For Machines with Code Number 11618,11735, 11791, 11798, 12094
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READING THIS MANUAL AND THE
SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
IM10028-C
April 2013
OPERATORʼS MANUAL
• World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 USA TEL: 1.216.481.8100
For Service in the USA and Canada: Call 1.888.935.3877 For Service outside the USA: Email globalservice@lincolnelectric.com
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Page 3
ii
SAFETY
ii
ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
skin or wet clothing. Wear dry, hole-free
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
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
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
ventilation and/or exhaust at the arc to keep
vapors
to
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Page 4
iii
SAFETY
iii
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Alway s keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered 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
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
Page 5
iv
SAFETY
iv
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 suivantes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼ arc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Page 6
Thank You
vv
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
CUSTOMER ASSISTANCE POLICY
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
Your Product”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
Page 7
vi
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
TECHNICAL SPECIFICATIONS - EAGLE™ 10,000 Plus ( K2343-3)
INPUT - GASOLINE ENGINE
Make/Model
Kohler
CH23S,
CH680
CH730
Description
2 cylinder
4 Cycle
Air-Cooled
Gasoline
Engine.
Aluminum Alloy
with Cast Iron
Liners,
Electronic
Ignition
RATED OUTPUT @ 104°F (40°C)- WELDER
RATED OUTPUT @ 104°F (40°C)- GENERATOR
Horsepower
23 HP @
3600 RPM
DC Constant Current 225A / 25V / 40%
DC Constant Current 210A / 25V / 100%
Operating
Speed (RPM)
High Idle 3700
Full Load 3500
Low Idle 2200
Welding Output
Auxiliary Power
Displacement
cu. in.
(cu.cm.)
41.1(674)
44.2(724)
1
Starting
System
12VDC
Battery
Electric Start
Group 58
Battery
(435 cold
Cranking
Amps)
A-1
Capacities
Fuel:
12 Gal (45.4 L)
Lubricating Oil:
2.0 Qts. (1.9 L)
9,000 Watts Continuous, 60 Hz AC
10,500 Watts Surge, 60 Hz AC
120/240 Volts
RECEPTACLES AND CIRCUIT BREAKERS
RECEPTACLES
(2) 120VAC Duplex (5-20R)
(1) 120/240VAC Dual Voltage
Full KVA (14-50R)
AUXILIARY POWER CIRCUIT BREAKER
Two 20AMP for Two Duplex Receptacle
(1) 40AMP for Dual Voltage (2-pole)
BATTERY CHARGING CIRCUIT BREAKER
20AMP for Engine Battery
Charging Circuit
PHYSICAL DIMENSIONS
HEIGHT WIDTHDEPTHMODEL / WEIGHT
Codes 11798 and below
30.00** in. 21.50 in 42.25 in.
762.0 mm546.0 mm1073.0 mm
** Top of enclosure, add 6.00”(152mm) for exhaust.
514 lbs. (233kg.)
Code 12094
523 lbs. (237kg.)
ENGINE COMPONENTS
LUBRICATION VALVE LIFTERSFUEL SYSTEMGOVERNOR
Full PressureHydraulicMechanical Fuel PumpMechanical Governor
with Full Flow Filter
5% Regulation
AIR CLEANER ENGINE IDLERMUFFLER ENGINE PROTECTION
Low noise Muffler: Top outlet Shutdown on low oil
Dual ElementAutomatic Idlercan be rotated. Made from pressure.
long life, aluminized steel.
1
Output rating in watts is equivalent to volt - amperes at unity factor.Output voltage is within +/-10% at all loads up to rated capacity.
When welding available auxiliary power will be reduced.
EAGLE™ 10,000 PLUS
Page 9
A-2
INSTALLATION
A-2
SAFETY PRECAUTIONS
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
When this welder is mounted on a truck or trailer, itʼs
frame must be electrically bonded to the metal frame
of the vehicle. Use a #8 or larger copper wire connected between the machine grounding stud and the
frame of the vehicle.
Where this engine driven welder is connected to
premises wiring such as that in your home or shop, itʼs
frame must be connected to the system earth ground.
See further connection instructions in the section entitled “Standby Power Connections”, as well as the article on grounding in the latest National Electrical Code
and the local code.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into
the ground for at least ten feet and having no insulated joints, or to the metal framework of a building
which has been effectively grounded. The National
Electrical Code lists a number of alternate means of
grounding electrical equipment. A machine grounding
stud marked with the symbol is provided on the
front of the welder.
Because this portable engine driven welder or generator creates itʼs own power, it is not necessary to connect itʼs frame to an earth ground, unless the machine
is connected to premises wiring (your home, shop,
etc.).
WARNING
To prevent dangerous electric shock, other equipment to which this engine driven welder supplies
power must:
• be grounded to the frame of the welder using a
grounded type plug, or be double insulated.
Do not ground the machine to a pipe that carries
explosive or combustible material.
Some federal, state, or local laws may require that
gasoline engines be equipped with exhaust spark
arresters when they are operated in certain locations
where unarrested sparks may present a fire hazard.
The standard muffler included with this welder does
not qualify as a spark arrester. When required by local
regulations, the K1898-1 spark arrester must be
installed and properly maintained.
CAUTION
An incorrect arrester may lead to damage to the
engine or adversely affect performance.
The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle
Lincolnʼs K2635-1. If the user adapts a non-Lincoln
trailer, he must assume responsibility that the method
of attachment and usage does not result in a safety
hazard nor damage the welding equipment. Some of
the factors to be considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
(1)
is
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
EAGLE™ 10,000 PLUS
Page 10
A-3
3. Proper placement of the equipment on the trailer to
insure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.
4. Typical conditions of use, i.e., travel speed; rough-
ness of surface on which the trailer will be operated;
environmental conditions.
5. Conformance with federal, state and local laws
(1) Consult applicable federal, state and local laws regarding specific
requirements for use on public highways.
VEHICLE MOUNTING
INSTALLATION
(1)
WARNING
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
• Only transport this Equipment on serviceable
vehicles which are rated and designed for such
loads.
• Distribute, balance and secure loads so vehicle
is stable under conditions of use.
• Do not exceed maximum rated loads for components such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of
vehicle.
The EAGLE™ 10,000 Plus is shipped with the engine
crankcase filled with SAE 10W-30 oil. Check the oil
level before starting the engine. If it is not up to the full
mark on the dip stick, add oil as required. Make certain that the oil filler cap is tightened securely. Refer to
the engine Ownerʼs Manual for specific oil recommendations.
This welder is shipped with the negative battery cable
disconnected. Make sure that the Engine Switch is in
the “STOP” position and attach the disconnected
cable securely to the negative battery terminal before
attempting to operate the machine. If the battery is
discharged and does not have enough power to start
the engine, see the battery charging instructions in the
Battery section.
NOTE: This machine is furnished with a wet charged
battery; if unused for several months, the battery may
require a booster charge. Be careful to charge the battery with the correct polarity.
EAGLE™ 10,000 PLUS
Page 11
A-4
INSTALLATION
WELDING OUTPUT CABLES
With the engine off, connect the electrode and work
cables to the studs provided. These connections
should be checked periodically and tightened if necessary. Loose connections will result in overheating of
the output studs.
When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
Listed below are copper cable sizes recommended for
the rated current and duty cycle. Lengths stipulated
are the distance from the welder to work and back to
the welder again. Cable sizes are increased for
greater lengths primarily for the purpose of minimizing
cable voltage drop.
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
225 Amps
100% Duty Cycle
0-100 Ft. (0-31m)
100-150 Ft. (31-46m)
150-200 Ft. (46-61m)
1 AWG
1 AWG
1/0 AWG
ANGLE OF OPERATION
Internal combustion engines are designed to run in a
level condition which is where the optimum performance is achieved. The maximum angle of operation
for the engine is 15 degrees from horizontal in any
direction. If the engine is to be operated at an angle,
provisions must be made for checking and maintaining the oil at the normal (FULL) oil capacity in the
crankcase in a level condition.
When operating at an angle, the effective fuel capacity
will be slightly less than the specified 12 Gal. (45 L).
A-4
ADDITIONAL SAFETY PRECAUTION
WARNING
• Lift only with equipment of
adequate lifting capacity.
• Be sure machine is stable
when lifting.
• Do not lift this machine using
lift bail if it is equipped with a
heavy accessory such as trailer or gas cylinder.
At higher altitudes, Welder output de-rating may be
necessary. For maximum rating, de-rate the welder
output 3.5% for every 1000 ft. (305m) above 3000 ft.
(914m). If operation will consistently be at altitudes
above 5,000 ft. (1525m), a carburetor jet designed for
high altitudes should be installed. This will result in
better fuel economy, cleaner exhaust and longer
spark plug life. It will not give increased power.
Contact your local authorized engine service shop for
high altitude jet kits that are available from the engine
manufacturer.
CAUTION
Do not operate with a high altitude jet installed at
altitudes below 5000 ft. (1525m). This will result in
the engine running too lean and result in higher
engine operating temperatures which can shorten
engine life.
The EAGLE™ 10,000 Plus weighs approximately
595lbs. (269.9kg) with a full tank of gasoline. A lift bail
is mounted to the machine and should always be used
when lifting the machine.
Using the clamp provided secure the outlet pipe to the
outlet tube with the pipe positioned such that it will
direct the exhaust in the desired direction. Tighten
using a 9/16” socket or wrench.
EAGLE™ 10,000 PLUS
Page 12
A-5
INSTALLATION
LOCATION / VENTILATION
The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to
avoid heated air coming out of the welder recirculating
back to the cooling air inlet. Also, locate the welder so
that engine exhaust fumes are properly vented to an
outside area.
STACKING
EAGLE™ 10,000 Plus machines cannot be stacked.
CONNECTION OF K930-2 TIG MODULE TO THE
EAGLE™ 10,000 PLUS.
The TIG Module is an accessory that provides high
frequency and shielding gas control for DC GTAW
(TIG) welding. See IM528 supplied with the TIG
Module for installation instructions.
NOTE: The TIG Module does not require the use of a
high frequency bypass capacitor. However, if the
EAGLE™ 10,000 Plus is used with any other high frequency equipment, the bypass capacitor must be
installed, order kit T12246.
A-5
INSTRUCTIONS
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the roof and case
sides in place as this provides maximum protection
from moving parts and assures proper cooling air flow.
Read and understand all Safety Precautions before
operating this machine. Always follow these and any
other safety procedures included in this manual and in
the Engine Ownerʼs Manual.
EAGLE™ 10,000 PLUS
Page 13
A-6
INSTALLATION
WELDER OPERATION
WELDER OUTPUT
• Maximum Open Circuit Voltage at 3700 RPM is 80
Volts RMS.
• Duty Cycle is the percentage of time the load is
being applied in a 10 minute period. For example, a
60% duty cycle represents 6 minutes of load and 4
minutes of no load in a 10 minute period. Duty
Cycle for the EAGLE™ 10,000 Plus is 100%.
EAGLE™ 10,000 Plus
Constant Current210 Amps DC @ 25 Volts
AUXILIARY POWER
The EAGLE™ 10,000 Plus can provide up to 9,000
watts of 120/240 volts AC, single phase 60Hz power
for continuous use, and up to 10,500 watts of 120/240
volts AC, single phase 60Hz power surge use. The
front of the machine includes three receptacles for
connecting the AC power plugs; one 50 amp 120/240
volt NEMA 14-50R receptacle and two 20 amp 120
volt NEMA 5-20R receptacles. Output voltage is within
+/-10% at all loads up to rated capacity.
A-6
120/240 VOLT DUAL VOLTAGE RECEPTACLE
The 120/240 volt receptacle can supply up to 38
amps of 240 volt power to a two wire circuit, up to 38
amps of 120 volts power from each side of a three
wire circuit (up to 76 amps total). Do not connect the
120 volt circuits in parallel. Current sensing for the
automatic idle feature is only in one leg of the three
wire circuit as shown in the following column.
GND
120 V
240 V
120 V*
*Current Sensing for Automatic Idle.
(Receptacle viewed from front of Machine)
All auxiliary power is protected by circuit breakers.
The 120V has 20 Amp circuit breakers for each
duplex receptacle. The 120/240V Single Phase has a
40 Amp 2-pole Circuit Breaker that disconnects both
hot leads simultaneously.
CAUTION
Do not connect any plugs that connect to the
power receptacles in parallel.
-----------------------------------------------------------------------Start the engine and set the “IDLER” control switch to
the desired operating mode. Set the “CONTROL” to
10. Voltage is now correct at the receptacles for auxiliary power.
EAGLE™ 10,000 Plus Extension Cord Length Recommendations
(Use the shortest length extension cord possible sized per the following table.)
Current
(Amps)
15
20
15
20
38
Voltage
Volts
120
120
240
240
240
Load
(Watts)
1800
2400
3600
4800
9000
Conductor size is based on maximum 2.0% voltage drop.
Maximum Allowable Cord Length in ft. (m) for Conductor Size
14 AWG
30 (9)
60 (18)
12 AWG
40 (19)
30 (9)
75 (23)
60 (18)
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 load through the
associated receptacle.
MOTOR STARTING
Most 1.5 hp AC single phase motors can be started if
there is no load on the motor or other load connected
to the machine, since the full load current rating of a
1.5 hp motor is approximately 20 amperes (10
amperes for 240 volt motors). The motor may be run
at full load when plugged into only one side of the
duplex receptacle. Larger motors through 2 hp can be
run provided the receptacle rating as previously stated
is not exceeded. This may necessitate 240V operation
only.
10 AWG
75 (23)
50 (15)
150 (46)
100 (30)
50 (15)
8 AWG
125 (38)
88 (27)
225 (69)
175 (53)
90 (27)
6 AWG
175 (53)
138 (42)
350 (107)
275 (84)
150 (46)
4 AWG
300 (91)
225 (69)
600 (183)
450 (137)
225 (69)
EAGLE™ 10,000 PLUS
Page 14
A-7
ELECTRICAL DEVICE USE WITH THE EAGLE™ 10,000 Plus.
TypeCommon Electrical DevicesPossible Concerns
ResistiveHeaters, toasters, incandescent NONE
light bulbs, electric range, hot
pan, skillet, coffee maker.
CapacitiveTV sets, radios, microwaves, Voltage spikes or high voltage
Appliances with electrical control.regulation can cause the capaci-
InductiveSingle-phase induction motors, These devices require large
Drills, well pumps, grinders, smallCurrent inrush for starting.
Refrigerators, weed and hedgeSome synchronous motors may
Trimmersbe frequency sensitive to attain
INSTALLATION
TABLE llyn
tative elements to fail. Surge
protection, transient protection,
and additional loading is recommended for 100% fail-safe oper-
ation. DO NOT RUN THESE
DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE
LOADS.
maximum output torque, but
they SHOULD BE SAFE from
any frequency induced failures.
A-7
Capacitive/InductiveComputers, high resolution TV sets,An inductive type line condition-
Complicated electrical equipment. er along with transient and
surge protection is required, and
liabilities still exist. DO NOT
USE THESE DEVICES WITH A
EAGLE™ 10,000 Plus
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected
to the EAGLE™ 10,000 Plus.
EAGLE™ 10,000 PLUS
Page 15
A-8
INSTALLATION
AUXILIARY POWER WHILE WELDING
Simultaneous welding and power loads are permitted
by following Table I. The permissible currents shown
assume that current is being drawn from either the
120V or 240V supply (not both at the same time).
Also, the “Output Control” is set at “10” for maximum
auxiliary power.
1. Install a double pole, double throw switch between
the power company meter and the premises disconnect.
Switch rating must be the same or greater than the
customerʼs premises disconnect and service overcurrent protection.
2. Take necessary steps to assure load is limited to
the capacity of the EAGLE™10,000 Plus by
installing a 40 amp 240V double pole circuit breaker. Maximum rated load for the 240V auxiliary is 38
amperes. Loading above 38 amperes will reduce
output voltage below the allowable -10% of rated
voltage which may damage appliances or other
motor-driven equipment.
3. Install a 50 amp 120/240V plug (NEMA type 14-50)
to the Double Pole Circuit Breaker using No. 8, 4
conductor cable of the desired length. (The 50 amp
120/240V plug is available in the optional plug kit.)
No Welding900076
**38
* Each duplex receptacle is limited to 20 amps.
**Not to exceed 40A per 120VAC branch circuit when
Splitting the 240 VAC output.
STANDBY POWER CONNECTIONS
The EAGLE™ 10,000 Plus is suitable for temporary,
standby, or emergency power using the engine manufacturerʼs recommended maintenance schedule.
The EAGLE™ 10,000 Plus can be permanently
installed as a standby power unit for 240V-3 wire, single phase 38 ampere service.
WARNING
(Connections must be made by a licensed electrician who can determine how the 120/240V power
can be adapted to the particular installation and
comply with all applicable electrical codes.) The
following information can be used as a guide by
the electrician for most applications (refer also to
the connection diagram shown in Figure 1.)
4. Plug this cable into the 50 amp 120/240V receptacle on the EAGLE™ 10,000 Plus case front.
EAGLE™ 10,000 PLUS
Page 16
A-9
INSTALLATION
Figure 1
CONNECTION OF EAGLE™ 10,000 Plus TO PREMISES WIRING
A-9
Connection of EAGLE™ 10,000 Plus to premises
wiring must be done by a licensed electrician and
must comply with the National Electrical Code and
all other applicable electrical codes.
WARNING
EAGLE™ 10,000 PLUS
Page 17
B-1
OPERATION
SAFETY PRECAUTIONS
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
The EAGLE™ 10,000 Plus is a twin-cylinder, gasoline
driven, multiprocess arc welder and AC power generator. It is built in a heavy gauge steel case for durability on the job site.
Codes 11791 and above meet EPA evaporative emission requirements.
B-1
WELDER CONTROLS - FUNCTION AND
OPERATION
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-energized to shut down the engine.
When held in the “START” position, the engine
starter motor is energized.
When in “HIGH IDLE” ( ) position, the engine will
run continuously at high idle.
When in “AUTO IDLE” ( / ) position, the
engine will run continuously and the idler operates as
follows:
• Welding
When the electrode touches the work, the welding Arc is initiated and the engine accelerates to
full Speed.
After welding ceases (and no auxiliary power is
being drawn), the engine will return to low idle
after approximately 10 to 14 seconds.
• Auxiliary Power
With the engine running at low idle and auxiliary
power for lights or tools are drawn (approximately 100-150 watts or greater) from the receptacles, the engine will accelerate to high speed. If
no power is being drawn from the receptacles
(and not welding) for 10-14 seconds, the idler
reduces the engine speed to low idle.
EAGLE™ 10,000 PLUS
Page 18
B-2
OPERATION
“ RANGE” SWITCH
The “Range” switch is used to select one of four
amperage ranges with generous overlap for Stick/TIG
welding.
Process Range Setting Current Range
STICK/TIG
(Constant current)
(3 range settings)
90 Max.
145 Max.
225 MAX.
40 to 90 Amps
70 to 145 Amps
120 to 225 Amps
CAUTION
Never change the “RANGE” Switch setting while
welding. This will damage the switch.
Provides a fine welding current adjustment within the
Range Switch settings in the STICK mode and welding voltage control with the Range switch set in the
wire feed mode.
B-2
EAGLE™ 10,000 PLUS APPROXIMATE FUEL CONSUMPTION
Low Idle - No Load
2400 RPM
High Idle - No Load
3700 RPM
DC CC Weld Output
210 Amps @ 25 Volts
Auxiliary Power
9000 Watts
KOHLER
23 H.P. COMMAND CH23S, CH680
.40 Gallons/Hour
(1.50 Liters/Hour)
.7 Gallons/Hour
(2.8 Liters/Hour)
1.3 Gallons/Hour
(4.9 Liters/Hour)
1.4 Gallons/Hour)
(5.3 Liters/Hour)
KOHLER
23 H.P. COMMAND CH730
.41 Gallons/Hour
1.6(Liters/Hour)
.9 Gallons/Hour
3.5(Liters/Hour)
1.5 Gallons/Hour
5.7(Liters/Hour)
1.7 Gallons/Hour)
6.4(Liters/Hour)
EAGLE™ 10,000 PLUS
Page 19
B-3
OPERATION
B-3
STARTING/SHUTDOWN INSTRUCTIONS
STARTING THE ENGINE
WARNING
• Do not touch electrically live parts
of electrode with skin or wet clothing.
• Keep flammable material away.
• Insulate yourself from work and
ground. Wear eye, ear, and body
protection.
• Keep your head out of the fumes.
• Use ventilation or exhaust to
remove fumes from breathing zone.
Be sure all Pre-Operation Maintenance has been performed. Also, read the Engine Ownerʼs Manual before
starting for the first time.
Remove all loads connected to the AC power receptacles. Use the choke control as follows:
KOHLER ENGINE - Always pull the choke control out
when starting the engine; cold, warm or hot.
Turn the engine switch to the “start”position and
crank the engine until it starts. Release the switch as
soon as the engine starts, slowly return the choke
control to the full “in” position (choke open),
And turn the switch to the Auto Idle(/ )
Position. Do not turn the switch to the “start” position
while the engine is running because this will cause
damage to the ring gear and/or starter motor
STOPPING THE ENGINE
Remove all welding and auxiliary power loads and
allow engine to run at low idle speed for a few minutes
to cool the engine.
Stop the engine by placing the Engine switch in the
“OFF” position.
A fuel shut off valve is not required on the EAGLE™
10,000 Plus because the fuel tank is mounted below
the engine.
BREAK-IN PERIOD
It is normal for any engine to use a greater amount of
oil until the break-in is accomplished. Check the oil
level twice a day during the break-in period (approximately 50 running hours).
IMPORTANT: IN ORDER TO ACCOMPLISH THIS
BREAK-IN, THE UNIT SHOULD BE
SUBJECTED TO MODERATE
LOADS, WITHIN THE RATING OF
THE MACHINE. AVOID LONG IDLE
RUNNING PERIODS. REMOVE
LOADS AND ALLOW ENGINE TO
COOL BEFORE SHUTDOWN.
The engine manufacturerʼs recommendation for the
running time until the first oil change is as follows:
KOHLER
CH23S, CH680, CH730
5 HRS
The oil filter is to be changed at the second oil
change. Refer to the Engine Ownerʼs Manual for more
information.
After running at high engine speed for 10-14 seconds,
the engine will go to low idle.
Allow the engine to warm up by letting it run at low idle
for a few minutes.
EAGLE™ 10,000 PLUS
Page 20
B-4
OPERATION
WELDING PROCESS
For any electrodes the procedures should be kept
within the rating of the machine. For electrode infor-
mation see the appropriate Lincoln publication.
STICK (CONSTANT CURRENT) WELDING
Connect welding cables to the "TO WORK” and
"ELECTRODE” studs. Start the engine. Set the
"Polarity” switch to the desired polarity. The “RANGE”
switch markings indicate the maximum current for that
range as well as the typical electrode size for that
range. The “OUTPUT” Control provides fine adjustment of the welding current within the select range.
For maximum output within a selected range set the
“OUTPUT” Control at 10. For minimum output within a
selected range set the “OUTPUT” Control at 5. (“OUTPUT” Control settings below 5 may reduce arc stability) For best overall welding performance set the
“RANGE” Switch to the lowest setting and the OUTPUT” Control near the maximum to achieve the
desired welding current.
RANGE SETTINGTYPICAL CURRENT RANGE
ELECTRODE SIZE
90 MAX.
3/32
40 TO 90 AMPS
B-4
The EAGLE™ 10,000 Plus can be used with a broad
range of DC stick electrodes. See “Welding Tips 1”
included with the EAGLE™ 10,000 Plus for electrodes
within the rating of this unit and recommended welding currents of each.
SCRATCH START TIG (CONSTANT CURRENT)
WELDING
The EAGLE™ 10,000 Plus can be used for Scratch-Start of DC
TIG welding applications. To initiate a weld, the course and fine
output control knobs must be set for the desired current. The
tungsten electrode is then scratch on the work which establishes the arc.
To stop the arc, simply lift the TIG torch away from the work
piece. The tungsten may then be scratched on the work piece
to restrike the arc.
If a high frequency start is desired, the K930-2 TIG Module can
be used with the EAGLE™ 10,000 Plus. The settings are referenced.
The EAGLE™ 10,000 Plus and any high frequency generating
equipment must be properly grounded. See the K930-2 TIG
Module operating manuals for complete instructions on installation, operation and maintenance.
145 MAX.
225 MAX.
1/8
5/32
70 TO 145 AMPS
120 TO 225 AMPS
When using the TIG Module, the OUTPUT control on
EAGLE™ 10,000 Plus is used to set the maximum range of
the
the CURRENT CONTROL on the TIG Module or an Amptrol if
connected to the TIG Module.
(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.
(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):
PureEWP
1% ThoriatedEWTh-1
2% ThoriatedEWTh-2
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.
(3) DAZE is not commonly used in these sizes.
(4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:
(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures
The EAGLE™ 10,000 Plus can be used for limited arc
gouging.
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:
ELECTRODE SETTING CURRENT RANGE (DC, electrode positive)
Welding starts immediately
And engine goes to high
Idle.
B-5
TIG, TIG MODULE WITHYesHIGH Cold Press Amptrol,
WITH CONTACTOR KITContactor closes,
CONTROL CABLE, & Welding starts immediately.
AMPTROL
EAGLE™ 10,000 PLUS
Page 22
C-1
ACCESSORIES
OPTIONAL EQUIPMENT (Field Installed)
K2635-1 SMALL TWO-WHEEL ROAD TRAILER
WITH DUO-HITCH-For heavy-duty road, off-road,
plant and yard use.
C-1
K704 Accessory Kit - Includes 35 ft (Im) 2/0 AWG elec-
trode cable, 30 ft. (Im) 2/0 AWG work cable, headshield with
No. 12 filter, GC300 work clamp and cooltong® 300 electrode holder. Cables are rated at 300 amps, 100% duty
cycle.
Includes pivoting jack stand, safety chains, and 13"
wheels. Overall width 60". Stiff .120" welded rectangular steel tube frame construction is phosphate etched
and powder coat painted for superior rust and corrosion resistance.
Low sway suspension gives outstanding stability with
manageable tongue weight. Wheels bearings are
packed with high viscosity, high pressure, low
washout luxuriates® grease.
Features a Duo-Hitch™ - a 2" Ball/Lunette Eye combination hitch.
K1737-1 FOUR WHEEL ALL-TERRAIN UNDERCARRIAGE - For moving by hand at construction
sites. Heavy duty puncture resistant pneumatic tires.
K1770-1 UNDERCARRIAGE (FACTORY) - For moving by hand on a smooth surface. One or two gas
cylinders can be mounted on the rear of the undercarriage with the installation of K1745-1 Cylinder
Holder(s). Heavy duty puncture resistant pneumatic
tires and front caster.
K875 Accessory Kit - For Stick welding. Includes ft.(.m)#
electrode cable with lug. ft.(.m)# work cable with lugs, headshield, filter plate, work clamp, electrode holder and sample
pack of mild steel electrode. 150 amp capacity.
K1898-1 Spark Arrester Kit - Attaches between muffler
and exhaust elbow. Virtually eliminates spark emissions.
K1690-1 GFCI RECEPTACLE KIT - Includes one UL
appraised ground fault circuit interrupter duplex type
receptacle with cover and installation instructions.
Replaces the factory installed 120V duplex receptacle.
Each receptacle of the GFCI Duplex is rated at 20 Amps,
the maximum total current from the GFCI Duplex is limited to the 20 Amps. Two kits are required.
K1816-1 FULL KVA ADAPTER KIT - Plugs into the
120/240V NEMA 14-50R receptacle on the case front
(which accepts 4-prong plugs) and converts it to a NEMA 650R receptacle, (which accepts 3-prong plugs.)
T12153-9 Full-KVA Power Plug - One dual voltage plug
rated at 120/240V, 50 amps.
K1745-1 WELDING GAS CYLINDER LOX TANK
HOLDER
Holds Welding Gas Cylinder for use on K1770-1
Undercarriage. One or two may be installed on an
undercarriage.
K1788-1 ROLL CAGE - Gives added damage protection.
Attaches to K1737-1, K1770-1, and K957-1.
K886-2 Canvas Cover -To protect the EAGLE™
10,000 Plus when not in use. Made from attractive red
canvas material which is flame retardant, mildew
resistant, and water repellent.
K802R Power Plug Kit - provides four 120V plugs
rated at 15 amps each and one dual voltage, Full
KVA plug rated at 120/240V, 50 amps.
K802N Power Plug Kit - Provides four 120V plugs
rated at 20 amps each and one dual voltage, full KVA
plug rated at 120/240V, 50 amps.
EAGLE™ 10,000 PLUS
Page 23
C-2
ACCESSORIES
RECOMMENDED EQUIPMENT
STICK
K704 Accessory Kit- (400 AMP Capacity) which
includes:
• Electrode Holder & Cable
• Work Clamp & Cable
• Headshield
K875 Accessory Kit- (150 AMP Capacity)
TIG
Magnum™ TIG Torch
K1783-4 - TIG Torch
KP509-Magnum Parts Kit and Argon Gas
K930-2 TIG Module - Provides high frequency and shield-
ing gas control. For AC and DC GTAW (TIG) welding applications. Its compact case is designed for easy carrying,
complete with a handle. High frequency bypass is built in
Requires K938-1 Contactor Kit, K936-4 Control Cable, and
K814 Arc Start Switch.
C-2
K938-1 Contactor Kit - For use with TIG Module, Provides a
“cold” electrode until the triggering device (Arc Start Switch)
is pressed.
K936-4 Control Cable - Connects TIG Module to EAGLE™
10,000 Plus.
Optional TIG Equipment:
K939-1 Docking Kit - For Mounting the K930-2 TIG Module
on top of the EAGLE™ 10,000 Plus.
K937-45 Control Cable Extension - Allows TIG Module to be
operated at distances up to 200ft. From the power source.
Available in 45ft. (Im).
K814 Arc Start Switch
Plasma
K1580-1 Pro-Cut 55
(Requires Full KVA Adapter K1816-1)
EAGLE™ 10,000 PLUS
Page 24
D-1
MAINTENANCE
D-1
SAFETY PRECAUTIONS
WARNING
Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. In some cases, it may be necessary
to remove safety guards to perform required
maintenance. Remove guards only when
necessary and replace them when the maintenance requiring their removal is complete.
Always use the greatest care when working near
moving parts.
Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.
Use in open, well ventilated areas
or vent exhaust outside.
CAUTION
Make certain that the oil filler cap is securely tightened after checking or adding oil. If the cap is not
tight, oil consumption can increase significantly
which may be evidenced by white smoke coming
from the exhaust.
• OIL - Maintenance schedule for changing the oil and
oil filter after break-in :
Kohler
CH23S, CH680, CH730
Oil100 Hrs.
Oil Filter200 Hrs.
The above schedule is for normal operating conditions. More frequent oil changes are required with
dusty, high temperature and other severe operating
conditions. Refer to the maintenance section of the
Engine Owner's Manual for more information.
: Engine life will be reduced if the oil and oil
NOTE
filter are not changed according to the manufacturerʼs
recommendation.
Read the Safety Precautions in the front of this manual
and the engine instruction manual before working on
this machine.
Keep all equipment safety guards, covers, and devices
in position and in good repair. Keep hands, hair, clothing, and tools away from gears, fans, and all other
moving parts when starting, operating, or repairing the
equipment.
Routine Maintenance
• At the end of each dayʼs use, refill the fuel tank to
Minimize moisture condensation in the tank.
Running out of fuel tends to draw dirt into the fuel
System. Also, check the crankcase oil level and
Add oil if indicated.
EAGLE™ 10,000 PLUS
ENGINE OIL CHANGE
Drain the oil while the engine is warm to assure rapid
and complete draining.
• Remove the oil filler cap and dipstick. Remove the yellow cap from the oil drain valve and attach the flexible
drain tube supplied with the machine. Push in and
twist the drain valve counterclockwise. Pull the valve
out and drain the oil into a suitable container.
• Close the drain valve by pushing in and twisting
clockwise. Replace the yellow cap.
• Refill to the upper limit mark on the dipstick with the
recommended oil. Tighten the oil filler cap securely.
ENGINE OIL REFILL CAPACITIES
Without oil filter replacement:
• 1.7qt. (1.6 liter)-Kohler
With oil filter replacement:
• 2.0qt. (1.9 liter)-Kohler
Page 25
D-2
MAINTENANCE
D-2
Use 4-stroke motor oil that meets or exceeds the
requirements for APIO service classification SG or SH.
Always check the APIO SERVICE label on the oil container to be sure it includes the letters SG or SH.
SAE 10W-30 is recommended for general, all-temperature use, -5 F to 104 F (-20 C to 40 C).
See Engine Ownerʼs Manual for more specific information on oil viscosity recommendations.
Wash your hands with soap and water after handling
used oil.
Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you take
it in a sealed container to your local service station or
recycling center for reclamation.
Do not throw it in the trash, pour it on the ground or
down a drain.
OIL FILTER CHANGE
1. Drain the engine oil.
2. Remove the oil filter, and drain the oil into a suitable
container. Discard the used oil filter.
AIR CLEANER AND OTHER MAINTENANCE
• Air Cleaner - With normal operating conditions, the
maintenance schedule for cleaning and re-oiling
the foam pre-filter is every 25 hours and replacement of the air cleaner filter every 100 hours.
More frequent servicing is required with dusty
operating conditions. Refer to the maintenance
section of the Engine Ownerʼs Manual for more
information.
• Refer to the maintenance section of the Engine
Ownerʼs Manual for the maintenance schedule,
spark plug servicing, cooling system servicing, and
fuel filter replacement.
• Blow out the machine with low pressure air periodically. In particularly dirty locations, this may be
required once a week.
• Output Ranger Selector and Polarity Switches:
Switch contacts should not be greased. To keep
contacts clean, rotate the switch through its entire
range frequently. Good practice is to turn the handle from maximum to minimum setting twice each
morning before starting to weld.
3. Clean the filter mounting base, and coat the gasket
of the new oil filter with clean engine oil.
4. Screw on the new oil filter by hand, until the gasket
contacts the filter mounting base, then use an oil filter socket tool to tighten the filter an additional 1/2 to
7/8 turn.
5. Refill the crankcase with the specified amount of the
recommended oil. Reinstall the oil filler cap.
6. Start the engine and check for oil filter leaks.
7. Stop the engine, and check the oil level. If necessary, add oil to the upper limit mark on the dipstick.
EAGLE™ 10,000 PLUS
Page 26
D-3
MAINTENANCE
D-3
ENGINE ADJUSTMENTS
OVERSPEED IS HAZARDOUS
WARNING
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 the
machine can result if operated at speeds above
maximum.
Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.
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 with a fine emery
paper.
CAUTION
Do not attempt to polish slip rings while engine is
running.
• Keep sparks, flame and cigarettes away from battery.
To prevent EXPLOSION when:
• INSTALLING A NEW BATTERY - disconnect negative
cable from old battery first and connect to new battery last.
• CONNECTING A BATTERY CHARGER - Remove battery from welder by disconnecting negative cable
first, then positive cable and battery clamp. When
reinstalling, connect negative cable last. Keep well
ventilated.
• USING A BOOSTER - connect positive lead to battery
first then connect negative lead to engine foot.
BATTERY ACID CAN BURN EYES AND SKIN.
• Wear gloves and eye protection and be careful when
working near battery. Follow instructions printed on
battery.
BATTERY
1. When replacing, jumping, or otherwise connecting
the battery to the battery cables, the proper polarity
must be observed. Failure to observe the proper
polarity could result in damage to the charging circuit. The positive (+) battery cable has a red terminal cover.
2. If the battery requires charging from an external
charger, disconnect the negative battery cable first
and then the positive battery cable before attaching
the charger leads. Failure to do so can result in
damage to the internal charger components. When
reconnecting the cables, connect the positive cable
first and the negative cable last.
HARDWARE
Both English and Metric fasteners are used in this
welder.
ENGINE MAINTENANCE PARTS
KOHLER C23S, CH680
KOHLER 12 050 01
Oil FilterFRAM PH8172*
Air FilterKOHLER 47 083 03
KOHLER CH730
KOHLER 12 050 01
FRAM PH8172*
KOHLER 47 083 03
ElementFRAM CA79
Air FilterKOHLER 24 083 02
KOHLER 24 083 05
Pre-Cleaner
Fuel FilterKOHLER 24 050 13
Spark PlugsCHAMPION RC12YC
(Resistor (.030” GAP)
KOHLER 24 050 13
CHAMPION RC12YC
(.030” GAP)
Type)
* Oil capacity increases from 2.0 Qts. to 2.1 Qts. when using this filter.
EAGLE™ 10,000 PLUS
Page 27
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
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 describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
EAGLE™ 10,000 PLUS
Page 28
E-2
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
E-2
No welder output power or Auxiliary
Power.
Engine will not idle down to low
speed.
1. Open in miscellaneous leads.
2. Open lead in flashing or field
circuit.
3. Faulty rotor.
4. Faulty Potentiometer (R1).
5. Faulty stator Field winding.
6. Faulty Field rectifier (On PCB*).
7. Faulty P.C. Board.
1. Idler switch on High Idle.
2. Insufficient voltage present on
idler solenoid terminals.
(Voltage should be 12V to 14V
DC).
3. External load on welder or
auxiliary power.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
Engine will not go to high idle when
attempting to weld.
* Printed Circuit Board (PCB)
4. Faulty wiring in solenoid circuit.
5. Faulty idler solenoid.
6. Faulty P.C. Board.
1. Poor work lead connection to
work.
2.No voltage signal from the
current sensor.
3.No open circuit voltage on
output studs.
4. Faulty P.C. Board.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
EAGLE™ 10,000 PLUS
Page 29
E-3
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
E-3
Engine will not go to high idle when
using auxiliary power.
Engine will not crank or is hard to
crank.
Engine shuts down.
1.No voltage signal from the
current sensor.
2.Auxiliary power load less than
100 to 150 watts.
3.Faulty P.C. Board.
1.Battery will not hold a charge.
Faulty Battery.
2.No or insufficient charging
current.
3.Loose battery cable
connection(s).
1.Out of fuel.
2.Low oil level.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
Engine does not develop full power.
Engine is hard to start.
1.Fuel filter clogged.
2.Air filter clogged.
1.Spark plugs do not have
specified gap.
2.Spark plugs are fouled.
3.Out of fuel.
4.Fuel filter clogged.
5.Electric fuel pump not working.
(Electric pump equipped models
only.)
6.Mechanical fuel pump not working.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
EAGLE™ 10,000 PLUS
Page 30
F-1
DIAGRAMS
F-1
EAGLE™ 10,000 PLUS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the
machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
Page 31
F-2
DIMENSION PRINT
F-2
B
36.24
33.62
29.88
10.2710.78
7.22
CIRCUIT
BREAKERS
M22195
NOTE: CASEFRONT GRAPHICS MAY NOT MATCH ALL CODES.
CENTER OF GRAVITY WITH OIL
IN ENGINE AND EMPTY FUEL TANK.
10.50
20.80
21.50
24.86
DIMENSION DIAGRAM CODES 11618,11735, 11791, 11798
2.6
42.10
19.50
17.50
41.20
TRUCK/UNDERCARRIAGE MOUNTING HOLES
EAGLE™ 10,000 PLUS
Page 32
F-3
DIMENSION PRINT
F-3
A
M24956
MM
INCH
36.24
920.43
33.62
853.97
29.88
758.95
10.78
273.93
10.27
260.98
7.22
183.39
CIRCUIT
BREAKERS
CENTER OF GRAVITY WI TH OIL
IN ENGINE AND EMPTY FUEL TANK .
15.25
20.80
528.28
21.38
DIMENSION DIAGRAM CODE 12094
542.92
24.86
631.33
2.6
66.55
NOTE: CASEFRONT GRAPHICS MAY NOT MATCH ALL CODES.
387.35
42.10
1069.46
19.50
495.3
17.50
444.5
41.20
1046.48
TRUCK/UNDERCARRIAGE MOUNTI NG HOLES
EAGLE™ 10,000 PLUS
Page 33
NOTES
EAGLE™ 10,000 PLUS
Page 34
WARNING
Spanish
AVISO DE
PRECAUCION
Do not touch electrically live parts or
electrode with skin or wet clothing.
Insulate yourself from work and
ground.
No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
Aislese del trabajo y de la tierra.
Keep flammable materials away.
Mantenga el material combustible
fuera del área de trabajo.
Wear eye, ear and body protection.
Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
Isolez-vous du travail et de la terre.
Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
Isolieren Sie sich von den
Elektroden und dem Erdboden!
Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
Isole-se da peça e terra.
Gardez à l’écart de tout matériel
inflammable.
Entfernen Sie brennbarres Material!
Mantenha inflamáveis bem guarda-
dos.
Protégez vos yeux, vos oreilles et
votre corps.
Tragen Sie Augen-, Ohren- und Kör-
perschutz!
Use proteção para a vista, ouvido e
corpo.
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Page 35
Keep your head out of fumes.
Use ventilation or exhaust to
remove fumes from breathing zone.
Turn power off before servicing.
Do not operate with panel open or
guards off.
WARNING
Los humos fuera de la zona de res-
piración.
Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
Gardez la tête à l’écart des fumées.
Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
Vermeiden Sie das Einatmen von
Schweibrauch!
Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
Mantenha seu rosto da fumaça.
Use ventilação e exhaustão para
remover fumo da zona respiratória.
Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.