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