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Lincoln Electric SVM192-A service manual April, Safety Depends on You, Return to Master TOC

Models: SVM192-A

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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

• 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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Lincoln Electric SVM192-A service manual April, Safety Depends on You, Return to Master TOC, EAGLE 10,000

Contents

View Safety Info View Safety Info View Safety Info View Safety Info Safety Depends on YouApril Return to Master TOC Return to Master TOC Return to Master TOCFOR ENGINE powered equipment iSAFETYiELECTRIC AND MAGNETIC FIELDS may be dangerous CALIFORNIA PROPOSITION 65 WARNINGSELECTRIC SHOCK can kill SAFETYARC RAYS can burn FUMES AND GASESWELDING powered equipmentCUTTING CYLINDER may explodeSAFETY PRÉCAUTIONS DE SÛRETÉReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSafety I - MASTER TABLE OF CONTENTS FOR ALL SECTIONSPage EAGLE 10,000Return to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - INSTALLATION SECTIONReturn to Master TOC EAGLE 10,000TECHNICAL SPECIFICATIONS - EAGLE 10,000 K2343-1,K2343-2 INSTALLATIONHorsepower Displacement cu. in cu.cmSee additional warning information at front of this operator’s manual SAFETY PRECAUTIONSMACHINE GROUNDING SPARK ARRESTERVEHICLE MOUNTING Stop engine while fueling Do not smoke when fuelingFUEL GASOLINE FUEL ONLY Follow vehicle manufacturer’s instructionswhen lifting ADDITIONAL SAFETY PRECAUTIONS HIGH ALTITUDE OPERATIONDo not lift this machine using heavy accessory such as trailADDITIONAL SAFETY PRECAUTIONS CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERSINSTRUCTIONS WELDER OPERATION120/240 VOLT DUAL VOLTAGE RECEPTACLE AUXILIARY POWER120 V DUPLEX RECEPTACLES MOTOR STARTINGELECTRICAL DEVICE USE WITH THE EAGLE 10,000 TABLE lType Common Electrical DevicesSIMULTANEOUS WELDING AND POWER AUXILIARY POWER WHILE WELDINGSTANDBY POWER CONNECTIONS the connection diagram shown inFigure A.1 CONNECTION OF EAGLE 10,000 TO PREMISES WIRINGSection TOC Master TOCReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - OPERATION SECTIONReturn to Master TOC EAGLE 10,000OPERATION ENGINE SWITCHGENERAL DESCRIPTION WELDER CONTROLS - FUNCTION AND OPERATIONRange Setting RANGE SWITCHOPERATIONB-3 EAGLE 10,000 APPROXIMATE FUEL CONSUMPTIONBREAK-IN PERIOD STARTING/SHUTDOWN INSTRUCTIONSSTARTING THE ENGINE Keep flammable material awayWELDING PROCESS WIRE FEED WELDING PROCESSESStick Constant Current Welding TIG CONSTANT CURRENT WELDINGTYPICAL CURRENT RANGES 1 FOR TUNGSTEN ELECTRODES2 WHEN NOTSummary of Welding Processes CONTROLReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - ACCESSORIES SECTIONReturn to Master TOC EAGLE 10,000OPTIONAL EQUIPMENT Field Installed ACCESSORIESK1745-1 GAS CYLINDER HOLDER Return to Section TOC Return to Section TOC Return to Section TOCRECOMMENDED EQUIPMENT WIRE FEEDPLASMA CUTTING STICKReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - MAINTENANCE SECTIONReturn to Master TOC EAGLE 10,000SAFETY PRECAUTIONS MAINTENANCERoutine Maintenance Kohler CH20S or CH23SOIL FILTER CHANGE AIR CLEANER AND OTHER MAINTENANCEMAINTENANCE Return to Section TOC Return to Section TOC Return to Section TOCBATTERY ENGINE ADJUSTMENTSENGINE MAINTENANCE PARTS Pre-Cleaner3. BASE/UNDERCARRIAGE ASSEMBLY 4. ENGINE/ROTOR/STATOR ASSEMBLY 1. CASEFRONT 2. OUTPUT RECTIFIER ASSEMBLY5. CASE TOP & SIDES FIGURE D.1 - MAJOR COMPONENT LOCATIONSReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCFIGURE E.1 BLOCK LOGIC DIAGRAM E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1Return to Master TOC TOC Return to Master Return to Master TOCTHEORY OF OPERATION BATTERY, STARTER, ENGINE, ROTOR, STATOR, AND IDLER SOLENOIDReturn to Section Section TOC Return to Master Master TOCFIGURE E.3 - ROTOR FIELD FEEDBACK AND AUXILIARY POWER ROTOR FIELD FEEDBACK AND AUXILIARY POWERTHEORY OF OPERATION Return to Section TOC Return to Section TOCFIGURE E.4 - WELD WINDING, REACTOR, AND RANGE SWITCH WELD WINDING, REACTOR, AND RANGE SWITCHOUTPUT BRIDGE, CHOKE, AND OUTPUT TERMINALS THEORY OF OPERATIONReturn to Master TOC Return to Master TOC Return to Master TOC F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1Return to Master TOC EAGLE 10,000HOW TO USE TROUBLESHOOTING GUIDE F-2TROUBLESHOOTING AND REPAIRF-2COURSE OF ACTION Return to Section TOC Return to Section TOC Return to Section TOCPC BOARD TROUBLESHOOTING PROCEDURES TROUBLESHOOTING AND REPAIRPC board can be damaged by static electricity Return to SectionSYMPTOMS PROBLEMSMISADJUSTMENTS OUTPUT PROBLEMSTROUBLESHOOTING AND REPAIR RECOMMENDED COURSE OF ACTIONPROBLEMS SYMPTOMSPOSSIBLE AREAS OF MISADJUSTMENTS PROBLEMS SYMPTOMSField Winding Voltage Test TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR Rotor Voltage2. PTestrform thePROBLEMS SYMPTOMSTROUBLESHOOTING AND REPAIR ENGINE PROBLEMSPROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTSTROUBLESHOOTING AND REPAIR WiringPROBLEMS SYMPTOMSCharging Circuit Test F-10TROUBLESHOOTING AND REPAIR PROBLEMSF-11 WELDING PROBLEMS3. BridgePerformTestthe. Output Rectifier TROUBLESHOOTING AND REPAIRF-12 F-12Return to Section TOC Return to Section TOCTEST DESCRIPTION ROTOR VOLTAGE TESTMATERIALS NEEDED F-134. Remove the case top, then reinstall the fuel cap TEST PROCEDUREROTOR VOLTAGE TEST continued F-14F-15 ROTOR RESISTANCE TESTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONF-16 ROTOR RESISTANCE TEST continuedFIGURE F.2 - LOCATION OF ROTOR SLIP RINGS 4. Remove the case top, then replace the fuel capTROUBLESHOOTING AND REPAIR F-17ROTOR RESISTANCE TEST continued Return to Section TOC Return to Section TOC Return to Section TOCF-18 F-18Return to Section TOC Return to Section TOCF-19 AUXILIARY AND FIELD WINDING TESTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONF-20 AUXILIARY AND FIELD WINDING TEST continuedFIGURE F.3 - LOCATION OF LEADS #3 AND #5 Return to Section TOC Section TOCReturn to Section Return to Section TOC Return to Section TOC F-21To test the field winding TROUBLESHOOTING AND REPAIRF-22 F-22Return to Section TOC Return to Section TOCF-23 OUTPUT RECTIFIER BRIDGE TESTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONENGINE OUTPUT RECTIFIER BRIDGE TEST continuedF-24 FIGURE F.4 - LOCATION OF OUTPUT RECTIFIER LEADSF-25 CHARGING CIRCUIT TESTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONF-26 CHARGING CIRCUIT TEST continuedFIGURE F.5 - LOCATION OF VOLTAGE REGULATOR TROUBLESHOOTING AND REPAIRF-27 ENGINE THROTTLE ADJUSTMENT TESTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONF-28 ENGINE THROTTLE ADJUSTMENT TEST continuedFIGURE F.6 - BLOWER PADDLE MARKED FOR STROBE-TACH METHOD Strobe-tach MethodLOW IDLE ADJUSTMENT NUT HIGH IDLE ADJUSTMENT NUTF-29 to SectionF-30 ENGINE THROTTLE ADJUSTMENT TEST continuedOscilloscope Method Vibratach MethodNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLY SCOPE SETTINGSHIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM F-31MACHINE LOADED TYPICAL DC WELD OUTPUT WAVEFORM CC MODEMACHINE LOADED TO 200 AMPS AT 26 VDC F-32ONE OUTPUT DIODE NOT FUNCTIONING ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORMF-33 TROUBLESHOOTING AND REPAIRF-34 NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM CC MODETROUBLESHOOTING AND REPAIR SCOPE SETTINGSF-35 BRUSH REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONPROCEDURE BRUSH REMOVAL AND REPLACEMENT continued5. Remove the case top, then reinstall the fuel cap F-36to Section TOC SLIP RINGSto Master TOC F-37F-38 F-38Return to Section TOC Return to Section TOCF-39 PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONF-40 PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT continuedFIGURE F.10 - PRINTED CIRCUIT BOARD LOCATION TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR F-41PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT continued Return to Section TOC Return to Section TOC Return to Section TOCF-42 F-42Return to Section TOC Return to Section TOCOUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT F-43TROUBLESHOOTING AND REPAIRF-43TEST DESCRIPTION MATERIALS NEEDEDOUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued F-44TROUBLESHOOTING AND REPAIRF-44TO POLARITY SWITCH 3 1/2 MOUNTING SCREWS ENGINE NO NUT L1 TO CHOKE W1OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued F-45TROUBLESHOOTING AND REPAIRF-45Return to Section Return to Section TOC Return to Section TOC Return to Section TOCF-46 F-46Return to Section TOC Return to Section TOCINSTRUCTIONS ENGINE/ROTOR REMOVAL AND REPLACEMENTF-47 Lincoln Electric Rotor Removal Kit S20788 - FOR ROTOR REMOVAL ONLYF-48 ENGINE/ROTOR REMOVAL AND REPLACEMENT continuedFIGURE F.12 - COMPONENT LOCATIONS, ENGINE/ROTOR REMOVAL TROUBLESHOOTING AND REPAIRF-49 ENGINE AND ROTOR REMOVAL PROCEDURETROUBLESHOOTING AND REPAIR ENGINE/ROTOR REMOVAL AND REPLACEMENT continuedF-50 ROTOR REMOVAL PROCEDUREFIGURE F.13 - ENGINE AND ROTOR REMOVED FROM STATOR THRU-BOLTREASSEMBLY PROCEDURE ENGINE/ROTOR REMOVAL AND REPLACEMENT KIT S20788 continuedF-51 TROUBLESHOOTING AND REPAIRRange Switch AUXILIARY POWER RECEPTACLE OUTPUT1RETEST AFTER REPAIR ENGINE OUTPUTReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - DIAGRAM SECTIONReturn to Master TOC EAGLE 10,000WIRING DIAGRAM - CODE 11096 M20317 ELECTRICAL DIAGRAMSELECTRICAL SYMBOLS PER E1537 EAGLE 10,000 KOHLERELECTRICAL DIAGRAMS WIRING DIAGRAM - CODE 11397 - M21271ELECTRICAL SYMBOLS PER E1537 EAGLE 10,000 KOHLERReturn to Section TOC SCHEMATIC - COMPLETE MACHINE - CODE 11096 L12259Return to Master TOC ELECTRODEPOSITIVE SCHEMATIC - COMPLETE MACHINE - CODE 11397 L13104ELECTRICAL DIAGRAMS Return to Section TOC Return to Section TOC Return to Section TOCELECTRICAL DIAGRAMS SCHEMATIC - IDLER/FIELD CONTROL P.C. BOARD L12197Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC