RECOMMENDED TOOLS FOR INSTALLATION OR SERVICE:

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)

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

 

 

 

All plumbing components

N/R

two 10 inch adjustable wrenches

 

 

 

S24505 WATER COOLER UPGRADE KIT CONTENTS:

1Cooler assembly, G3503-[ ]

Empty Weight: 36 lbs.

Overall Size: 22.38x14.00x12.50, LxWxH

Electrical Input: 230VAC, 2.8A max. steady state

Coolant Connections:

Welding Industry Standard Quick-Disconnect (QD) female fittings. Top: Coolant In, Bottom: Coolant Out

1 Cooler access panel, L9387-2

1 “P4” Electrical power harness (long), S14165-467

1“P3” Electrical extension harness (short), S14165-466

1Circuit breaker, T12287-14, spare replacement

2fasteners, S9225-8, (1/4-20 thread, spares for cooler mounting)

4fasteners, S8025-91, (spares for cooler access panel mounting)

2Hole plugs, T10397-11

1Ground Decal, T13260-4

8cable ties, T13770-2

1Electrical sleeving, E1159/B-1.00-7.00

1“B” Stencil, S21212

1Power Wave machine label: S24503-1

2Mounting Brackets, S10040-93

2Fasteners, T9447-42, (#10-24 UNC-3A)

2Plain washers, S9262-77 (Socket head- cap screws)

RECOMMENDED COOLANTS

1.The following coolants have been determined to be compatible with the wetted materials used in the

G3503-[ ] cooler assembly:

Distilled or deionized water

Potable tap water

Sediment-free mixtures containing a maxi- mum of 50% ethylene glycol or automotive- grade antifreeze and the balance of distilled or deionized water.

2.Ethylene glycol mixtures should be selected if the cooler may be exposed to a temperature below the freezing point of water.

3.Consult gun, torch, and wire feeder manuals for coolant recommendations and select one from the above list.

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

5.The cooler’s reservoir has a nominal liquid capacity of 1.6 gallons.

G3503-[ ] POWER WAVE 450 WATER COOLER UPGRADE KIT

2

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Lincoln Electric IM645-A Recommended Tools for Installation or Service, G3503- Installation or SER Vice Tool Usage

IM645-A specifications

The Lincoln Electric IM645-A is a highly regarded multi-process welding machine, designed to meet the needs of both professional welders and serious DIY enthusiasts. It seamlessly integrates multiple functionalities, allowing users to perform MIG, TIG, Stick, and flux-cored welding. This versatility makes it an essential tool in various applications, from metal fabrication to repairs and maintenance tasks.

One of the standout features of the IM645-A is its advanced inverter technology. This innovation reduces the machine's weight and size, making it more portable and easier to maneuver compared to traditional transformer-based welders. Additionally, the inverter technology provides superior energy efficiency, leading to lower operating costs over time.

The IM645-A is equipped with an intuitive digital display that provides real-time information on voltage, amperage, and other critical parameters. This user-friendly interface allows welders to make precise adjustments on-the-fly, ensuring high-quality welds across different materials and thicknesses. Furthermore, the machine supports a wide range of wire diameters, accommodating a variety of welding tasks.

A notable characteristic of the Lincoln Electric IM645-A is its robust construction. Built with high-quality materials, the machine is designed to withstand demanding work environments, ensuring durability and longevity. The cooling system is also well-designed, preventing overheating during prolonged use, which is an important factor for maintaining performance and extending the life of the machine.

The IM645-A supports advanced technologies such as Synergic Control, which automatically adjusts the welding parameters based on the chosen wire diameter and material type. This feature simplifies the setup process, allowing users to focus on the quality of their work rather than struggling with settings.

Moreover, safety is a top priority for Lincoln Electric, and the IM645-A includes multiple safety features such as overcurrent protection and thermal overload shutdown. These safeguards enhance user safety while minimizing the risk of damage to the machine itself.

In conclusion, the Lincoln Electric IM645-A stands out in the market for its multi-process capabilities, advanced inverter technology, user-friendly interface, durable construction, and safety features. Whether you're a seasoned professional or a hobbyist, this welding machine provides an excellent balance of performance, versatility, and reliability, making it a valuable addition to any workshop.