SVM192-A
April, 2009
EAGLE™ 10,000
For use with machine code number: 11096, 11397
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.
SERVICE MANUAL
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
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SAFETY
ELECTRIC SHOCK can kill.
ARC RAYS can burn.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.a. Use a 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 Z87. I standards.
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.
4.b. Use suitable clothing made from durable flame-resistant
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.
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
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
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.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
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 limits.
3.g. Never dip the electrode in water for cooling.
3.h. 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.
5.c. 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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.d. 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
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.
5.f. Also see item 1.b.
Jan ‘09
EAGLE™ 10,000
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SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can cause fire or
explosion.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
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.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
6.c. 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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. 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).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. 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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.g. 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 chains, crane cables or other alternate circuits. This can
create fire hazards or overheat lifting chains or cables until
they fail.
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 accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.h. Also see item 1.c.
6.I. 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.
6.j. Do not use a welding power source for pipe thawing.
Jan ‘09
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SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
PRÉCAUTIONS DE SÛRETÉ
prévenir tout risque d’incendie dû aux étincelles.
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:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés 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
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayon-
nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant
à
proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Mar ‘93
EAGLE™ 10,000
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-481 Series
EAGLE™ 10,000
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A-1
TABLE OF CONTENTS - INSTALLATION SECTION
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Pre-Operation Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Location/Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Connection of Wire Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Additional Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Welder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
120V Duplex Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Electrical Devices used w/Eagle 10,000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
Auxiliary Power While Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
Connection of EAGLE 10,000 to Premises Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10
EAGLE™ 10,000
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INSTALLATION
TECHNICAL SPECIFICATIONS - EAGLE 10,000 (K2343-1,K2343-2)
INPUT - GASOLINE ENGINE
Make/Model
Description
Operating
Displacement
cu. in.
Capacities
Horsepower
Starting
System
Speed (RPM)
(cu.cm.)
K2341-1
Kohler
2 cylinder
4 Cycle
Air-Cooled
Gasoline
Engine.
12VDC
Battery
Electric Start
Group 58
Battery
High Idle 3700
CH20S
Fuel:
23 HP@
41(724)
Kohler
9 Gal (34 L)
Lubricating Oil:
2.0 Qts. (1.9 L)
Aluminum Alloy 3600 RPM
with Cast Iron
Liners,
Full Load 3500
Low Idle 2200
(435 cold
Cranking
Amps)
Honda
K2343-2
Kohler
Electronic Start
CH23HS
RATED OUTPUT @ 104°F (40°C)- WELDER
Welding Output
DC Constant Current 210A / 25V / 100%
RATED OUTPUT @ 104°F (40°C)- GENERATOR
1
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
HEIGHT
WIDTH
DEPTH
WEIGHT
502 lbs. (228kg)
30.3 in.
19.1 in.
42.0 in.
770 mm
485 mm
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.
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INSTALLATION
SAFETY PRECAUTIONS
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.
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.
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’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.
• Insulate yourself from work and
ground
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
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------
MOVING PARTS can injure.
marked with the symbol
the welder.
is provided on the front of
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
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.
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.).
CAUTION
An incorrect arrester may lead to damage to the
engine or adversely affect performance.
------------------------------------------------------------------------
TOWING
WARNING
The recommended trailer for use with this equipment
(1)
for road, in-plant and yard towing by a vehicle is
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.
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:
Do not ground the machine to a pipe that carries
explosive or combustible material.
------------------------------------------------------------------------
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.
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A-4
INSTALLATION
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.
OIL
LUBRICATION SYSTEM CAPACITY
(INCLUDING FILTER)
Kohler CH23S - 2.0 Quarts (1.9 Liters)
4. Typical conditions of use, i.e., travel speed; rough-
ness of surface on which the trailer will be operated;
environmental conditions.
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 is tightened securely. Refer to the
engine Owner’s Manual for specific oil recommenda-
tions.
(1)
5. Conformance with federal, state and local laws
(1) Consult applicable federal, state and local laws regarding specif-
ic requirements for use on public highways.
WARNING
CAUTION
VEHICLE MOUNTING
BATTERY CONNECTIONS
Improperly mounted concentrated loads may cause unstable
vehicle handling and tires or other components to fail.
• Only transport this Equipment on serviceable 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.
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.
CAUTION
READ the engine operating and maintenance
instructions supplied with this machine.
WELDING OUTPUT CABLES
WARNING
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.
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away from
tank.
• Do not leave unattended while fueling.
• Wipe up spilled fuel and allow fumes
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.
GASOLINE
to clear before starting engine.
can cause fire
• Do not overfill tank, fuel expansion
or explosion.
may cause overflow.
--------------------------------------------------------------------------------
FUEL (GASOLINE FUEL ONLY)
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Fil the fuel tank with clean, fresh, lead-free gasoline. Observe fuel
gauge while filling to prevent overfilling.
225 Amps
100% Duty Cycle
WARNING
0-100 Ft.
1 AWG
(0-328 m)
•
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.
100-200 Ft.
(328-656 m)
1 AWG
200-250 Ft.
(656-820 m)
1/0 AWG
-----------------------------------------------------------------------
EAGLE™ 10,000
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A-5
A-5
INSTALLATION
ANGLE OF OPERATION
CAUTION
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.
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.
When operating at an angle, the effective fuel capacity
will be slightly less than the specified 9 gallons.
Muffler Relocation
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
• 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.)
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.
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 heated 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.
• Do not lift machine if lift bale
FALLING
EQUIPMENT can • Do not operate machine while
cause injury. suspended from lift bale.
is damaged.
------------------------------------------------------------------------
STACKING
ADDITIONAL SAFETY PRECAUTIONS
HIGH ALTITUDE OPERATION
EAGLE 10,000 machines cannot be stacked.
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.
EAGLE™ 10,000
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A-6
A-6
INSTALLATION
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.
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
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.
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.
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
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.
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.
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.
a. Shut the welder off.
b. For electrode 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 "+" terminal of
the welder.
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.
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.
d. Set the “RANGE” switch to a suitable position.
e. Place the Engine switch in the “Auto Idle” position.
f. Set the Welding Mode on the LN-15 to the “CC” mode.
g. 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.
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
Note: LN-15 Control Cable model will not work with
the EAGLE 10,000.
80 Volts RMS.
CONNECTION OF THE LN-25 TO THE EAGLE 10,000
a. Shut the welder off.
• Duty Cycle is the percentage of time the load is
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%.
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.
EAGLE 10,000
c. Position the “RANGE” switch to a suitable position.
Constant Current
210 Amps DC @ 25 Volts
EAGLE™ 10,000
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A-7
A-7
INSTALLATION
GND
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 I for more infor-
mation.
120 V
240 V
120 V*
CAUTION
*Current Sensing for Automatic Idle.
(Receptacle viewed from front of Machine)
Do not connect any plugs that connect to the
power receptacles in parallel.
------------------------------------------------------------------------
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.
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.
The current rating of any plug used with the system
must be at least equal to the current load through the
associated receptacle.
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.
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.)
Voltage
Volts
120
120
240
Maximum Allowable Cord Length in ft. (m) for Conductor Size
12 AWG 10 AWG 8 AWG 6 AWG
Current
(Amps)
15
Load
(Watts)
1800
2400
3600
4800
9000
14 AWG
4 AWG
30
(9)
40
(12)
(9)
75
(23)
(15)
(46)
(30)
(15)
125
(38)
(27)
(69)
(53)
(27)
175
(53)
(42)
(107)
(84)
(46)
300
(91)
(69)
20
15
20
38
30
75
60
50
150
100
50
88
225
175
90
138
350
275
150
225
600
450
225
60
(18)
(23)
(18)
(183)
(137)
(69)
240
240
Conductor size is based on maximum 2.0% voltage drop.
EAGLE™ 10,000
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A-8
A-8
INSTALLATION
TABLE l
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, high 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
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A-9
A-9
INSTALLATION
AUXILIARY POWER WHILE WELDING
-
1. Install a double pole, double throw switch between
the power company meter and the premises
disconnect.
Simultaneous welding and power loads are permitted
by following Table II. 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.
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.
TABLE II
SIMULTANEOUS WELDING AND POWER
Output Selector
Setting
Permissible Power
Watts (Unity Power
Factor)
Permissible Auxiliary
Current in Amperes
@ 120V *-or- @ 240V
Max. Stick or Wire
Feed Setting
None
3450
0
0
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.)
145 Stick Setting
90 Stick Setting
NO WELDING
32
16
6000
9000
50**
76**
25
38
4. Plug this cable into the 50 amp 120/240V
receptacle on the EAGLE 10,000 case front.
* 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 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.
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.)
------------------------------------------------------------------------
EAGLE™ 10,000
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A-10
A-10
INSTALLATION
Figure A.1
CONNECTION OF EAGLE 10,000 TO PREMISES WIRING
240 VOLT
GROUNDED CONDUCTOR
POWER
240 Volt
60 Hz.
3-Wire
Service
120 VOLT
COMPANY
120 VOLT
METER
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GROUND
40 AMP
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
240 VOLT
GND
N
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
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B-1
B-1
TABLE OF CONTENTS - OPERATION SECTION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Welder Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Controls Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Break-in Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Welding Process (Stick/Tig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Summary of Welding Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
EAGLE™ 10,000
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B-2
B-2
OPERATION
SAFETY PRECAUTIONS
WELDER CONTROLS - FUNCTION AND
OPERATION
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
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.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
When placed in the “OFF”
position, the ignition
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
circuit is de-energized to shut down the engine.
When held in the “START”
starter motor is energized.
position, the engine
• Always wear dry insulating gloves.
When in “HIGH IDLE” (
run continuously at high idle.
) position, the engine will
• Always operate the welder with the hinged door
closed and the side panels in place.
When in “AUTO IDLE” (
engine will run continuously and the idler operates as
follows:
/
) position, the
• 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.
•
Welding
------------------------------------------------------------------------
When the electrode touches the work, the welding
arc is initiated and the engine accelerates to full
speed.
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.
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
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B-3
B-3
OPERATION
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
Process
Range Setting
Current Range
STICK/TIG
(constant current)
(3 range settings)
90 Max.
145 Max.
210 Max.
50 to 90 Amps
70 to 145 Amps
120 to 210 Amps
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 or CH23S
Low Idle - No Load
2200 RPM
High Idle - No Load
3700 RPM
DC CC Weld Output
210 Amps @ 25 Volts
Auxiliary Power
9000 Watts
.39 Gallons/Hour
(1.49 Liters/Hour)
.74 Gallons/Hour
(2.79 Liters/Hour)
1.29 Gallons/Hour
(4.87 Liters/Hour)
1.40 Gallons/Hour)
(5.31 Liters/Hour)
EAGLE™ 10,000
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B-4
B-4
OPERATION
STOPPING THE ENGINE
STARTING/SHUTDOWN INSTRUCTIONS
STARTING 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.
WARNING
• Do not touch electrically live parts
of electrode with skin or wet
clothing.
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.
• Keep flammable material away.
BREAK-IN PERIOD
• Insulate yourself from work and
ground. Wear eye, ear, and body
protection.
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).
• Keep your head out of the fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
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.
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:
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 ENGINE - Always pull the choke control out
when starting the engine; cold, warm or hot.
Turn the engine switch to the “start”
position and
KOHLER
CH20S or CH23S
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),
5 HRS
and turn the switch to the Auto Idle(
/
)
position. 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
Refer to the Engine Owner’s Manual or Maintenance
section of this manual for more information.
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.
EAGLE™ 10,000
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B-5
B-5
OPERATION
WELDING PROCESS
WIRE FEED WELDING PROCESSES
For any electrodes the procedures should be kept with-
in the rating of the machine. For electrode information
see the appropriate Lincoln publication.
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:
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.
Diameter
(in.)
Wire Speed
Range In./Min.
Approximate
Current Range
.035
.045
.068
80 - 110
70 - 130
40 - 90
75A to 120A
120A to 170A
125A to 210A
The EAGLE 10,000 is recommended for limited “MIG”
welding (GMAW - gas metal arc welding). The recom-
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% CO2). The welding ranges
that can be used with the EAGLE 10,000 are shown in
the following table:
RANGE SETTING
TYPICAL
ELECTRODE SIZE
CURRENT RANGE
90 MAX.
145 MAX.
210 MAX.
3/32
1/8
50 TO 90 AMPS
70 TO 145 AMPS
120 TO 210 AMPS
Diameter
(in.)
Wire Speed
Range In./Min.
Approximate
Current Range
5/32
.030
.035
75 - 300
100 - 250
50A to 130A
80A to 175A
TIG (CONSTANT CURRENT) WELDING
ARC GOUGING
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 TIG Module is not
functional. After flow time is adjustable from 0 to 55
seconds. A K814 Arc Start Switch is required.
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:
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.
Carbon Diameter
CURRENT RANGE (DC+)
1/8
5/32
60 - 90 Amps
90 - 250 Amps
EAGLE™ 10,000
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B-6
B-6
OPERATION
Summary of Welding Processes
CONTROL
ELECTRODE
CABLE
USED
IDLE
MODE
WHEN NOT
WELDING
TO START
WELDING
PROCESS
STICK
No
No
AUTO
Hot
Touch electrode to work.
Welding starts immediately
and engine goes to high
idle.
WIRE FEED, LN-25 WITH
INTERNAL CONTACTOR
AUTO
Cold
Press gun trigger, LN-25
contactor closes. Welding
starts immediately and
engine goes to high idle.
NOTE: Output Control
must be set above “3”
TIG, TIG MODULE WITH
WITH CONTACTOR KIT
CONTROL CABLE, & ARC
START SWITCH
Yes
No
High
High
Cold
Cold
Press Arc Start Switch
contactor closes,
welding starts immediately.
WIRE FEED, LN-15
ACROSS the ARC
(has internal contactor)
Press gun trigger.
LN-15 contactor closes,
Welding starts immediately
Note: Output Control must
be set above “3”.
(1)
(2)
TYPICAL CURRENT RANGES
FOR TUNGSTEN ELECTRODES
Tungsten Electrode
Diameter in. (mm)
DCEN (-)
DCEP (+)
Approximate Argon Gas Flow
Flow Rate C.F.H. ( l /min.)
TIG TORCH
Nozzle Size (4), (5)
1%, 2% Thoriated
Tungsten
1%, 2% Thoriated
Tungsten
Aluminum
Stainless Steel
.010
0.020
0.040
(.25)
(.50)
(1.0)
2-15
5-20
15-80
(3)
(3)
(3)
3-8
5-10
5-10
(2-4)
(3-5)
(3-5)
3-8
5-10
5-10
(2-4)
(3-5)
(3-5)
#4, #5, #6
1/16
(1.6)
70-150
10-20
5-10
(3-5)
9-13
(4-6)
#5, #6
3/32
1/8
(2.4)
(3.2)
150-250
250-400
15-30
25-40
13-17
15-23
(6-8)
(7-11)
11-15
11-15
(5-7)
(5-7)
#6, #7, #8
5/32
3/16
1/4
(4.0)
(4.8)
(6.4)
400-500
500-750
750-1000
40-55
55-80
80-125
21-25
23-27
28-32
(10-12)
(11-13)
(13-15)
13-17
18-22
23-27
(6-8)
(8-10)
(11-13)
#8, #10
(1) 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
2% Thoriated
EWTh-1
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.
# 5 = 5/16 in.
# 6 = 3/8 in.
# 7 = 7/16 in.
# 8 = _ in.
(6 mm)
(8 mm)
(10 mm)
(11 mm)
(12.5 mm)
(16 mm)
#10 = 5/8 in.
(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
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C-1
C-1
TABLE OF CONTENTS - ACCESSORIES SECTION
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Wirefeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3
Plasma Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3
EAGLE™ 10,000
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C-2
C-2
ACCESSORIES
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.
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.)
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.
Order K957-1 Trailer
K894-1 Spark Arrester Kit - Includes a heavy gauge
steel, approved spark arrester and clamp for easy
mounting to muffler exhaust pipe.
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
K959-2 Fender & Light Kit
K965-1 Cable Storage Rack
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.
K889-2 & -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.
K1816-1 FULL KVA ADAPTER KIT - Plugs into the
120/240V NEMA 14-50R receptacle on the case front
(which accepts 4-prong plugs) and converts it to a
NEMA 6-50R receptacle, (which accepts 3-prong
plugs.)
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.
T12153-9 Full-KVA Power Plug - One dual voltage plug
rated at 120/240V, 50 amps.
K934-1 Cylinder Brackets - For use with K933-1. For
transporting one welding gas cylinder.
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
K1737-1 FOUR WHEEL ALL-TERRAIN UNDERCAR-
RIAGE - For moving by hand at construction sites.
Heavy duty puncture resistant pneumatic tires.
Requires K938-1 Contactor Kit, K936-4 Control Cable,
and K814 Arc Start Switch.
K1770-1 UNDERCARRIAGE (FACTORY) - For mov-
ing by hand on a smooth surface. 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.
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.
K1745-1 GAS CYLINDER HOLDER
Holds Welding Gas Cylinder for use on K1770-1
Undercarriage. One or two may be installed on an
undercarriage.
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).
K1788-1 ROLL CAGE - Gives added damage protec-
tion.
Attaches to K1737-1, K1770-1, and K957-1.
K844-1 Water Valve Kit - For use with water cooled
TIG torch, Installs inside of TIG Module.
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.
K939-1 Docking Kit - For Mounting the K930-2 TIG
Module on top of the Eagle 10,000.
EAGLE™ 10,000
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C-3
C-3
ACCESSORIES
PLASMA CUTTING:
RECOMMENDED EQUIPMENT
K1580-1- Pro-Cut 55 (Requires full KVA Adapter
STICK
K1816-1).
K704 Accessory 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 & 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
EAGLE™ 10,000
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C-4
C-4
NOTES
EAGLE™ 10,000
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D-1
D-1
TABLE OF CONTENTS - MAINTENANCE SECTION
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Change the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Hardware & Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Major Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
EAGLE™ 10,000
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D-2
D-2
MAINTENANCE
SAFETY PRECAUTIONS
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.
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.
• OIL - Maintenance schedule for changing the oil and
oil filter after break-in :
Kohler
CH20S or CH23S
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.
Oil
100 Hrs.
200 Hrs.
Oil Filter
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.
• Do not touch electrically live parts
or electrode with skin or wet
clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
NOTE: Engine life will be reduced if the oil and oil fil-
ter are not changed according to the manufac-
turer’s recommendation.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas
or vent exhaust outside.
ENGINE OIL CHANGE
Drain the oil while the engine is warm to assure rapid
and complete draining.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Remove the oil filler cap and dipstick. Remove the
yellow cap from the oil drain 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 in and twisting
clockwise. Replace the yellow cap.
• 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.
------------------------------------------------------------
• Refill to the upper limit mark on the dipstick with the
recommended oil. Tighten the oil filler cap securely.
ual and the engine instruction manual before working
on this machine.
ENGINE OIL REFILL CAPACITIES
Without oil filter replacement:
• 1.7qt. (1.6 liter)-Kohler
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.
With oil filter replacement:
• 2.0qt. (1.9 liter)-Kohler
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.
EAGLE™ 10,000
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D-3
D-3
AIR CLEANER AND OTHER MAINTENANCE
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.
•
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.
SAE 10W-30 is recommended for general, all-temper-
ature use, -5 F to 104 F (-20 C to 40 C).
See Engine Owner’s Manual for more specific infor-
mation on oil viscosity recommendations.
•
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.
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
recycling center for reclamation.
•
•
Blow out the machine with low pressure air peri-
odically. In particularly dirty locations, this may be
required once a week.
Do not throw it in the trash, pour it on the ground or
down a drain.
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.
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.
EAGLE™ 10,000
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D-4
D-4
MAINTENANCE
ENGINE ADJUSTMENTS
WARNING
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes away from battery.
WARNING
To prevent EXPLOSION when:
• INSTALLING A NEW BATTERY - disconnect negative
cable from old battery first and connect to new battery
last.
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 above
maximum.
• CONNECTING A BATTERY CHARGER - Remove bat-
tery from welder by disconnecting negative cable first,
then positive cable and battery clamp. When rein-
stalling, connect negative cable last. Keep well venti-
lated.
• USING A BOOSTER - connect positive lead to bat-
tery first then connect negative lead to engine foot.
------------------------------------------------------------------------
Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.
BATTERY ACID CAN BURN EYES AND SKIN.
• Wear gloves and eye protection and be careful when
working near battery. Follow instructions printed on
battery.
BATTERY
SLIP RINGS
1. When replacing, jumping, or otherwise connecting
the battery to the battery cables, the proper
polarity must be observed. Failure to observe
the proper polarity could result in damage to the
charging circuit. The positive (+) battery cable
has a red terminal cover.
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.
2. If the battery requires charging from an external
charger, disconnect the negative battery cable
first and then the positive battery cable before
attaching the charger leads. Failure to do so
can result in damage to the internal charger
components. When reconnecting the cables,
connect the positive cable first and the negative
cable last.
CAUTION
Do not attempt to polish slip rings while engine is
running.
------------------------------------------------------------------------
HARDWARE
Both English and Metric fasteners are used in this
welder.
ENGINE MAINTENANCE PARTS
KOHLER C23S
KOHLER 12 050 01
Oil Filter
FRAM PH8172*
Air Filter
Element
KOHLER 47 083 03
FRAM CA79
Air Filter
Pre-Cleaner
KOHLER 24 083 02
KOHLER 24 050 10
Fuel Filter
Spark Plugs
(Resistor
Type)
CHAMPION RC12YC
(.030” GAP)
*
Oil capacity increases from 2.0 Qts. to 2.1
Qts. when using this filter.
EAGLE™ 10,000
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D-6
D-6
NOTES
EAGLE™ 10,000
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E-1
E-1
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
Rotor Field Feedback and Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Weld Winding, Reactor, and Range Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
Output Bridge, Choke, and Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
FIGURE E.1 BLOCK LOGIC DIAGRAM
RANGE
SWITCH
AC
POSITIVE
TERMINAL
CHOKE
OUTPUT
BRIDGE
AC
REACTOR
NEGATIVE
TERMINAL
STATOR
ROTOR
STATOR
MECHANICAL
ROTATION
ROTOR
SLIP
RINGS
STARTER
ENGINE
FLYWHEEL
ALTERNATOR
IDLER
SOLENOID
TOROID
BATTERY
FIELD
CAPACITOR
115 & 230VAC
RECEPTACLES
OUTPUT
CONTROL
PRINTED CIRCUIT
BOARD
EAGLE™ 10,000
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 – BATTERY, STARTER, ENGINE, ROTOR, STATOR AND IDLER SOLENOID
RANGE
SWITCH
AC
POSITIVE
TERMINAL
CHOKE
OUTPUT
BRIDGE
AC
REACTOR
NEGATIVE
TERMINAL
STATOR
ROTOR
STATOR
MECHANICAL
ROTATION
ROTOR
SLIP
RINGS
STARTER
ENGINE
FLYWHEEL
ALTERNATOR
IDLER
SOLENOID
TOROID
BATTERY
FIELD
CAPACITOR
115 & 230VAC
RECEPTACLES
OUTPUT
CONTROL
PRINTED CIRCUIT
BOARD
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.
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
The flywheel alternator, located on the engine, supplies
“charging” current for the battery circuit. The battery
circuit provides power for the printed 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
EAGLE™ 10,000
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E-3
E-3
THEORY OF OPERATION
FIGURE E.3 – ROTOR FIELD FEEDBACK AND AUXILIARY POWER
RANGE
SWITCH
AC
POSITIVE
TERMINAL
CHOKE
OUTPUT
BRIDGE
AC
REACTOR
NEGATIVE
TERMINAL
STATOR
ROTOR
STATOR
MECHANICAL
ROTATION
ROTOR
SLIP
RINGS
STARTER
ENGINE
FLYWHEEL
ALTERNATOR
IDLER
SOLENOID
TOROID
BATTERY
FIELD
CAPACITOR
115 & 230VAC
RECEPTACLES
OUTPUT
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.
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
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E-4
E-4
THEORY OF OPERATION
FIGURE E.4 – WELD WINDING, REACTOR, AND RANGE SWITCH
RANGE
SWITCH
AC
POSITIVE
TERMINAL
CHOKE
OUTPUT
BRIDGE
AC
REACTOR
NEGATIVE
TERMINAL
STATOR
ROTOR
STATOR
MECHANICAL
ROTATION
ROTOR
SLIP
RINGS
STARTER
ENGINE
FLYWHEEL
ALTERNATOR
IDLER
SOLENOID
TOROID
BATTERY
FIELD
CAPACITOR
115 & 230VAC
RECEPTACLES
OUTPUT
CONTROL
PRINTED CIRCUIT
BOARD
WELD WINDING, REACTOR, AND
RANGE SWITCH
OUTPUT BRIDGE, CHOKE, AND
OUTPUT TERMINALS
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.
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
output is filtered and on to the Output Terminals.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
EAGLE™ 10,000
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F-1
F-1
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F4 - F-12
Test Procedures
Rotor Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Rotor Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15
Auxiliary and Field Winding Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-19
Output Rectifier Bridge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23
Charging Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 . . . . . . . . . . . . . . . . . . . . . . . . . .F-32
Normal Open Circuit DC Weld Voltage Waveform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-34
Replacement Procedures
Output Rectifier Bridge Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-43
Engine Rotor Removal and Replacement (Kit S20788) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47
EAGLE™ 10,000
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F-2
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.
---------------------------------------------------------------------------------------------------------------------------
Step 3. RECOMMENDED
This Troubleshooting Guide is provided to
help you locate and repair possible machine
COURSE OF ACTION
The last column labeled “Recommended
malfunctions. Simply follow the three-step
Course of Action” lists the most likely com-
procedure listed below.
ponents that may have failed in your
machine. It also specifies the appropriate
Step 1. LOCATE PROBLEM (SYMPTOM).
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.
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.
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
Test 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.
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.
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
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F-3
F-3
TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- 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.
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.
- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop-
er failure analysis.
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:
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.
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board
to assure that the PC board is properly
connected.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
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:
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.
PC board can be damaged by static electricity.
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.
- 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
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
to
a
grounded part of the
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
equipment frame.
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.
- 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.
Workstations
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
EAGLE™ 10,000
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F-4
Observe Safety Guidelines detailed in the beginning of this manual.
F-4
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major Physical or Electrical Damage
is Evident.
1. Contact The Lincoln Electric
Service Dept. 1-888-935-3877.
1. Contact your local Lincoln
Authorized Field Service Facility.
No weld output and no auxiliary 1. Check the brushes for wear and 1. Perform the Rotor Voltage Test.
power. Engine runs normally.
proper contact to the rotor slip
rings.
2. Check for the presence of
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
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
3. If Rotor Voltage Test is normal,
then
preform
the
4. If the Rotor Voltage Test is NOT
normal, perform the Auxiliary
Test. Then check the Field
Diode Bridge (D2) and the Field
Capacitor (C1). Replace if nec-
essary. If the Field Bridge and
Field Capacitor are good, then
the Printed Circuit Board may be
faulty. Replace.
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
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F-5
Observe Safety Guidelines detailed in the beginning of this manual.
F-5
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
No weld output, the auxiliary power
(230-115VAC) is operating normal-
ly. Engine runs normally.
1. Disconnect lead W1 from the
Output Bridge (D1) and check
for the presence of 80VAC from
lead W1 to lead W2 on the main
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.
1. Check the open circuit voltage
(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 #2. If the
OCV is not present at the welder
output terminals, contact your
local Lincoln Authorized Field
Service Facility.
2. Check the welding cables,
clamps and electrode holder for
loose or broken connections.
2. Check the Reactor, Range
Switch (S1) 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.
3. Check the Choke (L1) 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.
4. Check the weld output terminals
and associated 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
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F-6
Observe Safety Guidelines detailed in the beginning of this manual.
F-6
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
No auxiliary power, welding output
is normal. Engine runs normally.
1. Check the auxiliary power
receptacles and associated
wires for loose or faulty connec-
tions.
1. If machine is equipped with cir-
cuit breakers, check circuit
breakers CB1 thru CB5. Reset if
tripped.
2. Make sure the Output Control
(R1) is set at the maximum posi-
tion.
3. If machine is equipped with cir-
cuit breakers, check for faulty
breakers and loose or faulty
connections on associated
wiring.
3. Check for loose or faulty plug(s)
at the power receptacle(s).
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
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F-7
Observe Safety Guidelines detailed in the beginning of this manual.
F-7
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine has low welding output
and low auxiliary output.
1. If the engine HIGH IDLE RPM
is low, then perform The
1. The brushes may be worn.
Contact your local Lincoln
Authorized Service Facility.
2. The engine RPM may be low.
3. If the rotor voltage is low the
Field Capacitor (C1) or the Field
Bridge (D2) may be faulty. Test
and replace if necessary.
4. Check the Output Control
Potentiometer. Normal resis-
tance is 10,000 ohms. Also
check associated wiring for
loose or faulty connections.
5. The Rotor may be faulty.
Perform the Rotor Resistance
6. The Printed Circuit Board may
be faulty. Replace.
7. If the engine HIGH IDLE RPM is
OK, then the engine may have
lost horsepower and be in need
of major repair.
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
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F-8
Observe Safety Guidelines detailed in the beginning of this manual.
F-8
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
ENGINE PROBLEMS
Engine will not idle down to low
speed. Machine has normal weld
output and auxiliary power.
1. With the Idler Switch (S4) in the
“Auto” position, check for the
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.
1. Make sure the Idler Switch (S4)
is in the “Auto” position.
2. Make sure there is NOT an exter-
nal load on the weld terminals
nor the auxiliary power recepta-
cles.
2. If there is NOT 12VDC at leads
#213 to #215, then test for
12VDC from lead #213 to
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
Board may be faulty. Replace.
3. If 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
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F-9
Observe Safety Guidelines detailed in the beginning of this manual.
F-9
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
ENGINE PROBLEMS
1. Check for broken or faulty con-
nections in the sensing lead
(#254). Make sure the connec-
tions are tight at the Electrode
Output Terminal and the Range
Engine will not go to high idle when 1. Make sure the welding cables
attempting to weld. Welding output
is normal when Idler Switch is in
“HIGH” position. Automatic idle
function works properly when the
auxiliary power is loaded.
and connections are tight.
2. Make sure the lead is routed
through the toroid.
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-
iliary power is loaded. Welding out-
put and auxiliary power output is
normal when Idler Switch is in the
“HIGH” position.
and connections are tight.
nections in the Toroid leads.
(#260 and #261). Make sure
their connections are tight at the
2. Automatic idler may not function
if the auxiliary power is loaded to
less than 150 Watts.
PC Board.
See
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 if 1. If the machine works OK when
the Auxiliary Power is loaded. The
Idle Circuit works OK with a weld-
ing load.
the auxiliary power is loaded to
less than 150 Watts.
set to High Idle,mMake sure that
leads #3 and #6 are wrapped
correctly through the Toroid.
2. 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
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F-10
Observe Safety Guidelines detailed in the beginning of this manual.
F-10
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
ENGINE PROBLEMS
1. If the battery is replaced or tests
good, then the charging circuit
may be faulty. Perform the
2. The starter motor or starter
solenoid may be faulty.
Engine will not crank or cranks very 1. Check for loose or faulty battery
slow.
cable connections.
2. The battery may be faulty.
3. Check the ammeter to see if the
battery is charging. If not, the
charging circuit may be defec-
tive.
3. The Engine may be hard to
crank due to a mechanical fail-
ure in the engine.
The Engine shuts off.
1. The Engine may be low on or out 1. The oil pressure switch may be
of fuel. faulty. Replace if necessary.
2. 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.
2. The air filter may be clogged.
Replace if necessary.
3. The spark plug(s) may be faulty.
Replace if necessary.
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
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F-11
Observe Safety Guidelines detailed in the beginning of this manual.
F-11
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
The welding arc is “cold.” Engine
runs normally (3700 RPM no load).
Auxiliary power is functioning nor-
mally.
1. 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
1. Check for loose or faulty connec-
tions at the weld output terminals
and welding cable connections.
2. The welding cable may be too
long or coiled, causing an exces-
sive voltage drop.
EAGLE 8.
See Wiring
2. If the OCV is low at the welder
output terminals, then Perform
3. Perform the Output Rectifier
4. Check for shorted or grounded
windings in the reactor and also
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
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F-13
F-13
TROUBLESHOOTING AND REPAIR
ROTOR VOLTAGE TEST
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
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F-14
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
Lead 200A
Lead 219
+
-
TEST PROCEDURE
1. With the 5/16” nut driver, remove the 6 sheet
9. Connect the negative meter probe to the other
metal screws from the case top.
brush (lead 219).
2. Remove the rubber gasket (cover seal) from the
lift bail.
10. Start the engine and run it at high idle (3650
RPM). Set the output control to the MAXI-
MUM position, (position 10).
3. Remove the fuel cap. The rubber gasket for the
fill tube will come off with the case top.
11. Check the voltage reading on the voltmeter. It
should read between 37 and 46 VDC.
4. Remove the case top, then reinstall the fuel
cap.
12. If the voltage reading is low or not present, the
generator field is not functioning properly.
Field Diode Bridge (D2), the Field Capacitor
(C1), and/or the Printed Circuit Board may be
faulty.
5. With the 5/16” nut driver, remove the 5 screws
holding the right case side.
6. Remove the right case side by lifting up and
out.
7. Set the volt/ohmmeter to the DC volts position.
13. If the voltage reading is normal, the field circuit
is 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.
8. Connect the positive meter probe to the brush
nearest the rotor lamination (lead 200A). See
Figure F.1 for location.
EAGLE™ 10,000
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F-15
F-15
TROUBLESHOOTING AND REPAIR
ROTOR RESISTANCE TEST
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
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F-16
F-16
TROUBLESHOOTING AND REPAIR
ROTOR RESISTANCE TEST (continued)
FIGURE F.2 – LOCATION OF ROTOR SLIP RINGS
+
-
Lead 200A
Lead 219
TEST PROCEDURE
9. Isolate the rotor electrically by removing the
generator brush leads. Refer to Figure F.2 as
you perform the remaining steps.
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.
10. Remove lead 219 from the negative brush.
11. Remove lead 200A from the positive brush.
3. Remove the fuel cap. The rubber gasket for the
fill tube will come off with the case top.
12. Measure the resistance across the rotor slip
rings.
4. Remove the case top, then replace the fuel
cap.
A. Set the ohmmeter on the low scale (X1).
5. With the 5/16” nut driver, remove the 5 screws
holding the right case side.
B. Place one meter probe on one of the rotor
slip rings. Place the other probe on the
other slip ring.
6. Remove the right case side by lifting up and
out.
C. Check the resistance across the slip rings.
It should read between 4 and 5 ohms.
7. Conduct the test with the gasoline engine OFF.
8. Remove the spark plug wires to prevent acci-
dental engine kickback or starting.
EAGLE™ 10,000
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F-17
F-17
TROUBLESHOOTING AND REPAIR
ROTOR RESISTANCE 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 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.
15. Reinstall the case side, case top, fuel cap, lift
bail gasket and spark plug wires.
EAGLE™ 10,000
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F-18
F-18
NOTES
EAGLE™ 10,000
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F-19
F-19
TROUBLESHOOTING AND REPAIR
AUXILIARY AND FIELD WINDING TEST
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
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F-20
F-20
TROUBLESHOOTING AND REPAIR
AUXILIARY AND FIELD WINDING TEST (continued)
FIGURE F.3 – LOCATION OF LEADS #3 AND #5
Machine
Case
Front
115V
Receptacle
Lead #3
Lead #5
TEST PROCEDURE
To test the 115 VAC winding:
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.
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 #3
and #5 where they connect to the 115 VAC
receptacle. See Figure F.3.
2. Connect the volt/ohmmeter probes to leads #6
and #3 where they connect to the 230 VAC
receptacle.
3. Start the engine and run it at high idle (3650
RPM).
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).
4. Set the output control to the maximum position
(position 10).
5. Check the AC voltage reading. It should be
approximately 125 VAC.
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
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F-21
F-21
TROUBLESHOOTING AND REPAIR
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.
If the voltage readings are within specifications,
then the windings are good and functioning prop-
erly.
2. Connect the volt/ohmmeter probes to leads #7
and #9 where they connect to the Field Idle
Control P.C. Board.
6. Reinstall the case side, case top, fuel cap, and
lift bail gasket.
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
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-
the windings are NOT grounded internally to the
stator iron. If the leads are intact, then the stator
may be faulty. Replace the stator.
EAGLE™ 10,000
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F-22
F-22
NOTES
EAGLE™ 10,000
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F-23
F-23
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER BRIDGE TEST
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
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F-24
F-24
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER BRIDGE TEST (continued)
FIGURE F.4 – LOCATION OF OUTPUT RECTIFIER LEADS
OUTPUT RECTIFIER
(-)
(+)
(-)
(+)
(+)
(-)
ENGINE
TEST PROCEDURE
10. With the 7/16” wrench or socket wrench and 6”
1. Remove the spark plug wires to prevent acci-
dental engine kickback or starting.
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.
2. With the 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.
11. Electrically isolate the (-) diode connectors by
slightly bending them back into “free air.”
4. Remove the fuel cap. The rubber gasket for the
fill tube will come off with the case top.
12. With an ohmmeter or diode tester, check each
of the four diodes from their connector to their
respective heat sinks. See Figure F.4.
5. Remove the case top, then replace the fuel
cap.
6. With the 5/16” nut driver, remove the 5 screws
holding the right case side.
13. Reverse the tester leads and check the diodes
again. Diodes should have a low resistance in
one polarity and a very high resistance in the
opposite polarity.
7. Remove the right case side by lifting up and
out.
8. Conduct the test with the gasoline engine OFF.
14. Replace any “shorted” or “open” diode bridge
assembly the tests indicate.
9. Locate the Output Rectifier Bridge behind the
machine case front.
15. Reconnect the diode connectors and heavy
leads to their respective studs.
16. Reinstall the case side, case top, fuel cap, lift
bail gasket and spark plug wires.
EAGLE™ 10,000
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F-25
F-25
TROUBLESHOOTING AND REPAIR
CHARGING CIRCUIT TEST
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 Flywheel Alternator, Regulator, and associated circuitry are
functioning properly.
MATERIALS NEEDED
Volt/Ohmmeter
5/16” Nut driver
Wiring Diagram
EAGLE™ 10,000
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F-26
F-26
TROUBLESHOOTING AND REPAIR
CHARGING CIRCUIT TEST (continued)
FIGURE F.5 – LOCATION OF VOLTAGE REGULATOR
Engine
Ground
Lead
(Green)
Voltage
Regulator
AC Lead
DC Lead
AC Lead
TEST PROCEDURE
1. Start the engine and run it at high idle (3650
RPM).
5. If the DC voltage reading is incorrect or not pre-
sent, the voltage regulator may be faulty.
Replace the entire voltage regulator module.
2. 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.
6. If the DC voltage reading is correct, check the
3. 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.
4. 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.
EAGLE™ 10,000
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F-27
F-27
TROUBLESHOOTING AND REPAIR
ENGINE THROTTLE ADJUSTMENT TEST
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
EAGLE™ 10,000
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F-28
F-28
TROUBLESHOOTING AND REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.6 – BLOWER PADDLE MARKED FOR STROBE-TACH METHOD
Blower Paddle
TEST PROCEDURE
This test can be conducted by any one of four
methods.
8. Connect the strobe-tach according the manu-
facturer’s instructions.
Strobe-tach Method:
9. 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.
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.
10. With the machine at HIGH IDLE the tach
should read between 3650 and 3750 RPM.
3. Remove the fuel cap. The rubber gasket for the
fill tube will come off with the case top.
With the machine at LOW IDLE the tach
should read between 2150 and 2250 RPM.
4. Remove the case top, then replace the fuel
cap.
5. Conduct this procedure with the gasoline
engine OFF.
6. Remove the spark plug wires to prevent acci-
dental engine kickback or starting.
7. With the black or red marking pencil, place a
mark on one of the blower paddles. See Figure
F.6 for location.
EAGLE™ 10,000
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F-29
F-29
TROUBLESHOOTING AND REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.7
FIGURE F.8
HIGH IDLE ADJUSTMENT NUT
LOW IDLE ADJUSTMENT NUT
Solenoid
3/8" Low Idle
Adjustment
Nut
Muffler
Housing
Throttle
linkage
Choke
Cable
Rod
3/8" High Idle
Adjustment Nut
11. If either of the readings is incorrect, adjust the
throttle as follows:
2. 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.
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.
3. If either of the readings is incorrect, adjust the
throttle as follows:
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.
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.
Frequency Counter Method
1. Plug the frequency counter into one of the 115
VAC auxiliary receptacles.
EAGLE™ 10,000
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F-30
F-30
TROUBLESHOOTING AND REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
Oscilloscope Method:
Vibratach Method:
1. Place the vibratach as close to the engine as
possible. With the machine case top
1. Connect the oscilloscope to the 115 VAC
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
LOAD in this section of the manual.
removed, the top of the air cleaner is the best
location.
2. 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:
2. If either waveform periods is incorrect, adjust
the throttle as follows:
Adjust HIGH IDLE: Use the 3/8” wrench to turn
the speed until the period is 16.2 milliseconds.
3. If either of the vibratach indications is incor-
rect, adjust the throttle as follows:
Adjust HIGH IDLE: Use the 3/8” wrench to turn
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 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
for location of the adjustment nut. Adjust the
speed until the period is 27.3 milliseconds.
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
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
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F-31
F-31
TROUBLESHOOTING AND REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)
HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM
16.2 ms
CH1
0 volts
5 ms
50 volts
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 115VAC receptacle.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
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F-32
F-32
TROUBLESHOOTING AND REPAIR
TYPICAL DC WELD OUTPUT WAVEFORM (CC MODE)
MACHINE LOADED
CH1
0 volts
5 ms
20 volts
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
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F-33
F-33
TROUBLESHOOTING AND REPAIR
ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
ONE OUTPUT DIODE NOT FUNCTIONING
CH1
0 volts
5 ms
50 volts
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.
Note: Scope probes connected at
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
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F-34
F-34
TROUBLESHOOTING AND REPAIR
NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM (CC MODE)
HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
CH1
0 volts
5 ms
50 volts
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
Volts/Div.....................50V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
EAGLE™ 10,000
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F-35
F-35
TROUBLESHOOTING AND REPAIR
BRUSH REMOVAL AND REPLACEMENT
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 accessing the generator brushes for
maintenance or replacement.
MATERIALS NEEDED
Misc. Hand tools
EAGLE™ 10,000
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F-36
F-36
TROUBLESHOOTING AND REPAIR
BRUSH REMOVAL AND REPLACEMENT (continued)
PROCEDURE
1. Remove the spark plug wires.
13. 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.
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.
14. 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
hold the brushes up so that you can easily
install the holder.
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 reinstall the fuel
cap.
6. WIth the 5/16” nut driver, remove the 5 screws
holding the right case side.
15. 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.
7. Remove the right case side by lifting up and
out.
16. With the 7/16” wrench, install the brush holder
assembly bracket to the stator frame.
8. With a needle nose pliers, gently remove the
9. With a 7/16” wrench, remove the brush holder
assembly bracket from the stator frame.
17. Slowly remove the non-metallic retainer from
the brush holder and let the brushes snap
back against the slip rings.
18. 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.
10. 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.
19. Check the wire connections for clearance and
tightness.
11. To change the brushes, use a slot head screw
driver to pop off the plastic retainer on the back
of the brush holder assembly.
20. Reinstall the case side, fuel cap, lift bail gas-
ket, case top, and spark plug wires.
12. 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.
EAGLE™ 10,000
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F-37
F-37
TROUBLESHOOTING AND REPAIR
BRUSH REMOVAL AND REPLACEMENT (continued)
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.
CAUTION
Do not attempt to polish slip rings while engine
is running.
FIGURE F.9 - BRUSH LEADS/BRUSHES RETAINED WITH CABLE TIE
Cable
Tie
Brushes
7/16" Brush
Assembly
Bracket Bolts
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F-38
F-38
NOTES
EAGLE™ 10,000
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F-39
F-39
TROUBLESHOOTING AND REPAIR
PRINTED CIRCUIT BOARD REMOVAL
AND REPLACEMENT
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 printed circuit board for
maintenance or replacement.
MATERIALS NEEDED
Misc. Hand Tools
Wiring Diagram
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F-40
F-40
TROUBLESHOOTING AND REPAIR
PRINTED CIRCUIT BOARD REMOVAL
AND REPLACEMENT (continued)
FIGURE F.10 - PRINTED CIRCUIT BOARD LOCATION
4 Self Tapping Screws (at corners)
4 Pin Plug
12 Pin Plug
1/4" Q.C. Tabs
PROCEDURE
8. Remove the 12-pin molex plug from the
Printed circuit board.
Before starting the following procedure, refer to the
at the beginning of this section.
9. Remove 4-pin molex from the current sensing
leads.
1. Remove the engine spark plug wires.
10. Remove leads from two 1/4” Q.C. connectors.
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 will come off with the case top.
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.
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F-41
F-41
TROUBLESHOOTING AND REPAIR
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 side, fuel cap, lift bail gas-
ket, case top, and spark plug wires.
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F-42
F-42
NOTES
EAGLE™ 10,000
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F-43
F-43
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER BRIDGE REMOVAL
AND REPLACEMENT
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 for
maintenance or replacement.
MATERIALS NEEDED
Misc. Hand Tools
Dow Corning 340
Wiring Diagram
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F-44
F-44
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER BRIDGE REMOVAL
AND REPLACEMENT (continued)
FIGURE F.11 - OUTPUT RECTIFIER CONNECTIONS
#8
L1 TO CHOKE
TO POLARITY SWITCH
W1
TO S2
(-)
(3) 1/2"
MOUNTING
SCREWS
(+)
(-)
(+)
(+)
(-)
ENGINE
(4) 7/16"
MOUNTING
SCREWS
TO S2
TO S1
254
NO NUT
PROCEDURE
1. Remove the engine spark plug wires.
For the remaining steps, refer to Figure F.11.
8. With a 1/2” wrench, remove the choke lead.
2. With a 5/16” nut driver, remove the 6 sheet
metal screws from the case top.
9. With the 1/2” wrench, remove the heavy cable
and the #8 lead (White) from the rectifier neg-
ative heat sink.
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.
10. WIth a 7/16” wrench, remove the W1 lead and
the heavy lead going to the S2 Polarity switch.
5. Remove the case top, then reinstall the fuel
11. With the 7/16” wrench, remove the S2 lead,
the heavy lead going to the S1 Range switch,
and 254 (White) lead to sense turroid.
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.
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F-45
F-45
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER BRIDGE REMOVAL
AND REPLACEMENT (continued)
12. With the 1/2” wrench remove the three mount-
17. With the 7/16” socket wrench, install the W1
ing nuts. Note the placement of the nylon
insulators.
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, flat washer, lock washer, and nut.
13. Remove the rectifier assembly by tilting it up
and lifting it toward the side of the machine.
18. 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.
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. With the 1/2” socket wrench, install the choke
lead and the #10 lead and note the order of
fasteners.
NOTE: Use Dow Corning 340 on all aluminum
electrical connection surfaces.
20. Reinstall the case side, fuel cap, lift bail gas-
ket, case top, and spark plug wire.
15. With the 1/2” wrench install the three mounting
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.
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F-46
F-46
NOTES
EAGLE™ 10,000
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F-47
F-47
TROUBLESHOOTING AND REPAIR
ENGINE/ROTOR REMOVAL AND REPLACEMENT
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 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 (S20788) - FOR ROTOR REMOVAL ONLY
Misc. Hand Tools
Impact wrench
Torque wrench (ft lbs
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
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F-48
F-48
TROUBLESHOOTING AND REPAIR
ENGINE/ROTOR REMOVAL AND REPLACEMENT (continued)
FIGURE F.12 – COMPONENT LOCATIONS, ENGINE/ROTOR REMOVAL
5
3
1
6
8
7
1
2
9
1. STATOR COWLING COVER
2. BLOWER FAN
3. IDLE LINKAGE
4
4. BRUSH HOLDER BRACKET
5. ENGINE LIFT BAILS
6. STATOR/ENGINE MOUNTING BOLTS
7. ROTOR
8. ROTOR SHAFT BEARING
9. ROTOR THRU-BOLT
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F-49
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.
15. 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.
3. With a 5/16” nut driver, remove the 6 sheet
metal screws from the case top.
16. 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.
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 case top.
17. 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.
6. Remove the case top, the reinstall the fuel
cap.
7. WIth the 5/16” nut driver, remove the 5 screws
holding the right case side and the 5 screws
holding the left case side.
18. Cut the cable ties and remove leads 224C and
210 from the oil pressure switch.
19. With a 9/16” wrenches, remove the ground
lead from the right engine foot mounting bolt.
8. Remove the case sides by lifting up and out.
9. WIth a 3/8” wrench, remove the battery cover.
20. With a 7/16” wrench, remove the brush holder
bracket and leads #219 & 200A from the sta-
tor frame.
10. 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.
21. Support the engine with a chain hoist. Lift
bails are provided on the top of the engine for
this purpose.
11. 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.
22. With a 9/16” wrench, remove the right and left
engine foot mounting bolts.
23. With the 9/16” wrench, remove the four bolts
that hold the stator to the engine. There is one
lock washer per bolt.
12. Disconnect the large black plug in front of the
fuel tank spout.
24. 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.
13. With the 3/8” wrench, remove the cowling cov-
ers at the rear on the stator, both sides of the
machine.
14. 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.
25. 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.
15. 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.
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F-50
F-50
TROUBLESHOOTING AND REPAIR
ENGINE/ROTOR REMOVAL AND REPLACEMENT (continued)
FIGURE F.13 - ENGINE AND ROTOR REMOVED FROM STATOR
2
1. THRU-BOLT
2. ROTOR
1
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.
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 lbs
with the torque or impact wrench.
2. With an impact wrench, remove the rotor thru-
bolt. See Figure F.13. If an impact wrench is
not available, 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.
5. If the rotor does not pop off, tighten the rotor
removal tool an additional 5 ft lbs. 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.
3. Install the appropriate long thru-bolt (two are
provided) supplied with Lincoln Electric Rotor
Removal Kit S20788. 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”.
EAGLE™ 10,000
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F-51
F-51
TROUBLESHOOTING AND REPAIR
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.
8. Attach leads to the oil pressure switch refer to
wiring diagram. Replace any cut cable ties.
9. Unplug the fuel tank connection and fuel hose
and connect them.
1. Clean the tapered engine crankshaft. Slide
the rotor onto the shaft.
10. Connect the idle linkage to the idler rod. Snap
the plastic clip back into place.
2. Insert the rotor thru-bolt, and with the torque
wrench tighten the bolt to 50 ft lbs.
11. Connect the engine choke cable at the posi-
tion marked during disassembly.
3. 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.
12. 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.
13. Reposition the vertical fan baffle and secure it
with the two screws.
4. 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-lb.
moving diagonally from bolt to bolt.
14. Install the two cowling covers at the rear of the
stator.
15. Connect the black plug in front of the fuel tank
fill spout.
5. 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.
16. Connect the leads to the starter solenoid and
replace any cable ties cut during disassembly.
17. Install the battery. Connect the positive bat-
tery cable, then the negative battery cable. BE
SURE TO CONNECT THE POSITIVE BAT-
TERY CABLE FIRST.
18. Replace the battery cover.
19. Reinstall the case side, fuel cap, lift bail gas-
ket, and case top. Connect the spark plug
wires.
6. Fasten the ground lead to the right engine
mounting bolt and install both bolts.
the following topic in this section of the manu-
al.
7. Install the brush holder bracket back into the
stator frame. Refer to the topic “Brush
the manual.
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F-52
F-52
TROUBLESHOOTING AND REPAIR
RETEST AFTER REPAIR
Retest a machine:
• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the
machine’s electrical characteristics.
OR
• If you repair or replace any electrical components.
ENGINE OUTPUT
Mode
Low Idle
High Idle
No Load RPM
2150-2250
3700-3750
Load RPM
NA
3100-3600
WELDER DC OUTPUT1
Output Control
Range Switch
Open Circuit
Volts
Load Volts
Load Amps
205 - 240
Maximum
Maximum
65 - 72
21 - 26.5
AUXILIARY POWER RECEPTACLE OUTPUT1
230 Volt Receptacle
115 Volt Receptacle2
Open Circuit
Voltage
Load Volts
Load Amps
Open Circuit
Voltage
Load Volts
Load Amps
246 - 264
216 - 250
34 - 41.5
123- 132
114 - 126
35 - 42
FIELD AMPS AND VOLTS
Slip Ring Volts
Field Amps
28.0 - 46.0 VDC
6.5 - 7.5 VDC
1 OUTPUT CONTROL switch set at MAXIMUM (position 10).
2 Output values of each receptacle can vary within the range shown but must be within 2 volts of each other.
EAGLE™ 10,000
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G-1
G-1
TABLE OF CONTENTS - DIAGRAM SECTION
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
Wiring Diagram - Code 11096 - (M20317) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Wiring Diagram -Code 11397 - (M21271) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 (L12198-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*
* 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
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G-2
G-2
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - CODE 11096 (M20317)
EAGLE 10,000 (KOHLER)
LEADS
2 TURNS
OPPOSITE DIRECTIONS
3
AND 6:
T
HRU
T
OROID
IN
213
1 TURN
6
3
S3
261
260
CCW
R1
254
OUTPU
CONTROL
T
GROUND S
CREW
L1
HOKE
209A
ON UPPE CASEFRONT
R
C
211
+
10
7
6A
75A
7
7A
D1
208C
8
-
PCB1
1
3
2
4
5D
254
J2
213A
CB7
5A
GN
D
-I
213A
2
S1
5F
12
7
S2
E
R1
8
10
-
+
J1
1
GND-E
R3
R5
IDLER
SOLENOID
6
210
S1
GND-G
224
W2
W1
7
9
+
224A
REACTOR
C1
STATOR
6
HOUR ME
TER
GND-C
GND-D
GROUND SCREW
ON OWER CASEFRONT
215
L
5D
3
3
9
6
7
5E
GND-E
75A
76A
77A
224A
6
209
2 VOLT
BATTERY
208 211
3
1
224C
5
209A
J5
+
GND-D
T
ERMINAL BLOCK
(SEE CONN.
B
B B
1
2
3
4
6A
)
P5
R
R
W
-
J2
120V
V
6
CB1
0A
GND-G
ENGINE
FOO
4
U
6B
T
210
200A
+
GND-H
12
5
CR1
219
N.A.
OI
L
5L
5K
3B
STARTER
SOLENOI
PRESSURE
SWITCH
D
ENGINE
ROSS
SUPPORT
J4
120V/240V
11
C
IGNITION
MODULE
REGULA
AC
T
OR
B-
CB4
0A
STARTER
AC B+
GND-C
11
CB2
FUEL
2
ROTOR
J3
120V
SHUTOFF
SOLENOID
5K
CB3
0A
40A
5
FLYWHEEL ALTERNATOR
2
SLIP RING NEAREST LAMINA
TION
5L
ENGINE COMPONENTS
3A
SILVER COLORED
ERMINALS
(WHI E WIRES)
3A
T
T
GENERATOR LEAD END
(NOTE CAVITY NUMBERS)
N
.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.
CO
N
NECTOR PIN NUMBERS:
12
LEAD CO
OR GRAY
R = RED OR IN
HITE
L
OR CODE
:
4
2
3
7
1
211 (CAVITY #3)
B
=
BLACK
U =
B
LU
E
224C (CAVITY #4)
208 (CAVITY #2)
P
K
V
=
VIOLET
1
3
2
6
LOCATING TA
B
W
=
W
J2
J1
ALL CASE FRONT COMPONENTS SHOWN VIE
ELECTRICAL SYMBOLS PER E1537
WED FROM REAR.
T
ERMINAL BLOCK
CO NECTION
N
B
M20317PRINT
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.
EAGLE™ 10,000
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G-3
G-3
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - CODE 11397 - (M21271)
EAGLE 10,000 (KOHLER)
LEADS
2 TURNS
OPPOSITE DIRECTIONS
3
AND 6:
T
HRU
T
OROID
IN
213
1 TURN
6
3
S3
261
260
L1
CCW
R1
254
C
HOKE
OUTPU
CONTROL
T
GROUND S
CREW
209A
ON UPPE CASEFRONT
R
POSITIVE
211
+
10
76A
7
5A
7
7A
D1
208C
8
-
S3
PCB1
1
3
2
4
5D
254
J2
213A
CB7
5A
GN
D
-I
213A
2
S1
5F
12
7
S2
E
R1
8
10
-
+
J1
1
GND-E
R3
R5
IDLER
SOLENOID
6
210
S1
GND-G
224
W2
W1
7
9
+
224A
REACTOR
C1
STATOR
6
HOUR ME
TER
GND-C
GND-D
GROUND SCREW
ON OWER CASEFRONT
215
L
5D
3
3
9
6
7
5E
GND-E
75A
76A
77A
224A
6
209
2 VOLT
BATTERY
208 211
3
6A
1
224C
209A
J5
5
3A
+
CB4
CB1
0A
T
ERMINAL BLOCK
(SEE CONN.
2
0A
B
B B
4
1
2
3
4
GND-D
3B
)
P5
J2
120V
R
R
6A
W
-
GND-G
V
ENGINE
FOO
U
CB3
0A
T
12
11
210
2
200A
+
GND-H
CR1
219
N.A.
OI
L
STARTER
SOLENOI
5L
5L
5K
PRESSURE
SWITCH
J4
120V/240V
D
ENGINE
ROSS
SUPPORT
6B
C
IGNITION
MODULE
REGULA
AC
T
OR
B-
STARTER
AC B+
FUEL
GND-C
ROTOR
SHUTOFF
SOLENOID
J3
120V
5K
5
FLYWHEEL ALTERNATOR
SLIP RING NEAREST LAMINA
TION
ENGINE COMPONENTS
SILVER COLORED TERMINALS
GENERATOR LEAD END
(NOTE CAVITY NUMBERS)
N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.
CONNECTOR PIN NUMBERS:
LEAD CO
OR GRAY
R = RED OR IN
HITE
L
OR CODE
:
4
2
3
12
7
1
211 (CAVITY #3)
B
=
BLACK
U =
B
LU
E
224C (CAVITY #4)
208 (CAVITY #2)
P
K
V
=
VIOLET
1
3
2
6
LOCATING TA
B
W
=
W
J2
J1
ALL CASE FRONT COMPONENTS SHOWN VIE
ELECTRICAL SYMBOLS PER E1537
WED FROM REAR.
T
ERMINAL BLOCK
CO NECTION
N
B
M21271PRINT
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.
EAGLE™ 10,000
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G-4
G-4
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - CODE 11096 (L12259)
STATO
R
TWO
POLE 3600 RPM
Choke mou
n base in
W
EL
D
front of genenrteadtoor.
WINDING
S
ELECTRODE
TERMINAL
ALTERNATO
R
210DC/225AC
S2
L1 CHOKE
POLA
R
ITY
D1 - BRIDG
E
RECTIFIER
W1
S1 - SELECTOR SWITCH
14
90
5
SWITC
H
DC+
37 TO 41 V
AN C1 AT HIGH
MA IMUM HEOSTAT NO LOAD.
A
C
BETWEE
N
W1
W
AC
Open Circuit Volts
:
D
I
DLE AND
D
C-
AC
Max
76
X
R
Min
CV
AC
DC
38
68
32
34
18
78 TO 82 V
AN W2 AT HIGH
MA IMUM HEOSTAT NO LOAD.
A
C
B
ETWEE
N
W1
25
4
C1
D
I
DLE AND
CV
AC
X
R
DC-
DC+
R3
R1
R5
WORK
1
AC
tapped
r
eactor m nted
74 TO 78 V
AN W2 AT HIGH
MA IMUM HEOSTAT NO LOAD.
A
C
B
ETWEE
N
WAC
on base in front of geonuerator.
D
I
DLE AND
E
S2
TERMINAL
T
X
R
Rectifier mounted on top of choke an
d
TOROID: SENSES
S1
W2
U
R
N
A
C reactor in front of generator..
W
EL
POWER LO
CTI AT I
D
OR AC
D TO
DLER
A
A
C TAPPED REACTOR
STATO
R
AUXILIARY
INDING
Torroid Core located on
REVOLVIN
G
BRUSHES
A
V
E
POWE
R
W
S
wiring behind
receptacles.
FIELD
S
6A
6
2 TURN
S
+
3
2 TURN
S
3A
1 TURN
S
AM
E
240 V AC
RESISTANCE
APPRO . 5 OHMS @ 75F
C
B3
C
B4
C
B1
DIRECTIO
N
AS LE
AD 6
C
B2
X
6
3
Rotor Flashing: 2.5
volts @ 0.5 amps.
Y
X
20A
20A
Z
40A
40A
C
B5
15 AM
3 POLE
37VAC
120 V AC
5
120 V AC
10 TO 50 VD AT
C
6B
until generator build-up.
P
3B
X
11
1.7 TO 6.8 AMPS
12
-
GND
E
J3
J2
LEADS
THROUGH TO
TWO TIME
OPPOSITE DIRECTIONS
3
AND 6 PASS
480
V
Y
SLI
P
RINGS
J4
5K
RROID
3
-PHASE
X
Z
S
IN
J1
Y
5L
5
Z
GND-D
GND-G
GND-C
7
21
9
200A
GND-I
EXCITATIO
N
W
INDING
V
OLTS MEASURE
D
AT
41 TO 45 VAC
MA
X
R
HEOSTAT HIGH
IDL
E
NO LOAD
9
P
C
Board
STATO
EXCITATIO
INDING
R
+14
V
IN
AUTO IDL
E
/
OV
IN HIGH IDLE
located on
of fan
r
ea
r
N
W
S
baffle near to
of machine.
p
2
1
A
UTO IDL
E
(2)
OF
F
4
3
HIGH
ST
I
DL (3
E
)
+14
V
RUN
IDLE SOLENOID COIL
-EN RGIZED FO
LO DLE.
S3 OPERATIO
N
S3
E
R
A
RT (4)
1
3
2
4
+BAT (1
)
SUPPRESSOR FOR
D1 RECTIFIE
9
260
219
200A
7
261
W
I
OF
UTO
HIGH
ST RT
F
21
3
R
(J2-4)
(J1-5)
(J1-11)
(
J2-3)
+10
V
X
X
X
A
FIELD
LASHING
CIRCUIT
Idle solenoid is
8 (J1-12)
LOAD
SENSOR
X
X
F
located on top of
.05
X
X
X
IDL
E
TIME
R
A
generabtolyr stato
r
12 to 14 volts
ac oss coil when
energized
130V
38
5K
+
-
X= CLOSED CIRCUIT
assem
15 Ohms
r
J
(
12 S
EC.)
10 (J1-6)
F
DIOD
LYBACK
E
213A (J2-1)
20
F
DIOD
LYBACK
E
21
1
224C
215 (J1-3)
CB7 25A
208C
+14V @ NORMA OIL PRES.
L
224 (J1-9)
J51-4
J51-3
IDLE SOLENOID
COIL
+10
REGULATOR
CIRCUIT
V
OL
T
+10
V
J51 - Engine
Connecto
20
8
FIELD
CURRENT
FEEDBACK
RESISTO
209A
r
SWITCHIN
TRANSISTO
G
0.1
R
B
ATTERY
Earngine diodes
wiereinhaernngeinsse.
R
224A 224C
Fu
mounte
d
on engine ca
r
el solenoidbisuretor.
Battery voltage:
12.6 volts at rest
OUTPUT
J51-2
CHARGIN
G
R
R
(OVER-CURRENT
+10
PROTECTED)
J51-1
CONTROL
10K
ALT/REG
U
V
HYSTERESIS SWITCH
68.1K
+
B+
14 volts engine
running
4.74 V
77A (J1-4)
76A (J1-8)
47.5
4700uF
80VD
IGNITION
MODUL
AC
E
NGIN
E
LE
CHANGIN
AN RIVER
CIRCUIT
VEL
+
E
C
ENGINE DIODES
R1
ST
A
RTE
R
12 VOLT
+
-
G
21
0
SOLENOID
BATTERY
AC
0.64 V
D
D
75A (J1-10)
E
NGINE OIL
47.5
FIELD CURRENT
SWITCHIN
TRANSISTO
44 TO 45 VAC
FUEL
SHUTOF
OLENOID
+
GN
D
PRESSURE
SWITCH
G
B
ETWEE
TERMINAL
AT HIGH
N
AC
E
NGIN
E
F
+
-
R
FRAM
E
S
ST RTE
A
R
S
5E (J1-2)
REVERSE VOLTAG
ROT CTION DIODE
HOUR
OPENS
ON
Control boa
r
d common is
op abov
ame g ound.
GROUND
IDL
E
FIELD CURRENT FEEDBACK
(OVER-CURRENT
P
ROT CTED)
E
METER
LO OIL
W
E
one diode d
r
e
FEEDBAC AMP
K
PRESSURE
P
E
welder f
r
r
Resistance of fuel
solenoid cannot be
CONNECTOR PIN NUMBERS:
If engine oil pressure drops below safe
FIELD & IDLE CONTROL
PC BOARD (L12198-1)
accurately
4
2
3
7
1
12
6
A
operating pressure, the oil pressure
measured th
diodes.
rough
switch opens
circuit 224 shutting off fuel solenoid to
stop engine. Hourmeter wi l also stop
unning and P B1 will dene gize idle
solenoid.
removing 12 volts from
1
3
2
L12259
J2
J1
l
r
C
r
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
EAGLE™ 10,000
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G-5
G-5
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - CODE 11397 (L13104)
STATO
R
Choke mou
n base in
W
EL
D
front of genenrteadtoor.
WINDING
S
POSITIVE
TERMINAL
210DC
L1 CHOKE
D1 - BRIDG
E
RECTIFIER
W1
S1 - SELECTOR SWITCH
14
90
5
NO
C
ONNECTIO
N
Open Circuit Volts
:
TO C1, E AN
D
S2
Max
68
Min
34
DC
74 TO 78 V
AN W2 AT HIGH
MA IMUM HEOSTAT NO LOAD.
A
C
B
ETWEE
N
W1
25
4
C1
D
I
DLE AND
X
R
R3
R1
R5
S2
NEGATIVE
TERMINAL
A
C
tapped
r
eactor m nted
on base in front of geonuerator.
TWO
POLE 3600
1
E
R
PM ALTERNATO
R
Rectifier mounted on top of choke an
d
TOROID: SENSES
S1
W2
T
A
C reactor in front of generator..
W
EL
POWER LO
CTI AT I
D
OR AC
D TO
DLER
U
R
N
A
A
C TAPPED REACTOR
STATO
R
AUXILIARY
INDING
Torroid Core located on
REVOLVIN
G
BRUSHES
A
V
E
POWE
R
W
S
wiring behind
receptacles.
FIELD
S
3
6A
6
2 TURN
S
+
3
LEADS
3
AND 6 PASS
ROID
2 TURN
S
3A
RESISTANCE
APPRO . 5 OHMS @ 75F
120 V AC
THROUGH TO
R
C
B3
C
B4
C
B1
X
Rotor Flashing: 2.5
volts @ 0.5 amps.
TWO TIME
S
IN
20A
20A
40A
240 V AC
OPPOSITE DIRECTIONS
10 TO 50 VD AT
C
6B
until generator build-up.
5
3B
11
1.7 TO 6.8 AMPS
12
GN
D
E
-
J3
J2
120 V AC
SLIP RINGS
J4
5K
5L
5
6
7
GND-D
GND-G
GND-C
21
9
200A
EXCITATIO
OLTS MEASURE
MA HEOSTAT HIGH
IDL O LOAD
N
W
INDING
V
D
AT
41 TO 45 VAC
X
R
E
N
9
P
C
Board
STATO
EXCITATIO
INDING
R
+14
V
IN
AUTO IDL
E
/
OV
IN HIGH IDLE
located on
of fan
r
ea
r
N
W
S
baffle near to
of machine.
p
2
1
A
UTO IDL
E
(2)
OF
F
4
3
HIGH
ST
I
DL (3
E
)
+14
V
RUN
IDLE SOLENOID COIL
-EN RGIZED FO
LO DLE.
S3 OPERATIO
N
S3
E
R
A
RT (4)
1
3
2
4
+BAT (1
)
SUPPRESSOR FOR
D1 RECTIFIE
9
260
219
200A
7
261
W
I
OF
UTO
HIGH
ST RT
F
21
3
R
(J2-4)
(J1-5)
(J1-11)
(
J2-3)
+10
V
X
X
X
A
FIELD
LASHING
CIRCUIT
Idle solenoid is
8 (J1-12)
LOAD
SENSOR
X
X
F
located on top of
.05
X
X
X
IDL
E
TIME
C.)
R
A
generabtolyr stato
r
12 to 14 volts
ac oss coil when
energized
130V
5K
+
-
X= CLOSED CIRCUIT
assem
15 Ohms
r
38J
(
12 S
E
10 (J1-6)
F
DIOD
LYBACK
E
213A (J2-1)
20
F
DIOD
LYBACK
E
21
1
224C
215 (J1-3)
CB7 25A
208C
+14V @ NORMA
L
OIL
PRES.
224 (J1-9)
J51-4
J51-3
IDLE SOLENOID
COIL
+10 VOLT
REGULATOR
CIRCUIT
+10
V
J51 - Engine
Connecto
20
8
FIELD
CURRENT
FEEDBACK
RESISTO
209A
r
SWITCHIN
TRANSISTO
G
0.1
R
B
ATTERY
Earngine diodes
wiereinhaernngeinsse.
R
224A 224C
Fu
mounte
d
on engine ca
r
el solenoidbisuretor.
Battery voltage:
12.6 volts at rest
OUTPUT
J51-2
CHARGIN
G
R
R
(OVER-CURRENT
+10
PROTECTED)
J51-1
CONTROL
10K
ALT/REG
U
V
HYSTERESIS SWITCH
68.1K
+
B+
14 volts engine
running
5.64 V
77A (J1-1)
76A (J1-8)
47.5
4700uF
80VD
IGNITION
MODUL
AC
E
NGIN
E
LE
CHANGIN
AN RIVER
CIRCUIT
VEL
+
E
C
ENGINE DIODES
R1
ST
A
RTE
R
12 VOLT
+
-
G
21
0
SOLENOID
BATTERY
AC
1.28 V
D
D
75A (J1-7)
E
NGINE OIL
47.5
FIELD CURRENT
SWITCHIN
TRANSISTO
44 TO 45 VAC
FUEL
SHUTOF
OLENOID
+
GN
D
PRESSURE
SWITCH
G
B
ETWEE
TERMINAL
AT HIGH
N
AC
E
NGIN
E
F
+
-
R
FRAM
E
S
ST RTE
A
R
S
5E (J1-2)
HOUR
OPENS
ON
Control boa
r
d common is
op abov
ame g ound.
GROUND
IDL
E
FIELD CURRENT FEEDBACK
(OVER-CURRENT ROT CTED)
P
E
METER
LO OIL
W
REVERSE VOLTAG
E
one diode d
r
e
FEEDBAC AMP
K
PRESSURE
P
ROT CTION DIODE
E
welder f
r
r
Resistance of fuel
solenoid cannot be
CONNECTOR PIN NUMBERS:
If engine oil pressure drops below safe
FIELD & IDLE CONTROL
PC BOARD (L12198-1)
accurately
4
2
3
12
6
7
1
A
operating pressure, the oil pressure
measured th
diodes.
rough
switch opens
circuit 224 shutting off fuel solenoid to
stop engine. Hourmeter wi l also stop
unning and P B1 will dene gize idle
solenoid.
removing 12 volts from
L13104
1
3
2
J2
J1
l
r
C
r
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
EAGLE™ 10,000
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G-6
G-6
ELECTRICAL DIAGRAMS
SCHEMATIC - IDLER/FIELD CONTROL P.C. BOARD (L12197)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
EAGLE™ 10,000
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