Lincoln Electric IM524-D manual G3503- Cooler Periodic Maintenance, G3503- Cooler Service

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D-6

D-6

MAINTENANCE

G3503-[ ] COOLER PERIODIC MAINTENANCE

1.Preparation:

Always switch off the Power Wave machine power.

Always disconnect the Power Wave machine from service input power.

Do not remove the pump relief valves 3/4 in. acorn hex nut or attempt to adjust the relief valve setting.

2.Remove the G3503-[ ] cooler from the Power Wave machine.

3.Clean the pumps inlet strainer:

Drain the reservoir of coolant and dispose of it in an environmentally responsible manner (see Recommended Coolants).

Place absorbent towels underneath pump head.

Hold pump head to apply countertorque when loos- ening strainers 7/8 acorn nut. Do not confuse with 3/4 acorn nut. Remove nut and slide inlet strainer down and out from pump head.

Gently rinse strainer under running water to thor- oughly clean it.

Use the mirror to inspect inside of pump for contam- ination. Carefully remove hardened debris with den- tal pick if necessary, without scratching inside of the pump.

Reinstall strainer and acorn nut, tightening with 75±15 in.-lbs. of torque. Wipe dry all areas wetted by coolant. Dispose of towels in an environmentally responsible manner (see Recommended Coolants).

4.Gently rinse the reservoirs strainer under running water to thoroughly clean it.

5.Remove fan shroud and inspect hoses and electrical har- nesses for kinking or damage (cut, abrasion, swelling, etc.). Replace if necessary.

6.Remove accumulated dust from cooler, especially from the motor and heat exchanger, by blowing it off with shop air or vacuuming it out.

The heat exchanger fins are sharp but can be easily bent. Treat them with care to avoid personal injury and damaging them.

Remove the cooler from the machine for a more thor- ough cleaning job.

7.Motor lubrication is recommended once a year:

Remove plug over lube port at top of motor near fan end.

Add 20 drops of electric motor or SAE 10 oil then reinstall plug.

8.Flush coolant from the system and replace with fresh, rec- ommended coolant at least once a year. More frequent flushing may be necessary, depending upon a users par- ticular system or its usage.

NOTE: Never run the pump dry. Always use a recommended

coolant, otherwise pump damage may result.

9.Reinstall the G3503-[ ] cooler into the Power Wave machine.

G3503-[ ] COOLER SERVICE

1.Preparation:

Always switch off the Power Wave machine power.

Always disconnect the Power Wave machine from service input power.

Do not remove the pump relief valves 3/4 in. acorn hex nut or attempt to adjust the relief valve setting.

2.Remove the G3503-[ ] cooler from the Power Wave machine whenever:

replacing major cooler components (i.e. pump, motor, heat exchanger, etc.).

replacing hoses and electrical harnesses that are kinked or damaged (cut, abraded, deteriorated or swollen, etc.).

investigating suspect coolant leakage.

3.Pump replacement:

a.Drain the reservoir of coolant and dispose of it in an environmentally responsible manner (see Recommended Coolants).

b.Remove fan shroud.

c.Place absorbent towels underneath pump head and wherever coolant system is opened.

d.Carefully pull pump inlet hose and its elbow from reservoir (bottom).

e.Loosen pump outlet hose clamp at QD then carefully remove from fitting.

f.Disconnect v-band clamp from motor and remove pump:

Do not drop or lose drive coupling between pump and motor.

Do not discard old pump. Remove both fittings, Keep v-clamp, Seal old pump in a waterproof bag, Package into protective container, and Return to nearest Lincoln Electric FSS center.

g.Install new pump and v-band clamp:

Do not apply any lubricant to pumps drive coupling.

Pump body is properly oriented with its strainer at the 6:00 position.

Tighten v-clamp with 15 to 30 in-lbs. of torque.

h.Attach coolant lines to QD and reservoir.

i.Wipe dry all areas wetted by coolant. Dispose of tow- els in an environmentally responsible manner (see Recommended Coolants).

j.Reinstall cooler into machine.

4.Motor removal or replacement:

Do not reuse the 4 internal-tooth star washers. Replace with new parts..

5.Installing the fan:

Slide onto motor shaft until the fan is located between 0.25 to 0.50 inches from the heat exchanger.

Tighten set screw with 65 to 75 in-lbs of torque against motor shafts flat.

Fan rotation is counterclockwise, as viewed from fan-end of motors shaft.

Fan pulls air through the heat exchanger, blows it over the motor, then exhausts it through the reser- voir.

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Contents For use with machines having Code Numbers Safety Depends on YouSafety Electric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Thank You Table of Contents Section D Section CSection E Section FFrequency Technical Specifications Power WavePulse Pulse and Background Current Range High Frequency Precautions Safety PrecautionsSelect Suitable Location Input ConnectionsInput Fuse and Supply Wire Considerations Input Power ConnectionsInput Voltage Reconnect Procedure Power WaveOutput Connections Wire Feeder ConnectionsWork and Electrode Cable Connections Water Cooler ConnectionsOperating Instructions Safety InstructionsSave process information if desired Select your process informationGeneral Description Case Front Controls Controls and SettingsOverview Installing AN OverlayOperating Overlays Name Overlay TypesOverlay Overlay ID Number = PULSE, GMAW, FCAW, and STICK/TIG Process Selection OverlayOperation Then Figure B.5 Weld from Memory Overlay Weld from Memory OverlayFigure B.6 Weld from MEMORY, Dual Procedure Overlay Weld from MEMORY, Dual Procedure OverlayOperation Position Procedure Dual Wire FEEDERS, Dual Procedure Overlay OptionalSET Limit KEY Limit UP / Down Keys Limits Overlay OptionalRecall from Memory KEY Memory Location Numbers Operation Figure B.9 Setup Overlay Setup Overlay+/- Polarity KEY Wire Feeder Setup DescriptionPositive Voltage Sensing Polarity Flux Cored ARC Welding Fcaw and Gmaw Procedures Overview of Welding ProceduresPulse Procedures ProceduresGmaw Table B.3 Adjustble ParametersFcaw Gmaw StickOverload Protection Pulse WeldingWire Feeder Setup OPTIONS/ACCESSORIESTable C.1 Recommended Guns for USE With Power Wave Guns and CablesPriming the Cooler Recommended CoolantsInput Filter Capacitor DIS Charge Procedure Routine and Periodic MaintenanceFigure D.1 Resistor Locations Connected Discharge labels, on each of the four Switch Locate the #9 and #12 terminals, identified by Preventive Maintenance Removing and Installing the G3503 Cooler G3503- Installation or SER Vice Tool UsageG3503- Cooler Service G3503- Cooler Periodic MaintenanceFigure D.4 General Component Locations Locate Problem Symptom HOW to USE Troubleshooting GuideConsult Local Authorized Field Service Facility Perform External RecommendSists, contact your local Lincoln Troubleshooting GuideAuthorized Field Service Facility 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 $700.00 Basic CoursePrecaucion Aviso DE