WABCO SYSTEM SAVER HP MM1736 Maintenance Manual Download Page 22 | Manualshive

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22

Component Removal and Installation

Troubleshooting and Testing

EN

2.

Disconnect the heater electrical plug from the heater receptacle.

3.

Remove the three mounting bolts. Remove the air dryer from its mounting location. Figure 21.

Fig. 21

4013563a

4.

Attach the new unit to the frame or mounting bracket with new mounting bolts and washers. Tighten the

bolts to 22-30 ft-lb (30-40 Nm). Figure 22.

Fig. 22

4013564a

5.

Connect the heater electrical plug to the heater receptacle.

6.

Reconnect all system air lines.

7.

Test the installation for correct operation. Refer to the procedure in this section.

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Summary of Contents for SYSTEM SAVER HP MM1736

Page 1: ...SYSTEM SAVER HP AIR DRYER MAINTENANCE MANUAL MM1736...

Page 2: ......

Page 3: ...rbo Cut Off 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 Troubleshoot...

Page 4: ...OTICE 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 A...

Page 5: ...tps 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 Pacific Drive Auburn Hills MI 48326 C...

Page 6: ...ive 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 p...

Page 7: ...entification 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...

Page 8: ...IR 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 col...

Page 9: ...for an extended period of time Dry system air flows 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 4013288...

Page 10: ...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 VALVE PORT 3 1 DESICCANT OR COALESCING CARTRIDG...

Page 11: ...enance Always replace cartridges with authentic WABCO brand cartridges Coalescing Cartridge Utilizes a filter element added to the standard desiccant to remove aerosols and oil particles Heater Locate...

Page 12: ...ge cycle Figure 8 Fig 8 4013321a Turbo Cut off 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 un...

Page 13: ...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...

Page 14: ...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 effectively 4 1 Component Replac...

Page 15: ...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...

Page 16: ...cartridge Pressurized air can cause serious personal injury i i The pressure protection elements are not serviceable on the System Saver HP The entire air dryer needs to be replaced if these parts ar...

Page 17: ...damage i i 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...

Page 18: ...lve 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 1...

Page 19: ...eceptacle 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 ne...

Page 20: ...r 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 dry...

Page 21: ...inspect the valve bore If the bore is damaged so that a tight seal cannot be maintained replace the air dryer 3 Install the purge valve assembly in the air dryer Use a 1 11 16 wrench to tighten it to...

Page 22: ...ing location Figure 21 Fig 21 4013563a 4 Attach the new unit to the frame or mounting bracket with new mounting bolts and washers Tighten the bolts to 22 30 ft lb 30 40 Nm Figure 22 Fig 22 4013564a 5...

Page 23: ...you disconnect any component including the desiccant cartridge Pressurized air can cause serious personal injury 5 1 Maintenance To keep the air dryer operating efficiently WABCO recommends the follow...

Page 24: ...e air dryer heater is in good working order by running a heater resistance test Refer to the procedure in this section Check the line from the compressor to port 4 of the dryer for oil and or water Ke...

Page 25: ...sary Make sure downward slope of signal line from compressor to dryer Regeneration cycle too long more than 30 seconds accompanied by loss of pressure in the supply tank Outlet check valve not seating...

Page 26: ...f valve not sealing Replace turbo cut off valve Outlet check valve not seating Replace outlet check valve Rapid spitting of air from purge valve in small amounts Frequency varies with engine speed NOT...

Page 27: ...cks out okay Dryer not suitable for application Review the application guidelines Refer to TP9672 For assistance call the WABCO Customer Care Center at 855 228 3203 5 2 1 Tests 5 2 1 1 Heater Resistan...

Page 28: ...are NOT sealed correctly To Repair Incorrectly Sealed Connections 1 Drain all reservoirs 2 Remove leaking connection 3 Inspect the connectors and ports for damaged threads or cracks Replace if necessa...

Page 29: ...he procedure in this maintenance manual 5 If the TCV is not leaking continue to run the engine until the compressor builds the system to cut out pressure typically 130 psi 8 96 bar 6 When cut out pres...

Page 30: ...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 regener...

Page 31: ...trict the flow of air back from the supply tank to the air dryer 7 1 1 Operating Environment Table G Operating Parameters Operating Parameter Requirement Temperature ambient operating range 40 F to 17...

Page 32: ...n time Normal running Two minutes maximum Occasional three times per day maximum Seven minutes Compressor unloaded time Minimum for purge cycle 20 seconds Maximum duty cycle Compressor on time total r...

Page 33: ...33 Notes...

Page 34: ...34 Notes...

Page 35: ...35 Notes...

Page 36: ...milestones in autonomous mobility and apply its extensive expertise to integrate the complex control and fail safe systems required to efficiently and safely govern vehicle dynamics at every stage of...

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