So I’ve finally had a chance to test this, and it does seem the unloader mechanism is working. At least when I follow American Locomotive’s directions above, I do hear the “pssshhh” of air coming out of the pressure switch.As someone else mentioned, the load on a compressor is proportional to how much air is flowing through it. If you completely restrict the inlet of a piston-type air compressor, it will essentially be unloaded.
Compressors normally have something called an unloader, that vents the pressure in the discharge (pressure side) of the line. This allows the compressor to get up to speed before experiencing load. It's possible the unloader mechanism on your compressor is not working correctly. Usually you can identify this as a second small diameter tube going to the pressure switch coming from the discharge pipe off the compressor pump.
The parts diagram I looked up for your compressor shows that it has an unloader pipe going to the pressure switch. You can figure out if this is working by flipping the lever to turn the compressor off while it's running. You should hear a "psssssshhh" of air coming out of the pressure switch.
It's also possible the motor just doesn't really have enough grunt, so they engineered a restriction into the intake to reduce the load a bit. Is the compressor plugged into an outlet, or into a cord?
I’ve since repeated the test - of either letting the compressor start and trip the breaker or covering the intake temporarily and having it run - a number of times, with the tank starting at varying pressures. It continues to exhibit the same behaviour. Filter off or Solberg filter without my finger results in tripping the breaker, original Mastercraft filter or my finger momentarily on the Solberg intake allows it to run without tripping.
My experience with the brand has me favoring the notion that the restrictor on the original filter was a deliberate add-on fix to deal with inadequate reliability of being able to operate on an everyday outlet.
