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Troubleshooting & Repair Section......................................................................................Section F
How to Use Troubleshooting Guide ...........................................................................................F-2
PC Board Troubleshooting Procedures ......................................................................................F-3
Troubleshooting Guide ...............................................................................................................F-4
Engine Starting Diagnostic Chart..............................................................................................F-13
Start-Up and OCV Diagnostic Chart .........................................................................................F-14
Test Procedures .......................................................................................................................F-15
Case Cover Removal and Replacement Procedure...........................................................F-15
Case Front Knobs - Removal and Replacement Procedure ..............................................F-18
Power Module Capacitor Discharge Procedure .................................................................F-19
Idler Solenoid Test ..............................................................................................................F-21
Shutdown Solenoid Test .....................................................................................................F-23
Engine Throttle Adjustment Test .........................................................................................F-25
Rotor Resistance Test.........................................................................................................F-29
Flashing and Rotor Voltage Test.........................................................................................F-31
Stator Voltage Test..............................................................................................................F-34
Analog Power Supply PC Board Voltage Test....................................................................F-39
Output Rectifier Bridge Test................................................................................................F-42
Power Module Test .............................................................................................................F-46
Charging Circuit Test...........................................................................................................F-50
Oscilloscope Waveforms ..........................................................................................................F-52
Normal Open Circuit Voltage Waveform (Stick) .................................................................F-53
Normal Weld Voltage Waveform (Stick CC) .......................................................................F-54
Normal Weld Voltage Waveform (Wire CV)........................................................................F-55
Normal TIG Mode Voltage Waveform.................................................................................F-56
Normal Open Circuit Voltage Waveform (Wire CV Tap).....................................................F-57
Replacement Procedures .........................................................................................................F-58
Shutdown Solenoid Removal and Replacement ................................................................F-58
Power Module/Output Rectifier Bridge Assembly Removal and Replacement ..................F-61
Power Module (Chopper) PC Board/Diode Module Removal and Replacement...............F-66
Output Rectifier Bridge Diode Removal and Replacement ................................................F-70
Stator/Rotor Removal and Replacement............................................................................F-73
Retest After Repair ...................................................................................................................F-82
Section F-1 Section F-1
TABLE OF CONTENTS
- TROUBLESHOOTING & REPAIR SECTION -
COMMANDER 500
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