Valve Plate With Lower Gasket N017592SV

When the motor stopped I could hear air leaking from somewhere inside the motor/compressor unit. I removed the screws holding the motor housing together and exposed the compressor. Air was leaking from a pinhole in the compressor cylinder head! I bled off the remaining air in the tank and filled the pinhole with epoxy. I assumed this was a defect in the casting. Wrong! The compressor stopped leaking air but now it was making weird noises. The hole is there to bleed off the air between the cylinder and the tank once the motor stops. The problem was a failed check valve. Air flows from the cylinder to the tank when the compressor is on. When the compressor stops, the check valve prevents the air from escaping from the tank back into the cylinder. Once you understand how the thing works fixing it is easy! Bought a new check valve from eReplacementParts. Took 2 minutes to remove the old one and install the new one. Replaced the cylinder head I ruined. While I had it apart I also replaced the valve plate. Works perfectly! The Porter Cable service center said to buy a new compressor! Fixing mine was so much more satisfying. eReplacementParts had what I needed.

This repair covers a blown head gasket on a Porter Cable pancake compressor.

While using the machine, it started making a strange noise and refused to develop pressure.

Using a socket drive I disconnected the high pressure hose exiting the motor/pump cover going to the one way check valve mounted on the tank.

Using a Philips head screwdriver, I removed the two screws holding the housing in place near the tank brackets.

Using a torx driver I removed the screws holding the two motor/pump cases together, pushed the assembly forward from the mounting brackets and then separated the plastic cases.
There are rubber mounting feet placed at various locations keeping the pump and motor mounted to the plastic cases. Be certain to retain all of these square feet. If one or more are lost, they are available at this site as a separate part number.

Once again, using a nut driver, I removed the pump head (four screws) and separated the gaskets, valve assembly and O-ring. This is when I discovered the missing piece of head gasket. As the parts were so inexpensive, I ordered everything except the head casting itself.
The gasket kit I received had a replacement gasket to go with the new valve assembly that no longer used the O-ring. The gasket kit contained an O-ring had I used the old valve assembly.
Installing the head required using a cross-tightening pattern for installing the head bolts. As I had no specifics regarding the actual torque suggested for the head bolts, I tightened them to a level I thought appropriate without stripping the cylinder threaded holes.

Re-assembly was a reversal of the process listed above.

Silly me! Had I known the repair was going to be successful, I would have ordered motor brushes as they are worn more than half way and are only another $20. Now I need to order additional parts and separate the motor/pump casing halves again in order to replace the brushes.

KL

I had disassembled the compressor earlier to discover the reason it wouldn't work. Upon arrival of the parts, I found all of the items that I had ordered were very well packed and accompanied by complete diagrams and instructions. This repair could not have gone any better! The order was processed faster than I had expected and the tracking of my order was extremely accurate. I will absolutely order parts again for any of my power tools as needed.

Removed the plastic housing.
Removed the motor and then removed the head gasket.
Then removed the defective part and installed the new one.
Put it all back together and it runs like a new one.
It holds pressure without any leak down.
Thanks ereplacementparts for quick shipping and quality part. You made my life easier and if I can do it anyone can. I will definitely use you for all of my future repairs.

Replaced the head plate and gaskets with the pressure switch. Very easy and eliminated the air leak. May not have needed the head plate and gasket but were replaced out of maintenance. Compressor works as new.

Repair went exactly as the Ereplacement video described.

1-removed compressor from tank. 2-removed outer plastic housings two halves. 3-removed head assembly. 4-clean old gaskets and remove old seals. 5-install new head,seals,and gaskets. 6-install pump assembly into both outer housings. 7-install pump assy. back onto tank.

removed the head removed the rod and cylinder installed new piston ring and cylinder installed new reed valve plate and gaskets assembled back together pumping air now

1. disconnect air line from compressor to tank
2. removed retaining screws on bottom of plastic case to slide compressor out of position
3. open plastic case by removing screws holding case hales together
4. removed copper air line. Faulty airline seal evident.
5. removed four hex head screws at top of cylinder
6. replaced valve, gaskets after cleaning and inspecting cylinder for wear.
7. Note: clean air line and position new air line gasket on tube first, then insert gasket and tube in cylinder head recess for gasket. Inserting tube after assembly is almost impossible.
8. assembly is reverse of disassembly

Removed all screws in housing, & 2 screws at the bottom holding the housing to the tank. Remove supply tube at the tank.Split the housing into & remove pump assembly. Remove 4 bolts in the head, Removed & replaced the valve plate & gaskets. Reassembled torquing the head bolts in a star pattern.