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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 valves' 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 the pump’s inlet strainer:
• 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
loosening strainer’s 7/8 acorn nut. Do not con-
fuse with 3/4 acorn nut. Remove nut and slide
inlet strainer down and out from pump head.
• Gently rinse strainer under running water to
thoroughly clean it.
• Use the mirror to inspect inside of pump for
contamination. Carefully remove hardened
debris with dental 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 wet-
ted by coolant. Dispose of towels in an envi-
ronmentally responsible manner (see
Recommended Coolants).
4. Gently rinse the reservoir’s strainer under running
water to thoroughly clean it.
5. Remove fan shroud and inspect hoses and electrical
harnesses for kinking or damage (cut, abrasion,
swelling, etc.). Replace if necessary.
6. 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 per-
sonal injury and damaging them.
• Remove the cooler from the machine for a
more thorough cleaning job.
7. 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.
8. Flush coolant from the system and replace with
fresh, recommended coolant at least once a year.
More frequent flushing may be necessary, depend-
ing upon a user’s particular system or its usage.
NOTE: Never run the pump dry. Always use a recom-
mended coolant, otherwise pump damage may
result.
9. 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 valves' 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, deterio-
rated 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 fit-
tings, Keep v-clamp, Seal old pump in a
waterproof bag, Package into protective con-
tainer, and Return to nearest Lincoln Electric
FSS center.
ACCESSORIES
C-4 C-4
POWER WAVE 450
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