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G3503-[ ] POWER WAVE 450 WATER COOLER UPGRADE KIT
5
G3503-[ ] COOLER PERIODIC MAINTENANCE
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.
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 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.