Lincoln Electric TOMAHAWK 1000 Service Manual
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Lincoln Electric TOMAHAWK 1000 Service Manual

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TOMAHAWK
For use with machines having Code Numbers:
11581
SERVICE MANUAL
SVM229-A
| Issue D ate 13-Apr
© Lincoln Global, Inc. All Rights Reserved.
1000
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 1000 For use with machines having Code Numbers: 11581 SERVICE MANUAL SVM229-A | Issue D ate 13-Apr ©...
  • Page 2 THANK YOU FOR SELECTING KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. Use corrective lenses if necessary to A QUALITY PRODUCT BY stay a reasonable distance away from LINCOLN ELEC TRIC. the arc. READ and obey the Material Safety Data Sheet (MSDS) and the warning label that appears on all containers of welding materials.
  • Page 3 ELECTRIC AND MAGNETIC FIELDS or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” MAY BE DANGEROUS booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor...
  • Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover plates to protect are electrically “hot” when the welder is on. your eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
  • 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 recommen- dations.
  • Page 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ..................i-vi Installation, Operation, Accessories, Maintenance .
  • Page 9 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 General Description .
  • Page 10 THEORY OF OPERATION FIGURE E .2 - GENERAL DESCRIPTION TORCH BUCK/BOOST CONNECTOR THERMOSTATS THERMOSTATS CHOKE MAIN INPUT INPUT MAIN SWITCH TRANSFORMER RECTIFIER – – ELECTRODE BUCK/BOOST INVERTER TRIGGER, PIP, COMM OUTPUT POWER 400VDC BOARD BOARD BOARD + NOZZLE / PILOT OUTPUT CHOKE BUCK/BOOST CONTROL...
  • Page 11 THEORY OF OPERATION FIGURE E .3 - INPUT SWITCH, RECTIFIER AND BUCK/BOOST POWER BOARD TORCH BUCK/BOOST CONNECTOR THERMOSTATS THERMOSTATS CHOKE MAIN INPUT INPUT MAIN SWITCH TRANSFORMER RECTIFIER – – ELECTRODE BUCK/BOOST INVERTER TRIGGER, PIP, COMM OUTPUT POWER 400VDC BOARD BOARD BOARD + NOZZLE / PILOT OUTPUT...
  • Page 12 THEORY OF OPERATION FIGURE E .4 - INVERTER BOARD, INPUT BOARD AND CONTROL BOARD TORCH BUCK/BOOST CONNECTOR THERMOSTATS THERMOSTATS CHOKE MAIN INPUT INPUT MAIN TRANSFORMER SWITCH RECTIFIER – – ELECTRODE BUCK/BOOST INVERTER TRIGGER, PIP, COMM OUTPUT POWER 400VDC BOARD BOARD BOARD + NOZZLE / PILOT OUTPUT...
  • Page 13 THEORY OF OPERATION FIGURE E .5 - MAIN TRANSFORMER, OUTPUT BOARD AND TORCH CONNECTOR TORCH BUCK/BOOST CONNECTOR THERMOSTATS THERMOSTATS CHOKE MAIN INPUT INPUT MAIN SWITCH TRANSFORMER RECTIFIER – – ELECTRODE BUCK/BOOST INVERTER TRIGGER, PIP, COMM OUTPUT POWER 400VDC BOARD BOARD BOARD + NOZZLE / PILOT OUTPUT...
  • Page 14 THEORY OF OPERATION FIGURE E .6 - TORCH ASSEMBLY AND WORK LEAD HANDLE LC 65 CABLE TORCH HEAD COOLING ELECTRODE SWIRL RING NOZZLE RETAINING RING CONNECTOR ASSEMBLY SPACER TORCH ASSEMBLY AND WORK LEAD The torch assembly and work lead are connected to the machine via the front panel.

  • Page 15: Table Of Contents

    TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1 How to Use Troubleshooting Guide .

  • Page 16: 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 17: 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 18 6. Perform the Input Board Test. 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 1000 ®...
  • Page 19 Test. 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 1000...
  • Page 20 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 1000 ®...
  • Page 21 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 1000...
  • Page 22 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 1000...
  • Page 23 Normal cutting or gouging can resume. 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 1000...

  • Page 24: Error Condition Test

    • Pull the Torch Trigger and verify correct operation. 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 1000 ®...

  • Page 25: Case Cover Removal And Capacitor Discharge Procedure

    CASE COVER REMOVAL AND 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 26 TROUBLESHOOTING AND REPAIR F-12 F-12 CASE COVER REMOVAL AND CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F .1 – CASE COVER SCREWS AND GROUNDING LEAD LOCATION HANDLE MOUNTING SCREWS (2 PLACES) HANDLE SHORTER CASE GROUNDING SCREWS LEAD LOCATION (4 PLACES) (INSIDE) CORNER CAPS SCREWS WITH WASHERS...
  • Page 27 TROUBLESHOOTING AND REPAIR F-13 F-13 CASE COVER REMOVAL AND CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F .2 – DC BUS CAPACITOR AND BUCK/BOOST BOARD LOCATION BUCK/BOOST BOARD DC BUS CAPACITOR FIGURE F .3 – BUS CAPACITOR TERMINALS TOMAHAWK 1000 ®...
  • Page 28 TROUBLESHOOTING AND REPAIR F-14 F-14 CASE COVER REMOVAL AND CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F .4 – DCIN – AND DCIN + TERMINAL LOCATIONS BUCK/BOOST BOARD TERMINAL DCIN – TERMINAL DCIN + REPLACEMENT PROCEDURE 7. Recheck the voltage across the capacitor termi- nals.

  • Page 29: Input Rectifier Test

    INPUT RECTIFIER 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 30 TROUBLESHOOTING AND REPAIR F-16 F-16 INPUT RECTIFIER TEST (continued) FIGURE F .5 – INPUT BRIDGE RECTIFIER LOCATION INPUT RECTIFIER PROCEDURE WARNING ELECTRIC SHOCK can kill . 3. Locate the Input Rectifier. See Figure. F.5. • Have a qualified individual 4. Perform the tests detailed in Table F.1. Also install and service this equip- See Figure F.6.
  • Page 31 TROUBLESHOOTING AND REPAIR F-17 F-17 INPUT RECTIFIER TEST (continued) TABLE F .1 – INPUT RECTIFIER TEST POINTS POSITIVE TEST PROBE NEGATIVE TEST PROBE EXPECTED RESULT Terminal AC1 Terminal DCIN+ 0.3 - 1.0V Forward Diode Drop Terminal AC2 Terminal DCIN+ 0.3 - 1.0V Forward Diode Drop Terminal AC3 Terminal DCIN+ 0.3 - 1.0V Forward Diode Drop...
  • Page 32 NOTES F-18 F-18 TOMAHAWK 1000 ®...

  • Page 33: Buck/Boost Board Test

    BUCK/BOOST 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 34 TROUBLESHOOTING AND REPAIR F-20 F-20 BUCK/BOOST BOARD TEST (continued) FIGURE F .7 – BUCK/BOOST BOARD LOCATION BUCK/BOOST BOARD PROCEDURE WARNING ELECTRIC SHOCK can kill . 3. Locate the Buck/Boost board. See Figure F.7. • Have a qualified individual 4. Perform the voltage and resistance checks install and service this equip- detailed in Table F.2.
  • Page 35 TROUBLESHOOTING AND REPAIR F-21 F-21 BUCK/BOOST BOARD TEST (continued) TABLE F .2 – BUCK/BOOST BOARD VOLTAGE CHECKS AC INPUT VOLTAGE TEST POINTS EXPECTED READING COMMENTS/CONDITIONS (SINGLE PHASE) 250 VAC DCIN+ to DCIN- 300VDC Input voltage to buck/boost cir- cuit. Will vary with input voltage applied.
  • Page 36 TROUBLESHOOTING AND REPAIR F-22 F-22 BUCK/BOOST BOARD TEST (continued) TABLE F .3 – BUCK/BOOST BOARD RESISTANCE CHECKS AC INPUT VOLTAGE TEST POINTS EXPECTED READING COMMENTS/CONDITIONS Machine disconnected IND1 to IND2 Zero Ohms Continuity of input choke. from input voltage and capacitors discharged.
  • Page 37 TROUBLESHOOTING AND REPAIR F-23 F-23 BUCK/BOOST BOARD TEST (continued) FIGURE F .8 – BUCK/BOOST BOARD TEST POINT LOCATIONS IND2 DC – PLUG J1 PIN 8 PLUG J1 DCIN – PIN 7 PLUG J1 R6 TEST PIN 1 POINT 1 PLUG J1 PIN 9 DCIN + IND1...
  • Page 38 TROUBLESHOOTING AND REPAIR F-24 F-24 BUCK/BOOST BOARD TEST (continued) FIGURE F .9 – BUCK/BOOST BOARD SCHEMATIC TOMAHAWK 1000 ®...

  • Page 39: Input Board Test

    INPUT 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 40 TROUBLESHOOTING AND REPAIR F-26 F-26 INPUT BOARD TEST (continued) FIGURE F .10 – INPUT BOARD LOCATION INPUT BOARD PROCEDURE WARNING ELECTRIC SHOCK can kill . 3. Locate the Input Board. See Figure F.10. • Have a qualified individual 4. Apply the correct input power to the machine install and service this equip- and carefully check the status LED lights on the ment.
  • Page 41 TROUBLESHOOTING AND REPAIR F-27 F-27 INPUT BOARD TEST (continued) TABLE F .4 – INPUT BOARD STATUS LED LIGHT TABLE AC INPUT VOLTAGE LED NUMBER EXPECTED STATUS COMMENTS/CONDITIONS SINGLE PHASE 250 VAC LED #1 ON-Green +15VDC primary is present 250 VAC LED #2 ON-Green +15VDC secondary is present...
  • Page 42 TROUBLESHOOTING AND REPAIR F-28 F-28 INPUT BOARD TEST (continued) TABLE F .5 – INPUT BOARD VOLTAGE CHECKS AC INPUT VOLTAGE TEST POINTS EXPECTED READING COMMENTS/CONDITIONS SINGLE PHASE 250 VAC Plug J6 Pin 3(+) to Pin 7(-) 225VDC Machine at idle no load. Rectified AC input line.

  • Page 43: Control Board Test

    CONTROL 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 44 TROUBLESHOOTING AND REPAIR F-30 F-30 CONTROL BOARD TEST (continued) FIGURE F .12 – CONTROL BOARD LOCATION CONTROL BOARD OUTPUT CONTROL KNOB FRONT PANEL PROCEDURE WARNING ELECTRIC SHOCK can kill . 3. Locate the Control Board. See Figure. F.12. • Have a qualified individual 4.
  • Page 45 TROUBLESHOOTING AND REPAIR F-31 F-31 CONTROL BOARD TEST (continued) TABLE F .6 – CONTROL BOARD STATUS LED LIGHT TABLE LED IDENTITY NORMAL STATUS FAULT STATUS COMMENTS/CONDITIONS Power ON D5 Green Blinking Input voltage out of range (below 208VAC or above 575VAC) Torch Energized Output Blinking Internal Aux.
  • Page 46 TROUBLESHOOTING AND REPAIR F-32 F-32 CONTROL BOARD TEST (continued) FIGURE F .13 – CONTROL BOARD TEST POINT LOCATIONS CONTROL BOARD D23 SW2 TOMAHAWK 1000 ®...

  • Page 47: 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 48 TROUBLESHOOTING AND REPAIR F-34 F-34 INVERTER BOARD TEST (continued) FIGURE F .14 – INVERTER BOARD LOCATION INVERTER BOARD PROCEDURE WARNING 3. Locate the Inverter Board. See Figure. F.14. ELECTRIC SHOCK can kill . 4. Apply the correct input power to the machine •...
  • Page 49 TROUBLESHOOTING AND REPAIR F-35 F-35 INVERTER BOARD TEST (continued) TABLE F .8 – INVERTER BOARD VOLTAGE CHECKS AC INPUT VOLTAGE TEST POINTS EXPECTED READING COMMENTS/CONDITIONS SINGLE PHASE 250 VAC Positive Terminal (Red Lead) 400VDC Filtered DC from Buck/Boost Board to Negative Terminal (Black Machine at idle - no load.
  • Page 50 TROUBLESHOOTING AND REPAIR F-36 F-36 INVERTER BOARD TEST (continued) TABLE F .9 – INVERTER BOARD RESISTANCE CHECKS Using the phillips screwdriver, carefully remove When testing is complete reconnect all leads pre- the following leads from the Inverter Board. See viously removed. Figure F.15 and the Wiring Diagram.

  • Page 51: Output Board Test

    OUTPUT 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 52 TROUBLESHOOTING AND REPAIR F-38 F-38 OUTPUT BOARD TEST (continued) FIGURE F .16 – OUTPUT BOARD LOCATION OUTPUT BOARD PROCEDURE WARNING 3. Locate the Output Board. See Figure F.16. ELECTRIC SHOCK can kill . 4. Apply the correct input power to the machine and •...
  • Page 53 TROUBLESHOOTING AND REPAIR F-39 F-39 OUTPUT BOARD TEST (continued) TABLE F .10 – OUTPUT BOARD VOLTAGE CHECKS AC INPUT VOLTAGE TEST POINTS EXPECTED COMMENTS/CONDITIONS READING SINGLE PHASE 250 VAC Plug J33 Pin 3 to Plug J33 Pin 5 -5VDC Secondary side auxiliary supply 250 VAC Plug J33 Pin 11 to Plug J33 Pin 5 +15VDC...
  • Page 54 TROUBLESHOOTING AND REPAIR F-40 F-40 OUTPUT BOARD TEST (continued) TABLE F .11 – OUTPUT BOARD RESISTANCE CHECKS Using the phillips screwdriver, carefully remove • Two transformer leads from terminals TR1 and the following leads from the Output Board. See Figure F.17 and the Wiring Diagram. Label leads When testing is complete reconnect all leads pre- for reconnection.

  • Page 55: 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 56 TROUBLESHOOTING AND REPAIR F-42 F-42 AIR/GAS SOLENOID TEST (continued) FIGURE F .18 – AIR/GAS SOLENOID LOCATION SOLENOID PROCEDURE WARNING ELECTRIC SHOCK can kill . 3. Locate the Air/Gas Solenoid. See Figure F.18. • Have a qualified individual 4. Apply the correct input power and air pressure install and service this equip- to the machine.
  • Page 57 TROUBLESHOOTING AND REPAIR F-43 F-43 AIR/GAS SOLENOID TEST (continued) FIGURE F .19 – PLUG J5 TEST POINT LOCATIONS INPUT BOARD BUCK/BOOST CONTROL MDULE GREEN LED 4 GREEN LED 3 GREEN LED 1 GREEN LED 2 7. Remove the input power from the Tomahawk Perform the Capacitor 1000 machine.
  • Page 58 NOTES F-44 F-44 TOMAHAWK 1000 ®...

  • Page 59: Torch Test

    TORCH 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 60 • Do not touch electrically hot parts. ------------------------------------------------------------------ 1. Remove the input power from the Tomahawk 1000 machine. 2. Locate and remove the Torch Assembly from the Tomahawk 1000 machine by turning the torch collar counter-clockwise. See Figure F.20. TOMAHAWK 1000 ®...
  • Page 61 TROUBLESHOOTING AND REPAIR F-47 F-47 TORCH TEST (continued) TABLE F .12 – TORCH ASSEMBLY RESISTANCE CHECKS TORCH TEST POINTS EXPECTED READING CONDITIONS/COMMENTS Torch trigger NOT activated Torch Connector Pin 1 to Pin 9 Open Torch Connector Pin 1 to Pin 9 Less than 1 ohm Torch trigger activated Torch Connector Pin 3 to Pin 9...
  • Page 62 TROUBLESHOOTING AND REPAIR F-48 F-48 TORCH TEST (continued) FIGURE F .22 – TORCH SCHEMATIC TOMAHAWK 1000 ®...

  • Page 63: Line Switch Removal And Replacement Procedure

    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 64 TROUBLESHOOTING AND REPAIR F-50 F-50 LINE SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .23 – LINE SWITCH LOCATION CASE BACK INPUT LINE SWITCH PROCEDURE WARNING ELECTRIC SHOCK can kill . 3. Locate the Input Line Switch. See Figure F.23. •...
  • Page 65 TROUBLESHOOTING AND REPAIR F-51 F-51 LINE SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .24 – INPUT LINE SWITCH HANDLE AND NAMEPLATE LOCATION INPUT LINE SWITCH HANDLE AND NAMEPLATE FIGURE F .25 – MOUNTING BRACKET POSITION PHILLIPS TAB-UP SCREWS (4 PLACES) LINE SWITCH OUTER MOUNTING BRACKET...
  • Page 66 TROUBLESHOOTING AND REPAIR F-52 F-52 LINE SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 8. Using the medium size phillips screwdriver, locate, label and remove the three input line 1. Carefully position the new line switch into the cord leads (red, black and white). Note lead machine.

  • Page 67: Input Rectifier Removal And Replacement Procedure

    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-54 F-54 INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .26 – INPUT RECTIFIER LOCATION INPUT RECTIFIER RECTIFIER AC P.C. BOARD PROCEDURE WARNING ELECTRIC SHOCK can kill . 3. Locate the Input Rectifier and the Rectifier AC P.C.
  • Page 69 TROUBLESHOOTING AND REPAIR F-55 F-55 INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .27 – INPUT RECTIFIER LEAD LOCATIONS RECTIFIER AC PC BOARD BLACK: TO BB DCIN – TERMINAL AC1 NEGATIVE TERMINAL TERMINAL AC2 RED: TO BB DCIN + TERMINAL AC3 REPLACEMENT PROCEDURE 6.
  • Page 70 NOTES F-56 F-56 TOMAHAWK 1000 ®...
  • 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-58 F-58 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .28 – CONTROL BOARD LOCATION CONTROL BOARD OUTPUT CONTROL KNOB FRONT PANEL PROCEDURE WARNING ELECTRIC SHOCK can kill . 3. Locate the Control Board. See Figure F.28. •...
  • Page 73 TROUBLESHOOTING AND REPAIR F-59 F-59 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .29 – PLUG J22 AND CONTROL BOARD MOUNTING POST LOCATIONS CONTROL BOARD MOUNTING POSTS MOUNTING POSTS AND NUTS (4 PLACES) AND NUTS (4 PLACES) REPLACEMENT PROCEDURE 8.
  • Page 74 NOTES F-60 F-60 TOMAHAWK 1000 ®...
  • Page 75 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-62 F-62 INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .30 – INPUT BOARD LOCATION INPUT BOARD PROCEDURE WARNING ELECTRIC SHOCK can kill . 3. Locate the Input Board. See Figure F.30. • Have a qualified individual 4.
  • Page 77 TROUBLESHOOTING AND REPAIR F-63 F-63 INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .31 – INPUT BOARD MOUNTING SCREW LOCATIONS BUCK/BOOST CONTROL MDULE GREEN LED 4 INPUT BOARD METAL PHILLIPS NYLON MOUNTING SCREWS (4 PLACES) GREEN SCREWS (3 PLACES) LED 3 GREEN LED 1...
  • Page 78 NOTES F-64 F-64 TOMAHAWK 1000 ®...
  • Page 79 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-66 F-66 OUTPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .32 – OUTPUT BOARD LOCATION OUTPUT BOARD PROCEDURE WARNING ELECTRIC SHOCK can kill . 3. Locate the Output Board. See Figure F.32. • Have a qualified individual 4.
  • Page 81 TROUBLESHOOTING AND REPAIR F-67 F-67 OUTPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .33 – OUTPUT BOARD CONNECTION LOCATIONS OUTPUT BOARD IND1 IND2 TO OUTPUT CHOKE OUT1 HSC 1 TO WORK FROM SEC. OF PILOT ARC MAIN TRANSFORMER D1 MODULE IGBT MODULE (4 SCREWS) SCREWS (3)
  • Page 82 TROUBLESHOOTING AND REPAIR F-68 F-68 OUTPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .34 – OUTPUT BOARD MODULE LOCATIONS OUTPUT BOARD REAR VIEW MODULE “U” SLOT “U” SLOT PILOT ARC IGBT MODULE MODULE “U” SLOT 14. Using the phillips screwdriver, locate and 17.
  • Page 83 TROUBLESHOOTING AND REPAIR F-69 F-69 OUTPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully clean the heat sink. 10. Using the screw and associated washers previously removed, reconnect the output 2. Apply a thin layer of Dow Corning 340 heat sink ELECTRODE lead to terminal EL2.
  • Page 84 NOTES F-70 F-70 TOMAHAWK 1000 ®...
  • Page 85 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 86 TROUBLESHOOTING AND REPAIR F-72 F-72 BUCK/BOOST BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .35 – BUCK/BOOST BOARD LOCATION BUCK/BOOST BOARD PROCEDURE WARNING ELECTRIC SHOCK can kill . 2. Perform the Case Cover Removal and Capacitor Discharge Procedure. • Have a qualified individual install and service this equip- 3.
  • Page 87 TROUBLESHOOTING AND REPAIR F-73 F-73 BUCK/BOOST BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .36 – BUCK/BOOST BOARD CONNECTION LOCATIONS CORNER MOUNTING SCREWS (4 PLACES) IND2 MODULE DC – DCIN – MODULE IND1 DCIN + MODULE CORNER MOUNTING SCREWS (4 PLACES) NOTE: Before preforming the following steps take 12.
  • Page 88 TROUBLESHOOTING AND REPAIR F-74 F-74 BUCK/BOOST BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .37 – BUCK/BOOST BOARD MODULE LOCATIONS BUCK/BOOST BOARD (REAR VIEW) “U” SLOT MODULE “U” SLOT MODULE MODULE “U” SLOT 18. Using the phillips screwdriver, locate and 22.
  • Page 89 TROUBLESHOOTING AND REPAIR F-75 F-75 BUCK/BOOST BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully clean the heat sink. 2. Apply a thin layer of Dow Corning 340 heat sink 10. Using the screw and associated washers pre- compound (Lincoln Part T12837) on the new viously removed, reconnect the lead to the DC- module(s).
  • Page 90 NOTES F-76 F-76 TOMAHAWK 1000 ®...
  • 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-78 F-78 INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .38 – INVERTER BOARD LOCATION INVERTER BOARD PROCEDURE WARNING ELECTRIC SHOCK can kill . 3. Locate the Inverter Board. See Figure F.38. • Have a qualified individual install 4.
  • Page 93 TROUBLESHOOTING AND REPAIR F-79 F-79 INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .39 – INVERTER BOARD CONNECTION LOCATIONS INVERTER BOARD MODULE MODULE TERMINAL CORNER MOUNTING SCREWS (4 PLACES) NEGATIVE POSITIVE TERMINAL TERMINAL TERMINAL MODULE MODULE NOTE: Before preforming the following steps take 11.
  • Page 94 TROUBLESHOOTING AND REPAIR F-80 F-80 INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.40 – INVERTER BOARD MODULE LOCATIONS INVERTER BOARD (REAR VIEW) MODULE “U” SLOT MODULE “U” SLOT MODULE “U” MODULE SLOT 16. Using the phillips screwdriver, locate and 20.
  • Page 95 TROUBLESHOOTING AND REPAIR F-81 F-81 INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully clean the heat sink. 10. Using the screw and associated washers pre- viously removed, reconnect the black negative 2. Apply a thin layer of Dow Corning 340 heat sink capacitor lead to the negative terminal.
  • Page 96 NOTES F-82 F-82 TOMAHAWK 1000 ®...

  • Page 97: Air Filter Assembly Removal And Replacement Procedure

    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 98 TROUBLESHOOTING AND REPAIR F-84 F-84 AIR FILTER ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .41 – AIR FILTER ASSEMBLY LOCATION AIR FILTER ASSEMBLY PROCEDURE 3. Locate the Air Filter assembly. See Figure F.41. 4. Carefully remove the two gas hoses from the top WARNING portion of the Air Filter assembly by depressing the locking collars and carefully extracting the...
  • Page 99 TROUBLESHOOTING AND REPAIR F-85 F-85 AIR FILTER ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Using the two screws and washers previously removed, attach the mounting bracket to the new Air Filter. 2. Carefully position the new Air Filter assembly into the machine.
  • Page 100 NOTES F-86 F-86 TOMAHAWK 1000 ®...

  • Page 101: Pressure Gauge And Regulator Removal And Replacement Procedure

    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 102 TROUBLESHOOTING AND REPAIR F-88 F-88 PRESSURE GUAGE AND REGULATOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .42 – PRESSURE GUAGE AND REGULATOR LOCATION PRESSURE GAUGE AND REGULATOR FRONT PANEL ASSEMBLY SCREWS PROCEDURE WARNING ELECTRIC SHOCK can kill . 3. Locate the Pressure Gauge and Regulator assembly.
  • Page 103 TROUBLESHOOTING AND REPAIR F-89 F-89 PRESSURE GUAGE AND REGULATOR REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 6. Carefully remove the two gas hoses from the Pressure Gauge and Regulator by depressing 1. Carefully position the new Pressure Gauge and the locking collars and carefully extracting the Regulator assembly into the machine.
  • Page 104 NOTES F-90 F-90 TOMAHAWK 1000 ®...
  • Page 105 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-92 F-92 GAS SOLENOID REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .43 – GAS SOLENOID LOCATION SOLENOID PROCEDURE WARNING ELECTRIC SHOCK can kill . 3. Locate the Gas Solenoid. See Figure F.43. • Have a qualified individual install 4.
  • Page 107 TROUBLESHOOTING AND REPAIR F-93 F-93 GAS SOLENOID REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F .44 – PLUG J5 ON INPUT BOARD LOCATION BUCK/BOOST CONTROL MDULE GREEN LED 4 GREEN LED 3 GREEN LED 1 GREEN LED 2 PLUG J5 REPLACEMENT PROCEDURE 1.

  • Page 108: Retest After Repair

    TROUBLESHOOTING AND REPAIR F-94 F-94 RETEST AFTER REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested.
  • Page 109 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram (M22322) .
  • Page 110 ElECTriCal DiaGramS WiriNG DiaGram - COmplETE maChiNE - (m22322) TOMAHAWK 1000 WIRING DIAGRAM WARNING Do not operate with covers removed. Disconnect input power by unplugging power cord before servicing. Do not touch electrically live parts IND1 IND2 BUCK BOOST Only qualified persons should install,...
  • Page 111 1000 - COmplETE maChiNE - (CODE 11581) (m22293) pG 1 ENGINEERING CONTROLLED CHANGE DETAIL: CHANGED EQUIPMENT TYPE. ADDED SCHEMATIC AND PAGES 2, 3, 4, 5, 6 AND 7. MANUFACTURER: TOMAHAWK 1000 COMPONENT LAYOUT RIGHT HEAT SINK BB Thermal sensor 15 Vdc IF OPEN 70C°...
  • Page 112 ElECTriCal DiaGramS SChEmaTiC TOmahaWK 1000 - COmplETE maChiNE - (CODE 11581) (m22293) pG 2 ENGINEERING CONTROLLED CHANGE DETAIL: CHANGED EQUIPMENT TYPE. ADDED SCHEMATIC AND PAGES 2, 3, 4, 5, 6 AND 7. MANUFACTURER: INPUT VOLTAGE 208 - 575Vac ± 15% 50/60Hz...
  • Page 113 ElECTriCal DiaGramS SChEmaTiC TOmahaWK 1000 - COmplETE maChiNE - (CODE 11581) (m22293) pG 3 ENGINEERING CONTROLLED CHANGED EQUIPMENT TYPE. ADDED SCHEMATIC AND PAGES 2, 3, 4, 5, 6 AND 7. CHANGE DETAIL: MANUFACTURER: CN1 PIN OUT (JTAG SIGNAL FOR CPLD)
  • Page 114 ElECTriCal DiaGramS SChEmaTiC TOmahaWK 1000 - COmplETE maChiNE - (CODE 11581) (m22293) pG 4 ENGINEERING CONTROLLED CHANGED EQUIPMENT TYPE. ADDED SCHEMATIC AND PAGES 2, 3, 4, 5, 6 AND 7. CHANGE DETAIL: MANUFACTURER: TO J3 OF INPUT BOARD W05X0987 FUNCTIONALITY OF THE BOARD W05X0858...
  • Page 115 ElECTriCal DiaGramS SChEmaTiC TOmahaWK 1000 - COmplETE maChiNE - (CODE 11581) (m22293) pG 5 ENGINEERING CONTROLLED CHANGE DETAIL: CHANGED EQUIPMENT TYPE. ADDED SCHEMATIC AND PAGES 2, 3, 4, 5, 6 AND 7. MANUFACTURER: J22 PIN OUT for voltages see page 3.
  • Page 116 ElECTriCal DiaGramS SChEmaTiC TOmahaWK 1000 - COmplETE maChiNE - (CODE 11581) (m22293) pG 6 CHANGED EQUIPMENT TYPE. ADDED SCHEMATIC AND PAGES 2, 3, 4, 5, 6 AND 7. ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: AIR SYSTEM PATH TO J5 OF INPUT W05X0987 AIR TUBE: POLYURETHANE TUBE Ø6 X 4...
  • Page 117 ElECTriCal DiaGramS SChEmaTiC TOmahaWK 1000 - COmplETE maChiNE - (CODE 11581) (m22293) pG 7 ENGINEERING CONTROLLED CHANGED EQUIPMENT TYPE. ADDED SCHEMATIC AND PAGES 2, 3, 4, 5, 6 AND 7. CHANGE DETAIL: MANUFACTURER: OUTPUT BOARD W05X0858 TO OUTPUT CHOKE NO LEAD CONNECTION...

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