Lincoln Electric TOMAHAWK 375 AIR Service Manual
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Lincoln Electric TOMAHAWK 375 AIR Service Manual

Lincoln Electric TOMAHAWK 375 AIR Service Manual

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TOMAHAWK
375 AIR
®
For use with machines having Code Numbers:
11579
SERVICE MANUAL
SVM221-A
| Issue D ate 12-Jul
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.

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  • Page 1 NOTE: This manual will cover most of the troubleshooting and repair procedures for the code numbers listed. Some variances may exist when troubleshooting/repairing later code numbers. TOMAHAWK 375 AIR ® For use with machines having Code Numbers: 11579 SERVICE MANUAL SVM221-A | Issue D ate 12-Jul ©...
  • Page 2 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.
  • Page 3 SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. explosion. 7.a. Use only compressed cylinders containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area.If process used and properly operating this is not possible, cover them to prevent the welding sparks regulators designed for the gas and from starting a fire.
  • Page 5 SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
  • Page 6 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
  • Page 7 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda- tions.
  • Page 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ................i-vi Installation .
  • Page 9 TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .
  • Page 10 INSTALLATION TECHNICAL SPECIFICATIONS -TOMAHAWK 375 AIR ® INPUT - SINGLE PHASE 60 HERTZ Standard Voltage 208V, 230V ±10% / 1 / 60Hz RATED OUTPUT AT 40° C Duty Cycle CURRENT AMPS VOLTAGE AMPS 13 A 85.2 VDC 100% 18 A 87.2 VDC 25 A 90 VDC...
  • Page 11 INSTALLATION HIGH FREQUENCY INTERFERENCE Read entire Installation Section before installing the TOMAHAWK 375 AIR. ® PROTECTION The TOMAHAWK 375 AIR employs a touch start ® SAFETY PRECAUTIONS mechanism for arc initiation which eliminates high fre- quency emissions from the machine as compared with WARNING spark gap and solid state type high frequency genera- tors.
  • Page 12 INSTALLATION NOTE: When using nitrogen gas from a cylinder, the The following Lincoln engine drives meet these condi- cylinder must have a pressure regulator. tions when run in the high idle mode: Ranger 250, 250LPG, 305G and 305D engine drives. •...

  • Page 13: Table Of Contents

    TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Precautions .

  • Page 14: Operation

    OPERATION DESCRIPTION SAFETY PRECAUTIONS WARNING The TOMAHAWK 375 AIR is a constant current, con- ® tinuous control plasma cutting power source. It pro- vides superior and reliable starting characteristics, cut- ELECTRIC SHOCK ting visibility and arc stability. The control system has a can kill.

  • Page 15: User Responsibility

    OPERATION 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 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.

  • Page 16: Cutting Capability

    OPERATION CUTTING CAPABILITY CONSUMABLE LIFE The TOMAHAWK ® 375 AIR is rated at 25 amps, at 35% The expected life for the TOMAHAWK ® 375 AIR's elec- duty cycle on a 10 minute basis. If the duty cycle is trode under normal operating conditions is approxi- exceeded, a thermal protector will shut off the output of mately 1000 starts/cuts.

  • Page 17: Limitations

    OPERATION LIMITATIONS LEDs Description Output Thermal (Red) (Yellow) Do not exceed output current and duty cycle rating of The cutting torch is energized. machine. Do not use the TOMAHAWK 375 AIR for ® Part in place error: the retaining pipe thawing. cap is not properly Attached.

  • Page 18: Cutting Process

    OPERATION 5. Internal / External Air selection: This switch WARNING selects the air supply. With the Internal Compressor position selected, the machine operates through the Clean, dry air must be supplied to the machine. A built-in compressor. With the External Air position pressure setting above 110 PSI (7.5 bar) could selected, the internal compressor is completely dis- damage the torch.
  • Page 19 OPERATION • When ready to cut, place the torch near the work, 5 - 15 Leading Angle make certain all safety precautions have been taken and pull the trigger. - The air will flow for a preflow time of 2 seconds and the pilot arc will start.

  • Page 20: Pilot Arc Discussion

    OPERATION • Replace the nozzle when the orifice exit is eroded PROCEDURE RECOMMENDATIONS away or oval shaped. When properly used, plasma arc cutting is a very eco- • After the problem is found, or if there is nothing nomical process. Improper use will result in a very high apparently wrong, reset the machine by turning the operating cost.

  • Page 21: Suggestions For Extra Utility From The Tomahawk

    OPERATION Suggestions for Extra Utility from the • Set air pressure to recommended setting. A higher or lower pressure will cause turbulence TOMAHAWK 375 AIR System: ® in the plasma arc, eroding the orifice of the nozzle tip. WARNING ELECTRIC SHOCK CAN KILL. •...

  • Page 22: Torch Part Configurations

    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. TOMAHAWK ®...
  • Page 23 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 General Options / Accessories .
  • Page 24 ACCESSORIES GENERAL OPTIONS /ACCESSORIES The following options/accessories are available for your Tomahawk Plasma cutter from your local Lincoln ® Distributor. K2377-1 - Small Canvas Cover Protect your machine when not in use. Made from attractive red canvas that is flame retardant, mildew resistant and water repellent.
  • Page 25 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .
  • Page 26 MAINTENANCE PERIODIC MAINTENANCE SAFETY  PRECAUTIONS WARNING WARNING ELECTRIC SHOCK CAN KILL. • Turn off machine at the disconnect ELECTRIC SHOCK CAN KILL. • Have an electrician install and ser- switch on the rear of the machine before tightening, cleaning or vice this equipment. replacing consumables.
  • Page 27 MAINTENANCE FIGURE D.1 MAJOR COMPONENT LOCATION 1. Case Front 2. Case Back 3. Handle 4. Base 5. Foot 6. Wraparound 8. Control Panel 9. Nameplate 10. Inverter P.C. Board 11. Control P.C. Board 12. Compressor 13. Air Filter (Internal/External Air) 14.
  • Page 28 NOTES TOMAHAWK ® 375 AIR...
  • Page 29 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description .
  • Page 30 THEORY OF OPERATION FIGURE E.2 - GENERAL DISCRIPTION 045.101.079 045.101.049 GENERAL DESCRIPTION The Tomahawk 375 AIR is an inverter based constant ® current, continuous control, plasma cutting power source. The control system has a safety mechanism to insure that the torch nozzle and electrode are correct- ly in place before cutting or gouging.

  • Page 31: Theory Of Operation

    THEORY OF OPERATION FIGURE E.3 - INVERTER BOARD INVERTER BOARD This machine is designed on the “single board” con- cept in which all of the electronic devices are housed on one printed circuit board. The single phase input voltage (208-230VAC) is con- nected to the Tomahawk inverter board via an input ®...
  • Page 32 THEORY OF OPERATION FIGURE E.4 - INVERTER BOARD INVERTER BOARD (continued) The 325VDC developed at the input bridge and filter The secondary winding supplies the electrode-to-noz- capacitors is applied to a half–bridge inverter circuit zle (pilot arc) and the electrode-to-work (cutting arc) that utilizes high speed switching transistors.
  • Page 33 THEORY OF OPERATION FIGURE E.5 - INVERTER BOARD INVERTER BOARD (continued) There are several other functions and circuits housed In the case of an overheating condition the thermal on the Inverter Board. The flyback circuit utilizes the sensor (located on the output diode heatsink) will shut (325VDC @ 230VAC) input to generate the auxiliary down the machine and prevent output.

  • Page 34: Control Board And Fan Motors

    THEORY OF OPERATION FIGURE E.6 - CONTROL BOARD AND FAN MOTORS 045.101.079 045.101.049 CONTROL BOARD AND FAN MOTORS RED LED YELLOW LED MEANING The control board is located on the front panel of the The cutting torch is Tomahawk ® 375 Air machine.

  • Page 35: Air Compressor

    THEORY OF OPERATION FIGURE E.7 - AIR COMPRESSOR 045.101.079 045.101.049 AIR COMPRESSOR The Tomahawk 375 Air has an internal air compressor ® so the machine does not need an external air supply to cut metal. The aluminum alloy compressor is driven by a single phase ½...

  • Page 36: Torch Assembly And Work Lead

    THEORY OF OPERATION FIGURE E.8 - TORCH ASSEMBLY AND WORK LEAD TORCH ASSEMBLY AND WORK LEAD The torch assembly and work lead are connected directly to the inverter board, inside the machine, using printed circuit board fast-on connections. This torch is designed to provide the best cutting performance and excellent consumable life.
  • Page 37 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 38: How To Use Troubleshooting Guide

    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.

  • Page 39: Pc Board Troubleshooting Procedures

    Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- CAUTION er failure analysis.
  • Page 40 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. TOMAHAWK ®...
  • Page 41 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. TOMAHAWK ®...
  • Page 42 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 the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. TOMAHAWK ®...
  • Page 43 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. TOMAHAWK ®...
  • Page 44 See Figure B.1. off smoothly. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. TOMAHAWK ®...
  • Page 45 TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual. STATUS BOARD INDICATORS SYMPTOM CHECK Red output LED is blinking or steady with 1. Make sure there is at least 80 psi connected to the gas connec- no air flow at trigger pull. tion at the back of the machine.
  • Page 46 TROUBLESHOOTING AND REPAIR F-10 F-10 TOMAHAWK ® 375 AIR...

  • Page 47: Input Filter Capacitor Discharge Procedure

    INPUT FILTER CAPACITOR DISCHARGE PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 48 TROUBLESHOOTING AND REPAIR F-12 F-12 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.1 – INVERTER BOARD LOCATION INVERTER BOARD NAMEPLATE ASSEMBLY PROCEDURE 4. If there is a voltage present at J17 to J22, obtain WARNING a high wattage resistor (25 ohm at 25 watts) ELECTRIC SHOCK CAN KILL.
  • Page 49 TROUBLESHOOTING AND REPAIR F-13 F-13 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.2 – INVERTER BOARD LEAD LOCATIONS CN15 CN2 CN16 – INPUT INPUT AUXILIARY TRANSFORMER 680uF 680uF 450Vdc 450Vdc MAIN TRANSFORMER PWM SIGNAL LED LOW SIDE OUTPUT CHOKE TOMAHAWK ®...
  • Page 50 NOTES F-14 F-14 TOMAHAWK ® 375 AIR...

  • Page 51: Torch Lc25 Test

    TORCH LC25 TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 52 TROUBLESHOOTING AND REPAIR F-16 F-16 TORCH LC25 TEST (continued) FIGURE F.3 – INVERTER BOARD MOUNTING SCREW LOCATIONS TORCH LEAD CONNECTION TABS PROCEDURE 6. To more easily gain access to the Torch leads WARNING and connection points, remove the four screws ELECTRIC SHOCK CAN KILL.
  • Page 53 TROUBLESHOOTING AND REPAIR F-17 F-17 TORCH LC25 TEST (continued) TABLE F.1 – TORCH TEST CONDITIONS TEST: TORCH CONDITION: EXPECTED RESULTS: TRIGGER TRIGGER PULLED; There should be continuity “0 Ohms” between lead J7 to lead J8 consumables in or out doesn't matter trigger wires.
  • Page 54 TROUBLESHOOTING AND REPAIR F-18 F-18 TORCH LC25 TEST (continued) FIGURE F.4 – TORCH LEAD LOCATIONS CN15 CN2 CN16 INPUT INPUT AUXILIARY TRANSFORMER 680uF 680uF 450Vdc 450Vdc 1.65k Ω 1.65k Ω 100k MAIN TRANSFORMER CHARGING CHARGING CAPACITOR EFFECT CAPACITOR EFFECT CHECK WITH OUTPUT “RESISTANCE”...

  • Page 55: Inverter Board Test

    INVERTER BOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 56 TROUBLESHOOTING AND REPAIR F-20 F-20 INVERTER BOARD TEST (continued) FIGURE F.6 – INVERTER BOARD LOCATION INVERTER BOARD NAMEPLATE ASSEMBLY PROCEDURE 6. Before turning on the Tomahawk ® with the new WARNING Inverter Board installed, perform the tests for ELECTRIC SHOCK CAN KILL. the Torch LC25 and Air / Gas Solenoid (resis- •...
  • Page 57 TROUBLESHOOTING AND REPAIR F-21 F-21 INVERTER BOARD TEST (continued) FIGURE F.7 – INVERTER BOARD TEST POINTS CONTROL BOARD RIBBON CABLE CONNECTOR CN15 CN2 CN16 – INPUT INPUT AUXILIARY TRANSFORMER 680uF 680uF 450Vdc 450Vdc TP12 1.65k Ω 1.65k Ω 100k MAIN TRANSFORMER TP10 TP11 CHARGING...
  • Page 58 TROUBLESHOOTING AND REPAIR F-22 F-22 INVERTER BOARD TEST (continued) FIGURE F.8 – METER PROBE CONNECTIONS (BEEP) (NO BEEP) CONDUCTION BLOCKING – – BLACK PROBE PROBE BLACK PROBE PROBE SWAP LEADS ON TEST POINTS TABLE F.2-A – INVERTER BOARD DIODE CHECKS CONDITIONS TEST POINT TEST POINT...
  • Page 59 TROUBLESHOOTING AND REPAIR F-23 F-23 INVERTER BOARD TEST (continued) TABLE F.2-B – INVERTER BOARD DIODE CHECKS CONDITIONS TEST POINT TEST POINT EXPECTED COMMENTS READING MACHINE NO “BEEP” REVERSE + PROBE – PROBE DIODE CONDUCTION READING MACHINE “BEEP” FORWARD + PROBE –...
  • Page 60 TROUBLESHOOTING AND REPAIR F-24 F-24 INVERTER BOARD TEST (continued) TABLE F.2-D – INVERTER BOARD DIODE CHECKS CONDITIONS TEST POINT TEST POINT EXPECTED COMMENTS READING MACHINE TP25 TP26 NO “BEEP” REVERSE + PROBE – PROBE DIODE CONDUCTION READING MACHINE TP28 TP27 “BEEP”...

  • Page 61: Air/Gas Solenoid Test

    AIR / GAS SOLENOID TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.

  • Page 62: Control Board Potentiometer

    TROUBLESHOOTING AND REPAIR F-26 F-26 AIR / GAS SOLENOID TEST (continued) FIGURE F.9 – INVERTER BOARD CONTROL BOARD RIBBON CABLE CONNECTOR CN15 CN2 CN16 – BLACK (SOLENOID) (SOLENOID) INPUT INPUT AUXILIARY TRANSFORMER 680uF 680uF 450Vdc 450Vdc TP12 1.65k Ω 1.65k Ω 100k MAIN TRANSFORMER TP10...
  • Page 63 CONTROL POTENTIOMETER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 64 TROUBLESHOOTING AND REPAIR F-28 F-28 CONTROL POTENTIOMETER TEST (continued) FIGURE F.10 – CONTROL BOARD TEST POINTS CONTROL BOARD FRONT PANEL MOUNTING SCREWS PROCEDURE 5. Locate the control board. See Figure F.10. WARNING 6. Using the phillips screwdriver, remove the four ELECTRIC SHOCK CAN KILL.
  • Page 65 TROUBLESHOOTING AND REPAIR F-29 F-29 CONTROL POTENTIOMETER TEST (continued) FIGURE F.11 – CONTROL BOARD RIBBON CABLE CONNECTOR LOCATION CONTROL BOARD RIBBON CABLE CONNECTOR CN15 CN2 CN16 – INPUT INPUT AUXILIARY TRANSFORMER 680uF 680uF 450Vdc 450Vdc TP12 1.65k Ω 1.65k Ω 100k MAIN TRANSFORMER TP10...
  • Page 66 TROUBLESHOOTING AND REPAIR F-30 F-30 CONTROL POTENTIOMETER TEST (continued) FIGURE F.12 – CONTROL BOARD TEST POINTS CONTROL CONTROL BOARD POTENTIOMETER WIPER 2.5k OHMS TOMAHAWK ® 375 AIR...

  • Page 67: Case Wraparound Removal And Replacement

    CASE WRAPAROUND REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 68 TROUBLESHOOTING AND REPAIR F-32 F-32 CASE WRAPAROUND REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.13 – HANDLE SCREW LOCATIONS HANDLE PHILLIPS SCREW PHILLIPS SCREW PROCEDURE 4. Using a phillips screwdriver, remove the four WARNING screws securing the rear panel and the two ELECTRIC SHOCK CAN KILL.
  • Page 69 TROUBLESHOOTING AND REPAIR F-33 F-33 CASE WRAPAROUND REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.14 – REAR PANEL SCREW LOCATIONS MOUNTING MOUNTING SCREWS SCREWS MACHINE REAR VIEW LONGER MOUNTING SCREWS REPLACEMENT PROCEDURE 1. Position case Wraparound on machine. Make sure to re-attach any case ground leads. 2.
  • Page 70 NOTES F-34 F-34 TOMAHAWK ® 375 AIR...
  • Page 71 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 72 TROUBLESHOOTING AND REPAIR F-36 F-36 NAMEPLATE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.15 – NAMEPLATE AND MOUNTING SCREW LOCATIONS NAMEPLATE NAMEPLATE MOUNTING SCREWS PROCEDURE 6. Label and disconnect the J11 ground lead con- WARNING necting the Nameplate to the inverter board. ELECTRIC SHOCK CAN KILL.
  • Page 73 TROUBLESHOOTING AND REPAIR F-37 F-37 NAMEPLATE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.16 – RIBBON CABLE CONNECTION LOCATION CONTROL BOARD RIBBON CABLE CONNECTOR CN15 CN2 CN16 – INPUT INPUT AUXILIARY TRANSFORMER 680uF 680uF 450Vdc 450Vdc TP12 1.65k Ω 1.65k Ω 100k MAIN TRANSFORMER TP10...
  • Page 74 NOTES F-38 F-38 TOMAHAWK ® 375 AIR...

  • Page 75: Front Panel Removal And Replacement

    FRONT PANEL REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 76 TROUBLESHOOTING AND REPAIR F-40 F-40 FRONT PANEL REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.17 – FRONT PANEL MOUNTING SCREW LOCATION FRONT NAMEPLATE PHILLIPS SCREWS PHILLIPS SCREWS (LOCATED BEHIND NAMEPLATE) PHILLIPS SCREWS REMOVAL PROCEDURE 6. Using a phillips screwdriver, remove the two WARNING screws on the feet of Front Panel.
  • Page 77 TROUBLESHOOTING AND REPAIR F-41 F-41 FRONT PANEL REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.18 – SOLENOID VALVE LOCATION SOLENOID VALVE SOLENOID VALVE MOUNTING SCREWS SOLENOID VALVE (BENEATH DIVIDER PANEL) SOLENOID VALVE MOUNTING SCREWS CENTER DIVIDER PANEL INVERTER BOARD NOT SHOWN FOR ILLUSTRATION PURPOSES ONLY 12.
  • Page 78 TROUBLESHOOTING AND REPAIR F-42 F-42 FRONT PANEL REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.19 – FRONT PANEL MOUNTING SCREW LOCATION CONTROL BOARD RIBBON CABLE CONNECTOR CN15 CN2 CN16 – INPUT INPUT AUXILIARY TRANSFORMER 680uF 680uF 450Vdc 450Vdc TP12 1.65k Ω 1.65k Ω...

  • Page 79: Torch Lc25 Removal And Replacement

    TORCH LC25 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 80 TROUBLESHOOTING AND REPAIR F-44 F-44 TORCH LC25 REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.20 – TORCH LC25 TORCH LEADS TORCH LC25 AIR HOSE REMOVAL PROCEDURE 6. Carefully remove the Torch air line from the air WARNING solenoid by gently pushing in on the retaining ELECTRIC SHOCK CAN KILL.
  • Page 81 TROUBLESHOOTING AND REPAIR F-45 F-45 TORCH LC25 REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.21 – SOLENOID VALVE AIR HOSE LOCATION SOLENOID VALVE SOLENOID VALVE MOUNTING SCREWS SOLENOID VALVE (BENEATH DIVIDER PANEL) SOLENOID VALVE MOUNTING SCREWS CENTER DIVIDER PANEL INVERTER BOARD NOT SHOWN FOR ILLUSTRATION PURPOSES ONLY FIGURE F.22 –...
  • Page 82 TROUBLESHOOTING AND REPAIR F-46 F-46 TORCH LC25 REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Route Torch leads through the Torch opening in the front panel. 2. Attach large plastic nut securing the Torch to the front panel. 3. Attach the six leads previously removed. See Figure F.22.

  • Page 83: Control Board Removal And Replacement

    CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 84 TROUBLESHOOTING AND REPAIR F-48 F-48 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.23 – CONTROL BOARD LOCATION CONTROL BOARD FRONT PANEL MOUNTING SCREWS PROCEDURE 6. Carefully disconnect the CN9 ribbon cable con- WARNING necting the Control Board to the inverter board. ELECTRIC SHOCK CAN KILL.
  • Page 85 TROUBLESHOOTING AND REPAIR F-49 F-49 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.24 – OUTPUT CURRENT KNOB LOCATION WARNING TOMAHAWK OUTPUT CURRENT KNOB REPLACEMENT PROCEDURE 1. While holding the Control Board in place, place the output control knob into position. 2.
  • Page 86 NOTES F-50 F-50 TOMAHAWK ® 375 AIR...
  • Page 87 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 88 TROUBLESHOOTING AND REPAIR F-52 F-52 REGULATOR / PRESSURE GAUGE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.25 – REGULATOR / PRESSURE GAUGE REGULATOR / PRESSURE GAUGE COMPRESSOR SWITCH NAMEPLATE ASSEMBLY SCREWS (4) PROCEDURE 6. Locate the Regulator / Pressure Gauge. See WARNING Figure F.25.

  • Page 89: Regulator / Pressure Gauge Removal And Replacement

    TROUBLESHOOTING AND REPAIR F-53 F-53 REGULATOR / PRESSURE GAUGE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.26 – REGULATOR / PRESSURE GAUGE FITTINGS LARGE PLASTIC ADJUSTMENT KNOB REPLACEMENT PROCEDURE 1. Place the Regulator / Pressure Gauge into its proper position. 2. Using a 7/32” nutdriver, tighten the two small nuts securing the Regulator / Pressure Gauge assembly to the rear of the nameplate.
  • Page 90 NOTES F-54 F-54 TOMAHAWK ® 375 AIR...
  • Page 91 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 92 TROUBLESHOOTING AND REPAIR F-56 F-56 COMPRESSOR SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.27 – NAMEPLATE ASSEMBLY MOUNTING SCREWS REGULATOR / PRESSURE GAUGE COMPRESSOR SWITCH NAMEPLATE ASSEMBLY SCREWS (4) PROCEDURE 6. Locate Compressor Switch. See Figure F.28. WARNING 7. Label and disconnect the four leads to the ELECTRIC SHOCK CAN KILL.
  • Page 93 TROUBLESHOOTING AND REPAIR F-57 F-57 COMPRESSOR SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.28 – COMPRESSOR SWITCH LOCATION COMPRESSOR SWITCH WARNING TOMAHAWK REPLACEMENT PROCEDURE 1. Align Compressor Switch on nameplate and press firmly into place. 2. Connect the four previously removed leads to the Compressor Switch.
  • Page 94 NOTES F-58 F-58 TOMAHAWK ® 375 AIR...

  • Page 95: Fan Removal And Replacement

    FAN REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 96 TROUBLESHOOTING AND REPAIR F-60 F-60 FAN REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.29 – FAN LOCATION FAN LEADS LOCATION RIVETS (4 PLACES) FANS PROCEDURE 5. The Fans are Pop Riveted to the rear case sup- WARNING port. (4 per Fan). Use the appropriate drill size ELECTRIC SHOCK CAN KILL.
  • Page 97 TROUBLESHOOTING AND REPAIR F-61 F-61 FAN REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Replace the Fan so air flow direction is from the rear to the front of the machine. 2. Using new rivets or the appropriate size bolts, washers and nuts, secure the new Fan to the vertical baffle.
  • Page 98 NOTES F-62 F-62 TOMAHAWK ® 375 AIR...
  • Page 99 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 100 TROUBLESHOOTING AND REPAIR F-64 F-64 INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.30 – INVERTER BOARD LOCATION INVERTER BOARD NAMEPLATE ASSEMBLY PROCEDURE 6. Using a phillips screwdriver, remove the four WARNING screws from the nameplate assembly and care- ELECTRIC SHOCK CAN KILL. fully tilt it away from the Inverter Board.
  • Page 101 TROUBLESHOOTING AND REPAIR F-65 F-65 INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.31 – INVERTER BOARD LEAD LOCATIONS TOMAHAWK ® 375 AIR...
  • Page 102 TROUBLESHOOTING AND REPAIR F-66 F-66 INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.32 – PLASTIC BAFFLE MOUNTING SCREWS PLASTIC BAFFLE MOUNTING SCREWS FIGURE F.33 – INVERTER BOARD MOUNTING SCREWS METAL INVERTER BOARD MOUNTING SCREWS NYLON INVERTER BOARD MOUNTING SCREW TOMAHAWK ®...

  • Page 103: Inverter Board Removal And Replacement

    TROUBLESHOOTING AND REPAIR F-67 F-67 INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Using a phillips screwdriver, attach the five steel screws and one nylon screw securing the Inverter Board to the center divider panel. NOTE: Make sure ALL the Inverter Board mounting screws are back in-place and tight after installing the new board.
  • Page 104 NOTES F-68 F-68 TOMAHAWK ® 375 AIR...

  • Page 105: Compressor Removal And Replacement

    COMPRESSOR REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 106 TROUBLESHOOTING AND REPAIR F-70 F-70 COMPRESSOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.34 – COMPRESSOR LOCATION COMPRESSOR SCREWS COMPRESSOR REMOVAL PROCEDURE 7. Locate the Compressor. See Figure F.34. WARNING NOTE: Compressor will be removed from the ELECTRIC SHOCK CAN KILL. front of the machine.
  • Page 107 TROUBLESHOOTING AND REPAIR F-71 F-71 COMPRESSOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.35 – CONTROL BOARD LOCATION CONTROL BOARD COMPRESSOR 13. Carefully place machine onto left side. 14. Using a phillips screwdriver, remove the bottom two screws securing the Compressor lower shock mounts to the base sheet metal.
  • Page 108 TROUBLESHOOTING AND REPAIR F-72 F-72 COMPRESSOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.36 – MAIN BOARD MOUNTING SCREW LOCATIONS METAL INVERTER BOARD MOUNTING SCREWS NYLON INVERTER BOARD MOUNTING SCREW REPLACEMENT PROCEDURE NOTE: The replacement Compressor should have 7. Connect the copper Compressor air line, locat- its mounting bracket attached for ease of ed on left side of the Compressor, to the air replacement.

  • Page 109: Pressure Switch Removal And Replacement

    PRESSURE SWITCH REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 110 TROUBLESHOOTING AND REPAIR F-74 F-74 PRESSURE SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.37 – PRESSURE SWITCH LOCATION PRESSURE SWITCH PROCEDURE 5. Locate Pressure Switch assembly. WARNING Pressure Switch is located near the bottom rear ELECTRIC SHOCK CAN KILL. on the right side of machine. See Wiring •...
  • Page 111 TROUBLESHOOTING AND REPAIR F-75 F-75 PRESSURE SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Using the 13mm and 14mm wrenches, secure the Pressure Switch to the elbow fitting. 2. Reconnect the two white wires to the Pressure Switch. See Wiring Diagram. 3.
  • Page 112 NOTES F-76 F-76 TOMAHAWK ® 375 AIR...

  • Page 113: Solenoid Valve Removal And Replacement

    SOLENOID VALVE REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 114 TROUBLESHOOTING AND REPAIR F-78 F-78 SOLENOID VALVE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.38 – SOLENOID VALVE LOCATION SOLENOID VALVE SOLENOID VALVE (BENEATH DIVIDER PANEL) MOUNTING SCREWS CENTER DIVIDER PANEL INVERTER BOARD NOT SHOWN FOR ILLUSTRATION PURPOSES ONLY PROCEDURE 5. Locate Solenoid Valve. The Solenoid Valve is WARNING located on right side of machine and is attached ELECTRIC SHOCK CAN KILL.
  • Page 115 TROUBLESHOOTING AND REPAIR F-79 F-79 SOLENOID VALVE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.39 – SOLENOID VALVE ASSEMBLY SOLENOID VALVE SOLENOID VALVE MOUNTING SCREWS FIGURE F.40 – SOLENOID LEAD LOCATIONS CONTROL BOARD RIBBON CABLE CONNECTOR CN15 CN2 CN16 – BLACK (SOLENOID) (SOLENOID) INPUT...
  • Page 116 TROUBLESHOOTING AND REPAIR F-80 F-80 SOLENOID VALVE REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Using a 90 degree phillips screwdriver or phillips head socket & ratchet, replace the two larger phillips screws securing the Solenoid Valve assembly to the center divider panel. 2.

  • Page 117: Oil And Water Trap Removal And Replacement

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 118 TROUBLESHOOTING AND REPAIR F-82 F-82 OIL AND WATER TRAP REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.41 – OIL AND WATER TRAP LOCATION OIL AND WATER TRAP OIL AND WATER TRAP (BENEATH DIVIDER PANEL) MOUNTING SCREWS CENTER DIVIDER PANEL INVERTER BOARD NOT SHOWN FOR ILLUSTRATION PURPOSES ONLY PROCEDURE 5.
  • Page 119 TROUBLESHOOTING AND REPAIR F-83 F-83 OIL AND WATER TRAP REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.42 – OIL AND WATER TRAP ASSEMBLY MOUNTING SCREWS AIR OUT AIR IN DRAIN HOSE REPLACEMENT PROCEDURE 1. Route the drain hose through the hole in the bottom of the sheet metal base.
  • Page 120 NOTES F-84 F-84 TOMAHAWK ® 375 AIR...

  • Page 121: Oil And Water Air Filter Removal And Replacement

    REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 122 TROUBLESHOOTING AND REPAIR F-86 F-86 OIL AND WATER AIR FILTER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.43 – OIL WATER AIR FILTER LOCATION OIL AND WATER TRAP (BENEATH DIVIDER PANEL) CENTER DIVIDER PANEL INVERTER BOARD NOT SHOWN FOR ILLUSTRATION PURPOSES ONLY PROCEDURE 6.
  • Page 123 TROUBLESHOOTING AND REPAIR F-87 F-87 OIL AND WATER AIR FILTER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.44 – OIL WATER AIR FILTER ASSEMBLY FILTER PHILLIPS SCREW PLASTIC LOWER TRAP SUMP DRAIN HOSE REPLACEMENT PROCEDURE 1. Route the drain hose to the bottom hole to drain water.
  • Page 124 TROUBLESHOOTING AND REPAIR F-88 F-88 RETEST AFTER REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machineʼs electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested.
  • Page 125 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram (M22320) .
  • Page 126 ELECTriCaL DiaGramS ENHANCED DIAGRAM WiriNG DiaGram - (m22320) WIRING DIAGRAM WARNING Donotoperate withcovers removed. Disconnectinputpower by unplugging power cordbefore servicing. Donottouchelectrically live parts Only qualifiedpersons shouldinstall, PLASMA use or service this machine. HIGH VOLTAGE TORCH can kill WORK CL AMP BLACK BROWN BLUE...
  • Page 127 TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 SCALE: CONTROL: CLEVELAND EQUIPMENT TYPE: TOMAHAWK 375 AIR UNLESS OTHERWISE SPECIFIED TOLERANCE: PAGE ___ OF ___ ON 2 PLACE DECIMALS IS ± .02 in. ( ± 0.5 mm) NONE DRAWN BY: jmilligan ON 3 PLACE DECIMALS IS ±...
  • Page 128 SCALE: CONTROL: CLEVELAND EQUIPMENT TYPE: TOMAHAWK 375 AIR UNLESS OTHERWISE SPECIFIED TOLERANCE: receive a PWM control signal for output cutting current; manage lift torch strike and PAGE ___ OF ___ ON 2 PLACE DECIMALS IS ± .02 in. ( ± 0.5 mm) NONE avoid the arc to switch off when your're going out of the work piece;...
  • Page 129 TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 SCALE: CONTROL: CLEVELAND EQUIPMENT TYPE: TOMAHAWK 375 AIR UNLESS OTHERWISE SPECIFIED TOLERANCE: PAGE ___ OF ___ ON 2 PLACE DECIMALS IS ± .02 in. ( ± 0.5 mm) NONE DRAWN BY: jmilligan ON 3 PLACE DECIMALS IS ±...
  • Page 130 TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 SCALE: CONTROL: CLEVELAND EQUIPMENT TYPE: TOMAHAWK 375 AIR UNLESS OTHERWISE SPECIFIED TOLERANCE: PAGE ___ OF ___ ON 2 PLACE DECIMALS IS ± .02 in. ( ± 0.5 mm) NONE DRAWN BY: jmilligan ON 3 PLACE DECIMALS IS ±...

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