Tomahawk 1000 Operator's Manual

TOMAHAWK ™1000

IM10026

T

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. However,
your overall safety can be
increased by proper installation ...
and thoughtful operation on your
part. DO NOT INSTALL, OPER-

ATE OR REPAIR THIS EQUIP­MENT WITHOUT READING
THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,

most importantly, think before you
act and be careful.

September, 2012

11581

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

IP23

Copyright © Lincoln Global Inc.

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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 manufacturerʼs instructions for this

equipment and follow your employerʼs safety practices.

FUMES AND GASES
can be dangerous.

3.a. Plasma cutting or gouging 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
observing plasma arc cutting or gouging.
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 welding
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 situa­tions. Refer to “Safety in Welding and Cutting” (ANSI
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
can cause an explosion even though they have been
“cleaned.” For information purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
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 overheat 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. Always keep cylinders in an upright position 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, 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.

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 manufacturerʼs rec­ommendations.

6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs 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 LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.

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

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

Your Product”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

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

Gouging Process..................................................................................................................B-6

Torch ....................................................................................................................................B-7

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

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

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

Suggestions for Extra Utility from the TOMAHAWK™ 1000 System ...........................B-8

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

Machine Interface...............................................................................................................B-11

________________________________________________________________________________

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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-7

________________________________________________________________________

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

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

________________________________________________________________________

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

TOMAHAWK™ 1000 .............................................................................P-627 Series

Torch (Hand Held)..........................................................................................P-210-X

Torch (Machine Held).....................................................................................P-210-Y

________________________________________________________________________

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS -TOMAHAWK™ 1000

INPUT - SINGLE PHASE/THREE PHASE/ 50 / 60 HERTZ

Input Voltage +/- 10%

208V/1/50/60

230V/1/50/60

208V/3/50/60

230V/3/50/60

460V/3/50/60

575V/3/50/60

Input Amperes @ Rated Output

38
25
34
23
25
16
21
13

9
6
8
5

50% Duty Cycle

100% Duty Cycle

50% Duty Cycle

100% Duty Cycle

50% Duty Cycle

100% Duty Cycle

50% Duty Cycle

100% Duty Cycle

50% Duty Cycle

100% Duty Cycle

50% Duty Cycle

100% Duty Cycle

RATED OUTPUT AT 40° C

Duty Cycle

100%

50%

CURRENT

40A

60A

OUTPUT

A-1

Circuit Breaker (Delay Type)

40 Amps

30 Amps

15 Amps

VOLTAGE

96VDC

104 VDC

Current

Range

20 - 60 Amps

Open Circuit

Voltage

270 VDC

Pilot Current

20 Amps

REQUIRED GAS FLOW RATE REQUIRED GAS INLET PRESSURE

80.0 PSI @ 275 SCFH

(5.5 Bar. @ 130 ±20% LITERS/MIN.)

87.0 to 109.0 PSI

(6.0 Bar. to 7.5 Bar.)

RECOMMEND INPUT WIRE

For all plasma cutting applications

Based on U.S. National Electrical Code

o

Ambient Temperature 30

Input Cord

Supplied with Machine

C or Less

Type S, SO, ST, STO

or Extra Hard Usage Cord

AWG (IEC) Sizes

1 Ground Wire

2

)

#10 (5.3 mm2)

STO, 600V

Input Supply Wires

#10 (5.3 mm

PHYSICAL DIMENSIONS

Weight

Height

Width

Depth

Including

Torch Cable

15.3 in.

389 mm

OPERATING TEMPERATURE RANGE

-10°C to +40°C

247 mm

9.7 in.

21.65 in.
550 mm

TEMPERATURE RANGES

TOMAHAWK™ 1000

63.9 lbs.
29 kgs

STORAGE TEMPERATURE RANGE

-25°C to +55°C

A-2

Read entire Installation Section before installing the TOMA­HAWK™ 1000 .

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK CAN

INSTALLATION

(1) Make sure the power supply chassis is connected to a

(2) Keep the work clamp isolated from other work clamps that

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

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

KILL.

• Only qualified personnel
should install this machine.

• Turn the input power OFF
at the disconnect switch or

fuse box and discharge input capacitors before
working inside the equipment.

• Do not touch electrically hot parts.

• Turn the TOMAHAWK™ 1000 Power Switch OFF
when connecting power cord to input power.

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

SELECT PROPER LOCATION

Place the TOMAHAWK™ 1000 where clean cool air can freely
circulate in and out of the 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.

A source of clean, dry air or nitrogen must be supplied to the
TOMAHAWK™ 1000. Oil in the air is a severe problem and
must be avoided. The supply pressure must be between 80 and
110 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™ 1000 cannot be stacked.

TILTING

The TOMAHAWK™ 1000 must be placed on a stable, level sur­face so it will not topple over.

Failure to observe these recommended installation procedures
may cause improper function of the TOMAHAWK™ 1000 or
possibly even damage to the control system or power supply
components.

INPUT ELECTRICAL CONNECTIONS

The TOMAHAWK™ 1000 is rated for 208VAC through 575VAC
input voltages. 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™ 1000 should be connected only by a
qualified electrician. Installation should be made in accor­dance with local codes.

INPUT PLUG INSTALLATION

POWER CORD CONNECTION

A power cord is provided and wired into the machine. Follow the
power cord connection instructions.

Single Phase Input

Connect green lead to ground per National Electrical Code.
Connect black and red leads to power.
Wrap white lead with tape to provide 600V insulation.

Three Phase Input

Connect green lead to ground per National Electric Code.
Connect black, red and white leads to power.

A-2

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

have high frequency.

as far as possible from other work clamp connections.

good earth driven electrical grounds around the periphery
of the building are recommended.

WARNING

HIGH FREQUENCY INTERFERENCE PRO­TECTION

The TOMAHAWK™ 1000 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™ 1000 can be minimized

Failure to wire as instructed may cause personal injury or

•

damage to equipment. To be installed or checked by an
electrician or qualified person only.

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

In all cases, the green or green/yellow grounding wire must be
connected to the grounding pin of the plug, usually identified by
a green screw.

TOMAHAWK™ 1000

A-3

Attachment plugs must comply with the Standard for
Attachment Plugs and Receptacles, UL498.

The product is considered acceptable for use only when
an attachment plug as specified is properly attached to
the supply cord.

INSTALLATION

ENGINE DRIVEN GENERATOR

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

The TOMAHAWK™ 1000 can be operated on engine
driven generators as long as the 230 volt auxiliary
meets the following conditions:

A-3

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™ 1000, 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™ 1000 as specified in the Installation section
of this instruction manual under the Gas Input
Connections heading.

• The AC waveform peak voltage is below 400 volts.

• The AC waveform frequency is between 45 and 65
Hz.

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

Outback 185, Ranger 225, Ranger 250, 250LPG,
305G and 305D engine drives.
Vantage 300, 400, 500 and Air Vantage engine drives.

Operation of the TOMAHAWK™ 1000 is not recom­mended on engine drives not conforming to these
conditions. Such combinations may overvoltage the
TOMAHAWK™ 1000 power source.

GAS INPUT CONNECTIONS

(External Air Supply)

Supply the TOMAHAWK™ 1000 with clean com­pressed air or nitrogen.

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

• Flow rate should be approximately 275 SCFH
(

130 ±20% LITERS/MIN.

NOTE: Oil in the air supply to the TOMAHAWK™

1000 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™ 1000.

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

).

NOTE: When using nitrogen gas from a cylinder, the

cylinder must have a pressure regulator.

• Maximum psi from a nitrogen gas cylinder to the
TOMAHAWK™ 1000 regulator should never
exceed 110 psi.

• Install a hose between the nitrogen gas cylinder
regulator and the TOMAHAWK™ 1000 gas inlet.

CYLINDER could explode if damaged.

WARNING

• Keep cylinder 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™ 1000 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.

TOMAHAWK™ 1000

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™ 1000 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™ 1000 comes standard with an air
regulator and pressure gauge. The machine also
comes with an input power cord and Hand-held torch
with a 25 Ft.(7.6m) cable length. Consumables are
included with each TOMAHAWK™ 1000 purchase so
that cutting can begin right out of the box.
Consumables can also be ordered as individual pack­ages.

The TOMAHAWK™ 1000 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).

Duty Cycle

The duty cycle of a plasma machine is the percentage
of time in a 10 minute cycle at which the operator can
operate the machine at rated cutting current.

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

Example: 60% duty cycle means that is possible cut
for 6 minutes, then the machine stops for 4 minutes.

Refer to the Technical Specification section for more
information about the machine rated duty cycles.

TOMAHAWK™ 1000

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™ 1000 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, 20 - 60 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™ 1000

B-3

OPERATION

B-3

CUTTING CAPABILITY

The TOMAHAWK™ 1000 is rated at 60 amps, at
50% 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™ 1000 when cutting mild steel.

Figure B.1

Tomahawk 1000 - Cut Capacity Chart

40

30

20

aaron neville you tube

CONSUMABLE LIFE

The expected life for the TOMAHAWK™ 1000 '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™
1000 system.

1 1/2

1 1/4

1

3/4

1/2

1/4

0

10

0

Travel Speed (IPM)

Recommended Torch

0.500 0.625 0.750 0.875 1.000

Metal Thickness (inches)

Tomahawk 1000

Recommended Cut @19 IPM Max Cut @ 10 IPM Sever Cut @ 5 IPM

TOMAHAWK™ 1000

B-4

V

OPERATION

B-4

LIMITATIONS

Do not exceed output current and duty cycle rating of
machine. Do not use the TOMAHAWK™ 1000 for
pipe thawing.

CONTROLS AND SETTINGS

(Figure B.2)

TOMAHAWK™ 1000 front command panel.

FIGURE B.2

2

8

7

When the machine is turned ON, an auto-test is exe­cuted; during this test all of the LEDs on the Control
Panel light up.

1. Output Current Knob: For setting the output

current used during cutting. Refer to the Technical
Specification section for more information about
the machineʼs rated current range.

Air, Gas 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.

Blinking: Input voltage out of range condition. The
machine is disabled: When the input voltage
returns to the correct range, the machine will
restart automatically.

3

4

5

6

1

3. Output red LED:

The cutting torch is energized.

Blinking: Internal auxiliary undervoltage condition.
The machine needs to be turned OFF then ON
again to restart.

4. Thermal yellow LED:

The machine is overheated and the
output has been 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.

5. Gas Pressure yellow LED:

The Input Gas pressure is out of
range. The machine will restart automatically
when a correct gas pressure is detected.

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

• When this LED illuminates, the machine will
automatically enter into Purge mode for 10 sec­onds.

• During Purge time verify and adjust the gas

pressure using the gas pressure regulator knob.

• If necessary, also verify and adjust the inlet gas
pressure to the unit.

6. Parts In Place (PIP) yellow LED:

Torch consumables are not attach correctly.

To reset the machine:

• Firmly attach the torch shielding Cup by hand.
Do not over tighten.

• After the torch is restored, the machine will
restart after 5 seconds. During this time the PIP
LED will blink.

Note: When the LED is blinking, if another PIP
error occurs or if the Torch Trigger pushbutton
is pressed the machine will return to the error
condition: PIP LED returns to steady ON and
the restoring procedure repeats.

• When the PIP LED turns OFF the machine is
ready to operate.

A

Note: The Fan may automatically turn OFF if the error

condition persists for more than 2 seconds.

TOMAHAWK™ 1000

B-5

7. Primary Air, Gas Pressure Gauge and
Regulator Knob:

Allows the regulation and monitoring of
the primary air/gas pressure.

The inlet primary air/gas pressure is
limited by this pressure regulator, set at
the factory to 80 PSI (5.5 bar). To
adjust the air/gas pressure, place the
machine in Purge mode.

8. Cutting Operating Mode

Selection: Press the pushbut-

ton to select the desired operat­ing mode (the LED indicates the
selected mode):

• CUT (Upper LED): for cutting or piercing opera­tions on a solid work piece.

• GRID (Middle LED): for cutting operations on a
grid work piece.

• GOUGE (Lower LED): for removing material from
a solid work piece (removing a weld).

The Operating Mode can only be changed with the
machine at idle or during Purge or Post Flow times.

Pressing the pushbutton during Pilot Arc or Cutting
will have no effect.

Items 9 thru 12 on the back of the TOMAHAWK™
1000 (See Figure B.3)

9. Fan: Provides machine cooling. When the machine

is switched ON, the fan runs continuously.

10. Power Switch: Turns ON / OFF the input power

to the machine.

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

12. Air or Gas Inlet: Compressed Air or Gas

Connection.

FIGURE B.3

OPERATION

1MPa = 145 psi

10

B-5

WARNING

Clean, dry air or gas 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

The air plasma cutting process uses air or nitrogen as
a cutting gas and to cool the torch.

The pilot arc is initiated as follows: The torch trigger
energizes a solenoid valve. This valve enables the
gas to flow during the cutting and post-flow stages.

The TOMAHAWK™ 1000 provides constant current at
the set value, independent of the plasma arc length.

When preparing to operate, make sure you have all
materials needed to complete the job and have taken
all safety precautions. Install the machine as instruct­ed in this manual and remember to attach the work
clamp to the work piece.

• With the machine switched OFF, prepare the torch
with the consumables adequate to the desired
process (CUT / GRID / GOUGE). Refer to the con­sumable Charts on pages B-9, B-10.

• Connect the Torch and the work cable to the
machine.

• Turn ON the Power Switch on the back of the
machine; the Input Power LED on the front panel
will illuminate. The unit is now ready to operate.

• Verify correct gas pressure using the Gas Purge
function.

• Select the desired process using Operating Mode
pushbutton.

• Set the desired cutting current using the Output
Current knob.

To start the selected process pull the torch trigger,
making sure you are not aiming the torch in an
unsafe manner.

Once the process is completed releasing the torch
trigger will cause the plasma arc to turn off. The gas
flow will continue, allowing the torch to cool.

11

12

9

TOMAHAWK™ 1000

B-6

30

0

VER

TICAL ANGLE

FOR CUTTING

OPERATION

B-6

• The Post Flow time is proportional to the selected
cutting current and it is divided into 4 time ranges:

Selected Cutting Current Post Flow Time

Less than 30A 15 seconds
Between 30A and 40A 20 seconds
Between 40A and 50A 25 seconds

Greater than 50A 30 seconds

• Pilot Arc

- 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, the initial trigger will
be ignored. This is a safety feature to prevent the
pilot arc from firing unexpectedly. 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™ 1000 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.

TORCH A T 300ANGLE

0

30

0

90

VER
FOR CUTTING

CUT

TO PIERCE

ROTATE TO

0

ANGLE TO CUT

90

TICAL ANGLE

• 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.

5 - 15

Leading Angle

1/16”

10 - 20

•

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

Direction of Travel

Arc Lag

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

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

PROCESS GOUGING

Gouging is a process used to remove material without
cutting entirely through the workpiece. The Tomahawk
1000 has the capability of performing plasma gouging
with the proper consumables attached to the torch. In
general, gouging consumables provide a wider plas­ma arc compared to a cutting arc. As the material
melts, it is blown forward by the pressurized gas com­ing out of the torch. The dross will land on the surface
of the workpiece and can easily be removed after the
gouging process is complete.

Technique:

Hold the torch at a 45º angle to the workpiece. Pull
the torch trigger to start the gouging arc. As the mate­rial is removed move the torch forward to continue
removing material. When the desired amount of
material has been removed, release the torch trigger
to stop the gouging process.

Typically, the larger the angle between the torch and
the workpiece, the deeper and slower the gouging.
As the torch angle is decreased, less material is
removed and the travel speeds can be increased.
Keeping the torch fixed while moving forward will
remove a straight line of material. Using a side-to­side, weaving motion will remove a wider area of
material. The output of the Tomahawk 1000 can also
be increased or decreased to control the amount of
material being removed. Most users tend to maximize
the output in order to remove the most material in a
short amount of time.

TOMAHAWK™ 1000

B-7

Applications:

OPERATION

PILOT ARC DISCUSSION

B-7

Removing weld imperfections – cracks, porosity, inclu­sions, etc.
Back gouging for welding preparation
Removal of temporary fit up methods – tack welds,
bracketing, etc.

WARNING

ELECTRIC SHOCK CAN KILL.

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

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

TORCH

• Clean spatter and scale from the nozzle frequently.

• During operation, if the Parts in Place Yellow LED
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

tight. Do not use pliers or over tighten.

The TOMAHAWK™ 1000 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.

The TOMAHAWK™ 1000 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.

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

• Check the conditions on the inside of the nozzle. If
debris has collected, rub the inside of the nozzle to
remove any oxide layer that may have built up.
Refer to "Suggestions for Extra Utility from the
TOMAHAWK™ 1000 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.

• 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, the machine may need to be
reset 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.

• 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 flammable
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.

Torch Standoff

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

TOMAHAWK™ 1000

1/16” Standoff

DRAG thru 1/16"

Standoff

B-8

OPERATION

B-8

• Where possible, start the cut from the edge of the

work piece.

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

pause.

Suggestions for Extra Utility from the

TOMAHAWK™ 1000 System:

WARNING

ELECTRIC SHOCK CAN KILL.

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

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

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 false starts. When this happens turn the power
off, remove the shield cup and nozzle. Rub the
inside surface of the nozzle, this will help remove
any oxide buildup. Also, clean any oxide build up
from the electrode. Replace the shield cup and
nozzle, turn on the power and continue cutting. If
false starts continue to occur 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 surfaces.

• 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™
1000 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™ 1000

B-9

OPERATION

TORCH PART CONFIGURATIONS

Different hand held torch configurations are available
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

3-10

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.

There are two types of contact cutting:

1. Direct contact. A special non-insulated nozzle is
used that can touch the work piece directly. This
set up is designed for applications below 40 amps.

2. Shielded contact. A special insulated nozzle is
used in conjunction with a special drag shield.
Shielded contact set-ups are for applications
greater than 40 amps.

www.lincolnelectric.com

TOMAHAWK™ 1000

B-10

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

3-10

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 PERFOR­MANCE.

www.lincolnelectric.com

TOMAHAWK™ 1000

B-11

OPERATION

MACHINE INTERFACE

The TOMAHAWK™ 1000 comes standard with a
machine interface. Interface signals provided include:
arc start, arc initiated, and arc voltage. These signals
are accessible through the 14 pin connector on the
case front.

ARC START:

The Arc Start circuit allows for triggering of the power
source to commence cutting. This circuit can be
accessed through pins K and M of the 14 pin connec­tor. The circuit has a 15 VDC nominal open circuit
voltage and requires a dry contact closure to activate.

ARC INITIATED:

The Arc Initiated circuit provides information as to
when a cutting arc has transferred to the work piece.
This circuit can be accessed through pins I and J of
the 14 pin connector. The circuit provides a dry con­tact closure when the arc has transferred. Input to this
circuit should be limited to 0.3 A for either 120VAC or
30VDC.

B-11

ARC VOLTAGE:

The Arc Voltage circuit can be used for activating a
torch height control. This circuit can be accessed
through pins D and G of the 14 pin connector. The
circuit provides full electrode to work arc voltage (no
voltage divider, 270VDC maximum).

Arc Start

14-PIN BOX RECEPTACLE, FRONT VIEW

Users wishing to utilize the Machine Interface can
order a K867 Universal Adapter (please adhere to the
pin locations stated above) or manufacture a 14 pin
connector cable assembly.

K

M

L

C

D

E

Arc Voltage

J

F

Arc Initiated

I

H

N

G

TOMAHAWK™ 1000

C-1

ACCESSORIES

GENERAL OPTIONS /ACCESSORIES

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

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

TORCHES

The following replacement or optional torches are
available:

K2848-1 LC65 Handheld Plasma Torch 25' (7.5m)
K2848-2 LC65 Handheld Plasma Torch 50' (15m)
K2848-3 LC65M Mechanized Plasma Torch 25'

(7.5m)

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 these
setups.

C-1

TOMAHAWK™ 1000

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.

Inspect the cable periodically for any slits or punc-

4.
ture 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™ 1000

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. RECOMMENDED 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 Recommended 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™ 1000

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS

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 required. See Technical
Specification page.

2. Install a larger input circuit or turn
the output control to a lower
amperage.

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

2. Check the power line fuses or
breakers and machine connection.

3. Disconnect input power at
fuse/breaker panel and check line
switch continuity. Replace line
switch if bad.

1. Possible faulty Control Board.

1. 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™ 1000

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS

E-3

RECOMMENDED

COURSE OF ACTION

The TOMAHAWK™ 1000 powers
up properly but there is no response
when the trigger is pulled and only
the POWER LED is lit.

1. Turn the output knob to purge
zone on the front of the TOMA­HAWK™ 1000 . If air does not
flow, then:

• The main gas solenoid assem­bly/pressure sensor 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
operation. Replace the trigger
switch or torch cable if defective.

4. 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™ 1000

E-4

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS

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 torch when the trigger is
pulled, check for loose connection
in the torch head.

5. Possible faulty Control board.

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

2. Make sure the air pressure is set
correctly.

Possible faulty in Control 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 greasy and in good shape.
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 filtered or the machine
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™ 1000

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS

E-5

RECOMMENDED

COURSE OF ACTION

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

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

2.

Plasma will only cut conductive
material. Do not attempt 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.

4. Check all connections to Control
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™ 1000

E-6

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

STATUS BOARD INDICATORS

E-6

SYMPTOM

Yellow Gas Pressure LED is lit and steady.

The Yellow Parts In Place LED is lit and
steady.

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 Control board.

1. Verify Torch consumables are in good condition and properly
installed. If torch and consumables are properly installed, the
Yellow LED should turn off. The unit may be required to have the
input power turned off then back on. 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.

3. Possible faulty Control board.

Error condition list.

At first, try turning the machine OFF, wait for a few seconds, then turn the machine ON again. If the error
remains, troubleshooting is required. Please contact the nearest technical service center or Lincoln Electric and
report the LED Status found on the machine Front Panel.

V

A

On (Green LED) Blink (Red LED) Blink (Yellow)

1. This occurs if after 4 seconds the Pilot Arc isnʼt transfered to the

Head Torch

workpiece. The machine stops the pilot arc to avoid overheating
the Torch Head.

2. To restore the machine:

• Release the Torch Trigger pushbutton. The blinking LEDs will
change to steady ON.

• Pull the Torch Trigger and verify correct operation.

TOMAHAWK™ 1000

E-7

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

Error condition list

V

On (Green LED) On (Yellow LED) On (Yellow LED)

E-7

No pilot arc established

Trigger Pushed

1. The Torch Trigger pushbutton is pressed. During this period the
machine will attempt to start the pilot arc for 4 times. If the pilot
arc does not start, the machine automatically will enter into a safe
status condition that will allow troubleshooting as necessary.

2. To restore the machine:

• Turn OFF the Power switch.

• Check the correct placement of the Torch Head consumables
and parts.

• Check the Torch electrical connections.

• Turn ON the machine.

V

On(Green LED) On (Yellow LED) On (Yellow LED) On (Yellow LED)

1. This occurs if the machine is turned ON (or if it is restarted after
Thermal reset) with the Torch Trigger pulled. This condition
avoids unsafe operating conditions. The machine is disabled such
that manual cutting or gouging processes can ONLY be initiated
under the direct control of the operator.

2. To restore the machine:

• Release the Torch Trigger.

• The LEDʼs will return to normal status and cutting or Gouging
may resume.

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.

3. If this error condition persists, check for eventual malfunctions of
the Torch Trigger pushbutton.

CAUTION

TOMAHAWK™ 1000

F-1

DIAGRAMS

F-1

TOMAHAWK™ 1000

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.

WARNING

Spanish

AVISO DE

PRECAUCION

 Do not touch electrically live parts or

electrode with skin or wet clothing.

 Insulate yourself from work and

ground.

 No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

 Aislese del trabajo y de la tierra.

 Keep flammable materials away.

 Mantenga el material combustible

fuera del área de trabajo.

 Wear eye, ear and body protection.

 Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

 Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

 Isolez-vous du travail et de la terre.

 Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

 Isolieren Sie sich von den

Elektroden und dem Erdboden!

 Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

 Isole-se da peça e terra.

 Gardez à l’écart de tout matériel

inflammable.

 Entfernen Sie brennbarres Material!

 Mantenha inflamáveis bem guarda-

dos.

 Protégez vos yeux, vos oreilles et

votre corps.

 Tragen Sie Augen-, Ohren- und Kör-

perschutz!

 Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

 Keep your head out of fumes.
 Use ventilation or exhaust to

remove fumes from breathing zone.

 Turn power off before servicing.

 Do not operate with panel open or

guards off.

WARNING

 Los humos fuera de la zona de res-

piración.

 Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

 Gardez la tête à l’écart des fumées.
 Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

 Vermeiden Sie das Einatmen von

Schweibrauch!

 Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

 Mantenha seu rosto da fumaça.
 Use ventilação e exhaustão para

remover fumo da zona respiratória.

 Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

 Débranchez le courant avant l’entre-

tien.

 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