Lincoln Electric SVM192-A - Manuals
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Manual Lincoln Electric SVM192-A
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EAGLE™ 10,000 SAFETY i i FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b.Operate engines in open, well-ventilated areas or vent the engine...
SAFETY ii ii EAGLE™ 10,000 FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breath...
EAGLE™ 10,000 SAFETY iii iii Jan ‘09 FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommend...
SAFETY iv iv EAGLE™ 10,000 Mar ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Proteg...
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS - I I EAGLE™ 10,000 Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
TABLE OF CONTENTS - INSTALLATION SECTION A-1 A-1 EAGLE™ 10,000 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . ...
INSTALLATION A-2 A-2 EAGLE™ 10,000 TECHNICAL SPECIFICATIONS - EAGLE 10,000 (K2343-1,K2343-2) INPUT - GASOLINE ENGINE RATED OUTPUT @ 104°F (40°C)- WELDER HEIGHT WIDTH DEPTH WEIGHT 30.3 in. 19.1 in. 42.0 in. 502 lbs. (228kg) 770 mm 485 mm 1067 mm RATED OUTPUT @ 104°F (40°C)- GENERATOR Welding Output D...
INSTALLATION A-3 A-3 EAGLE™ 10,000 SAFETY PRECAUTIONS MACHINE GROUNDING Because this portable engine driven welder or genera- tor creates it’s own power, it is not necessary to con- nect it’s frame to an earth ground, unless the machine is connected to premises wiring (your home, shop, etc.). To pre...
INSTALLATION A-5 A-5 EAGLE™ 10,000 ANGLE OF OPERATION Internal combustion engines are designed to run in a level condition which is where the optimum perfor- mance is achieved. The maximum angle of operation for the engine is 15 degrees from horizontal in any direction. If the engine is to be operat...
INSTALLATION A-6 A-6 EAGLE™ 10,000 EAGLE 10,000 Constant Current 210 Amps DC @ 25 Volts CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS NOTE: A constant voltage (CV) power source is rec- ommended for wire feeder applications. The LN-15 and LN-25 may be used with a constant current (CC) power source, suc...
INSTALLATION A-7 A-7 EAGLE™ 10,000 120 V DUPLEX RECEPTACLES The 120V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any plug used with the system must be at least equal to the current l...
INSTALLATION A-10 A-10 EAGLE™ 10,000 240 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION GND N NOTE: No. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDA...
TABLE OF CONTENTS - OPERATION SECTION B-1 B-1 EAGLE™ 10,000 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . ...
OPERATION B-2 B-2 EAGLE™ 10,000 W E L D E R C O N T R O L S - F U N C T I O N A N DOPERATION ENGINE SWITCH The engine switch is used to Start the Engine, Select High Idle or Auto Idle while the engine is running, and stop the Engine. When placed in the “OFF” position, the ignition circuit is de-ener...
OPERATION B-3 B-3 EAGLE™ 10,000 RANGE SWITCH The “Range” switch is used to select one of three amperage ranges with generous overlap for Stick/TIG welding, or one Wire Feed welding range Never change the “RANGE” Switch setting while welding. This will damage the switch. -----------------------------...
OPERATION B-4 B-4 EAGLE™ 10,000 STARTING/SHUTDOWN INSTRUCTIONS STARTING THE ENGINE Be sure all Pre-Operation Maintenance has been per- formed. Also, read the Engine Owner’s Manual before starting for the first time. Remove all loads connected to the AC power recepta- cles. Use the choke control as f...
OPERATION B-5 B-5 EAGLE™ 10,000 ARC GOUGING The EAGLE 10,000 can be used for limited arc goug- ing. Set the Range switch to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following table: WELDING PROCESS For any electrodes the procedur...
OPERATION B-6 B-6 EAGLE™ 10,000 Summary of Welding Processes CONTROL ELECTRODE CABLE IDLE WHEN NOT TO START PROCESS USED MODE WELDING WELDING STICK No AUTO Hot Touch electrode to work. Welding starts immediately and engine goes to high idle. WIRE FEED, LN-25 WITH No AUTO Cold Press gun trigger, LN-2...
TABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 EAGLE™ 10,000 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . ...
ACCESSORIES C-2 C-2 EAGLE™ 10,000 OPTIONAL EQUIPMENT (Field Installed) K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS - For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc....
ACCESSORIES C-3 C-3 EAGLE™ 10,000 RECOMMENDED EQUIPMENT STICK K704 Accessory Kit - For Stick Welding. Includes 35 ft (10.7m). • 2/0 AWG electrode cable, 30 ft. (9.1m) • 2/0 AWG work cable with lugs, headshield, filter plate, work clamp, and electrode holder. 400 amp capacity. K875 Accessory Kit - Fo...
NOTES C-4 C-4 EAGLE™ 10,000 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC
TABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 EAGLE™ 10,000 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
MAINTENANCE D-2 D-2 EAGLE™ 10,000 Have qualified personnel do the maintenance work. Turn the engine off before working inside t h e m a c h i n e . I n s o m e c a s e s , i t m a y b e necessary to remove safety guards to perform r e q u i r e d m a i n t e n a n c e . R e m o v e g u a r d s o n l...
MAINTENANCE D-3 D-3 EAGLE™ 10,000 Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SG or SH. Always check the API SERVICE label on the oil con- tainer to be sure it includes the letters SG or SH. SAE 10W-30 is recommended for general, all-temper- ature use...
MAINTENANCE D-4 D-4 EAGLE™ 10,000 ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3750 RPM, no load. Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed. Severe personal injury and damage to...
MAINTENANCE D-5 D-5 EAGLE™ 10,000 FIGURE D.1 - MAJOR COMPONENT LOCATIONS 4 4 1 1 3 3 5 5 2 2 1. CASEFRONT 2. OUTPUT RECTIFIER ASSEMBLY 3. BASE/UNDERCARRIAGE ASSEMBLY 4. ENGINE/ROTOR/STATOR ASSEMBLY 5. CASE TOP & SIDES Return to Section T OC Return to Section T OC Return to Section T OC Return to...
TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1 E-1 EAGLE™ 10,000 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 Battery, Starter, Engine, Excitation, Rotor, Stator, and Idler Solenoid...
THEORY OF OPERATION E-2 E-2 EAGLE™ 10,000 NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion BATTERY, STARTER, ENGINE, ROTOR, STATOR, AND IDLER SOLENOID The 12VDC battery powers the starter motor. When the engine is started and running, the battery circuit voltage is fed, thro...
THEORY OF OPERATION E-3 E-3 EAGLE™ 10,000 ROTOR FIELD FEEDBACK AND AUXILIARY POWER The AC voltage developed in the field winding is fed to the full wave field bridge. The DC output of the bridge is filtered by the field capacitor and controlled by the printed circuit board according to the output co...
THEORY OF OPERATION E-4 E-4 EAGLE™ 10,000 NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion WELD WINDING, REACTOR, AND RANGE SWITCH The stator weld winding is connected to the reactor and range switch. The inductance in the reactor offers an impedance to current flow. The rea...
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1 F-1 EAGLE™ 10,000 Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . ...
TROUBLESHOOTING AND REPAIR F-2 F-2 EAGLE™ 10,000 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column ...
TROUBLESHOOTING AND REPAIR F-3 F-3 EAGLE™ 10,000 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure: 1. Determine...
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln E...
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln E...
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln E...
ENGINE PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln E...
Observe Safety Guidelines detailed in the beginning of this manual. 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 1-888-9...
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 obse...
Slip Rings Brushes Lead 219 + - Lead 200A FIGURE F.1 – LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST ROTOR VOLTAGE TEST (continued) TEST PROCEDURE 1. With the 5/16” nut driver, remove the 6 sheet metal screws from the case top. 2. Remove the rubber gasket (cover seal) from the lift bail. 3. R...
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 obse...
Lead 219 Lead 200A + - FIGURE F.2 – LOCATION OF ROTOR SLIP RINGS ROTOR RESISTANCE TEST (continued) TEST PROCEDURE 1. With the 5/16” nut driver, remove the 6 sheet metal screws from the case top. 2. Remove the rubber gasket (cover seal) from the lift bail. 3. Remove the fuel cap. The rubber gasket fo...
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 obse...
Lead #3 Lead #5 115V Receptacle MachineCaseFront FIGURE F.3 – LOCATION OF LEADS #3 AND #5 AUXILIARY AND FIELD WINDING TEST (continued) TEST PROCEDURE To test the 115 VAC winding: 1. Remove the fuel cap and lift bail rubber gasket. With the 5/16” nut driver, remove the case top and left side; then re...
AUXILIARY AND FIELD WINDING TEST (continued) To test the field winding: 1. Remove the fuel cap and lift bail rubber gasket. With the 5/16” nut driver, remove the case top and left side; then reinstall the fuel cap. 2. Connect the volt/ohmmeter probes to leads #7 and #9 where they connect to the Fiel...
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 obse...
(-) (+) (+) (+) (-) (-) OUTPUT RECTIFIER ENGINE FIGURE F.4 – LOCATION OF OUTPUT RECTIFIER LEADS OUTPUT RECTIFIER BRIDGE TEST (continued) TEST PROCEDURE 1. Remove the spark plug wires to prevent acci- dental engine kickback or starting. 2. With the 5/16” nut driver, remove the 6 sheet metal screws fr...
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 obse...
VoltageRegulator GroundLead(Green) Engine AC Lead DC Lead AC Lead FIGURE F.5 – LOCATION OF VOLTAGE REGULATOR CHARGING CIRCUIT TEST (continued) TEST PROCEDURE 1. Start the engine and run it at high idle (3650 RPM). 2. Set the voltmeter for AC volts and place one meter probe on each of the two outside...
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 obse...
Blower Paddle FIGURE F.6 – BLOWER PADDLE MARKED FOR STROBE-TACH METHOD ENGINE THROTTLE ADJUSTMENT TEST (continued) TEST PROCEDURE This test can be conducted by any one of four methods. Strobe-tach Method: 1. With the 5/16” nut driver, remove the 6 sheet metal screws from the case top. 2. Remove the ...
ENGINE THROTTLE ADJUSTMENT TEST (continued) 11. If either of the readings is incorrect, adjust the throttle as follows: Adjust HIGH IDLE: Use the 3/8” wrench to turn the spring-loaded adjustment nut. See Figure F.8 for location of the adjustment nut. Turn the nut clockwise to increase HIGH IDLE spee...
ENGINE THROTTLE ADJUSTMENT TEST (continued) Oscilloscope Method: 1. Connect the oscilloscope to the 115 VAC receptacle, according to the manufacturer’s instructions. At 3700 RPM, the waveform should exhibit a period of 16.2 milliseconds. At 2200 RPM, the waveform should exhibit a period of 27.3 mill...
This is the typical auxiliary output volt- age generated from a properly operat- ing machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time. Note: Scope probes connected at machine 115VAC receptacle. SCOPE SETTINGS Volts/Div ...
TROUBLESHOOTING AND REPAIR F-32 F-32 EAGLE™ 10,000 This is the typical DC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 20 volts and that each horizontal division represents 5 milliseconds in time. The machine was loaded with a resistance g...
TROUBLESHOOTING AND REPAIR F-33 F-33 EAGLE™ 10,000 This is NOT the typical DC (+) output voltage waveform. One output diode is not functioning. Note the “gap” in the waveform. One output diode was disconnected to simulate an open or nonfunctioning output diode. Each vertical division represents 50 v...
TROUBLESHOOTING AND REPAIR F-34 F-34 EAGLE™ 10,000 This is the typical DC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 50 volts and that each horizontal division represents 5 milliseconds in time. Note: Scope probes connected at machine ou...
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 obse...
BRUSH REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove the spark plug wires. 2. With a 5/16” nut driver, remove the 6 sheet metal screws from the case top. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. Remove the fuel cap. The rubber gasket for the fill tube with come off wi...
BRUSH REMOVAL AND REPLACEMENT (continued) TROUBLESHOOTING AND REPAIR F-37 F-37 EAGLE™ 10,000 SLIP RINGS A slight amount of darkening and wear of the slip rings and brushes is normal. Brushes should be inspected when a general overhaul is necessary. If brushes are to be replaced, clean slip rings wit...
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 obse...
12 Pin Plug 4 Pin Plug 4 Self Tapping Screws (at corners) 1/4" Q.C. Tabs FIGURE F.10 - PRINTED CIRCUIT BOARD LOCATION PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (continued) PROCEDURE Before starting the following procedure, refer to the topic “ PC Board Troubleshooting Procedures ” at the beg...
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 obse...
(-) (+) (+) (+) (-) (-) ENGINE NO NUT TO POLARITY SWITCH #8 L1 TO CHOKE (4) 7/16" MOUNTING SCREWS W1 TO S2 TO S2 TO S1 254 (3) 1/2" MOUNTING SCREWS FIGURE F.11 - OUTPUT RECTIFIER CONNECTIONS OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove the engine spark plug...
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 obse...
FIGURE F.13 - ENGINE AND ROTOR REMOVED FROM STATOR ENGINE/ROTOR REMOVAL AND REPLACEMENT (continued) ROTOR REMOVAL PROCEDURE 1. To remove the rotor, double check that the engine spark plug wires are disconnected. You will be turning the rotor during this proce- dure, and this could accidentally cause...
ENGINE/ROTOR REMOVAL AND REPLACEMENT (KIT S20788) (continued) REASSEMBLY PROCEDURE NOTE: Lincoln Electric recommends that a new bearing (Lincoln part #M9300-85) be installed when you replace the rotor and blower assembly. 1. Clean the tapered engine crankshaft. Slide the rotor onto the shaft. 2. Ins...
TROUBLESHOOTING AND REPAIR F-52 F-52 EAGLE™ 10,000 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. OR • If you repair or replace any electrical components....
TABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 EAGLE™ 10,000 Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram - Code 11096 - (M20317) . . . . . . . . . . . . . . . . . . . . . ...
ELECTRICAL DIAGRAMS G-2 EAGLE™ 10,000 WIRING DIAGRAM - CODE 11096 (M20317) STARTER CR1 STARTER SOLENOID 12 VOLT IDLER SOLENOID BATTERY AC AC B+ SWITCH REGULATOR FLYWHEEL ALTERNATOR B- HOUR METER 5E 5D 224 ENGINE COMPONENTS 224A 1 2 3 CONNECTOR PIN NUMBERS: 7 6 12 1 2 3 4 J1 N.A. B J2 SOLENOID FUEL S...
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- Lincoln Electric SVM194-A Manual