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Tomahawk TWG120A Operation Manual

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WELDER GENERATOR
Operation Manual
MODEL NUMBER: TWG120A
ON
DC120V
OFF
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+
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ON
To reduce the risk of injury, the user must read and understand the Operator's
Manual before using this product. Save these instructions for future reference.

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Summary of Contents for Tomahawk TWG120A

  • Page 1 WELDER GENERATOR Operation Manual MODEL NUMBER: TWG120A DC120V To reduce the risk of injury, the user must read and understand the Operator’s Manual before using this product. Save these instructions for future reference.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1. SAFETY INFORMATION 1.1 Operating Safety 1.2 Arc Welding Safety 1.3 Service Safety 2. TECHNICAL PERFORMANCE 3. SPECIFICATIONS 3.1 Welding Generator Parts 3.2 Unpacking the Unit 4. ASSEMBLY 4.1 Wheel and Handle Kit Assembly 4.2 Cable Assembly 5.
  • Page 3 Register Your Equipment Thank you for purchasing TOMAHAWK equipment! Your product is covered by the TOMAHAWK Warranty policy, but in order to activate your warranty, we need you to register your product. In addition to activating your equipment warranty, product registration will grant you access to important product updates, streamlined customer service and more.

  • Page 4: Safety Information

    TOMAHAWK®. The information contained in this manual is based on equipment’s production at the time of publication. TOMAHAWK® reserves the right to change any portion of this information without notice. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission from TOMAHAWK®.

  • Page 5: Operating Safety

    1.1.10 DO NOT use AC output in damp areas. 1.1.11 NEVER use accessories or attachments that are not recommended by Tomahawk Power. Damage to equipment and injury to the user may result. 1.1.12 NEVER leave machine running unattended. 1.1.13 ALWAYS be sure operator is familiar with proper safety precautions and operation techniques before using machine.

  • Page 6: Arc Welding Safety

    1.2 Arc Welding Safety 1.2.1 DO NOT touch live electrical parts. DANGER Contact with live electrical parts can result in fatal shocks or severe burns. The electrode and work circuit are live whenever the output is active. The input power circuit and internal machine circuits are also live when the power is DANGER on.
  • Page 7 1.2.18 ALWAYS use a safety harness when working above ground level. 1.2.19 ALWAYS ensure all panels and covers are securely in place. 1.2.20 ALWAYS secure the work cable with good metal-to-metal contact to the workpiece or worktable as close to the weld as possible. 1.2.21 ALWAYS insulate the work clamp when it is not connected to the workpiece to avoid contact with any metal object.
  • Page 8 1.2.32 AVOID welding near degreasing, cleaning, or spraying activities. 1.2.33 The heat and light from the arc can interact with vapors to create highly toxic and irritating gases. 1.2.34 DO NOT weld on coated metals, such as galvanized, lead, or cadmium-plated steel, unless the coating is removed from the welding area, the area is well-ventilated, and you are wearing an air-supplied respirator.

  • Page 9: Service Safety

    1.3 Service Safety Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. DANGER Using a generator indoors can be fatal within minutes. Generator exhaust contains carbon monoxide, a deadly, odorless gas.

  • Page 10: Technical Performance

    2. TECHNICAL PERFORMANCE The Tomahawk TWG120A Generator / Welder is designed for high power and durability. Ideal for farms, construction sites, or any job that requires electrical power and CC (constant current) stick welding. Producing up to 120 Amps of DC output with a 60% duty cycle, it is suitable for welding from 6010 rods up to 7024 rods.

  • Page 11: Specifications

    3. SPECIFICATIONS TWG120A WELDER Mode MMA and TIG Welding Current 40 - 120 Rod Types 6011, 6013, 7014 Welding Rod Length 2.0 - 3.2 mm Diameter 3/32 - 1/4 Duration of Load Connector Type Dinse: DKJ 35-50 TWG120A GENERATOR Engine...

  • Page 12: Welding Generator Parts

    Do not throw away the packaging or packing material until you have inspected all parts and successfully operated the machine. Do not discard this operations manual. If any parts are missing or damaged, please contact TOMAHAWK® customer support by email at support@tomahawk-power.com or call (866) 577-4476.

  • Page 13: Assembly

    4. ASSEMBLY 4.1 Wheel and Handle Kit Assembly 4.1.1 Attach the Feet(FIGURE 1): • Align the studs on the foot bracket assembly with the holes on the bottom of the generator frame. • Secure in place with two hex flange nuts. •...

  • Page 14: Cable Assembly

    WELDING PLUG 4.2 Cable Assembly 4.2.1 To connect the welding leads, begin by stripping COPPER CASING 1” of rubber off the electrode holder cable. FIGURE 4. 4.2.2 Slide the red rubber guard over the top of the cable. 4.2.3 Wrap the exposed cable in a copper casing then insert FIGURE 4 into the welding plug.

  • Page 15: Recommended Battery Information

    5.2.3 Open the fuel valve.FIGURE 9. Engine Switch 5.2.4 For a cold start, move the choke lever to the CLOSED position; if the engine is already warm, the choke can remain in the OPEN position.FIGURE 10. 5.2.5 Hold the top handle securely and pull the recoil starter grip until you feel resistance, then pull FIGURE 8 briskly.FIGURE 11.

  • Page 16: Welder Generator Panel Display

    5.4 Welder Generator Panel Display Connections for ARC WELDING 120 V DC Outlets 40-80 AMP 80-125 AMP DC120V Engine Switch Circuit Breaker Earth Terminal...

  • Page 17: Selecting Cable Sizes

    6. SELECTING CABLE SIZES 6.1 Weld Cable Size and Total Cable (copper) Length in Weld Circuit Not Exceeding: 100 FT OR LESS 10-60% AWG Welding Amperes 60-100% AWG 4 (20) 4 (20) 3 (30) 3 (30) 3 (30) 2 (35) 2 (35) 1 (50) 1 (50)

  • Page 18: Storage

    8. STORAGE 8.1 Clean and Inspect Thoroughly: Clean the generator to remove any dirt and grease buildup. Inspect it for any signs of damage, such as loose bolts or frayed wires, and address these issues as needed. 8.2 Prepare the Fuel System: Either drain the fuel tank and run the generator until it stops to clear any fuel from the system, or add a fuel stabilizer if it will be stored for less than six months.

  • Page 19: Types Of Groove Joints

    9.1.5 Welding the Joint • Maintain a Steady Speed: Move the electrode steadily along the joint, keeping the arc length consistent. • Control the Weld Pool: Watch the molten pool of metal and ensure it flows smoothly into the joint. •...

  • Page 20: Double Groove Welds

    • V-Groove: Easy to machine, can cause significant angular deformation, requires more welding for thicker plates.FIGURE 13. • J-Groove: Curved single-sided bevel, less filler material, good for thick plates. FIGURE 14. • U-Groove: Rounded sides, complex machining, reduces welding for very thick plates. FIGURE 15.

  • Page 21: Weld Test

    11.2 Types of Welds for Tee Joints 11.2.1 Fillet Weld: Common for basic joints. 11.2.2 Beveled Weld: Used for thicker materials for better penetration. 11.2.3 J-Weld: Provides additional strength with more material contact. NOTE: Practice steady movements with the welding gun. Ensure proper alignment to avoid weak joints.

  • Page 22: Replacement Parts

    13. REPLACEMENT PARTS 13.1 For replacement parts and technical questions visit www.tomahawk-power.com or scan the QR code on the front of this manual. 13.2 Not all equipment components are available for replacement. The illustrations within this manual are a convenient reference to the location and position of parts in the assembly sequence.
  • Page 23 Clean the slip rings when they are not in use if they are dirty. Workpiece is not connected. Contact an authorized Electrode holder is loose. Tomahawk Power Service Loose connection at the output stud. Center Generator power is available but unit No open circuit voltage at the does not weld.

  • Page 24: Maintenance Record

    15. MAINTENANCE RECORD TOMAHAWK® tools are assembled with care and will provide years of service when properly maintained. Preventative maintenance and routine service are essential to the long life of your welding generator. Adhere to reading through this manual thoroughly. You will find that you can do some of the regular maintenance yourself.

  • Page 25: Equipment Warranty

    16. EQUIPMENT WARRANTY Your new TOMAHAWK® equipment is warranted to the original purchaser for a period of one-year (12 months) from the original date of purchase. The TOMAHAWK® warranty is against defects in design, materials and workmanship. The following are not covered under the warranty: 16.1.1 Damage caused by abuse, misuse, dropping or other similar damage caused by or as...

  • Page 26: Parts Manual

    WELDER GENERATOR Parts Manual MODEL NUMBER: TWG120A DC120V...

  • Page 28: Parts Explosion

    PARTS EXPLOSION...

  • Page 29: Parts List

    PARTS LIST Description Description 170F gasoline engine Fuel tank shock-absorbing gasket Hexagon flange nut M8 Fuel tank cap kit Bracket Fuel tank strainer Hexagon flange bolt M8X35 Cross screw M5X10 Hexagon flange bolt M6X12 Fuel level indicator Air filter bracket Fuel tank Muffler kit Fuel supply switch...
  • Page 30 WHEEL EXPLOSION...
  • Page 31 WHEEL EXPLOSION Description Handle Sleeve Handle Hexagon Flange Nuts M8 Hexagon Flange Bolt M8x45 Rubber Handle Spacer Dc120 Welder Generator Kit Hexagon Cap Nut M10 7' Plastic Solid Wheel Level Gasket 14x28x15 Wheel Spindle Split Pin 3x50 Hexagon Flange Bolt M8x16 Hexagon Flange Nut M6 Rack Base Plate Square Rack Base...
  • Page 32 WORK SMARTER NOT HARDER For big areas and busy schedules, Tomahawk Push Sweepers cover a wider path to reach more surface area so you can finish sweeping faster around indoor and outdoor spaces and on wet or dry surfaces! Item #: TOS38 38"...
  • Page 33 LIGHTEST 3KW INVERTER When the lights go out, have peace of mind that the Tomahawk TG3000i Portable Generator will keep your home powered. Each unit comes standard with an easy fueling system, low oil sensor, voltage regulation, and two 120 volt plugs and one 120 volt twist lock outlet.
  • Page 34 30" Diameter, 4-Blade Assembly 10 ft Full Hydrostatic, 74 HP Hatz TRT60V TPT46H Adjustable Blade Pitch from 0-28 4 ft, Honda GX270/GX390, 0-28 Blade Pitch Diesel HAVE QUESTIONS? Contact us. We’re here to help! (866) 577-4476 Email us at sales@tomahawk-power.com...
  • Page 35 6010-7024 Rods Compatible 48V-20Ah Battery 3" Pump, Honda GX270, 375 GPM, 120 Amp Welder, 60% Duty Cycle, TW3H TWG120A Handles up to 8 cu ft or 660 lbs. Bucket Capacity Elevation: 89ft, Suction: 25ft 2000w, Includes Wheel Kit Hydraulic Bucket with 92 Tilt, 8 Hour Run Time 4"...
  • Page 36 With same day shipping and faster delivery times, count on Tomahawk to keep you powered throughout the day! With long lasting parts and engines, Tomahawk equipment will be the star of your fleet for years to come. Visit www.tomahawk-power.com to get started today! TOMAHAWK®, LLC...

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