Maintenance

D-1	MAINTENANCE	D-1

SAFETY PRECAUTIONS

WARNING

Have qualified personnel do the maintenance work. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the mainte- nance requiring their removal is complete. Always use the greatest care when working near moving parts.

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ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

•Insulate yourself from work and ground

•Always wear dry insulating gloves.

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MOVING PARTS can injure.

•Do not operate with doors open or guards off.

• Keep away from moving parts.

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Observe all Safety Guidelines detailed throughout this manual. Be sure to disconnect the Under- Cooler cart from the Power Source before performing any maintenance procedures.

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ROUTINE

Remove accumulated dust and dirt from the internal components of the cooler by blowing it out with a low- pressure air hose or removing it with a vacuum hose.

PERIODIC

In dirty or dusty environments or if biological growth occurs in the coolant, it may be necessary to flush the coolant reservoir. Dump the old coolant, rinse the inside of the reservoir and circulate rinsing solution through coolant system. Add new coolant when cleaning is finished. It is recommended to flush the coolant at least once a year. A cooling system free from debris offers increased cooling efficiency and longer pump and torch life. See the coolant treatment recommendation in “Section D-2”.

NOTE: Pure solutions and mixtures of, or materials (i.e. towels) wetted with ethylene glycol are toxic to humans and animals. They must not be haphazardly discarded, especially by pouring liquids down the drain. Contact the local EPA office for responsible disposal methods or for recycling information.

PUMP

The pump head has a "built in" strainer on the inlet side of the pump. It is recommended to clean or replace the pump’s inlet strainer at least annually as follows:

•Drain the coolant reservoir and all coolant lines. Dispose of the coolant properly as specified above.

•Hold the pump head firmly to apply a counter-torque when loosing the strainers 7/8" acorn nut located on the bottom. Do not confuse with 3/4" acorn nut. Remove nut and slide inlet strainer down and out from the pump head.

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

•Use a mirror to inspect the inside of the pump for contamination. Carefully remove hardened debris with a dental pick if necessary, without scratching the inside of the pump.

•Reinstall the strainer and 7/8 acorn nut, tighten to 75 in-lbs.(8.5N-m) of torque. Wipe dry all area wetted with coolant. Dispose of coolant soaked towels properly as specified above.

PUMP MOTOR

The Under-Cooler cart is rated for continuous operation. It is recommended to re-oil the pump motor bearings once a year as follows:

•Remove the plastic plugs located on the top of both the inboard and outboard bearing end-caps.

•Re-oil each bearing with 30-35 drops of SAE 20 oil then reinstall both plugs.

HEAT EXCHANGER

To maintain maximum cooler efficiency, the heat exchanger should be kept free of dust and dirt build- up. Clean the heat exchanger periodically using a vacuum hose or a low-pressure air line. Avoid placing the unit near a flux hopper or a flux waste container. A clean heat exchanger offers better cooling perfor- mance and longer product life. In extremely dirty environments, it may be necessary to remove the heat exchanger completely from the cooler and clean the fins with soap and water. Use care to avoid damaging the fins.

UNDER-COOLER CART