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Pump damage will cccur if it is run for a period of time without coolant. To perform regular maintenance on the cutting fluid system: 1. Remove the access cover at the rear of the lathe (Figure 56). Figure 57. Coolant pump switch. Figure 56. Coolant pump and reservoir. -42- G0509 & G0509G 16" x 40" Lathe SECTION 7: SERVICE Troubleshooting Review the troubleshooting and procedures in this section to fix your machine if a problem / .✓I® develops. If you need replacement parts or you are unsure of your repair skills, then feel free ( J0 to call our Technical Support at (570) 546-9663. Motor & Gearbox Symptom Possible Cause Possible Solution Motor will not start. 1. Main power panel switch is OFF. 2. Emergency switch is pushed in. 3. Spindle rotation switch at fault. 4. Circuit breaker or fuse has tripped. 5. No voltage or open connection. 6. Motor direction switch is at fault. 7. Power switch or magnetic contactor is at fault. 8. Motor is at fault. 1. Turn the main power panel switch ON. 2. Emergency switch is pushed in. 3. Rotate the switch so it points to 1 or 2, or replace bad switch. 4. Seek an electrician to troubleshoot and repair the shop power supply. 5. Test circuit, replace wires and connections as required. 6. Replace switch. 7. Replace power switch or magnetic contactor. 8. Replace motor. Fuses or circuit breakers trip open. 1. Short circuit in line cord or plug. 2. Short circuit in motor or loose connections. 3. Incorrect fuses or circuit breakers in power supply. 1. Inspect cord or plug for damaged insulation and shorted wires. 2. Inspect all connections on motor for loose or shorted terminals or worn insulation. 3. Install correct fuses or circuit breakers. Machine is loud, belt slips, or bogs down during a cut. 1. Excessive depth of cut. 2. RPM or feed rate wrong for operation. 3. Dull cutters. 4. Belt is slipping. 5. Belt is at fault. 1. Decrease depth of cut. 2. Refer to RPM feed rate chart for appropriate rates. 3. Sharpen or replace cutters. 4. Remove grease or oil on belt or pulleys/tighten belt tensioner against low range belt. 5. Replace belt. Gear change levers will not shift into position. 1. Gears not aligned in headstock. 1. Rotate spindle by hand until gear falls into place. Loud, repetitious noise coming from machine at or near the motor. 1. Pulley set screws or keys are missing or loose. 2. Motor fan is hitting the cover. 1. Inspect keys and set screws. Replace or tighten if necessary. 2. Tighten fan or shim cover, or replace items. Motor is loud when cutting. Overheats or bogs down in the cut. 1. Excessive depth of cut or feed rate. 2. RPM or feed rate wrong for cutting operation. 3. Cutting tool is dull. 4. Gear setup is too tight, causing them to bind. 1. Decrease depth of cut or feed rate. 2. Refer to RPM feed rate chart for appropriate rates. 3. Sharpen or replace the cutting tool. 4. Readjust the gear setup with a small amount of backlash so the gears move freely and smoothly when the chuck is rotated by hand. G0509 & G0509G 16" x 40" Lathe -43- Troubleshooting Operation and Work Results Symptom Possible Cause Possible Solution Entire machine vibrates excessively upon startup and while running. 1. Workpiece is unbalanced. 2. Worn or broken gear present. 3. Chuck or faceplate has become unbalanced. 4. Spindle bearings at fault. 1. Reinstall workpiece so it is as centered with the spindle bore as possible. 2. Inspect gears and replace if necessary. 3. Rebalance chuck or faceplate; contact a local machine shop for help. 4. Tighten or replace spindle bearings. Cutting tool or machine components vibrate excessively during cutting. 1. Tool holder not tight enough. 2. Cutting tool sticks too far out of tool holder; lack of support. 3. Gibs are out of adjustment. 4. Dull cutting tool. 5. Incorrect spindle speed or feed rate. 1. Check for debris, clean, and retighten. 2. Reinstall cutting tool so no more than 1/3 of the total length is sticking out of tool holder. 3. Tighten gib screws at affected component. 4. Replace or re-sharpen cutting tool. 5. Use the recommended spindle speed. Can't remove tapered tool from tailstock quill. 1. Quill was not retracted all the way back into the tailstock. 2. Debris was not removed from taper before inserting into quill. 1. Turn the quill handwheel until it forces taper out of quill. 2. Always make sure that taper surfaces are clean. Cross slide, compound rest, or carriage feed has sloppy operation. 1. Gibs are out of adjustment. 2. Handwheel is loose. 3. Lead screw mechanism worn or out of adjustment. 1. Tighten gib screw(s). 2. Tighten handwheel fasteners. 3. Tighten any loose fasteners on lead screw mechanism. Cross slide, compound rest, or carriage feed handwheel is hard to move. 1. Carriage lock is engaged. 2. Gibs are loaded up with shavings or grime. 3. Gib screws are too tight. 4. Backlash setting too tight (cross slide only). 5. Bedways are dry. 1. Loosen the carriage lock. 2. Remove gibs, clean ways/dovetails,...