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Check Coolant Tank Level

Visually inspect the coolant tank level through the sight gauge. Minimum level should be above the pump intake fitting.

Never run coolant pump dry as this will damage the pump seals and impeller

Refill Coolant Tank

Add appropriate coolant mixture (typically 5-10% concentration) to bring level to proper operating height marked on tank.

Use a refractometer to verify coolant concentration - too weak reduces cooling effectiveness

Prime Coolant System

Press COOLANT button on control panel to activate pump and purge air from system. Monitor pressure gauge for proper reading.

May take 30-60 seconds for system to fully prime and reach operating pressure

Access Coolant Filter Housing

Turn off coolant pump and locate the spin-on filter housing typically mounted on the coolant tank or nearby panel.

Allow system to depressurize before removing filter to prevent coolant spray

Replace Coolant Filter

Remove old filter using filter wrench, clean housing threads, and install new filter hand-tight plus 3/4 turn.

Apply thin coat of coolant to new filter gasket before installation

Test System Operation

Restart coolant pump and verify pressure returns to normal range (typically 30-60 PSI). Check for leaks around filter housing.

Replace filters every 3-6 months or when pressure differential exceeds 10 PSI

Verify Actual System Pressure

Check mechanical pressure gauge on coolant system while pump is running to confirm actual pressure versus alarm condition.

Normal operating pressure should be 30-60 PSI depending on machine configuration

Test Pressure Switch Continuity

Using multimeter, check continuity across pressure switch terminals with pump running. Switch should be closed (continuity) at proper pressure.

Disconnect power before testing electrical connections

Replace Pressure Switch

If switch tests faulty, remove old switch using appropriate wrench and install new switch with thread sealant.

Typical switch setting is 15-20 PSI opening pressure - verify replacement matches original specifications

Check Pump Motor Operation

Listen for pump motor operation when COOLANT button is pressed. Motor should run smoothly without unusual noise or vibration.

Ensure electrical disconnect is accessible before troubleshooting motor issues

Test Motor Electrical Supply

Using multimeter, verify proper voltage supply to pump motor terminals (typically 115V or 230V depending on machine configuration).

Check all three phases on 3-phase motors - voltage imbalance should be less than 2%

Inspect Pump Impeller

If motor runs but no pressure develops, remove pump housing to inspect impeller for damage, wear, or debris blockage.

Mark impeller orientation before removal to ensure proper reassembly direction

Inspect Coolant Lines for Leaks

Visually inspect all coolant lines, fittings, and connections for external leaks while system is pressurized.

Look for coolant stains or mineral deposits that indicate chronic leak locations

Check Coolant Nozzle Flow

Verify adequate coolant flow from spindle and flood coolant nozzles. Clean or replace restricted nozzles as needed.

Use appropriate PPE when cleaning coolant nozzles to avoid exposure to cutting fluids

Repair Identified Leaks

Tighten loose fittings or replace damaged coolant lines using appropriate fittings and thread sealant rated for coolant compatibility.

Use PTFE tape or liquid thread sealant specifically designed for coolant systems