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G3503-[ ] POWER WAVE 450 WATER COOLER UPGRADE KIT
3
INSTALLATION INSTRUCTIONS
REPLACING A G2725 COOLER WITH A
G3503-[ ] COOLER
1. Preparation:
• Always switch off the Power Wave machine
power.
• Always disconnect the Power Wave machine
from service input power.
2. Remove the G2725 cooler assembly:
a. Remove gas cylinder(s) from machine’s rear
tray.
b. Remove cooler access panel P/N L9387-1 and
set aside. It is no longer needed.
c. Remove machine’s left side panel (adjacent to
power input cord).
d. Disconnect coolant hoses’ mounting bracket
from machine’s case back.
e. Disconnect all of the coolant hoses’ tie-down
points. These plastic clips may be removed and
discarded if desired.
f. Remove and save both fasteners from Power
Wave base holding cooler in place. Carefully
pull cooler rearward, partially out of the Power
Wave.
g. Disconnect Molex in-line connectors P4 or P5
(cooler power) and P3 (cooler relay and pres-
sure switch) and slide cooler completely from
machine.
h. Optionally remove circuit breaker from case
back and install replacement.
i. Peal off "coolant in / coolant out" decal from
machine’s case back and discard. Remove
residual adhesive from case back with an alco-
hol wipe.
j. Remove auxiliary transformer #2 (mounted to
Power Wave base, ahead of G2725 cooler) and
set aside. It is no longer needed.
3. Slide electrical sleeving over the non-P4 connector
in the Power Wave’s harness that runs from its ter-
minal strip.
• Fold sleeving over itself and firmly secure it to
the harness with a cable tie.
4. Install cooler G3503-[ ]:
a. Install plugs into case back to fill coolant hose
holes. Bend tabs as required to secure plugs in
place.
b. Install new circuit breaker into case back if
replacing the old part.
c. Install new P4 electrical harness into Power
Wave:
• Mate together the labeled P4 connectors.
• Note: H[X]A lead in new harness carries 230
VAC cooler power: (See Table for [X] valve).
[X] Power Wave Wiring
Code Numbers Diagram
2 10406 G2153-5
2 10431 G2153-4
2 10433 G2153-6
3 10106, 10195, 10366 G2153-1
3 10197, SPLC14895 G2153-2
3 10345, 10347 G2153-3
3 10512 G2153-7
3 10514, 10516 G2153-8
3 10520 G3177-1
• Connect insulated terminals to circuit breaker
(order is unimportant).
d. Connect P3 electrical extension harness to the
machine.
e. Apply ground decal to cooler’s base:
• Apply next to mounting screw hole nearest to
circuit breaker.
f. Mate cooler’s connector to the P3 extension
harness.
g. Mate cooler’s power connector to the P4 electri-
cal harness.
h. Carefully slide retrofit cooler G3503-[ ] forward
into Power Wave. Verify that front tabs on cool-
er base are properly guided into slots in base of
Power Wave (base’s underside may be exam-
ined with a mirror and flashlight).
i. Attach ground lead in P4 harness to top of cool-
er’s base or top of mounting bracket, ( if brack-
ets are necessary). Secure cooler to Power
Wave base by installing both fasteners.
j. Install Power Wave machine’s left side panel.
ELECTRIC SHOCK Can Kill
• Only qualified persons should perform this installa-
tion.
HOT COOLANT CAN BURN SKIN
• Always be sure coolant is not hot before doing any
work on cooler parts.
ROTATING FAN BLADES ARE HAZARDOUS
• Do not put your hands near an operating fan.
• Keep all equipment safety guards, covers and devices in position
and in good repair.Keep hands, hair, clothing and tools away from
fans and all other moving parts when starting, operating or repair-
ing equipment.
• In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when neces-
sary and replace them when the maintenance requiring their
removal is complete.
Always use the greatest care when working
near moving
parts.
------------------------------------------------------------------------
WARNING