Table of Contents SAFETY Safety.......................................................... 2 Setup........................................................... 5 Specifications.............................................. 5 Operation.................................................... 10 Techniques................................................. 12 Maintenance............................................... 13 Troubleshooting.......................................... 14 Parts List and Diagrams.............
Exposure to welding or cutting exhaust fumes can increase the risk of developing certain cancers, such as cancer of the larynx and lung cancer.
General Tool Safety Warnings (cont.) Proper cylinder care. Secure cylinders to a cart, wall, or post, to prevent them from falling. All cylinders should be used and stored in an upright position. Never drop or strike a cylinder. Do not use cylinders that have been dented. Cylinder caps should be used when moving or storing cylinders. Empty cylinders should be kept in specified areas and clearly marked “empty.” 13. Never use oil or grease on any inlet connector, outlet connector, or cylinder valves. 14.
Specifications 60% @ 40 A 80% @ 34.6 A 100% @ 31 A Air Requirements 3.5 CFM @ 60-80 PSI Power Switch Rocker Type Weight 49.6 lb. Cutting Current 15-40 A Cutting Thickness 1/2″ Mild Steel Maximum Arc Striking System Pilot Arc Unit Size 20″ L x 8-1/8″ W x 14-3/8″ H Air Inlet 1/4″ - 18 NPT SAFETY Rated Duty Cycle 240V~, 50/60Hz, 19.
Setup SAFETY Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. Note: For additional information regarding the parts listed in the following pages, refer to the Assembly Diagram near the end of this manual. Note: This air tool may be shipped with a protective plug covering the air inlet. Remove this plug before set up. Grounding SETUP OPERATION 1. Attach a ground wire of at least 14 Ga.
TO PREVENT SERIOUS INJURY FROM EXPLOSION: Use only clean, dry, regulated, compressed air with this tool. Do not use oxygen, acetylene, carbon dioxide, combustible gases, or any other bottled gas as a power source for this tool. Note: An oiler system should not be used with this tool. The oil will mix with the material being propelled, causing poor results. Attach an air hose to the compressor’s air outlet. Connect the air hose to the air inlet on the back of the Plasma Cutter.
A B C D E F G H TECHNIQUES Air Hose Filter Regulator Lubricator (optional) Coupler and Plug Leader Hose (optional) Air Cleaner / Dryer (optional) Air Adjusting Valve (optional) Description Non-lubricated Tools A OPERATION Lubricated Tools B B C C A Function A E E F H Connects air to tool Prevents dirt and condensation from damaging tool or work piece Adjusts air pressure to tool For air tool lubrication Provides quick connection and release Increases coupler life Prevents water vapor from
SKU 95136 For technical questions, please call 1-800-444-3353.
Operating Instructions SAFETY Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. Controls and Indicators 4 2 POWER ON 1 POWER WORKING 7 OFF MIN CUTTER AIR 2. Digital Amp Meter. Shows actual cutting current, which will vary during operation. 3. Thermal Overload Indicator Lamp. This light will come on, and the device will shut down if the tool becomes overheated.
Basic Operation Mount the metal to be cut to the metal welding‑cutting table. It should be mounted so that the cutting debris falls to the cement floor. Connect an air hose and coupling (not supplied) from the air supply tank to the Air Input Coupling at the rear of the unit. See photo on page 6, bottom. The air supply must be regulated to between 60 and 80 PSI as read on the Air Pressure Gauge. The air supply must be dry. It is recommended to install a moisture filter (not included) on the compressor.
Technique SAFETY Using a plasma cutter is a skill that requires time and effort to do well. Practice striking and maintaining an arc on scrap work pieces before beginning work. This will help you gauge the best settings for the plasma cutter for the material at hand. SETUP 1. You can cut any metal that will conduct electricity up to approximately ½″ thick mild steel or equivalent. Very thin or very thick metals are more difficult to cut cleanly. 2.
Service SAFETY Procedures not specifically explained in this manual must be performed only by a qualified technician. TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION OR ELECTRIC SHOCK: Make sure the Power Switch of the Plasma Cutter is in its "OFF" position and that the tool is unplugged from the electrical outlet before performing any inspection, maintenance, or cleaning procedures.. 2. Periodically recheck all nuts, bolts, and screws for tightness. 3.
Troubleshooting IMPORTANT! SAFETY Be CERTAIN to shut off the Plasma Cutter, and disconnect it from power and air before adjusting, cleaning, or repairing the unit. A technician should discharge all capacitors before performing any internal procedures. FAN RUNS WHEN SWITCHED ON BUT ARC WILL NOT IGNITE Air pressure too high or too low. Check the Air Pressure setting on the regulator’s gauge. SETUP AIR PRESSURE TOO HIGH Adjust the Air Regulator to deliver only 60‑80 PSI to the Cutter.
Troubleshooting (cont.) ARC IGNITES FOR SEVERAL SECONDS BUT THEN GOES OUT SAFETY IMPORTANT! Be CERTAIN to shut off the Plasma Cutter, and disconnect it from power and air before adjusting, cleaning, or repairing the unit. A technician should discharge all capacitors before performing any internal procedures. DIRTY OR COATED METAL METAL IS CLEAN IN BOTH AREAS Use a wire wheel brush or sander (not included) to thoroughly clean both the grounding point and the area that will be cut.
Troubleshooting (cont.) IMPORTANT! SAFETY Be CERTAIN to shut off the Plasma Cutter, and disconnect it from power and air before adjusting, cleaning, or repairing the unit. A technician should discharge all capacitors before performing any internal procedures. CUT GOES ONLY PARTIALLY THROUGH THE WORKPIECE Material being cut is too thick. Maximum thickness for steel is 1/2″. SETUP WITHIN THICKNESS RANGE Turn up the current adjustment knob and try again.
Troubleshooting (cont.) FAST NOZZLE WEAR OR EXCESSIVE SLAG FORMATION SAFETY IMPORTANT! Be CERTAIN to shut off the Plasma Cutter, and disconnect it from power and air before adjusting, cleaning, or repairing the unit. A technician should discharge all capacitors before performing any internal procedures. SETUP These two problems have similar causes and will often appear simultaneously. The same diagnostic procedures and remedies apply to both.
Parts List and Diagrams PLEASE READ THE FOLLOWING CAREFULLY SAFETY THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT.
SERVICE TECHNIQUES OPERATION SETUP SAFETY Assembly Diagram SKU 95136 For technical questions, please call 1-800-444-3353.
Wiring Diagram SAFETY CN2 CN1 CN3 CN4 2 2V SERVICE LED1 YL/D5 LED2 RED/D5 LED2 RED/D5 LED3 RED/D5 LED3 RED/D5 22V I out 11 22v 11 35 34 52 51 52 11 51 31 32 35 11 34 30 11 20 28 11 22 11 20 24 I25 out 11 11 22v 28 15V 22V BK1 22V TH1 TH1 t 15V 22V BK1 19 11 17 16 15 14 13 BK1 TH2 TH2 t 2 2V LED1 YL/D5 Page 20 BK1 S4 t S4 t QA17050HA2BL/230V QA17050HA2BL/230V TECHNIQUES FAN1 FHP06650604-1 19 10 11 FHP06060506-3 FHP06060506-3 11 17 11 16 12 15 14 13 11 22 20 24 25 11
_ L1 103/3KV 400R/60W 103/3KV 2*102/2KV 1KV/20D 1KV/20D L=2mH FL1 1 2 FL1 1 2 50A/75MV C5 103/3KV 50A/75MV S2 L=2mH S2 + + φ10×20 AC 11 IN FHP06110508 PCB6 C5 103/3KV C4 103/3KV +5VDC PCB6 GND FHP06110508 IN +5VDC +5VDC GND GND ININ PCB7 LED +5VDC GND IN PCB7 LED LGK-40-cpu LGK-40-cpu SERVICE AC 11 IN ZK1 L1 φ10×20 R1 C4 103/3KV C3 OPERATION ZK1 C3 400R/60W R1 400R/60W DA2F75P12SA _ R2 10R/50W 400R/60W 1KV/20D 10R/50W R2 2*102/2KV DA2F75P12SA 1KV/20D 1KV/20D
90 Day Warranty SAFETY SETUP Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of 90 days from the date of purchase.
SKU 95136 For technical questions, please call 1-800-444-3353.
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