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