MAINTENANCE
D-5 D-5
POWER WAVE 450
RECOMMENDED TOOLS FOR INSTAL-
LATION OR SERVICE OF COOLER:
• 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
REMOVING AND INSTALLING THE G3503-[ ]
COOLER
1. Preparation:
• Always switch off the Power Wave machine
power.
• Always disconnect the Power Wave machine
from service input power.
2. Remove cooler assembly G3503-[ ]:
a. remove gas cylinder(s) from tray.
b. remove cooler access panel.
c. Remove both fasteners from base that hold cool-
er in place. Remove ground lead, if present.
Carefully pull cooler assembly rearward, until
cooler’s Molex connectors are visible.
d. disconnect cooler’s connectors from the P3 and
P4 harnesses. Continue pulling the cooler out of
the Power Wave.
3. If necessary, perform periodic maintenance or ser-
vice on the cooler.
4. Reinstall cooler by reversing tasks in step 2. Be sure
to reattach ground lead, if previously removed.
5. If necessary, fill cooler with selected coolant to spec-
ified level (see Fig. 1).
6. Attach desired water-cooled accessory (gun and
wire feeder or TIG torch) to cooler’s QDs.
7. Reconnect service input power to the Power Wave:
• verify that the reconnect panel setting and lead
placement match the service voltage.
8. Prime the cooler:
a. Install the Set-up overlay.
b. Keep accessories’ hose lengths horizontal,
either coiled or straight, and no higher than 4
feet of the specified coolant level (Fig. 1).
c. Switch on the Power Wave machine.
d. Press the "WATER COOLER ENABLE" button
so that the "WATER COOLER ENABLED" light
is illuminated .
e. Press the "PRIME WATER COOLER" button
until the "WATER COOLER PRESSURE" light is
steadily illuminated.
9. Check coolant level. Add more if required.
