Water Cooler Problems

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I'm trying to convert the air cooled torch on my miller 180 tig welder to a water cooled torch. i'm using a used bernard water cooler that I put a new motor & waterpump on, it doesn't seem to want to push the fluid through the power cable & bogs the motor down to where it stops. I've pulled the lines off to see where the restriction is & I narrowed it down to the power cable. does anyone have suggestions on what could be causing this?
Reply:I just water cooled my Tig 185 and had a sililar problem!  I found a kink in my return line!  Take a close look, as these lines will kink pretty easiliy where they enter and exit the machine. Attached ImagesAEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:Thanks for the reply! I rechecked & none of the lines are kinked, it appears to work fine if I unhook the power cable from the torch end & turn it on, the flow coming directly out of the torch (by passing the powercable) is what I believe it should be. When the power cable is hooked back up to the torch, the flow coming directly out of the end that goes into the dinse conector is a 1\3 or less like it is building up a lot of back pressure. I don't know of this is normal. The tig torch Is also a new weldcraft unit. Should the flow go through the dinse connector first or the torch head?
Reply:The water should come IN thru the hose WITHOUT the power cable in it.OUT thru the power cable end....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:http://stickweld.com/wp-content/uplo...02/fig5-22.gifHope this helpsV
Reply:Are you getting a flow thru the return but it does not have the pressure like the intake?If this is what is going on this is normal, It's called friction loss.  If your not getting a flow thru the return then something is not connected correctly.AEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:It is a reduced flow but it is enough back pressure that it strains the motor & shuts it down. I wander what the pressure is supposed to be, the Procon pump I bought has a sticker on it that says 250 PSI.
Reply:Originally Posted by TimmonsIt is a reduced flow but it is enough back pressure that it strains the motor & shuts it down. I wander what the pressure is supposed to be, the Procon pump I bought has a sticker on it that says 250 PSI.
Reply:If you disconect the return line from the pump and let it dump directly back into the tank does the pump lock up?  Make sure the problem is not the motor it's self!  These pumps are rotary vane design and if you are pretty mechanical they are not to difficult to work on!  Removing the snap ring and the cover plate reveals the workings, be careful there are small parts inside, 2 paddles and 2 little roll pins that crisscross thru the shaft!These may be sticking, check for drag marks on the linning. The paddles work thru centrifugal force. Also there is a sealed bearing in the pump, could be sticking!  There is a pressure adjust ment spring located behind the side hex cap.  there is a screen that should be cleaned out located behind the lower hex cap.  If all else fails procon will refurb the pump for a resaonable price or you can find a new one out there!   Shop around as prices vary a hell of a lot!Keep us updated.   here is a link for procon.  http://www.proconpumpsinternationala...sentative.com/Last edited by houseoffire; 12-05-2011 at 10:38 PM.AEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:Timmons, The serial # should have the GPH and the PSI listed in it!  mine is 100 GPH 60 PSI  you may have a pump for another application!   Check it out.  Sorry I just realized this.AEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:Ilooked at it last night the pump says it is 250 psi. I got another pump at work that has been rebuilt for a welder water cooler that is 50 psi. If it still doesn't work I think the motor may be burned up thanks for the replies!
Reply:Oh yea, it is a brand new pump.
Reply:Let us know how it go's !AEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:The problem was the pump, as I stated earlier the new pump was rated at 250 psi, through your suggestions I removed the adjustment spring from the new pump & replaced it with the old spring from the old pump. You could tell the old spring didn't have as much tension when compressing them. It works great now!Thanks for all the help
Reply:Good on ya Timmons, thats using your brain man!!!AEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.