Lincoln Electric TOMAHAWK TM 625 IM10020 Operator's Manual

IM10020

TOMAHAWK ™625

For use with machines having Code Number:

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. H oweve r,
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.

January, 2011

11580

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

Copyright © Lincoln Global Inc.

i

SAFETY

i

WARNING

PLASMA CUTTING or GOUGING 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.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

ELECTRIC SHOCK can
kill.

1.a. The electrode and work (or ground) circuits
are electrically “hot” when the power source is on.
Do not touch these “hot” parts with your bare skin
or wet clothing. Wear dry, hole-free gloves to

insulate hands.

1.b. When the power source is operating voltages in excess of
250 volts are produced. This creates the potential for serious
electrical shock - potentially even fatal.

1.c. Insulate yourself from work and ground using dry insulation.
When cutting or gouging in damp locations, on metal frame­work such as floors, gratings or scaffolds and when in posi­tions such as sitting or lying, make certain the insulation is
large enough to cover your full area of physical contact with
work and ground.

1.d. Always be sure the work cable makes a good electrical con­nection with the metal being cut or gouged. The connection
should be as close as possible to the area being cut or
gouged.

1.e. Ground the work or metal to be cut or gouged to a good elec­trical (earth) ground.

1.f. Maintain the plasma torch, cable and work clamp in good,
safe operating condition. Replace damaged insulation.

1.g. Never dip the torch in water for cooling or plasma cut or
gouge in or under water.

1.h. When working above floor level, protect yourself from a fall
should you get a shock.

1.i. Operate the pilot arc with caution. The pilot arc is capable of
burning the operator, others or even piercing safety clothing.

1.j. Also see Items 4c and 6.

or gouging, keep your head out of the fumes. Use enough
ventilation and/or exhaust at the arc to keep fumes and
gases away from the breathing zone. When plasma cutting

or gouging 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.

3. b. The operation of plasma cutting or gouging fume control
equipment is affected by various factors including proper use
and positioning of the equipment, maintenance of the equip­ment and the specific 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.

3.c. Do not use plasma cutting or gouging equipment in locations

near chlorinated hydrocarbon vapors coming from degreas­ing, cleaning or spraying operations. The heat and rays of the
arc can react with solvent vapors to form phosgene, a highly
toxic gas, and other irritating products.

3.d. Gases used for plasma cutting and gouging can displace air

and cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

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

equipment and follow your employer’s safety practices.

FUMES AND GASES
can be dangerous.

3.a. Plasma cutting or gougin g may produce
fumes and gases hazardous to health. Avoid
breathing these fumes and gases. When cutting

ARC RAYS can burn.

2.a. Use safety glasses and a shield with the prop­er filter and cover plates to protect your eyes from
sparks and the rays of the arc when performing or
ob s e r v ing plas m a a r c c u t ting or gougin g .
Glasses,headshield and filter lens should conform
to ANSI Z87. I standards.

2.b. Use suitable clothing including gloves made from durable
flame-resistant material to protect your skin and that of your
helpers from the arc rays.

2.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.

CUTTING SPARKS can
cause fire or explosion.

4.a. Remove fire hazards from the plasma cut­ting or gouging area. If this is not possible, cover
them to prevent the cutting or gouging sparks

from starting a fire. Remember that weldi ng
sparks and hot materials from plasma cutting or gouging can
easily go through small cracks and openings to adjacent
areas. Avoid cutting or gouging near hydraulic lines. Have a
fire extinguisher readily available.

4.b. Where compressed gases are to be used at the job site, spe­cial precautions should be used to prevent hazardous situa­ti ons . R efe r to “Sa fet y i n Wel ding a nd Cut tin g” (AN SI
Standard Z49.1) and the operating information for the equip­ment being used.

ii

SAFETY

ii

4.c. When not cutting or gouging, make certain no part of the elec­trode circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.

4.d. Do not cut or gouge 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
ca n cause an expl o s i on e v e n thou g h they ha ve b e e n
“cleaned.” For information purchase “Recommended Safe
Practice s for the Prepara ti on for Weldi ng a nd Cutting o f
Co n t a i ners a nd Pi p i ng Th a t Hav e Held H a zardo u s
Substances”, AWS F4.1 from the American Welding Society
(see address above).

4.e. Vent hollow castings or containers before heating, cutting or
gouging. They may explode.

4.f. Do nor fuel engine driven equipment near area where plasma
cutting or gouging.

4.g. Sparks and spatter are thrown from the plasma arc. Wear
safety glasses, ear protection and oil free protective garments
such as leather gloves, heavy shirt, cuffless trousers, high
shoes and a cap over your hair. Wear ear plugs when cutting
or gouging out of position or in confined places. Always wear
safety glasses with side shields when in a cutting or gouging
area.

4.h. Connect the work cable to the work as close to the cutting or
gouging area as practical. Work cables connected to the build­ing framework or other locations away from the cutting or
gouging area increase the possibility of the current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overhe at lifting chains or
cables until they fail.

4.I. Read and follow NFPA 51B “ Standard for Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101.

CYLINDER may explode
if damaged.

5.a. Use only compressed gas cylinders contain­ing the correct 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.

5.b. Alway s keep cylinde rs i n an upright pos it ion securely
chained to an undercarriage or fixed support.

5.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from plasma cutting or gouging, arc weld-

ing operations and any other source of heat, sparks,
or flame.

5.d. Never allow any part of the electrode, torch or any other
electrically “hot” parts to touch a cylinder.

5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

5.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

5.g. Read and follow the instructions on compressed gas cylin­ders, associate d equi pm en t, a nd C GA p ublication 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.

6.a. Turn off input power using the disconnect
switch at the fuse box before working on the
equipment.

6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s rec­ommendations.

6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

PLASMA ARC can injure.

7.a. Keep your body away from nozzle and
plasma arc.

7.b. Operate the pilot arc with caution. The pilot arc is capable of
burning the operator, others or even piercing safety clothing.

ELECTRIC AND MAGNETIC
FIELDS
may be dangerous

8.a. Electric current flowing through any con­ductor causes localized Electric and Magnetic
Fields (EMF). Cutting or gouging current cre­ates EMF fields around torch cables and cutting
machines.

8.b. EMF fields may interfere with some pacemakers, so opera­tors having a pacemaker should consult their physician
before cutting or gouging.

8.c. Exposure to EMF fields during cutting or gouging may have
other health effects which are now not known.

8d. All operators should use the following procedures in order to

minimize exposure to EMF fields from the cutting or gouging
circuit:

8.d.1. Route the torch and work cables together - Secure
them with tape when possible.

8.d.2. Never coil the torch cable around your body.

8.d.3. Do not place your body between the torch and
work cables. If the torch cable is on your right side,
the work cable should also be on your right side.

8.d.4. Connect the work cable to the workpiece as close as
possible to the area being cut or gouged.

8.d.5. Do not work next to cutting power source.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

NOTES

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. U n cour t-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’o pérations de d égraissage, nettoyage ou pist olage. 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. Proté ge r l’autre p er sonnel travaillant à p roximité au

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

4. Des gout tes de laitier en fusion sont émises d e 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.

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 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.

TABLE OF CONTENTS

Page

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

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

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

Select Proper Location .........................................................................................................A-2

Stacking................................................................................................................................A-2

Tilting....................................................................................................................................A-2

High Frequency Interference Protection...............................................................................A-2

Input Electrical Connections.................................................................................................A-2

Gas Input Connections.........................................................................................................A-3

Output Connections..............................................................................................................A-3

Torch .............................................................................................................................A-3

________________________________________________________________________________

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

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

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

Preheat Temperature for Plasma Cutting.............................................................................B-1

User Responsibility...............................................................................................................B-2

Operational Features and Controls ......................................................................................B-2

Design Features and Advantages ........................................................................................B-2

Cutting Capability .................................................................................................................B-3

Consumable Life ..................................................................................................................B-3

Limitations ............................................................................................................................B-4

Controls and Settings ...................................................................................................B-4, B-5

Cutting Process ............................................................................................................B-5, B-6

Pilot Arc Discussion..............................................................................................................B-7

Procedure Recommendations..............................................................................................B-7

General .........................................................................................................................B-7

Suggestions for Extra Utility from the TOMAHAWK™ 625 System ..............................B-8

Torch Part Configuration.............................................................................................B-9, B-10

________________________________________________________________________________

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

________________________________________________________________________

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

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

Routine Maintenance.............................................................................................D-1

Periodic Maintenance............................................................................................D-1

________________________________________________________________________

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

Safety Precautions.................................................................................................E-1

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

Troubleshooting Guide ...........................................................................E-2 Thru E-6

________________________________________________________________________

Wiring Diagrams..............................................................................................Section F

Wiring Diagram ......................................................................................................F-1

________________________________________________________________________

Parts Lists........................................................................................................Appendix

TOMAHAWK™ 625................................................................................P-626 Series

Torch.............................................................................................................P-210-W

________________________________________________________________________

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS -TOMAHAWK™ 625

INPUT - SINGLE PHASE 50 / 60 HERTZ

Standard Voltage

208V, 230V ±10% / 1 / 50 / 60Hz

RATED OUTPUT AT 40° C

Duty Cycle

100%

60%
35%

CURRENT AMPS

24 A
29 A
40 A

OUTPUT

A-1

VOLTAGE VOLTS

89.6VDC

91.8VDC

96.0VDC

Output

40 A

Current

Range

10-40 Amps

Open Circuit

Voltage

460 VDC

Pilot Current

12 Amps

REQUIRED GAS FLOW RATE REQUIRED GAS INLET PRESSURE

70 PSI @ 125-200 SCFH

( 5 Bar. @ 80±20 LITERS/MIN.)

80 to 110 PSI

(6 Bar. to 7.5 Bar.)

RECOMMEND INPUT WIRE AND FUSE SIZES

For all plasma cutting applications

AC Input

Voltage

at
50/60
Hertz

230V-1Ø
208V-1Ø

Based on U.S. National Electrical Code

Ambient Temperature 30

Input Cord Plug Size

6-50P

(Super Lag)

Circuit Breaker

(Delay Type)

30 AMPS #12 (3.3 mm

Fuse

o

C or Less

Type S, SO, ST, STO or extra

2 Input Supply Wires

hard usage input cord

AWG (IEC) Sizes

1 Ground Wire

2

)

#12 (3.3 mm2)

PHYSICAL DIMENSIONS

Weight

Height

Width

Depth

Including

Torch Cable

15.2 in.

385 mm

OPERATING TEMPERATURE RANGE

-10°C to +40°C

215 mm

8.5 in.

18.9 in.

480 mm

TEMPERATURE RANGES

TOMAHAWK™ 625

34.0 lbs.

15.4 kg.

STORAGE TEMPERATURE RANGE

-10°C to +40°C

A-2

INSTALLATION

A-2

Read entire Installation Section before installing the
TOMAHAWK™ 625.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK CAN KILL.

• Only qualified personnel
should install this machine.

• Turn the input power OFF
at the disconnect switch or
fuse box and disch arge
input capacitors befo re
working inside the equip­ment.

• Do not touch electrically hot parts.

• Turn the TOMAHAWK™ 625 Power Switch
OFF when connecting power cord to input
power.

___________________________________________

SELECT PROPER LOCATION

Place the TOMAHAWK™ 625 where clean cool air
can freely circulate in and out of the side louvers. Dirt,
dust or any foreign material that can be drawn into the
machine should be kept at a minimum. Failure to
observe these precautions can result in excessive
operating temperatures and nuisance shutdown of the
machine.

HIGH FREQUENCY INTERFERENCE
PROTECTION

The TOMAHAWK™ 625 employs a touch start mech­anism for arc initiation which eliminates high frequen­cy emissions from the machine as compared with
spark gap and solid state type high frequency genera­tors. Keep in mind, though, that these machines may
be used in an environment where other high frequen­cy generating machines are operating. By taking the
following steps, high frequency interference into the
TOMAHAWK™ 625 can be minimized

(1) Make sure the power supply chassis is connected

to a good earth ground. The work terminal ground
does NOT ground the machine frame.

(2) Keep the work clamp isolated from other work

clamps that have high frequency.

(3) If the work clamp cannot be isolated, then keep

the clamp as far as possible from other work
clamp connections.

(4) When the machine is enclosed in a metal building,

severa l good ear th driv en electrical grounds
around the periphery of the building are recom­mended.

Failure to observe these recommended installation
procedures may cause improper function of the TOM­AHAWK™ 625 or possibly even damage to the control
system or power supply components.

INPUT ELECTRICAL CONNECTIONS

A source of clean, dry air or nitrogen must be supplied
to the TOMAHAWK™ 625 when using external air
supply. Oil in the air is a severe problem and must be
avoided. The supply pressure must be between 80
and 150 psi. The flow rate is approximately 4.0 cfm
(113 l/min.). Failure to observe these precautions
could result in excessive operating temperatures or
damage to the torch.

STACKING

The TOMAHAWK™ 625 cannot be stacked.

TILTING

The TOMAHAWK™ 625 must be placed on a stable,
level surface so it will not topple over.

The TOMAHAWK™ 625 is rated for 208VAC and
230VAC input voltage. Before installing the machine,
check that input supply voltage, phase, and frequency
are the same as the machine's voltage, phase, and
frequency as specified on the machine's rating plate.

• The TOMAHAWK™ 625 should be connected only
by a qualified electrician. Installation should be
made in accordance with local codes.

For use on engine drives, keep in mind the above
input draw restrictions and the following precaution.

The TOMAHAWK™ 625 can be operated on engine
driven generators as long as the 230 volt auxiliary
meets the following conditions:

• The AC waveform peak voltage is below 400 volts.

• The AC waveform frequency is between 45 and 65

Hz.

• The RMS voltage of the AC waveform is always

greater than 208VAC.

TOMAHAWK™ 625

A-3

The following Lincoln engine drives meet these condi­tions when run in the high idle mode:

Outback 189, Ranger 225, 250, 250LPG, 305G and
305D engine drives.
Vantage 300, 400, 500 and Air Vantage engine drives.

Some engine drives do not meet these conditions
(e.g. Miller Bobcats, etc). Operation of the TOMA­HAWK™ 625 is not recommended on engine drives
not conforming to these conditions. Such combina­tions may overvoltage the TOMAHAWK™ 625 power
source.

INSTALLATION

GAS INPUT CONNECTIONS

(External Air Supply)

Sup ply the TO MAHAWK™ 625 w ith clean com­pressed air or nitrogen.

• Supply pressure must be between 80 psi
and 110 psi.

• Flow rate should be approximately 125 - 200
SCFH (80 ±20 L/min).

NOTE: Oil in the air supply to the TOMAHAWK™ 625

can cause severe problems. Use only a clean
air supply.

Compressed gas can be supplied either through the air

•

fitting supplied with the machine or through the 1/4-19

BSPP

thread at the rear of the machine. To use the air
fitting supplied with the machine (packaged in the con­sumable kit), apply teflon tape to the fitting threads and
install the fitting in the port at the rear of the machine.

• If compressed air is being used, it is highly recom­mended that an in line filter be installed in the air
supply line ahead of the air connection to the TOMA­HAWK™ 625.

• A standard nominal 5 micron in line filter is recom­mended; however, for optimum performance, select
a prefilter with a 3 micron absolute rating.

A-3

NOTE: When using nitrogen gas from a cylinder, the

cylinder must have a pressure regulator.

• Maximum psi from a nitrogen gas cylinder to
th e TO MAHAWK™ 625 reg ulator sho uld
never exceed 110 psi.

• Install a hose between the nitrogen gas cylin­der regulator and the TOMAHAWK™ 625 gas
inlet.

.

WARNING

CYLINDER could explode if dam-

aged.

• Keep c ylin der upright and
chained to a fixed support.

• Keep cylinder away from areas
where it could be damaged.

• Never lift machine with cylinder attached.

• Never allow the cutting torch to touch the
cylinder.

• Keep cylinder away from live electrical
parts.

• Maximum inlet pressure 110 psi.

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

OUTPUT CONNECTIONS

Torch

The TOMAHAWK™ 625 is sent from the factory with
a cutting torch and work clamp included. The work
clamp must be securely connected to the work piece.
If the work piece is painted or extremely dirty it may
be necessary to expose the bare metal in order to
make a good electrical connection.

If these filter ratings are unavailable, anything with a
rating less than, or equal to, 20 micron would be
acceptable to use. In line filter elements will generally
filter the air with little restriction to the airflow until the
element is about 75% contaminated. After this point,
there will be a noticeable pressure drop in the line.
Filter elements should be replaced when a pressure
drop of 8-10 psi is indicated; however, for optimum
performance of the TOMAHAWK™ 625, the filter ele­ment should be replaced at or before the pressure
drop reaches 8 psi. Be sure to select a filter that will
accommodate the necessary flow rating for the TOM­AHAWK™ 625 as specified in the Installation section
of thi s instruction ma nua l under th e Gas In p u t
Connections heading.

TOMAHAWK™ 625

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

WARNING

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.

FUMES AND GASES
can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to
remove fumes from breathing
zone.

DESCRIPTION

The TOMAHAWK™ 625 is a constant current, contin­uous control plasma cutting power source. It provides
superior and reliable starting characteristics, cutting
visibility and arc stability. The control system has a
safety mechanism to insure that the nozzle and elec­trode are in place before cutting or gouging. This is
extremely important due to the high voltages involved.

The TOMAHAWK™ 625 comes standard with an air
regulator and pressure gauge. The machine also
comes with an input power cord, Hand-held torch with
a 20' cable length. Consumables are included with
each TOMAHAWK™ 625 purchase so that cutting can
begin right out of the box. Consumables can also be
ordered as individual packages.

The TOMAHAWK™ 625 initiates the plasma arc with
a simple, yet reliable, touch start mechanism. This
system eliminates many of the failure problems asso­ciated with hi-frequency start systems.

WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion

• Keep flammable material away.

• Do not weld, cut or gouge on
containers that have held combustibles.

ARC RAYS
can burn.

• Wear eye, ear and body
protection.

PLASMA ARC
can injure

• Keep your body away from nozzle
and plasma arc.

• Operate the pilot arc with caution. The
pilot arc is capable of burning the
operator, others or even piercing
safety clothing.

PREHEAT TEMPERATURE FOR
PLASMA CUTTING

Preheat temperature control is not necessary in most
applications when plasma arc cutting or gouging.
Preheat temperature control may be necessary on high
carbon alloy steels and heat treated aluminum for crack
resistance and hardness control. Job conditions, pre­vailing codes, alloy level, and other considerations may
also require preheat temperature control. The following
minimum preheat temperature is recommended as a
starting point. Higher temperatures may be used as
required by the job conditions and/or prevailing codes.
If cracking or excessive hardness occurs on the cut
face, higher preheat temperature may be required. The
recommended minimum preheat temperature for plate
thickness up to 1/2" (12.7mm) is 70°F (21.1°C).

Observe additional Safety Guidelines detailed in
the beginning of this manual.

TOMAHAWK™ 625

B-2

OPERATION

USER RESPONSIBILITY

Because design, fabrication, erection and cutting vari­ables affect the results obtained in applying this type
of information, the serviceability of a product or struc­ture is the responsibility of the user. Variation such as
plate chemistry, plate surface condition (oil, scale),
plate thickness, preheat, quench, gas type, gas flow
rate and equipment may produce results different than
those expected. Some adjustments to procedures
may be necessary to compensate for unique individ­ual conditions. Test all procedures duplicating actual
field conditions.

DESIGN FEATURES AND
ADVANTAGES

The TOMAHAWK™ 625 design makes plasma cutting
uncomplicated. This list of design features and advan­tages will help you understand the machine's total
capabilities so that you can get maximum use from
your machine.

B-2

- Light weight and portable design for industrial use.

- Continuous control, 10 - 40 amps.

- Reliable touch start mechanism for plasma arc initi­ation.

- Rapid arc restrike for fast cutting of expanded metal.

- Input over voltage protection.

- Bright 3.0 second timed pilot arc.

- Purge section on output dial.

- Air regulator and pressure gage included.

- Internal water separator included.

- Parts-in-Place mechanism to detect proper installa­tion of consumables and torch.

- Preflow/Postflow timing. Preflow is eliminated if arc
is re-initiated in Postflow.

- Thermostatic Protection.

- Solid state over-current protection.

- Unique electrode and nozzle design for optimum
cooling and long life.

TOMAHAWK™ 625

B-3

TOMAHAWK 625

Tomahawk 625 - Cut Capacity Chart

0
10
20
30
40
50
60
70
80
90

0.1250.250.3750.50.6250.75

Metal Thickness (inches)

RECOMMENDED TORCH

TRAVEL SPEED (IPM)

TOMAHAWK 625

Tomahawk 625 - Cut Capacity Chart

0

10

20

30

40

50

60

70

80

90

0.125 0.25 0.375 0.5 0.625 0.75

Metal Thickness (inches)

RECOMMENDED TORCH

TRAVEL SPEED (IPM)

OPERATION

B-3

CUTTING CAPABILITY

The TOMAHAWK™ 625 is rated at 40 amps, at 35%
duty cycle on a 10 minute basis. If the duty cycle is
exceeded, a thermal protector will shut off the output
of the machine until it cools to the normal operating
temperature.

Figure B.1 shows the cut capacity of the TOMA­HAWK™ 625 when cutting mild steel. (The graph
plots cut thickness vs. torch travel speed with a torch
standoff of 0.15".)

Figure B.1

CONSUMABLE LIFE

The expected life for the TOMAHAWK™ 625's elec­trode under normal operating conditions is approxi­mately 1000 starts/cuts. An erosion of .060" is typical
for end of electrode life, however, the electrode life
may last longer. A green and erratic arc will indicate
definite electrode failure and the electrode should be
replaced immediately.

It is recommended that consumables be replaced in
complete sets. (Example: Electrode and Nozzle). This
will maximize the performance of the TOMAHAWK™
625 system.

TOMAHAWK™ 625

1

MPa = 145 psi

A

V

A

1

0

40

25

TOMAHAWK

625

www.lincolnelectric.com

1

2

3

4

5

1

MPa = 145 psi

A

V

A

1

0

40

25

TOMAHAWK

625

www.lincolnelectric.com

1

2

3

4

5

B-4

OPERATION

B-4

LIMITATIONS

Do not exceed output current and duty cycle rating of
machine. Do not use the TOMAHAWK™ 625 for pipe
thawing.

If the arc turns off while cutting using low input volt­age, that is below 208V, lower the air pressure by
adjusting the regulator knob.

When using with the Outback 180, gouging is not rec­ommended.

CONTROLS AND SETTINGS

(Figure B.2)

TOMAHAWK™ 625 front command panel.

FIGURE B.2

LEDs
Output Thermal
(Red) (Yellow)

On Off
On On

Off On

Description

The cutting torch is energized.
Part in place error: the retaining
cap is not properly Attached.

To restore the machine:

• Install the torch retaining cap
firmly in place.

• Wait for 5 seconds; during this
time the output and the r m a l
LED’s blinks alternately.

• After 5 seconds the machine is
automatically restored and ready
to operate.

The machine is overheated and
the output has bee n disabled.
This usually occurs when the duty
cycle of the machine has been
exceeded. Leave the machine On
to allow the internal components to
cool. When the thermal LED turns
off, normal operation is again pos­sible.

1. Output Current Knob: Potentiometer used to set

the output current used during cutting. Refer to
the Technical Specification section for more infor­mation about the machine’s rated current range.

Air Purge: The Output Current Knob completely
rotated counterclockwise enables the air purge
function. A five minute timeout stops the purge
function; this will occur only if the Output Current
Knob remains in the purge mode for an extended
time.

2. Power ON/OFF green LED: Illuminates when

the machine is ON.

3. Output red LED: See the following table.

Off Blink

Blink Off

Power undervoltage error: the

machine is disabled. When the
power returns to the correct range,
the machine will restart automati­cally.

Low air pressure error.

To check / adjust the air pressure
(see recommended values in the
Technical Specifications of this
manual):

• Put the machine in Purge mode
[1].

• Check and adjust the air pres­sure using the pressure gauge
and air pressure regulator knob
[6].

• If necessary, check and adjust
als o the i n l e t air pressur e by
adjusting the external compres­sor.

4. Thermal yellow LED: See the following table.

TOMAHAWK™ 625

B-5

9

8

7

6

9

8

7

6

OPERATION

B-5

5. Air Pressure Gauge and Regulator Knob: Allows

regulation and monitoring of the air pressure.

Items 6 thru 9 on the back of the TOMAHAWK™
625 (See Figure B.3)

6. Fan: Provides machine cooling. When the machine

is switched ON, the fan runs continuously.

7. Power Switch: Turns ON / OFF the input power to

the machine.

8. Input cable: Connects unit to the input power.

9. Air Inl et: Ext e r n al Air operati n g mod e only .

Compressed Air Connection.

WARNING

Clean, dry air must be supplied to the machine. A
pressure setting above 110 PSI (7.5 bar) could
damage the torch. Failure to observe these pre­cautions could result in excessive operating tem­peratures or damage to the torch.

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

CUTTING PROCESS

When preparing to cut, position the machine as close
to the work as possible. Make sure to have all materi­als needed to complete the job and have taken all
safety precautions. It is important to follow these oper­ating steps each time the machine is used.

FIGURE B.3

Turn the machine's ON/OFF POWER SWITCH to the
OFF position.

• Connect the air supply to the machine.

• Turn the main power on and the machine power
switch to the ON position.

- The fan will start.

- The pre-charge circuit will operate for 3 seconds,
then the green "Power" LED will illuminate.

• Attach the work lead clamp to the workpiece before
cutting.

• Set the output current control knob to maximum
position for higher cutting speed and less dross for­mation. Reduce the current, if desired to reduce the
kerf (cut) width, heat affected zone, or travel speed
as required.

Note: If the circuit breaker trips while cutting at high-

er amperages - reduce the cutting amperage
on the unit, or provide an input circuit with
higher current capacity.

• Rotate the output knob into the purge zone to check

or set the gas pressure. Pull the pressure regulator
cap out and turn it to set the pressure.

- Adjust the gas regulator for 75-80 PSI (0.50-0.55
MPa).

- Turn the output knob out of the purge zone.

- The gas will immediately turn off. The pressure
gage may show an increase in pressure after the
air turns off but this is normal. Do NOT reset the
pressure while the air is NOT flowing.

TOMAHAWK™ 625

D

irection of Travel

5 - 15

1

/16”

1

0 - 20

Arc Lag

Leading Angle

D

irection of Travel

5 - 15

1

/16”

1

0 - 20

Arc Lag

Leading Angle

B-6

3030

00

VERVERTICAL ANGLETICAL ANGLE
FOR CUTTINGFOR CUTTING

CUT

90

0

TORCH AT 300ANGLE

TO PIERCE

ROTATE TO

90

0

ANGLE TO CUT

OPERATION

• When ready to cut, place the torch near the work,
make certain all safety precautions have been
taken and pull the trigger.

- The air will flow for a preflow time of 2 seconds
and the pilot arc will start. (Exceptions: the first
time that the trigger is pulled after the machine is
turned on, or after a thermal trip out, initial trigger
will be ignored. This is a safety feature to prevent
the pilot arc from firing unexpectedly or if the
torch trigger is inadvertently pressed. The other
exception is if the machine is in postflow, then
the preflow time is skipped and the pilot arc will
start immediately.)

- The pilot arc will run for 3.0 seconds and shut off
unless the arc is brought in contact with the work
and the arc is transferred. Avoid excessive pilot
arc time by transferring the arc to the workpiece
quickly. This will extend consumable life.

- When the arc is brought within 1/8” - 1/4" from
the work piece: the arc will transfer, the current
will ramp to the setting on the control panel, and
the cut can last indefinitely (or until the duty
cycle of the TOMAHAWK™ 625 is exceeded).

• Pierce the work piece by slowly lowering the torch

0

onto the metal at a 30

angle away from the opera­tor. This will blow the dross away from the torch
tip. Slowly rotate the torch to vertical position as
the arc becomes deeper.

B-6

•

Use a 5° - 15° leading angle in the direction of the cut.

• Finish the cut to be made and release the trigger.

• When the trigger is released, the arc will stop.

- The gas will continue to flow for 15 seconds of
postflow. If the trigger is activated within this time
period, the pilot arc will immediately restart.

• If the dross is difficult to remove, reduce the cutting
speed. High speed dross is more difficult to remove
than low speed dross.

WARNING

ELECTRIC SHOCK CAN KILL.

• Turn off machine at the disconnect
switch on the rear of the machine
before tightening, cleaning or

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

replacing consumables.

• Clean spatter and scale from the nozzle frequently.

TORCH

• During operation, if the Red and Yellow LED’s light
together:

• Check the assembly of the torch consumables. If
they are not properly in place, the machine will not
start. Make sure that the shield cup is hand

• Keep moving while cutting. Cut at a steady speed
without pausing. Maintain the cutting speed so that
the arc lag is 10° to 20° behind the travel direction.

TOMAHAWK™ 625

tight. Do not use pliers or over tighten.

• Check the conditions of the inside of the nozzle. If
debris has collected, rub the electrode on the inside
bottom of the nozzle to remove any oxide layer that
may have built up. Refer to "Suggestions for Extra
Utility from the TOMAHAWK™ 625 system".

• Check the condition of the electrode. If the end has
a crater-like appearance, replace it along with the
nozzle. The maximum wear depth of the electrode
is approximately .062”. A green and erratic arc will
indicate definite electrode failure and the electrode
should be replaced immediately.

Torch Standoff

DRAG thru 1/16"

Standoff

Output Setting

Min. thru Mid. Range

Machine Output Setting

B-7

OPERATION

B-7

• Replace the nozzle when the orifice exit is eroded
away or oval shaped.

• After the problem is found, or if there is nothing
apparently wrong, reset the machine by turning the
power switch OFF and then ON again. (It is possi­ble for electrical noise to trip the safety circuit on
rare occasions. This should not be a regular occur­rence.)

• If the machine does not reset or continues to trip,
consult the Troubleshooting Section.

• Use the proper cutting procedures referred to in
Procedure Recommendations.

PILOT ARC DISCUSSION

The TOMAHAWK™ 625 has a smooth, continuous
pilot arc. The pilot arc is only a means of transferring
the arc to the workpiece for cutting. Repeated pilot arc
starts, in rapid succession, is not recommended as
these starts will generally reduce consumable life.
Occasionally, the pilot arc may sputter or start inter­mittently. This is aggravated when the consumables
are worn or the air pressure is too high. Always keep
in mind that the pilot arc is designed to transfer the arc
to the workpiece and not for numerous starts without
cutting.

PROCEDURE RECOMMENDATIONS

When properly used, plasma arc cutting is a very eco­nomical process. Improper use will result in a very
high operating cost.

General - In All Cases

• Follow safety precautions as printed throughout this
operating manual and on the machine.

• If piercing is required, slowly lower the torch at an
angle of about 30° to blow the dross away from
the torch tip and slowly rotate the torch to a ver­tical position as the arc becomes deeper. This
process will blow a lot of molten metal and
dross. Be careful! Blow the dross away from
the torch, the operator and any fla mmable
objects.

• The nozzle should not be dragged on the metal
surface. A drag spacer is provided to maintain a
consistant touch height. Refer to Touch Parts
Configurations in this Section.

The TOMAHAWK™ 625 does not utilize high frequen­cy starting. When the pilot arc is started, a slight
impulse will be felt in the torch handle. This occur­rence is normal and is the mechanism which starts the
plasma arc. This impulse can also be used to help
troubleshoot a "no start" condition.

1/16” Standoff

• Where possible, start the cut from the edge of the
work piece.

• Keep moving! A steady speed is necessary. Do
not pause.

TOMAHAWK™ 625

B-8

OPERATION

Suggestions for Extra Utility from the

TOMAHAWK™ 625 System:

WARNING

ELECTRIC SHOCK CAN KILL.

• Turn off machine at the disconnect
switch on the rear of the machine
before tightening, cleaning or replacing

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

1. Occasionally an oxide layer may form over the tip
of the electrode, creating an insulating barrier
between the electrode and nozzle. This will result
in the tripping of the TOMAHAWK™ 625's safety
circuit. When this happens turn the power off,
remove the nozzle and electrode and use the elec­trode to rub against the inside bottom surface of
the n o z z l e . This w i l l help re m o v e any ox i d e
buildup. Replace the nozzle, turn on the power and
continue cutting. If the safety circuit continues to
trip after cleaning the consumables, then replace
them with a new set. Do not continue to try and
cut with excessively worn consumables as this can
cause damage to the torch head and will degrade
cut quality. Do not allow torch cable or body to
contact hot surface.

consumables.

B-8

• Set air pressure to recommended setting. A
higher or lower pressure will cause turbulence
in the plasma arc, eroding the orifice of the
nozzle tip.

• Use only Lincoln consumable parts. These
parts are patented and using any other replace­ment consumables may cause damage to the
torch or reduce cut quality.

2. To improve consumable life, here are some sug­gestions that may be useful:

• Make sure the air supply to the TOMAHAWK™
625 is clean and free of oil. Use several extra in
line filters if necessary.

• Minimize dross buildup on the nozzle tip by
starting the cut from the edge of the plate when
possible.

• Pierce cutting should be done only when nec­essary. If piercing, angle torch about 30° from
the plane perpendicular to the work piece,
transfer the arc, then bring the torch perpendic­ular to the work and begin parallel movement.

• Reduce the number of pilot arc starts without
transferring to the work.

• Reduce the pilot arc time before transferring to
the work.

TOMAHAWK™ 625

B-9

www.lincolnelectric.com

www.lincolnelectric.com

OPERATION

TORCH PART CONFIGURATIONS

There are different torch configurations depending on
the cutting or gouging application.

Standard Cutting Setup:

In the Standard Cutting configuration the nozzle is
designed not to touch the work piece. The advantage
of this cutting method is good visibility of the arc.
However it requires a steady hand to avoid touching
the nozzle to the work piece which will cause prema­ture nozzle wear and a jagged cut. An optional drag
spacer can be attached to the retaining cap to main­tain a consistent arc height.

B-9

Contact Cutting Setup:

Contact Cutting uses special expendable parts that
allow the torch to touch the work piece. The advan­tage of contact cutting is that the torch can touch the
work piece, steadily dragging it across the surface.
The disadvantage of contact cutting is the plasma arc
is not as visible as with a standard torch set-up. Since
this machine cuts at 40 amps or less it uses the direct
contact torch configuration which allows a special noz­zle to come in contact with the work piece.

TOMAHAWK™ 625

B-10

www.lincolnelectric.com

www.lincolnelectric.com

OPERATION

Gouging Setup:

If gouging metal and not cutting completely through
the part is required, a special gouging nozzle is used
in conjunction with a gouge shield to protect the noz­zle from molten metal blow back.

B-10

Refer to the torch parts decal located on your machine
or the parts pages at the back of this manual for the
specific part numbers required for each of these
setups.

ALWAYS USE GENUINE LINCOLN ELECTRIC
ELECTRODES, NOZZLES, AND EXPENDABLE
PARTS FOR THE BEST CUTTING PERF OR­MANCE.

TOMAHAWK™ 625

C-1

ACCESSORIES

GENERAL OPTIONS /ACCESSORIES

The following options/accessories are available for
your Tomahawk Plasma cutter from your local Lincoln
Distributor.

K2377-1 - Small Canvas Cover
Protect your machine when not in use. Made from
attractive red canvas that is flame retardant, mildew
resistant and water repellent. It includes a convenient
side pocket to hold the plasma torch.

K2886-1 - Plasma Circle Cutting Kit
For cutting circles from 3” to 33” in diameter (77mm to
838mm).

TORCHES

The following replacement torch is available:

K2847-1 LC40 Handheld Plasma Torch 20' (6m)

C-1

EXPENDABLE PARTS

Refer to the torch parts decal located on your machine
or the parts pages at the back of this manual for the
specific part numbers required for each of the avail­able setups.

TOMAHAWK™ 625

D-1

MAINTENANCE

D-1

WARNING

ELECTRIC SHOCK CAN KILL.

• Have an electrician install and ser­vice this equipment.

• Turn the input power off at the fuse
box before working on equipment.

• Do not touch electrically hot parts.

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

ROUTINE MAINTENANCE

1. Keep the cutting or gouging area and the area
around the machine clean and free of combustible
materials. No debris should be allowed to collect
which could obstruct air flow to the machine.

2. Every 6 months or so, the machine should be
cleaned with a low pressure airstream. Keeping the
machine clean will result in cooler operation and
higher reliability. Be sure to clean these areas:

- Printed circuit boards and heat sinks

- Power switch

CAUTION

• When using a low pressure air stream, wear
appropriate eye protection.

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

3. Examine the sheet metal case for dents or break­age. Repair the case as required. Keep the case in
good condition to insure that high voltage parts are
protected and correct spacings are maintained. All
external sheet metal screws must be in place to
insure case strength and electrical ground continu­ity.

PERIODIC MAINTENANCE

WARNING

ELECTRIC SHOCK CAN KILL.

• Turn off machine at the disconnect
switch on the rear of the machine
before tightening, cleaning or
replacing consumables.

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

Change consumables as required.

THERMAL PROTECTION

Thermal Detection Devices protect the machine from
excessive operating temperatures. Excessive temper­atures may be caused by a lack of cooling air or oper­ating the machine beyond the duty cycle and output
rating. If excessive operating temperatures should
occur, the yellow thermal LED will light and the
Detection Devices will prevent output voltage or cur­rent.

These Detection Devices are self-resetting once the
machine cools sufficiently. If the thermostat shutdown
was caused by excessive output or duty cycle and the
fan is operating normally, the Power Switch may be
left on and the reset should occur within a 15 minute
period. If the fan is not turning or the air intake louvers
were obstructed, then the power must be switched off
and the fan problem or air obstruction must be cor­rected.

A protection circuit is included to monitor the voltage
across filter capacitors. In the event that the capacitor
voltage is too high, the protection circuit will prevent
output.

4. Inspect the cable periodically for any slits or punc­ture marks in the cable jacket. Replace if neces­sary. Check to make sure that nothing is crushing
the cable and blocking the flow of air through the
air tube inside. Also, check for kinks in the cable
periodically and relieve any so as not to restrict the
flow of air to the torch.

TOMAHAWK™ 625

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.

E-1

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.

WARNING

ELECTRIC SHOCK CAN KILL.

• Turn off machine at the disconnect
switch on the rear of the machine and
remove main power supply connec­tions before doing any troubleshooting.

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

Step 3. R E C O M M EN D E D COURSE OF
ACTION

This column provides a course of action for
the Possible Cause, generally it states to
contact you local Lincoln Authorized Field
Service Facility.

If you do not understand or are unable to
perform the Re c o m me n d e d Course of
Action safely, contact you 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

TOMAHAWK™ 625

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-2

RECOMMENDED

COURSE OF ACTION

Input circuit breaker trips repeatedly.

No Status indicators light and the fan
does not operate 5 seconds after the
power switch is turned on.

No Status indicators light 5 seconds
after the power switch is turned on,
but the fan operates.

The Thermal LED does not go out.

1. This may be normal. If output is
set to maximum a 30 amp circuit
is requir e d . Se e T e c h ni c a l
Specification page.

2. Install a larger input circuit or turn
the out p u t control to a low e r
amperage.

1. Check the input power to be sure
it is on.

2. Check t he power lin e fuses o r
breakers and machine connection.

3. Disconne c t input po w er at
fuse/breaker panel and check line
switch continuity. Replace line
switch if bad.

1. Possible faulty Inverter Board.

2. Possible faulty Control Board.

1. Check co nsumables - Thermal
and output LED’s light when an
unsafe condition exists at the
torch.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

2. Possible faulty Inverter Board.

3. Possible faulty Control Board.

CAUTION

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.

TOMAHAWK™ 625

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-3

RECOMMENDED

COURSE OF ACTION

The TOMAHAWK™ 625 powers up
properly but there is no response
when the trigger is pulled and only
the POWER LED is lit.

1. Turn the o utput kno b to pu rge
zone on the front of the TOMA­HAWK™ 625. If air does not flow,
then:

• The main gas solenoid assem­bly/pressure se n s o r may be
faulty. Check or replace.

• Possible faulty Control board.

2. Remove the handles (or barrel) of
the torch and examine all the con­nections.

3. Check for proper trigger switch
op e ration. Repl ace the trigger
switch or torch cable if defective.

4. Possible faulty Inverter Board.

5. Possible faulty Control board.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, 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

TOMAHAWK™ 625

E-4

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-4

RECOMMENDED

COURSE OF ACTION

When the trigger is pulled air begins
to flow, but there is no pilot arc after
at least 3 seconds.

The air begins to flow and there is a
very brief arc that snaps out consis­tently with repeated trigger pulls.

1.

Check the torch consumables to be
sure they are not dirty or greasy,
and are in good shape. Replace
the consumables if necessary.

2. Make sure the air pressure is set
correctly.

3. Make sure there are no kinks or
restrictions for air flow in the torch
cable. Replace cable as needed.

4. If a slight thump cannot be felt in
the tor c h when th e trigger is
pulled, check for loose connection
in the torch head.

5. Possible faulty Inverter board.

1. Check the torch consumables to
be sure they are in tight, not dirty
or g r e a s y and in good s h a p e .
Replace if necessary.

2. Make sure the air pressure is set
correctly.

Possible faulty Inverter board.

3.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

The arc starts but sputters badly.

1. Check the torch consumables to
be sure they are in tight, not dirty
or g r e a s y and in good s h a p e .
Replace if necessary.

2. Check air supply for oil or a great
deal of water. If there is oil or a
great deal of water, the air must
be filt e r e d o r t he m a ch i n e
switched to nitrogen or bottled air.

3. Make sure the air pressure is set
correctly.

CAUTION

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.

TOMAHAWK™ 625

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-5

RECOMMENDED

COURSE OF ACTION

Pilot arc starts but will not transfer
when brought near work.

Pilot arc initiates but turns off before
tra n sferring to w o rk. Cu tting arc
appears to turn off while cutting.

1. Check work lead connection for
clean, secure connection.

2.

Plasma will only cut conductive
ma teria l. Do not attem pt to cut
fiberglass, plastic, rubber, PVC or
any other non-conductive material.

3. Make sure work piece is clean
and dry. Remove any scale, rust
or dross.

Possible faulty Inverter board.

4.

5. Check all connections to Control
Board.

1. Input voltage is below 208V.

2. Air pressure is set too high.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

Lower air pressure by turning regula­tor knob. Pressure may requir e
being set lower than blue arrow indi­cator.

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

TOMAHAWK™ 625

E-6

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

STATUS BOARD INDICATORS

E-6

SYMPTOM

When trigger is pulled Red output LED is
Blinking or steady with no air flow.

The Green, Red and Yellow LED’s are lit
and steady. Indicates safety circuit is open.

The Thermal LED is lit.

CHECK

1. Make sure there is at least 80 psi connected to the gas connec­tion at the back of the machine.

2. Turn the output knob to the purge zone and set the regulator to
the correct pressure. The pressure may increase when air stops
flowing but this is normal. Do not reset the pressure while the air
is OFF.

3. Possible faulty Pressure Switch.

4. Possible faulty Inverter board.

1. Turn the power OFF and then ON. If torch and consumables are
properly installed and they are the correct parts, the Red and
Yellow LED’s should turn off. Normal cutting or gouging can
resume.

1. The machine's thermostat has tripped due to exceeded duty
cycle limits. Do NOT turn the power off. Allow the machine to
cool for 15 - 30 minutes and the thermostat will reset itself.

2. The machine's air louvers or fans are obstructed such that air
cannot flow to properly cool the machine. Remove any foreign
material that may block air flow. Blow the machine out with a
clean, dry air stream.

When the trigger is pulled the Red and
Yellow LED’s are blinking together and the
Green light is on.

When the trigger is pulled the Red LED is lit,
air flows and no pilot arc occurs.

The Red and Yellow LED’s are blinking
alternately.

When the trigger is pulled no air flows, Red
LED is lit, no pilot arc. Then LED goes out.

3. The input voltage is not within ±10% of rated values.

4. Possible faulty Inverter board.

1. Check that nozzle and swirl ring are properly installed and they
are the correct parts. Note: Swirl ring can only go in one way.

2. Input voltage is too low and /or air pressure is set too high.
Lower air pressure.

1. Check that swirl ring is properly installed.
Note: Swirl ring can only go in one way.

1. The torch safety circuit has been opened, when reconnected this
condition should correctly reset automatically.

1. Check that the pressure gauge shows pressure.
Air supply may not be connected or properly installed.

TOMAHAWK™ 625

F-1

SS

11

TOMAHAWK 625

WIRING DIAGRAM

045.101.079

045.101.049

6-24-09

SS

11

TOMAHAWK 625

WIRING DIAGRAM

045.101.079

045.101.049

6-24-09

DIAGRAMS

F-1

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.

TOMAHAWK™ 625

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 vête­ments 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 electro­dos 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 guarda­dos.

•

Protégez vos yeux, vos oreilles et
votre corps.

•

Tragen Sie Augen-, Ohren- und Kör­perschutz!

•

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.

•

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 res­piración.

•

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 aspira­teur 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 ali­mentación de poder de la máquina
antes de iniciar cualquier servicio.

•

Débranchez le courant avant l’entre­tien.

•

Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen;
Maschine anhalten!)

•

Não opere com as tampas removidas.

•

Desligue a corrente antes de fazer
serviço.

•

Não toque as partes elétricas nuas.

•

No operar con panel abierto o
guardas quitadas.

•

N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.

•

Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!

•

Mantenha-se afastado das partes
moventes.

•

Não opere com os paineis abertos
ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES
DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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