Lincoln Electric Air Vantage 566 SD Hydraulic Service Manual
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Lincoln Electric Air Vantage 566 SD Hydraulic Service Manual

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Air Vantage ® 566 SD Hydraulic
For use with machines having Code Numbers:
Air Vantage ® 566 SD Hydraulic: 12580,
12587
SERVICE MANUAL
SVM296
| Issue D ate 18-Nov
© Lincoln Global, Inc. All Rights Reserved.

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Summary of Contents for Lincoln Electric Air Vantage 566 SD Hydraulic

  • Page 1 Air Vantage ® 566 SD Hydraulic For use with machines having Code Numbers: Air Vantage ® 566 SD Hydraulic: 12580, 12587 SERVICE MANUAL SVM296 | Issue D ate 18-Nov © Lincoln Global, Inc. All Rights Reserved.
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Air Vantage® 566 SD Hydraulic Service Manual Last update: 2018/11/01 AIR VANTAGE® 566 SD HYDRAULIC ......................1 Service Manual ..............................1 Troubleshooting & Repair ..........................3 HOW TO USE TROUBLESHOOTING GUIDE ..................... 3 PC BOARD TROUBLESHOOTING PROCEDURES ....................
  • Page 7 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual VOLTAGE AND CURRENT FEEDBACK TEST PROCEDURE ................70 CHOKE TEST PROCEDURE ..........................74 CHOPPER USER INTERFACE BOARD TEST PROCEDURE ................76 ENGINE ALTERNATOR TEST PROCEDURE ....................79 ROTOR RESISTANCE AND GROUND TEST PROCEDURE (STATIC) ..............81 ROTOR RESISTANCE AND GROUND TEST PROCEDURE (DYNAMIC) ............

  • Page 8: Troubleshooting & Repair

    Troubleshooting & Repair HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 9: Pc Board Troubleshooting Procedures

    ELECTRIC SHOCK can kill. • If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will • Have an electrician install and service this prevent further damage and allow proper failure analysis.

  • Page 10: Troubleshooting Guide

    8. Perform the D1 Rectifier Test Procedure. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 11 Operators Manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 12 7. Perform the D1 & D2 Rectifier Test Procedure. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 13 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS The machine will weld but the 1. Make sure the machine is 1.
  • Page 14 8. Perform the Choke Test Procedure. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 15 Perform the Remote Receptacle Resistance Test Procedure. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 16 2. Perform the Mode Select Board Test Procedure. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 17 4. The wire feeder may be defective. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 18 (CR1) or hydraulic pump (CR2) relays. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 19 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 20 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 21 7. The engine may be in need of mechanical repairs. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 22 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 23 3. The air filter may be clogged, replace if necessary. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 24 6. The engine ECU may be faulty. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 25 4. The toroidal current sensor may be faulty. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 26 2. The engine ECU may be Service Shop. faulty. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 27: Test Procedures

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 28 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual 13. Using a 1/2” nutdriver, remove the two screws securing the left side front panel to the machine. 14. Using a 3/8” nutdriver, loosen (do not remove) the two bottom screws securing the left side front panel to the machine.
  • Page 29 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.1 – Engine access door, door slide rail, roof panel, fuel cap and right side front panel location Figure F.2 – Front panel mounting screw location...

  • Page 30: Capacitor Discharge Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 31 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual 8. NEVER USE A SHORTING STRAP TO DISCHARGE CAPACITORS. If the Lincoln recommended resistor or an equivalent resistor is used, the capacitors can be discharged by holding the resistor with insulated gloves and insulated pliers and using the resistor terminals to bridge the capacitor terminals.
  • Page 32 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.4 – Right side chopper board location Figure F.5 – Left side chopper board discharge...
  • Page 33 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.6 – Right side chopper board discharge Figure F.7 – Bus capacitor location...
  • Page 34 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.8 – Capacitor discharge...

  • Page 35: Brush And Slip Ring Service Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 36 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual CLEANING SLIP RINGS: 10. In the event that the slip rings have become dirty, discolored or mildly pitted, it will be necessary to clean them, using very fine, 500 or 600 grit sand paper.

  • Page 37: Thermostat Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 38 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.9 – Thermostat and plug J22 locations Figure F.10 – Right side chopper board plug J22 lead locations...

  • Page 39: 40 Vdc Bus Board Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 40 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Table F.1 – 40 VDC bus board voltage tests DESCRIPTION TEST POINT TEST POINT EXPECTED READING INPUT POWER FROM D2 PLUG J46 PIN 3 PLUG J46 PIN 2 APPROX. 58 VDC...
  • Page 41 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.12 – 40 VDC bus board plug and LED locations Figure F.13 – 40 VDC bus board pin and lead locations...

  • Page 42: D1 & D2 Rectifier Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 43 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Table F.2 – D1 & D2 rectifier forward diode drop tests TEST POINT (POS) TEST POINT (NEG) EXPECTED READING TOP AC TERMINAL POSITIVE TERMINAL 0.3 VDC – 0.7 VDC BOTTOM AC TERMINAL POSITIVE TERMINAL 0.3 VDC –...
  • Page 44 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.15 – D1 & D2 rectifier schematic and lead locations...

  • Page 45: Mode Select Board Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 46 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Table F.3 – Mode select board resistance tests TEST POINT TEST POINT EXPECTED READING MODE SWITCH POSITION PLUG J1 PIN 1 PLUG J1 PIN 2 4.66K OHMS CV MODE PLUG J1 PIN 1...
  • Page 47 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.17 – Mode select board plug and pin locations...

  • Page 48: Run / Idle Switch Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 49 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Table F. 4 – Run / idle switch resistance tests TEST POINT (+) TEST POINT (–) EXPECTED READING POSITION LESS THAN ONE OHM TERMINAL 2 TERMINAL 3 HIGH IDLE/RUN (LOW RESISTANCE)
  • Page 50 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.19 – Run / idle switch lead locations...

  • Page 51: Start / Glow Switch Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 52 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.20 – Start / glow switch location Figure F.21 – Start / glow switch lead locations...

  • Page 53: Hydraulic Pump / Air Compressor Power Switch Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 54 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Table F. 7 – Hydraulic pump / air compressor power switch resistance tests TEST POINT (+) TEST POINT (–) EXPECTED READING POSITION LESS THAN ONE OHM HYDRAULIC PUMP ON TERMINAL 2...
  • Page 55 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.23 – Hydraulic pump / air compressor power switch lead locations...

  • Page 56: Fuel, Idle, Air Compressor (Cr1) And Hydraulic Pump (Cr2) Relay Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 57 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Table F.8 – Relay resistance tests TEST POINT TEST POINT EXPECTED READING MACHINE CONDITION TERMINAL 87 TERMINAL 30 OPEN NO POWER APPLIED TO (HIGH RESISTANCE) RELAY COILS. TERMINAL 87A TERMINAL 30...
  • Page 58 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.25 – Fuel relay and idle relay locations Figure F.26 – Relay terminal locations and schematic...

  • Page 59: Glow Relay Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 60 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Table F.9 – Glow relay resistance tests TEST POINT TEST POINT EXPECTED READING MACHINE CONDITION TERMINAL 87 TERMINAL 30 OPEN NO POWER APPLIED TO (HIGH RESISTANCE) RELAY COILS. TERMINAL 87 TERMINAL 30...

  • Page 61: Arc Control Potentiometer Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 62 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.29 – Chopper user interface board plug J32 location Figure F.30 – Chopper user interface board plug J32 pin and lead locations...

  • Page 63: Remote Receptacle Resistance Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 64 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Table F.11 – 14 pin Amphenol resistance tests OHMMETER CONNECTION EXPECTED READING PIN G (75B) TO PIN A (32) 500,000 (500K) OHMS OR HIGHER PIN G (75B) TO PIN B (GND-A)
  • Page 65 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Table F.12 – 12 pin Amphenol resistance tests OHMMETER CONNECTION EXPECTED READING PIN E (77B) TO PIN A (53A) 500,000 (500K) OHMS OR HIGHER PIN E (77B) TO PIN B (54A)
  • Page 66 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.31 – Chopper user interface board plugs J31 and J33 location Figure F.32 – 40 VDC bus board plug J47 location...
  • Page 67 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.33 – Amphenol terminal locations...

  • Page 68: Output Rectifier Bridge Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 69 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Table F.14 – Output rectifier bridge diode drop tests TEST POINT (+) TEST POINT (–) EXPECTED RESULT LEADS W1/W6 (AC1) LEAD POS B (DC+) 0.3 - .7V LEADS W2/W3 (AC2) LEAD POS B (DC+) 0.3 - .7V...

  • Page 70: Chopper Board Function Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 71 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual 13. Using a volt/ohmmeter, check for about 60 VDC between chopper board terminals B2+ to B3- and B5+ to B6 and between the welder output terminals. See Figures F.35 and F.36. See Wiring Diagram.
  • Page 72 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.36 – Right side chopper board terminal locations...

  • Page 73: Chopper Board Diode Drop Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 74 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.37 – Left side chopper board terminal locations Figure F.38 – Right side chopper board terminal locations...

  • Page 75: Voltage And Current Feedback Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 76 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual 14. Restart the machine and apply a load across the weld terminals that measures about 200 amps. 15. Using the voltmeter, measure and note the DC voltage at the weld output terminals.
  • Page 77 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.40 – Chopper user interface board lead locations Figure F.41 – Right side chopper board plug J20 location...
  • Page 78 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.42 – Right side chopper board plug J20 lead locations...

  • Page 79: Choke Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 80 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.43 – Left side chopper board terminal locations Figure F.44 – Right side chopper board terminal locations...

  • Page 81: Chopper User Interface Board Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 82 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Table F.16 – Chopper user interface board voltage tests TEST POINT TEST POINT EXPECTED READING MACHINE CONDITION PLUG J34 PIN 15 PLUG J34 PIN 1 3- 7 VDC MACHINE RUNNING. (LEAD 200N)
  • Page 83 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.46 – Chopper user interface board plug locations Figure F.47 – Chopper user interface board lead locations...

  • Page 84: Engine Alternator Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 85 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual 14. The meter should read about 13.7 to 14.2 VDC. 15. If the meter reads correctly, check the connections between the alternator and the battery. See Wiring Diagram. 16. If the voltage at both of the above test points reads the same or less than the battery voltage measurement in Step 3, the alternator is defective.

  • Page 86: Rotor Resistance And Ground Test Procedure (Static)

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 87 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.49 – Capacitor lead and terminal locations...

  • Page 88: Rotor Resistance And Ground Test Procedure (Dynamic)

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 89: Rotor Voltage Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 90 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual 15. Check the field bridge rectifier and capacitor, also check the wiring and terminals connecting them. See Wiring Diagram. 16. Perform the Case Cover Replacement Procedure.

  • Page 91: Flashing Voltage Test Procedure (Engine Not Running)

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 92: Stator Voltage Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 93 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual To test the 240 VAC auxiliary winding: 11. Connect the negative meter probe to lead GND-L or insert into the ground terminal of the three- phase 240VAC receptacle. See Figure F.51. See Wiring Diagram.
  • Page 94 If there are no wiring problems, the stator is defective and should be replaced. 33. Turn off the engine on the Air Vantage 566 SD Hydraulic. 34. Perform the Case Cover Replacement Procedure.
  • Page 95 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.51 – 14 Pin Amphenol terminal locations Figure F.52 – D2 rectifier AC terminal locations...

  • Page 96: Pwm Gate Signal Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 97 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual 16. If the 20KHz gate signal is present, place the weld terminals switch in the ”REMOTELY CONTROLLED” position. The gate signal should turn off. 17. If the 20 KHz gate signal responds as described above, this test is complete.
  • Page 98 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.53 – Chopper user interface board plug J31 location Figure F.54 – Right side chopper board plug J21 and J22 locations...
  • Page 99 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.55 – Left side chopper board terminal B7 and B8 locations Figure F.56 – Chopper user interface board and right side chopper board lead locations...

  • Page 100: Removal And Replacement Procedures

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 101 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.57 – Thermostat lead and mounting screw locations...

  • Page 102: 40 Vdc Bus Board Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 103 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.58 – 40 VDC bus board plug and mounting nut locations...

  • Page 104: D1 & D2 Rectifier Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 105 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Using a 3/8” nutdriver, attach the nut, lock washer, flat washer and spacer securing the D1 rectifier to the fan baffle. Perform the Case Cover Replacement Procedure. 8. Perform the Retest After Repair Procedure.

  • Page 106: Mode Select Board Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 107 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.61 – Mode select board plug J1 location Figure F.62 – Mode select knob location...

  • Page 108: Run / Idle Switch Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 109 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.63 – Run / idle switch lead and mounting tab locations...

  • Page 110: Start / Glow Switch Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 111 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.64 – Start / glow switch lead and mounting tab locations...

  • Page 112: Hydraulic Pump / Air Compressor Power Switch Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 113 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.65 – Hydraulic Pump / Air Compressor Power Switch lead and mounting tab locations...

  • Page 114: Power Module Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 115 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual 12. Using a 7/16” nutdriver, remove the six bolts, lock washers and flat washers securing leads to terminals B1, B2, B3, B4, B5 and B6 to the right side chopper board. See Figure F.67. See Wiring Diagram.
  • Page 116 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Using a 7/16” open-end wrench and a 1/2” open-end wrench, attach the bolt, nut, lock washer and two flat washers securing each set of leads to the three ac terminals of the output rectifier. See Wiring Diagram.
  • Page 117 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.66 – Machine front component locations Figure F.67 – Right side chopper board plug and terminal locations...
  • Page 118 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.68 – Left side chopper board plug and terminal locations Figure F.69 – Output rectifier terminal locations...
  • Page 119 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.70 – Power module component locations...

  • Page 120: Output Rectifier Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 121: Right Side Chopper Board Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 122 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.71 – Power module bracket and heat sink locations...

  • Page 123: Left Side Chopper Board Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 124 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.72 – Power module bracket and heat sink locations...

  • Page 125: Choke Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 126 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual 3. Using a 1/2” open-end wrench and a 1/2” nutdriver, attach the bolt, nut, lock washer and two flat washers securing the leads to the lower terminals of the choke. See Wiring Diagram.
  • Page 127 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.74 – Choke lower terminal location...

  • Page 128: Chopper User Interface Board Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 129 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.75 – Output control knob location Figure F.76 – Chopper user interface board plug and mounting screw locations...

  • Page 130: Fuel Tank Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 131 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual REPLACEMENT PROCEDURE 1. Carefully position the fuel tank support into the machine. 2. Using a 3/8” nutdriver, attach the two screws securing the fuel tank support to the machine. 3. Carefully position the fuel tank into the machine.

  • Page 132: Rotor And Stator Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 133 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual 10. Label and disconnect leads 41 and 41A from the quick-connect terminals. See Wiring Diagram. 11. Label and disconnect leads 45 and 46A from the quick-connect terminals. See Wiring Diagram. 12. Label and disconnect leads 5H and F1 from the D1 rectifier. See Wiring Diagram.
  • Page 134 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual REPLACEMENT PROCEDURE 1. Using a hoist and appropriate rigging, carefully mate the rotor and shaft assembly with the engine. Attach the eight screws securing the rotor coupling disc to the engine. See Wiring Diagram.
  • Page 135 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual 34. Using two 7/16” open-end wrenches, attach the bolt, nut, lock washer and flat washer securing lead 5A to the insulated neutral stud on the bottom of the control box. See Wiring Diagram.
  • Page 136 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.79 – Hydraulic pump inlet and outlet locations Figure F.80 – Field capacitor lead locations...
  • Page 137 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual Figure F.81 – D1 Rectifier lead locations Figure F.82 – Stator, fan and rotor assembly locations...

  • Page 138: Retest After Repair

    LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual RETEST AFTER REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics. • If you repair or replace any electrical components.
  • Page 139 LINCOLN ELECTRIC Air Vantage® 566 SD Hydraulic Service Manual HYDRAULIC PUMP SPECIFICATIONS OUTPUT AT HIGH PTO TYPE HYDRAULIC PUMP INLET FITTING OUTLET FITTING IDLE TYPE: CAST IRON GEAR PUMP BELT DRIVEN WITH 10 GAL/MIN @ SAE12, 37° JIC SAE10, 37° JIC...

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