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
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 |
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| Screw to | 4 | 3 mm allen wrench (G3503 only) | |
| fasten reservoir to cooler base |
| 5/16 Hex Socket | |
| Hose Clamp | 10 | 1/4 hex or medium slotted screwdriver | |
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| Fan set screw | 1 | 5/32 allen socket with wrench and 4 | |
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| 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 | |
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| Motor access door | 2 | 1/4 hex socket with wrench | |
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| Motor harness ground at motor | 1 | 1/4 hex socket with wrench | |
| terminals | 2 | needlenose pliers |
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| relay terminals 1 and 2 | 2 | large blade slotted screwdriver 8 in. | |
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| 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
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
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
