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Devilbiss Compressor Unloader Valve

sreno

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Can someone tell me where the Unloader Valve is on my old compressor?
Compressor_01.jpg


While installing tires this weekend, my compressor worked well for a while and then the gremlins came.

Once stopped, there was a loud leak from here (see pic)
Compressor_03.jpg


After backing the valve out, the hissing stopped but later on, the compressor could no longer restart. The motor hummed/growled and jumped the breaker.
I've heard that the unloader valve is often the cause and I'd like to know how to locate it.
IMG_0993.jpg


A plate on the pump says:
Model #44634
Serial #11280

Stamped into the metal on the pump is: 50228 -- 445-325 -- W 30144-102

Any help would be appreciated!
 
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scw1991

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you are pointing at it. It's a pump mounted centrifugal activated unloader valve. Typically only found on industrial rated compressors and higher horsepower models.

there are a set of flyweights at the end of the crankshaft under the cast iron cover. Same principal as a centrifugal switch on an electric motor.
 

b-body-bob

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Sounds to me like you tried to fix a leaky check valve by de-adjusting the unloader, making the problem worse. If the check valve doesn't close, the unloader will hiss until the tank is empty.
 
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sreno

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you are pointing at it. It's a pump mounted centrifugal activated unloader valve. Typically only found on industrial rated compressors and higher horsepower models.

there are a set of flyweights at the end of the crankshaft under the cast iron cover. Same principal as a centrifugal switch on an electric motor.

Thanks for the answer!

(It sounds like my old Ford's distributor)

I've been hearing a rattling sound for a couple of weeks now.

What kind of damage should I expect when I pop the cover?
 

Major Ramifications

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Is the unloader valve being activated by the lever on the pump? Is it leaking when it is closed?
If the unloader is doing what it is supposed to, then the problem is your check valve, not the unloader.
 

scw1991

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you're compressor couldn't start because you were not relieving the head pressure. When the compressor cuts out (stops when tank is full), this actuates the unloader valve through a set of flyweights. Time to relieve head pressure varies but usually lasts no more than 5 seconds. If for some reason, it continues to hiss, then the tank mounted check valve is bad and will continue to hiss until the entire tank is empty.

The unloader valve is similar in design to schrader valve (as found on your car wheel) and has a small rubber o-ring to seal it. I'll assume you can get to the valve by removing the copper lines screwed into the side of the cast iron cover. I can't imagine you'd need to take the cast iron cover off.

The tank mounted check valve consists of a spring, teflon seat (typical), and a internal snap ring. All it takes is the slightest amount of debris in the tank to get the valve to not seat properly.
 
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sreno

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Is the unloader valve being activated by the lever on the pump? Is it leaking when it is closed?
If the unloader is doing what it is supposed to, then the problem is your check valve, not the unloader.

Yes. The first hint I had of a problem on Saturday was a loud hissing from the front cap. (see photo)

I backed the valve off and the hissing stopped.

Later, the compressor refused to restart. The motor hummed and the breaker popped.
 
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sreno

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you're compressor couldn't start because you were not relieving the head pressure. When the compressor cuts out (stops when tank is full), this actuates the unloader valve through a set of flyweights. Time to relieve head pressure varies but usually lasts no more than 5 seconds. If for some reason, it continues to hiss, then the tank mounted check valve is bad and will continue to hiss until the entire tank is empty.

The unloader valve is similar in design to schrader valve (as found on your car wheel) and has a small rubber o-ring to seal it. I'll assume you can get to the valve by removing the copper lines screwed into the side of the cast iron cover. I can't imagine you'd need to take the cast iron cover off.

The tank mounted check valve consists of a spring, teflon seat (typical), and a internal snap ring. All it takes is the slightest amount of debris in the tank to get the valve to not seat properly.

I'll need to look at the check valve, then.

Is this the unloader valve? (looks like schrader valve- good comparison).
IMG_0964.jpg


If I follow the copper line back to the tank, is it the check valve at the other end?
 

MacMcMacmac

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The little brass finger should be pressing in on the needle valve when the pump is stopped. It looks like it has been backed off so far that it will never blow down the pump as it sits right now. What you need to do is blow down the pump by pressing in the brass pin, then loosen the Swagelock fitting and thin lock nut, and screw in the unloader valve until you see the brass finger push the brass pin back into the unloader valve body by about 1/4". Let the compressor start. The valve should be bleeding continuously. Unscrew the valve assembly back out of the case while the compressor is running, until the hissing stops through the threaded port below the valve. Once it stops, lock the thin brass locknut again, don't keep moving the valve out. Re-tighten the Swagelock. This should solve the leaking. At cut out, the brass finger should move to the right and push the pin in far enough to blow down the pump.

If it doesn't stop the hissing, there are several things to look for:

1) The brass pin in the picture can be pulled out of the valve by removing the Swagelock fitting. It is a simple brass pin which is threaded on one end. The thread has a small brass nut which retains a rubber seal inside a small cup. Many times this rubber seal will dry out and crack. This is the only thing which seals the blowdown when the brass lever pulls away from the brass pin. It is pushed against a seat by a spring (confused yet?). It's really very simple when you take it apart and look at it. You can either make a new rubber seal with a hole punch and pin punch and put it in the cup, or you can use an o-ring of the proper size. Once you replace the seal, you may need to go through the adjustment procedure again. Do not over torque the small brass nut on the pin, it is very easy to strip the threads.

2) If the hissing is continuous after shutdown, there is something wrong with the check valve. This type of check valve can be disassembled by pulling the contents out through the hex-head cap on the side of the valve body (de-pressurize the tank and system entirely before pulling this cap!!!). There should be a brass piston, a spring and a seat, probably teflon. The seat will often split and fall apart, either holding the check valve open, or creating a leak path in the space left by the missing pieces. There used to be rebuild kits available for these check valves. Contact a DV Systems retailer to find out for sure. Any good compressor shop should be able to source them if they are still available. The spring in the check valve may also have broken, producing the same results.

If it is not the check valve itself, you may have lost some valve springs, which have now migrated to the check valve and are now holding it open. Time for a spring kit! Your valve seats may have also taken a beating, so you'll only know for sure by pulling the valves. Did the intercooler safety valve blow by any chance?

3) The unloader valve has lost some of its travel and is not actuating the blowdown valve correctly. There is an aluminum piece inside the cone-shaped cover that rides on the face of a steel plate on the end of the crankshaft. The two pads that contact the steel plate can wear over time, and not allow the brass lever to fully travel and move the brass pin. It's an easy, pull out the old and replace with the new type of job, not hard at all. This problem usually results in the compressor failing to unload, however, so it is likely not your problem.

If you go messing about inside the unloader cover, be warned that pulling the bolt in the end of the crankshaft will allow the steel plate to come off and you'll be cussing trying to pick up all the ball bearings that will fall out.
 

MacMcMacmac

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Ok, you pulled the valve before I got my post finished.

Pull the 1/4" Swagelock fitting out of the end of this valve and pull out the spring and piston. Check the brass cup for a rubber seal. If missing, make a new one by the method I described above, or insert an o-ring of the proper size. reassemble, reinstall and adjust.

The unloader valve is the brass one you removed. The check valve is the big orange one in the third picture. DeVilbiss loved these all in one check valves, allowing a one point connection for unloader line, pressure gauge, safety relief valve and pressure switch.

If you pulled this valve with pressure in the tank and there is no leaking, your check valve is working properly.
 
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sreno

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Success! Thank you.

It was definitely the check valve that malfunctioned the other day. That's why the finger pushed on the unloader valve pin and allowed air to escape, as it should, from what you've explained so well. BUT the air flow from the unloader valve never stopped.

Thanks to all for the quick and clear descriptions. My compressor is working fine after simply reassembling, now that I've readjusted the unloader valve.

To be honest, I think it was probably the lack of draining that's at the root of it all. Lesson learned.

Thanks again for the guidance!

Shawn


I took a chance and decided the check valve was in here (later verified by a member of this board)
IMG_1081.jpg


This is what I pulled out.
IMG_1084.jpg


Part of it remained inside.
IMG_1090.jpg


Not having a replacement, I put it back together.
IMG_1094.jpg


It worked 'as is' but I have a feeling it's not supposed to come apart.
IMG_1097.jpg
 
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MacMcMacmac

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It's been a few years since I had one apart now, but I'm 99% sure the soft seat on that plunger should reach right out to the lip of the cup. If i'm correct, as is stands right now, if your plunger does not seat itself just right, you will have leakage. I'd pull that plunger when you have some time, and take it to a decent compressor shop, or DV Systems (DeVair, DeVilbiss etc.) dealer and see if he has a rebuild kit. If you are far away from a shop and you feel handy, you might try drilling out that center rivet and making a new seat, re-installing it with a strong panhead screw, double nuts and red loctite. It might get you going again if it fails permanently, but the best bet is the kit. You might get by for a good long while with giving everything inside a good cleaning. I see a bit of carbon there. That plus rust on the face of the plunger will cause seating problems.
 
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sreno

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It's been a few years since I had one apart now, but I'm 99% sure the soft seat on that plunger should reach right out to the lip of the cup. If i'm correct, as is stands right now, if your plunger does not seat itself just right, you will have leakage. I'd pull that plunger when you have some time, and take it to a decent compressor shop, or DV Systems (DeVair, DeVilbiss etc.) dealer and see if he has a rebuild kit. If you are far away from a shop and you feel handy, you might try drilling out that center rivet and making a new seat, re-installing it with a strong panhead screw, double nuts and red loctite. It might get you going again if it fails permanently, but the best bet is the kit. You might get by for a good long while with giving everything inside a good cleaning. I see a bit of carbon there. That plus rust on the face of the plunger will cause seating problems.

No leaks that I noticed; though I didn't really pay attention as I was busy celebrating! :)

But I will check against a new one to make sure.

Here's the surface it mates with.
IMG_1100.jpg
 
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sreno

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Well, well. Nobody seems to have the check valve kit (or even a clue about what it looks like- until I show them a picture).

I'm going to have to resort to the internet stores.

Do any of you guys know where I might start my search?

Shawn
 

Major Ramifications

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Don't feel bad, you are only about the umpteenth million person who has attacked the poor unloader for just doing it's job. The check valve has a much tougher job, but it doesn't hiss or call attention to itself so everyone wants to "fix" the unloader.
 

MacMcMacmac

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Well, well. Nobody seems to have the check valve kit (or even a clue about what it looks like- until I show them a picture).

I'm going to have to resort to the internet stores.

Do any of you guys know where I might start my search?

Shawn

You might try to email MPS Industrial in Ottawa. Jim McDonald has been selling DeVilbiss since 1979 at least.

http://www.mpsindustrial.com/
 

MacMcMacmac

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I think I would just give the valve and housing a good cleaning and button it up. The seat looks good. I'm starting to think it might have been a momentary problem with a bit of rust or carbon sticking the valve open. At least you can use it until you figure out if it is a serious issue.
 
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sreno

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I think I would just give the valve and housing a good cleaning and button it up. The seat looks good. I'm starting to think it might have been a momentary problem with a bit of rust or carbon sticking the valve open. At least you can use it until you figure out if it is a serious issue.

Thanks, MacMcMacmac (try saying THAT 5 times quickly) for all the great advice during my compressor crisis! :)

I've copied/pasted your advice from post#9 to print out and keep at hand in case more troubleshooting is required.

I agree that the check valve is a 'back burner' item now that the Devilbiss is humming along nicely again. I'll keep looking but without as much urgency. I need to replace the pressure gauge and drain-**** anyway.

Shawn

My shop: http://www.garagejournal.com/forum/showthread.php?t=28505
 
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sreno

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scw1991

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It's amazing how the slightest amount of rust from within the tank can cause the check valve to not seat properly.

Glad the source of the problem was found and you've got it back up and purring!
 
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sreno

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It's amazing how the slightest amount of rust from within the tank can cause the check valve to not seat properly.

Glad the source of the problem was found and you've got it back up and purring!

Or maybe just moisture (from neglect) that produces frost from rapid air passage. Like a wheel valve stem with the valve removed and the air streaming out. Sometimes the air flow stops, blocked by the frost until it melts. Just a theory; rust particles could very well be to blame. :)

Shawn
 
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