Lincoln Electric IM524-D manual G3503- Installation or SER Vice Tool Usage

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D-5

D-5

MAINTENANCE

RECOMMENDED TOOLS FOR INSTAL- LATION OR SERVICE OF COOLER:

•absorbent towels

•alcohol wipe

•3 mm allen wrench (G3503 only)

•socket wrench

•4 inch long minimum socket extension

•1/4, 5/16, and 3/8 hex standard depth sockets

•5/32 allen socket

•medium blade slotted screwdriver

•large blade slotted screwdriver, 8 inches long minimum

•two 7/16 open or box end wrenches

•one 7/8 open or box end wrench

•needlenose pliers

•two 10 inch long adjustable wrenches

•wire cutter

•molex pin removal tools

•tape measure

•small mechanic’s mirror

•flashlight

•dental pick

•digital multimeter (DMM)

REMOVING AND INSTALLING THE G3503-[ ]

COOLER

1.Preparation:

•Always switch off the Power Wave machine power.

•Always disconnect the Power Wave machine from service input power.

2.Remove cooler assembly G3503-[ ]:

a.remove gas cylinder(s) from tray.

b.remove cooler access panel.

c.Remove both fasteners from base that hold cool- er in place. Remove ground lead, if present. Carefully pull cooler assembly rearward, until cooler’s Molex connectors are visible.

d.disconnect cooler’s connectors from the P3 and P4 harnesses. Continue pulling the cooler out of the Power Wave.

3.If necessary, perform periodic maintenance or ser- vice on the cooler.

4.Reinstall cooler by reversing tasks in step 2. Be sure to reattach ground lead, if previously removed.

G3503-[ ] INSTALLATION OR SER-

VICE TOOL USAGE

 

Fastener Usage

Qty.

Tool

 

Shroud to cooler base

4

all use 5/16 hex screw and 3/8 hex

 

Quick Disconnect (QD) bracket

2

nut. Relay may require large blade

 

Heat exchanger to cooler base

2

slotted screwdriver 8 in. long min.

 

Relay to cooler base

2

 

 

 

Screw to

4

3 mm allen wrench (G3503 only)

 

fasten reservoir to cooler base

 

5/16 Hex Socket (G3503-1 only)

 

Hose Clamp

10

1/4 hex or medium slotted screwdriver

 

 

 

 

 

 

Fan set screw

1

5/32 allen socket with wrench and 4

 

 

 

in. min. extension

 

Pump carbonator clamp screw

1

5/16 hex socket with ratchet wrench

 

Motor mounting bolts

4

two 7/16 open or box end wrenches

 

 

 

 

 

 

Motor access door

2

1/4 hex socket with wrench

 

 

 

 

 

 

Motor harness ground at motor

1

1/4 hex socket with wrench

 

terminals

2

needlenose pliers

 

 

relay terminals 1 and 2

2

large blade slotted screwdriver 8 in.

 

 

 

minimum long.

 

relay terminals 3 and 4

2

medium slotted screwdriver

5.If necessary, fill cooler with selected coolant to spec- ified level (see Fig. 1).

6.Attach desired water-cooled accessory (gun and wire feeder or TIG torch) to cooler’s QDs.

7.Reconnect service input power to the Power Wave:

•verify that the reconnect panel setting and lead placement match the service voltage.

8.Prime the cooler:

a.Install the Set-up overlay.

b.Keep accessories’ hose lengths horizontal, either coiled or straight, and no higher than 4 feet of the specified coolant level (Fig. 1).

c.Switch on the Power Wave machine.

d.Press the "WATER COOLER ENABLE" button so that the "WATER COOLER ENABLED" light is illuminated .

e.Press the "PRIME WATER COOLER" button until the "WATER COOLER PRESSURE" light is steadily illuminated.

9.Check coolant level. Add more if required.

All plumbing components

N/R two 10 inch adjustable wrenches

POWER WAVE 450

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Contents Safety Depends on You For use with machines having Code NumbersSafety Electric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Thank You Table of Contents Section C Section DSection E Section FPulse Pulse and Background Current Range Technical Specifications Power WaveFrequency Safety Precautions High Frequency PrecautionsSelect Suitable Location Input ConnectionsInput Power Connections Input Fuse and Supply Wire ConsiderationsInput Voltage Reconnect Procedure Power WaveWire Feeder Connections Output ConnectionsWork and Electrode Cable Connections Water Cooler ConnectionsSafety Instructions Operating InstructionsSelect your process information Save process information if desiredGeneral Description Controls and Settings Case Front ControlsOperating Overlays Installing AN OverlayOverview Overlay Overlay TypesName PULSE, GMAW, FCAW, and STICK/TIG Process Selection Overlay Overlay ID Number =Operation Then Weld from Memory Overlay Figure B.5 Weld from Memory OverlayWeld from MEMORY, Dual Procedure Overlay Figure B.6 Weld from MEMORY, Dual Procedure OverlayOperation Dual Wire FEEDERS, Dual Procedure Overlay Optional Position ProcedureRecall from Memory KEY Memory Location Numbers Limits Overlay OptionalSET Limit KEY Limit UP / Down Keys Operation Setup Overlay Figure B.9 Setup OverlayWire Feeder Setup Description +/- Polarity KEYPositive Voltage Sensing Polarity Overview of Welding Procedures Flux Cored ARC Welding Fcaw and Gmaw ProceduresPulse Procedures ProceduresTable B.3 Adjustble Parameters GmawFcaw Gmaw StickPulse Welding Overload ProtectionOPTIONS/ACCESSORIES Wire Feeder SetupTable C.1 Recommended Guns for USE With Power Wave Guns and CablesRecommended Coolants Priming the CoolerRoutine and Periodic Maintenance Input Filter Capacitor DIS Charge ProcedureFigure D.1 Resistor Locations Locate the #9 and #12 terminals, identified by Discharge labels, on each of the four SwitchConnected Preventive Maintenance G3503- Installation or SER Vice Tool Usage Removing and Installing the G3503 CoolerG3503- Cooler Periodic Maintenance G3503- Cooler ServiceFigure D.4 General Component Locations HOW to USE Troubleshooting Guide Locate Problem SymptomConsult Local Authorized Field Service Facility Perform External RecommendAuthorized Field Service Facility Troubleshooting GuideSists, contact your local Lincoln Play fans run Check circuit breaker 5-amp Observe Safety Guidelines Controls and Settings Power-up Inspect the overlay bar code Saved in memory are different Check for proper shielding gas Basic Course $700.00Precaucion Aviso DE
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