# Troubleshooting Symptoms and Required Action

Symptom | Probable Cause | Required Action
--- | --- | ---
Gauge shows pressure build-up but the tool will not cycle | Couplings are loose or not working Solenoid is not working | Tighten and/or replace couplings. Use Test #1 to isolate problem Use test #2. if not working replace solenoid
Cylinder will not retract | 1.See above. | 1. See above.
2.Voltage to electric pump is too low to line drop or inadequate amperage is available. | 2. Get shorter extension cord or upgrade to 12AWG, 25 amp rating or better. If shop power is adequate, draw power from welding machine or cal rod transformer.
3.Linkage between piston rod and drive pawl are broken. | 3. Replace parts as necessary.
Cylinder pressure will not build | 1. Oil blow by in tool (Piston seal leak, blown O-ring, cracked piston) | 1. Replace defective parts. SHOP JOB
2. Pump Problem. | 2. Remove screws from pump motor to reservoir, slide pump motor to the back while keeping pistons into oil. Turn pump on. If you have no oil coming out from the solenoid tube, change the solenoid. 2A. If pump sounds like a lot of pebbles in a tin can, the problem may be a worn motor coupling-remove motor from base plate-using a pair of needle nose pliers removes the motor coupling-if worn replace. SHOP JOB. 2B. If pump sounds like a lot of pebbles in a tin can, the problem may be a worn motor coupling-remove motor from base plate-using a pair of needle nose pliers removes the motor coupling-if worn replace. SHOP JOB. 2C. AIR PUMP-Fault FLR due to excessive moisture and/or dirt in air supply. Disassemble and change. SHOP JOB. 2D. Air pumps- Faulty remote control vv valve cartridge. Replace.
Cylinder/tool leaks | 1. Safety relief valve on swivel has lifted. | 1A. Tighten all hose and couplers. If leak continues, adjust safety setting – Test #4. 1B. Check to see if the system is properly plumbed by running test #5 (high pressure on retract side will lift the safety relief valve).
2. Blown O-ring in cylinder. | 2. Replace O-Ring with proper high pressure O-Ring. SHOP JOB.
3.Defective gland seal. | 3. Replace gland seal. SHOP JOB.
Tool operates backwards | 1. Couplings reversed. | 1. Run test #5. Replumb system as necessary.
2. Multiple hoses in even numbers. | 2. As plumbed, Atlas Copco hoses may only be joined together in odd numbers ONLY if it is necessary to use 2, 4, 6 hoses-make an adapter from spare high pressure couplings and nipples.
Ratchet returns with retract stroke | Broken or otherwise inoperable reaction pawl. |
Ratchet will not take successive strokes. | 1. Broken or otherwise inoperative drive pawl or spring. | 1. Replace drive pawl and/or spring. SHOP JOB.
2. Cylinder not retracting completely. Ratchet will not take successive strokes. | 2.Remove tool from nut and cycle freely for several strokes. If problem persists, check pawls. 2A. Operator not allowing adequate time for cylinder to retract fully
3. Linkage between piston rod and drive plates is broken. | 3. Replace parts as necessary -SHOP JOB.
Tool locks onto nut. | 1. Reaction pawl is loaded when the tool is maxed out in torque. | 1. Press advance button on remote and build pressure- continue to press down on remote while pulling back on one of the disengagement levers- release remote while continuing to hold back on levers.
2. Tool is operating backwards. | 2. Push advance button down-tool should immediately fall free- Run test #5.
3.Tool is wedged under a fixed object. | 3. Remove shroud from around ratchet. Using any tool available, pry the drive pawl out of the ratchet and at the same time pull back on the disengagement levers. Tool should swing free or turn away the socket or obstruction.
Gauge records no pressure | 1. Gauge connection is loose. | 1. Tighten coupling.
2. Bad gauge. | 2. Replace gauge.
3. Pump will not build pressure. | 3. See cylinder will not build pressure above.See cylinder will not build pressure above.
4. Tools seals are blown. | 4. Replace defective seals. SHOP JOB.