System Saver 1200 Plus Series Air Dryers – MERITOR

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For more information, see Maintenance Manual 34 or dial our toll-free number: 866-OnTrac1 (668-7221).
TP 1033
Revised 03-16
16579
COMPRESSOR
INTAKE LINE
SIGNAL LINE
COMPRESSOR
COMPRESSOR
DISCHARGE
LINE
CHECK
VALVE
SYSTEM RESERVOIR
SYSTEM RESERVOIR
SUPPLY TANK
PURGE VALVE
(EXHAUST)
System Saver 1200 Plus
Series Air Dryers
CONDITION POSSIBLE CAUSE SOLUTION
Air dryer purges too often,
perhaps as frequently as
every 15 seconds,
accompanied by excessive
cycling of the compressor.
Repair air line.
Repair leaks.
Increase air system capacity or reduce air demand.
Inspect and replace outlet check valve as needed.
Replace air governor.
Inspect compressor. Repair/replace per manufacturer’s instructions.
Replace gasket and retorque fasteners.
Leak in line between governor and dryer port 4.
Excessive air system leaks.
Excessive air system demands.
Outlet check valve not sealing.
Air governor has less than 16 psi range.
Leaking air compressor unloader(s).
Loose governor or leak at governor gasket.
Air dryer does not purge
when compressor unloads
(no blast of air from purge
valve).
Repair air line.
Replace purge valve.
Inspect air governor. Repair/replace per manufacturer’s instructions.
Check for air leaks in system and repair as needed. If no leaks in system, check
compressor output. Repair/replace per manufacturer’s instructions.
Air line between governor and air dryer port 4 kinked or plugged.
Purge valve stuck closed.
Air governor not working properly.
Cut-out pressure never achieved by air compressor.
Rapid “spitting” of air from
purge valve in small
amounts. Frequency varies
with engine speed.
Replace air dryer with an SS1200E air dryer.
Inspect compressor. Repair/replace per manufacturer’s instructions.
Holset E-Type compressor used, but non-1200E dryer installed.
Compressor not completely unloading when cut-out pressure is
reached.
Normal for non-TCV air dryers.
Air leak at turbo cut-off
valve vent. Hole burned in
piston.
Move dryer farther from compressor. Add additional compressor discharge line
before air dryer. Add cooling coil or heat exchanger before air dryer.
NOTE: Inlet air temperature must not exceed 175°F (80°C).
Install lip seal correctly.
Inspect valve bore for wear. If a new turbo cut-off valve does not seal in a clean,
lubricated bore, replace the air dryer.
Replace the turbo cut-off valve.
Temperature of air coming into dryer is too high — not enough
cooling takes place before dryer inlet.
Lip seal installed upside-down on piston. Lip must face UP (towards
dryer).
Valve bore worn excessively.
Piston is broken.
Air dryer frozen (water
collecting in base of dryer
is freezing).
Check for a blown fuse. Repair heater circuit.
NOTE: There must be power to the heater connector the entire time the
vehicle’s ignition is “on.”
Repair cause of low voltage, such as poor electrical ground, bad connections,
corroded wire splices, etc.
Replace heater assembly.
Replace with correct voltage air dryer.
No electrical power to heater connector.
Low voltage to heater connector.
Heater assembly not working.
Wrong voltage air dryer used; i.e., 12-volt air dryer used in a 24-volt
system.
No air pressure build-up in
system.
Ensure compressor discharge line is plumbed to air dryer port 1, and air dryer port
21 is connected to vehicle’s supply tank.
Ensure dryer port 4 line is connected to the “UNL” port of the air governor.
Inspect governor per manufacturer’s instructions. Repair or replace as needed.
Locate leak(s) and repair.
See purge valve conditions listed in this chart.
Air dryer not plumbed correctly (connections reversed).
Wrong air line connected to dryer port 4.
Air governor not working properly.
Air system leaks, such as compressor discharge line, air dryer,
reservoirs, brake or suspension valves, etc.
Air dryer leaks from purge valve.
Water, oil, or sludge in air
system tanks.
Desiccant contaminated with oil. Replace desiccant. Inspect compressor per manufacturer’s instructions.
Water in system tanks,
everything else checks out
okay.
Review application guidelines. For assistance, call the Meritor OnTrac™ Customer
Call Center at 866-OnTrac1 (668-7221).
Dryer not suitable for application.
Dryer leaks from purge
valve during compressor
loaded cycle. The leak may
cause excessive
compressor cycling or
prevent the system from
building air pressure.
Check heater. Repair/replace if necessary. Make sure governor to dryer port 4 line
is free of water/oil. Remove and inspect purge valve and clean water/oil from top
of piston.
Disassemble and clean purge valve. Remove cartridge and clean dryer sump area.
Ensure lip on aluminum washer faces down, away from dryer.
Verify correct air line installation and correct as needed.
Seat snap ring fully into groove.
Purge valve frozen open (cold weather operation).
Debris under purge valve seat, such as particles from fittings or air
inlet line.
Purge valve washer installed upside-down.
Wrong air line connected to dryer port 4 (unloader port).
Purge valve snap ring not fully seated in groove.
Regeneration cycle too
short (less than 10
seconds).
Increase air system capacity or reduce air demands.
Inspect per manufacturer’s instructions and repair/replace as needed.
High air system demands during compressor unloaded cycle.
Air governor not working properly.
Regeneration cycle too
long (more than 30
seconds), accompanied by
loss of pressure in the
supply tank.
Outlet check valve not seating. Inspect and replace outlet check valve as needed.
PRESSURE RELIEF VALVE
S2206-D-1226
PURGE VALVE
R950014
GOVERNOR
TURBO
CUT-OFF VALVE
S432 470 921 2
DATE CODE INFORMATION
Date Code
First 2 Digits = Build Week
Last 2 Digits = Build Year
Manufacturing
Location Code
I.D. Tag No.
Note: A Part Number with an “S”
In Front of It Indicates a Rockwell
WABCO Service Part Number.
1696
WABCO
OUTLET CHECK
VALVE
S432 470 922 2
HEATER
12 VOLT – R950015
24 VOLT – R950016
S432 470 920 2
DESICCANT CARTRIDGE
R950011
COALESCING CARTRIDGE
R950068

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