Lincoln Electric Cool Arc 40 Operating instructions
- Category
- Welding System
- Type
- Operating instructions
Operator’s Manual
COOL ARC
®
40 STAND ALONE WATER COOLER
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
IM696-C | Issue D ate J
un-16
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
10791, 11066, 11577, 11845,
11846
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser
upon receipt by the carrier. Consequently, claims for material
damaged in shipment must be made by the purchaser against the
transportation company at the time the shipment is received.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and built
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
U
se corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you de velop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 06/15/2016
SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel Engines
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.
Gasoline Engines
The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other
reproductive harm.
ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS SHOULD CONSULT WITH
THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For
additional safety information, it is strongly recommended
that you purchase a copy of “Safety in Welding & Cutting -
ANSI Standard Z49.1” from the American Welding Society,
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205 is available from the Lincoln Electric Company,
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE POWERED
EQUIPMENT.
1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
t
heir removal is complete. Always use the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding current creates EMF fields around welding cables
and welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 06/15/2016
ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
o
f physical contact with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage
between the
two can be the total of the open circuit voltage of both
welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see It ems 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these fumes and gases.
When welding, keep your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep fumes and gases
away from the breathing zone. When welding hardfacing
(see instructions on container or SDS) or on lead
or cadmium plated steel and other metals or
coatings which produce highly toxic fumes, keep
exposure as low as possible and within applicable
OSHA PEL and ACGIH TLV limits using local
exhaust or mechanical ventilation unless exposure
assessments indicate otherwise. In confined
spaces or in some circumstances, outdoors, a
respirator may also be required. Additional
precautions are also required when welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 06/15/2016
WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks
f
rom starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
e
tc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected
to physical damage.
• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 06/15/2016
v
i vi
TABLE OF CONTENTS
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Installation .......................................................................................................Section A
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Operation .........................................................................................................Section B
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Accessories .....................................................................................................Section C
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Maintenance ....................................................................................................Section D
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Wiring Diagrams ..............................................................................................Section F
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Parts List.................................................................................................................P-385
________________________________________________________________________
7
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INSTALLATION
COOL ARC
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SAFETY PRECAUTIONS
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0.=.AA523?<;A:61192<3A52B;6A&2:<C2A5236990.=/F=?2@@
6;4A5202;A2?<3A520.=6;D.?1D5692=B996;4.AA52A./<;A52
<BA2?2142
92.;A.=D.A2?16@A69921D.A2?126<;6G21D.A2?.:6E<3
=B?2 2A5F92;2 49F0<9 .;1 D.A2? <? .;F <A52? 0<<9.;A @=2063621
/FA52:.;B3.0AB?2?<3A52D.A2?0<<921=?<1B0AA5.AA52<<92?
6@B@21D6A50.;/2.11216;A<A520<<9.;A?2@2?C<6?(52<=2;
6;4 <3 A52 3699 0.= :.A2@ D6A5 :<@A 0<<9.;A 0<;A.6;2?@ /BA A<
.C<61 @=699.42 <3 0<<9.;A . 3B;;29 @5<B91 /2 =9.021 6;A< A52
?2@2?C<6?5<92D52;36996;4A52
$$!&
I
NOTE: %B?2@<9BA6<;@.;1:6EAB?2@<3<?:.A2?6.9@62A<D
29@ D2AA21 D6A5 2A5F92;2 49F0<9 .?2 A<E60 A< 5B:.;@ .;1 .;6
:.9@ (52F :B@A ;<A /2 5.=5.G.?19F 16@0.?121 2@=206.99F /F
=<B?6;496>B61@1<D;A521?.6;<;A.0AA529<0.9%<336023<?
?2@=<;@6/9216@=<@.9:2A5<1@<?3<??20F096;46;3<?:.A6<;
<?/2@A?2@B9A@D52;B@6;4A52
$$!&
I
D6A5!6;0<9;
4B;@<?A<?052@B@216@A69921<?126<;6G21D.A2?.9A5<B4563;<A
.C.69./92A.= D.A2?0.; /2 B@213 =?<A20A6<; 3?<:3?22G6;4 6@
12@6?21 B@2 . D.A2? .;1 =B?2 2A5F92;2 49F0<9
?2.42;A<?6;1B@A?6.94?.12:6EAB?2;.90<5<9.;1D.A2?:6E
AB?26@.9@<.002=A./92
+52;B@6;4A52
$$!&
I
D6A5<A52?=?<1B0A@0<;@B9A
A52 :.;B3.0AB?2?@ 6;@A?B0A6<; :.;B.9 3<? ?20<::2;121
0<<9.;A@
DO NOT USE OIL BASED COOLANTS OR COOLANTS
THAT CONTAIN RUST INHIBITORS OR LEAK STOPPERS.
(52B;6A0.;/236992126A52?C2?A60.99F<?5<?6G<;A.99F
UNPLUG THE COOLER BEFORE FILLING THE COOLANT
RESERVOIR:
UPRIGHT (VERTICAL):
H (69AA52B;6A/.08D.?1.;1=<B?4.99<;@96A2?@<30<<9.;A
6;A<A520<<9.;A?2@2?C<6?36995<92A5?<B45.3B;;29
H3 . 4.99<; 96A2?@ 3699 /<AA92 6@ .C.69./92 A69A A52 B;6A 3<?
D.?1B;A69A52/<AA92:.A2@D6A5 A520<<9.;A?2@2?C<6?36995<92
(52;A69AA52B;6A/.08D.?1B;A69A523699/<AA926@2:=A621699A52
B;6AD6A54.99<;@96A2?@<30<<9.;A
ELECTRIC SHOCK can kill.
• Only qualified persons should perform
this installation.
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 operating fan.
• Keep all equipment safety guards, covers
and devices in position and in good repair.Keep
hands, hair, clothing and tools away from V-belts,
gears, fans and all other moving parts when starting,
operating or repairing equipment.
• In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when
the maintenance requiring their removal is complete.
Always use the greatest care when working near mov-
ing
parts.
WARNING
CAUTION
A-3
INSTALLATION
COOL ARC
I
40
A-3
LYING DOWN (HORIZONTAL):
.?23B99F.114.99<;@96A2?@<30<<9.;AA5?<B45.
3
B;;29 6;A< A52 0<<9.;A ?2@2?C<6? 3699 5<92 AVOID
SPILLING COOLANT INTO THE LOUVERS ON THE
TOP OF THE COOLER.
(
520<<92?6@)!!D52;A520<<9.;A962@7B@A/29<D
A52 0<<9.;A ?2@2?C<6? <=2;6;4 D6A5 A52 0<<92? 6; A52
B=?645AC2?A60.9=<@6A6<;
NOTE: DO NOT ADD MORE THAN 2 GALLONS
(7.6 LITERS) OF COOLANT INTO THE RESER-
VOIR. (52 3699 0.= 0<;A.6;@ . =?2@@B?2 ?292.@2 .6?
5<92 D5605 :B@A ;<A /2 /9<0821 /F <C2?36996;4 A52
?2@2?C<6?D6A50<<9.;A
2 02?A.6; A< ?2=9.02 A52 ?2@2?C<6? 3699 0.= D52; A52
?2@2?C<6? 6@ 3B99 '6:=9F =?2@@ <; A52 6;@612 02;A2? <3
A5236990.=B;A69A520.=@;.=@6;A<=9.02$=2?.A6<;<3
A52 $$! &
I
D6A5<BA A52 3699 0.= 6; =9.02 0.;
0.B@2 =<<? 0<<96;4 2336062;0F 2C.=<?.A6<; 9<@@ <3
0<<9.;A.;1?21B021=?<1B0A9632
COOLANT "IN" AND "OUT"
CONNECTIONS
(52 36AA6;4@ 9<0.A21 <; A52 /.08 02;A2? <3 A52 $$!
&
I
.?2 AD< 32:.92 5/8-18 left-hand threaded
fittings. 'AF92 (52@2 :.A2 D6A5 D.A2? 5<@2@
AF=60.99FB@216;A52D2916;46;1B@A?F
Refer to Figure 1
W
ater or Coolant Line Connections
to the
COOL ARC
I
40
(.82A520<;;20A<?;BA<3A52D.A2?5<@2.;10520863
A
52A5?2.1<3A52:.920<;;20A<?;BA:.A052@A52
923A5.;132:.92A5?2.16;A5236AA6;4<;A52/.08<3
A
52B;6A
<? .99 !6;0<9; =?<1B0A@ .;1 A5<@2 D6A5 . 0<;;20A<?
;BA<;A52D.A2?5<@2A5.A:.A2D6A5A5236AA6;4@<;A52
/.08<3A52$$!&
I
(Reference FIG. 1) (.82A52.002@@<?F#!(5<@2
0<9<?21<?A.4421/9B2<;:<@A5<@2@.;1A5?2.16A
6;A<A520<<9.;A$)(36AA6;49<0.A21<;A52?645A@612
<3A52/.08<3A520<<92?'20B?2A520<;;20A<?;BA<3
A52 5<@2 A645A9F 6;A< A52 36AA6;4 D6A5 . D?2;05 @< A5.A
92.86;4 1<2@ ;<A <00B? (52; A.82 A52 .002@@<?F
$)(!( 5<@2 0<9<?21 <? A.4421 ?21 <; :<@A
5<@2@.;1A5?2.16A6;A<A520<<9.;A#36AA6;49<0.A21
<;A52923A@612<3A52/.08<3A520<<92?4.6;A645A9F
@20B?2A520<;;20A<?;BA<3A525<@26;A<A5236AA6;4<3
A52 0<<92? D6A5 . D?2;05 A< 6;@B?2 A5.A ;< 92.86;4
<00B?@
NOTE: BE CERTAIN THAT NO LEAKS EXIST
WHEN THE COOLER IS TURNED ON. A LEAK
WILL DEPLETE RESERVOIR VOLUME, CAUSING
POOR COOLING PERFORMANCE AND REDUCING
GUN OR TORCH LIFE.
3 A52 0<;;20A<? ;BA <; . D.A2? 5<@2 1<2@ ;<A :.A2
D6A5 A52 36AA6;4@ <; A52 /.08 <3 A52 $$! &
I
<?12?A523<99<D6;4
(See Parts Lists for Item’s below)
<;;20A<?#BA@
#6==92@3<?5<@2
<@29.:=@
FIGURE 1
;92A.;1$BA92A<@2<;;20A6<;6.4?.:
COOLANT
IN
COOLANT
OUT
FROM
HEAT
SOURCE
(RED)
TO
HEAT
SOURCE
(BLUE)
A-4
INSTALLATION
COOL ARC
I
40
A-4
HORIZONTAL INSTALLATION ON THE
TOP OF A POWER SOURCE
<?=?<=2?6;@A.99.A6<;3<99<DA526;@A?B0A6<;@=?<C6121
D6A5 A52 <<92? <?6G<;A.9 "<B;A6;4 ?.082A
6A(520<<92?6@@20B?21A<A52=<D2?@<B?02963A/.92
&232?2;02A52A./92/29<D3<?.96@A<3=<D2?@<B?02@
A5.A .99<D@ A52 $$! &
I
A< /2 :<B;A21 5<?6
G<;A.99F<;A<=
VERTICAL INSTALLATION ON POWER
SOURCE WITH A DUAL CYLINDER
UNDERCARRIAGE.
<?=?<=2?6;@A.99.A6<;3<99<DA526;@A?B0A6<;@=?<C6121
D6A5A52 <<92?*2?A60.9"<B;A6;4?.082A 6A
(52 0<<92? 6@ @20B?29F :<B;A21 A< A52 1B.9 0F96;12?
@B==<?A/?.082A&232?2;02A52A./92/29<D3<?.96@A<3
=<D2? @<B?02@ .;1 1B.9 0F96;12? B;12?0.??6.42@ A5.A
.99<D@A52$$!&
I
A</2:<B;A21C2?A60.99F.A
A52?2.?<3A52:.056;2<;A524.@/<AA92?.08
If the COOL ARC
I
40 is not securely mounted hor-
izontally on top of a power source or vertically on
a dual cylinder undercarriage.
THE COOL ARC
I
40 MUST BE OPERATED IN THE
HORIZONTAL POSITION. This will prevent the
cooler from being accidentally tipped over.
&2:<C2 A52 0<;;20A<? ;BA 3?<: A52 #!( 5<@2 /F
:.86;4 . @A?.645A 0BA :: .D.F 3?<:
A
522;1<3A52;6==929<0.A216;@612<3A525<@2(.82
A52 ;6==92 .;1 A52 0<;;20A<? ;BA <?12?21 ./<C2 .;1
6;@2?A A52 ;6==92 6;A< A52 0<;;20A<? ;BA @< A5.A A52
A5?2.121 2;1 <3 A52 0<;;20A<? ;BA =<6;A@ .D.F 3?<:
A
52/.?/212;1<3A52;6==92(D6@AA52/.?/212;1<3
A52;6==926;A<A525<@2 B;A69 A52 @5<B912? <3 A52 ;6=
=
926@39B@5D6A5A522;1<3A525<@2'20B?2A525<@2
<;A<A52;6==92D6A5A525<@209.:=A<6;@B?2A5.AA52
0<;;20A6<; 6@ D.A2?A645A #< D.A2? 0.; 92.8 3?<: A52
0<;;20A6<;636A6@=?<=2?9F.AA.0521&2=2.AA52=?<02
1B?23<?A52$)(!(5<@2+52;0<:=92A23<99<DA52
0<;;20A6<; =?<021B?2 12A.6921 ./<C2 3<? 0<;;20A6;4
A525<@2@A<A52$$!&
I
36AA6;4@
(52 0<;;20A<? .;1 ;6==92 96@A21 36A A645A9F <;A<
::A< ::6;;2? 16.:2A2?5<@2/BA 63
09.:=21 A645A9F A< A52 5<@2 0.; 36A B= A< .
::6;;2?16.:2A2?5<@2
INPUT POWER CONNECTION
%9B4A526;=BA=<D2?0<?1<;A52$$!&
I
6;A<
. @A.;1.?1 * #" 06?0B6A /?2.82? =?<A20A21
?202=A.092
INSTALLATION ON UNDERCARRIAGE OR
POWER SOURCE
(52$$! &
I
0.; /2 :<B;A21 26A52? 5<?6G<;
A.99F <? C2?A60.99F <; . =<D2? @<B?02 (< :<B;A A52
0<<92? 5<?6G<;A.99F <?12? A52 <<92?
<?6G<;A.9"<B;A6;4?.082A(<:<B;AA520<<92?C2?
A60.99F <; . =<D2? @<B?02 D6A5 . 1B.9 0F96;12? B;12?
0.??6.42 <?12? <<92? *2?A60.9 "<B;A6;4
?.082A
WARNING
Power Source
CV-300
CV-400
CV-655
DC-250
DC-400
DC-600, DC-655
Square Wave TIG 275
Square Wave TIG 355
Power Wave 455
Power MIG 255
K559-3
Cooler Vertical Mounting
Bracket on a Dual
Cylinder Undercarriage
K874 Undercarriage
Not Available
Not Available
Not Available
Not Available
Not Available
K932-1 Undercarriage
Not Available
K1570-1 Undercarriage
Not Available
K559-2
Cooler Horizontal
Mounting Bracket
Can be used On Top
of a Power Source
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
No
No
A-5
INSTALLATION
COOL ARC
I
40
A-5
INSTALLATION OF WATER COOLED
ACCESSORIES
3A2? 3<99<D6;4 A52 6;@A.99.A6<; 6;@A?B0A6<;@ ./<C2 A52
$$! &
I
6@ ?2.1F 3<? 0<;;20A6<; A< . D.A2?
0
<<921.002@@<?F
WATER COOLED TIG TORCH AND MIG GUN
<99<D64B?2D52;B@6;4A52$$!&
I
D6A5
D.A2?0<<921 ( A<?052@ Follow Figure 4 D52;
B@6;4A52$$!&
I
D6A5D.A2?0<<921"4B;
<;@B9A A52 :.;B3.0AB?2?@ 6;@A?B0A6<; :.;B.9 D52;
B@6;4A52$$!&
I
D6A5<A52?D.A2?0<<921(
.;1".002@@<?62@
CONNECTION TO WIRE FEEDERS
Follow Figure 3 D52; B@6;4 A52 $$! &
I
6;
0<;7B;0A6<;D6A5.D6?232212?(5232212?D699;221A<
5.C2 =.@@A5?<B45 D.A2? 5<@2@ 6;@A.9921 6; <?12? A<
0<??20A9F3B;0A6<; D6A5 A52 $$! &
I
@6;02 A52
0<<92? ?2>B6?2@ 0<;A6;B<B@ 39<D $ #$( )'
+(&'$!#$*!*D6A5A52$$!&
I
+.A2? =.@@A5?<B45 0<;;20A6<; 86A@ .?2 .C.69./92 3<?
D6?2 32212?@ &232? A< =?<1B0A 96A2?.AB?2 <? A52 D6?2
32212?@6;@A?B0A6<;@:.;B.93<?86A.C.69./696AF.;13B?
A52? 0<;;20A6<; 12A.69@ A 6@ ;<A ?2>B6?21 A< ?B; A52
D.A2? 96;2@ A5?<B45 A52 D6?2 32212? /BA 6@ 1<2@ =?<
C612 . C2?F ;2.A " 4B; 0<;;20A6<;3 =.@@A5?<B45
D.A2?5<@2@.?2B;.C.69./920<;;20AA52"4B;.@
shown in
Figure 4.
DO NOT USE A WATER SOLENOID VALVE with
the COOL ARC
I
40. When a solenoid valve closes,
t
he pump would dead-head, causing the pump to
heat up excessively leading to premature failure of
the pump.
K529-10 POWER INPUT CABLE WITH WATER
AND GAS HOSES
(56@ 0./92 .@@2:/9F 6;09B12@ . =<D2? 0./92
0<;A?<9 0./92 4.@ 5<@2 .;1 D.A2? 5<@2@ A<
0<;;20A . =<D2? @<B?02 A< . D6?2 32212? (52 0./92
92;4A56@(52D.A2?5<@2@5.C2923A5.;1
:.92 5<@2 36AA6;4@ .;1 A52 4.@ 5<@2 5.@ .
?645A 5.;1 :.92 5<@2 36AA6;4 (52 0./92 .;1 5<@2
92;4A5@ .?2 12@64;21 A< 0<;;20A . D6?2 32212? A< .
$$!&
I
A5.A6@C2?A60.99F :<B;A21.AA52 ?2.?
<3.=<D2?@<B?02<;.1B.90F96;12?B;12?0.??6.42
Refer to Figure 5 3<?.;699B@A?.A6<;<3A56@0<;;20A6<;
CAUTION
REGULATOR
FLOWMETER
GAS*
ARGON GAS
CYLINDER
COOLANT
OUT
COOLANT
IN
COOLANT*
GAS
COOLANT*
GAS
IN
OUT
COOLANT
GAS
TO WORK
POWER / COOLANT
POWER CABLE ADAPTER*
TIG TORCH
*INCLUDED IN
FEMALE TO FEMALE*
C
GA FITTING
KP504 HOOK-UP KIT
POWER SOURCE
C
OOLANT
IN
COOLANT
OUT
C
OOLANT
COOLANT
GUN CABLE
KP504-WATER HOSES AND
FEMALE TO FEMALE 5/8" LH
CGA ADAPTER COUPLINGS
KP1529-1
FEMALE TO FEMALE 5/8" LH
CGA ADAPTER COUPLINGS
(COUPLINGS ONLY)
SHIELDING
GAS
COOLANT
OUT
NOTE:
ORDER K1859-1 ALONG WITH
K529-10 FOR WIRE FEEDERS
WITH QUICK DISCONNECT
FITTINGS.
COOLANT
COOLANT
GUN CABLE
IN
OUT
K529-10
COOLANT
COOLANT
ELECTRODE CABLE
TO WORK
CONTROL CABLE
COOLANT
IN
NOTE:
BLUE HOSE
RED HOSE
=
COOLANT
OUT
COOLANT
IN
=
COOLANT
IN
COOLANT
OUT
COOLANT
COOLANT
COOLANT
COOLANT
GUN CABLE
NOTE:
COOLANT
OUT
K1859-1 FOR WIRE
FEEDERS WITH QUICK
DISCONNECT FITTINGS
KP504 FOR HOOK-UP
TO WIRE FEEDERS
WITH CGA FITTINGS
COOLANT
IN
=
=
BLUE HOSE
RED HOSE
FIGURE 2
+.A2?<<921((<?05<;;20A6<;
FIGURE 3
+.A2?<<921"B;<;;20A6<;
FIGURE 4
<;;20A6<;A<+6?22212?<#<A)@2+.A2?'<92;<61
FIGURE 5
<;;20A6<;A<+6?22212?<#<A)@2+.A2?'<92;<61
B-1
OPERATION
B-1
PRODUCT DESCRIPTION
(
52 $$! &
I
6@ . @A.;1 .9<;2 ?206?0B9.A6<;
0<<96;4 @F@A2: 12@64;21 3<? B@2 D6A5 D.A2?0<<921
( " % %9.@:. ?0 BAA6;4 .;1 %+
%9.@:.?0+2916;44B;@.;1 A<?052@ (520<<9.;A
# .;1 $)( 0<;;20A6<;@ .?2 923A5.;1
3
2:.92 A5?2.1@ D5605 :.A05 A52 @A.;1.?1 0<;;20A<?
;BA <3 1<:2@A60 D.A2? 5<@2@ @AF92 .;1 D.A2?
0<<921(A<?052@(52$$!&
I
6@.0<;A6;B
<B@1BAF0<<92?
(52<C2?.99@6G2.;1@5.=2<3A520<<92?6@612;A60.9A<
A52".4;B:(52 $$!&
I
0.;<=2?.A26;
26A52? A52 C2?A60.9 <? 5<?6G<;A.9 =<@6A6<; (52 $$!
&
I
6@C2?F2.@FA<B@2.;1B;12?@A.;1D6A5<;9F
<;2=<D2?@D6A05<;A520<;A?<9=.;29(520<<92?5.@
. @A.;1.?1 * =<D2? 6;=BA ?202=A.092 :.86;4 6A
C2?F2.@FA<=<D2?B=116;40<<9.;AA<A52?2@2?C<6?
6@ @6:=92 .;1 0<;;20A6;4 A< A52 0<<9.;A # .;1
$)(0<;;20A6<;@.?22.@69F:.12D6A5.;.17B@A./92
D?2;05
(52$$!&
I
0<<9.;A39<D6@06?0B9.A21A5?<B45
. 52.A 2E05.;42? A< ?2:<C2 52.A 2;2?4F 3?<: A52
0<<9.;A (52 0<<9.;A 39<D 6@ A52; 12=<@6A21 6;A< A52
0<<9.;A?2@2?C<6? (52=B:= 1?.D@6A@ 0<<9.;A@B==9F
3?<:A520<<9.;A?2@2?C<6?.;1 1296C2?@0<<9.;AA<A52
D2916;4A<?05<?4B;Refer to Figure 6
RECOMMENDED PROCESSES AND EQUIPMENT
&20<::2;121 %?<02@@2@ >B6=:2;A .;1
002@@<?62@ (52$$!&
I
6@12@64;213<?B@2
D6A5 D.A2?0<<921 ( " % %9.@:. ?0
BAA6;4 .;1 %+ %9.@:. ?0 +2916;4 4B;@ .;1
A<?052@ (52 $$! &
I
0.; /2 B@21 D6A5 "
D6?232212?@.;1=<D2?@<B?02@.@D299.@(=<D2?
@<B?02@
TURNING THE SYSTEM "ON"
3A2?0<;;20A6;4A52$$!&
I
=2?A526;@A.99.
A6<; 6;@A?B0A6<;@ ./<C2 =9B4 A52 B;6A 6;A< . *
#" 2920A?60.9 ?202=A.092 3<? @A.?AB= <=2?.A6<; 2
02?A.6;A5.AA52=<D2?6;=BA6;A<A52B;6A:.A052@A52
<<92?@?.A216;=BA
(52 !( %$+& '+( 6@ 9<0.A21 <; A52
?645A@612<3A520<;A?<9=.;29(520<<92?D699/2$#
D52;=?2@@21A<9.;1$D52;=?2@@21A<$
(52 @D6A05 D699 .9@< 699B:6;.A2 D52; 6; A52 $#
=<@6A6<;
,<BD699 /2./92 A<52.? A523.; ?B;;6;4.;1 3229.6?
39<D <BA <3 A52 /.08 <3 A52 B;6A D52; A52 0<<92? 6@
<=2?.A6;4(520<<92?D699?B;0<;A6;B<B@9FB;92@@6A6@
=9B4421 6;A< . @D6A0521 ?202=A.092 <; A52 =<D2?
@<B?02
COOL ARC
I
40
SAFETY PRECAUTIONS
ELECTRIC SHOCK c
an kill.
• Disconnect input power by
r
emoving plug from receptacle
before working inside Cooler.
• Do not operate with covers
removed.
• Use only grounded receptacle.
• Do not remove the power cord ground prong.
• Do not touch electrically “hot” parts inside
Cooler.
• Have qualified personnel do the installation,
maintenance and troubleshooting work.
• Unplug the cooler before performing general
maintenance without removing drawer.
• High voltage typical of welding operations can
kill.
• Immersion in water around electrical lines can
cause electrical shock.
• Moving parts can injure. Never place fingers
into openings of Cooler.
• Unplug the cooler and remove water hoses to
remove drawer from the cabinet for mainte-
nance purposes. A jumper hose between the
coolant in and out connections should be
installed to avoid excessive loss of coolant in
the system.
• Hot coolant can burn skin. Always be sure
coolant is NOT HOT before servicing the cooler.
• Do not pour used ethylene glycol coolant down
the drain.
• Do not remove the pump relief valve's 3/4" hex
nut or attempt to adjust the relief valve setting.
• The cooler should be turned "OFF" when weld-
ing is not taking place for long periods of time.
• Be certain that the cooler is "ON" (power switch
in the " l " position) before beginning to weld.
• Never operate the cooler with the reservoir fill
cap removed. Unless checking coolant flow.
• Avoid placing the cooler near areas of extreme
heat.
• Avoid placing the cooler near a flux hopper or
an area where dust build-up is extreme.
• Avoid kinking or putting sharp bends in any
water lines.
• Keep all water lines clean and free of any block-
age.
• Do not operate cooler without coolant in reser-
voir. Never run pump dry.
See additional warning information at
front of this operator’s manual.
WARNING
B-2
OPERATION
B-2
(52 0<<9.;A !$+ #($& 6@ .002@@21 /F
?
2:<C.9<3A5236990.=0AB.9?2AB?;39<D6@16?20A9FC6@
6/92C6.A523699<=2;6;4D6A5A52B;6A6;A52C2?A60.9<?
5<?6G<;A.9=<@6A6<;
+
52; 36?@A @A.?A6;4 A52 B;6A 05208 .99 <3 A52 0<<9.;A
5<@2@ A< 6;@B?2 A5.A ;< D.A2? 92.8@ .?2 =?2@2;A
+.A2? 92.8.42 0.B@2@ =<<? D2916;4 =2?3<?:.;02
=<<?0<<96;4=2?3<?:.;029<DD2916;40<:=<;2;A9632
.
;1=<A2;A6.92920A?60.9@.32AF5.G.?1@
COOLING EFFICIENCY
(52 5645 0<<96;4 2336062;0F <3 A52 $$! &
I
<332?@ . 0<<92? :<?2 0<:3<?A./92 D291 A5.; 0<;C2;
A6<;.9 .6?0<<921 =?<021B?2@ .@ D299 .@ 92.16;4 0<:
=2A6A<?@D.A2?0<<921@F@A2:@
(52 $$! &
I
23320A6C29F ?2:<C2@ A52 52.A <3
A52.?0.D.F3?<:A524B;<?A<?055.;192.;1=9.02@
6A 6;A< A52 2E6A6;4 .6? 39<D .A A52 /.08 <3 A52 <<92?
:/62;A.6? A2:=2?.AB?2 .3320A@ A52 0<<9.;A A2:=2?.
AB?2<3A52$$!&
I
For example
)
;9682 <A52? D.A2? 0<<92?@ A5.A 12=2;1 <; . /B98F
?2@2?C<6? @6G2 A52 5645 2336062;0F 0<:=<;2;A@ <3 A52
$$!&
I
.99<D@A52?2@2?C<6?@6G2A</2@:.99
(52?2@B9A6@.9645AD2645A=<?A./92B;6A
COOL ARC
I
40
COOL ARC® 40 WATER COOLER
M19724
3-23-2001
COOLANT
RESERVOIR
PUMP
HEAT
EXCHANGER
FAN
AIR
FLOW
WELDING
TORCH
OR
GUN
HEAT
"IN"
COOL-ARC 40
COOLANT "OUT"
COOLANT "IN"
ROOM AIR
IN
HEATED
AIR OUT
HEAT
EXCHANGER
FAN
PUMP
COOLANT
RETURN
COOLANT
INTAKE
C
OOLA
N
T
C
OOLA
N
T
NOTE:
COOLANT
O
UT
COOLANT
IN
=
=
B
LUE HOSE
RED HOSE
FIGURE 6
<<9.;A6?0B9.A6<;6.4?.:
FIGURE 7
C-1
ACCESSORIES
C-1
OPTIONAL EQUIPMENT (Field Installed)
K559-2 Cooler Horizontal Mounting Bracket:
"<B;A@A52$$!&
I
5<?6G<;A.99FA<A52A<=<3.
=
<D2?@<B?02@20B?6;4A520<<92?A<A52963A/.92(52
86A6;09B12@.99;202@@.?F:<B;A6;45.?1D.?2
K559-3 Cooler Vertical Mounting Bracket:
"<B;A@ A52 $$! &
I
C2?A60.99F A< . =<D2?
@<B?02A5.A5.@.1B.90F96;12?B;12?0.??6.42.9?2.1F
6;@A.9921 (52 /?.082A @20B?29F :<B;A@ A52 0<<92? A<
A521B.9 0F96;12?@B==<?A /?.082A(52 86A6;09B12@ .99
;202@@.?F:<B;A6;45.?1D.?2
K1536-1 Magnum Flow Sensor:
%?<A20A@ C.9B./92 A<?052@ 4B;@ .;1 ?</<A60 D2916;4
@F@A2:@ 3?<: 1.:.42 D52; 9<@@ <3 0<<9.;A 39<D 5.@
<00B??213<?.;F?2.@<; @B05.@. /9<0821 <?86;821
D.A2?96;2<?.?B=AB?215<@2
KP1529-1 Quick Connect Water Adapter:
<;C2?A@ . :.92 923A 5.;1 5<@2 36AA6;4
'AF92 A< . 32:.92 >B608 0<;;20A 36AA6;4 (52 32:.92
>B6080<;;20A:.A2@D6A5A52:.92>B6080<;;20A@<;
D.A2?0<<921"4B;@<?5<@2@
K1859-1 Water Cooler to Wire Feeder Hoses:
(56@86A6;09B12@AD<N:KD.A2?5<@2@
D6A5 . ! @AF92 36AA6;4 <; <;2 2;1 .;1 .
:.92>B60816@0<;;20A<;A52<A52?"<@AD6?232212?@
5.C2 32:.92 >B608 16@0<;;20A@ .;1 A56@ 86A .99<D@
16?20A5<<8B=/2AD22;A52D.A2?0<<92?.;1A52D6?2
32212?
5/8"-18 Left Hand Male Hose Fitting Parts: (CGA Style)
6AA6;4@ A5.A 0<;C2?A . @A.;1.?1 5<@2 A< .
923A 5.;1 :.92 5<@2 36AA6;4 (52@2 :.92 5<@2
36AA6;4@:.A2D6A5A5236AA6;4@<;A52/.08<3A52$$!
&
I
Order the following:
'22%.?A@!6@A@3<?A2:N@/29<D
<;;20A<?#BA@
#6==92@3<?<@2
<@29.:=@
(52 0<;;20A<? .;1 ;6==92 96@A21 36A A645A9F <;A< M
::A< ::6;;2? 16.:2A2?5<@2/BA 63
09.:=21 A645A9F A< A52 5<@2 0.; 36A B= A< . M
:: 6;;2? 16.:2A2? 5<@2 (52@2 36AA6;4@ .?2 .9@<
?2.169F.C.69./923?<:.;F6;1B@A?6.9D2916;4@B==962?
COOL ARC
I
40
K529-10
Power Input Cable with Water and Gas Hoses:
(56@0./92.@@2:/9F6;09B12@A523<99<D6;4=<D2?
0./92 0<;A?<9 0./92 4.@ 5<@2 .;1 D.A2?
5<@2@(520./92.@@2:/9F0<;;20A@.=<D2?@<B?02
A< . D6?2 32212? 3<? D.A2?0<<921 " .==960.A6<;@
(520./9292;4A56@:(52D.A2?5<@2@5.C2
923A5.;1:.925<@236AA6;4@.;1A524.@5<@2
5.@.?645A5.;1:.925<@236AA6;4(520./92
.;15<@292;4A5@.?212@64;21A<0<;;20A.D6?23221
2? A< . $$! &
I
A5.A 6@ C2?A60.99F :<B;A21 .A
A52?2.? <3 . =<D2?@<B?02 <; . 1B.90F96;12? B;12?
0.??6.42Refer to Figure 5 3<?.; 699B@A?.A6<;<3 A56@
0<;;20A6<;
KP504 TIG Hook Up Kit:
(52 <<8)= 6A 6;09B12@ D.A2? 5<@2@ 4.@
5<@2D.A2?.1.=A2?36AA6;4@:.92A<:.92!
A5?2.1D.A2?5<@20<B=92?32:.92A<32:.92
!A5?2.1.;1=<D2?0./92.1.=A2?(5?2.1@<;.99
5<@2@.;136AA6;4@.?2@AF92
DO NOT USE A WATER SOLENOID VALVE with
the COOL ARC
I
40. When a solenoid valve clos-
es, the pump would dead-head, causing the pump
to heat up excessively leading to premature failure
of the pump.
Coolant Hoses:
<<9.;A5<@2@.?2?2.169F.C.69./923?<:.;6;1B@A?6.9
D2916;4@B==962?<?6;C.?6<B@"<?(5<<8B=86A@
=?<C6121/F!6;0<9;920A?60&232?A<".4;B:.002@
@<?F96A2?.AB?2@522A@
<?92;4A5@<30<<9.;A5<@2@<C2?A:.;1B=
A<A:5<@26@?20<::2;121
5<@2 .;1 .00<::<1.A6;4 36AA6;4@ .?2 .C.69./92
3?<:.;6;1B@A?6.9D2916;4@B==962?
CAUTION
D
-1
MAINTENANCE
D
-1
ROUTINE MAINTENANCE
&2:<C2 .00B:B9.A21 1B@A .;1 16?A 3?<: A52 6;A2?;.9
0<:=<;2;A@<3A520<<92?/F/9<D6;46A<BAD6A5.9<D
=?2@@B?2.6?5<@2<??2:<C6;46AD6A5.C.0BB:5<@2
PERIODIC MAINTENANCE
; 16?AF <? 1B@AF 2;C6?<;:2;A@ <? 63 /6<9<460.9 4?<DA5
<00B?@6;A520<<9.;A6A:.F/2;202@@.?FA<39B@5A52
0<<9.;A ?2@2?C<6? ?.6; A52 <91 0<<9.;A ?6;@2 A52
6;@612 <3 A52 ?2@2?C<6? .;1 06?0B9.A2 ?6;@6;4 @<9BA6<;
A5?<B45 A52 0<<9.;A @F@A2: 11 ;2D 0<<9.;A D52;
092.;6;46@36;6@521It is recommended to flush the
coolant at least once a year. 0<<96;4@F@A2:3?22
3?<: 12/?6@ <332?@ 6;0?2.@21 0<<96;4 2336062;0F .;1
9<;42? =B:= .;1 A<?05 9632 '22 A52 <<9.;A
(?2.A:2;A&20<::2;1.A6<;6;A56@L'20A6<;M
NOTE: %B?2 @<9BA6<;@ .;1 :6EAB?2@ <3 <? :.A2?6.9@
62 A<D29@ D2AA21 D6A5 2A5F92;2 49F0<9 .?2 A<E60 A<
5B:.;@ .;1 .;6:.9@ (52F :B@A ;<A /2 5.=5.G.?19F
16@0.?121 2@=206.99F /F =<B?6;4 96>B61@ 1<D; A52
1?.6;<;A.0AA529<0.9%<336023<??2@=<;@6/9216@
=<@.9:2A5<1@<?3<??20F096;46;3<?:.A6<;
PUMP MAINTENANCE
(52=B:=52.15.@./B69A6;@A?.6;2?<;A526;92A@612<3A52
=B:= It is recommended to clean or replace the pump's
inlet strainer at least once a year. (See Above):
H?.6; A52 0<<9.;A ?2@2?C<6? .;1 .99 0<<9.;A 96;2@ 6@=<@2 <3
A520<<9.;A=?<=2?9F.@@=2063621./<C2
H<91 A52 =B:= 52.1 36?:9F A< .==9F . 0<B;A2?A<?>B2 D52;
9<<@6;4A52@A?.6;2?@.0<?;;BA9<0.A21<;A52/<AA<:<
;<A 0<;3B@2 D6A5 .0<?; ;BA &2:<C2 ;BA .;1 @9612 6;92A
@A?.6;2?1<D;.;1<BA3?<:A52=B:=52.1
H2;A9F ?6;@2 A52 @A?.6;2? B;12? ?B;;6;4 D.A2? A< A5<?<B459F
092.;6A
H)@2.:6??<?A<6;@=20AA526;@612<3A52=B:=3<?0<;A.:6;.
A6<; .?23B99F ?2:<C2 5.?12;21 12/?6@ D6A5 . 12;A.9 =608 63
;202@@.?FD6A5<BA@0?.A056;4A526;@612<3A52=B:=
H&26;@A.99A52 @A?.6;2?.;1 .0<?; ;BAA645A2;6;4 D6A5
6;9/@ <3 A<?>B2 +6=2 1?F .99 .?2. D2AA21 D6A5 0<<9.;A
6@=<@2<30<<9.;A@<.821A<D29@=?<=2?9F.@@=2063621./<C2
H<?.:<?26;12=A5=?<021B?2'22'20A6<;L%B:=;92A
69A2?M
PUMP MOTOR
(52
$$!&
I
6@?.A213<?0<;A6;B<B@<=2?.A6<;A6@
?20<::2;121A<?2<69A52=B:=:<A<?/2.?6;4@<;02.F2.?.@
3<99<D@
H&2:<C2 A52 =9.@A60 =9B4@ 9<0.A21 <; A52 A<= <3 /<A5 A52
6;/<.?1.;1<BA/<.?1/2.?6;42;10.=@
H&2<692.05/2.?6;4D6A51?<=@<3'<69A52;?26;
@A.99/<A5=9B4@
HEAT EXCHANGER
(< :.6;A.6; :.E6:B: 0<<92? 2336062;0F A52 52.A 2E05.;42?
@5<B91 /2 82=A 3?22 <3 1B@A .;1 16?A /B691B= 92.; A52 52.A
2E05.;42?=2?6<160.99FB@6;4.C.0BB:5<@2<?.9<D=?2@@B?2
.6?96;2C<61=9.06;4A52B;6A;2.?.39BE5<==2?<?.39BED.@A2
0<;A.6;2? 092.; 52.A 2E05.;42? <332?@/2AA2? 0<<96;4 =2?3<?
:.;02.;19<;42?=?<1B0A9632;2EA?2:29F16?AF2;C6?<;:2;A@
6A:.F/2;202@@.?FA<?2:<C2A5252.A2E05.;42?0<:=92A29F
3?<: A52 0<<92? .;1 092.; A52 36;@ D6A5 @<.= .;1 D.A2? )@2
0.?2A<.C<611.:.46;4A5236;@
RESERVOIR COOLANT LEVEL
(52?2@2?C<6?C<9B:2@5<B91/205208211.69F/23<?2B@6;4A52
0<<92? &2:<C2 A52 ?2@2?C<6? 3699 0.= .;1 05208 A52 0<<9.;A
92C29(52?2@2?C<6?6@3B99D52;A520<<9.;A92C296@7B@A/29<D
A52?2@2?C<6?3699 <=2;6;4
D6A5A52B;6A 6;A52 B=?645A=<@6
A6<; 22= A52 ?2@2?C<6? 3B99 2@=206.99F .3A2? 16@0<;
;20A6;4 A52 D.A2? 96;2@ <? 05.;46;4 A52 .002@@<?F
/26;40<<921
COOL ARC
I
40
Have qualified personnel do the maintenance
work. In some cases, it may be necessary to
remove safety guards to perform required
maintenance. Remove guards only when
necessary and replace them when the mainte-
n
ance requiring their removal is complete.
Always use the greatest care when working near
moving parts.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Keep away from moving parts.
------------------------------------------------------------------------
Observe all Safety Guidelines detailed throughout
this manual. Be sure to disconnect the Under-
Cooler cart from the Power Source before
performing any maintenance procedures.
WARNING
SAFETY PRECAUTIONS
D
-2
MAINTENANCE
D
-2
COOLANT TREATMENT
RECOMMENDATION
(56@ =?<021B?2 6@ 6;A2;121 A< =?<C612 . :2.;@ <3
?21B06;4A52</720A6<;./92.:<B;A<33B;4.9.;1/.0
A
2?6.90<;A.:6;.A6<;A5.A5.@<00B??216;$$!&
I
D.A2?0<<92?@.;10<<96;4@F@A2:@
Additive:
(52?20<::2;121.116A6C20.;/2=B?05.@21.A9<0.9
=<<9@B==9F@A<?2@;2E.:=926@".6;A.6;%<<9%?<
#<;<.:94.20612
Limitations:
H(56@.116A6C2@5<B91/2B@21D6A53?2@50<<9.;A@0<;
A.6;6;4<;9F=B?2D.A2?
H(56@.116A6C2@5<B91 ;<A/2 B@21D6A5 0<<9.;A@0<;
A.6;6;4 .;F <A52? @B/@A.;02 6;09B16;4 .;A63?22G2
@B/@A.;02@
H#< <A52? .116A6C2@ @5.99 /2 B@21 D6A5 A52 @=2063621
0<<9.;AA5.A5.@/22;A?2.A21D6A5A52?20<::2;121
.116A6C2
H(56@=?<021B?26@;<=2?:.;2;A@B/@A6ABA23<?.=2?6
<160:.6;A2;.;02@0521B923<?A52@=20636210<<92?@
H >B.?A /<AA92 <3 .116A6C2 6@ @B336062;A A< 16@6;320A
.;1A?2.A./<BA0<<92?@
• Check with the manufacturer of your guns or
torches to be sure that this procedure is compat-
ible with your equipment.
Prepare the disinfectant:
".82 . >B.;A6AF <3 <;9F D5.A 6@ ;22121 A< .C<61 .;
2E02@@B98=?2=.?.A6<;3<?0<<92?@@2?C60216;>B.;
A6AF
4.9@96A2?@<3=B?23?2@5D.A2?=2?0<<9
2? :9 <3 .116A6C2 =2? 0<<92? E.:=92 3<?
0<<92?@ .11 :9 A< 4.9@ <3 =B?2 3?2@5
D.A2? %<B? 4.9@ 96A2?@ <3 16@6;320A.;A 6;A<
A52 2:=AF ?2@2?C<6? &20.= A52 ?2@2?C<6? A.=2 <C2?
A52 .6? C2;A 6; A52 0.= ?<99 16@6;320A.;A .?<B;1 A52
6;@612 A52 ?2@2?C<6? A< A5<?<B459F 0<.A .99 <3 6A@ @B?
3.02@&2:<C2A52A.=23?<:A52?2@2?C<6?0.=%?6:2
A52 0<<96;4 @F@A2: /F =<@6A6<;6;4 0<<92? 5<?6G<;A.99F
.;1 06?0B9.A2 16@6;320A.;A A5?<B45 6A 3<? A< :6;
BA2@ ?.6; 16@6;320A.;A 3?<: A52 0<<96;4 @F@A2: <
;<A?2B@2A56@@<9BA6<;11;2D3?2@50<<9.;AA<A52
0<<96;4@F@A2:114.9@96A2?@<33?2@5
16@6;320A.;AA<A52@F@A2:/F=<B?6;46A6;A<A52?2@2?
C<6?A52;?21B02A520<;02;A?.A6<;A<A52;<:6;.9
==:
11 A52 /.9.;02 4.9@ 96A2?@ <3 3?2@5
=B?2 D.A2? A< A52 ?2@2?C<6? A< 0?2.A2 A52 A?2.A21
0<<9.;A0<;02;A?.A6<;%?6:2A520<<96;4@F@A2:
5208 0<<9.;A 92C29 11 :<?2 3?2@5 =B?2 D.A2? 63
?2>B6?21 D6A5<BA .116;4 :<?2 A5.; 4.9
96A2?@ <3 =B?2 D.A2? A< =?2C2;A 169BA6;4 A52 0<<9.;A
.116A6C2
PUMP INLET STRAINER
%<<? 0<<92? =2?3<?:.;02 0.; B@B.99F /2 A?.021 A< .
=
.?A6.99F <? 0<:=92A29F /9<0821 =B:= 6;92A @A?.6;2?
(56@ 6@ . B@2?@2?C602./92 6A2: .;1 0.; /2 092.;21
.;1 ?2B@21 <? ?2=9.021 <;A6;B21 =B:= <=2?.A6<;
D6A5./9<0821@A?.6;2?0.;0.B@2
H*<616;4<30<<92?@2?C602D.??.;AF
H.C6A.A6<;1.:.42A<A52=B:=52.1N@6;92A.?2.@
H+2916;4.002@@<?F1.:.423?<:<C2?52.A6;41B2A<
6;@B336062;A0<<9.;A39<D?.A2
;2D<?=?<=2?9F092.;21=B:=6;92A@A?.6;2?@5<B91
?2@A<?2A520<<92?N@=2?3<?:.;02
<? .116A6<;.9 @2?C602 .;1 =2?6<160 :.6;A2;.;02
12A.69@.;13<??20<::2;1210<<9.;A@3<99<DA52?20
<::2;1.A6<;@96@A21/29<D
Procedure and Preparation:
• Always switch off the COOL ARC
I
40 machine
power
• Always disconnect the COOL ARC
I
40 machine
from service input power.
• Always allow the coolant in the system to cool
enough to avoid burn injuries.
• Avoid contact with contaminated coolant. Wear
waterproof gloves and protective eye wear.
• Do not remove the pump relief valve’s 3/4 in.
acorn hex nut or attempt to adjust the relief valve
setting.
INSPECT CONDITION OF COOLANT
30<<9.;A6@0<;A.:6;.A21<?<91
H?.6; A52 @F@A2: <3 0<<9.;A .;1 16@=<@2 <3 6A 6; .;
2;C6?<;:2;A.99F?2@=<;@6/92:.;;2?
H9B@5@F@A2:<3<910<<9.;A
H699D6A5 3?2@5 A.=<? 16@A69921 D.A2??B; 3<? A2; :6;
BA2@.;11?.6;
H%?<0221A<.116;40<<9.;A
30<<9.;A6@092.;.;13?2@5
H3 092.; 12160.A21 0<<9.;A 5.;196;4 2>B6=:2;A
6;09B16;4 . 092.; @6=5<; =B:= .;1 . 092.; 5<916;4
A.;8 .?2 .C.69./92 A52; =?<0221 A< @2?C606;4 A52
%B:=;92A'A?.6;2?
COOL ARC
I
40
WARNING
D
-3
MAINTENANCE
D
-3
Removing Coolant:
.?.6;0<<9.;A3?<:A52?2@2?C<6?B@6;4092.;@6=5<;
6
;42>B6=:2;A
/<<9.;A92C29@5<B91/21?.6;21/29<DA52@A?.6;2?N@
=?2@@B?236AA6;4
• (56@ =?2C2;A@ 0<<9.;A 3?<: @A?2.:6;4 <BA <3 B;6A
D52;@A?.6;2?;BA6@?2:<C21
SERVICE THE PUMP’S INLET STRAINER:
.%9.02 ./@<?/2;A A<D29@ B;12?;2.A5 =B:= 52.1 A<
=?2C2;A@A?.F0<<9.;A3?<:D2AA6;40<<92?N@2920A?60.9
0<:=<;2;A@
/'22 364B?2 <91 =B:= 52.1 A< .==9F 0<B;A2?
A<?>B2D52;9<<@2;6;4@A?.6;2?N@.0<?;;BA<
;<A 0<;3B@2 D6A5 .0<?; ;BA &2:<C2 ;BA .;1
@96126;92A@A?.6;2?1<D;.;1<BA3?<:=B:=52.1
0;@=20A@A?.6;2?3<?1.:.42<?2E02@@6C209<446;4
H&2=9.02 <? 2;A9F ?6;@2 @A?.6;2? B;12? ?B;;6;4
D.A2?A<A5<?<B459F092.;6A
1)@2.:6??<?A<6;@=20A6;@612<3=B:=3<?0<;A.:6
;.A6<;35.?12;2112/?6@6@=?2@2;A.;16;A2?32?2@
D6A5 369A2? @2.A6;4 0.?23B99F ?2:<C2 6A D6A5 12;A.9
=608 D6A5<BA @0?.A056;4 6;@612 <3 A52 =B:= )@2
0.?2;<AA<1?<=12/?6@6;A<=B:=
2&26;@A.99 @A?.6;2? .;1 .0<?; ;BA A645A2;6;4 D6A5
J6;9/@<3A<?>B2
H<91 =B:= 52.1 A< .==9F 0<B;A2?A<?>B2 D52;
9<<@2;6;4@A?.6;2?@.0<?;;BA
3+6=2 1?F .99 .?2.@ D2AA21 /F 0<<9.;A 6@=<@2 <3
A<D29@6;.;2;C6?<;:2;A.99F?2@=<;@6/92:.;;2?
Add coolant:
.
11 4.99<;@ <3 0<<9.;A 26A52? A52 ?20<::2;1.
A6<;@<33A52D.A2?0<<921.002@@<?F<?63;<;2@22
A5212@64;@=206360.A6<;@B::.?F96@A216;A56@:.;
B.9
ADDITIONAL SERVICE NOTES:
9D.F@B@2./.08B=D?2;05<;=B:=52.1D52;
9<<@2;6;4<?A645A2;6;4=B:=36AA6;4@
#2C2??B;A52=B:=1?F9D.F@B@2.?20<::2;1
210<<9.;A<A52?D6@2=B:=1.:.42:.F?2@B9A
3. Flush coolant from system and replace with
fresh, recommended coolant at least once a
year. More frequent flushing may be necessary,
depending upon the user’s particular system or
its usage, especially if it is prone to clogging
from biological growth in the coolant.
COOL ARC
I
40
FIGURE 7
E-1
TROUBLESHOOTING
E-1
COOL ARC
I
40
33<? .;F?2.@<; F<B1< ;<A B;12?@A.;1A52 A2@A=?<021B?2@ <?.?2 B;./92 A<=2?3<?: A52A2@A@?2=.6?@ @.329F0<;A.0A F<B?
Local Lincoln Authorized Field Service Facility 3<?A205;60.9A?<B/92@5<<A6;4.@@6@A.;02/23<?2F<B=?<0221
CAUTION
(56@ (?<B/92@5<<A6;4 B612 6@ =?<C6121 A< 529= F<B
9<0.A2 .;1 ?2=.6? =<@@6/92 :.056;2 :.93B;0A6<;@
'6:=9F3<99<DA52A5?22@A2==?<021B?296@A21/29<D
Step 1. LOCATE PROBLEM (SYMPTOM).
!<<8 B;12? A52 0<9B:; 9./2921 L%&$!" ',"%
($"'M (56@ 0<9B:; 12@0?6/2@ =<@@6/92 @F:=A<:@
A5.A A52 :.056;2 :.F 2E56/6A 6;1 A52 96@A6;4 A5.A
/2@A 12@0?6/2@ A52 @F:=A<: A5.A A52 :.056;2 6@
2E56/6A6;4
Step 2. POSSIBLE CAUSE.
(52@20<;10<9B:;9./2921L%$''!)'M96@A@
A52 </C6<B@ 2EA2?;.9 =<@@6/696A62@ A5.A :.F 0<;A?6/BA2
A<A52:.056;2@F:=A<:
Step 3. RECOMMENDED COURSE OF ACTION
(56@ 0<9B:; =?<C612@ . 0<B?@2 <3 .0A6<; 3<? A52
%<@@6/92 .B@2 42;2?.99F 6A @A.A2@ A< 0<;A.0A F<B?
9<0.9!6;0<9;BA5<?6G216291'2?C602.0696AF
3F<B1<;<AB;12?@A.;1<?.?2B;./92A<=2?3<?:A52
&20<::2;121 <B?@2 <3 0A6<; @.329F 0<;A.0A F<B?
9<0.9!6;0<9;BA5<?6G216291'2?C602.0696AF
HOW TO USE TROUBLESHOOTING GUIDE
'2?C602 .;1 &2=.6? @5<B91 <;9F /2 =2?3<?:21 /F !6;0<9; 920A?60 .0A<?F (?.6;21 %2?@<;;29
);.BA5<?6G21 ?2=.6?@ =2?3<?:21 <; A56@ 2>B6=:2;A :.F ?2@B9A 6; 1.;42? A< A52 A205;606.; .;1
:.056;2 <=2?.A<? .;1 D699 6;C.961.A2 F<B? 3.0A<?F D.??.;AF <? F<B? @.32AF .;1 A< .C<61 920A?60.9
'5<08=92.@2</@2?C2.99@.32AF;<A2@.;1=?20.BA6<;@12A.6921A5?<B45<BAA56@:.;B.9
--------------------------------------------------------------------------
WARNING
E-2
TROUBLESHOOTING
E-2
COOL ARC
I
40
$/@2?C2.99'.32AFB61296;2@12A.6921A5?<B45<BAA56@:.;B.9
33<? .;F?2.@<; F<B1< ;<A B;12?@A.;1A52 A2@A=?<021B?2@ <?.?2 B;./92 A<=2?3<?: A52A2@A@?2=.6?@ @.329F0<;A.0A F<B?
Local Lincoln Authorized Field Service Facility 3<?A205;60.9A?<B/92@5<<A6;4.@@6@A.;02/23<?2F<B=?<0221
CAUTION
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
<<92? 1<2@ ;<A <=2?.A2 D6A5 =<D2?
@D6A05$#
'D6A05=B@521A<=<@6A6<;
;A2?;.9D.A2?92.8
(<?05<?4B;?B;@5<A
.;<=2?.A2@/BAA52?26@9<D0<<9.;A
39<D
.;<=2?.A2@/BAA52?26@;<0<<9.;A
39<D
%B:=<=2?.A2@/BA3.;1<2@;<A
<<92?A?6=@<BA92A06?0B6A/?2.82?
<<92?A?6=@<BA92A06?0B6A/?2.82?
;=BA0<?1B;=9B4421
%<D2?@D6A053.B9AF
%<D2?5.?;2@@1.:.421
+.A2?96;2@/9<0821<?0?6:=21
!2.86;4B;<?D.A2?5<@2@
<<9.;A?2@2?C<6?2:=AF
(52@F@A2:;221@A</2=?6:21
<@209.:=9<<@2<;<;2<36;A2?
;.95<@2@
;A2?;.95<@2=B;0AB?21
2.A2E05.;42?92.86;4
%B:=@2.96@92.86;4
);6A =9.021 /F .?2. <3 2EA?2:2
52.A
!<D0<<9.;A39<D
#<0<<9.;A39<D
.;;<A<=2?.A6;4
2.A2E05.;42?09<4421
!2.86;A<?054B;<?5<@2@
(<?054B; <? 5<@2@ =.?A6.99F
</@A?B0A21
&2@2?C<6?2:=AF<?C2?F9<D
%B:=@A?.6;2?6@16?AF
%B:=<?=B:=:<A<?3.69B?2
%B:=@A?.6;2?6@/9<0821
!<<@2<?16@0<;;20A213.;92.1
$/@A?B0A6<;6;3.;/9.12
.;:<A<?3.69B?2
6?0B6A<C2?9<.121
.;<?=B:=:<A<?3.69B?2
3.99?20<::2;121=<@@6/92.?2.@<3
:[email protected]@A:2;A5.C2/22;0520821
.;1A52=?</92:=2?@6@A@Contact
your local Lincoln Authorized
Field Service Facility.
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Lincoln Electric Cool Arc 40 Operating instructions
- Category
- Welding System
- Type
- Operating instructions
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