Lincoln Electric IM926 User Manual

EAGLE™10,000

R

RETURN TO MAIN MENU

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 op eration on your part. DO

NOT INSTALL, OPERATE O R
REP A I R THI S EQUIP M E NT
WIT H O UT REA D I NG THI S
MAN U A L AND T HE SA F E TY
PRE CAUT IONS CONT AINE D
THR O U GHOUT . And , mos t

importantly, think before you act
and be careful.

IM926

June, 2009

For Machines with Code Number: 11397

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

C US

OPERATOR’S MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

i

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.b.Operate engines in open,well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

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.

Mar ‘95

ii

SAFETY

ii

ELE CTR IC 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
skin or wet clot hing. Wear dry, hole -free

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
mu s t be per form ed und er ele ctri call y haza r dou s
con ditions (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,
elect rode reel, we lding he ad, nozz le or se miautomat ic
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. N ever sim ul taneous ly touch elect ri cally “hot” pa rts 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.

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. Weldin g may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and g as es . When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and g ases away fro m the breathing zone. When

we l ding w i th el e ctr o des wh i ch req u ire s p eci a l
ve n til atio n suc h as s t ain less or har d fac i ng ( see
in str uct ion s on cont ain er or M SDS ) or on l ead or
cadmi um plated s teel and other metals or coating s
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 circum­st a nce s, ou t doo r s, a resp i rat or m a y be r equ i red .
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 en ou gh ventilation,
especially in confined areas, to insure breathing air is safe.

vapors

to

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
ma t eria l s afet y d ata sh e et (MS D S) and fol low you r
employer’s safety practices. MSDS forms are available from
yo u r weld ing d i str i but o r or fro m the m a nuf a ctu r er.

5.f. Also see item 1.b.

Jan ‘09

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

Re m embe r th a t we l din g spa r ks an d ho t
materials from welding can easily go through small cracks
an d op eni ngs to a dj ace nt are as. Avo id w el din g ne ar
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
Standar d Z49.1) an d the operating info rmation fo r 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
Co n tain ers a n d Pip ing T hat H a ve H e ld H a zard ous
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
incre ase the p ossibil ity of the welding curr ent pass ing
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 sp arks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. U se on l y co m pres sed ga s cy l ind e rs
containing the correct shielding gas for the
pr o cess used and pr ope r ly o per a tin g
re g ulat ors d e sig n ed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. A lw ays keep cylinders in an upright po si ti on 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. R ead and follo w t he ins truct ions o n c ompre ssed g as
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 eq uipment in accordance with the U.S. Natio nal
Electrical Code, all local codes and the ma nufacturer’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.

Jan ‘09

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 L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode 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 s’isoler 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 l’eau 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 s’applicuent aussi au pistolet de
soudage.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie 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 d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
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 d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils 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
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc 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 n’importe quelle partie
du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, 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 l’on 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
l’électricité 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, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

TThhaannkk YYoouu

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 customer’s 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.

Product _________________________________________________________________________________
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

“Product Registration”. 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 “Quick Links” and then

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.

vi

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Safety Precautions........................................................................................................A-2

Machine Grounding.......................................................................................................A-2

Spark Arrester...............................................................................................................A-2

Towing...........................................................................................................................A-2

Pre-Operation Engine Service..............................................................................................A-3

Fuel ...............................................................................................................................A-3

Oil..................................................................................................................................A-3

Battery Connections......................................................................................................A-3

Welding Cable Connections..........................................................................................A-3

Angle of Operation ........................................................................................................A-4

Lifting.............................................................................................................................A-4

High Altitude Operation.................................................................................................A-4

Location and Ventilation................................................................................................A-4

Stacking ........................................................................................................................A-4

Connection of Wire Feeders .........................................................................................A-4

Connection of TIG Module............................................................................................A-5

Additional Safety Precautions,Welding Operation Output.............................................A-5

Auxiliary Power Receptacles, and Plugs ......................................................................A-5,A-6

Motor Starting and Extension Cord Length Table................................................................A-6

Electrical Device Used with the Ranger 10,000 ...................................................................A-7

Auxiliary Power While Welding, Standby Power Connections............................................A-8

Premises Wiring ...................................................................................................................A-9

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

General Description..............................................................................................................B-1

Welder Controls Function and Operation.............................................................................B-1

Range and Control Switch....................................................................................................B-2

Start in/Shutdown Instructions.....................................................................................................B-3

Starting the Engine........................................................................................................B-3

Safety Precautions........................................................................................................B-3

Stopping the Engine......................................................................................................B-3

Break-In Period .............................................................................................................B-3

Welding Process ..................................................................................................................B-4

Stick (Constant Current) Welding..................................................................................B-4

TIG (Constant Current) Welding ...................................................................................B-4

Wire Feed Welding Processes .....................................................................................B-4

Arc Gouging ..................................................................................................................B-4

Summary of Welding Processes and Current Ranges for Tungsten Electrodes ..........B-5

________________________________________________________________________________

Accessories ........................................................................................................Section C

Optional Equipment...............................................................................................C-1

Recommended Equipment....................................................................................C-1

________________________________________________________________________

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Engine Maintenance ..........................................................................D-1,D2

Engine Adjustments...............................................................................................D-3

Slip Rings ..............................................................................................................D-3

Battery Maintenance.......................................................................................D-3

Engine Maintenance Parts..............................................................................D-3

________________________________________________________________________

Troubleshooting..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide...................................................................................E-2, E-3

________________________________________________________________________

Wiring Diagrams & Dimension Print..............................................................Section F

Wiring and Connection Diagrams....................................................................F-1,F-2

Dimension Print......................................................................................................F-3

________________________________________________________________________

Parts List.................................................................................................................P-488

________________________________________________________________________

vi

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - EAGLE™ 10,000 (K2343-2 )

INPUT - GASOLINE ENGINE

Make/Model

Description

Horsepower

Operating

Speed (RPM)

Displacement

cu. in.

(cu.cm.)

Starting

System

A-1

Capacities

Kohler

CH23S

2 cylinder

4 Cycle

Air-Cooled

Gasoline

Engine.

Aluminum Alloy

with Cast Iron

Liners,

Electronic Start

RATED OUTPUT @ 104°F (40°C) - WELDER

RATED OUTPUT @ 104°F (40°C) - GENERATOR

High Idle 3700

23 HP @

3600 RPM

(Kohler)

DC Constant Current 210A / 25V / 100%

10,500 Watts Peak, 60 Hz AC

9,000 Watts Continuous, 60 Hz AC

Full Load 3500

Low Idle 2200

Welding Output

Auxiliary Power

120/240 Volts

41(674)

Kohler

1

12VDC
Battery

Electric Start

Group 58

Battery
(435 cold
Cranking

Amps)

Fuel:

9 Gal (34 L)

Lubricating Oil:

2.0 Qts. (1.9 L)

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

30.3 in. 19.1 in. 42.3 in.
770 mm 485 mm 1074 mm 502 lbs. (228kg)

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

A-2

INSTALLATION

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrode with skin or wet clothing.

• Insulate yourself from work and
ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or
vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or
guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

A-2

When this welder is mounted on a truck or trailer, it’s
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, it’s
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.

SPARK ARRESTER

See additional warning information at

front of this operator’s manual.

-----------------------------------------------------------

MACHINE GROUNDING

Because this portable engine driven welder or genera­tor creates it’s own power, it is not necessary to con­nect it’s 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 K894-1 spark arrester must be
installed and properly maintained.

CAUTION

An incorrect arrester may lead to damage to the
engine or adversely affect performance.

------------------------------------------------------------------------

TOWING

The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle
Lincoln’s K957-1. 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.

2. Proper support of, and attachment to, the base of

the welding equipment so there will be no undue
stress to the framework.

(1)

is

EAGLE™ 10,000

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.

INSTALLATION

(1)

VEHICLE MOUNTING

WARNING

A-3

OIL

LUBRICATION SYSTEM CAPACITY

(INCLUDING FILTER)

Kohler CH23S - 2.0 Quarts (1.9 Liters)

The EAGLE™ 10,000 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 Owner’s Manual for specific oil recommenda­tions.

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.

• Follow vehicle manufacturer’s instructions.

------------------------------------------------------------------------

CAUTION

READ the engine operating and maintenance

BATTERY CONNECTIONS

------------------------------------------------------------------------

This welder is shipped with the negative battery cable disconnected.
Make sure that the Engine Switch is in the “OFF” 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.

instructions supplied with this machine.

WELDING OUTPUT CABLES

WARNING

With the engine off, connect the electrode and work cables to the

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from
tank.

• Do not leave unattended while fuel-

GASOLINE

can cause fire
or explosion.

------------------------------------------------------------------------

ing.

• Wipe up spilled fuel and allow fumes
to clear before starting engine.

• Do not overfill tank, fuel expansion
may cause overflow.

GASOLINE FUEL ONLY

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.

Use caution as the electrolyte is a strong acid that can
burn skin and damage eyes.

FUEL

Fil the fuel tank with clean, fresh, lead-free gasoline. Observe fuel
gauge while filling to prevent overfilling.

WARNING

• Damage to the fuel tank may cause
fire or explosion. Do not
in the EAGLE™ 10,000 base or weld

to

the EAGLE™ 10,000 base.

drill holes

EAGLE™ 10,000

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

225 Amps

100% Duty Cycle

0-100 Ft.

(0-328 m)

100-200 Ft.

(328-656 m)

200-250 Ft.

(656-820 m)

1 AWG

1 AWG

1/0 AWG

A-4

INSTALLATION

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 9 gal (34 L).

LIFTING

The EAGLE™ 10,000 weighs approximately 575 lbs.
(281kg) with a full tank of gasoline. A lift bail is
mounted to the machine and should always be used
when lifting the machine.

ADDITIONAL SAFETY PRECAUTIONS

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.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

-----------------------------------------------------------------------

HIGH ALTITUDE OPERATION

At higher altitudes, Welder output de-rating may be neces­sary.

A-4

Contact your local Kohler Authorized Dealer for high altitude
jet kits that are available from the engine manufacturer.

Muffler Relocation

WARNING

Shut off welder and allow muffler to cool before touch-

•

ing muffler.

------------------------------------------------------------------------

The EAGLE™ 10,000 is shipped with the exhaust coming
out on the left side. The exhaust can be changed to the
opposite side by removing the two screws that hold the
exhaust port cover in place and installing the cover on the
opposite side. (Operating the EAGLE™ 10,000 without the
cover in place will result in a higher noise level and no
increase in machine output.)

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 machines cannot be stacked.

CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS

Note: A constant voltage (CV) power source is recommend-

ed for wire feeder applications. The LN-15 and LN-25
may be used with a constant current (CC) power
source, such as the EAGLE™ 10,000, for non-critical
applications where weld quality and deposition prop-

erties are not critical.

WARNING

For maximum rating, de-rate the welder output 3.5% for
every 1000ft. (305m) above 3000ft. (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. This will result in the engine run­ning too lean and result in higher engine operating
temperatures which can shorten engine life.

EAGLE™ 10,000

Shut off welder before making any electrical connec­tions.

------------------------------------------------------------------------

WIRE FEED CONNECTION OF LN-15 ACROSS-THE-ARC
WIRE FEEDER

The LN-15 has an internal contactor and the electrode is not
energized until the gun trigger is closed. When the gun trig­ger is closed the wire will begin to feed and the welding
process is started.

a. Shut the welder off.
b. For electrode Positive, connect the electrode cable to

the "+" terminal of the welder and work cable to the "-"
terminal of the welder. For electrode Negative, connect
the electrode cable "-" terminal of the welder and work
cable to the "+" terminal of the welder.