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April
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iSAFETYi
FOR ENGINE powered equipment
ELECTRIC AND MAGNETIC FIELDS may be dangerous
CALIFORNIA PROPOSITION 65 WARNINGS
SAFETY
ELECTRIC SHOCK can kill
ARC RAYS can burn
FUMES AND GASES
powered equipment
WELDING
CUTTING
CYLINDER may explode
PRÉCAUTIONS DE SÛRETÉ
SAFETY
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I - MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Safety
Page
EAGLE 10,000
TABLE OF CONTENTS - INSTALLATION SECTION
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EAGLE 10,000
INSTALLATION
TECHNICAL SPECIFICATIONS - EAGLE 10,000 K2343-1,K2343-2
Horsepower
Displacement cu. in cu.cm
SAFETY PRECAUTIONS
See additional warning information at front of this operator’s manual
MACHINE GROUNDING
SPARK ARRESTER
Stop engine while fueling Do not smoke when fueling
VEHICLE MOUNTING
FUEL GASOLINE FUEL ONLY
Follow vehicle manufacturer’s instructions
ADDITIONAL SAFETY PRECAUTIONS HIGH ALTITUDE OPERATION
when lifting
Do not lift this machine using
heavy accessory such as trail
CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS
ADDITIONAL SAFETY PRECAUTIONS
INSTRUCTIONS
WELDER OPERATION
AUXILIARY POWER
120/240 VOLT DUAL VOLTAGE RECEPTACLE
120 V DUPLEX RECEPTACLES
MOTOR STARTING
TABLE l
ELECTRICAL DEVICE USE WITH THE EAGLE 10,000
Type
Common Electrical Devices
AUXILIARY POWER WHILE WELDING
SIMULTANEOUS WELDING AND POWER
STANDBY POWER CONNECTIONS
the connection diagram shown in
CONNECTION OF EAGLE 10,000 TO PREMISES WIRING
Figure A.1
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TABLE OF CONTENTS - OPERATION SECTION
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EAGLE 10,000
ENGINE SWITCH
OPERATION
GENERAL DESCRIPTION
WELDER CONTROLS - FUNCTION AND OPERATION
RANGE SWITCH
Range Setting
OPERATIONB-3
EAGLE 10,000 APPROXIMATE FUEL CONSUMPTION
STARTING/SHUTDOWN INSTRUCTIONS
BREAK-IN PERIOD
STARTING THE ENGINE
Keep flammable material away
WIRE FEED WELDING PROCESSES
WELDING PROCESS
Stick Constant Current Welding
TIG CONSTANT CURRENT WELDING
WHEN NOT
TYPICAL CURRENT RANGES 1 FOR TUNGSTEN ELECTRODES2
Summary of Welding Processes
CONTROL
TABLE OF CONTENTS - ACCESSORIES SECTION
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EAGLE 10,000
ACCESSORIES
OPTIONAL EQUIPMENT Field Installed
K1745-1 GAS CYLINDER HOLDER
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WIRE FEED
RECOMMENDED EQUIPMENT
PLASMA CUTTING
STICK
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TABLE OF CONTENTS - MAINTENANCE SECTION
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EAGLE 10,000
MAINTENANCE
SAFETY PRECAUTIONS
Routine Maintenance
Kohler CH20S or CH23S
AIR CLEANER AND OTHER MAINTENANCE
OIL FILTER CHANGE
MAINTENANCE
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ENGINE ADJUSTMENTS
BATTERY
ENGINE MAINTENANCE PARTS
Pre-Cleaner
1. CASEFRONT 2. OUTPUT RECTIFIER ASSEMBLY
3. BASE/UNDERCARRIAGE ASSEMBLY 4. ENGINE/ROTOR/STATOR ASSEMBLY
5. CASE TOP & SIDES
FIGURE D.1 - MAJOR COMPONENT LOCATIONS
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E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1
FIGURE E.1 BLOCK LOGIC DIAGRAM
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BATTERY, STARTER, ENGINE, ROTOR, STATOR, AND IDLER SOLENOID
THEORY OF OPERATION
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ROTOR FIELD FEEDBACK AND AUXILIARY POWER
FIGURE E.3 - ROTOR FIELD FEEDBACK AND AUXILIARY POWER
THEORY OF OPERATION
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WELD WINDING, REACTOR, AND RANGE SWITCH
FIGURE E.4 - WELD WINDING, REACTOR, AND RANGE SWITCH
OUTPUT BRIDGE, CHOKE, AND OUTPUT TERMINALS
THEORY OF OPERATION
F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1
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EAGLE 10,000
F-2TROUBLESHOOTING AND REPAIRF-2
HOW TO USE TROUBLESHOOTING GUIDE
COURSE OF ACTION
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TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
PC board can be damaged by static electricity
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PROBLEMS
SYMPTOMS
MISADJUSTMENTS
OUTPUT PROBLEMS
RECOMMENDED COURSE OF ACTION
TROUBLESHOOTING AND REPAIR
PROBLEMS
SYMPTOMS
PROBLEMS SYMPTOMS
POSSIBLE AREAS OF MISADJUSTMENTS
Field Winding Voltage Test
TROUBLESHOOTING AND REPAIR
Rotor Voltage2. PTestrform the
TROUBLESHOOTING AND REPAIR
PROBLEMS
SYMPTOMS
ENGINE PROBLEMS
TROUBLESHOOTING AND REPAIR
PROBLEMS SYMPTOMS
POSSIBLE AREAS OF MISADJUSTMENTS
Wiring
TROUBLESHOOTING AND REPAIR
PROBLEMS
SYMPTOMS
F-10
Charging Circuit Test
TROUBLESHOOTING AND REPAIR
PROBLEMS
WELDING PROBLEMS
F-11
3. BridgePerformTestthe. Output Rectifier
TROUBLESHOOTING AND REPAIR
F-12
F-12
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ROTOR VOLTAGE TEST
TEST DESCRIPTION
MATERIALS NEEDED
F-13
TEST PROCEDURE
4. Remove the case top, then reinstall the fuel cap
ROTOR VOLTAGE TEST continued
F-14
ROTOR RESISTANCE TEST
F-15
TROUBLESHOOTING AND REPAIR
TEST DESCRIPTION
ROTOR RESISTANCE TEST continued
F-16
FIGURE F.2 - LOCATION OF ROTOR SLIP RINGS
4. Remove the case top, then replace the fuel cap
F-17
TROUBLESHOOTING AND REPAIR
ROTOR RESISTANCE TEST continued
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F-18
F-18
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AUXILIARY AND FIELD WINDING TEST
F-19
TROUBLESHOOTING AND REPAIR
TEST DESCRIPTION
AUXILIARY AND FIELD WINDING TEST continued
F-20
FIGURE F.3 - LOCATION OF LEADS #3 AND #5
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F-21
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To test the field winding
TROUBLESHOOTING AND REPAIR
F-22
F-22
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OUTPUT RECTIFIER BRIDGE TEST
F-23
TROUBLESHOOTING AND REPAIR
TEST DESCRIPTION
OUTPUT RECTIFIER BRIDGE TEST continued
ENGINE
F-24
FIGURE F.4 - LOCATION OF OUTPUT RECTIFIER LEADS
CHARGING CIRCUIT TEST
F-25
TROUBLESHOOTING AND REPAIR
TEST DESCRIPTION
CHARGING CIRCUIT TEST continued
F-26
FIGURE F.5 - LOCATION OF VOLTAGE REGULATOR
TROUBLESHOOTING AND REPAIR
ENGINE THROTTLE ADJUSTMENT TEST
F-27
TROUBLESHOOTING AND REPAIR
TEST DESCRIPTION
ENGINE THROTTLE ADJUSTMENT TEST continued
F-28
FIGURE F.6 - BLOWER PADDLE MARKED FOR STROBE-TACH METHOD
Strobe-tach Method
HIGH IDLE ADJUSTMENT NUT
LOW IDLE ADJUSTMENT NUT
F-29
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ENGINE THROTTLE ADJUSTMENT TEST continued
F-30
Oscilloscope Method
Vibratach Method
SCOPE SETTINGS
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLY
HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
F-31
TYPICAL DC WELD OUTPUT WAVEFORM CC MODE
MACHINE LOADED
MACHINE LOADED TO 200 AMPS AT 26 VDC
F-32
ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
ONE OUTPUT DIODE NOT FUNCTIONING
F-33
TROUBLESHOOTING AND REPAIR
NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM CC MODE
F-34
TROUBLESHOOTING AND REPAIR
SCOPE SETTINGS
BRUSH REMOVAL AND REPLACEMENT
F-35
TROUBLESHOOTING AND REPAIR
TEST DESCRIPTION
BRUSH REMOVAL AND REPLACEMENT continued
PROCEDURE
5. Remove the case top, then reinstall the fuel cap
F-36
SLIP RINGS
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F-37
F-38
F-38
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PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT
F-39
TROUBLESHOOTING AND REPAIR
TEST DESCRIPTION
PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT continued
F-40
FIGURE F.10 - PRINTED CIRCUIT BOARD LOCATION
TROUBLESHOOTING AND REPAIR
F-41
TROUBLESHOOTING AND REPAIR
PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT continued
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F-42
F-42
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F-43TROUBLESHOOTING AND REPAIRF-43
OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT
TEST DESCRIPTION
MATERIALS NEEDED
F-44TROUBLESHOOTING AND REPAIRF-44
OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued
TO POLARITY SWITCH 3 1/2 MOUNTING SCREWS ENGINE NO NUT
L1 TO CHOKE W1
F-45TROUBLESHOOTING AND REPAIRF-45
OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued
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F-46
F-46
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ENGINE/ROTOR REMOVAL AND REPLACEMENT
INSTRUCTIONS
F-47
Lincoln Electric Rotor Removal Kit S20788 - FOR ROTOR REMOVAL ONLY
ENGINE/ROTOR REMOVAL AND REPLACEMENT continued
F-48
FIGURE F.12 - COMPONENT LOCATIONS, ENGINE/ROTOR REMOVAL
TROUBLESHOOTING AND REPAIR
ENGINE AND ROTOR REMOVAL PROCEDURE
F-49
TROUBLESHOOTING AND REPAIR
ENGINE/ROTOR REMOVAL AND REPLACEMENT continued
ROTOR REMOVAL PROCEDURE
F-50
FIGURE F.13 - ENGINE AND ROTOR REMOVED FROM STATOR
THRU-BOLT
ENGINE/ROTOR REMOVAL AND REPLACEMENT KIT S20788 continued
REASSEMBLY PROCEDURE
F-51
TROUBLESHOOTING AND REPAIR
AUXILIARY POWER RECEPTACLE OUTPUT1
Range Switch
RETEST AFTER REPAIR
ENGINE OUTPUT
TABLE OF CONTENTS - DIAGRAM SECTION
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EAGLE 10,000
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - CODE 11096 M20317
ELECTRICAL SYMBOLS PER E1537
EAGLE 10,000 KOHLER
WIRING DIAGRAM - CODE 11397 - M21271
ELECTRICAL DIAGRAMS
ELECTRICAL SYMBOLS PER E1537
EAGLE 10,000 KOHLER
SCHEMATIC - COMPLETE MACHINE - CODE 11096 L12259
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ELECTRODE
SCHEMATIC - COMPLETE MACHINE - CODE 11397 L13104
POSITIVE
ELECTRICAL DIAGRAMS
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SCHEMATIC - IDLER/FIELD CONTROL P.C. BOARD L12197
ELECTRICAL DIAGRAMS
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