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Lincoln Electric SVM192-A manual

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Table of contents for the manual

  • Page 1

    SVM192-A April, 2009 Safety Depends on Y ou 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 INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRECAUTIO[...]

  • Page 2

    EAGLE™ 10,000 SAFETY i i FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. _____________________[...]

  • Page 3

    SAFETY ii ii EAGLE™ 10,000 FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrodes which req[...]

  • Page 4

    EAGLE™ 10,000 SAFETY iii iii Jan ‘09 FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recommendations. 8.c. Ground the equipment in acc[...]

  • Page 5

    SAFETY iv iv EAGLE™ 10,000 Mar ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse él[...]

  • Page 6

    - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - I I EAGLE™ 10,000 Page S a f e t y ........................................................................... i - i v I n s t a l l a t i o n .................................................................. S e c t i o nA O p e r a t i o n ..........................................................[...]

  • Page 7

    T ABLE OF CONTENTS - INST ALLA TION SECTION A-1 A-1 EAGLE™ 10,000 I n s t a l l a t i o n ............................................................................. A - 1 T e c h n i c a l S p e c i f i c a t i o n s ................................................................ A - 2 S a f e t y P r e c a u t i o n s .......................[...]

  • Page 8

    INST ALLA TION A-2 A-2 EAGLE™ 10,000 TECHNICAL SPECIFICA TIONS - EAGLE 10,000 (K2343-1,K2343-2) INPUT - GASOLINE ENGINE RA TED OUTPUT @ 104°F (40°C)- WELDER HEIGHT WIDTH DEPTH WEIGHT 30.3 in. 19.1 in. 42.0 in. 502 lbs. (228kg) 770 mm 485 mm 1067 mm RA TED OUTPUT @ 104°F (40°C)- GENERA TOR Welding Output DC Constant Current 210A / 25V / 100% A[...]

  • Page 9

    INST ALLA TION A-3 A-3 EAGLE™ 10,000 SAFETY PRECAUTIONS 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.). T o prevent dangerous electric shock, other equ[...]

  • Page 10

    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. T ypical conditions of use, i.e., travel speed; rough- ness of surface on which the trailer will be operated; environmental conditions. 5. Conformance with federal, [...]

  • Page 11

    INST ALLA TION A-5 A-5 EAGLE™ 10,000 ANGLE OF OPERA TION 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 c[...]

  • Page 12

    INST ALLA TION A-6 A-6 EAGLE™ 10,000 EAGLE 10,000 Constant Current 210 Amps DC @ 25 V olts 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 appli[...]

  • Page 13

    INST ALLA TION A-7 A-7 EAGLE™ 10,000 120 V DUPLEX RECEPT ACLES 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 [...]

  • Page 14

    INST ALLA TION A-8 A-8 EAGLE™ 10,000 T ABLE l ELECTRICAL DEVICE USE WITH THE EAGLE 10,000. T ype Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker . Capacitive TV sets, radios, microwaves, V oltage spikes or high voltage appliances with electrical[...]

  • Page 15

    INST ALLA TION A-9 A-9 EAGLE™ 10,000 ST ANDBY POWER CONNECTIONS The EAGLE 10,000 is suitable for temporary , standby , or emergency 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. (Connections must be [...]

  • Page 16

    INST ALLA TION A-10 A-10 EAGLE™ 10,000 2 40 Volt 60 Hz. 3-Wire S ervice POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT L OAD N NEUTRAL BUS GROUND PREMISES D ISCONNECT AND SERVICE OVERCURRENT P ROTECTION GND N NOTE: No. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS. 240 VOLT GROUNDED CONDUCTOR 4 0 AM[...]

  • Page 17

    T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 EAGLE™ 10,000 O p e r a t i o n .............................................................................. B - 1 S a f e t y P r e c a u t i o n s .................................................................... B - 2 G e n e r a l D e s c r i p t i o n ......................................[...]

  • Page 18

    OPERA TION B-2 B-2 EAGLE™ 10,000 WELDER CONTROLS - FUNCTION AND OPERA TION 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 “ST ART” p[...]

  • Page 19

    OPERA TION B-3 B-3 EAGLE™ 10,000 RANGE SWITCH The “Range” switch is used to select one of three amperage ranges with generous overlap for Stick/TIG welding, or one Wire Feed welding range Never change the “RANGE” Switch setting while welding. This will damage the switch. --------------------------------------------------------------------[...]

  • Page 20

    OPERA TION B-4 B-4 EAGLE™ 10,000 ST ARTING/SHUTDOWN INSTRUCTIONS ST ARTING THE ENGINE Be sure all Pre-Operation Maintenance has been per- formed. Also, read the Engine Owner ’s Manual before starting for the first time. Remove all loads connected to the AC power recepta- cles. Use the choke control as follows: KOHLER ENGINE - Always pull the ch[...]

  • Page 21

    OPERA TION B-5 B-5 EAGLE™ 10,000 ARC GOUGING 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 in the following table: WELDING PROCESS For any electrodes the procedures should be kept with- in the rating of the ma[...]

  • Page 22

    OPERA TION B-6 B-6 EAGLE™ 10,000 Summary of Welding Processes CONTROL ELECTRODE CABLE IDLE WHEN NOT TO ST ART PROCESS USED MODE WELDING WELDING STICK No AUTO Hot T ouch electrode to work. Welding starts immediately and engine goes to high idle. WIRE FEED, LN-25 WITH No AUTO Cold Press gun trigger , LN-25 INTERNAL CONT ACTOR contactor closes. Weld[...]

  • Page 23

    T ABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 EAGLE™ 10,000 A c c e s s o r i e s............................................................................ C - 1 O p t i o n a l E q u i p m e n t ................................................................... C - 2 R e c o m m e n d e d E q u i p m e n t..................................[...]

  • Page 24

    ACCESSORIES C-2 C-2 EAGLE™ 10,000 OPTIONAL EQUIPMENT (Field Installed) K957-1 HEA VY DUTY , TWO WHEEL TRAILER FOR SMALL WELDERS - For road, of f-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 T railer K958-1 Ball Hitch K95[...]

  • Page 25

    ACCESSORIES C-3 C-3 EAGLE™ 10,000 RECOMMENDED EQUIPMENT STICK K704 Accessory Kit - For Stick Welding. Includes 35 ft (10.7m). • 2/0 A WG electrode cable, 30 ft. (9.1m) • 2/0 A WG 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).[...]

  • Page 26

    NOTES C-4 C-4 EAGLE™ 10,000 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 27

    T ABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 EAGLE™ 10,000 M a i n t e n a n c e ........................................................................... D - 1 S a f e t y P r e c a u t i o n s .................................................................... D - 2 R o u t i n e M a i n t e n a n c e ....................................[...]

  • Page 28

    MAINTENANCE D-2 D-2 EAGLE™ 10,000 Have qualified personnel do the maintenance work. T urn 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 [...]

  • Page 29

    MAINTENANCE D-3 D-3 EAGLE™ 10,000 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. SAE 10W-30 is recommended for general, all-temper- ature use, -5 F to 104 F (-20 C to 40 C). See Engine Owne[...]

  • Page 30

    MAINTENANCE D-4 D-4 EAGLE™ 10,000 ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this 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 ab[...]

  • Page 31

    MAINTENANCE D-5 D-5 EAGLE™ 10,000 FIGURE D.1 - MAJOR COMPONENT LOCA TIONS 4 4 1 1 3 3 5 5 2 2 1. CASEFRONT 2. OUTPUT RECTIFIER ASSEMBL Y 3. BASE/UNDERCARRIAGE ASSEMBL Y 4. ENGINE/ROTOR/ST A T OR ASSEMBL Y 5. CASE TOP & SIDES Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur[...]

  • Page 32

    NOTES D-6 D-6 EAGLE™ 10,000 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 33

    T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 EAGLE™ 10,000 T h e o r y o f O p e r a t i o n ..................................................................... E - 1 Battery , Starter , Engine, Excitation, Rotor , Stator , and Idler Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2 R o t o r F i e l d F e e d b [...]

  • Page 34

    THEOR Y OF OPERA TION E-2 E-2 EAGLE™ 10,000 NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion BA TTER Y , ST ARTER, ENGINE, ROT OR, ST A TOR, 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 [...]

  • Page 35

    THEOR Y OF OPERA TION E-3 E-3 EAGLE™ 10,000 ROT OR FIELD FEEDBACK AND AUXILIAR Y 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 controlle[...]

  • Page 36

    THEOR Y OF OPERA TION E-4 E-4 EAGLE™ 10,000 NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion WELD WINDING, REACT OR, 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 th[...]

  • Page 37

    T ABLE OF CONTENTS - TROUBLESHOOTING AND REP AIR F-1 F-1 EAGLE™ 10,000 T r o u b l e s h o o t i n g a n dR e p a i r .............................................................. F - 1 H o w t o U s eT r o u b l e s h o o t i n g G u i d e ....................................................... F - 2 P C B o a r dT r o u b l e s h o o t i n g P[...]

  • Page 38

    TROUBLESHOOTING AND REP AIR F-2 F-2 EAGLE™ 10,000 This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPT OM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible symptoms that the [...]

  • Page 39

    TROUBLESHOOTING AND REP AIR F-3 F-3 EAGLE™ 10,000 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure: 1. Determine to the best of your technical ability that th[...]

  • Page 40

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

  • Page 41

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

  • Page 42

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

  • Page 43

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

  • Page 44

    ENGINE PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

  • Page 45

    ENGINE PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

  • Page 46

    Observe Safety Guidelines detailed in the beginning of this manual. 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. CAUTION TROUBLESHOOTING AND REP AIR F-10[...]

  • Page 47

    WELDING PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 trouble[...]

  • Page 48

    NOTES F-12 F-12 EAGLE™ 10,000 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 49

    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 thr[...]

  • Page 50

    Slip Rings Brushes Lead 219 + - Lead 200A FIGURE F .1 – LOCA TION OF LEAD 200A AND 219 FOR ROT OR VOL T AGE TEST ROT OR VOL T AGE TEST (continued) TEST PROCEDURE 1. With the 5/16” nut driver , remove the 6 sheet metal screws from the case top. 2. Remove the rubber gasket (cover seal) from the lift bail. 3. Remove the fuel cap. The rubber gasket[...]

  • Page 51

    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 thr[...]

  • Page 52

    Lead 219 Lead 200A + - FIGURE F .2 – LOCA TION OF ROTOR SLIP RINGS ROT OR RESIST ANCE TEST (continued) TEST PROCEDURE 1. With the 5/16” nut driver , remove the 6 sheet metal screws from the case top. 2. Remove the rubber gasket (cover seal) from the lift bail. 3. Remove the fuel cap. The rubber gasket for the fill tube will come off with the ca[...]

  • Page 53

    ROT OR RESIST ANCE TEST (continued) 13. Measure the resistance to ground. A. 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. C. Check the resistance. It should read very high, at least 0.5 megohm (500,000 ohms). If[...]

  • Page 54

    NOTES F-18 F-18 EAGLE™ 10,000 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 55

    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 thr[...]

  • Page 56

    Lead #3 Lead #5 1 15V Receptacle Machine Case Front FIGURE F .3 – LOCA TION OF LEADS #3 AND #5 AUXILIAR Y AND FIELD WINDING TEST (continued) TEST PROCEDURE T o test the 1 15 V AC 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[...]

  • Page 57

    AUXILIAR Y AND FIELD WINDING TEST (continued) T o 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. 2. Connect the volt/ohmmeter probes to leads #7 and #9 where they connect to the Field Idle Control P .C. Board. 3. Start the engi[...]

  • Page 58

    NOTES F-22 F-22 EAGLE™ 10,000 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 59

    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 thr[...]

  • Page 60

    (-) (+) (+) ( +) (-) ( -) OUTPUT RECTIFIER ENGINE FIGURE F .4 – LOCA TION OF OUTPUT RECTIFIER LEADS OUTPUT RECTIFIER BRIDGE TEST (continued) TEST PROCEDURE 1. Remove the spark plug wires to prevent acci- dental engine kickback or starting. 2. With the 5/16” nut driver , remove the 6 sheet metal screws from the case top. 3. Remove the rubber gas[...]

  • Page 61

    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 thr[...]

  • Page 62

    V oltage Regulator Ground Lead (Green) Engine AC Lead DC Lead AC Lead FIGURE F .5 – LOCA TION OF VOL T AGE REGULA TOR CHARGING CIRCUIT TEST (continued) TEST PROCEDURE 1. Start the engine and run it at high idle (3650 RPM). 2. Set the voltmeter for AC volts and place one meter probe on each of the two outside leads that attach to the engine voltag[...]

  • Page 63

    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 thr[...]

  • Page 64

    Blower Paddle FIGURE F .6 – BLOWER P ADDLE MARKED FOR STROBE-T ACH METHOD ENGINE THROTTLE ADJUSTMENT TEST (continued) TEST PROCEDURE This test can be conducted by any one of four methods. Strobe-tach Method: 1. With the 5/16” nut driver , remove the 6 sheet metal screws from the case top. 2. Remove the rubber gasket (cover seal) from the lift b[...]

  • Page 65

    ENGINE THROTTLE ADJUSTMENT TEST (continued) 1 1. 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. T urn the nut clockwise to increase HIGH IDLE speed. Adjust the speed until the tach reads betw[...]

  • Page 66

    ENGINE THROTTLE ADJUSTMENT TEST (continued) Oscilloscope Method: 1. Connect the oscilloscope to the 1 15 V AC receptacle, according to the 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- MAL OPEN CIRCUIT VOL [...]

  • Page 67

    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 milliseconds in time. Note: Scope probes connected at machine 1 15V AC receptacle. SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep[...]

  • Page 68

    TROUBLESHOOTING AND REP AIR F-32 F-32 EAGLE™ 10,000 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 machi[...]

  • Page 69

    TROUBLESHOOTING AND REP AIR F-33 F-33 EAGLE™ 10,000 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- se[...]

  • Page 70

    TROUBLESHOOTING AND REP AIR F-34 F-34 EAGLE™ 10,000 This is the typical DC output voltage generated from a properly operating machine. 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. SCOPE SETTINGS V olts/Div .....[...]

  • Page 71

    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 thr[...]

  • Page 72

    BRUSH REMOV AL AND REPLACEMENT (continued) PROCEDURE 1. Remove the spark plug wires. 2. With a 5/16” nut driver , remove the 6 sheet 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 with come off with the case top. 5. Remove the case top, then [...]

  • Page 73

    BRUSH REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING AND REP AIR F-37 F-37 EAGLE™ 10,000 SLIP RINGS A slight amount of darkening and wear of the slip rings and brushes is normal. Brushes should be inspected when a general overhaul is necessary . If brushes are to be replaced, clean slip rings with a fine emery paper . Do not attempt to poli[...]

  • Page 74

    NOTES F-38 F-38 EAGLE™ 10,000 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 75

    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 thr[...]

  • Page 76

    12 Pin Plug 4 Pin Plug 4 Self T apping Screws (at corners) 1/4" Q.C. T abs FIGURE F .10 - PRINTED CIRCUIT BOARD LOCA TION PRINTED CIRCUIT BOARD REMOV AL AND REPLACEMENT (continued) PROCEDURE Before starting the following procedure, refer to the topic “ PC Board Troubleshooting Procedures ” at the beginning of this section. 1. Remove the en[...]

  • Page 77

    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[...]

  • Page 78

    NOTES F-42 F-42 EAGLE™ 10,000 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 79

    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 thr[...]

  • Page 80

    (-) (+) ( +) (+) ( -) (-) ENGINE NO NUT TO POLARITY SWITCH #8 L1 TO CHOKE (4) 7/16" MOUNTING SCREWS W1 TO S2 TO S2 TO S1 254 (3) 1/2" MOUNTING SCREWS FIGURE F .1 1 - OUTPUT RECTIFIER CONNECTIONS OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) PROCEDURE 1. Remove the engine spark plug wires. 2. With a 5/16” nut driver , remo[...]

  • Page 81

    OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) 12. With the 1/2” wrench remove the three mount- 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[...]

  • Page 82

    NOTES F-46 F-46 EAGLE™ 10,000 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 83

    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 thr[...]

  • Page 84

    FIGURE F .12 – COMPONENT LOCA TIONS, ENGINE/ROT OR REMOV AL ENGINE/ROT OR REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING AND REP AIR F-48 F-48 EAGLE™ 10,000 3 1 9 2 4 1 8 7 6 5 1. ST A TOR COWLING COVER 2. BLOWER F AN 3. IDLE LINKAGE 4. BRUSH HOLDER BRACKET 5. ENGINE LIFT BAILS 6. ST A TOR/ENGINE MOUNTING BOL TS 7. ROTOR 8. ROTOR SHAFT BE[...]

  • Page 85

    ENGINE AND ROTOR REMOV AL 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. 4. Remove the rubber gasket (cover seal) from the lift bail. 5. Remove the fuel cap. The rubber gasket for the fill tube will come off with the[...]

  • Page 86

    FIGURE F .13 - ENGINE AND ROTOR REMOVED FROM ST A TOR ENGINE/ROT OR REMOV AL AND REPLACEMENT (continued) ROTOR REMOV AL PROCEDURE 1. T o remove the rotor , double check that the engine spark plug wires are disconnected. Y ou will be turning the rotor during this proce- dure, and this could accidentally cause engine kickback. 2. With an impact wrenc[...]

  • Page 87

    ENGINE/ROT OR REMOV AL AND REPLACEMENT (KIT S20788) (continued) REASSEMBL Y PROCEDURE NOTE: Lincoln Electric recommends that a new bearing (Lincoln part #M9300-85) be installed when you replace the rotor and blower assembly . 1. Clean the tapered engine crankshaft. Slide the rotor onto the shaft. 2. Insert the rotor thru-bolt, and with the torque w[...]

  • Page 88

    TROUBLESHOOTING AND REP AIR F-52 F-52 EAGLE™ 10,000 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could af fect the machine’s electrical characteristics. OR • If you repair or replace any electrical components. ENGINE OUTPUT Mode No Load RPM Load RP[...]

  • Page 89

    T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 EAGLE™ 10,000 E l e c t r i c a l D i a g r a m s ..................................................................... G - 1 W i r i n g D i a g r a m -C o d e 1 1 0 9 6 - ( M 2 0 3 1 7 ) ................................................. G - 2 W i r i n g D i a g r a m - C o d e1 1 3 9 7 - ( M 2 1 2 7[...]

  • Page 90

    ELECTRICAL DIAGRAMS G-2 EAGLE™ 10,000 WIRING DIAGRAM - CODE 1 1096 (M20317) ST ART ER CR1 ST ART ER SOLENOI D 1 2 VO LT IDLER SOLENOID BA TT ERY AC AC B+ SWI TCH REG ULA T OR FL Y WHEEL A LT ER NATOR B- HO UR ME T ER 5E 5D 2 24 ENGINE CO MPO NE NTS 22 4A 1 2 3 CO N NE CTOR PIN N UMBE RS: 7 6 12 1 2 3 4 J1 N. A. B J2 SOLENOID FUEL SH UTOFF OI L PR[...]

  • Page 91

    ELECTRICAL DIAGRAMS G-3 EAGLE™ 10,000 WIRING DIAGRAM - CODE 1 1397 - (M21271) ST ART ER CR1 ST ART ER SOLENOI D 1 2 VO LT IDLER SOLENOID BA TT ERY AC AC B+ SWI TCH REG ULA T OR FL Y WHEEL A LT ER NATOR B- HO UR ME T ER 5E 5D 224 ENGINE CO MPO NE NTS 22 4A 1 2 3 CO N NE CTOR PIN N UMBE RS: 7 6 12 1 2 3 4 J1 N. A. B J2 SOLENOID FUEL SH UTOFF OI L P[...]

  • Page 92

    ELECTRICAL DIAGRAMS G-4 EAGLE™ 10,000 SCHEMA TIC - COMPLETE MACHINE - CODE 1 1096 (L12259) L12259 A W2 D1 - B RI DG E R E CTIFIE R 7 21 9 20 0A W 1 L1 CH OKE 3 5 6 GN D E 12 0 V AC 24 0 V AC 12 0 V AC ST ATO R A UX ILI A RY P OW E R W INDI NG S 9 TWO P OLE 360 0 R PM ALTE RN ATO R R1 OUT P UT CO NTROL 10K 77A (J1 -4) 76A (J1 -8) 75A (J1 - 10 ) 26[...]

  • Page 93

    ELECTRICAL DIAGRAMS G-5 EAGLE™ 10,000 SCHEMA TIC - COMPLETE MACHINE - CODE 1 1397 (L13104) L13104 A W2 D1 - B RI DG E R E CTIFIE R 7 21 9 20 0A W1 L1 CH OKE 3 5 6 GN D E 12 0 V AC 24 0 V AC 12 0 V AC ST ATO R A UX ILI A RY P OW E R W INDI NG S 9 TWO P OLE 360 0 R PM ALTE RN ATO R R1 OUT P UT CO NTROL 10K 77A (J1 -1) 76A (J1 -8) 75A (J1 -7) 260 (J[...]

  • Page 94

    ELECTRICAL DIAGRAMS G-6 EAGLE™ 10,000 SCHEMA TIC - IDLER/FIELD CONTROL P .C. BOARD (L12197) G-6 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Maste[...]