Lincoln Electric IM645-A G3503- Cooler Periodic Maintenance G3503- Cooler Service

G3503-[ ] COOLER PERIODIC MAINTENANCE 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 valve’s 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, or replace the pump’s inlet strainer: Clogged or partially blocked strainer is the most common cause for unacceptal coolant flow.

•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 strainer’s 7/8 acorn nut. Do not confuse with 3/4 acorn nut. Remove nut and slide inlet strainer down and out from pump head.

•Replace or gently rinse strainer under running water to thouroughly 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.Remove fan shroud and inspect hoses and electrical har- nesses for kinking or damage (cut, abrasion, swelling, etc.). Replace if necessary.

5.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 thorough cleaning job.

6.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.

7.Flush coolant from the system and replace with fresh, recommended coolant at least once a year. More fre- quent flushing may be necessary, depending upon a user’s particular system or its usage.

NOTE: Never run the pump dry. Always use a recommend- ed coolant, otherwise pump damage may result.

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

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 valve’s 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 pump’s 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 exchang- er.

•Tighten set screw with 65 to 75 in-lbs of torque against motor shaft’s flat.

•Fan rotation is counterclockwise, as viewed from fan-end of motor’s shaft.

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

G3503-[ ] POWER WAVE 450 WATER COOLER UPGRADE KIT

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