do i need reverse

[Les Jones 1Participant @lesjones1]

Hi Kevin,
The reversing switch is faulty. Which two of the wires A, B, C, D were connected to the motor terminals ? The reason I want to know this is that the results from your tests to not seem to fit with the fact that the motor only ran when the switch was in the reverse position. I would like to understand this apparent discrepancy.

Les.

[kevin largeParticipant @kevinlarge76611]

Hi les the wires where a and d so it looks like a new switch can you tell what kind of switch to get ie rating etc I see several types on ebay as I doubt I will be able to get one from warco
kevin

[Nicholas FarrParticipant @nicholasfarr14254]

Hi Kevin, I've been suspecting your switch is faulty, because it looks as if the red wires on terminal 11 and the black one on terminal 2 have been rather hot, so its probably been overloaded at some point and burnt the other contacts, but I'm as confused as Les because you say that you have connections on A and B in both forward and reverse and no connections on any of the others, so it should run forwards in both forwards and reverse.

Regards Nick.

[kevin largeParticipant @kevinlarge76611]

After les comment I looked again and noticed the bar going through the the switch wasn’t all the way through after pushing it in all the way this is what I found
3 4 r
5 6 f
7 9 f
9 10 r
11 12 r
r reverse
f forward
kevin

[Les Jones 1Participant @lesjones1]

Hi Kevin,
Your post this morning explains the mystery of why the motor only ran in the reverse position of the switch. With your previous information that there was no connections to C and D the motor could not run at all. (As my initial theory as to why the motor only ran with the switch in the reverse position was correct.) Is the line "7 9 r" a typing error ?
If the shaft through the switch is square it is possible the cams could be in the wrong position on the shaft after pulling it out.

Les

Edited By Les Jones 1 on 13/04/2015 09:02:15

[kevin largeParticipant @kevinlarge76611]

Yes sorry 7 8 f
kevin

[kevin largeParticipant @kevinlarge76611]

And the shaft running through the switch is square
kevin

[Les Jones 1Participant @lesjones1]

Hi Kevin,
9 and 10 should show continuity in forward and reverse. They must have done when you tested the connecton from wire B and the live pin on the mains plug as you said B connected to live in forward and reverse. The back two cams seem to be in the correct positions on the shaft now but if now 9 and 10 only connect in reverse then the front cam may be wrong. Did you pull the shaft out far enough to disengage with the front cam ?

Les.

[kevin largeParticipant @kevinlarge76611]

Hi les quit possible
kevin

[Les Jones 1Participant @lesjones1]

Hi Kevin,
The contacts 1 & 2 and 9 & 10 are operated by the front cam. Create a table of these two sets of contacts for the three positions of the switch. This is for two reasons. 1 To confirm you have not made an error testing. 2 To try to work out how to get the front cam in the correct position on the shaft. Does the shaft rotate a full 360 Deg or just 180 Deg ?

Les.

[kevin largeParticipant @kevinlarge76611]

I will have a fiddle tonight and see if I can get 9 10 right and then test all again
kevin

[kevin largeParticipant @kevinlarge76611]

It must of been my error I have continuity on 9 10 r f
kevin

[Les Jones 1Participant @lesjones1]

Hi Kevin,
Now go back to the test to create a table of which of the mains plug pins each of the 4 wires show continuity to in the three positions of the switch. I suggest you copy and paste the sample table with the question marks that I posted and just edit in L, N or NC to replace the question marks

Les.

Edited By Les Jones 1 on 13/04/2015 17:16:17

[kevin largeParticipant @kevinlarge76611]

Hi led

Forward

A. N

B. L

C. L

D. N

Reverse

A. N

B. L

C. N

D. L

Middle All no connection

Kevin

[Les Jones 1Participant @lesjones1]

Hi Kevin,
That is all correct now. First confirm that I have read the coding on the motor terminals correctly. This is from your picture of the motor connection box.

Top right U1
Bottom right Z2
Top middle V1
Bottom middle U2
Top left Z1
Bottom left V2

If I have this correct then this is what to do in the motor connection box.

Remove the one wire from the reversing switch that I assume is still connected to the motor.

Then remove the two metal links between V1 & U1 and between U2 and Z2 Be careful not to mix up any of the wires from inside the motor or from the capacitors.

Connect the four wires as follows.

A to U1
B to U2
C to Z2
D to V1

If you find that forward and reverse are the wrong way round then swap over wires C and D so that

C goes to V1
D goes to Z2
I think it should be correct without having to do this.

Les.

[kevin largeParticipant @kevinlarge76611]

Conect ed up forward now in forward position but no reverse

[Les Jones 1Participant @lesjones1]

Hi Kevin,
Disconnect wires C and D from the motor and make them safe by putting them into some connector block or tape them up so they do not short to anything else or each other. Fit the link bars between U1 and Z2 and between V1 and U2 (At right angles to the the position that they were in. (As shown on the diagram on the connector box cover.) This is to confirm that the motor is wired as in the diagram in the cover. The motor should run in reverse with the switch in both forward and reverse positions.

Les

[Les Jones 1Participant @lesjones1]

Hi Kevin,
An alternative test you could do is to swap over wires C and D so that C goes to V1
D goes to Z2 This is probably quicker to do. I would expect this to make the motor run in reverse when the switch is in the forward position and not work with the switch in reverse. Do you remember what sort of resistance reading you got when testing from the 4 wires to the plug pins ? I am wondering if there is a high resistance connection one one of the sets of contacts.

Les.

[Nicholas FarrParticipant @nicholasfarr14254]

Hi Kevin, not sure if you have the lever pointing in the right direction for forward and reverse. While all your contact now look to be correct, you seem to have the forward contacts correct for reverse and reverse for forwards. which way the lever is pointing does not matter really, however the manual designates that the lever is turned to the right for forwards and therefore A and C should be N and B and D should be L according to the box diagram on the circuit diagram. Les seems to be guiding you in the right direction for diagnosing your problem.

Regards Nick.

Edited By Nicholas Farr on 14/04/2015 02:07:46

[kevin largeParticipant @kevinlarge76611]

Checked connection this morning found 1 not crimped properly after that reverse working forward if I wiggled the switch would sometimes work after refitting switch to lathe reverse ok but forward just hums but does not turn ?
kevin

[Les Jones 1Participant @lesjones1]

Hi Kevin,
Are the connections as they were in your post at 20:38 on the 13th (Or have you swapped over wires C & D) ? Which connection was the bad crimp on ? I do not understand your statement "reverse working forward "

Les.

[kevin largeParticipant @kevinlarge76611]

Hi les I connected a b c d as you said noticed 1 of the connections looked a bit dodgy re crimped and with the switch not bolted to the lathe reverse and forward worked although forward seemed a bit hit and miss after re bolting switch reverse fine in correct position forward just get a humming sound from motor even if I try spinning chuck it still doesn’t start I suspect the switch as every thing is connected as in your post

[Les Jones 1Participant @lesjones1]

Hi Kevin,
I too suspect the switch. With the switch in the reverse (CORRECTION – FORWARD ) position measure the resistance between the 4 wires in the motor connection box and the live and neutral at the plug.(Leave the wires connected to the terminals.) You will need to resolve quite low resistance values as the windings will now effect the readings. You should finish up with 8 resistance values. (Some may show very high values call these NC if they are outside the range of your meter.) Did you notice any manufacturers name on the switch ? (I suspect Warco will not have any in stock.)

Les.

Edited By Les Jones 1 on 14/04/2015 11:12:29

Edited By Les Jones 1 on 14/04/2015 11:14:26

Edited By Les Jones 1 on 14/04/2015 11:24:04

[kevin largeParticipant @kevinlarge76611]

Hi les
I didn’t see any name on the switch previous I set meter beap for tests shall I set it to 200 ?
kevin

[kevin largeParticipant @kevinlarge76611]

Also l noticed on meter the longer you leave the 2 test prong the reading changes to I take the initional reading or wait for it to settle
kevin

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