
Introduction
EN
3.4.1 Dryer Identication Tag
Theidenticationtagonthefaceofthedryerprovidesimportantinformationabouttheairdryer—
informationyouwillneedwhenservicingorreplacingcomponents.Figure4.
Fig.4
4013290a
17114
DATE CODE
FIRST TWO DIGITS =
BUILD YEAR
SECOND TWO DIGITS =
BUILD WEEK
LAST DIGIT =
DAY OF THE WEEK
MANUFACTURING
LOCATION CODE
PART NUMBER
3.4.2 Description of Components
Replacementcomponentsforsinglecanisterairdryersaredescribedbelow.
Spin-on/spin-o󰀨designallowsquickandeasymaintenance.
Always replace cartridges with authentic WABCO brand cartridges.
Coalescing Cartridge:Utilizesalterelementaddedtothestandarddesiccanttoremoveaerosolsandoil
particles.
Heater:Locatedintheairdryerbase,theheaterpreventswaterthatcollectsintheairdryerfromfreezing.
Itconsistsofacylindricalresistive-typeheatingelementandasmallcircularthermostat.Heaterisavailable
for12-and24-voltairdryers.Figure5.
Fig.5
1002149a
HEATER MAY BE STAINLESS
STEEL CLAD OR CERAMIC
Outlet Check Valve:Avalvelocatedintheoutletport(port21)oftheairdryer.Itpreventsairfromowing
backthroughtheairdryerandescapingoutthepurgevalveduringacompressorunloadcycle.Figure6.
Fig.6
1002151a

12
Introduction Introduction
EN Pressure Relief Valve: Avalvethatprotectstheairdryerfromover-pressurization.Figure7.
Fig.7
1002153a
Purge Valve Assembly:Avalveassemblylocatedonthebottomoftheairdryer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8.
Fig.8
4013321a
Turbo Cut-o󰀨 Valve: Avalvelocatedintheinletportoftheairdryer.Itclosesthepathbetweentheair
compressorandtheairdryerpurgevalveduringcompressorunload.Thispreventsalossofturbocharger
boostpressureduringacompressorunloadcycle,therebymaintainingboostpressureformaximumengine
horsepower(usedexclusivelyon1200PlusandHPmodels).Figure9.
Fig.9
4013365a
Heater Power Harness: Twelve-inchcablewithMetri-Packplugprovideselectricalconnectiontoairdryer
heatingunit.Figure10.
Fig.10
1002157a

13
Introduction
EN
Governor:Locatedinport3.3oftheairdryerbase.Controlsthecut-inandcut-outpressureofthe
compressor.Figure11.
Fig.11
4014745a

14
Component Removal and Installation Component Removal and Installation
EN 4 Component Removal and Installation
WARNING
Topreventseriouseyeinjury,alwayswearsafeeyeprotectionwhenyouperformvehicle
maintenanceorservice.
WARNING
Parkthevehicleonalevelsurface.Blockthewheelstopreventthevehiclefrommoving.Supportthe
vehiclewithsafetystands.Donotworkunderavehiclesupportedonlybyjacks.Jackscanslipand
fallover.Seriouspersonalinjuryanddamagetocomponentscanresult.
WARNING
Removeallpressurefromtheairsystembeforeyoudisconnectanycomponent,includingthe
desiccantcartridge.Pressurizedaircancauseseriouspersonalinjury.
i
i
ThepressureprotectionelementsarenotserviceableontheSystemSaverHP.Theentire
dryerneedstobereplacedifthesepartsarenotoperatinge󰀨ectively.
4.1 Component Replacement
4.1.1 Requirements
RefertoTableBforcomponentreplacementrequirements.Ifnecessary,youmayalsorefertoTableEfor
SystemSaverSeriesairdryertroubleshooting.Beforereplacinganyairdryercomponent,verifythattheair
compressorandairgovernorareworkingcorrectly,thendraintheairtanks.Repairorreplacetheseparts,
ifnecessary.Checktheentireairsystemforleaks,andrepairasnecessary.Whendrainingairtanksbefore
servicingtheairdryer,checkforwaterand/oroilthatmayhaveaccumulatedinthetanks.Waterand/oroil
intheairtankscouldindicateaproblemwiththedryerorcompressor.

15
Component Removal and Installation
EN
Table B: Replacement Requirements
Component When to Replace Why
Cartridge Everytwotothreeyearsforstandard
dessicant.
Everyonetotwoyearsforcoalescing.
Preventativemaintenance.
Whencompressorisreplaced. Contaminatedcartridge.
Waterinsupplytank. Saturatedorcontaminatedcartridge,
highdutycycle(wrongapplicationof
airdryer).
Heater
Assembly
Watercollectinginairdryerisfreezing—
electricalpowertodryerisOK.
Heaterassemblynotworking
(internalshortoropencircuit).
OutletCheck
Valve
Aircontinuestoowfrompurgevalveafter
purgecycle,butstopsowingwhenthe
compressorloadcyclebegins.
Valveisstuckintheopenposition,or
notfunctioningcorrectly.
Nopressurebuild-upinsystem,everything
elseisOK.
Valveisstuckinclosedposition.
PurgeValve Nopurgecyclewhencompressorunloads
—normalpressureatdryercontrolport4
(governorport).
Valveisstuckintheclosedposition,
ornotfunctioningcorrectly.
Airowsfrompurgevalveduring
compressor’sloadcycle—nopressureat
dryercontrolport.
Valveisstuckintheopenposition,or
notfunctioningcorrectly.
TurboCut-O󰀨
Valve
Aircompressorstuckpumping,TCUremains
open.Systemwillbuildpressureuntilsafety
valveopensinsystem.
Signallineloss.
Airowsfrompurgevalveduring
compressorunloadcycleafterpurgecycle,
andowisnoticeablystrongerathigh
engineRPM,especiallyunderload.
Turbocut-o󰀨valveleaking.
Nopressurebuild-upinsystem—high
compressordischargelinepressure.
Valvestuckinclosedposition.

16
Component Removal and Installation Component Removal and Installation
EN 4.2 Component Removal and Installation Procedures
WARNING
Topreventseriouseyeinjury,alwayswearsafeeyeprotectionwhenyouperformvehicle
maintenanceorservice.
WARNING
Parkthevehicleonalevelsurface.Blockthewheelstopreventthevehiclefrommoving.Supportthe
vehiclewithsafetystands.Donotworkunderavehiclesupportedonlybyjacks.Jackscanslipand
fallover.Seriouspersonalinjuryanddamagetocomponentscanresult.
WARNING
Removeallpressurefromtheairsystembeforeyoudisconnectanycomponent,includingthe
desiccantcartridge.Pressurizedaircancauseseriouspersonalinjury.
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ThepressureprotectionelementsarenotserviceableontheSystemSaverHP.Theentireair
dryerneedstobereplacedifthesepartsarenotoperatinge󰀨ectively.
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Whenreplacingairdryercomponents,useonlyWABCOreplacementparts.
TheexplodedviewoftheairdryerinSection3showsthelocationofthevariousairdryercomponents.
4.2.1 Desiccant Cartridge
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IMPORTANT NOTE:RefertoTableCforcorrectdesiccantcartridgepartnumberstousewith
theairdryer.
Table C: Replacement Cartridges
Air Dryer Part Number Replacement Cartridge Part Number
4324800010 4329012382
4324801010 4329012382
4324801410 432 901 248 2
4324802010 4329012382
4324803010 4329012382
4324803410 432 901 248 2

17
Component Removal and Installation
EN
1. VerifythereplacementkitcontainsonecartridgeandoneO-ring.Figure12.
Fig.12
1002234a
2. Loosenandremovetheoldcartridge.Usestrapawrenchifnecessary.
3. RemoveanddiscardO-ringfromdryerbase.
4. Inspectandcleansealseat.Figure13.Repairanyminordamage.
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Ifthesealseatsaredamagedsobadlythatatightsealcannotbemaintained,replacetheair
dryer.
Fig.13
1002164a
SEAL
SEAL SEAT
O-RING
5. LubricateandinstallthenewO-ringonthestem.
6. Lubricatecartridgeseal.
7. Threadthereplacementcartridgeontothebaseuntilthesealtouchesthebase.Then,tightenthe
cartridgeONEadditionalturn.DO NOT OVERTIGHTEN.Figure13.Ifthecartridgewillnotfullyspinon
thedryer,thewrongcartridgeisbeinguse.RefertotheIMPORTANTNOTEandtable.

18
Component Removal and Installation Component Removal and Installation
EN 4.2.2 Outlet Check Valve Assembly
1. ReviewFigure14toensureyouhaveallofthepartsrequiredtoreplacetheoutletcheckvalve.Usethe
greaseincludedwiththereplacementkittolubricatetheO-ringseal.
Fig.14
4013363a
O-RING
VALV E
BODY
SNAP
RING
SPRING
WASHER
GREASE
2. Removethesnapring,washer,spring,valvebodyandO-ring.
3. Cleanandinspectthevalvebore.Iftheboreisdamagedsothatatightsealcannotbemaintained,
replacetheairdryer.
4. InstallthenewO-ringonthevalvebody.Figure15.
Fig.15
1002166a
SNAP RING
WASHER
SPRING
O-RING
VA LV E
BODY
5. Applyathinlayerofgreasefromthekit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nsonthevalvebody.
8. Installthenewwasherandthenewsnapringtoholdthecomponentsinplace.

19
Component Removal and Installation
EN
4.2.3 Heater Assembly
1. ReviewFigure16toensureyouhaveallofthepartsrequiredtoreplacetheheaterassembly.
Fig.16
1002167a
THERMOSTAT
RECEPTACLE
O-RING
HEATER
ELEMENT
2. Disconnecttheplug.
3. Removethescrews,receptacleandO-ringfromthebasetoaccesstheretainerscrew.
4. Removetheretainerscrewandthenremovetheentireheaterassembly.
5. InstalltheO-ringtoheaterconnectorhousing.
6. Installthenewelementandthermostatintheircavities.
7. Installthenewretainerandscrewtoholdtheelementandthethermostatinplace.
8. Installthereceptacleandfastenitinplacewiththescrews.Figure17.
Fig.17
1002168a
O-RING
HEATER
ELEMENT
THERMOSTAT
RECEPTACLE

20
Component Removal and Installation Component Removal and Installation
EN 4.2.4 Turbo Cut-O󰀨 Valve Assembly
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UsethegreaseincludedwiththereplacementkittolubricatetheO-ringsandseals.
1. Removethesnapring.Figure18.
Fig.18
4013287a
O-RING
PISTON
O-RING
SLEEVE
COVER
SNAP
RING
2. Removethecover.
3. Removethepistonandsleeve.
4. Cleanandinspectthevalvebore.Iftheboreisdamagedsothatatightsealcannotbemaintained,
replacetheairdryer.
5. ApplyathinlayerofgreasetothevalveboreandtheO-rings.
6. InstallnewO-ringsonthepistonandsleeve.
7. Pressthepistonintothesleeve.
8. Pressthepiston-sleeveassemblyintotheairdryer.
9. Installthecoverandsnapring.
10.Replacethedesiccantcartridgeusingthedetailedinstructionsprovidedearlierinthissection.
4.2.5 Governor
Function—Thegovernorcontrolsthecut-inandcut-outpressureofthecompressorthroughsignallines
fromthesystemreservoiraswellasthecompressorheadcontrollingonloadando󰀪oad.
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UseonlytheWABCOgovernorspeciedforusewiththeSystemSaverHPairdryer.