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Lincoln Electric EAGLE 10,000 Service Manual

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See also: Operator's Manual
All manuals and user guides at all-guides.com
SVM192-A
April, 2009
™
EAGLE
10 000
11096, 11397
For use with machine code number:
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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Summary of Contents for Lincoln Electric EAGLE 10,000

  • Page 1: Service Manual

    All manuals and user guides at all-guides.com SVM192-A April, 2009 ™ EAGLE 10 000 11096, 11397 For use with machine code number: 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...
  • Page 2 Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    All manuals and user guides at all-guides.com SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 All manuals and user guides at all-guides.com SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. explosion. 7.a. Use only compressed cylinders containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area.If process used and properly operating this is not possible, cover them to prevent the welding sparks regulators designed for the gas and...
  • Page 5 All manuals and user guides at all-guides.com 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 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
  • Page 6 All manuals and user guides at all-guides.com - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ................i-iv Installation .

  • Page 7: Table Of Contents

    Connection of EAGLE 10,000 to Premises Wiring ........
  • Page 8 All manuals and user guides at all-guides.com INSTALLATION TECHNICAL SPECIFICATIONS - EAGLE 10,000 (K2343-1,K2343-2) INPUT - GASOLINE ENGINE Make/Model Description Operating Displacement Capacities Horsepower Starting Speed (RPM) cu. in. System (cu.cm.) K2341-1 2 cylinder 12VDC 4 Cycle Kohler Battery Air-Cooled...

  • Page 9: Installation

    All manuals and user guides at all-guides.com 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 WARNING the vehicle. Use a #8 or larger copper wire connected Do not attempt to use this equipment until you between the machine grounding stud and the frame of have thoroughly read the engine manufacturer’s...

  • Page 10: Oil

    Kohler CH23S - 2.0 Quarts (1.9 Liters) 4. Typical conditions of use, i.e., travel speed; rough- The EAGLE 10,000 is shipped with the engine ness of surface on which the trailer will be operated; crankcase filled with SAE 10W-30 oil. Check the oil environmental conditions.

  • Page 11: Angle Of Operation

    ANGLE OF OPERATION CAUTION Internal combustion engines are designed to run in a Do not operate a EAGLE 10,000 with a high altitude level condition which is where the optimum perfor- jet installed at altitudes below 5000 ft. This will mance is achieved.

  • Page 12: Welder Operation

    However, if the welding process is started. the EAGLE 10,000 is used with any other high frequency equipment, the bypass capacitor a. Shut the welder off.

  • Page 13: Auxiliary Power

    All manuals and user guides at all-guides.com INSTALLATION AUXILIARY POWER The EAGLE 10,000 can provide up to 9,000 watts of 120/240 volts AC, single phase 60Hz power for contin- uous use, and up to 10,000 watts of 120/240 volts AC, single phase 60Hz power peak use.
  • Page 14 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...

  • Page 15: Auxiliary Power While Welding

    2. Take necessary steps to assure load is limited to the capacity of the EAGLE 10,000 by installing a TABLE II 38 amp 240V double pole circuit breaker. SIMULTANEOUS WELDING AND POWER Maximum rated load for the 240V auxiliary is 38 amperes.

  • Page 16: Connection Of Eagle 10,000 To Premises Wiring

    All manuals and user guides at all-guides.com A-10 INSTALLATION A-10 Figure A.1 CONNECTION OF EAGLE 10,000 TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 120 VOLT 60 Hz. COMPANY 3-Wire 120 VOLT Service METER NEUTRAL LOAD DOUBLE POLE DOUBLE THROW...
  • Page 17 All manuals and user guides at all-guides.com TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Precautions .

  • Page 18: Operation

    All manuals and user guides at all-guides.com OPERATION SAFETY PRECAUTIONS WELDER CONTROLS - FUNCTION AND OPERATION Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s ENGINE SWITCH manual supplied with your welder. It includes The engine switch is used to Start the Engine, Select important safety precautions, detailed engine High Idle or Auto Idle while the engine is running, and...

  • Page 19: Range Switch

    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 .39 Gallons/Hour 2200 RPM (1.49 Liters/Hour)

  • Page 20: Starting The Engine

    Stop the engine by placing the Engine switch in the clothing. “OFF” position. A fuel shut off valve is not required on the Eagle 10,000 • Keep flammable material away. because the fuel tank is mounted below the engine. BREAK-IN PERIOD •...

  • Page 21: Welding Process (Stick/Tig

    They must be used with a blended shielding gas such achieve the desired welding current. as C25 (75% Argon - 25% CO ). The welding ranges that can be used with the EAGLE 10,000 are shown in RANGE SETTING TYPICAL CURRENT RANGE...

  • Page 22: Summary Of Welding Processes

    All manuals and user guides at all-guides.com OPERATION Summary of Welding Processes CONTROL ELECTRODE CABLE IDLE WHEN NOT TO START PROCESS USED MODE WELDING WELDING STICK AUTO Touch electrode to work. Welding starts immediately and engine goes to high idle. WIRE FEED, LN-25 WITH AUTO Cold...
  • Page 23 All manuals and user guides at all-guides.com TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Optional Equipment .
  • Page 24 Attaches to K1737-1, K1770-1, and K957-1. K844-1 Water Valve Kit - For use with water cooled K886-1 Canvas Cover -To protect the EAGLE 10,000 TIG torch, Installs inside of TIG Module. when not in use. Made from attractive red canvas...
  • Page 25 All manuals and user guides at all-guides.com ACCESSORIES RECOMMENDED EQUIPMENT PLASMA CUTTING: 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) •...
  • Page 26 All manuals and user guides at all-guides.com NOTES EAGLE™ 10,000...
  • Page 27 All manuals and user guides at all-guides.com TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .

  • Page 28: Maintenance

    All manuals and user guides at all-guides.com MAINTENANCE SAFETY PRECAUTIONS CAUTION Make certain that the oil filler cap is securely tight- WARNING ened after checking or adding oil. If the cap is not Have qualified personnel do the maintenance tight, oil consumption can increase significantly work.
  • Page 29 All manuals and user guides at all-guides.com MAINTENANCE Use 4-stroke motor oil that meets or exceeds the AIR CLEANER AND OTHER MAINTENANCE requirements for API service classification SG or SH. Always check the API SERVICE label on the oil con- •...

  • Page 30: Engine Adjustments

    All manuals and user guides at all-guides.com 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 OVERSPEED IS HAZARDOUS cable from old battery first and connect to new battery last.
  • Page 31 All manuals and user guides at all-guides.com MAINTENANCE FIGURE D.1 - MAJOR COMPONENT LOCATIONS 1. CASEFRONT 2. OUTPUT RECTIFIER ASSEMBLY 3. BASE/UNDERCARRIAGE ASSEMBLY 4. ENGINE/ROTOR/STATOR ASSEMBLY 5. CASE TOP & SIDES EAGLE™ 10,000...
  • Page 32 All manuals and user guides at all-guides.com NOTES EAGLE™ 10,000...
  • Page 33 All manuals and user guides at all-guides.com TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 Battery, Starter, Engine, Excitation, Rotor, Stator, and Idler Solenoid .

  • Page 34: Theory Of Operation

    The rotor is mechanically If no current is drawn from the EAGLE 10,000, the coupled to the engine. This rotating magnet induces a printed circuit board activates the idler solenoid, which voltage in the stationary windings of the main alterna- then brings the engine to a low idle state.
  • Page 35 All manuals and user guides at all-guides.com THEORY OF OPERATION FIGURE E.3 – ROTOR FIELD FEEDBACK AND AUXILIARY POWER RANGE SWITCH POSITIVE POSITIVE CHOKE OUTPUT BRIDGE TERMINAL REACTOR NEGATIVE TERMINAL STAT OR MECHANICAL ROTAT ION ROTOR STARTER ENGINE SLIP ROTOR RINGS FLYWHEEL ALTERNATOR...
  • Page 36 All manuals and user guides at all-guides.com THEORY OF OPERATION FIGURE E.4 – WELD WINDING, REACTOR, AND RANGE SWITCH RANGE SWITCH POSITIVE POSITIVE CHOKE OUTPUT BRIDGE TERMINAL REACTOR NEGATIVE TERMINAL STAT OR MECHANICAL ROTAT ION ROTOR STARTER ENGINE SLIP ROTOR RINGS FLYWHEEL ALTERNATOR...
  • Page 37 All manuals and user guides at all-guides.com TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 38: 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.

  • Page 39: Pc Board Troubleshooting Procedures

    Do not touch electrically hot parts. - 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- CAUTION er failure analysis.
  • Page 40 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...
  • Page 41 5. Perform the Output Bridge Test. 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...
  • Page 42 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...
  • Page 43 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...
  • Page 44 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...
  • Page 45 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...
  • Page 46 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...
  • Page 47 Diagram 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...
  • Page 48 All manuals and user guides at all-guides.com F-12 NOTES F-12 EAGLE™ 10,000...

  • Page 49: Rotor Voltage Test

    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.
  • Page 50 All manuals and user guides at all-guides.com F-14 TROUBLESHOOTING AND REPAIR F-14 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.

  • Page 51: Rotor Resistance Test

    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.
  • Page 52 All manuals and user guides at all-guides.com F-16 TROUBLESHOOTING AND REPAIR F-16 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 1. With the 5/16” nut driver, remove the 6 sheet generator brush leads.
  • Page 53 All manuals and user guides at all-guides.com F-17 TROUBLESHOOTING AND REPAIR F-17 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.
  • Page 54 All manuals and user guides at all-guides.com F-18 NOTES F-18 EAGLE™ 10,000...

  • Page 55: Auxiliary And Field Winding Test

    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.
  • Page 56 All manuals and user guides at all-guides.com F-20 TROUBLESHOOTING AND REPAIR F-20 AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.3 – LOCATION OF LEADS #3 AND #5 Machine Case 115V Front Receptacle Lead #3 Lead #5 TEST PROCEDURE To test the 115 VAC winding: To test the 230 VAC winding: 1.
  • Page 57 All manuals and user guides at all-guides.com F-21 TROUBLESHOOTING AND REPAIR F-21 AUXILIARY AND FIELD WINDING TEST (continued) To test the field winding: 1. Remove the fuel cap and lift bail rubber gasket. If the voltage readings are within specifications, With the 5/16”...
  • Page 58 All manuals and user guides at all-guides.com F-22 NOTES F-22 EAGLE™ 10,000...

  • Page 59: Output Rectifier Bridge Test

    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.
  • Page 60 All manuals and user guides at all-guides.com F-24 TROUBLESHOOTING AND REPAIR F-24 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.

  • Page 61: Charging Circuit Test

    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.
  • Page 62 All manuals and user guides at all-guides.com F-26 TROUBLESHOOTING AND REPAIR F-26 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 5.

  • Page 63: Engine Throttle Adjustment Test

    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.
  • Page 64 All manuals and user guides at all-guides.com F-28 TROUBLESHOOTING AND REPAIR F-28 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 8.
  • Page 65 All manuals and user guides at all-guides.com F-29 TROUBLESHOOTING AND REPAIR F-29 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 Muffler Housing Throttle linkage Choke Cable 3/8"...
  • Page 66 All manuals and user guides at all-guides.com F-30 TROUBLESHOOTING AND REPAIR F-30 ENGINE THROTTLE ADJUSTMENT TEST (continued) Oscilloscope Method: Vibratach Method: 1. Connect the oscilloscope to the 115 VAC 1. Place the vibratach as close to the engine as receptacle, according to the manufacturer’s possible.

  • Page 67: Normal Open Circuit Voltage Waveform (115 Vac Supply

    All manuals and user guides at all-guides.com F-31 TROUBLESHOOTING AND REPAIR F-31 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY) HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 16.2 ms 0 volts 5 ms 50 volts This is the typical auxiliary output volt- age generated from a properly operat- ing machine.
  • Page 68 All manuals and user guides at all-guides.com F-32 TROUBLESHOOTING AND REPAIR F-32 TYPICAL DC WELD OUTPUT WAVEFORM (CC MODE) MACHINE LOADED 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.

  • Page 69: Abnormal Open Circuit Dc Weld Voltage Waveform (Ccmode

    All manuals and user guides at all-guides.com F-33 TROUBLESHOOTING AND REPAIR F-33 ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING 0 volts 5 ms 50 volts This is NOT the typical DC (+) output voltage waveform.

  • Page 70: Normal Open Circuit Dc Weld Voltage Waveform

    All manuals and user guides at all-guides.com F-34 TROUBLESHOOTING AND REPAIR F-34 NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM (CC MODE) HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM 0 volts 5 ms 50 volts This is the typical DC output voltage generated from a properly operating machine.

  • Page 71: Brush Removal And Replacement

    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.
  • Page 72 All manuals and user guides at all-guides.com F-36 TROUBLESHOOTING AND REPAIR F-36 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- 2.
  • Page 73 All manuals and user guides at all-guides.com F-37 TROUBLESHOOTING AND REPAIR F-37 BRUSH REMOVAL AND REPLACEMENT (continued) SLIP RINGS A slight amount of darkening and wear of the CAUTION slip rings and brushes is normal. Brushes should be inspected when a general overhaul is necessary.
  • Page 74 All manuals and user guides at all-guides.com F-38 NOTES F-38 EAGLE™ 10,000...
  • Page 75 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.

  • Page 76: Printed Circuit Board Removal And Replacement

    All manuals and user guides at all-guides.com F-40 TROUBLESHOOTING AND REPAIR F-40 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 topic “PC Board Troubleshooting Procedures”...
  • Page 77 All manuals and user guides at all-guides.com F-41 TROUBLESHOOTING AND REPAIR F-41 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.
  • Page 78 All manuals and user guides at all-guides.com F-42 NOTES F-42 EAGLE™ 10,000...
  • Page 79 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.

  • Page 80: Output Rectifier Bridge Removal And Replacement

    All manuals and user guides at all-guides.com F-44 TROUBLESHOOTING AND REPAIR F-44 OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.11 - OUTPUT RECTIFIER CONNECTIONS L1 TO CHOKE TO POLARITY SWITCH (3) 1/2" TO S2 MOUNTING SCREWS ENGINE (4) 7/16" MOUNTING SCREWS TO S2...
  • Page 81 All manuals and user guides at all-guides.com F-45 TROUBLESHOOTING AND REPAIR F-45 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 lead and the heavy lead going to the S2 insulators.
  • Page 82 All manuals and user guides at all-guides.com F-46 NOTES F-46 EAGLE™ 10,000...
  • Page 83 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.
  • Page 84 All manuals and user guides at all-guides.com F-48 TROUBLESHOOTING AND REPAIR F-48 ENGINE/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.12 – COMPONENT LOCATIONS, ENGINE/ROTOR REMOVAL 1. STATOR COWLING COVER 2. BLOWER FAN 3. IDLE LINKAGE 4. BRUSH HOLDER BRACKET 5. ENGINE LIFT BAILS 6.
  • Page 85 All manuals and user guides at all-guides.com F-49 TROUBLESHOOTING AND REPAIR F-49 ENGINE/ROTOR REMOVAL AND REPLACEMENT (continued) ENGINE AND ROTOR REMOVAL PROCEDURE 1. Refer to Figure F.12 for component locations. 15. With a 1/4” nut driver, disconnect the engine choke cable from the engine. Mark the loca- 2.
  • Page 86 6. Slide the rotor the rest of the way off the crank- 3. Install the appropriate long thru-bolt (two are shaft. Be careful not to lose the washer that fits provided) supplied with Lincoln Electric Rotor between the blower fan and the rotor. Removal Kit S20788. The slot head must face out.
  • Page 87 F-51 ENGINE/ROTOR REMOVAL AND REPLACEMENT (KIT S20788) (continued) REASSEMBLY PROCEDURE NOTE: Lincoln Electric recommends that a new 8. Attach leads to the oil pressure switch refer to bearing (Lincoln part #M9300-85) be installed wiring diagram. Replace any cut cable ties.

  • Page 88: Retest After Repair

    All manuals and user guides at all-guides.com F-52 TROUBLESHOOTING AND REPAIR F-52 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.
  • Page 89 All manuals and user guides at all-guides.com TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram - Code 11096 - (M20317) .
  • Page 90 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - CODE 11096 (M20317) EAGLE 10,000 (KOHLER) LEADS 3 AND 6: 2 TURNS THRU TOROID IN OPPOSITE DIRECTIONS 1 TURN OUTPUT GROUND SCREW CONTROL 209A ON UPPER CASEFRONT CHOKE...
  • Page 91 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - CODE 11397 - (M21271) EAGLE 10,000 (KOHLER) LEADS 3 AND 6: 2 TURNS THRU TOROID IN OPPOSITE DIRECTIONS 1 TURN CHOKE OUTPUT GROUND SCREW CONTROL 209A ON UPPER CASEFRONT...
  • Page 92 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS SCHEMATIC - COMPLETE MACHINE - CODE 11096 (L12259) STATOR Choke mounted on base in TWO POLE 3600 RPM ELECTRODE WELD ALTERNATOR front of generator. 210DC/225AC WINDINGS TERMINAL L1 CHOKE D1 - BRIDGE RECTIFIER POLARITY S1 - SELECTOR SWITCH SWITCH...
  • Page 93 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS SCHEMATIC - COMPLETE MACHINE - CODE 11397 (L13104) STATOR Choke mounted on base in WELD POSITIVE front of generator. 210DC WINDINGS TERMINAL D1 - BRIDGE RECTIFIER L1 CHOKE S1 - SELECTOR SWITCH Open Circuit Volts: NO CONNECTION TO C1, E AND S2...
  • Page 94 All manuals and user guides at all-guides.com 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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