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Lincoln Electric IM10020 - page 1
TOMAHAWK ™ 625 OPERA T OR’S MANUAL IM10020 January, 2011 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ- ING T ...
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Lincoln Electric IM10020 - page 2
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 ...
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Lincoln Electric IM10020 - page 3
Refer to http://www .lincolnelectric.com/safety for additional safety information. 4.c. When not cutting or gouging, make certain no part of the elec- trode 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 t ...
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Lincoln Electric IM10020 - page 4
NOTES ...
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Lincoln Electric IM10020 - page 5
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ? ...
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Lincoln Electric IM10020 - page 6
v v Thank Y ou 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pa ...
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Lincoln Electric IM10020 - page 7
T ABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ................................. ...
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Lincoln Electric IM10020 - page 8
A-1 INST ALLA TION A-1 Weight Including T orch Cable 34.0 lbs. 15.4 kg. INPUT - SINGLE PHASE 50 / 60 HERTZ RA TED OUTPUT A T 40° C OUTPUT RECOMMEND INPUT WIRE AND FUSE SIZES REQUIRED GAS FLOW RA TE REQUIRED GAS INLET PRESSURE PHYSICAL DIMENSIONS TECHNICAL SPECIFICA TIONS -TOMAHA WK™ 625 Standard V oltage Duty Cycle 100% 60% 35% Current Range 10- ...
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Lincoln Electric IM10020 - page 9
A-2 INST ALLA TION TOMAHAWK™ 625 A-2 Read entire Installation Section before installing the TOMAHAWK™ 625. SAFETY PRECAUTIONS ELECTRIC SHOCK CAN 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 equip- ment. ? ...
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Lincoln Electric IM10020 - page 10
A-3 INST ALLA TION TOMAHAWK™ 625 A-3 The following Lincoln engine drives meet these condi- tions 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 TOMA- ...
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Lincoln Electric IM10020 - page 11
B-1 OPERA TION TOMAHAWK™ 625 B-1 SAFETY PRECAUTIONS DESCRIPTION The TOMAHAWK™ 625 is a constant current, contin- uous 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 elec- trode are in pl ...
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Lincoln Electric IM10020 - page 12
B-2 OPERA TION B-2 USER RESPONSIBILITY Because design, fabrication, erection and cutting vari- ables affect the results obtained in applying this type of information, the serviceability of a product or struc- ture is the responsibility of the user. Variation such as pl at e ch em ist ry , pl at e s urf ac e c ond iti on ( oi l, s ca le) , plate thi ...
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Lincoln Electric IM10020 - page 13
B-3 OPERA TION B-3 CUTTING CAP ABILITY 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. F i g u r e B . 1 s h o w s t h e c u t c a p a c i t y o f t h e T O M A - HAWK™ 625 ...
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Lincoln Electric IM10020 - page 14
CONTROLS AND SETTINGS (Figure B.2) TOMAHAWK™ 625 front command panel. FIGURE B.2 1. Output Current Knob: Potentiometer used to set the output current used during cutting. Refer to the Technical Specification section for more infor- mation about the machine’s rated current range. Air Purge: The Output Current Knob completely rotated counterclock ...
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Lincoln Electric IM10020 - page 15
B-5 OPERA TION B-5 5. Air Pressure Gauge and Regulator Knob : Allows regulation and monitoring of the air pressure. Items 6 t hru 9 on the ba ck o f t he T OMAHAWK™ 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. I ...
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Lincoln Electric IM10020 - page 16
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 • 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 sec ...
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Lincoln Electric IM10020 - page 17
PROCEDURE RECOMMENDA TIONS When properly used, plasma arc cutting is a very eco- nomical 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° t ...
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Lincoln Electric IM10020 - page 18
B-8 OPERA TION B-8 Suggestions for Extra Utility from the TOMAHA WK™ 625 System: 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 noz ...
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Lincoln Electric IM10020 - page 19
B-9 OPERA TION B-9 TORCH P ART CONFIGURA TIONS 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 ha ...
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Lincoln Electric IM10020 - page 20
B-10 OPERA TION B-10 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 noz- zle from molten metal blow back. Refer to the torch parts decal located on your machine or the parts pages at the back of this manual for the specific p ...
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Lincoln Electric IM10020 - page 21
C-1 ACCESSORIES C-1 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 convenie ...
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Lincoln Electric IM10020 - page 22
D-1 MAINTENANCE D-1 TOMAHAWK™ 625 PERIODIC MAINTENANCE Change consumables as required. THERMAL PROTECTION Thermal Detection Devices protect the machine from excessive operating temperatures. Excessive temper- atures may be caused by a lack of cooling air or oper- ating the machine beyond the duty cycle and output rating. If excessive operating ...
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Lincoln Electric IM10020 - page 23
E-1 TROUBLESHOOTING E-1 TOMAHAWK™ 625 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 This Troubleshooting Guide is provided to help you locate and repair ...
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Lincoln Electric IM10020 - page 24
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/break ...
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Lincoln Electric IM10020 - page 25
E-3 TROUBLESHOOTING E-3 TOMAHAWK™ 625 Observe all Safety Guidelines detailed throughout this manual 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 PROBLEM ...
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Lincoln Electric IM10020 - page 26
E-4 TROUBLESHOOTING E-4 TOMAHAWK™ 625 Observe all Safety Guidelines detailed throughout this manual 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 PROBLEM ...
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Lincoln Electric IM10020 - page 27
E-5 TROUBLESHOOTING E-5 TOMAHAWK™ 625 Observe all Safety Guidelines detailed throughout this manual 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 PROBLEM ...
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Lincoln Electric IM10020 - page 28
E-6 TROUBLESHOOTING E-6 TOMAHAWK™ 625 Observe all Safety Guidelines detailed throughout this manual ST A TUS BOARD INDICA TORS 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. When the trigger is p ...
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Lincoln Electric IM10020 - page 29
F-1 DIAGRAMS F-1 TOMAHAWK™ 625 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 num ...
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Lincoln Electric IM10020 - page 30
W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇ Ã O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF A CTURER’S INSTR UCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLL O W Y OUR EMPL O YER’S SAFETY PRA CTICES. SE RECOMIEND A LEER Y ENTENDER LAS INS TRUCCIONES DEL F ABRIC ...
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Lincoln Electric IM10020 - page 31
W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇ Ã O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREEND A AS INS TR UÇÕES DO F ABRIC ANTE P ARA ES TE EQUIP AMENT O E A S P ARTES DE USO , E SIGA AS PR Á TIC A S DE SEGUR ANÇ A DO EMPREG ADOR. • Kee p yo ur h ead out of f umes . • Use ven tila tion or ...
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Lincoln Electric IM10020 - page 32
• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products • ...
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