Lincoln Electric Tomahawk 1000 User manual

Operator’s Manual
Tomahawk
®
1000
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
IM10026-A | Issue Date May-19
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
11581, 12850
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: [email protected]
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)

THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELECTRIC.
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.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and built
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you develop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 5/16/2018

SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to the State
of California to cause cancer and birth defects,
or other reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS SHOULD CONSULT WITH
THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For
additional safety information, it is strongly recommended
that you purchase a copy of “Safety in Welding & Cutting -
ANSI Standard Z49.1” from the American Welding Society,
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205 is available from the Lincoln Electric Company,
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE POWERED
EQUIPMENT.
1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engine
exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding
arc or when the engine is running. Stop the
engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact
with hot engine parts and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding current creates EMF fields around welding cables
and welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 5/16/2018

ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
of physical contact with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage
between the
two can be the total of the open circuit voltage of both
welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon 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.
5.d. Shielding gases used for arc welding can displace air and
cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 5/16/2018

WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even 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).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected
to physical damage.
• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018

2
SAFETY
+*+)('&%$#"+(!)
)&% $(!!*!( +%)
*
<;:9 87699 5 432:104/. :9 /-. :/.4/,4, +-*
294 :/ *49:,4/.:67 7-)6.:-/9 (;4*4 .;4
474).*:)67 1-(4* :9 1*-':,4, &% .;4 12&7:)
7-($'-7.6#4 92117% 9%9.40" <;4*4 06% &4
1-.4/.:67 ,:++:)27.:49 :/ 4/92*:/#
474).*-06#/4.:) )-016.:&:7:.% :/ .;-94
7-)6.:-/9! ,24 .- )-/,2).4, 69 (477 69
*6,:6.4, *6,:-$+*4324/)% ,:9.2*&6/)49"
#
<;4 294* :9 *491-/9:&74 +-* :/9.677:/# 6/,
29:/# .;4 432:104/. 6))-*,:/# .- .;4
06/2+6).2*4* 9 :/9.*2).:-/9"
+ 474).*-06#/4.:) ,:9.2*&6/)49 6*4 ,4.4).4,!
.;4/ :. 9;677 &4 .;4 *491-/9:&:7:.% -+ .;4 294*
-+ .;4 432:104/. .- *49-7'4 .;4 9:.26.:-/
(:.; .;4 .4);/:)67 699:9.6/)4 -+ .;4
06/2+6).2*4*" / 9-04 )6949 .;:9 *404,:67
6).:-/ 06% &4 69 9:0174 69 46*.;:/# .;4
(47,:/# -* )2..:/# ):*)2:.! 944 /-.4" / -.;4*
)6949 :. )-27, :/'-7'4 )-/9.*2).:/# 6/
474).*-06#/4.:) 9)*44/ 4/)7-9:/# .;4 1-(4*
9-2*)4 6/, .;4 (-* )-0174.4 (:.;
699-):6.4, :/12. +:7.4*9" / 677 )6949
474).*-06#/4.:) ,:9.2*&6/)49 9;677 &4
*4,2)4, .- .;4 1-:/. (;4*4 .;4% 6*4 /-
7-/#4* .*-2&749-04"
NOTE<;4 1*6).:)4 +-* 46*.;:/# .;4
(47,:/# -* )2..:/# ):*)2:. :9 ,414/,4/. -/
7-)67 96+4.% *4#276.:-/9" 8;6/#:/# .;4
46*.;:/# 6**6/#404/.9 .- :01*-'4 8 )6/
6++4). .;4 *:9 -+ :/2*% -* 432:104/.
,606#4" 2*.;4* #2:,6/)4 :9 #:'4/ :/
8$ -* /6.:-/67 6/, 7-)67 )-,49"
$  
4+-*4 :/9.677:/# 432:104/. .;4 294* 9;677
064 6/ 69949904/. -+ 1-.4/.:67
474).*-06#/4.:) 1*-&7409 :/ .;4 92**-2/,:/#
6*46" <;4 +-77-(:/# 9;677 &4 .64/ :/.-
6))-2/.
=" -.;4* 92117% )6&749! )-/.*-7 )6&749!
9:#/67:/# 6/, .4741;-/4 )6&749 6&-'4!
&47-( 6/, 6,6)4/. .- .;4 432:104/.
" *6,:- 6/, .474':9:-/ .*6/90:..4*9 6/,
*4)4:'4*9
" )-012.4* 6/, -.;4* )-/.*-7 432:104/.
" 96+4.% )*:.:)67 432:104/.! 4"#"! #26*,:/#
-+ :/,29.*:67 432:104/.
" .;4 ;467.; -+ .;4 14-174 6*-2/,! 4"#"! .;4
294 -+ 16)4064*9 6/, ;46*:/# 6:,9
" 432:104/. 294, +-* )67:&*6.:-/ -*
04692*404/.
" .;4 :002/:.% -+ -.;4* 432:104/. :/ .;4
4/':*-/04/." <;4 294* 9;677 4/92*4 .;6.
-.;4* 432:104/. &4:/# 294, :/ .;4
4/':*-/04/. :9 )-016.:&74" <;:9 06%
*432:*4 6,,:.:-/67 1*-.4).:-/ 04692*49
" .;4 .:04 -+ ,6% .;6. (47,:/#! )2..:/# -*
-.;4* 6).:':.:49 6*4 .- &4 )6**:4, -2."
<;4 9:4 -+ .;4 92**-2/,:/# 6*46 .- &4
)-/9:,4*4, (:77 ,414/, -/ .;4 9.*2).2*4 -+
.;4 &2:7,:/# 6/, -.;4* 6).:':.:49 .;6. 6*4
.6:/# 176)4" <;4 92**-2/,:/# 6*46 06%
4.4/, &4%-/, .;4 &-2/,6*:49 -+ .;4
1*40:949"
$    

/ 6,,:.:-/ .- .;4 69949904/. -+ .;4 6*46! .;4
69949904/. -+ :/9.6776.:-/9 06% &4 294, .-
4'6726.4 6/, *49-7'4 )6949 -+ :/.4*+4*4/)4"
5/ 40:99:-/ 69949904/. 9;-27, :/)72,4 
 04692*404/.9 69 914):+:4, :/ 876294 =
-+ 8== -* /6.:-/67 6/, 7-)67 )-,49"
  04692*404/.9 06% 679- &4 294, .-
)-/+:*0 .;4 4++:):4/)% -+ 0:.:#6.:-/
04692*49"
% 
  
47,:/# 6/, )2..:/# 432:104/. 9;-27, &4
)-//4).4, .- .;4 12&7:) 92117% 9%9.40
6))-*,:/# .- .;4 06/2+6).2*4* 9

3
SAFETY
%$#"!!$ "    $%$%$ #$ "##% 
! $ $#$% " $ " 
%$#"  #  $%  " $ $!
" $%" " $ $ " $ 
$  #$ " $%! $   $
$!$   !$# #"  "% $$ 
$  " $ $$#%# #"  "
%""  $  $ $  "
$ #" $#$ " $ "$% "%#$ " 
"" $$#%# #" #  !  $
$$$ $ #"    $ "$% "%#$
$ #"%$
&%$#"!#%# !  $!#"
$ $!$  " $ %" $
!  $ ##"%  " $ ! #%$%
%$#"!!$ "   ##$   $%#$
""%   #"$% " $ #"$  
%"$% $ $ $ $ $!$   
"$%"  $ $!$  " " $
!"$     $#$ "% "$
# $   !$  #"$%$  $
! #%$%  %#"   %#% $
%  " %# %     
$#$ " $ $   !  $
##"%  " $ ! #%$%
%$#"!!$ " 
!$# %# ""$# %!
$ $    #  #$ " $
$  "%  "$   " $
"" $ #"$ "$$% %    "% #"$
" $ ""% $$
$"!#"$% #$#
"   "  !$# "$#  $
%%"   %$ " $ #" $%$
"$$% !$# #"!" $  " $ "
$ "% $#$   #%$$ $ %  $
"$%"% #" %$#$$  "#  "# 
$$ !$# #"!" $    $ $$#%"$
 $ !$ !$ $ "$%"% " $
 $ %"!  # " $ !$#
#"!" $ 
%"$#  "! $! !
$%$ $ "%$#$  " " $ " $%
"% $$#%# $ "% #" $#$ " $%
$#$ "  $   ""  "% $!$
  "%   $$"% 
#" $#" "   $ "%$#$ " $%
! %$#$ $!"   "!$  " 
  #$ %$ " $ $ " %$$ 
$ $%  " $ "%$#$  #%$  $
% "  % " $% "% !$ " "$%
$$#%# $!$  $%$ $#$% $
#" $#" " $ "%$#$ " $% "
$ !$   %$# #" $#" " $
"%$#$   "!$ #" %$ $%$
%$# #" $#"  " $%!$ $
"   " $ #$$  $
## #$ $$#$ ##"%  " " 
%$" 
 !!#$# %# $!$#
$$#$ #%$$     $  " "$%
#$   $!$   $ %%"  
%$ ! $$ %"$! "  $%$%$ #$
#%$$   " $ $ %$ $   "
! $ #" $%$ "% $# #" )
)( )'&%$#&"! & $ %#" $$ % &"$#" #"  ) $%&"$# &$###$  %&$ !$"% &% % #"
#"$(

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 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.
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 ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons 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.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
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 debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

INSTALLATION ...........................................................................................................................SECTION A
TECHNICAL SPECIFICATIONS - TOMAHAWK®1000 - CODE 12850 ..........................................................A-1
TECHNICAL SPECIFICATIONS - TOMAHAWK®1000 - CODE 11581 ..........................................................A-2
SELECT PROPER LOCATION.....................................................................................................................A-3
STACKING ............................................................................................................................................A-3
TILTING ............................................................................................................................................A-3
HIGH FREQUENCY INTERFERENCE PROTECTION ......................................................................................A-3
INPUT ELECTRICAL CONNECTIONS..........................................................................................................A-3
INPUT PLUG INSTALLATION.....................................................................................................................A-3
ENGINE DRIVEN GENERATOR...................................................................................................................A-4
GAS INPUT CONNECTIONS.......................................................................................................................A-4
OUTPUT CONNECTIONS...........................................................................................................................A-4
OPERATION ................................................................................................................................SECTION B
GENERAL DESCRIPTION ..........................................................................................................................B-1
PREHEAT TEMPERATURE FOR PLASMA CUTTING ....................................................................................B-1
DUTY CYCLE............................................................................................................................................B-1
USER RESPONSIBILITY ............................................................................................................................B-2
DESIGN FEATURES AND ADVANTAGES ....................................................................................................B-2
CUTTING CAPABILITY .............................................................................................................................B-3
CONSUMABLE LIFE .................................................................................................................................B-3
LIMITATIONS...........................................................................................................................................B-4
CONTROLS AND SETTINGS......................................................................................................................B-4
CUTTING PROCESS..................................................................................................................................B-5
PROCESS GOUGING.................................................................................................................................B-6
TORCH ............................................................................................................................................B-7
PILOT ARC DISCUSSION ..........................................................................................................................B-7
PROCEDURE RECOMMENDATIONS ..........................................................................................................B-7
SUGGESTIONS FOR EXTRA UTILITY FROM THE TOMAHAWK®1000 SYSTEM: .........................................B-8
TORCH PART CONFIGURATIONS ..............................................................................................................B-9
GOUGING SETUP: .................................................................................................................................B-10
MACHINE INTERFACE ............................................................................................................................B-11
ACCESSORIES ............................................................................................................................SECTION C
MAINTENANCE...........................................................................................................................SECTION D
ROUTINE MAINTENANCE .........................................................................................................................D-1
PERIODIC MAINTENANCE ........................................................................................................................D-1
TROUBLESHOOTING ...................................................................................................................SECTION E
DIAGRAMS .................................................................................................................................SECTION F
PARTS LIST...............................................................................................PARTS.LINCOLNELECTRIC.COM
CONTENT/DETAILS MAY BE CHANGED OR UPDATED WITHOUT NOTICE. FOR MOST CURRENT INSTRUCTION
MANUALS, GO TO PARTS.LINCOLNELECTRIC.COM.
5
TABLE OF CONTENTS

A-1
INSTALLATIONTOMAHAWK®1000
INSTALLATION
TECHNICAL SPECIFICATIONS -
TOmAHAwk
®
1000 - COdE 12850
INPUT - SINGLE PHASE/THREE PHASE/ 50 / 60 HERTZ
INPUT VOLTAGE +/- 10% INPUT AMPERES @ RATED OUTPUT CIRCUIT BREAKER (DELAY TYPE)
208V/1/50/60 38 50% Duty Cycle
40 Amps
25 100% Duty Cycle
230V/1/50/60 34 50% Duty Cycle
23 100% Duty Cycle
208V/3/50/60 25 50% Duty Cycle
30 Amps
16 100% Duty Cycle
230V/3/50/60 21 50% Duty Cycle
13 100% Duty Cycle
460V/3/50/60 9 50% Duty Cycle
15 Amps
6 100% Duty Cycle
575V/3/50/60 8 40% Duty Cycle
5 100% Duty Cycle
RATED OUTPUT AT 40° C
DUTY CYCLE CURRENT VOLTAGE
100% 40A 96VDC
50% 60A 104 VDC
40% 60A 104 VDC
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH
WEIGHT
INCLUDING
TORCH CABLE
15.3 in.
389 mm 9.7 in. 247 m 21.65 in. 550 mm 63.9 lbs. 29 kgs
OUTPUT
CURRENT RANGE OPEN CIRCUIT VOLTAGE PILOT CURRENT
20 - 60 Amps 270 VDC 20 Amps
TEMPERATURE RANGES
OPERATING TEMPERATURE
RANGE
STORAGE TEMPERATURE
RANGE
-10°C to +40°C -25°C to +55°C
REQUIRED GAS FLOW RATE
80.0 PSI @ 275 SCFH
(5.5 Bar. @ 130 ±20% LITERS/MIN.)
REQUIRED GAS INLET PRESSURE
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
Ambient Temperature 30oC or Less
Input Cord
Supplied with
Machine
Type S, SO, ST, STO
or Extra Hard Usage Cord
AWG (IEC) Sizes
Input Supply Wires 1 Ground Wire
STO, 600V #10 (5.3 mm2) #10 (5.3 mm2)

A-2
INSTALLATIONTOMAHAWK®1000
TECHNICAL SPECIFICATIONS -
TOmAHAwk
®
1000 - COdE 11581
INPUT - SINGLE PHASE/THREE PHASE/ 50 / 60 HERTZ
INPUT VOLTAGE +/- 10% INPUT AMPERES @ RATED OUTPUT CIRCUIT BREAKER (DELAY TYPE)
208V/1/50/60 38 50% Duty Cycle
40 Amps
25 100% Duty Cycle
230V/1/50/60 34 50% Duty Cycle
23 100% Duty Cycle
208V/3/50/60 25 50% Duty Cycle
30 Amps
16 100% Duty Cycle
230V/3/50/60 21 50% Duty Cycle
13 100% Duty Cycle
460V/3/50/60 9 50% Duty Cycle
15 Amps
6 100% Duty Cycle
575V/3/50/60 8 50% Duty Cycle
5 100% Duty Cycle
RATED OUTPUT AT 40° C
DUTY CYCLE CURRENT VOLTAGE
100% 40A 96VDC
50% 60A 104 VDC
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH
WEIGHT
INCLUDING
TORCH CABLE
15.3 in.
389 mm 9.7 in. 247 m 21.65 in. 550 mm 63.9 lbs. 29 kgs
OUTPUT
CURRENT RANGE OPEN CIRCUIT VOLTAGE PILOT CURRENT
20 - 60 Amps 270 VDC 20 Amps
TEMPERATURE RANGES
OPERATING TEMPERATURE
RANGE
STORAGE TEMPERATURE
RANGE
-10°C to +40°C -25°C to +55°C
REQUIRED GAS FLOW RATE
80.0 PSI @ 275 SCFH
(5.5 Bar. @ 130 ±20% LITERS/MIN.)
REQUIRED GAS INLET PRESSURE
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
Ambient Temperature 30oC or Less
Input Cord
Supplied with
Machine
Type S, SO, ST, STO
or Extra Hard Usage Cord
AWG (IEC) Sizes
Input Supply Wires 1 Ground Wire
STO, 600V #10 (5.3 mm2) #10 (5.3 mm2)

A-3
INSTALLATIONTOMAHAWK®1000
SAFETY PRECAUTIONS
Read entire Installation Section before installing the Tomahawk®
1000 .
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
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.
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
(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, several
good earth driven electrical grounds around the periphery of
the building are recommended.
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.
• Automatically senses and adjusts to input power for a range
of 200 up to 600 volts, single or three phase, 50 to 60 hertz.
Cutting output remains constant throughout the entire input
voltage range.
• 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.
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.
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.
WARNING
WARNING

A-4
INSTALLATIONTOMAHAWK®1000
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:
• 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.
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.
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.
• 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.
WARNING

OPERATION
SAFETY PRECAUTIONS
Read and understand this entire section before
operating your Tomahawk 1000
• Do not attempt to use this equipment until you have
thoroughly read the engine manufacturer’s manual
supplied with your welder. It includes important safety
precautions, detailed engine starting, operating and
maintenance instructions, and parts lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and ground
• Always wear dry insulating gloves.
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove fumes
from breathing zone.
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.
• Only qualified personnel should operate this equipment.
• Always operate the welder with the door closed and the
side panels in place as these provide maximum
protection from moving parts and insure proper cooling
air flow.
GENERAL 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.
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.
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.
WARNING
B-1
OPERATIONTOMAHAWK®1000

B-2
OPERATIONTOMAHAWK®1000
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 uncom-
plicated. 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.
- 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.

B-3
OPERATIONTOMAHAWK®1000
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.
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.
aaron neville you tube
Tomahawk 1000 - Cut Capacity Chart
0
10
20
30
40
0.500 0.625 0.750 0.875 1.000
Metal Thickness (inches)
Recommended Torch
Travel Speed (IPM)
Tomahawk 1000
0
1/4
1/2
3/4
1
1 1/4
1 1/2
Recommended Cut @19 IPM Max Cut @ 10 IPM Sever Cut @ 5 IPM
Figure B.1

B-4
OPERATIONTOMAHAWK®1000
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
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 machine’s 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.
Note: The Fan may automatically turn OFF if the
error condition persists for more than 2
seconds.
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.
V
A
7
8
2
3
4
5
6
1

B-5
OPERATIONTOMAHAWK®1000
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
pushbutton 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
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.
WARNING
1MPa = 145 psi
11
10
9
12

B-6
OPERATIONTOMAHAWK®1000
• The Post Flow time is proportional to the selected cutting
current and it is divided into 4 time ranges:
• 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 onto the
metal at a 300 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.
• 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.
• Use a 5° - 15° leading angle in the direction of the cut.
• 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-to-side, 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.
Direction of Travel
5 - 15
1/16”
10 - 20 Arc Lag
Leading Angle
303000
VERVERTICAL ANGLETICAL ANGLE
FOR CUTTINGFOR CUTTING
CUT
900
TORCH AT 300ANGLE
TO PIERCE
ROTATE TO
900ANGLE TO CUT
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

B-7
OPERATIONTOMAHAWK®1000
Applications:
Removing weld imperfections – cracks, porosity, inclusions, etc.
Back gouging for welding preparation
Removal of temporary fit up methods – tack welds, bracketing,
etc.
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.
• 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.
• Use the proper cutting procedures referred to in Procedure
Recommendations.
PILOT ARC dISCUSSION
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
• 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.
• Where possible, start the cut from the edge of the work piece.
• Keep moving! A steady speed is necessary. Do not pause.
WARNING
Torch Standoff
DRAG thru 1/16"
Standoff
1/16” Standoff