Lincoln Electric EAGLE SVM192-A Manual do Utilizador

SVM192-AApril, 2009Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However,your overall safety

3. Proper placement of the equipment on the trailer toinsure stability side to side and front to back whenbeing moved and when standing by itself whil

INSTALLATIONA-5 A-5EAGLE™ 10,000ANGLE OF OPERATIONInternal combustion engines are designed to run in alevel condition which is where the optimum perfo

INSTALLATIONA-6 A-6EAGLE™ 10,000EAGLE 10,000Constant Current 210 Amps DC @ 25 VoltsCONNECTION OF LINCOLN ELECTRICWIRE FEEDERSNOTE: A constant voltage

INSTALLATIONA-7 A-7EAGLE™ 10,000120 V DUPLEX RECEPTACLESThe 120V auxiliary power receptacles should only beused with three wire grounded type plugs or

INSTALLATIONA-8 A-8EAGLE™ 10,000TABLE lELECTRICAL DEVICE USE WITH THE EAGLE 10,000.Type Common Electrical Devices Possible ConcernsResistive Heaters,

INSTALLATIONA-9 A-9EAGLE™ 10,000STANDBY POWER CONNECTIONSThe EAGLE 10,000 is suitable for temporary, standby,or emergency power using the engine manuf

INSTALLATIONA-10 A-10EAGLE™ 10,000240 Volt60 Hz.3-WireServicePOWERCOMPANYMETER240 VOLT120 VOLT120 VOLTLOADNNEUTRALBUSGROUNDPREMISESDISCONNECT ANDSERVI

TABLE OF CONTENTS - OPERATION SECTIONB-1 B-1EAGLE™ 10,000Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATIONB-2 B-2EAGLE™ 10,000WELDER CONTROLS - FUNCTION ANDOPERATIONENGINE SWITCHThe engine switch is used to Start the Engine, SelectHigh Idle or Aut

OPERATIONB-3 B-3EAGLE™ 10,000RANGE SWITCHThe “Range” switch is used to select one of threeamperage ranges with generous overlap for Stick/TIGwelding,

EAGLE™ 10,000SAFETYi iFOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requ

OPERATIONB-4 B-4EAGLE™ 10,000STARTING/SHUTDOWN INSTRUCTIONSSTARTING THE ENGINEBe sure all Pre-Operation Maintenance has been per-formed. Also, read th

OPERATIONB-5 B-5EAGLE™ 10,000ARC GOUGINGThe EAGLE 10,000 can be used for limited arc goug-ing.Set the Range switch to adjust output current to thedesi

OPERATIONB-6 B-6EAGLE™ 10,000Summary of Welding ProcessesCONTROL ELECTRODECABLE IDLE WHEN NOT TO STARTPROCESS USED MODE WELDING WELDINGSTICK No AUTO H

TABLE OF CONTENTS - ACCESSORIES SECTIONC-1 C-1EAGLE™ 10,000Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIESC-2 C-2EAGLE™ 10,000OPTIONAL EQUIPMENT (Field Installed)K957-1 HEAVY DUTY, TWO WHEEL TRAILER FORSMALL WELDERS - For road, off-road and in-p

ACCESSORIESC-3 C-3EAGLE™ 10,000RECOMMENDED EQUIPMENTSTICKK704 Accessory Kit - For Stick Welding. Includes 35 ft (10.7m).• 2/0 AWG electrode cable, 30

NOTESC-4 C-4EAGLE™ 10,000Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

TABLE OF CONTENTS - MAINTENANCE SECTIOND-1 D-1EAGLE™ 10,000Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCED-2 D-2EAGLE™ 10,000Have qualified personnel do the maintenancework. Turn the engine off before working insidethe machine. In some cases, i

MAINTENANCED-3 D-3EAGLE™ 10,000Use 4-stroke motor oil that meets or exceeds therequirements for API service classification SG or SH.Always check the A

SAFETYii iiEAGLE™ 10,000FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing thesefumes and ga

MAINTENANCED-4 D-4EAGLE™ 10,000ENGINE ADJUSTMENTSOVERSPEED IS HAZARDOUSThe maximum allowable high idle speed for thismachine is 3750 RPM, no load. Do

MAINTENANCED-5 D-5EAGLE™ 10,000FIGURE D.1 - MAJOR COMPONENT LOCATIONS44113355221. CASEFRONT2. OUTPUT RECTIFIER ASSEMBLY3. BASE/UNDERCARRIAGE ASSEMBLY4

NOTESD-6 D-6EAGLE™ 10,000Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

TABLE OF CONTENTS-THEORY OF OPERATION SECTIONE-1 E-1EAGLE™ 10,000Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THEORY OF OPERATIONE-2 E-2EAGLE™ 10,000NOTE: Unshaded areas of Block LogicDiagram are the subject of discussionBATTERY, STARTER, ENGINE,ROTOR, STATOR,

THEORY OF OPERATIONE-3 E-3EAGLE™ 10,000ROTOR FIELD FEEDBACK ANDAUXILIARY POWERThe AC voltage developed in the field winding is fed tothe full wave fie

THEORY OF OPERATIONE-4 E-4EAGLE™ 10,000NOTE: Unshaded areas of Block LogicDiagram are the subject of discussionWELD WINDING, REACTOR, ANDRANGE SWITCHT

TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIRF-1 F-1EAGLE™ 10,000Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING AND REPAIRF-2 F-2EAGLE™ 10,000This Troubleshooting Guide is provided tohelp you locate and repair possible machinemalfunctions. Simply

TROUBLESHOOTING AND REPAIRF-3 F-3EAGLE™ 10,000Sometimes machine failures appear to be due to PCboard failures. These problems can sometimes betraced t

EAGLE™ 10,000SAFETYiii iiiJan ‘09FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

ENGINE PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

ENGINE PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

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 perfor

WELDING PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURS

NOTESF-12 F-12EAGLE™ 10,000Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

SAFETYiv ivEAGLE™ 10,000Mar ‘93PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté

Slip RingsBrushesLead 219+-Lead 200AFIGURE F.1 – LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TESTROTOR VOLTAGE TEST (continued)TEST PROCEDURE1. Wi

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

Lead 219Lead 200A+-FIGURE F.2 – LOCATION OF ROTOR SLIP RINGSROTOR RESISTANCE TEST (continued)TEST PROCEDURE1. With the 5/16” nut driver, remove the 6

ROTOR RESISTANCE TEST (continued)13. Measure the resistance to ground.A. Set the ohmmeter on the high scale(X100,000).B. Place one probe on either of

NOTESF-18 F-18EAGLE™ 10,000Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

Lead #3Lead #5115VReceptacleMachineCaseFrontFIGURE F.3 – LOCATION OF LEADS #3 AND #5AUXILIARY AND FIELD WINDING TEST (continued)TEST PROCEDURETo test

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, re

NOTESF-22 F-22EAGLE™ 10,000Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -I IEAGLE™ 10,000PageSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(-)(+)(+)(+)(-)(-)OUTPUT RECTIFIERENGINEFIGURE F.4 – LOCATION OF OUTPUT RECTIFIER LEADSOUTPUT RECTIFIER BRIDGE TEST (continued)TEST PROCEDURE1. Remove

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

VoltageRegulatorGroundLead(Green)EngineAC LeadDC LeadAC LeadFIGURE F.5 – LOCATION OF VOLTAGE REGULATORCHARGING CIRCUIT TEST (continued)TEST PROCEDURE1

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

Blower PaddleFIGURE F.6 – BLOWER PADDLE MARKED FOR STROBE-TACH METHODENGINE THROTTLE ADJUSTMENT TEST (continued)TEST PROCEDUREThis test can be conduct

ENGINE THROTTLE ADJUSTMENT TEST (continued)11. If either of the readings is incorrect, adjust thethrottle as follows:Adjust HIGH IDLE: Use the 3/8” wr

ENGINE THROTTLE ADJUSTMENT TEST (continued)Oscilloscope Method:1. Connect the oscilloscope to the 115 VACreceptacle, according to the manufacturer’sin

This is the typical auxiliary output volt-age generated from a properly operat-ing machine. Note that each verticaldivision represents 50 volts and th

TROUBLESHOOTING AND REPAIRF-32 F-32EAGLE™ 10,000This is the typical DC output voltagegenerated from a properly operatingmachine. Note that each vertic

TROUBLESHOOTING AND REPAIRF-33 F-33EAGLE™ 10,000This is NOT the typical DC (+) outputvoltage waveform. One output diodeis not functioning. Note the “g

TABLE OF CONTENTS - INSTALLATION SECTIONA-1 A-1EAGLE™ 10,000Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING AND REPAIRF-34 F-34EAGLE™ 10,000This is the typical DC output voltagegenerated from a properly operatingmachine. Note that each vertic

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

BRUSH REMOVAL AND REPLACEMENT (continued)PROCEDURE1. Remove the spark plug wires.2. With a 5/16” nut driver, remove the 6 sheetmetal screws from the c

BRUSH REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-37 F-37EAGLE™ 10,000SLIP RINGSA slight amount of darkening and wear of theslip ri

NOTESF-38 F-38EAGLE™ 10,000Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

12 Pin Plug4Pin Plug4Self Tapping Screws (at corners)1/4" Q.C. TabsFIGURE F.10 - PRINTED CIRCUIT BOARD LOCATIONPRINTED CIRCUIT BOARD REMOVALAND R

Be sure to follow the recommended static-freemethods for handling printed circuit boards.Failure to do so can result in permanent damage tothe equipme

NOTESF-42 F-42EAGLE™ 10,000Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

INSTALLATIONA-2 A-2EAGLE™ 10,000TECHNICAL SPECIFICATIONS - EAGLE 10,000 (K2343-1,K2343-2)INPUT - GASOLINE ENGINERATED OUTPUT @ 104°F (40°C)- WELDERHEI

(-)(+)(+)(+)(-)(-)ENGINENO NUTTO POLARITY SWITCH#8L1 TO CHOKE(4) 7/16"MOUNTINGSCREWSW1TO S2TO S2TO S1254(3) 1/2"MOUNTINGSCREWSFIGURE F.11 -

OUTPUT RECTIFIER BRIDGE REMOVALAND REPLACEMENT (continued)12. With the 1/2” wrench remove the three mount-ing nuts. Note the placement of the nylonins

NOTESF-46 F-46EAGLE™ 10,000Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

FIGURE F.12 – COMPONENT LOCATIONS, ENGINE/ROTOR REMOVALENGINE/ROTOR REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-48 F-48EAGLE™ 10,00

ENGINE AND ROTOR REMOVALPROCEDURE1. Refer to Figure F.12 for component locations.2. Remove the engine spark plug wires.3. With a 5/16” nut driver, rem

FIGURE F.13 - ENGINE AND ROTOR REMOVED FROM STATORENGINE/ROTOR REMOVAL AND REPLACEMENT (continued)ROTOR REMOVAL PROCEDURE1. To remove the rotor, doubl

ENGINE/ROTOR REMOVAL ANDREPLACEMENT (KIT S20788) (continued)REASSEMBLY PROCEDURENOTE: Lincoln Electric recommends that a newbearing (Lincoln part #M93

TROUBLESHOOTING AND REPAIRF-52 F-52EAGLE™ 10,000RETEST AFTER REPAIRRetest a machine:• If it is rejected under test for any reason that requires you to

TABLE OF CONTENTS - DIAGRAM SECTIONG-1 G-1EAGLE™ 10,000Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATIONA-3 A-3EAGLE™ 10,000SAFETY PRECAUTIONSMACHINE GROUNDINGBecause this portable engine driven welder or genera-tor creates it’s own power, it

ELECTRICAL DIAGRAMSG-2EAGLE™ 10,000WIRING DIAGRAM - CODE 11096 (M20317)STARTERCR1STARTERSOLENOID12 VOLTIDLERSOLENOIDBATTERYAC ACB+SWITCHREGULATORFLYWH

ELECTRICAL DIAGRAMSG-3EAGLE™ 10,000WIRING DIAGRAM - CODE 11397 - (M21271)STARTERCR1STARTERSOLENOID12 VOLTIDLERSOLENOIDBATTERYAC ACB+SWITCHREGULATORFLY

ELECTRICAL DIAGRAMSG-4EAGLE™ 10,000SCHEMATIC - COMPLETE MACHINE - CODE 11096 (L12259)L12259AW2D1 - BRIDGERECTIFIER7219200AW1L1 CHOKE356GNDE120 VAC240

ELECTRICAL DIAGRAMSG-5EAGLE™ 10,000SCHEMATIC - COMPLETE MACHINE - CODE 11397 (L13104)L13104AW2D1 - BRIDGERECTIFIER7219200AW1L1 CHOKE356GNDE120 VAC240

ELECTRICAL DIAGRAMSG-6EAGLE™ 10,000SCHEMATIC - IDLER/FIELD CONTROL P.C. BOARD (L12197)G-6NOTE: This diagram is for reference only. It may not be accur