UNLOADER VALVE KIT INSTALLATION
DO NOT
ALTER !
These instructions are provided to assist a qualified technician to
rebuild a malfunctioning unloader valve. Refer to the instruction
manual provided with the compressor unit before attempting
to service any component on the unit. Follow all safety precautions as outlined in the instruction manual.
Step 1
load
adjustment
screw
assembly
Make a note of how the control tubing is connected to the
unloader valve to facilitate re-assembly.
Do not alter the load adjustment screw assembly on
the valve! Tampering with this assembly will affect the
control settings of the valve.
Step 2
Disconnect the tubing from the valve with correctly sized
wrenches and remove the valve from the unit.
Step 3
Remove 4 screws from the valve housing. Separate the load
adjustment screw housing from the valve. Clean all surfaces
with a non-flammable solvent. Replace the round diaphragm,
metal plunger, screen and small o-ring (bottom of housing).
Re-assemble with 4 screws and tighten evenly.
Step 4
Remove the large hex head fitting on the bottom of the valve
(labeled “OUT”). Clean all surfaces with a non-flammable
solvent. Replace the poppet, spring and o-ring (see photo for
proper orientation of components). Screw the large hex head
fitting back into the valve and tighten.
Step 5
Remove the other large hex head fitting on the side or top of
the valve (labeled “IN”). Clean all surfaces with a nonflammable solvent. Replace the poppet (w/ recess), spring
and o-ring (see photo for proper orientation of components).
Note that the poppet must fit over the end of the piston shaft
inside the valve, the spring must must slide over the smaller
diameter of the poppet, and the locating knob of the large hex
head fitting. Screw the large hex head fitting back into the
valve and tighten.
Step 6
Replace the existing muffler (located on the side of the valve)
with the new muffler included in the kit. Tighten securely.
Step 7
Remove old thread sealant from all pipe fittings. Inspect and
replace any damaged fittings. Apply fresh pipe compound to
the threads of the valve assembly. Re-install the valve on the
compressor unit and connect all tubing.
Step 8
Refer to the instruction manual provided with the unit to
start the compressor and check for proper operation of the
unloader valve and the relief valve.
plunger
diaphragm
o-ring
screen
poppet
screws
spring
o-ring
relief valve
poppet (w/ recess)
spring
o-ring
locating
knob
muffler
typical photos / variations of valves exist
112711UVKI, 5/05
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