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Service Notes
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Section 1: Introduction
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Description
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Maintenance Intervals
Cylinder Head
Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Section 2: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Section 3: Compressor Replacement
Compressor Replacement Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Compressor Removal
Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Cylinder Head Replacement
Removal
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Performance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Air System Leakage Test
Section 1
Introduction
Application
Section 1
Introduction
Description
O Used on Mack engines. Figure 1.1. The Meritor WABCO System Saver 636 twin
cylinder air compressor provides and maintains
O Swept volume displacement: 37.4 cubic feet per air under pressure to operate devices in the air
minute. brake and auxiliary air systems of a vehicle. It
O Flange mounted to the engine. consists of two major subassemblies: Cylinder
head and crankcase. Figure 1.2.
Coupling driven through the auxiliary shaft.
Inlet air, oil lubrication and coolant supplied
from the engine. Figure 1.2
O Pneumatic pressure signal from the governor
controls compression: 1
4000263d
Figure 1.3
4000266c
1 SLIDING LEAF VALVES
Maintenance Intervals
The Meritor WABCO System Saver 636 twin
cylinder air compressor receives inlet air, oil and
coolant from the engine, so it is important to
1 follow the engine manufacturers
recommendations and maintenance schedules
4000265b regarding fluid levels, air filter and recommended
1 GOVERNOR PORT change intervals.
Cylinder Head
The unloader mechanisms control the air Remove carbon deposits from the discharge cavity
compression cycle; an air compression cycle has and rust and scale from the cooling passages of
three phases: the cylinder head.
1. Induction: Air flows from the engine to the Clean carbon and dirt from the inlet and unloader
compressor, opening the inlet valves in the passages.
cylinder head of the compressor.
2. Compression: Air pressure is increased,
causing the compressors discharge valves to
open.
3. Unloading: Air passes from the cylinders to
the inlet chambers of the cylinder head via a
port controlled by sliding leaf valves.
When system cut-in pressure is reached, air is
exhausted from the unloader ports.
Visual Inspection
A visual check of the compressor can detect minor problems (see legend for examples of these problems).
This check should be part of the vehicle preventive maintenance program. Figure 1.5.
Figure 1.5
1
2
4000267c
1 Check water ports for leakage.
2 Check air inlet and discharge ports for leakage.
3 Check around end cover for oil leakage.
4 Check flanges for cracks or breaks.
Use the following chart to troubleshoot the Meritor WABCO System Saver 636 twin cylinder air
Section 2
Troubleshooting
compressor.
NOTE: If you have any questions or need additional information, please contact the Meritor WABCO
Customer Service Center at 866-668-7221.
Restricted air inlet or excessive Verify engine air cleaner is functioning properly. Replace if
vacuum present at compressor necessary.
inlet Repair compressor air inlet kinks or excessive bends.
Check vehicle specifications to ensure air and coolant lines meet
all requirements.
Compressor duty cycle too high Check system for leaks. Make necessary repairs.
Compressor Compressor unloader piston With compressor unloaded check for air leakage. If leaking,
continuously cycles leaking replace the cylinder head.
Governor air leak Refer to the manufacturers manual for governor maintenance
and troubleshooting procedures.
Dryer purge valve air leakage Check for air dryer malfunction. Refer to air dryer manufacturers
service instructions.
Air leak at governor-compressor Inspect connection for physical damage. Inspect and repair
attachment. connection.
Inlet line kinked or restricted Inspect the compressor air induction line for kinks and
restrictions. Repair or replace as necessary.
External contamination Replace broken, defective or dirty air filters. Clean contaminants
from surface of compressor.
Air dryer purge valve stuck open Check for air dryer malfunction. Refer to air dryer manufacturers
or leaking service instructions.
Noisy air compressor Loose drive hub Check fit of drive coupling.
Loose accessory drive coupling Ensure hub is completely seated and crankshaft nut is tight.
Inspect crankshaft for damage replace compressor if
crankshaft is damaged.
Broken connecting rod Oil starvation to crank pin or Check oil pressure. Verify oil passage is free of obstructions.
or crankshaft front main bearing Make necessary repairs.
Failed power steering pump Verify power steering pump is in proper operating order. Refer to
the component manufacturers service instructions.
Leaking of gasket internal to the Verify cylinder head bolts are properly torqued. Make necessary
cylinder head adjustments.
Inspect gasket for cracks or signs of wear. Replace if necessary.
Replace cylinder head.
Compressor pressurizes Leaking of gasket internal to the Inspect gasket. Replace if necessary.
coolant system or cylinder head
coolant leakage to
compressor inlet Cavitation or corrosion in Replace cylinder head.
cylinder head
Unloader leakage Possible internal damage, Replace compressor cylinder head assembly.
including worn or damaged
unloader piston O-ring, porosity
in unloader piston bore, loose or
leaking seal at unloader piston
bore
Compressor head gasket Discharge line blocked due to Check for trap (low spots) in lines.
failure freezing or carbon build-up Make necessary repairs.
Clear discharge line. Replace line if necessary.
Check for carbon build-up. If carbon build-up is present, replace
the discharge line.
Improper cylinder head bolt Inspect gasket. Replace if necessary. Verify all bolts are properly
torque, machining defect on torqued. If problem persists, replace cylinder head.
cylinder head or block, defective
cylinder head gasket
None of the above, but condition Replace compressor cylinder head assembly.
persists
Figure 3.1
1003382a
1003382a
1
Figure 3.4
1
1 INLET VALVE
2 CYLINDER HEAD GASKET
1
Figure 3.6
3
4000271c
1 SLIDING LEAF VALVES
2 UNLOADER PASSAGE
3 GUIDE BUSHINGS
5. Install the six hex head mounting bolts that Table B: Bolt Tightening Sequence
hold the cylinder head in place. Tighten the
mounting bolts in sequence per Table B, Torque
Rotation
following Steps 1-12. Figure 3.7. Step Bolt (Nm) lb-ft (Degrees)
6. Use a Torx tool to tighten the seven Torx 1 A 25 +0
-5 18.5 +0
-3.7
head screws in sequence per Table B, 2 B 25 +0
-5 18.5 +0
-3.7
following Steps 13-26. Figure 3.8. 3 C 25 +0
18.5 +0
-5 -3.7
+0 +0
4 D 25 -5 18.5 -3.7
CAUTION 5 E 25 +0
18.5 +0
-5 -3.7
Use the proper tools to perform this torque-turn 6 F 25 +0
-5 18.5 +0
-3.7
bolt tightening sequence exactly as shown in +15
7 A 150 -5
Table B. Accuracy is CRITICAL to your field service +15
success! 8 B 150 -5
+15
9 C 120 -5
+15
10 D 120 -5
Figure 3.7 +15
11 E 120 -5
+15
1 12 F 120 -5
C A E
+6 +4.4
13 G 6 -6 4.4 -4.4
+6 +4.4
14 H 6 -6 4.4 -4.4
+6 +4.4
15 I 6 -6 4.4 -4.4
B D +6 +4.4
16 J 6 -6 4.4 -4.4
F +6 +4.4
17 K 6 -6 4.4 -4.4
+6 +4.4
18 L 6 -6 4.4 -4.4
4000274b +6 +4.4
19 M 6 -6 4.4 -4.4
1 Tighten bolts in sequence shown. +15
20 G 135 -5
+15
21 H 135 -5
+15
22 I 135
Figure 3.8 -5
+15
23 J 135 -5
1 24 K 135 +15
-5
+15
25 L 135 -5
K
H G +15
26 M 135 -5
Performance Testing
Test the vehicle air system as follows:
1. Bleed the vehicle air system reservoir gauges
down (apply brakes several times) to
approximately 85 psig.
2. With the engine running at full governed
speed (no load, no air accessories being used),
the compressor should reach governor cutout
pressure, then unload.
If the compressor does not reach governor
cutout pressure, check for air leaks in the
system. If reservoir volume and engine RPM
are per original vehicle manufacturers
specifications, system plumbing leakage must
be checked and, if necessary, repaired. See air
system leakage test procedures which follow.
If the compressor fails to unload, verify proper
governor operation.