System Saver

TWIN Air Dryer

Maintenance Manual 35
Revised 11-02
Service Notes

This publication provides maintenance and service procedures for Meritor WABCO’s System Saver TWIN
air dryers. The information contained in this publication was current at the time of printing and is subject to
revision without notice or liability.
1. You must understand all procedures and instructions before you begin maintenance and service
procedures.
2. You must follow your company’s maintenance and service guidelines.
3. You must use special tools, when required, to avoid serious personal injury and damage to
components.
Meritor WABCO uses the following notations to warn the user of possible safety problems and to provide
information that will prevent damage to equipment and components.

WARNING NOTE: A NOTE indicates an operation, procedure

A WARNING indicates a procedure that or instruction that is important for proper service.
you must follow exactly to avoid serious A NOTE can also supply information that will
personal injury. help to make service quicker and easier.

CAUTION
A CAUTION indicates a procedure that
you must follow exactly to avoid damaging
equipment or components. Serious personal
injury can also occur.
T
This symbol indicates that you must tighten
fasteners to a specific torque.

Visit Our Web Site

Visit the Meritor WABCO website for
additional product and service information:
meritorauto.com

Drivetrain Plus™ Technical

Electronic Library (TEL) on CD
The CD includes product and service
information on Meritor’s Drivetrain Plus™
component lineup. $20. Order TP-9853.

How to Order
Call Meritor’s Customer Service Center at
800-535-5560.

Copyright 2002 Meritor WABCO

 Table of Contents
Section 1: Introduction
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TWIN Support Documentation
How the TWIN Air Dryer Works
TWIN Air Drying Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Air Dryer Parts
Wiring Harness Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Standard Wiring Harness
Wiring/Plumbing Kit for E-Type Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Section 2: Troubleshooting and Testing
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Troubleshooting the TWIN Air Dryer System
Pressure Relief Valve
Meritor WABCO TWIN Air Dryer Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.
System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Heater Resistance
Leak Test
Section 3: Installing Replacement Parts
Desiccant Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Left Piston Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Left Piston Assembly
Right Piston Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Right Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Charging Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Solenoid and Armature Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Heater Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Purge Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Outlet Check Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Orifice Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Purge Silencer (Muffler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Air Dryer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Appendix I: Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-A
Appendix II: Application Information
General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-A
Operating Environment Requirements
Installation Instructions for Special Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-A
Bulk-Unloading or Central Tire Inflation (CTI) Air Systems
Installing a Back-Pressure Control Valve
Holset E-Type Compressor Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-A
Function
Econ Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-A
Econ Valve Operation
Replacing the Econ and Check Valves on a Holset E-Type Compressor System
Replacing the Solenoid Valve
Installing a Turbo Cutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-A
Installation Instructions
Vehicle Air System E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-A
Quick-Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inside back cover
Notes
 Section 1
Introduction

System Overview
Section 1Introduction

This maintenance manual provides an overview of A typical Meritor WABCO System Saver TWIN
the Meritor WABCO System Saver TWIN Air Dryer. installation is illustrated below. Figure 1.1.
If you are servicing a Meritor WABCO System
Saver Series Single Air Dryer, use Maintenance
Manual 34.

Figure 1.1
GOVERNOR
COMPRESSOR
INTAKE LINE
RESERVOIR
UNLOADER TO GOVERNOR
PORT LINE

SYSTEM SAVER TWIN

AIR DRYER
DRYER
OUTLET
PORT
COMPRESSOR
CHECK TO BRAKE
CONTROL SYSTEM
VALVE
(PURGE)
PORT SYSTEM
RESERVOIR
DRYER SYSTEM
COMPRESSOR INLET RESERVOIR
DISCHARGE PORT
LINE

SUPPLY CHECK
TANK VALVE
1002211c

TWIN Support Documentation T-97106V ($20.00) is a 30-minute videotape

TP-94104, Installing the Meritor WABCO System
Saver TWIN Air Dryer, provides complete
installation instructions for the TWIN Air Dryer.
TP-94104 is shipped with all TWIN dryers. For
additional copies, contact Meritor Customer
Service at 800-535-5560.
PB-96135 contains a complete listing of System
Saver TWIN replacement parts.
TP-9773 is a poster-size troubleshooting guide. It
also illustrates the various components that make
up the System Saver TWIN air dryer. TP-97100 is a
pocket-size version of TP-9773.
TP-9672, Air Dryer Application Guide, provides an
in-depth look at System Saver TWIN air dryer
applications.
covering application, maintenance and service
information for System Saver TWIN air dryers.
Literature and videos are available on our web site
(meritorwabco.com) or call the ArvinMeritor
Customer Service Center (800-535-5560) to order.
How the TWIN Air Dryer Works
TWIN air dryer cartridges contain desiccant
material that filters and dries compressed air. The
process begins when supply tank pressure drops
below cut-in pressure (approximately 100 psi).
When this happens, the governor turns the
compressor on. The compressor sends air to the
supply port of the dryer, and an air drying cycle
begins.

MM-35
Revised 11-02 Page 1
Section 1
Introduction

TWIN Air Drying Cycle

Figure 1.2 Figure 1.4

1002212b
1002214b
1 Dryer Inlet 3 Governor Port
2 Dryer Outlet 4 Purge Valve 1 Dryer Inlet 3 Governor Port
2 Dryer Outlet 4 Purge Valve
Air drying cycle begins
Air enters the dryer at the supply port (Port 1) Air drying cycle continues,
cartridge functions reversed
O Air flows past piston in to the first (right) cartridge.
O Air flows through cartridge where it is dried; O Incoming air enters the second (left) cartridge for
moisture and contaminants are filtered out through drying and then flows to the delivery port.
the desiccant material in the cartridge. O Small amount of dried air flows into the first (right)
O Dry, clean air flows to the delivery port (Port 2) of cartridge to regenerate desiccant.
the dryer for delivery to the supply tank. O Alternating air drying cycles continue, one cartridge
— Some air is diverted to the second cartridge to the other, every 60 seconds as long as the
where it moves upward through the desiccant. compressor is running.
This cleans and dries (regenerates) the
desiccant.
Figure 1.5
While the compressor is running, a mild flow of air
will vent to atmosphere through the purge valve.

Figure 1.3

3 1 1002215b

4 1002213b 1 Dryer Inlet 3 Governor Port

2 Dryer Outlet 4 Purge Valve
1002213b
1 Dryer Inlet 3 Governor Port
2 Dryer Outlet 4 Purge Valve Dryer purges

At 60 psi or greater, the air dryer
switches cartridges every 60 seconds
O Switching is controlled by timer/solenoid.
O Pistons shift from right to left, reversing airflow
pattern.
A mild purge, or puff of air, can be heard at the
purge valve at the time of shift.
MM-35
Page 2
O Supply tank reaches cutout pressure. Governor
unloads compressor.
O Governor supplies air to unloader port (Port 4) of
dryer.
O Moisture and contaminants pass through purge
valve and out of dryer.
A burst of air occurs when dryer purges; airflow from
purge valve ceases for duration of unloaded cycle.
Revised 11-02
 Section 1
Introduction

System Components
Air Dryer Parts
Figure 1.6

Air Dryer Base: The aluminum casting to which

all air dryer components are assembled. Base
contains threaded mounting holes. Refer to
Figure 1.6.

1002216a

Figure 1.7

Desiccant Cartridge: A cylindrical steel housing

that contains the filter element and desiccant
necessary to filter and dry the air that passes
through it. For easy maintenance, all Meritor
WABCO air dryer cartridges are of spin-on/spin-off
design. Refer to Figure 1.7.

1002217a

Figure 1.8

Heater Assembly: Located in the air dryer base, the

heater keeps the water that collects in the air dryer
from freezing. The assembly consists of a
cylindrical resistive-type heating element and a
small circular thermostat. The thermostat turns the
heater on at 45°F (7°C) and turns it off at 86°F
(30°C). Refer to Figure 1.8.
1002218a

Figure 1.9

Orifice and Check Valve Assembly: Controls the

flow of air for regeneration. There are three sizes:
0.8 mm for systems with compressor ratings less
than 21 CFM, 1.0 mm for compressor ratings
between 21 and 35 CFM, and 1.3 mm for
compressor ratings greater than 35 CFM.
Refer to Figure 1.9.
1002219a

MM-35
Revised 11-02 Page 3
 Section 1
Introduction

Air Dryer Parts, Continued Figure 1.10

Charging Valve: Keeps control valves from

shuttling while the system is filling and pressure
is too low to ensure proper operation. Refer to
Figure 1.10.
100220a

Figure 1.11

Outlet Check Valve: Prevents air from flowing back

through the air dryer and escaping out the purge
valve during the compressor unload cycle, or while
the vehicle is shut off. It is located in the outlet port
of the air dryer. Refer to Figure 1.11.
100221a

Figure 1.12

Purge Valve: Allows collected moisture and

contaminants to be expelled from the air dryer
during the unloaded cycle. The purge valve
remains open for the entire compressor unload
cycle. Refer to Figure 1.12.
NOTE: While the compressor is running, a mild
flow of air will vent to atmosphere through the
purge valve. This is a normal condition.

100222a

Figure 1.13

Solenoid and Armature Assembly: Controls timing

and operation of right and left piston assemblies.
This determines which cartridge dries and which
one regenerates. Refer to Figure 1.13.

100223a

MM-35
Page 4 Revised 11-02
 Section 1
Introduction

Air Dryer Parts, Continued Figure 1.14

Pressure Relief Valve: Protects the dryer from

over-pressurization. May be installed using a
street-T fitting, shown in Figure 1.14, or directly
into the dryer casting on dryers with the
appropriate port (Port 31). Refer to Figure 2.2. 100225a

Figure 1.15

Piston Assemblies (Left and Right): Control

air-flow direction between TWIN cartridges. Both
piston assemblies have their own covers. Refer
to Figure 1.15.

1 Left Piston Kit 3 Right Piston Kit

2 Left Piston Cover Kit 4 Right Piston Cover Kit

Figure 1.16

Purge Silencer: Optional equipment. Used to

reduce the noise level of dryer purge. Refer to
Figure 1.16.
100227a

Wiring Harness Options

Two types of power harnesses are used with the TWIN; the Standard Wiring Harness and the E-Type Wiring
Harness. The wiring harness is included with the original installation. For part numbers and other ordering
information, refer to PB-96135, the TWIN parts book.

Standard Wiring Harness

Figure 1.17

The TWIN uses a standard two-circuit power

harness for heater and timer/solenoid in most
applications (standard compressors). Refer to
Figure 1.17.

100224a

MM-35
Revised 11-02 Page 5
 Section 1
Introduction

Wiring Harness Options, Continued

Wiring/Plumbing Kit for E-Type Compressor

Figure 1.18
A three-circuit power harness must be used with
Holset E-Type compressors. An Econ valve and
check valve assembly, as well as a special solenoid
valve, are also required. Refer to Figure 1.18.
1. Three-circuit power harness
2. Econ valve
3. Solenoid valve
4. Check valve assembly
1002228b

An exploded view of the TWIN air dryer components appears in Figure 1.19.

Figure 1.19

1002229b
1 Left Piston Kit 9 Purge Valve Kit
2 Orifice Kit 10 Outlet Check Valve Kit
3 Desiccant Cartridge 11 Heater Kit
4 AIR DRYER BASE 12 Left Piston Cover Kit
5 Right Piston Kit 13 Manufacturing Location Code
6 Right Piston Cover Kit 14 Part Number
7 Solenoid & Armature Parts (3 Kits) 15 Date Code — First 2 Digits = Build Week/Last 2 Digits = Build Year
8 Charging Valve Kit

MM-35
Page 6 Revised 11-02
 Section 2
Troubleshooting and Testing

Routine Maintenance
Section 2Troubleshooting and Testing

To keep your Meritor WABCO System Saver TWIN operating efficiently, the following routine maintenance
is recommended:

Interval Required Action

Weekly.
Weekly, or as recommended by the vehicle OEM,
whichever is most frequent.
O Every 2-3 years — or more often depending on
usage, vocation and condition of compressor.
O Whenever compressor is rebuilt.
Check the exhaust from the air dryer.
Check for moisture in the system by draining the
supply tank.
Replace the desiccant cartridge with new
cartridges.

Troubleshooting the TWIN Air Dryer System

WARNING
To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance
or service.
Engage the parking brake to prevent the vehicle from moving before you begin maintenance or service
procedures that require you to be under the vehicle. Serious personal injury can result.
Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Serious personal
injury can result.
Remove all air from the air system before servicing any component in the air system. Pressurized air can
cause serious personal injury.

Pressure Relief Valve

Check the build date on the part identification tag to determine whether or not it has an integral pressure
relief valve. Refer to Figure 2.1. If the build date is 11/96, or higher, it has an integral pressure relief valve
which can be seen at the back of the dryer. Refer to Figure 2.2. Dryers without integral relief valves must use
a pressure relief valve and street Tee fitting.

Figure 2.1 Figure 2.2

1002230b 1002231a

1 ID Tag
2 Pressure Relief Valve Assembly 1 Pressure Relief Valve

MM-35
Revised 11-02 Page 7
Section 2
Troubleshooting and Testing
Meritor WABCO TWIN Air Dryer Troubleshooting Guide
Condition Possible Cause
Air dryer does not work Air dryer mounted too close to heat
properly. source, such as engine exhaust stack
or muffler.
Air delivered to air dryer exceeds
175°F (79°C).
Lines blocked with dirt.
Loose fittings.
Air dryer not switching every 50 to
60 seconds during compressor
loaded cycle.
Water in air system Desiccant saturated.
Dryer leaks heavily from Improper air pressure maintained at
purge valve every other dryer; 35-75 psi allows partial
60-second timer cycle. switching but does not seal valves
for a second cycle.
Dryer frozen (water in air Problem with heater assembly.
dryer is freezing).
Power supply to heater interrupted or
short-circuited.
Low voltage to heater unit.
Wrong voltage air dryer used
(e.g., 24-volt in 12-volt system).
Excessive amount of oil Problem with air compressor.
released from exhaust of
air dryer.
or Worn turbocharger oil seals
(turbocharged compressors only.)
Sludge build-up on air
dryer base.
MM-35
Page 8
Suggested Repair
Verify proper installation.
Extend length of compressor
discharge line as required, or install
cooling coil.
Clear or replace lines.
Tighten or seal fittings.
Verify solenoid operating properly.
Check timer (solenoid) and make
necessary repairs.
NOTE: If timer is working properly
but dryer does not switch, check for
sludge on valves. Clean the dryer.
If condition is not corrected:
Check pistons and make necessary
repairs.
Replace desiccant cartridge(s).
Install back-pressure control valve in
system between outlet of dryer and
source of air take-off.
Replace heater assembly.
Repair or replace power supply
circuit. Replace fuse if needed.
Ensure voltage is at least 10.5 volts
(12-volt system) or 20 volts (24-volt
system).
Replace with proper air dryer.
Repair or replace compressor.
Replace desiccant cartridge(s).
Repair or replace turbocharger.
Revised 11-02
 Section 2
Troubleshooting and Testing

Condition Possible Cause Suggested Repair

Dryer does not purge Wrong air line or no air line Connect air lines properly.
when compressor connected to dryer Port 4.
unloads.
Control line from governor unloader Repair any leaks.
port to air dryer leaking.

Purge valve stuck closed. Replace purge valve.

Problem with governor. Repair or replace governor.

Cutout pressure never reached by air Check air system for leaks.
compressor. If condition is not corrected:
Check/repair compressor.

Air pressure does not Leak in air system. T ighten all air line connections, test
build in brake system. system for leaks, make necessary
repairs.

Problem with compressor. Repair or replace the compressor.

Repair or replace problem air system
components.

Air dryer control port (Port 4) Verify proper installation.

plumbed wrong.

Obstruction in air compressor Check lines for crimps or blockages.

discharge line or air dryer outlet line. Make necessary repairs.

Air compressor discharge line Verify proper installation. Make

plumbed to air dryer outlet port necessary repairs.
(Port 2).

CTI Applications: Back-pressure Verify installation of back-pressure

control valve installed incorrectly. control valve.

Faulty compressor discharge hose. Check for pinhole leaks along length
of compressor discharge line from
compressor to air dryer. If found,
replace hose. Make sure replacement
hose is capable of sustained high
temperature use.
Air continues to flow Compressor intake is turbocharged Install a turbo cutoff valve.
from purge valve after air and there is no turbo cutoff valve in
compressor unloads. system.
NOTE: This could be
accompanied by a loss of
engine power.
Internal valves not Orifice blocked, internal passages Clean as needed, replace worn parts.
switching. blocked, valve components covered
with sludge.
O-rings in bad condition (cut, worn). Make sure O-rings are properly
installed and in good condition.

MM-35
Revised 11-02 Page 9
Section 2
Troubleshooting and Testing

System Tests Solenoid Check

Heater Resistance Turn ignition on. Do not start engine.
To ensure power to solenoid, check at cable
Figure 2.3 with volt-ohmmeter, or test light. Refer to
Figure 2.4.
Go to TWIN dryer and listen for the solenoid
to click. There should be one click every
50-60 seconds. If not, solenoid is defective.

Figure 2.4

1 Heater 2 3

To avoid damaging components, Meritor WABCO

recommends performing this resistance check with
4
the heater in place.
5
1. Set volt-ohmmeter to ohms.
2. With wires connected and properly secured,
attach one probe to the heater connector and 6
the second to the lead on the thermostat. Refer
to Figure 2.3.
3. Measure the resistance.
1
12-volt system: If 1.0–2.0 ohms, resistance is 1003340a
acceptable.
1 Standard Harness 4 Positive (+)
If the resistance is less than 1.0 ohm or more P/N R950041 5 Timer/Solenoid
than 2.0 ohms, replace heater. 2 Ground (–) 6 Heater
24-volt system: If 5.0–7.0 ohms, resistance is 3 Locating Pin
acceptable.
If the resistance is less than 5.0 ohms or more 5. Shut off the engine.
than 7.0 ohms, replace heater.
4. Reinstall components and vehicle harness. 6. Apply a soap solution to each connection that
contains pressurized air. Check the connections
Leak Test to see if soap solution bubbles.
1. Drain the air from all system tanks.
No soap Connections are sealed
2. Close the draincocks on all reservoirs. bubbles properly.
3. Start the vehicle. Allow the air system pressure Soap bubbles Connections not sealed
to build while the engine idles.
appear. properly. To repair:
4. There will be a light airflow from the purge
valve. This is normal and will continue until the 1. Drain all reservoirs.
air compressor unloads. 2. Remove leaking
After 50–60 seconds, and if the system pressure connection.
has built to at least 60 psi, there will be a mild 3. Inspect the connectors and
purge, or exhaust of air, as the dryer switches ports for damaged threads
cartridges. If there is no purge, the solenoid may or cracks. Replace if
be bad. Refer to “Solenoid Check” box for a necessary.
quick solenoid test.
4. Apply pipe sealant or
When the air system reaches cutout pressure,
the dryer will purge completely. After purging, Teflon tape to connection.
the dryer will not exhaust any air until the
compressor starts up again. Repeat leak test until all connections are sealed.

MM-35
Page 10 Revised 11-02
 Section 3
Installing Replacement Parts
Section 3Installing Replacement Parts

WARNING
To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance
or service.
Remove all pressure from the air system before you disconnect any component including the desiccant
cartridge. Pressurized air can cause serious personal injury.
Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Serious personal
injury can result.

A Component Replacement Guide appears on the inside back cover.

Desiccant Cartridge
NOTE: You may replace one or both TWIN cartridges.

Figure 3.1

1. Replacement kit contains one cartridge and

one O-ring. Refer to Figure 3.1.
2. Loosen and remove the old cartridge. Use
strap wrench if necessary.
3. Remove and discard O-ring from dryer base.

1002234a

Figure 3.2

4. Inspect and clean seal seats. Repair any

damage.
NOTE: If seats are damaged so badly that a tight
seal cannot be maintained, replace the air dryer.
5. Lubricate and install new O-ring on stem.
6. Thread replacement cartridge onto the base
until the seal touches the base. Then, tighten
the cartridge one-half (½) additional turn.
Do Not Overtighten. Refer to Figure 3.2.
1002235a

1 O-Ring
2 Seal Seat
3 Seal

MM-35
Revised 11-02 Page 11
 Section 3
Installing Replacement Parts

Left Piston Cover

Figure 3.3 1. Remove the old cover. Use a 5 mm Allen
wrench to loosen the mounting bolts. Remove
bolts. Lift cover off of dryer. Refer to Figure 3.3.
NOTE: If you are replacing the left piston
assembly, refer to the following instructions.
2. If you are replacing the cover only:
The two small O-rings that fit in the air
passages and the two large O-rings that fit in
the grooves in the outer diameter of the
cover guide are not included in the cover
replacement kit. Remove these O-rings
1002236a from the old cover, clean, apply Meritor
1 Remove WABCO-recommended lubricant, and install
2 Install them in the new cover.
3 77-85 in-lbs (8.5-9.5 N•m) T 3. Install the replacement cover. T ighten bolts to
O-rings not included in cover replacement kit. 77–85 inch-pounds (8.5–9.5 N•m). T

Left Piston Assembly

Figure 3.4

1. Review Figure 3.4 to make sure you have all of

the parts required to replace the left piston
assembly. Use the grease included with the
replacement kit to lubricate O-rings and seals.
2. Remove the left piston cover (refer to
instructions, above). Remove the two small
O-rings from the breather holes and the two
large O-rings from the grooves in the outer
diameter of the cover guide.
1002237a
Clean the cover. Save cover and mounting
bolts for reassembly.
These O-rings are installed in the cover, but are included
with the piston assembly replacement kit. They should be
replaced whenever you replace the piston assembly.

Seals, O-rings and springs are included in a separate replacement kit

from the hard parts (piston, spool and lip seal). Refer to PB-96135, the
TWIN Parts Book.

MM-35
Page 12 Revised 11-02
 Section 3
Installing Replacement Parts

Left Piston Assembly, Continued

Figure 3.5

3. Remove the left piston and spring assembly

from the piston bore.
Inspect and clean the bore area. Refer to
Figure 3.5.

1002238a

Figure 3.6

4. Lubricate and install the large replacement

O-ring in groove on head of piston guide. Refer
to Figure 3.6.
1002239a

5. If O-rings and spool are already installed on

Figure 3.7
the piston, lubricate the rubber parts, then go
to Step 6. If not:
a. Install lubricated O-ring in first groove of
piston guide.
b. Use snap ring pliers to install snap ring in
snap ring groove on shaft of piston.
c. Install lubricated lip seal in groove of spool.
Insert spool with lip seal onto piston. Lip of
seal must face away from the dryer.
1002240a
d. Install lubricated O-ring in groove on
Lip of seal must face away from dryer. piston shaft.
e. Use snap ring pliers to install snap ring in
snap ring groove under spool.
f. Install lubricated O-ring in groove on
piston shaft. Refer to Figure 3.7.
6. Install the two large, lubricated O-rings in the
Figure 3.8
grooves in the outer diameter of the cover
guide. Install the small lubricated O-ring in the
breather hole on the cover. Refer to Figure 3.3.
7. Install spring in left piston cover. Insert piston
assembly into left piston cover. Stem of piston
will face away from dryer. Refer to Figure 3.8.
8. Replace the left piston cover. (Refer to
1002241a instructions under “Left Piston Cover.”)

MM-35
Revised 11-02 Page 13
 Section 3
Installing Replacement Parts

Right Piston Cover

Figure 3.9

The right piston cover replacement kit contains

only the cover. When you remove the old cover,
retain the mounting bolts for reassembly. Also,
remove and save the two small, air passage
O-rings. Refer to Figure 3.9.

The right piston cover houses the solenoid/

armature and charging valve assemblies.
Carefully remove and save these assemblies.
Clean and inspect them before reinstalling in
the new cover. You must also remove the right
piston assembly when replacing the cover.
If you are replacing any of these assemblies,
you should follow the instructions that appear
in this manual:
O Right Piston Assembly, (in this section)
O Charging Valve Assembly, (in this section)
O Solenoid and Armature Assembly,
(in this section)

1. Unscrew the power harness and disconnect it

Figure 3.10 from the solenoid. Remove and save the
solenoid. Refer to Figure 3.10.
2. Carefully remove the armature assembly end
cap and O-ring from the solenoid. Save these
for reassembly.
3. Use a 5 mm Allen wrench to loosen and
remove the three long piston cover bolts from
the armature plate.
Remove the armature assembly. Lift the cover
off of the dryer. Save parts for reassembly.

4. Loosen and remove the short piston cover bolt. Save bolt for reassembly.
5. Remove the right piston cover. Remove and save the two small O-rings from the cover breather holes.

MM-35
Page 14 Revised 11-02
 Section 3
Installing Replacement Parts

Right Piston Cover, Continued

Figure 3.11

6. Loosen and remove the charging valve nut —

remove carefully, this is a spring-loaded valve.
Remove the charging valve assembly from the
right piston cover. Refer to Figure 3.11.
7. Carefully remove the right piston assembly
from the dryer cavity. This will help avoid
damage to the assembly when the new cover
is installed.

8. Clean and lubricate the two small O-rings removed from the old cover. Install them in the breather
holes in the replacement cover.
9. Replace the charging valve assembly in the right piston cover.

10. Insert the piston assembly into the piston

Figure 3.12 cover cavity. Do not damage the lip seal during
this procedure. Use the flat side of a small, flat
screwdriver to tuck the assembly into the
cover. Refer to Figure 3.12.
11. Install the cover, charging valve down, over the
piston assembly.
12. Replace the short mounting bolt. Finger tighten
only.

13. Replace solenoid and armature assembly. Refer to “Solenoid and Armature Assembly” in this section.
14. Connect the power harness to the solenoid. Make sure connection is tight.
15. Test the installation.

MM-35
Revised 11-02 Page 15
Section 3
Installing Replacement Parts

Right Piston Assembly

Figure 3.13

1. Review Figure 3.13 to make

sure you have all of the parts
1002246a required to replace the right
piston assembly. Use the
grease provided with the
replacement kit to lubricate
O-rings.

1 These O-rings are installed in the cover, but are included with the piston
assembly replacement kit. They should be replaced whenever you replace
the piston assembly.

Seals, O-rings and springs are a separate replacement kit from hard
parts (piston, spool and lip seal). Refer to PB-96135, TWIN Parts Book, for
additional information.

NOTE: You do not have to remove the charging valve when replacing only the right piston assembly.

1. Disconnect the power harness. Remove the 5. Insert piston and spring assembly into the right
solenoid and armature assembly. Remove the piston cover.
right piston cover.
Remove the two small O-rings from the piston
2. Remove right piston assembly. Clean piston cover. Lubricate the two new O-rings included
bore thoroughly. in the right piston assembly replacement kit
and install them in the piston cover.
3. Install large lubricated O-ring in groove on
head of piston. 6. Replace the right piston cover, armature and
spring assembly, and solenoid. For detailed
4. If O-rings and spool are already installed on
instructions:
the replacement piston, lubricate the rubber
parts. Then, go to Step 5. If not: O Right Piston Cover, (in this section)
a. Use snap ring pliers to install a snap ring O Solenoid and Armature Assembly,
into snap ring groove closest to piston (in this section)
head.
b. Insert lubricated lip seal in groove of spool.
c. Install lubricated O-ring in groove on
piston shaft.
d. Install spring over piston shaft.
e. Install spool with lip seal into piston shaft.
Lip of seal will face away from air dryer.
f. Install snap ring in groove on piston shaft
to hold spool in place.
g. Install O-ring into groove on piston shaft.

MM-35
Page 16 Revised 11-02
 Section 3
Installing Replacement Parts

Charging Valve Assembly

Figure 3.14
NOTE: You do not have to remove the right piston
cover or solenoid when replacing the charging
valve assembly.
1. Check Figure 3.14 to make sure you have all of
the parts needed to replace the charging valve
assembly.
Use the grease provided with the replacement
kit to lubricate the O-ring and spring.
1002247a

Figure 3.15
2. Remove dust cap from charging valve nut.
Then, loosen and remove the nut — remove
nut carefully, this is a spring-loaded valve.
Remove the old charging valve from the right
piston cover. Refer to Figure 3.15.
3. Clean the charging valve bore and seat. Use
the grease included with the replacement kit to
lube the area.
1002248a

Figure 3.16
4. Install piston and spring in cover bore. Refer to
Figure 3.16.
5. Install lubricated O-ring in bore groove of
special nut.
6. Install washer on nut. Insert nut into cover
bore. Carefully guide piston into the bore in
1002249a the nut.

Figure 3.17

7. Install lubricated rubber dust plug at end of

nut. Refer to Figure 3.17.

1002248a

MM-35
Revised 11-02 Page 17
Section 3
Installing Replacement Parts

Solenoid and Armature Assembly

This assembly requires two replacement kits: Solenoid and Mounting Sleeve and Other Solenoid Parts.
You will need both kits to complete the installation. (Refer to PB-96135, the TWIN parts book.)

CAUTION
To avoid damaging the solenoid, make sure you install the proper solenoid, 12-volt or 24-volt. Solenoid
voltage is determined by the vehicle's electrical system.
NOTE: Solenoid and Armature Assembly is installed on the right piston cover.

1. Check Figure 3.18 to make sure you have all of

Figure 3.18 the parts needed to replace the solenoid and
armature assembly.
Use the grease included in the replacement kit
to lubricate all O-rings.
2. Remove the old solenoid and armature
assembly:
a. Disconnect power harness.
b. Lift solenoid off of cover. Refer to
Figure 3.19.
c. Remove the three piston cover mounting
bolts that hold the solenoid mounting plate
1002250a in place. Retain bolts for use in reassembly.
1 (2 Kits) d. Remove breather from end of nut.
e. Unscrew nut and remove from solenoid.
Figure 3.19 f. Remove the O-rings, one from each side,
from the solenoid.
g. Remove the armature retaining plate.
h. Remove Armature and Spring assembly.

1002251a

1 Insert O-Ring

3. Inspect and clean the solenoid bore. Do not

Figure 3.20 lube this area — apply lube to O-rings only.
4. Install lubricated O-ring in groove on solenoid
sleeve.
5. Insert the open end of the sleeve through hole
in retaining plate. Refer to Figure 3.20.
6. Insert sleeve with armature and spring into
cavity.

1002252a

MM-35
Page 18 Revised 11-02
 Section 3
Installing Replacement Parts

Solenoid and Armature Assembly, Continued

7. Position armature retainer plate on cover, lining up holes on plate with holes in the cover.
8. Install the three long bolts through the armature retainer plate. T ighten all four bolts to 77–85 in-lbs
(8.5–9.5 N•m). T

Figure 3.21
9. Install lubricated O-ring on sleeve and position
against mounting plate.
10. Position solenoid over sleeve, writing side
facing dryer. Install lubricated O-ring in bore on
dryer side of solenoid. Refer to Figure 3.21.
11. Install lubricated O-ring over end of sleeve.
12. Install nut at end of sleeve. Screw breather
onto nut. Finger tighten.

13. Connect the power harness to the solenoid. Follow these steps to test solenoid.
O Turn ignition on. Ensure power to solenoid.
O Listen for click to sound after 50–60 seconds.
Click occurs: Solenoid O.K.
No click: Voltage not sufficient or solenoid damaged or improperly installed.

Heater Assembly
NOTE: Select 12- or 24-volt replacement kit, depending upon vehicle voltage.

1. Check Figure 3.22 to make sure you have all of

Figure 3.22 the parts needed to replace the heater
assembly.
2. Disconnect the power harness.
3. Remove the two screws holding wiring
connector in place.

1002254a

Figure 3.23 4. Remove wiring harness and O-ring to access

retainer screw. Refer to Figure 3.23.
5. Remove retainer screw.
6. Remove thermostat retainer.

1002255a

MM-35
Revised 11-02 Page 19
Section 3
Installing Replacement Parts

Heater Assembly, Continued

Figure 3.24

7. Remove and discard the old heater assembly.

8. Inspect and clean the heater cavity. Area must
be free of dust and oil.
9. If not assembled, attach power leads to
thermostat and wiring connector.
Insert the heater and thermostat with power
leads into the heater cavity. Refer to
Figure 3.24.

Figure 3.25

10. Install the retainer and tighten the screw that

holds the element and thermostat in place.
11. Install lubricated O-ring in base of wire
connector.
12. Gently press wire connector into place in
heater cavity. Tighten down the two mounting
screws. Refer to Figure 3.25.
13. Connect heater assembly to power harness.

1 Mounting Screws

MM-35
Page 20 Revised 11-02
 Section 3
Installing Replacement Parts

Purge Valve Assembly

Figure 3.26

1. Review Figure 3.26 to make sure you have all

of the parts required to replace the purge valve
assembly.
Use the grease included with the replacement
kit to lubricate O-rings.
NOTE: The shim may not be included with the kit.
If it is not included, it is not required. If it is
included, install it between the spring and valve
body.

1002258a

1 Shim — Refer to Note

Figure 3.27

2. Remove old purge valve assembly from

bottom of air dryer. Refer to Figure 3.27.
O Remove snap ring, valve body and spring.
O Pull valve assembly out of dryer base.
O Remove O-ring.
3. Inspect and clean valve bore.
4. Apply a thin layer of grease to the valve bore
(use grease included in replacement kit).
5. Install lubricated O-rings: one in dryer base,
one on valve head.
6. Install spring in valve head.

1 Spring
2 Valve Head
3 Valve Assembly

7. Insert valve body, wide end toward dryer, onto the piston shaft.
NOTE: If a shim is included in the kit, install it between the spring and valve body.
8. Install the retainer ring.

MM-35
Revised 11-02 Page 21
Section 3
Installing Replacement Parts

Outlet Check Valve Assembly

Figure 3.28

1. Review Figure 3.28 to make sure you have all

of the parts required to replace the outlet check
valve assembly.
Use grease provided with the replacement kit
to lubricate O-rings and seals.
1002260a

Figure 3.29

2. Remove the snap ring from dryer Port 2.

Then, remove the old check valve assembly.
Refer to Figure 3.29.
3. Inspect and clean valve bore. Remove any
1002261b excess debris.

Figure 3.30

4. Install lubricated O-ring in groove on

underside of check valve. Refer to Figure 3.30.
5. Install check valve in bore with shaft facing
dryer.
1002262a

Figure 3.31

6. Install perforated washer over top of spring.

Refer to Figure 3.31.
7. While holding spring and washer in place,
install snap ring in the bore groove.

1002263a

MM-35
Page 22 Revised 11-02
 Section 3
Installing Replacement Parts

Orifice Assembly
NOTE: Select 0.8 mm, 1.0 mm or 1.3 mm orifice replacement kit. Check the part number of the air dryer to
determine orifice size. (Refer to PB-96135, the TWIN parts book.)

1. Review Figure 3.32 to make sure you have all

Figure 3.32
of the parts required to replace the orifice
assembly.
Use the grease included with the replacement
kit to lubricate O-rings and seals.
2. To access the orifice assembly, unscrew and
remove the desiccant cartridge from the dryer
base. Remove the O-ring. Save the cartridge
and O-ring for reassembly.
1002264a Refer to ”Desiccant Cartridge” in this section
for information about removing the desiccant
cartridge.
Figure 3.33

3. Remove the old snap ring and orifice assembly

from the base of the dryer. Refer to Figure 3.33.
4. Inspect and clean the orifice bore.
5. Install the perforated washer in dryer bore.

1002265a

Figure 3.34 6. Install the spring on top of the perforated

washer. Refer to Figure 3.34.
7. Install lubricated O-ring in groove on check
valve stem.
8. Insert check valve into bore with the stem
facing away from dryer.

1002266a

MM-35
Revised 11-02 Page 23
 Section 3
Installing Replacement Parts

Orifice Assembly, Continued

9. Install lubricated O-ring in groove on orifice part.
10. Install plastic orifice in bore. Carefully guide check valve into center hole. Refer to Figure 3.35.
NOTE: Molded ribs on orifice must face away from dryer.
11. Install snap ring to hold orifice assembly in place.

Figure 3.35

12. Install large lubricated O-ring over the dryer

base where cartridge screws on.
13. Install the desiccant cartridge. Refer to
”Desiccant Cartridge” in this section.

Purge Silencer (Muffler)

NOTE: This is an optional part designed to reduce dryer purge noise level.

Figure 3.36

1. Remove snap ring. Remove old silencer from

purge valve head. Do not damage purge valve
head.
2. Clean purge valve head.
3. Insert replacement silencer into purge valve
head. Secure with snap ring. Refer to
Figure 3.36.

1 Purge Valve Head

2 Silencer

MM-35
Page 24 Revised 11-02
 Section 3
Installing Replacement Parts

Air Dryer Assembly

NOTE: This procedure is for removing and replacing a unit. For instructions on an initial installation, refer
to TP-94104, Installing a System Saver TWIN Air Dryer.

Figure 3.37

1. Drain all pressure from the air system.

Disconnect all air lines.
Use markers to label the lines for proper
reinstallation. Refer to Figure 3.37.
2. Disconnect the heater electrical plug from the
heater receptacle and the solenoid connector
from the solenoid/timer.
1002269a

1 Drain air pressure and disconnect these air lines before

replacing the dryer.

Figure 3.38

3. Remove the air dryer mounting bolts. Remove

the air dryer from its mounting bracket. Refer
to Figure 3.38.
4. Attach the new unit to the frame or mounting
bracket with new mounting capscrews and
washers. Tighten the capscrews to 22–30 lb-ft
(30–40 N•m). Refer to Figure 3.39. T

1002270a

Figure 3.39

5. Connect heater electrical plug to heater

receptacle. Connect solenoid cable to
solenoid/timer.
6. Reconnect all system air lines.
7. Test the installation.

1002271b

1 22-30 lb-ft (30-40 N•m) T

MM-35
Revised 11-02 Page 25
Notes

MM-35
Page 26 Revised 11-02
 Appendix I
Glossary
Appendix IGlossary

Basic Air System/Air Dryer Terms

Air Compressor A device that pumps air to and builds air pressure in an air system.

Air Dryer A device that cools, filters, and dries the air delivered by an air
compressor.

Air Governor A device that controls the operation of the air compressor by
constantly monitoring air pressure in the supply tank of the air
system.
The air governor initiates the compressor unload cycle when the
cutout pressure is reached. It also controls the air dryer by sending
an air signal — at the beginning of the compressor unload cycle —
to the control port of the air dryer. This initiates the purge cycle.
When the signal is stopped, the purge valve closes and the drying
cycle begins.

Compressor Load Cycle The time during which the air compressor is building air pressure in
an air system.

Compressor Unload Cycle The time during which the air compressor is idling and is not
building air pressure in an air system.

Cut-in Pressure The pressure level in the air system supply tank that triggers the
compressor load cycle.

Cut-out Pressure The pressure level in the air system supply tank that triggers the
compressor unload cycle.

Desiccant A granular substance that has a high affinity for water. It catches and
retains moisture from the air stream.

Drying Cycle The time during which the air dryer cools, filters and removes
moisture from the air delivered by the air compressor.

Purge The initial blast of air (decompression) from the air dryer purge
valve at the beginning of the compressor unload cycle.

Purge Cycle The time during which the air dryer is undergoing purge and
regeneration. It begins at the start of the compressor unload cycle
and normally ends well before the beginning of the compressor
load cycle.

Regeneration The mild backflow of air through the non-loaded air dryer cartridge
and out the purge valve. A small amount of air from one cartridge is
used to remove moisture from the other cartridge. This readies the
cartridge for the next cycle. The cycle lasts 50–60 seconds, then the
timer switches it to the other cartridge.

MM-35
Revised 11-02 Page 1-A
Notes

MM-35
Page 2-A Revised 11-02
 Appendix II
Application Information
Appendix IIApplication Information

General Requirements
Compressor discharge line should have a continual downhill turn to the air dryer. There should be no water
traps (low points or kinks) in the line before or after the dryer.
Mount air dryer so that there is no direct splash or spray from a wheel.
Keep air dryer at least 12 inches from any heat-producing sources like exhaust manifolds or pipes,
transmissions, etc.
Make sure there are no valves or other devices in the dryer-to-supply-tank line to prohibit or restrict the
flow of air back from the supply tank to the air dryer.
The purge valve must be fed by a direct line from the air governor.
For applications where the working pressure in the system could be lower than 85 psi (for example, bulk
unloading or central tire inflation), install a back-pressure control valve.

Operating Environment Requirements

Figure 1-A Operating Parameter Requirement

Temperature (ambient –40°F to 175°F
operating range) (–40°C to 80°C)
Electrical Power (for heater 12 or 24 volts
and solenoid/timer power) available
Thermostat Range 45°F, 86°F
(On/Off temp) (7°C, 30°C)

MM-35
Revised 11-02 Page 3-A
Appendix II
Application Information

Operating Environment Requirements, Continued

Figure 2-A
GOVERNOR
COMPRESSOR
INTAKE LINE
RESERVOIR
UNLOADER TO GOVERNOR
PORT LINE

SYSTEM SAVER TWIN

AIR DRYER
DRYER
OUTLET
PORT
COMPRESSOR
CHECK TO BRAKE
CONTROL SYSTEM
VALVE
(PURGE)
PORT SYSTEM
RESERVOIR
DRYER SYSTEM
COMPRESSOR INLET RESERVOIR
DISCHARGE PORT
LINE

SUPPLY CHECK
TANK VALVE
1002273d

Discharge Line: Rated Compressor size:

O Diameter from compressor to air dryer O Less than 21 cfm
TWIN with 0.8 mm orifice
1/2" i.d. minimum
O Between 21 and 35 cfm
O Length from compressor to air dryer
TWIN with 1.0 mm orifice
Determined by temperature of air at the inlet O Greater than 35 cfm
port of the air dryer. At normal vehicle operating
TWIN with 1.3 mm orifice
temperature, length must be sufficient to keep
temperature below 175×F (80×C). cfm = cubic feet/minute

O Recommendations for minimum/maximum Pressure Requirements:

length: O Maximum
— Under 21 cfm: 6 ft. min./20 ft. max. Use 140 psi
copper-pipe stainless-steel braided-Teflon O Minimum
tubing for the first 10 feet (minimum).
85 psi
Any line over 10 feet should be insulated.
— Over 21 cfm: 10 ft. min./20 ft. max. Use Flow Capacity:
copper-pipe stainless-steel braided-Teflon Compressor rating 50 cfm maximum
tubing for the first 10 feet (minimum).
Any line over 10 feet should be insulated. Compressor On-T ime (normal running):
Unlimited
Maximum Duty Cycle:
100%

MM-35
Page 4-A Revised 11-02
 Appendix II
Application Information

Installation Instructions for Special Applications

Bulk-Unloading or Central Tire Inflation (CTI) Air Systems

Bulk-unloading or CTI air systems require a

Figure 3-A
back-pressure control valve. Refer to Figure 3-A.
The back-pressure control valve maintains
adequate pressure at the outlet of the dryer to
ensure proper operation in high air usage
applications.
It is installed between the air dryer and the air
distribution system, a minimum of five feet from
the dryer. The arrow on the valve must point in the
direction of the airflow. Refer to Figure 4-A.
NOTE: These instructions are for adding a
back-pressure control valve to an existing TWIN
application. For new installations, refer to TP94104.
NOTE: Back-pressure control valve not required
for Eaton CTI.

1 Arrow points in the direction of airflow.

Installing a Back-Pressure Control Valve

CAUTION
The System Saver TWIN air dryer is designed and engineered to minimize moisture and contaminants in
truck air brake systems. It is not designed to provide moisture-free or contaminant-free air in a bulk
unloading application. The TWIN air dryer should not be used in bulk unloading applications if
contaminants could cause load spoilage. The TWIN air dryer is not to be used in food-grade bulk unloading
applications.

WARNING
To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance
or service.
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 can result.
Remove all air from the air system before servicing any component in the air system. Pressurized air can
cause serious personal injury.

MM-35
Revised 11-02 Page 5-A
Appendix II
Application Information

Installing a Back-Pressure Control Valve, Continued

Figure 4-A
RESERVOIR
SYSTEM SAVER TWIN TO GOVERNOR
AIR DRYER TO BULK
LINE
UNLOADER
UNLOADER OR CTI
PORT

DRYER
OUTLET
PORT

TO BRAKE
CHECK SYSTEM
CONTROL VALVE SYSTEM
(PURGE) RESERVOIR
PORT
SYSTEM
DRYER RESERVOIR
COMPRESSOR INLET
DISCHARGE PORT C
LINE
B

A
CHECK
SUPPLY
VALVE
TANK

1002275d

Back-Pressure Control Valve (BPCV)

NOTE: Locate the BPCV anywhere BETWEEN the air dryer and the air distribution system.
Points A, B and C show several possible locations for the BPCV. If you select location C, air supply cannot be taken from Line B .
Arrow on BPCV must point in direction of airflow.

NOTE: The end user must provide bulk tank 4. Test the installation for leaks.
overpressure protection either in the system or
For part number and order information, refer to
on the trailer.
PB-96135. If you need assistance determining
1. Drain all air from the system. the necessity of a back-pressure control valve
in your application, contact Meritor Customer
2. Determine where the back-pressure control
Service, 800-535-5560.
valve will be installed. It must be at least 5 feet
from the air dryer. Do not nipple mount the
back-pressure control valve to the dryer.
Refer to Figure 4-A for suggested mounting
locations.
3. Find the directional arrow on the replacement
valve.
O Install the valve so that the arrow points in
the direction of airflow.
O Installation orientation is not important.
It does not matter which end faces up or
down.

MM-35
Page 6-A Revised 11-02
 Appendix II
Application Information

Holset E-Type Compressor Systems

Function
Meritor WABCO offers a special Holset E-Type wiring harness for systems using a Holset E-type
compressor. This harness is shown in Figure 1.18. In addition, an Econ valve, check valve and solenoid
valve assembly are also required. Refer to Figure 5-A.
O E-type compressors can be identified by the serial number tag on the compressor. Tag will indicate:
“This is an E-Type compressor.”
O For proper operation, the discharge line must be kept at reservoir pressure when the governor is in the
unloaded position (compressor not pumping). If this is not done, the compressor will pass excessive oil
into the air system.

Figure 5-A
FROM AIR
COMPRESSOR
DISCHARGE LINE
A

RESERVOIR FROM AIR TO AIR

TO GOVERNOR GOVERNOR DRYER
LINE UNLOADER INLET
GOVERNOR PORT PORT
COMPRESSOR
INTAKE LINE
FROM
UNLOADER SUPPLY
PORT TANK
SYSTEM
UNLOADER SAVER TWIN
LINE AIR DRYER
DRYER
OUTLET
PORT
COMPRESSOR

TO BRAKE
TEE CHECK SYSTEM
COMPRESSOR FITTING VALVE SYSTEM
DISCHARGE DRYER
RESERVOIR
LINE INLET
CHECK PORT SYSTEM
VALVE RESERVOIR

ECON
VALVE
(REFER TO SOLENOID SUPPLY
INSET — A) VALVE TANK
(REFER TO
CHECK
INSET — B)
VALVE 1002276b
TO SUPPLY
TANK
B
TO ECON
VALVE

1002276d

NOTE: Normally-closed solenoid valve installed such that when ignition is on, solenoid is energized and
solenoid valve is open, allowing air to flow from supply tank to compressor discharge line.

MM-35
Revised 11-02 Page 7-A
Appendix II
Application Information
Econ Valve
Econ Valve Operation
The Econ valve allows supply tank pressure to
reach the compressor discharge line during
compressor idle. When the compressor is
pumping, the Econ valve lets compressor air flow
into the air dryer, then on to the supply tank. When
cutout pressure is reached, the governor unloads
the compressor, and pressurizes Port 4 of the
dryer. This opens the purge valve in the dryer and
expels moisture and contaminants.
At the same time, the piston in the Econ valve
shifts position and blocks the flow of air into the
dryer. This also allows air to flow from the supply
tank into the compressor discharge line. When the
compressor starts pumping again, the cycle is
repeated.
A check valve at the supply tank prevents air from
bypassing the dryer and going directly to the
supply tank during the pumping cycle. Refer to
Figure 5-A for an illustration of this system.
Replacing the Econ and Check
Valves on a Holset E-Type
Compressor System
NOTE: When the OEM installed the Holset E-type
compressor system, a one-way check valve, Econ
valve and solenoid valve were plumbed into the
system between the air dryer and the supply tank.
The Econ valve must be located two to seven feet
from the compressor.
1. Remove air from the system tanks and
disconnect the air lines from the Econ and
check valves. To ensure proper replacement,
use markers to identify the lines. Econ valve
ports are identified below. Refer to Figure 6-A.
Figure 6-A
MM-35
Page 8-A
Econ Valve Ports
O Inlet Port (1/2"-14 NPTF, female)
O Outlet Port (1/2"-14 NPTF, male)
O Unloader Port (1/8" NPTF, marked “UNL” on
valve)
O Make-up Air Port (1/8" NPTF)
2. Attach check valve to Econ valve or supply
tank.
3. Reconnect the air lines. Test the system for
leaks.
Replacing the Solenoid Valve
The solenoid valve can be mounted anywhere in
the line between the Econ valve and the supply
tank.
Refer to Figure 5-A.
1. Remove air from all system tanks. Disconnect
the air line from the solenoid valve.
2. Unplug the solenoid from the wiring harness.
3. Look at the existing installation and remember
how the old solenoid valve is installed. The
replacement valve will be installed the same
way.
4. Remove the old solenoid valve.
5. Install the replacement solenoid valve exactly
the way the old valve was installed:
O The normally-closed solenoid must be
installed so that when the ignition is on, the
solenoid is energized and the solenoid valve
is open.
6. Reconnect the solenoid valve to the wiring
harness.
O Insert plug until latch snaps over tab on the
mating connector.
7. Test the system for leaks.
Revised 11-02
 Appendix II
Application Information

Installing a Turbo Cutoff Valve Installing the T-Fitting

If your vehicle has a turbocharged engine and the
air compressor draws its intake air from the
pressurized side of the turbocharger (at the intake
manifold or aftercooler), you may want to install a
turbo cutoff valve on your Meritor WABCO air
dryer.
This installation will prevent leakage of turbo
boost through the air compressor and out of the
purge valve of the air dryer when the compressor
is operating in the unloaded mode.
Contact Meritor Customer Service for part number
information (1-800-535-5560).
Installation Instructions
1. Remove the unloader line from port 4 on the
air dryer.
2. Install a standard braking systemT-fitting that
has three 1/8-inch NPTF ports on the unloader
line.
3. Connect a line from the T-fitting to port 4 on the
air dryer. Use 1/4-inch (6.3-mm) standard
braking-system nylon tubing.
4. Connect a line from the remaining port on
the T-fitting to the 1/8-inch MPT port marked
“UNL” on the turbo cutoff valve. Use 1/4-inch
(6.3-mm) standard braking-system nylon
tubing.

CAUTION
Make sure there are no kinks or sags in the lines
connected to the turbo cutoff valve. Moisture and
dirt can build up and block the lines. The turbo
cutoff valve and the air dryer will not work when
these lines are blocked.
1. Park the vehicle on a level surface.
2. Stop the engine.
3. Drain pressurized air from all reservoirs to
0 psi (0 bar).
4. Disconnect the delivery line at port 1 on the
air dryer.
NOTE: If there is not enough room to install the
turbo cutoff valve to port 1 on the air dryer,
connect a 90° fitting to port 1 of the air dryer. Then
connect the threaded end of the turbo cutoff valve
to the fitting.
5. Install the threaded end of the turbo cutoff to
port 1 on the air dryer. Make sure the arrow on
the turbo cutoff valve points toward port 1.
6. Connect the delivery line from the compressor
to the 1/2-14 NPT port marked with an arrow
( ) on the turbo cutoff valve.

MM-35
Revised 11-02 Page 9-A
Appendix II
Application Information

Figure 7-A
FROM AIR
COMPRESSOR
DISCHARGE LINE
A
RESERVOIR
TO GOVERNOR FROM AIR TO AIR
LINE GOVERNOR DRYER
GOVERNOR UNLOADER INLET
COMPRESSOR PORT PORT
INTAKE LINE
UNLOADER PLUG
PORT
SYSTEM
UNLOADER SAVER TWIN
LINE AIR DRYER
DRYER
OUTLET
PORT
COMPRESSOR

TO BRAKE
TEE CHECK SYSTEM
COMPRESSOR FITTING VALVE SYSTEM
DISCHARGE DRYER
RESERVOIR
LINE INLET
PORT SYSTEM
RESERVOIR

TURBO CUTOFF VALVE

(PLUMB ECON VALVE PER INSET A)
SUPPLY
TANK
CHECK
VALVE

1002278d

Testing the Turbo Cutoff Valve Final Checks

1. Close the drain cocks on all reservoirs.
2. Start the vehicle. Wait for the braking system to
pressurize.
3. If you hear the air dryer exhaust air after the
compressor cuts out, the air dryer is working
correctly.
You can also use the following test:
1. Apply the brakes of the vehicle several times to
reduce pressure in the air system below the
cut-in pressure of the governor.
2. If the air dryer exhausts air after the
compressor cuts out, the air dryer is working
correctly.
1. Start the vehicle. Wait for the air system of the
vehicle to reach maximum normal pressure.
2. Apply a soap solution to each connection that
contains pressurized air.
a. If soap bubbles do not appear, you
correctly sealed the connections.
b. If soap bubbles appear:
O Turn off the ignition.
O Depressurize all air tanks.
O Remove the leaking connection.
O Apply pipe sealant to the connection.
O Repeat Steps 1 and 2.

MM-35
Page 10-A Revised 11-02
 Appendix II
Application Information

Vehicle Air System E

This layout is similar to the Cummins “System E” air system arrangement.

Application
Used with high volume air compressors (Meritor WABCO, Holset, Bendix, Knorr, etc.). This air system
arrangement may also be found on vehicles with other engine makes.

Figure 8-A

Min 1/4 I.D. gov line

(down to
condenser tank)
GOV
ENGINE HIGH VOLUME Set compressor
AIR AIR COMPRESSOR governor to 3-WAY NORMALLY OPEN SOLENOID VALVE
FILTER 130 psi cutout. WIRED TO IGNITION CIRCUIT

15 FT (7/8" I.D.) 175 PSI OUT IN

TURBO SAFETY VALVE
TEFLON WIRE 18 SCFM MAX
BRAID TUBING WABCO SS TWIN EXH
ACCESSORY PORT
12 (5/8" I.D.)

REPLACEMENT CARTRIDGE PART NO. R950011

SYSTEM
STEM SSAVER TWIN

TP-95192
2500 LINE SUPPLY CHECK VALVE
OPTIONAL TURBO INLET
CU IN TANK
RECEIVER TANK Ensure dryer has PRIMARY
1 mm orifices in TANK
regen circuit. SPITTER
HEATED SPITTER CHECK BRAKE
ENGINE VALVE SYSTEM
SECONDARY
TANK

2 SCFM Normal usage

for brake system
Maximum air supply volume
is 8000 cubic inches (3 tanks).

1003387a

MM-35
Revised 11-02 Page 11-A
Notes

MM-35
Page 12-A Revised 11-02
Meritor WABCO Information contained in this publication was in effect at the time the publication was approved for
Vehicle Control Systems printing and is subject to change without notice or liability. Meritor WABCO reserves the right to revise
3331 West Big Beaver Road, Suite 300 the information presented or discontinue the production of parts described at any time.
Troy, MI 48084 USA
800-535-5560 Copyright 2002 Maintenance Manual 35
meritorwabco.com ArvinMeritor, Inc. Revised 11-02
All Rights Reserved Printed in the USA 16579/24240