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Lincoln Electric EAGLE SVM192-A User's Manual

1. olo OJO els STATOR WELD E POSITIVE 210DC WINDINGS b TERMINAL L1 CHOKE D1 BRIDGERECTIFIER 4 SELECTOR SWITCH Ps w1 2 TT 90 cic Open Circuit Volts NO CONNECTION 5 5 Max Min TO C1 E AND S2 L8 DC 68 34 9 74 TO 78 VAC BETWEEN W1 AND W2 AT HIGH IDLE AND MAXIMUM RHEOSTAT NO LOAD NEGATIVE TWO POLE 3600 1 TERMINAL RPM ALTERNATOR O TOROID SENSES 1 e we QWELDORAC TO AC TAPPED REACTOR STATOR AUXILIARY ACTIVATE IDLER REVOLVING BRUSHES N POWER WINDINGS FIELDS 6A 6 ZTURNS T 3 2 TURNS LEADS 3 AND 6 PASS olo THROUGH TORROID APPROX 5 OHMS 75F O 20A 0 6 20 TWO TIMES IN 240 V AC Rotor Flashing 2 5 OPPOSITE DIRECTIONS 10 TO 50 VDC A volts 0 5 amps cjs 6B 3B 5 until generator build up 12 11 1 7 TO 6 8 AMPS 5 59 GNDE 6256 J3 626 2
2. O o E gt 2 ee TWO POLE 3600 RPM 9 d 1 210DC 225AC WINDINGS ALTERNATOR ois L1 CHOKE Di BRIDGERECTIFIER 1 445 w1 EIE 9 WAC 37 TO 41 VAC BETWEEN Open Circuit Volts 53 AND C1 AT HIGH IDLE AND 515 ey MAXIMUM RHEOSTAT NO LOAD 2 3 AC 76 38 DC 68 34 78 TO 82 VAC BETWEEN cv 32 18 C1 AND W2 AT HIGH IDLE AND MAXIMUM RHEOSTAT NO LOAD WORK R5 R3 Rl 0 1 t 74 TO 78 VAC BETWEEN WAC TERMINAL 2 AND W2 AT HIGH IDLE AND O TOROID SENSES 1 w2 MAXIMUM RHEOSTAT NO LOAD WELD ORAC mme POWER LOAD AC TAPPED REACTOR N ACTIVATE IDLER STATOR AUXILIARY REVOLVING BRUSHES POWER WINDINGS FIELDS 6A 6 2 TURNS 3 li 1 TURN SAME N 2 TURNS 240 V AC RESISTANCE CB3 DIRECTION AS LEAD 6 20 40A i 2 20A APPROX 5 OHMS 75F Rotor Flashing 2 5 5 5 6B 120 V AC 120 V AC 40 TO 50 VOC AT volts 0 5 amps 9 42 11 15 B 9 X 17 68 AMPS until generator build
3. 5 MONO IN je Ja 4 in LOOK ECODE t e X TEK E 4 e 3368 2901N X Jo DS 2 1A FR 33 0 CLOCK IN VAI lt Return to Section TOC Return to Master TOC 3 lt o o o v z 5 9 3 29 E 27 Ps Es 6 lL po H
4. 71 B 2 Welder Controls 0 B 2 Ernigirie SWIteh s edi dU Du e Rok BORA oj B 2 Range dI 3 Controls Dial ek 3 Fuel Consumption 3 Engine Operation t RR a 4 Before Starting the Engine 1 B 4 Starting the Engine eine era ae damien B 4 Stopping the Engine B 4 Break In Period serere e n 4 Welding Process Stick Tig B 5 Summary of Welding Processes 4 B 6 EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O ci a o 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC EM OPERATION End SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes impor
5. GND w 1 1 120 240 V Y A 120 V Y Current Sensing for Automatic Idle Receptacle viewed from front of Machine 120 V DUPLEX RECEPTACLES The 120V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current load through the associated receptacle MOTOR STARTING Most 1 5 hp AC single phase motors can be started if there is no load on the motor or other load connected to the machine since the full load current rating of a 1 5 hp motor is approximately 20 amperes 10 amperes for 240 volt motors The motor may be run at full load when plugged into only one side of the duplex receptacle Larger motors through 2 hp can be run pro vided the receptacle rating as previously stated is not exceeded This may necessitate 240V operation only EAGLE 10 000 Extension Cord Length Recommendations Use the shortest length extension cord possible sized per the following table Current Voltage Load Amps Volts Maximum Allowable Cord Length in ft m for Conductor Size Watts 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG 15 120 1800 30 9 40 12 75 23 125 38 175 53 300 _ 120 2400 1 30 9 5 15 27 138 42 225 3600 60 18 75 23 150 46 225 69
6. The Above For Diesel Engines The Above For Gasoline Engines 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 amp Cutting ANSI Standard 749 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 3 1 b Operate engines open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing 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
7. Start the engine and check the frequency counter At HIGH IDLE 3700 RPM the counter should read 60 8 to 62 5 Hz At LOW IDLE 2200 RPM the counter should read 35 8 to 37 5 Hz Note that these are median measurements hertz readings may vary slightly above or below If either of the readings is incorrect adjust the throttle as follows Adjust HIGH IDLE Use the 3 8 wrench to turn the spring loaded adjustment nut See Figure F 7 for location of the adjustment nut Turn the nut clockwise to increase HIGH IDLE speed Adjust the speed until the frequency reads between 60 8 and 62 5 Hz Adjust LOW IDLE First make sure there is no load on the machine Set the IDLER switch to AUTO and wait for the engine to change to low idle speed Use the 3 8 wrench to adjust the solenoid nut which changes the amount of throw in the throttle lever arm See Figure F 8 for location of the adjustment nut Adjust the nut until the frequency reads between 35 8 and 375 Hz EAGLE 10 000 LINCOLN B F 29 Return to Section TOC Return to Master TOC Return to Section TOC O ci 2 2 c a o 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 30 TROUBLESHOOTING AND REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued Oscilloscope Method 1 2 Connect the oscilloscope to the 115 receptacle according to th
8. 8 Maintenance 8 D Theory of Operation E Troubleshooting and Repair Section F Electrical Diagrams Section G Parts Manual eer RE P 481 Series EAGLE 10 000 LINCOLN B Return to Master TOC Return to Master TOC 5 io 2 tc Return to Master TOC A 1 1 TABLE OF CONTENTS INSTALLATION SECTION Installations EP 1 Technical Specifications A 2 Safety Precautions A 3 Machine Grounding 4 A 3 Spark Arresto T E 3 TOWING UN DR Scan ete 3 Pre Operation Service 4 A 4 gi PI PIU A 4 Battery Connections 1 4 Welding Output Cables 0
9. 4 Angle of Operation 1 143 5 High Altitude Operation 1 0 5 Location Ventilation 2 A 5 Connection of Wire Feeders 6 Additional Safety Precautions A 6 Welder Operation A 6 Auxillary POWOT 1 us ee MUR A 7 120V Duplex Receptacles A 7 Motor Starting A 7 Electrical Devices used w Eagle 10 000 A 8 Auxiliary Power While Welding 4 A 9 Stand by Power Connections 2 A 9 Connection of EAGLE 10 000 to Premises Wiring A 10 EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O cu 2 2 c a o 5 5 5 amp c Return to Section TOC Return to Master TOC ii INSTALLATION ais TECHNICAL SPECIFICATION
10. 5K SLIP RINGS o pe 5L 6 GND C GND G GND D 7 219 200A E EXCITATION WINDING au 41 TO 45 VOLTS MEASURED AT MAX RHEOSTAT HIGH IDLE NO LOAD 9 STATOR 14V IN AUTO IDLE OV IN HIGH IDLE EXCITATION WINDINGS AUTO IDLE 2 OFF 14V RUN HIGH IDLE 3 3 OPERATION IDLE SOLENOID COIL 1121314 START 4 1 ME FOR SUPPRESSOR FOR 251 260 EXE 9 219 200 OFF 2 du 01 RECTIFIER 23 24 15 1 11 lo AUTO 8 01 12 LOAD FIELD HIGH x x SENSOR pe TIMER FLASHING cils START 12 to 14 volts BK aN 130V CIRCUIT X CLOSED CIRCUIT 15 Ohms across coil when 38J 7 12 SEC gt 1 9 energized 10 J1 6 4 213A 2 1 FLYBACK V 20 FLYBACK olo 211 224C 215 DIODE DIODE 7 25 208 A o 5 14V NORMAL OIL PRES o 8 8 51 3 224 1 9 IDLE SOLENOID 5 208 209 J51 Engine COIL 10 VOLT 10V FIELD Connector REGULATOR CURRENT SWITCHING CIRCUIT 04 5 TRANSISTOR FEEDBACK E 224A 224C V RESISTOR 51 2 CHARGING R R OVER CURRENT PROTECTED J51 1 V Battery voltage CONTROL Y J 12 6 volts at rest 10K i 10V HYSTERESIS SWITCH v 14 volts engine running 5 64 V IGNITION AC ENGINE TIA J1 1 475 68 1K 47006ET 3 LEVEL MODULE STARTER W Encneniones RI 76A 11 8
11. E 4 Output Bridge Choke and Output Terminals E 4 FIGURE E 1 BLOCK LOGIC DIAGRAM RANGE SWITCH NC AC OUTPUT __ POSITIVE DAR BRIDGE TERMINAL NEGATIVE TERMINAL STATOR MECHANICAL ROTATION ROTOR STARTER ENGINE SLIP ROTOR 255 RINGS C FLYWHEEL G ALTERNATOR TATOR IDLER e SOLENOID T te BATTERY T FIELD CAPACITOR 115 amp 230VAC T RECEPTACLES OUTPUT CONTROL PRINTED CIRCUIT BOARD EAGLE 10 000 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O ci olg c a o 5 5 5 cle Return to Section TOC Return to Master TOC EM FIGURE E 2 BATTERY STARTER ENGINE ROTOR STATOR AND IDLER SOLENOID RANGE SWITCH 55 OUTPUT __ POSITIVE es BRIDGE AA TERMINAL NEGA
12. cu 2 c a o 515 5 amp c CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 EAGLE 10 000 LINCOLN B Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC O cu 2 c a o 5 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 5 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S OUTPUT PROBLEMS No weld output the auxiliary power 1 Check the open circuit voltage 230 115VAC is operating normal ly Engine runs normally Check OCV at the welder output termi nals engine at high idle 3650 RPM Normal maximum is 73 to 80VAC Normal DC maximum is 67 to 72VDC If the OCV is OK then proceed to Step 42 If the OCV is not present at the welder output terminals contact your local Lincoln Authorized Field Service Facility the welding cables clamps and electrode holder for loose or broken connections TROUBLESHOOTING AND REPAIR F 5 RECOMMENDED COURSE OF ACTION 1 5 Check the Reactor Disconnect lead W1 from the
13. ci 2 2 c a 2 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 21 TROUBLESHOOTING AND REPAIR F 21 AUXILIARY AND FIELD WINDING TEST continued To test the field winding 1 Remove the fuel cap and lift bail rubber gasket With the 5 16 nut driver remove the case top and left side then reinstall the fuel cap Connect the volt ohmmeter probes to leads 7 and 9 where they connect to the Field Idle Control P C Board Start the engine and run it at high idle 3650 RPM Set the output control to the maximum position position 10 Check the AC voltage reading It should be between 36 and 43 VAC If any one or more of the readings are missing or not within specifications then check for loose or broken wires between the test points and the sta tor windings See the Wiring Diagram Make sure the windings are NOT grounded internally to the stator iron If the leads are intact then the stator may be faulty Replace the stator If the voltage readings are within specifications then the windings are good and functioning prop erly 6 Reinstall the case side case top fuel cap and lift bail gasket EAGLE 10 000 LINCOLN B F 22 NOTES EAGLE 10 000 LINCOLN F 22 DOL 01 DOL DOL DOL DOL uonoeg
14. LEVEL 80VDC SOLENOID ENGINE OIL Mangan C M 128 V 754 1 7 475 pei FIELD CURRENT PRESSURE GND BETWEEN AC ENGINE SHUTOFF A SWITCHING SWITCH TERMINALS STARTER SOLENOID FRAME 01 2 4 TRANSISTOR OPENS ON AT HIGH IDLE GROUND Control board common is FIELD CURRENT FEEDBACK OVER CURRENT PROTECTED LOW OIL 777 one diode drop above REVERSE VOLTAGE J FEEDBACK AMP rH PRESSURE Resistance af tue welder frame ground If engine oil pressure drops below safe soleno be connector 7 FIELD amp IDLE CONTROL A operating pressure the oil pressure accurately 419 2 switch opens removing 12 volts from measured through 590090 PC BOARD L12198 1 L13104 circuit 224 shutting off fuel solenoid to diodes x ENTE J2 stop engine Hourmeter will also stop running and PCB1 will denergize idle solenoid Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual 3 EAGLE 10 000 8 ELECTRICAL DIAGRAMS G 6 SCHEMATIC IDLER FIELD CONTROL P C BOARD L12197 Return to Section TOC Return to Master TOC
15. DOL uonoeg oi DOL uonoeg oi DOL uonoeg Return to Section Return to Master TOC Return to Section TOC O ci a o 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 23 TROUBLESHOOTING AND REPAIR F 23 OUTPUT RECTIFIER BRIDGE TEST A WARNING 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 or 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 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if there are faulty diodes in the Output Rectifier Bridge MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver 7 16 wrench or 7 16 socket wrench and 6 socket extension Wiring Diagram EAGLE 10 000 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC O ci 2 2 c a 2 5 5 5 amp c Return to Section TOC Return to
16. F 32 Abnormal Open Circuit DC Weld Voltage Waveform CCMode F 33 Normal Open Circuit DC Weld Voltage Waveform F 34 Replacement Procedures Brush Removal and Replacement F 35 Printed Circuit Board Removal and Replacement F 39 Output Rectifier Bridge Removal and Replacement F 43 Engine Rotor Removal and Replacement Kit 520788 F 47 Retest After 1 F 52 EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O ci a o 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 2 TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by 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 This Troubleshooting Guide is provided to help you locate and repai
17. 6 If the DC voltage reading is correct check the associated wiring and circuitry See the EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O ci a o 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 27 TROUBLESHOOTING AND REPAIR ENGINE THROTTLE ADJUSTMENT TEST A WARNING 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 or 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 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION If the machine output is low this test will determine whether the gasoline engine is oper ating at the correct speed RPM during both HIGH and LOW idle conditions Directions for adjusting the throttle to the correct RPM are given MATERIALS NEEDED 5 16 Nut driver 3 8 open end or box wrench Strobe tach frequency counter oscilloscope or vibratach Black or red marking pencil EA
18. 1 d Keep all equipment safety guards covers and devices in posi tion 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 moving parts ue 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 AX while the engine is running 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 23 ELECTRIC AND x MAGNETIC FIELDS 58 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Exposure to EMF fields in welding may have other health effects which are now not known All welders should us
19. ao Bg E tc Return to Section TOC Return to Master TOC 5 Yn 2 3 ES TROUBLESHOOTING AND REPAIR pur BRUSH REMOVAL AND REPLACEMENT continued SLIP RINGS A slight amount of darkening and wear of the slip rings and brushes is normal Brushes A CAUTION should be inspected when a general overhaul is necessary If brushes are to be replaced clean Do not attempt to polish slip rings while engine slip rings with a fine emery paper is running FIGURE F 9 BRUSH LEADS BRUSHES RETAINED WITH CABLE TIE 7 16 Brush Assembly Bracket Bolts EAGLE 10 000 LINCOLN B F 38 NOTES EAGLE 10 000 LINCOLN F 38 DOL 01 DOL DOL DOL DOL uonoeg DOL uonoeg oi DOL uonoeg oi DOL uonoeg Return to Section Return to Master TOC Return to Section TOC O ci a o 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 39 TROUBLESHOOTING AND REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT A WARNING 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 or machine operator and will inva
20. Sis amp c Return to Section TOC Return to Master TOC Return to Master TOC F 14 TROUBLESHOOTING AND REPAIR ROTOR VOLTAGE TEST continued FIGURE F 1 LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST Brushes Slip Rings TEST PROCEDURE With the 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bail Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Remove the case top then reinstall the fuel cap With the 5 16 nut driver remove the 5 screws holding the right case side Remove the right case side by lifting up and out Set the volt ohmmeter to the DC volts position Connect the positive meter probe to the brush nearest the rotor lamination lead 200A See Figure F 1 for location Lead 219 Connect the negative meter probe to the other brush lead 219 Start the engine and run it at high idle 3650 RPM Set the output control to the MAXI MUM position position 10 Check the voltage reading on the voltmeter It should read between 37 and 46 VDC If the voltage reading is low or not present the generator field is not functioning properly Perform the Rotor Resistance Test The Field Diode Bridge D2 the Field Capacitor C1 and or the Printed Circuit Board may be faulty If the voltage reading is normal the field circuit i
21. CHAMPION RC12YC 030 GAP Oil capacity increases from 2 0 to 2 1 Qts when using this filter EAGLE 10 000 LINCOLN B 0 5 EAGLE 10 000 LINCOLN 5 LELECTRIC MAINTENANCE FIGURE D 1 MAJOR COMPONENT LOCATIONS K y ENGINE ROTOR STATOR ASSEMBLY BASE UNDERCARRIAGE ASSEMBLY CASE TOP amp SIDES OUTPUT RECTIFIER ASSEMBLY CASEFRONT D 5 1 2 3 4 5 DOL 01 DOL DOL DOL 49159 01 DOL uonoeg DOL uonoeg oi DOL uonoeg DOL uonoeg 0 6 NOTES EAGLE 10 000 LINCOLN D 6 DOL 01 DOL DOL DOL DOL uonoeg DOL uonoeg oi DOL uonoeg oi DOL uonoeg Return to Master TOC Return to Master TOC 5 io 2 tc Return to Master TOC E TABLE OF CONTENTS THEORY OF OPERATION SECTION Theory of Operation eem exe xe eme e RE RENI E 1 Battery Starter Engine Excitation Rotor Stator and Idler Solenoid E 2 Rotor Field Feedback and Auxiliary Power E 3 Weld Winding Reactor and Range Switch
22. COURSE OF ACTION OUTPUT PROBLEMS Machine has low welding output 1 The brushes be worn 1 the engine HIGH IDLE RPM and low auxiliary output Contact your local Lincoln is low then perform Authorized Service Facility Throttle Adjustment Test 2 The engine RPM may be low 2 Perform the Rotor Voltage the rotor voltage is low the Field Capacitor C1 or the Field Bridge D2 may be faulty Test and replace if necessary Check the Output Control Potentiometer Normal resis tance is 10 000 ohms Also check associated wiring for loose or faulty connections The Rotor may be faulty Perform the Rotor Resistance The Printed Circuit Board may be faulty Replace If the engine HIGH IDLE RPM is OK then the engine may have lost horsepower and be in need of major repair A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O cu 2 c a o 5 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC is TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS PO
23. Code 11096 20317 G 2 Wiring Diagram Code 11397 21271 G 3 Machine Schematic Entire Machine Code 11096 L12259 G 4 Machine Schematic Entire Machine Code 11397 L13104 G 5 Idler Field Control PC Board Schematic Codes Above 11050 Only L12197 G 6 Idler Field Control PC Board Assembly 112198 1 j NOTE Many PC Board Assemblies are now totally encapsulated surface mounted and or multi lay ered and are therefore considered to be unserviceable Assembly drawings of these boards are no longer provided EAGLE 10 000 LINCOLN B 62 ELECTRICAL DIAGRAMS iin WIRING DIAGRAM CODE 11096 M20317 EAGLE 10 000 KOHLER LEADS 3 AND 6 2 TURNS THRU TOROID IN OPPOSITE DIRECTIONS Return to Master TOC COW OUTPUT GROUND SCREW CONTROL R1 ON UPPER CASEFRONT Return to Section TOC 77A 76A 75A IDLER SOLENOID GROUND SCREW ON LOWER CASEFRONT Return to Master TOC O 5 HOUR 50 Return to Section GND E 6 208 211 TERMINAL i CONN OIL STARTER PRESSURE SWITCH SOLENOI REGULATOR STARTER SHUTOFF SOLENOID SLIP RING NEAREST LAMINATION SILVER
24. Output Bridge D1 and check for the presence of 80VAC from lead W1 to lead W2 on the main stator winding See wiring dia If the AC voltage is NOT present the winding in the sta tor may be faulty Check the winding for continuity and test to be sure it is NOT grounded to the stator iron Replace if nec essary If the correct AC volt age is present proceed to step 2 Range Switch 51 and associated wires for loose or faulty connec tions Check the reactor wind ing for continuity and test to be sure it is NOT grounded to the reactor iron Check the Choke 11 and associated wires for loose or faulty connections Check the choke winding for continuity and test to be sure it is NOT ground ed to the choke iron Check the weld output terminals and associated wires for loose or faulty connections Perform the Output Bridge CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O cu 2 c a o 5 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING REPAIR Observe Safety Guidelines detailed
25. Retest a machine f itis rejected under test for any reason that requires you to remove any mechanical part which could affect the machine s electrical characteristics OR f you repair or replace any electrical components Return to Section TOC Return to Master TOC ENGINE OUTPUT Mode No Load RPM Load RPM Low Idle 2150 2250 NA High Idle 3700 3750 3100 3600 WELDER DC OUTPUT Output Control Range Switch Open Circuit Load Volts Load Amps Volts Maximum Maximum 65 72 21 26 5 205 240 Return to Section Return to Master TOC AUXILIARY POWER RECEPTACLE OUTPUT 230 Volt Receptacle 115 Volt Receptacle Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps Voltage Voltage 246 264 216 250 34 41 5 123 132 114 126 35 42 FIELD AND VOLTS Slip Ring Volts Field Amps 28 0 46 0 VDC 6 5 7 5 VDC OUTPUT CONTROL switch set at MAXIMUM position 10 Output values of each receptacle can vary within the range shown but must be within 2 volts of each other O Ci 2 2 c a o 5 5 5 amp c Return to Section TOC Return to Master TOC EAGLE 10 000 LINCOLN B Return to Master TOC Return to Master TOC 5 2 tc Return to Master TOC e TABLE OF CONTENTS DIAGRAM SECTION ii Electrical Diagrams sce ea ia a RON RU eee a G 1 Wiring Diagram
26. Where this engine driven welder is connected to premises wiring such as that in your home or shop it s frame must be connected to the system earth ground See further connection instructions in the section enti tled Standby Power Connections as well as the arti cle on grounding in the latest National Electrical Code and the local code In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints or to the metal framework of a building which has been effectively grounded The National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symbol is provided on the front of the welder SPARK ARRESTER Some federal state or local laws may require that gasoline engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard The standard muffler included with this welder does not qualify as a spark arrester When required by local reg ulations the K894 1 spark arrester must be installed and properly maintained A CAUTION An incorrect arrester may lead to damage to the engine or adversely affect performance TOWING The recommended trailer for use with this equipment for road in plant and yard towing by a v
27. flat washer lock washer and nut With a 1 2 socket wrench install the heavy cable and the 8 lead White to the rectifier negative heat sink Note the order of fasten ers With the 1 2 socket wrench install the choke lead and the 10 lead and note the order of fasteners Reinstall the case side fuel cap lift bail gas ket case top and spark plug wire EAGLE 10 000 LINCOLN B 46 NOTES EAGLE 10 000 LINCOLN F 46 DOL 01 DOL DOL DOL DOL uonoeg DOL uonoeg oi DOL uonoeg oi DOL uonoeg Return to Section Return to Master TOC Return to Section TOC O ci a o 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 47 TROUBLESHOOTING AND REPAIR A WARNING 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 or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the
28. 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 23 FUMES AND GASES 4 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 with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS 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 ven tilation In confined spaces or in some circumstances outdoors a respirator may be required Additional pre cautions 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 expo sure level should be checked upon installation and periodi cally thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV li
29. may be faulty Perform the The battery may be faulty Charging Circuit Test 2 2 The starter motor or starter aee solenoid may faulty charging circuit may be defec tive The Engine may be hard to crank due to a mechanical fail ure in the engine The Engine shuts off The Engine may be low or 1 The oil pressure switch may be of fuel faulty Replace if necessary The Oil level may be low Check 2 The fuel shut off solenoid may and fill to proper level be faulty 3 The fuel filter may be clogged Engine does not develop full 1 The fuel filter may be clogged 1 Due to wear the engine may be power Replace if necessary in need of repair The air filter may be clogged Replace if necessary The spark plug s may be faulty Replace if necessary A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O ci c a o 5 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 11 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF S
30. mounting bolt and install both bolts Install the brush holder bracket back into the stator frame Refer to the topic Removal and Replacement in this section of the manual 8 18 19 20 Attach leads to the oil pressure switch refer to wiring diagram Replace any cut cable ties Unplug the fuel tank connection and fuel hose and connect them Connect the idle linkage to the idler rod Snap the plastic clip back into place Connect the engine choke cable at the posi tion marked during disassembly Screw the blower fan back onto the end of the rotor shaft Be sure the washer is in place and hand tighten the fan only Reposition the vertical fan baffle and secure it with the two screws Install the two cowling covers at the rear of the stator Connect the black plug in front of the fuel tank fill spout Connect the leads to the starter solenoid and replace any cable ties cut during disassembly Install the battery Connect the positive bat tery cable then the negative battery cable BE SURE TO CONNECT THE POSITIVE BAT TERY CABLE FIRST Replace the battery cover Reinstall the case side fuel cap lift bail gas ket and case top Connect the spark plug wires Conduct the Retest after Repair procedure the following topic in this section of the manu al EAGLE 10 000 LINCOLN B F 51 TROUBLESHOOTING AND REPAIR is RETEST AFTER REPAIR
31. 350 107 600 20 240 4800 18 100 30 175 53 275 84 450 38 __ 240 9000 5 1 90 150 46 225 Conductor size is based on maximum 2 0 voltage drop EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O ci 2 2 c a o 5 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC A 8 INSTALLATION TABLE I A 8 ELECTRICAL DEVICE USE WITH THE EAGLE 10 000 Type Common Electrical Devices Possible Concerns Resistive Heaters toasters incandescent light bulbs electric range hot pan skillet coffee maker NONE Capacitive TV sets radios microwaves appliances with electrical control Voltage spikes or high voltage regulation can cause the capacitative elements to fail Surge protection transient pro tection and additional loading is recommended for 100 fail safe operation DO NOT RUN THESE DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS Inductive Single phase induction motors drills well pumps grinders small refrigerators weed and hedge trimmers These devices require large current inrush for starting Some synchronous motors may be frequency sensitive to attain maximum output torque but they SHOULD BE SAFE from any frequency induced failures Capacitive Inductive Computers hig
32. B TROUBLESHOOTING AND REPAIR Fe Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION ENGINE PROBLEMS Engine will not go to high idle when 1 Make sure the welding cables 1 Check for broken or faulty con attempting to weld Welding output and connections are tight nections in the sensing lead is normal when Idler Switch is in 254 Make sure the connec HIGH position Automatic idle tions are tight at the Electrode function works properly when the Output Terminal and the Range auxiliary power is loaded Switch See Wiring Diagram Make sure the lead is routed through the toroid Return to Section TOC Return to Master TOC Engine will not go to high idle when 1 Make sure the welding cables 1 Check for broken or faulty con attempting to weld or when the aux and connections are tight nections in the Toroid leads iliary power is loaded Welding out 260 and 261 Make sure put and auxiliary power output is their connections are tight at the normal when Idler Switch is in the PC Board See Return to Master TOC 2 Automatic idler may not function if the auxiliary power is loaded to Return to Section TOC HIGH position less than 150 Watts 2 The Toroid may be faulty 3 The Printed Circuit Board may be faulty Replace Engine will not go to high idle when 1 Automatic idler may not function
33. COLORED 3A TERMINALS WHITE WIRES 515 0 5 a gt S 5 GENERATOR LEAD END GROUNDING THIS TERMINAL STOPS THE ENGINE LEAD COLOR CODE B BLACK OR GRAY U BLUE 211 CAVITY 3 RED OR V VIOLET 224 CAVITY 4 W WHITE LOCATING TAB 208 CAVITY 2 ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR TERMINAL BLOCK CONNECTION B ELECTRICAL SYMBOLS PER E1537 M20317PRINT Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN amp EAGLE 10 000 G 3 ELECTRICAL DIAGRAMS os WIRING DIAGRAM CODE 11397 M21271 EAGLE 10 000 KOHLER LEADS 3 AND 6 2 TURNS THRU TOROID IN OPPOSITE DIRECTIONS CCW REL OUTPUT GROUND SCREW CONTR L R1 ON UPPER CASEFRONT Return to Section TOC Return to Master TOC 77A 76A 75A GND E 5 IDLER SOLENOID 210 HOUR METER 9 GROUND SCREW ON LOWER CASEFRONT 224A 7 224C Return to Section TOC Return to Master TOC TERMINAL BLOCK SEE CONN OIL PRESSURE SWITCH SOLENOI N ENGINE IGNITION REGULATO
34. EAGLE 10 000 LINCOLN B F 28 Return to Section Return to Master TOC Return to Section TOC O ci 2 2 c a 2 5 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 29 TROUBLESHOOTING AND REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued FIGURE F 7 HIGH IDLE ADJUSTMENT NUT Throttle linkage qnon Cab e e 11 3 8 High Idle Adjustment Nut If either of the readings is incorrect adjust the throttle as follows Adjust HIGH IDLE Use the 3 8 wrench to turn the spring loaded adjustment nut See Figure F 8 for location of the adjustment nut Turn the nut clockwise to increase HIGH IDLE speed Adjust the speed until the tach reads between 3650 and 3750 RPM Adjust LOW IDLE First make sure there is no load on the machine Set the IDLE switch to AUTO and wait for the engine to change to low idle speed Use the 3 8 wrench to adjust the solenoid nut which changes the amount of throw in the throttle lever arm See Figure F 8 for location of the adjustment nut Adjust the nut until the tach reads between 2150 and 2250 RPM Frequency Counter Method 1 Plug the frequency counter into one of the 115 VAC auxiliary receptacles FIGURE F 8 LOW IDLE ADJUSTMENT NUT 3 8 Low Idle Adjustment Solenoid Housing
35. Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure will aid the technician in removing the engine and or rotor for maintenance or replacement of either component NOTE The procedures described here are for a Kohler engine The same basic proce dures apply to the other engines although there may be a few slight wiring variations MATERIALS NEEDED Lincoln Electric Rotor Removal Kit 820788 FOR ROTOR REMOVAL ONLY Misc Hand Tools Impact wrench Torque wrench ft Ibs Feeler gauge 017 INSTRUCTIONS For Engine and Rotor removal only follow steps 1 25 under ENGINE AND ROTOR REMOVAL PROCEDURE For reassembly of engine and rotor go to REASSEMBLY PROCEDURE For rotor removal follow the ENGINE AND ROTOR REMOVAL PROCEDURE and ROTOR REMOVAL PROCEDURE EAGLE 10 000 LINCOLN B F 47 ENGINE ROTOR REMOVAL AND REPLACEMENT din TROUBLESHOOTING AND REPAIR ENGINE ROTOR REMOVAL AND REPLACEMENT continued FIGURE 12 COMPONENT LOCATIONS ENGINE ROTOR REMOVAL Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Ci 2 2 2 c a o 5 5 5 amp c STATOR COWLING COVER BLOWER FAN IDLE LINKAGE BRUSH HOLDER BRACKET ENGINE LIFT BAILS STATOR ENGINE MOUNTING BOLTS ROTOR ROTOR SHAFT BEARING ROTOR
36. Return to Master TOC Return to Section TOC Return to Master TOC O Ci 2 c a o 5 5 cio Return to Section TOC Return to Master TOC Und MAINTENANCE D SAFETY PRECAUTIONS WARNING Have qualified personnel do the maintenance work Turn the engine off before working inside the machine 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 moving parts Do not put your hands near the engine cooling blower fan If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop 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 ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside 3 SN MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts See additional warning information throughout this operator s manual and the Engine manual as well Read the Safety Precautions n the front of this man ual and the engine instruction manual befor
37. TEST DESCRIPTION The following procedure will aid the technician in accessing the generator brushes for maintenance or replacement MATERIALS NEEDED Misc Hand tools EAGLE 10 000 LINCOLN B F 35 Return to Section Return to Master TOC Return to Section TOC O ci 2 c a o 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 36 TROUBLESHOOTING AND REPAIR BRUSH REMOVAL AND REPLACEMENT continued PROCEDURE Remove the spark plug wires With a 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bail Remove the fuel cap The rubber gasket for the fill tube with come off with the case top Remove the case top then reinstall the fuel cap With the 5 16 nut driver remove the 5 screws holding the right case side Remove the right case side by lifting up and out With a needle nose pliers gently remove the blue and the red wires from the brushes With a 7 16 wrench remove the brush holder assembly bracket from the stator frame With a 5 16 open end wrench remove the two screws that secure the brush holder assembly to the bracket Slide the brush holder assem bly out of the bracket To change the brushes use a slot head screw driver to pop off the plastic retainer on the back of
38. TOC Return to Section TOC O 2 2 c a o 5 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC Heo OPERATION B WELDING PROCESS For any electrodes the procedures should be kept with in the rating of the machine For electrode information see the appropriate Lincoln publication Stick Constant Current Welding Connect welding cables to the and studs Start the engine The RANGE switch markings indicate the maximum current for that range as well as the typical electrode size for that range The OUTPUT Control provides fine adjustment of the welding current within the select range For maximum output within a select ed range set the OUTPUT Control at 10 For mini mum output within a selected range set the OUTPUT Control at 5 OUTPUT Control settings below 5 may reduce arc stability For best overall welding perfor mance set the RANGE Switch to the lowest setting and the OUTPUT Control near the maximum to achieve the desired welding current RANGE SETTING TYPICAL CURRENT RANGE ELECTRODE SIZE 3 32 50 TO 90 AMPS 145 MAX 1 8 TIG CONSTANT CURRENT WELDING 70 TO 145 AMPS 210 MAX 120 TO 210 AMPS The K930 TIG Module installed on a EAGLE 10 000 provides high frequency and shielding gas control for GTAW TIG welding processes Output Control is from the Eagle 10 000 The control on the
39. and 5 ohms EAGLE 10 000 LINCOLN B F 16 TROUBLESHOOTING AND REPAIR ROTOR RESISTANCE TEST continued 13 Measure the resistance to ground Set the ohmmeter on the high scale X100 000 B Place one probe on either of the slip rings Place the other probe on any good unpainted ground The machine ground stud works well Return to Section TOC Return to Master TOC Check the resistance It should read very high at least 0 5 megohm 500 000 ohms the test does not meet the resistance speci fications then the rotor may be faulty Replace the rotor If the test does meet the resistance specifica tions then the rotor is okay 14 Connect lead 200A to the positive brush which is the one nearest the rotor lamination Connect lead 219 to the negative brush Return to Master TOC 15 Reinstall the case side case top fuel cap lift bail gasket and spark plug wires Return to Section TOC O ci a 2 5 5 5 cle Return to Section TOC Return to Master TOC EAGLE 10 000 LINCOLN B F 18 NOTES EAGLE 10 000 LINCOLN F 18 DOL 01 DOL DOL DOL DOL uonoeg DOL uonoeg oi DOL uonoeg oi DOL uonoeg Return to Section Return to Master TOC Ret
40. cable last Keep well venti lated gt ACID CAN BURN EYES AND SKIN Adjustments to the engine are to be made only by a Wear gloves and eye protection and be careful when Lincoln Service Center or an authorized Field Service working near battery Follow instructions printed on Sh op battery BATTERY SLIP RINGS 1 When replacing jumping or otherwise connecting A slight amount of darkening and wear of the slip rings the battery to the battery cables the proper and brushes is normal Brushes should be inspected polarity must be observed Failure to observe when a general overhaul is necessary lf brushes are to the proper polarity could result in damage to the be replaced clean slip rings with a fine emery paper charging circuit The positive battery cable has a red terminal cover A CAUTION 2 If the battery requires charging from an external charger disconnect the negative battery cable Do not attempt to polish slip rings while engine is first and then the positive battery cable before running attaching the charger leads Failure to do so can result in damage to the internal charger HARDWARE components When reconnecting the cables connect the positive cable first and the negative Both English and Metric fasteners are used in this le last welder cable last ENGINE MAINTENANCE PARTS KOHLER 12 050 01 FRAM PH8172 KOHLER 47 083 03 FRAM CA79 KOHLER 24 083 02 KOHLER 24 050 10
41. for maintenance or replacement MATERIALS NEEDED Misc Hand Tools Dow Corning 340 Wiring Diagram EAGLE 10 000 LINCOLN B F 43 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o ao Bg E tc Return to Section TOC Return to Master TOC 5 2 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued FIGURE F 11 OUTPUT RECTIFIER CONNECTIONS 8 ae TO POLARITY SWITCH 3 1 2 MOUNTING SCREWS ENGINE PROCEDURE Remove the engine spark plug wires With a 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bail Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Remove the case top then reinstall the fuel cap With the 5 16 nut driver remove the 5 screws holding the right case side Remove the right case side by lifting up and out L1 TO CHOKE 4 7 16 MOUNTING SCREWS For the remaining steps refer to Figure F 11 8 With a 1 2 wrench remove the choke lead 9 With the 1 2 wrench remove the heavy cable and the 8 lead White from the rectifier neg ative heat sink With a 7 16 wrench remove the W1 lead and the heavy lead going to the S2 Polarity switch With the
42. in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S OUTPUT PROBLEMS No auxiliary power welding output 1 If machine is equipped with cir is normal Engine runs normally cuit breakers check circuit breakers CB1 thru CB5 Reset if tripped Make sure the Output Control R1 is set at the maximum posi tion Check for loose or faulty plug s at the power receptacle s RECOMMENDED COURSE OF ACTION 1 Check the auxiliary power receptacles and associated wires for loose or faulty connec tions Perform the Auxiliary and Field Winding Voltage Test machine is equipped with cir cuit breakers check for faulty breakers and loose or faulty connections on associated wiring A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O cu 2 c a o 5 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S
43. in the following table Carbon Diameter 60 90 Amps 90 250 Amps 1 8 5 32 EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O cu 2 2 c a o 5 5 5 amp c Return to Section TOC Return to Master TOC 89 OPERATION PS Summary of Welding Processes ELECTRODE WHEN NOT TO START PROCESS WELDING WELDING Touch electrode to work Welding starts immediately and engine goes to high idle WIRE FEED LN 25 WITH Press gun trigger LN 25 INTERNAL CONTACTOR contactor closes Welding starts immediately and engine goes to high idle NOTE Output Control must be set above 3 TIG TIG MODULE WITH i Press Arc Start Switch WITH CONTACTOR KIT contactor closes CONTROL CABLE amp ARC welding starts immediately START SWITCH WIRE FEED LN 15 Press gun trigger ACROSS the ARC LN 15 contactor closes has internal contactor Welding starts immediately Note Output Control must be set above 3 TYPICAL CURRENT RANGES 1 FOR TUNGSTEN ELECTRODES 2 Tungsten Electrode DCEN Approximate Argon Gas Flow TIG TORCH Diameter in mm Flow Rate C F H 1 min Nozzle Size 4 5 1 2 Thoriated 1 2 Thoriated Aluminum Stainless Steel 2 15 3 8 4 5 6 5 20 15 80 70 150 5 6 150 250 6 7 8 250 400 400 500 500 750 750 1000 8 10 1
44. terminal of the welder c Attach the single lead from the front of the LN 15 to work using the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current Set the HANGE switch to a suitable position Place the Engine switch in the Auto Idle position Set the Welding Mode on the LN 15 to the CC mode Adjust the wire feed speed at the LN 15 and adjust the welding current with the output CONTROL at the welder Output CONTROL must be set above 3 Note LN 15 Control Cable model will not work with the EAGLE 10 000 CONNECTION OF THE LN 25 TO THE EAGLE 10 000 a Shutthe welder off b For electrode Positive connect the electrode cable from the LN 25 to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable from the LN 25 to the terminal of the welder and work cable to the terminal of the welder Position the RANGE switch to a suitable position aro a d Attach the single lead from the LN 25 control box to the work using the spring clip on the end of the lead it carries no welding current e Place the engine switch in the AUTO IDLE posi tion f Set the Wire Feed Mode switch on the LN 25 to the CC mode g Adjust wire feed speed at the LN 25 and adjust the welding current with the output CONTROL at the welder
45. uonoeg oi DOL uonoeg oi DOL uonoeg Return to Section Return to Master TOC Return to Section TOC O ci a o 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 13 TROUBLESHOOTING AND REPAIR ROTOR VOLTAGE TEST A WARNING 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 or 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 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the correct DC voltage is being applied to the rotor at maximum engine speed 3700 RPM This information will aid the technician in determining if the generator field is operating properly MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver Wiring Diagram EAGLE 10 000 LINCOLN B F 13 Return to Section TOC Return to Master TOC Return to Section TOC O ci Hw c a 2
46. up 8 3 POLE es 0 29 Y LEADS 3 AND 6 PASS are olo 5K a PHASE THROUGH TORROID P 2 TWO TIMES cjg 5 OPPOSITE DIRECTIONS 7 2 GND C GND G P als NDS 7 219 200 E d 77 77 777 7 EXCITATION WINDING 41 45 VAC VOLTS MEASURED AT MAX RHEOSTAT HIGH IDLE NO LOAD 9 STATOR 14V IN AUTO IDLE OV IN HIGH IDLE EXCITATION WINDINGS AUTO IDLE 2 OFF 14V RUN HIGH IDLE 3 3 OPERATION IDLE SOLENOID COIL 1121314 START 4 1 ENERGIZED FOR BUPPRESSORFOR 28 280 7 770 0 0O LOW IDLE 213 D1 RECTIFIER 2 3 24 4 5 31 11 E H 80112 7 LOAD FIELD cis START XIX _ 45 SENSOR DIE TIMER FLASHING 12014 volts i 5K 130V CIRCUIT O 2 5 8 X CLOSED CIRCUIT 15 Ohms C across coil when 38J 12 SEC gt 1 energized 2 5 10 01 6 A 213A 2 1 FLYBACK Y 20 018 211 224C DIODE FLYBACK 215 01 3 DIODE cleg 7 25A 208 A 2 Ny 14V NORMAL OIL PRES 224 1 9 4 2 5 mn i Engne 913 J51 4 Lei SOLENOID s EE 5 Connector SWITCHING REGULATOR CURRENT I4 8 TRANSISTOR FEEDBACK 01 RESISTOR 9 224A 224C OUTPUT M dd pos R R Battery voltage CONTROL OVER CURRENT PROTECTED 126 volts at rest 10K 10V HYSTERESIS SWITCH 14 volts engine running 474V TTA 14 prm IGNITION AC ENGINE ms an LEV
47. use a 5 8 box wrench Hold the rotor with one hand and shock the wrench with the mallet to loosen the thru bolt The thru bolt has a star washer and lock washer beveled to conform to the rotor shaft Pull out the thru bolt Install the appropriate long thru bolt two are provided supplied with Lincoln Electric Rotor Removal Kit 520788 The slot head must face out Screw in the bolt with the slot head screw driver until the bolt bottoms out on the engine crankshaft about 3 4 1 THRU BOLT 2 ROTOR 4 Turning it counterclockwise screw in the left hand thread rotor removal tool from the kit into the rotor shaft Support the rotor with one hand and tighten the tool to approximately 50 ft Ibs with the torque or impact wrench If the rotor does not pop off tighten the rotor removal tool an additional 5 ft 16 Hold the rotor with one hand until the rotor pops off the engine crankshaft HINT If the rotor does not pop off hit the end of the rotor removal tool with a hammer 6 Slide the rotor the rest of the way off the crank shaft Be careful not to lose the washer that fits between the blower fan and the rotor EAGLE 10 000 LINCOLN B F 50 Return to Section Return to Master TOC Return to Section TOC O ci c a o 5 5 gt amp c Return to Section TOC Return to Master TOC Return to Master TOC F 51 TROUBLESHOOTING AND REPA
48. 0 1 Pro Cut 55 Requires full KVA Adapter K1816 1 EAGLE 10 000 LINCOLN B C 4 NOTES EAGLE 10 000 LINCOLN C 4 DOL 01 DOL Winey DOL DOL DOL uonoeg DOL uonoeg oi DOL uonoeg oi DOL uonoeg Return to Master TOC Return to Master TOC 5 2 tc Return to Master TOC TABLE CONTENTS MAINTENANCE SECTION pi Maintenance pU D 1 Safety Precautions D 2 Routine Maintenance 1 0 D 2 Engine Maintenance D 2 Change the Qil insera ruani EE ew lee date den D 2 Engine Refill D 2 Change the Oil 4 D 3 Engine Adjustments 1 D 4 SIP ea ee D 4 Hardware amp Battery 1 D 4 Major Component Locations 1 D 5 EAGLE 10 000 LINCOLN B Return to Section
49. 00 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O ci 2 2 c a o 5 5 5 cle Return to Section TOC Return to Master TOC INSTALLATION AUXILIARY POWER The EAGLE 10 000 can provide up to 9 000 watts of 120 240 volts AC single phase 60Hz power for contin uous use and up to 10 000 watts of 120 240 volts AC single phase 60Hz power peak use The front of the machine includes three receptacles for connecting the AC power plugs one 50 amp 120 240 volt NEMA 14 50R receptacle and two 20 amp 120 volt NEMA 5 20R receptacles Output voltage is within 10 at all loads up to rated capacity See Table more infor mation CAUTION Do not connect any plugs that connect to the power receptacles in parallel Start the engine and set the IDLER control switch to the desired operating mode Set the CONTROL to 10 Voltage is now correct at the receptacles for auxil iary power 120 240 VOLT DUAL VOLTAGE RECEPTACLE The 120 240 volt receptacle can supply up to 38 amps of 240 volt power to a two wire circuit up to 38 amps of 120 volts power from each side of a three wire cir cuit up to 76 amps total Do not connect the 120 volt circuits in parallel Current sensing for the automatic idle feature is only in one leg of the three wire circuit as shown in the following column
50. 15V ee TEST PROCEDURE To test the 115 VAC winding 1 Remove the fuel cap and lift bail rubber gasket With the 5 16 nut driver remove the case top and left side then reinstall the fuel cap Connect the volt ohmmeter probes to leads 3 and 5 where they connect to the 115 VAC receptacle See Figure F 3 Start the engine and run it at high idle 3650 RPM Set the output control to the maximum position position 10 Check the AC voltage reading It should be approximately 125 VAC Machine Case To test the 230 VAC winding 1 Remove the fuel cap and lift bail rubber gasket With the 5 16 nut driver remove the case top and left side then reinstall the fuel cap 2 Connect the volt ohmmeter probes to leads 6 and 3 where they connect to the 230 VAC receptacle NOTE It is easier to insert the probes directly into the receptacle to perform this test However the probes may not reach in far enough to make or keep a good connection In this case before you start the gasoline engine insert two test probes into the receptacle Hold the test probes firmly in place to measure voltage Step 5 3 Start the engine and run it at high idle 3650 RPM 4 Set the output control to the maximum position position 10 5 Check the AC voltage reading It should be approximately 240 VAC EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O
51. 16 Nut driver Wiring Diagram EAGLE 10 000 LINCOLN B F 25 Return to Section Return to Master TOC Return to Section TOC O ci c a 2 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 26 TROUBLESHOOTING AND REPAIR F 26 CHARGING CIRCUIT TEST continued FIGURE F 5 LOCATION OF VOLTAGE REGULATOR TEST PROCEDURE 1 Start the engine and run it at high idle 3650 RPM Set the voltmeter for AC volts and place one meter probe on each of the two outside leads that attach to the engine voltage regulator See Figure F 5 for location Check for 42 52 VAC at the voltage regulator If the AC voltage is low or not present the engine flywheel alternator may be faulty This is an engine problem consult your local engine repair facility If the voltage reading is correct then check the output of the voltage regulator to determine the charging voltage for the battery Run the engine at high idle 3650 RPM Set the volt meter for DC volts and place one meter probe on the middle lead and one probe on the green ground wire connected to the voltage regulator See Figure F 5 for location Check for 13 15 VDC Ground Lead Green Voltage Regulator DC Lead AC Lead 5 lf the DC voltage reading is incorrect or not pre sent the voltage regulator may be faulty Replace the entire voltage regulator module
52. 7 16 wrench remove the S2 lead the heavy lead going to the S1 Range switch and 254 White lead to sense turroid EAGLE 10 000 LINCOLN B F 44 Return to Section Return to Master TOC Return to Section TOC O ci a 2 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 45 po TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued 12 With the 1 2 wrench remove the three mount 17 ing nuts Note the placement of the nylon insulators 13 Remove the rectifier assembly by tilting it up and lifting it toward the side of the machine 14 Reassembly Refer to the Wiring Diagram for proper connections to the positive and nega tive sides of the rectifier assembly The two sides of the bridge are marked and respectively 19 NOTE Use Dow Corning 340 on all aluminum electrical connection surfaces 15 With the 1 2 wrench install the three mounting S nuts 16 With a 7 16 socket wrench install the S2 lead and the heavy lead going to the S1 Range switch Note the order of fasteners flat wash er at the bottom followed by pigtails heavy leads flat washer lock washer and nut With the 7 16 socket wrench install the W1 lead and the heavy lead going to the S2 Polarity switch Note the order of fasteners flat washer at the bottom followed by pigtails heavy leads
53. E Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp EAGLE 10 000
54. EAGLE 10 000 For use with machine code number 11096 11397 Return to Master TOC View Safety Info 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 READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful Return to Master TOC View Safety Info View Safety Info Q 5 ss 2 View Safety Info LI N COLN Copyright Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com Return to Master TOC Return to Master TOC Return to Master TOC I 5 2 tc Return to Master TOC SAFETY A WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductive harm A CALIFORNIA PROPOSITION 65 WARNINGS 1 The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm
55. EL A MODULE do STARTER VW ENGINE DIODES 1 ovo Rile 76A J1 8 SOLENOID BATTERY ENGINE OIL 44 TO 45 DEV 31 10 475 AND DRIVER FIELD CURRENT d PRESSURE GND BETWEEN ENGINE SWITCHING SWITCH TERMINALS STARTER FRAME j TRANSISTOR HOUR ENS DH SOLENOID ca 5E J1 2 c i METER LOW OIL GROUND is REVERSE VO TAGE FIELD CURRENT FEEDBACK OVER CURRENT PROTECTED 777 FEEDBACK AMP TH PRESSURE oT Tal 77 welder frame ground PROTECTION DIODE If engine pressure drops below safe 2 ome be connectorpinnumeens 77 FIELD amp IDLE CONTROL operating pressure the pressure accurately 413 a snitch removing from measured through b o 6 009090 PC BOARD L12198 1 L12259 circuit 224 shutting off fuel solenoid to diodes Rom EE stop engine Hourmeter will also stop i running and PCB1 will denergize idle solenoid Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp EAGLE 10 000 ELECTRICAL DIAGRAMS of SCHEMATIC COMPLETE MACHINE CODE 11397 L13104
56. GLE 10 000 LINCOLN B F 27 Return to Section Return to Master TOC Return to Section TOC O ci c a 2 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 28 TROUBLESHOOTING AND REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued FIGURE F 6 BLOWER PADDLE MARKED FOR STROBE TACH METHOD ml Blower Paddle TEST PROCEDURE This test can be conducted by any one of four methods Strobe tach Method With the 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bail Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Remove the case top then replace the fuel cap Conduct this procedure with the gasoline engine OFF Remove the spark plug wires to prevent acci dental engine kickback or starting With the black or red marking pencil place a mark on one of the blower paddles See Figure F 6 for location Connect the strobe tach according the manu facturer s instructions Reconnect the spark plug wires and start the engine Direct the strobe tach light on the blower paddle and synchronize it to the rotat ing mark With the machine at HIGH IDLE the tach should read between 3650 and 3750 RPM With the machine at LOW IDLE the tach should read between 2150 and 2250 RPM
57. H OF ELECTRODE AND WORK CABLES 225 Amps 100 Duty Cycle 0 100 Ft 0 328 m 100 200 Ft 200 250 Ft 1 0 AWG EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O Ci 2 2 c a o 5 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC AS INSTALLATION nes ANGLE OF OPERATION Internal combustion engines are designed to run in a level condition which is where the optimum perfor mance is achieved The maximum angle of operation for the engine is 15 degrees from horizontal in any direction If the engine is to be operated at an angle provisions must be made for checking and maintaining the oil at the normal FULL oil capacity in the crankcase in a level condition When operating at an angle the effective fuel capacity will be slightly less than the specified 9 gallons LIFTING The EAGLE 10 000 weighs approximately 575 lbs with a full tank of gasoline A lift bail is mounted to the machine and should always be used when lifting the machine WARNING Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trail er or gas cylinder Do not lift machine if lift bale FALLING is damaged EQUIPMENT can Do not operate machine while cause in
58. IR ENGINE ROTOR REMOVAL AND REPLACEMENT KIT S20788 continued REASSEMBLY PROCEDURE NOTE Lincoln Electric recommends that a new bearing Lincoln part M9300 85 be installed when you replace the rotor and blower assembly Clean the tapered engine crankshaft Slide the rotor onto the shaft Insert the rotor thru bolt and with the torque wrench tighten the bolt to 50 ft 5 Support the engine rotor assembly with the chain hoist Fit the rotor into the stator frame being careful not to damage the rotor core against the stator The bearing will seat into its race about half way Insert the four bolts and lock washers that hold the engine to the stator With the 9 16 wrench draw the bolts up evenly in order to seat the bearing properly Tighten to 22 ft Ib moving diagonally from bolt to bolt Check the rotor stator air gap with the 017 feeler gauge The measurement is taken at the blower end of the rotor before the fan is reinstalled Turn the rotor with a pair of lock ing pliers as necessary so that the rotor iron is up to take the measurement The rotor has two flat sides which are not measured for air gap Slide in the gauge Then rotate the shaft 180 degrees and measure again If the gauge does not clear loosen the four engine stator bolts retighten the bolts and recheck the air gap Repeat until the proper 017 minimum air gap is achieved Fasten the ground lead to the right engine
59. LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O cu olg 3 c a 2 5 5 5 amp c Return to Section TOC Return to Master TOC ia INSTALLATION die Figure A 1 CONNECTION OF EAGLE 10 000 TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR T rower PUR x 60 Hz 3 Wire COMPANY E Service METER NEUTRAL LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION PREMISES DISCONNECT AND GROUND OVERCURRENT 240 VOLT PROTECTION DOUBLE POLE CIRCUIT 240 VOLT BREAKER 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 50 1 50 AMP 120 240 VOLT RECEPTACLE NOTE No 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS WARNING Connection of EAGLE 10 000 to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and all other applicable electrical codes EAGLE 10 000 LINCOLN B Return to Master TOC Return to Master TOC 5 io 2 tc Return to Master TOC 1 _____ TABLE OF CONTENTS OPERATION SECTION ___ rer B 1 Safety Precautions B 2 General Description
60. M 1 49 Liters Hour High Idle No Load 74 Gallons Hour 3700 RPM 2 79 Liters Hour DC CC Weld Output 1 29 Gallons Hour Auxiliary Power 1 40 Gallons Hour EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O cu 2 2 a o 5 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC ud STARTING SHUTDOWN INSTRUCTIONS STARTING THE ENGINE WARNING Do not touch electrically live parts of electrode with skin or wet clothing N Keep flammable material away Insulate yourself from work and ground Wear eye ear and body protection Keep your head out of the fumes 3 SA Be sure all Pre Operation Maintenance has been per formed Also read the Engine Owner s Manual before starting for the first time Use ventilation or exhaust to remove fumes from breathing zone Remove all loads connected to the AC power recepta cles Use the choke control as follows KOHLER ENGINE Always pull the choke control out when starting the engine cold warm or hot Turn the engine switch to the start position and crank the engine until it starts Release the switch as soon as the engine starts slowly return the choke control to the full in position choke open and turn the switch to the Auto Idle X pos
61. Master TOC Return to Master TOC F 24 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER BRIDGE TEST continued FIGURE F 4 LOCATION OF OUTPUT RECTIFIER LEADS OUTPUT RECTIFIER ENGINE TEST PROCEDURE Remove the spark plug wires to prevent acci dental engine kickback or starting With the 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bail Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Remove the case top then replace the fuel cap With the 5 16 nut driver remove the 5 screws holding the right case side Remove the right case side by lifting up and out 8 Conduct the test with the gasoline engine OFF Locate the Output Rectifier Bridge behind the machine case front With the 7 16 wrench or socket wrench and 6 extension remove the nuts and washers hold ing the diode bridge pigtails and the heavy cur rent carrying leads to the studs located in the middle of the rectifier assembly Note their locations and the order of fasteners for reassembly Electrically isolate the diode connectors by slightly bending them back into free air With an ohmmeter or diode tester check each of the four diodes from their connector to their respective heat sinks See Figure F 4 Reverse the tester leads and check the diodes again Diodes should have a low res
62. NOTE The welding electrode is energized at all times unless an LN 25 with built in contactor is used If the output CONTROL is set below 3 the LN 25 contactor may not pull in CONNECTION OF K930 2 TIG MODULE TO THE EAGLE 10 000 The TIG Module is an accessory that provides high frequency and shielding gas control for AC and DC GTAW TIG welding See IM528 supplied with the TIG Module for installation instructions NOTE The TIG Module does not require the use of a high frequency bypass capacitor However if the EAGLE 10 000 is used with any other high frequency equipment the bypass capacitor must be installed order kit T12246 INSTRUCTIONS ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the roof and case sides in place as this provides maximum protection from moving parts and assures proper cooling air flow Read and understand all Safety Precautions before operating this machine Always follow these and any other safety procedures included in this manual and in the Engine Owner s Manual WELDER OPERATION WELDER OUTPUT Maximum Open Circuit Voltage at 3700 RPM is 80 Volts RMS Duty Cycle is the percentage of time the load 15 being applied in a 10 minute period For example a 60 duty cycle represents 6 minutes of load and 4 minutes of no load in a 10 minute period Duty Cycle for the EAGLE 10 000 is 100 EAGLE 10 000 210 Amps DC 25 Volts Constant Current EAGLE 10 0
63. R SUPPOR MODULE STARTER SHUTOFF SOLENOID o o o 5 SLIP RING NEAREST LAMINATION o 5 o 2 E SILVER COLORED TERMINALS GENERATOR LEAD END GROUNDING THIS TERMINAL STOPS THE ENGINE da EAU NUMBERS LEAD COLOR CODE 4 n 3 B BLACK OR GRAY U BLUE 2 1 J2 12 ri 7 x o o 224C CAVITY 4 Pd 8 2 1 P LOCATING TAB R RED OR PINK V VIOLET W WHITE 6 J1 208 CAVITY 2 ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR TERMINAL BLOCK CONNECTION ELECTRICAL SYMBOLS PER E1537 M21271PRINT Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LIN LN 3 EAGLE 10 000 Ga ELECTRICAL DIAGRAMS SCHEMATIC COMPLETE MACHINE CODE 11096 12259
64. Return to Section TOC Return to Master TOC Return to Section TOC O ci a 2 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 16 TROUBLESHOOTING AND REPAIR ROTOR RESISTANCE TEST continued FIGURE F 2 LOCATION OF ROTOR SLIP RINGS Lead 219 TEST PROCEDURE With the 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bail Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Remove the case top then replace the fuel cap With the 5 16 nut driver remove the 5 screws holding the right case side Remove the right case side by lifting up and out Conduct the test with the gasoline engine OFF 8 Remove the spark plug wires to prevent acci dental engine kickback or starting 9 10 11 12 Lead 200A Isolate the rotor electrically by removing the generator brush leads Refer to Figure F 2 as you perform the remaining steps Remove lead 219 from the negative brush Remove lead 200A from the positive brush Measure the resistance across the rotor slip rings A Set ohmmeter the low scale X1 B Place one meter probe on one of the rotor slip rings Place the other probe on the other slip ring C Check the resistance across the slip rings It should read between 4
65. S EAGLE 10 000 K2343 1 K2343 2 INPUT GASOLINE ENGINE Horsepower Operating Displacement K2341 1 2 cylinder Speed RPM in cu cm Kohler 4 Cycle E Air Cooled High Idle 3700 AMEN Gasoline 7 Electric Start Te 90088 eca Aluminum Alloy Battery K2343 2 with Cast Iron Full Load 3500 Kohler 435 cold 2 Liners Cranking 2 0 Qts 1 9 L Spade Electronic Start ps Make Model Capacities Starting System RATED OUTPUT 104 F 40 C WELDER DC Constant Current 210A 25V 100 RATED OUTPUT 104 F 40 GENERATOR Auxiliary Power 9 000 Watts Continuous 60 Hz AC 10 000 Watts Peak 60 Hz AC K2343 1 10 500 Watts Peak 60 Hz AC K2343 2 120 240 Volts PHYSICAL DIMENSIONS DEPTH WEIGHT 42 0 in 502 Ibs 228kg 1067 mm 1 Output rating in watts is equivalent to volt amperes at unity factor Output voltage is within 10 at all loads up to rated capacity When welding available auxiliary power will be reduced EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O cu 2 2 c a o 5 5 5 amp c Return to Section TOC Return to Master TOC A3 INSTALLATION idi SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manu
66. SSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION ENGINE PROBLEMS Engine will not idle down to low 1 Make sure the Idler Switch 54 1 With the Idler Switch 54 in the speed Machine has normal weld is in the Auto position Auto position check for the output and auxiliary power presence of 12VDC at leads 213 to 215 located at the Idler Solenoid If 12VDC is pre sent and the Idler Solenoid is not activating then the solenoid may be faulty or there is a mechanical restriction prevent ing it from functioning If there is NOT 12VDC at leads 213 to 215 then test for 12VDC from lead 213 to ground lead 5 See Wiring If 12VDC is present then check lead 215 for conti nuity zero ohms from the Idler Solenoid to the Printed Circuit Board plug 3J1 If lead 215 is OK then the Printed Circuit Make sure there is NOT an exter nal load on the weld terminals nor the auxiliary power recepta cles Board may be faulty Replace there is NOT 12VDC from lead 213 to ground lead 5 then check the Idler Switch S4 for proper operation and as sociated wires for loose or faulty connections CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 EAGLE 10 000 LINCOLN
67. TCH RANGE SWITCH NC AC OUTPUT CHOKE POSITIVE DY AC BRIDGE TERMINAL 1 NEGATIVE TERMINAL STATOR MECHANICAL ROTAT ION ROTOR STARTER ENGINE SLIP ROTOR T RINGS ee ALTERNATOR PPro STATOR IDLER e SOLENOID BATTERY FIELD CAPACITOR L F am OUTPUT CONTROL PRINTED CIRCUIT BOARD WELD WINDING REACTOR AND RANGE SWITCH The stator weld winding is connected to the reactor and range switch The inductance in the reactor offers an impedance to current flow The reactor coil is tapped at various points As the range switch is rotated dif ferent amounts of reactor coil are brought into the cur rent path As more turns of reactor are brought into the circuit the more impedance there is to current flow Simply stated the more reactor in the circuit the lower the welding current TOROID 115 amp 230VAC RECEPTACLES OUTPUT BRIDGE CHOKE AND OUTPUT TERMINALS The AC voltage developed in the stator weld winding is delivered through the reactor and range switch to the output bridge The DC output current path is from the Output Bridge where the AC voltage is rectified to a DC voltage and then through the choke where the DC out
68. THRU BOLT B amp Return to Section TOC Return to Master TOC EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O ci a o 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 49 TROUBLESHOOTING AND REPAIR ENGINE ROTOR REMOVAL AND REPLACEMENT continued ENGINE AND ROTOR REMOVAL PROCEDURE 1 Refer to Figure F 12 for component locations 2 Remove the engine spark plug wires 3 With a 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bail Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Remove the case top the reinstall the fuel cap WIth the 5 16 nut driver remove the 5 screws holding the right case side and the 5 screws holding the left case side 8 Remove the case sides by lifting up and out With a 3 8 wrench remove the battery cover Disconnect the negative battery cable then the positive battery cable BE SURE TO DIS CONNECT THE NEGATIVE BATTERY CABLE FIRST Remove the battery and set it aside With the diagonal cutters cut the cable ties around the leads from the starter solenoid and disconnect the leads Remove lead 209A from the harness bundle Disconnect the large black plu
69. TIG Module is not functional After flow time is adjustable from 0 to 55 seconds A K814 Arc Start Switch is required The K930 TIG Module should be used with the EAGLE 10 000 on HIGH IDLE to maintain satisfactory operation It can be used in the AUTO position but the delay going to low idle after welding is ceased will be increased if the AFTER FLOW CONTROL is set above 10 seconds A K814 Arc Start Switch is required WIRE FEED WELDING PROCESSES The Innershield electrode recommended for use with the EAGLE 10 000 is NR 211 MP The electrode sizes and welding ranges that can be used with the EAGLE 10 000 are shown in the following table Approximate Current Range 80 110 75A to 120A 70 130 120A to 170A 40 90 125A to 210A The EAGLE 10 000 is recommended for limited MIG welding GMAW gas metal arc welding The mended electrodes are 030 and 035 L 50 and L 56 They must be used with a blended shielding gas such as C25 75 Argon 25 The welding ranges that can be used with the EAGLE 10 000 are shown in the following table Approximate Diameter Wire Speed in Range In Min Current Range 75 300 50A to 130A 100 250 80A to 175A ARC GOUGING Diameter Wire Speed in Range In Min The EAGLE 10 000 can be used for limited arc goug ing Set the Range switch to adjust output current to the desired level for the gouging electrode being used according to the ratings
70. TIVE TERMINAL STATOR MECHANICAL ROTATION ROTOR STARTER ENGINE SLIP ROTOR cu RINGS FLYWHEEL O G ALTERNATOR STATOR IDLER SOLENOID icem BATTERY T FIELD CAPACITOR 24 115 amp 230VAC d RECEPTACLES OUTPUT CONTROL ES PRINTED CIRCUIT BOARD BATTERY STARTER ENGINE ROTOR STATOR AND IDLER SOLENOID The 12VDC battery powers the starter motor When the engine is started and running the battery circuit voltage is fed through the printed circuit board to the rotating field coil in the rotor via a brush and slip ring configuration This excitation flashing voltage mag netizes the rotor lamination The rotor is mechanically coupled to the engine This rotating magnet induces a voltage in the stationary windings of the main alterna tor stator Three separate and isolated windings are incorporated in the stator lamination assembly Each winding set has a different number of turns producing different magnitudes of AC output voltages The three windings are the weld winding the auxiliary power winding and the field feedback winding The field feed back winding provides rotor current during machine operation The output of the EAGLE 10 000 is depen dent on two criteria the engine RPM and the amount of current in the rotor winding The flywheel alternator located on the engine supplies charging current for the battery circuit The battery circuit provides power for the print
71. TPUT CONTROL PRINTED CIRCUIT BOARD ROTOR FIELD FEEDBACK AND AUXILIARY POWER The AC voltage developed in the field winding is fed to the full wave field bridge The DC output of the bridge is filtered by the field capacitor and controlled by the printed circuit board according to the output control set ting This filtered and controlled voltage is fed to the rotor winding via the brush and slip ring configuration As the feedback voltage is increased or decreased the outputs of the weld and auxiliary windings are increased or decreased O cu 2 2 2 c a o 5 5 5 amp c When full field voltage is applied to the rotor and the engine is running at high speed 3700 RPM a 230 AC voltage is developed in the stator auxiliary winding This winding is tapped to provide 115 VAC The two voltages 115 VAC and 230 VAC are connected to the appropriate receptacles and offer 9000 watts total of AC power NOTE Unshaded areas of Block Logic Diagram are the subject of discussion EAGLE 10 000 LINCOLN B Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O ci c a o 5 5 5 amp c Return to Section TOC Return to Master TOC ET THEORY OF OPERATION i FIGURE E 4 WELD WINDING REACTOR AND RANGE SWI
72. TROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING CH1 Return to Section TOC Return to Master TOC 0 volts Return to Section TOC Return to Master TOC 50 volts 5 ms This is NOT the typical DC output voltage waveform One output diode is not functioning Note the gap in the waveform One output diode was disconnected to simulate an open or nonfunctioning output diode Each vertical division represents 50 volts and each horizontal division repre sents 5 milliseconds in time O ci 2 c a o 5 5 5 amp c Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Internal Return to Section TOC Return to Master TOC EAGLE 10 000 LINCOLN B roe TROUBLESHOOTING AND REPAIR NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM MODE HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM CH1 Return to Section TOC Return to Master TOC 0 volts LL ee Return to Section Return to Master TOC 50 volts 5 ms This is the typical DC output voltage generated from a properly operating mach
73. When used with argon gas The current ranges shown must be reduced when using argon helium or pure helium shielding gases 2 Tungsten electrodes are classified as follows by the American Welding Society AWS Pure EWP 1 Thoriated EWTh 1 2 Thoriated EWTh 2 Though not yet recognized by the AWS Ceriated Tungsten is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applications 3 DCEP is not commonly used in these sizes 4 TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4 in 6 mm 5 5 16 in 8 mm 6 3 8 in 10 mm 7 7 16 in 11 mm 8 in 12 5 mm 10 5 8 in 16 mm 5 TIG torch nozzles are typically made from alumina ceramic Special applications may require lava nozzles which are less prone to breakage but cannot withstand high temperatures and high duty cycles EAGLE 10 000 LINCOLN B TABLE OF CONTENTS ACCESSORIES SECTION lt o D ACCeSSOLIGS uui see aces Sees ee ee ee ae ee C 1 9 gt 9 5 Optional Equipment euni 2 Recommended 4 4 C 3 SUCRE cc C 3 LII EX Ile IP C 3 C 3 Plasma Cutting dieu C 3 Return to Master TOC 5 2 tc Return to Master TOC EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Ret
74. YMPTOMS MISADJUSTMENT S WELDING PROBLEMS The welding arc is cold Engine 1 Check for loose or faulty connec runs normally 3700 RPM no load Auxiliary power is functioning nor mally tions at the weld output terminals and welding cable connections The welding cable may be too long or coiled causing an exces sive voltage drop TROUBLESHOOTING AND REPAIR F 11 RECOMMENDED COURSE OF ACTION 1 2 3 4 Check for the correct open cir cuit voltage OCV at the welder output terminals 80VAC Max 72VDC Max If the correct voltage is present at the output terminals then check for loose connections on the heavy cur rent carrying leads inside the EAGLE 8 See If the OCV is low at the welder output terminals then Perform The Engine Throttle Adjustment Perform the Output Rectifier Bridge Test Check for shorted or grounded windings in the reactor and also in the main stator See Wiring CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 EAGLE 10 000 LINCOLN B F 12 NOTES EAGLE 10 000 LINCOLN F 12 DOL 01 DOL DOL DOL DOL uonoeg DOL
75. accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use 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 787 standards 4 b Use suitable clothing made from durable flame resistant
76. ajor Physical or Electrical Damage 1 Contact your local Lincoln 1 Contact The Lincoln Electric is Evident Authorized Field Service Facility Service Dept 1 888 935 3877 Return to Section TOC Return to Master TOC No weld output and no auxiliary 1 Check the brushes for wear 1 Perform the Rotor Voltage Test power Engine runs normally proper contact to the rotor slip Check for the presence of rings 12VDC at the pc board from lead 216 to frame ground This is the flashing voltage and is present only when the Start Run Stop switch S3 is in the Start position If the 12 VDC is missing check the leads switch es and connections associated with the lead 216 See Check for the presence of 12 VDC at the pc board from lead 224 to frame ground This is the supply voltage to the board and is present when the engine is running and the S3 switch is in the Run position If the 12VDC is missing check the leads switches and connections asso ciated with the lead 224 See Wiring Diagram If Rotor Voltage Test is normal then preform the Resistance Test 4 f the Rotor Voltage Test is NOT normal perform the and Field Winding Voltage Then check the Field Diode Bridge D2 and the Field Capacitor C1 Replace if nec essary the Field Bridge and Field Capacitor are good then the Printed Circuit Board may be faulty Replace Return to Section TOC Return to Master TOC O
77. arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables 1 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier iv SAFETY iv 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou to
78. ates to full speed After welding ceases and no auxiliary power is being drawn the engine will return to low idle after approximately 10 to 14 seconds Auxiliary Power With the engine running at low idle and auxiliary power for lights or tools is drawn approximately 100 150 watts or greater from the receptacles the engine will accelerate to high speed If no power is being drawn from the receptacles and not welding for 10 14 seconds the idler reduces the engine speed to low idle EAGLE 10 000 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC O ci a o 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC B 3 OPERATION a SWITCH Range switch is used to select one of three amperage ranges with generous overlap for Stick TIG welding or one Wire Feed welding range Process Range Setting Current Range STICK TIG 90 Max 50 to 90 Amps constant current 145 Max 70 to 145 Amps 3 range settings 210 Max 120 to 210 Amps A CAUTION Never change the RANGE Switch setting while welding This will damage the switch CONTROL DIAL The Control Dial provides a fine welding current adjust ment within the Range Switch settings EAGLE 10 000 APPROXIMATE FUEL CONSUMPTION KOHLER CH20S CH23S Low Idle No Load 39 Gallons Hour 2200 RP
79. cycling center for reclamation Do not throw it in the trash pour it on the ground or down a drain OIL FILTER CHANGE 1 Drain the engine oil 2 Remove the oil filter and drain the oil into a suitable container Discard the used oil filter 3 Clean the filter mounting base and coat the gasket of the new oil filter with clean engine oil 4 Screw on the new oil filter by hand until the gasket contacts the filter mounting base then use an oil fil ter socket tool to tighten the filter an additional 1 2 to 7 8 turn 5 Refill the crankcase with the specified amount of the recommended oil Reinstall the oil filler cap 6 Start the engine and check for oil filter leaks 7 Stop the engine and check the oil level If neces sary add oil to the upper limit mark on the dipstick AIR CLEANER AND OTHER MAINTENANCE Air Cleaner With normal operating conditions the maintenance schedule for cleaning and re oiling the foam pre filter is every 25 hours and replace ment of the air cleaner filter every 100 hours More frequent servicing is required with dusty operating conditions Refer to the maintenance section of the Engine Owner s Manual for more information Refer to the maintenance section of the Engine Owner s Manual for the maintenance schedule spark plug servicing cooling system servicing and fuel filter replacement Blow out the machine with low pressure air peri odically In particularly dirty locations
80. d air coming out of the welder recirculating back to the cooling air inlet Also locate the welder so that engine exhaust fumes are properly vented to an outside area STACKING EAGLE 10 000 machines cannot be stacked EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O ci 2 2 c a o 5 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC 56 INSTALLATION nb CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS NOTE A constant voltage CV power source is rec ommended for wire feeder applications The LN 15 and LN 25 may be used with a constant current CC power source such as the EAGLE 10 000 for non critical applications where weld quality and deposition properties are not critical WARNING Shut off welder before making any electrical connections WIRE FEED CONSTANT VOLTAGE CONNECTION OF LN 15 ACROSS THE ARC WIRE FEEDER The LN 15 has an internal contactor and the electrode is not energized until the gun trigger is closed When the gun trigger is closed the wire will begin to feed and the welding process is started a Shut the welder off b Forelectrode Positive connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable terminal of the welder and work cable to the
81. de fuel cap lift bail gas ket case top and spark plug wires EAGLE 10 000 LINCOLN B F 41 pM TROUBLESHOOTING AND REPAIR 42 NOTES EAGLE 10 000 LINCOLN F 42 DOL 49159 01 DOL DOL DOL DOL uonoeg DOL uonoeg oi DOL uonoeg oi DOL uonoeg Return to Section Return to Master TOC Return to Section TOC O ci a o 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 43 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT A WARNING 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 or 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 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure will aid the technician in removing the output rectifier bridge
82. de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l
83. e manufacturer s instructions At 3700 RPM the waveform should exhibit a period of 16 2 milliseconds At 2200 RPM the waveform should exhibit a period of 27 3 milliseconds Refer to NOR FORM 115 VAC SUPPLY HIGH IDLE NO in this section of the manual If either waveform periods is incorrect adjust the throttle as follows Adjust HIGH IDLE Use the 3 8 wrench to turn the spring loaded adjustment nut See E8 for location of the adjustment nut Adjust the speed until the period is 16 2 milliseconds Adjust LOW IDLE First make sure there is no load on the machine Set the IDLER switch to AUTO and wait for the engine to change to low idle speed Use the 3 8 wrench to adjust the solenoid nut which changes the amount of throw in the throttle lever arm 9 for location of the adjustment nut Adjust the speed until the period is 27 3 milliseconds Vibratach Method 1 Place the vibratach as close to the engine as possible With the machine case top removed the top of the air cleaner is the best location Start the engine and observe the whip handle of the vibratach At HIGH IDLE 3700 RPM the whip handle should exhibit maximum oscillation At LOW IDLE 2200 RPM the whip handle should exhibit minimum oscilla tion Note that these are median measure ments vibratach readings may vary slightly above or below If either of the vibratach indications is incor rect adjust the thrott
84. e on the case front which accepts 4 prong plugs and converts it to a NEMA 6 50R receptacle which accepts 3 prong plugs T12153 9 Full KVA Power Plug One dual voltage plug rated at 120 240V 50 amps K930 2 TIG Module Provides high frequency and shielding gas control for AC and DC GTAW TIG weld ing applications Its compact case is designed foe easy carrying complete with a handle High frequency bypass is built in Requires K938 1 Contactor Kit K936 4 Control Cable and K814 Arc Start Switch K938 1 Contactor Kit For use with TIG Module Provides a cold electrode until the triggering device Arc Start Switch is pressed K936 4 Control Cable Connects TIG Module to Eagle 10 000 K814 Arc Start Switch Attaches to the TIG torch for convenient finger control K937 45 Control Cable Extension Allows TIG Module to be operated at distances up to 200ft from the power source Available in 45ft 13 7m K844 1 Water Valve Kit For use with water cooled TIG torch Installs inside of TIG Module K939 1 Docking Kit For Mounting the K930 2 TIG Module on top of the Eagle 10 000 EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O cu 2 2 c a 2 5 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC ACCESSORIES Gs RECOMMENDED EQUIPMENT STICK K704 Accesso
85. e 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 4 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 Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source EAGLE 10 000 LINCOLN B Return to Master TOC Return to Master TOC 5 2 tc Return to Master TOC SAFETY ELECTRIC SHOCK can kill 8 a The electrode and work or ground circuits are electrically hot when the welder is 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 of 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
86. e working on this machine Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair cloth ing and tools away from gears fans and all other moving parts when starting operating or repairing the equipment Routine Maintenance At the end of each day s use refill the fuel tank to minimize moisture condensation in the tank Running out of fuel tends to draw dirt into the fuel System Also check the crankcase oil level and add oil if indicated A CAUTION Make certain that the oil filler cap is securely tight ened after checking or adding oil If the cap is not tight oil consumption can increase significantly which may be evidenced by white smoke coming from the exhaust OIL Maintenance schedule for changing the oil and oil filter after break in Kohler CH20S or CH23S Oil 100 Hrs Oil Filter 200 Hrs The above schedule is for normal operating conditions More frequent oil changes are required with dusty high temperature and other severe operating conditions Refer to the maintenance section of the Engine Owner s Manual for more information NOTE Engine life will be reduced if the oil and oil fil ter are not changed according to the manufac turer s recommendation ENGINE OIL CHANGE EP Drain the oil while the engine is warm to assure rapid and complete draining Remove the oil filler cap and dipstick Remove the yellow cap from the oil drain
87. eck for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame ATTENTION Static Sensitive Devices Handle only at Static Safe Workstations If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the PC board must be either conductive anti static or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag If the PC board uses protective shorting jumpers don t remove them until installation is complete f you return a PC board to The Lincoln Electric Company for credit it must be
88. ed circuit board and also for the idler solenoid The idler solenoid is mechanically connected to the engine throttle linkage If no current is drawn from the EAGLE 10 000 the printed circuit board activates the idler solenoid which then brings the engine to a low idle state When either weld or auxiliary output current is sensed by the toroid the printed circuit board deactivates the idler solenoid and the engine goes to high RPM After 12 to 15 sec onds of no load the solenoid is reactivated to reduce the speed NOTE Unshaded areas of Block Logic Diagram are the subject of discussion EAGLET 10 000 LINCOLN B FIGURE ROTOR FIELD FEEDBACK AND AUXILIARY POWER cle SWITCH 5 o OUTPUT CHOKE POSITIVE COUT ARAN O TERMINAL Ree NEGATIVE TERMINAL STATOR MECHANICAL ROTATION ROTOR STARTER ENGINE SLIP ROTOR RINGS 5 FLYWHEEL e STATOR efs IDLER 212 SOLENOID o 915 ol o i gt 515 Em 5 BATTERY jo FIELD CAPACITOR CO 115 amp 230VAC RECEPTACLES OU
89. ehicle is Lincoln s K957 1 If the user adapts a non Lincoln trail er he must assume responsibility that the method of attachment and usage does not result in a safety haz ard nor damage the welding equipment Some of the factors to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln equip ment and likely additional attachments 2 Proper support of and attachment to the base of the welding equipment so there will be no undue stress to the framework EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O ci 2 2 c a o 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC net INSTALLATION A 3 Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself while being operated or serviced 4 Typical conditions of use i e travel speed rough ness of surface on which the trailer will be operated environmental conditions 5 Conformance with federal state and local laws 1 1 Consult applicable federal state and local laws regarding specif ic requirements for use on public highways A WARNING VEHICLE MOUNTING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport this Equipment on se
90. est Procedure All of the specified test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 EAGLE 10 000 LINCOLN B F 2 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o ao Bg E tc Return to Section TOC Return to Master TOC 5 Yn gt 2 Fa TROUBLESHOOTING AND REPAIR ES PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Ch
91. face One or two gas cylin ders can be mounted on the rear of the undercarriage with the installation of K1745 1 Cylinder Holder s Heavy duty puncture resistant pneumatic tires and front caster K1745 1 GAS CYLINDER HOLDER Holds Welding Gas Cylinder for use on K1770 1 Undercarriage One or two may be installed on an undercarriage K1788 1 ROLL CAGE Gives added damage protec tion Attaches to K1737 1 K1770 1 and K957 1 K886 1 Canvas Cover To protect the EAGLE 10 000 when not in use Made from attractive red canvas material which is flame retardant mildew resistant and water repellent K802 R Power Plug Kit provides four 120V plugs rated at 15 amps each and one dual voltage Full KVA plug rated at 120 240V 50 amps K802 N Power Plug Kit Provides four 120V plugs rated at 20 amps each and one dual voltage full KVA plug rated at 120 240V 50 amps K894 1 Spark Arrester Kit Includes a heavy gauge steel approved spark arrester and clamp for easy mounting to muffler exhaust pipe K1690 1 GFCI RECEPTACLE KIT Includes one UL approved120V ground fault circuit interrupter duplex type receptacle with cover and installation instructions Replaces the factory installed 120V duplex receptacle Each receptacle of the GFCI Duplex is rated at 20 Amps the maximum total current from the GFCI Duplex is limit ed to the 20 Amps Two kits are required K1816 1 FULL KVA ADAPTER KIT Plugs into the 120 240V NEMA 14 50R receptacl
92. facturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure Do not operate with doors open guards off Ww Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual MACHINE GROUNDING Because this portable engine driven welder or genera tor creates it s own power it is not necessary to con nect it s frame to an earth ground unless the machine is connected to premises wiring your home shop etc WARNING To prevent dangerous electric shock other equip ment to which this engine driven welder supplies power must be grounded to the frame of the welder using a grounded type plug or be double insulat ed Do not ground the machine to a pipe that carries explosive or combustible material When this welder is mounted on a truck or trailer it s frame must be electrically bonded to the metal frame of the vehicle Use a 8 or larger copper wire connected between the machine grounding stud and the frame of the vehicle
93. g in front of the fuel tank spout With the 3 8 wrench remove the cowling cov ers at the rear on the stator both sides of the machine With the 3 8 wrench remove the two screws that hold the vertical fan baffle in place Slide the baffle forward toward the rectifier bridge heat sink assembly Hold the rotor shaft with locking pliers and unscrew the blower fan Turn the fan counter clockwise You do not need to remove the fan from the machine but be sure it is completely unscrewed from the rotor shaft 15 20 21 22 23 24 25 With a 1 4 nut driver disconnect the engine choke cable from the engine Mark the loca tion of the retainer for reassembly The other end can remain connected Disconnect the idle linkage by unsnapping the plastic clip at the engine end of the idler rod Snap the clip back onto the rod to avoid losing it remove the rod for reassembly Disconnect the fuel line from the fuel tank Plug the hose and also plug the connection at the fuel tank to prevent the escape of gasoline fumes Cutthe cable ties and remove leads 224C and 210 from the oil pressure switch With a 9 16 wrenches remove the ground lead from the right engine foot mounting bolt With a 7 16 wrench remove the brush holder bracket and leads 219 amp 200A from the sta tor frame Support the engine with a chain hoist Lift bails are provided on the top of the engine for th
94. h resolution TV sets complicated electrical equipment An inductive type line condi tion along with transient and surge protection is required and liabilities still exist DO NOT USE THESE DEVICES WITH THE EAGLE 10 000 The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect ed to the EAGLE 10 000 EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O cu 2 2 c a o EIE Sis 5 amp c Return to Section TOC Return to Master TOC INSTALLATION a AUXILIARY POWER WHILE WELDING Simultaneous welding and power loads are permitted by following Table The permissible currents shown assume that current is being drawn from either the 120V or 240V supply not both at the same time Also the Output Control is set at 10 for maximum auxil iary power TABLE Il SIMULTANEOUS WELDING AND POWER Permissible Power Watts Unity Power Factor Output Selector Setting Permissible Auxiliary Current in Amperes 120V or 240V Max Stick or Wire Feed Setting 145 Stick Setting 90 Stick Setting NO WELDING Each duplex receptacle is limited to 20 amps Not to exceed 40A per 120VAC branch circuit when splitting the 240 VAC output STANDBY POWER CONNECTIONS The EAGLE 10 000 is suitable for temporary standby or emerge
95. if 1 If the machine works OK when the Auxiliary Power is loaded The the auxiliary power is loaded to set to High Idle mMake sure that Idle Circuit works OK with a weld less than 150 Watts leads 3 and 6 are wrapped ing load correctly through the Toroid O ci 2 2 c a o 5 5 5 amp c If the machine does not function properly at High Idle check that the connections are good at the circuit breakers and that the cir cuit breakers are functional CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 EAGLE 10 000 LINCOLN B Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC O cu 2 2 c a o 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION ENGINE PROBLEMS Engine will not crank or cranks very 1 Check for loose or faulty battery 1 If the battery is replaced or tests cable connections good then the charging circuit
96. in the static shielding bag This will prevent further damage and allow prop er failure analysis 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims EAGLE 10 000 LINCOLN 5 TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS M
97. ine Note that each vertical divi sion represents 50 volts and that each horizontal division represents 5 milliseconds in time Note Scope probes connected at machine output terminals O ci 2 c a o 5 5 5 amp c SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal Return to Section TOC Return to Master TOC EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O ci a o 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 35 TROUBLESHOOTING AND REPAIR BRUSH REMOVAL AND REPLACEMENT A WARNING 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 or 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 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 trou bleshooting assistance before you proceed Call 1 888 935 3877
98. ins crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c 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 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 etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment a
99. is purpose With a 9 16 wrench remove the right and left engine foot mounting bolts With the 9 16 wrench remove the four bolts that hold the stator to the engine There is one lock washer per bolt With the chain hoist unweight the engine gen tly Use a pry bar to carefully pry between the engine and the stator frame in order to unseat the bearing on the end of the rotor shaft Separate the engine and rotor from the stator frame supporting the rotor by hand to prevent damage to the rotor core Move the engine and rotor assembly to a bench The engine is off balance with the rotor still attached therefore support the end of the rotor with a wooden two by four before unhooking the chain hoist EAGLE 10 000 LINCOLN B F 49 Return to Section TOC Return to Master TOC Return to Section TOC O ci 2 2 c a o 5 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 50 TROUBLESHOOTING AND REPAIR ENGINE ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 13 ENGINE AND ROTOR REMOVED FROM STATOR ROTOR REMOVAL PROCEDURE 1 To remove the rotor double check that the engine spark plug wires are disconnected You will be turning the rotor during this proce dure and this could accidentally cause engine kickback With an impact wrench remove the rotor thru bolt See Figure F 13 If an impact wrench is not available
100. is tightened securely Refer to the engine Owner s Manual for specific oil recommenda tions A CAUTION BATTERY CONNECTIONS Use caution as the electrolyte is a strong acid that can burn skin and damage eyes This welder is shipped with the negative battery cable discon nected Make sure that the Engine Switch is in the OFF posi tion and attach the disconnected cable securely to the negative battery terminal before attempting to operate the machine If the battery is discharged and does not have enough power to start the engine see the battery charging instructions in the Battery section NOTE This machine is furnished with a wet charged battery if unused for several months the battery may require a booster charge Be careful to charge the battery with the correct polarity WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the studs provided These connections should be checked periodi cally and tightened if necessary Loose connections will result in overheating of the output studs When welding at a considerable distance from the welder be sure you use ample size welding cables Listed below are cop per cable sizes recommended for the rated current and duty cycle Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable volt age drop TOTAL COMBINED LENGT
101. istance in one polarity and a very high resistance in the opposite polarity Replace any shorted or open diode bridge assembly the tests indicate Reconnect the diode connectors and heavy leads to their respective studs Reinstall the case side case top fuel cap lift bail gasket and spark plug wires EAGLE 10 000 LINCOLN B F 24 Return to Section Return to Master TOC Return to Section TOC O ci a o 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 25 TROUBLESHOOTING AND REPAIR CHARGING CIRCUIT TEST A WARNING 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 or 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 If for any reason you do not understand the test procedures are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the Flywheel Alternator Regulator and associated circuitry are functioning properly MATERIALS NEEDED Volt Ohmmeter 5
102. ition Do not turn the switch to the start position while the engine is running because this will cause damage to the ring gear and or starter motor After running at high engine speed for 10 14 seconds the engine will go to low idle Allow the engine to warm up by letting it run at low idle for a few minutes STOPPING THE ENGINE Remove all welding and auxiliary power loads and allow engine to run at low idle speed for a few minutes to cool the engine Stop the engine by placing the Engine switch in the OFF position A fuel shut off valve is not required on the Eagle 10 000 because the fuel tank is mounted below the engine BREAK IN PERIOD It is normal for any engine to use a greater amount of oil until the break in is accomplished Check the oil level twice a day during the break in period approxi mately 50 running hours IMPORTANT IN ORDER TO ACCOMPLISH THIS BREAK IN THE UNIT SHOULD BE SUBJECTED TO MODERATE LOADS WITHIN THE RATING OF THE MACHINE AVOID LONG IDLE RUNNING PERIODS REMOVE LOADS AND ALLOW ENGINE TO COOL BEFORE SHUTDOWN The engine manufacturer s recommendation for the running time until the first oil change is as follows The oil filter is to be changed at the second oil change KOHLER 20 or 23 5 Refer to the Engine Owner s Manual or Maintenance section bf this manual for more information EAGLE 10 000 LINCOLN B Return to Section Return to Master
103. jury suspended from lift bale ADDITIONAL SAFETY PRECAUTIONS HIGH ALTITUDE OPERATION If the EAGLE 10 000 will be consistently operated at altitudes above 5000 ft a carburetor jet designed for high altitudes should be installed This will result in bet ter fuel economy cleaner exhaust and longer spark plug life It will not give increased power which is decreased at higher altitudes Engine horsepower is reduced by 3 5 per 1000 feet for altitudes above 377 feet CAUTION Do not operate a EAGLE 10 000 with a high altitude jet installed at altitudes below 5000 ft This will result in the engine running too lean and result in higher engine operating temperatures which can shorten engine life Contact your local Kohler Authorized Dealer for high altitude jet kits that are available from the engine man ufacturer Muffler Relocation A WARNING Shut off welder and allow muffler to cool before touching muffler The EAGLE 10 000 is shipped with the exhaust com ing out on the left side The exhaust can be changed to the opposite side by removing the two screws that hold the exhaust port cover in place and installing the cover on the opposite side Operating the EAGLE 10 000 without the cover in place will result in a higher noise level and no increase in machine output LOCATION VENTILATION The welder should be located to provide an unrestrict ed flow of clean cool air to the cooling air inlets and to avoid heate
104. le as follows Adjust HIGH IDLE Use the 3 8 wrench to turn the spring loaded adjustment nut See 8 location of the adjustment nut Turn the nut clockwise to increase HIGH IDLE speed Adjust the speed until the vibratach whip han dle exhibits maximum oscillation at 3650 to 3750 RPM Adjust LOW IDLE First make sure that there is no load on the machine Set the IDLER switch to AUTO and wait for the engine to change to low idle speed Use the 3 8 wrench to adjust the solenoid nut which changes the amount of throw in the throttle lever arm See Figure F 9 for location of the adjustment nut Adjust the speed until the vibratach whip handle exhibits minimum oscillation at 2150 to 2250 RPM EAGLE 10 000 LINCOLN B F 30 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O ci 2 2 c a o 5 5 5 amp c Return to Section TOC Return to Master TOC F 31 TROUBLESHOOTING AND REPAIR F 31 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLY HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM 16 2 ms ty ttt etH 50 volts 5 ms This is the typical auxiliary output volt age generated from a properly operat ing machine Note that each vertical division represents 50 volts and that each horizontal division represents 5 mil
105. lidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure will aid the technician in removing the printed circuit board for maintenance or replacement MATERIALS NEEDED Misc Hand Tools Wiring Diagram EAGLE 10 000 LINCOLN B F 39 ae TROUBLESHOOTING AND REPAIR PRINTED CIRCUIT BOARD REMOVAL olo AND REPLACEMENT continued 5 5 FIGURE 10 PRINTED CIRCUIT BOARD LOCATION D 4 Self Tapping Screws at corners 312 4 Pin Plug gt 12 Pin Plug gt 2 lt a 2 2 ele 5 5 2 c 1 4 Tabs PROCEDURE Before starting the following procedure refer to the 8 Remove the 12 pin molex plug from the topic PC Board Troubleshooting Procedures Printed circuit board at the beginning of this section 9 Remove 4 pin molex from the current sensing 1 Remove the engine spark plug wires leads 2 With a 5 16 nut driver remove the 6 sheet 10 Remo
106. liseconds in time Note Scope probes connected at machine 115VAC receptacle SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Trigger Internal EAGLE 10 000 LINCOLN B 0 volts Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O ci a o 5 5 5 cle Return to Section TOC Return to Master TOC Paa TROUBLESHOOTING AND REPAIR ibus TYPICAL DC WELD OUTPUT WAVEFORM CC MODE MACHINE LOADED CH1 Heee 0 volts 20 volts 5 ms MACHINE LOADED TO 200 AMPS AT 26 VDC This is the typical DC output voltage generated from a properly operating machine Note that each vertical divi sion represents 20 volts and that each horizontal division represents 5 milliseconds in time The machine was loaded with a resistance grid bank Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal EAGLE 10 000 LINCOLN B TROUBLESHOOTING AND REPAIR pos ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE NO LOAD OUTPUT CON
107. mits 5 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 prod ucts 5 9 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 54 equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Jan 09 EAGLE 10 000 LINCOLN B Return to Master TOC Return to Master TOC 5 2 tc Return to Master TOC SAFETY 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 from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjcent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardo
108. ncy power using the engine manufacturer s recommended maintenance schedule The EAGLE 10 000 can be permanently installed as a standby power unit for 240V 3 wire single phase 38 ampere service WARNING Connections must be made by a licensed electri cian who can determine how the 120 240V power can be adapted to the particular installation and comply with all applicable electrical codes The following information can be used as a guide by the electrician for most applications refer also to the connection diagram shown in Figure A 1 1 Install a double pole double throw switch between the power company meter and the premises disconnect Switch rating must be the same or greater than the customer s premises disconnect and service overcurrent protection 2 Take necessary steps to assure load is limited to the capacity of the EAGLE 10 000 by installing a 38 amp 240V double pole circuit breaker Maximum rated load for the 240V auxiliary is 38 amperes Loading above 38 amperes will reduce output voltage below the allowable 10 of rated voltage which may damage appliances or other motor driven equipment 3 Install a 50 amp 120 240V plug NEMA type 14 50 to the Double Pole Circuit Breaker using No 8 4 conductor cable of the desired length The 50 amp 120 240V plug is available in the optional plug kit 4 Plug this cable into the 50 amp 120 240V receptacle on the EAGLE 10 000 case front EAGLE 10 000
109. nd CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations 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 Jan 09 EAGLE 10 000 LINCOLN B Return to Master TOC Return to Master TOC 5 2 tc Return to Master TOC PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention
110. put is filtered and on to the Output Terminals NOTE Unshaded areas of Block Logic Diagram are the subject of discussion EAGLE 10 000 LINCOLN B Return to Master TOC Return to Master TOC 5 io 2 tc Return to Master TOC F1 TABLE OF CONTENTS TROUBLESHOOTING AND REPAIR F Troubleshooting and Repair F 1 How to Use Troubleshooting Guide F 2 PC Board Troubleshooting Procedures F 3 Troubleshooting Guide 1 F4 F 12 Test Procedures Rotor Voltage Test 0 4 F 13 Rotor Resistance Test F 15 Auxiliary and Field Winding Test 1 F 19 Output Rectifier Bridge 0 F 23 Charging Circuit Test 4 1 F 25 Engine Throttle Adjustment Test F 27 Oscilloscope Waveforms Normal Open Circuit Voltage Waveform 115 VAC Supply F 31 Typical DC Weld Output Waveform CC Mode Machine Loaded
111. r possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhib it Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into the following categories output problems function prob lems wire feeding problems and welding problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION The last column labeled Recommended Course of Action lists the most likely com ponents that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific T
112. rviceable vehicles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use Do not exceed maximum rated loads for components such as suspension axles and tires Mount equipment base to metal bed or frame of vehicle Follow vehicle manufacturer s instructions CAUTION READ the engine operating and maintenance instructions supplied with this machine WARNING Stop engine while fueling not smoke when fueling h y Keep sparks and flame away from Sp y tank Do not leave unattended while fueling Wipe up spilled fuel and allow fumes GASOLINE to clear before starting engine not overfill tank fuel expansion may cause overflow can cause fire or explosion FUEL GASOLINE FUEL ONLY Fil the fuel tank with clean fresh lead free gasoline Observe fuel gauge while filling to prevent overfilling A WARNING Damage to the fuel tank may cause fire or explosion Do not drill holes in the EAGLE 10 000 base or weld to the EAGLE 10 000 base OIL gt LUBRICATION SYSTEM CAPACITY INCLUDING FILTER Kohler 235 2 0 Quarts 1 9 Liters The EAGLE 10 000 is shipped with the engine crankcase filled with SAE 10W 30 oil Check the oil level before starting the engine If it is not up to the full mark on the dip stick add oil as required Make certain that the oil filler cap
113. ry Kit For Stick Welding Includes 35 ft 10 7m 2 0 AWG electrode cable 30 ft 9 1m 2 0 AWG work cable with lugs headshield filter plate work clamp and electrode holder 400 amp capacity K875 Accessory Kit For stick welding Includes 20 Ft 6 1m 6 electrode cable with lug 15 Ft 4 6m 6 work cable with lugs headshield filter plate work clamp and electrode holder and sample pack of mild steel electrode 150 amp capacity WIRE FEED K449 LN 25 Includes internal contactor for across the arc operation no control cable Provides cold elec trode until gun trigger is pressed Includes gas sole noid K1870 1 LN 15 Across the Arc Magnum Gun and Magnum Gun Connector Kit are required for gas shielded welding Innershield Gun is required for gasless welding K126 2 Magnum 350 Innershield Gun for LN 25 LN 15 K1802 1 Magnum 300 MIG Gun for LN 25 includes Connector Kit K470 2 Magnum 300 MIG Gun for LN 15 requires K466 10 Magnum Gun Connector Kit K1500 1 Gun Receiver Bushing for LN 15 K126 2 Note See Wire Feeder IM Manual for appropriate Drive Roll amp Guide Tube Kits TIG WELDING K1783 9 PTA 26V TIG Torch KP509 Magnum Parts Kit and Argon gas K930 2 TIG Module Required TIG Equipment K938 1 Connector Kit K936 4 Control Cable K814 Arc Start Switch Optional TIG Equipment K939 1 Docking Kit K937 45 Control Cable Extension K844 1 Water Valve Kit PLASMA CUTTING K158
114. s functioning properly Install the right case side with the 5 sheet metal screws with the 5 16 nut driver Remove the fuel cap install the case top and tighten the 6 sheet metal screws with the 5 16 nut driver Install the rubber gasket over the lift bail and install the fuel cap EAGLE 10 000 LINCOLN B F 14 Return to Section Return to Master TOC Return to Section TOC O ci a o 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 15 TROUBLESHOOTING AND REPAIR ROTOR RESISTANCE TEST A WARNING 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 or 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 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if there is a shorted winding in the rotor or if the rotor is grounded MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver Wiring Diagram EAGLE 10 000 LINCOLN B F 15
115. tant safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e insulate yourself from work and ground Always wear dry insulating gloves Always operate the welder with the hinged door closed and the side panels in place e Read carefully the Safety Precautions page before operating this machine Always follow these and any other safety procedures included in this manual and in the Engine Instruction Manual GENERAL DESCRIPTION The EAGLE 10 000 is a twin cylinder gasoline driven multi process arc welder and AC power generator It is built in a heavy gauge steel case for durability on the job site WELDER CONTROLS FUNCTION AND OPERATION ENGINE SWITCH The engine switch is used to Start the Engine Select High Idle or Auto Idle while the engine is running and stop the Engine When placed in the OFF position the ignition circuit is de energized to shut down the engine When held in the START position the engine starter motor is energized When in HIGH IDLE 69 position the engine will run continuously at high idle When in AUTO IDLE gt gt position the engine will run continuously and the idler operates as follows e Welding When the electrode touches the work the welding arc is initiated and the engine acceler
116. the brush holder assembly Remove the old brushes and insert the new ones One corner of the terminal clip is beveled so that the brush can go in only one way 20 Snap the plastic retainer back onto the brush holder The brushes may need some reposi tioning wiggle them slightly to help them seat properly on the slip rings To reinstall the brushes depress the spring loaded brushes into the holder and slip a suit able non metallic fairly stiff retainer through the slots at the top and bottom of the holder A cable tie works well See Figure F 9 This will hold the brushes up so that you can easily install the holder Slide the brush holder assembly back into the bracket and with the 5 16 open end wrench install the two screws that hold it in place With the 7 16 wrench install the brush holder assembly bracket to the stator frame Slowly remove the non metallic retainer from the brush holder and let the brushes snap back against the slip rings With the needle nose pliers connect the red and the black wires to the appropriate termi nals on the brushes The red wire is inboard Check the wire connections for clearance and tightness Reinstall the case side fuel cap lift bail gas ket case top and spark plug wires EAGLE 10 000 LINCOLN B F 36 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o
117. this may be required once a week Output Eagle Selector and Polarity Switches Switch contacts should not be greased To keep contacts clean rotate the switch through its entire range frequently Good practice is to turn the handle from maximum to minimum setting twice each morning before starting to weld EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O ci 2 2 c a o 5 5 5 amp c Return to Section TOC Return to Master TOC De MAINTENANCE ai ENGINE ADJUSTMENTS A WARNING GASES FROM BATTERY can explode WARNING A Keep sparks and cigarettes away from battery To prevent EXPLOSION when INSTALLING NEW BATTERY disconnect negative OVERSPEED IS HAZARDOUS cable from old battery first and connect to new battery The maximum allowable high idle speed for this last machine is 3750 RPM no load Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed Severe personal injury and damage to the machine can result if operated at speeds above USING A BOOSTER connect positive lead to bat maximum tery first then connect negative lead to engine foot CONNECTING BATTERY CHARGER Remove bat tery from welder by disconnecting negative cable first then positive cable and battery clamp When rein stalling connect negative
118. urn to Section TOC O ci a o 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 19 TROUBLESHOOTING AND REPAIR AUXILIARY AND FIELD WINDING TEST A WARNING 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 or 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 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the correct AC voltages are being generated from the stator windings MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver Wiring Diagram EAGLE 10 000 LINCOLN B F 19 Return to Section Return to Master TOC Return to Section TOC O ci 2 0 c a 2 5 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 20 TROUBLESHOOTING AND REPAIR F 20 AUXILIARY AND FIELD WINDING TEST continued FIGURE F 3 LOCATION OF LEADS 3 AND 5 1
119. urn to Section TOC O ci 2 2 c a o 5 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC ACCESSORIES OPTIONAL EQUIPMENT Field Installed K957 1 HEAVY DUTY TWO WHEEL TRAILER FOR SMALL WELDERS For road off road and in plant and yard towing For highway use consult applicable federal state and local laws regarding requirements for brakes lights fenders etc Order K957 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 2 Fender amp Light Kit K965 1 Cable Storage Rack K889 2 amp 3 Two Wheel Undercarriage For moving by hand Overall Width 29 in 74m Both have pneu matic tires Puncture proof tires included with K889 3 K1631 1 Puncture Proof Wheel Kit For converting K889 2 or K933 1 to puncture proof pneumatic tires K893 1 Caster for Undercarriage Mounts to the front of the K889 2 or 3 to allow easy movement on smooth surfaces Includes 6 diameter hard rubber wheel and convenient toe on toe off locking brake K933 1 Four Wheel Undercarriage For Hand Moving Rear pneumatic tires front molded wheels K934 1 Cylinder Brackets For use with K933 1 For transporting one welding gas cylinder K1737 1 FOUR WHEEL ALL TERRAIN UNDERCAR RIAGE For moving by hand at construction sites Heavy duty puncture resistant pneumatic tires K1770 1 UNDERCARRIAGE FACTORY For mov ing by hand on a smooth sur
120. us situations Refer to Safety in Welding and Cutting ANSI Standard 749 1 and the operating information for the equipment being used 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 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 cha
121. ut autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 EAGLE 10 000 LINCOLN B MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Page Safety RP EE a eee i iv installati n s 2 212254 oat alee dt ee di Section Operation _ _
122. valve and attach the flex ible drain tube supplied with the machine Push in and twist the drain valve counterclockwise Pull the valve out and drain the oil into a suitable container Close the drain valve by pushing and twisting clockwise Replace the yellow cap Refill to the upper limit mark on the dipstick with the recommended oil Tighten the oil filler cap securely ENGINE OIL REFILL CAPACITIES Without oil filter replacement 1 7qt 1 6 liter Kohler With oil filter replacement 2 0qt 1 9 liter Kohler EAGLE 10 000 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o ao Bg E E tc Return to Section TOC Return to Master TOC 5 2 sd MAINTENANCE Use 4 stroke motor oil that meets or exceeds the requirements for API service classification SG or SH Always check the API SERVICE label on the oil con tainer to be sure it includes the letters SG or SH 10W 30 is recommended for general all temper ature use 5 to 104 20 C to 40 C See Engine Owner s Manual for more specific infor mation on oil viscosity recommendations Wash your hands with soap and water after handling used oil Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service station or re
123. ve leads from two 1 4 connectors metal screws from the case top 3 Remove the rubber gasket cover seal from the lift bail 4 Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Return to Section TOC Return to Master TOC 5 Remove the case top then reinstall the fuel cap 6 With the 5 16 nut driver remove the 5 screws holding the right case side 7 Remove the right case side by lifting up and out Return to Section TOC Return to Master TOC EAGLE 10 000 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O ci a o 5 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT continued CAUTION Be sure to follow the recommended static free methods for handling printed circuit boards Failure to do so can result in permanent damage to the equipment 12 With a Phillips head screw driver remove four self tapping screws holding the printed circuit board 13 Replace the old printed circuit board with a new one 14 Connect the 12 pin molex plug 15 Connect the 4 pin molex plug 16 Connect two 1 4 Q C wires to P C Board 17 Replace any cable ties that were cut during the removal procedure 18 Replace 4 self tapping screws previously removed 19 Reinstall the case si

Lincoln Electric EAGLE SVM192-A User's Manual

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