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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:
1 Cooler 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
1 Circuit breaker, T12287-14, spare replacement
2 fasteners, S9225-8, (1/4-20 thread, spares for
cooler mounting)
4 fasteners, S8025-91, (spares for cooler access
panel mounting)
2 Hole plugs, T10397-11
1 Ground Decal, T13260-4
8 cable ties, T13770-2
1 Electrical sleeving, E1159/B-1.00-7.00
1 “B” Stencil, S21212
1 Power Wave machine label: S24503-1
2 Mounting Brackets, S10040-93
2 Fasteners, T9447-42, (#10-24 UNC-3A)
2 Plain 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