Chicago Electric 45949 User manual

PLASMA CUTTER - 35 AMPPLASMA CUTTER - 35 AMP
PLASMA CUTTER - 35 AMPPLASMA CUTTER - 35 AMP
PLASMA CUTTER - 35 AMP
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our Web site at http://www.harborfreight.com
Copyright © 2003 by Harbor Freight Tools®. All rights reserved. No portion of
this manual or any artwork contained herein may be reproduced in any shape or
form without the express written consent of Harbor Freight Tools.
For technical questions and replacement parts, please call 1-800-444-3353
45949

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Specifications
 
 

 
 
 
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 
 
 
 
 

 
 
Save This Manual
You will need the manual for the safety warnings and precautions, assembly instructions,
operating and maintenance procedures, parts list and diagram. Keep your invoice with this
manual. Write the invoice number on the inside of the front cover. Keep the manual and
invoice in a safe and dry place for future reference.
Safety Warnings and Precautions
WARNING: When using tool, basic safety precautions should always be followed to re-
duce the risk of personal injury and damage to equipment.
Read all instructions before using this tool!
1. Keep work area clean. Cluttered areas invite injuries.
2. Observe work area conditions. Do not use machines or power tools in damp or wet
locations. Don’t expose to rain. Keep work area well lighted. Do not use electrically
powered tools in the presence of flammable gases or liquids.
3. Keep children away. Children must never be allowed in the work area. Do not let
them handle machines, tools, or extension cords.
4. Store idle equipment. When not in use, tools must be stored in a dry location to
inhibit rust. Always lock up tools and keep out of reach of children.
5. Use the right tool for the job. Do not attempt to force a small tool or attachment to do
the work of a larger industrial tool. There are certain applications for which this tool
was designed. It will do the job better and more safely at the rate for which it was
intended. Do not modify this tool and do not use this tool for a purpose for which it was
not intended.

Page 3SKU 45949
6. Dress properly. Do not wear loose clothing or jewelry as they can be caught in
moving parts. Protective, electrically non-conductive clothes and non-skid footwear
are recommended when working. Wear restrictive hair covering to contain long hair.
7. Use eye and ear protection. Always wear ANSI approved impact safety glasses.
Wear a shaded lens welding helmet when cutting or welding. Wear an ANSI approved
dust mask or respirator when working around metal, welding, and chemical dusts and
mists.
8. Do not overreach. Keep proper footing and balance at all times. Do not reach over or
across running machines.
9. Maintain tools with care. Keep tools sharp and clean for better and safer
performance. Follow instructions for lubricating and changing accessories. Inspect tool
cords periodically and, if damaged, have them repaired by an authorized technician.
The handles must be kept clean, dry, and free from oil and grease at all times.
10. Disconnect power. Unplug tool when not in use.
11. Avoid unintentional starting. Be sure the switch is in the Off position when not in
use and before plugging in. Do not carry any tool with your finger on the trigger,
whether it is plugged in or not.
12. Stay alert. Watch what you are doing, use common sense. Do not operate any tool
when you are tired.
13. Check for damaged parts. Before using any tool, any part that appears damaged
should be carefully checked to determine that it will operate properly and perform its
intended function. Check for alignment and binding of moving parts; any broken parts
or mounting fixtures; and any other condition that may affect proper operation. Any part
that is damaged should be properly repaired or replaced by a qualified technician. Do
not use the tool if any switch does not turn On and Off properly.
14. Guard against electric shock. Prevent body contact with grounded surfaces such as
pipes, radiators, ranges, and refrigerator enclosures.
15. Replacement parts and accessories. When servicing, use only identical
replacement parts. Use of any other parts will void the warranty. Only use accessories
intended for use with this tool. Approved accessories are available from Harbor Freight
Tools.
16. Do not operate tool if under the influence of alcohol or drugs. Read warning
labels if taking prescription medicine to determine if your judgment or reflexes are
impaired while taking drugs. If there is any doubt, do not operate the tool.
17. Use proper size and type extension cord. If an extension cord is required, it must be
of the proper size and type to supply the correct current to the tool without heating up.
Otherwise, the extension cord could melt and catch fire, or cause electrical damage to
the tool. This tool requires use of an extension cord with up to 35 amps capability (up
to 50 feet), with wire size rated at 11 AWG. Longer extension cords require larger size
wire. If you are using the tool outdoors, use an extension cord rated for outdoor use.
(signified by “WA” on the jacket).

Page 4SKU 45949
18. Maintenance. For your safety, service and maintenance should be performed
regularly by a qualified technician.
19. Pacemaker safety warning. People with pacemakers should consult with their
physician(s) before using this product; operation of equipment in close proximity to a
heart pacemaker could cause interference or failure of the pacemaker.
Note: Performance of this tool may vary depending on variations in local line voltage. Exten-
sion cord usage may also affect tool performance.
Warning: The warnings, cautions, and instructions discussed in this instruction manual
cannot cover all possible conditions and situations that may occur. It must be under-
stood by the operator that common sense and caution are factors which cannot be
built into this product, but must be supplied by the operator.
Plasma Cutting Safety Precautions
Setup and Use
1. Connect the earth ground as near as possible to the operating area. Earth connections
to structural parts of the building or other places distant to the operating area will
reduce their effectiveness and increase the danger of electric shock.
2. Do not pass equipment cables through or near lifting chains, crane cables, or any
electrical lines.
3. Besides grounding the workpiece with the Plasma Cutter Grounding Cable, an earth
grounding of the workpiece is recommended. Ground it directly to an earth pipe or
grounding rod with a separate cable of appropriate size.
4. Do not touch the electrode if you are in contact with the workpiece, ground, or another
electrode from a different machine.
5. Never use the Plasma Cutter near water. Ensure that the surrounding area and cutting
objects are dry. Do not spray water or other liquids on or near the Plasma Cutter.
6. Avoid all direct contact between the skin or wet garments and metal parts under
electrical power. Check that gloves and protective clothing are dry.
7. Always wear welding gloves and rubber soled shoes when working in damp areas, or
standing on metal objects.
8. Always turn off the Plasma Cutter when it is not in use, or in the event of a power
failure. Do not allow the Torch Head to touch earth ground. Accidental earth
discharges may cause overheating and fire hazards.
9. Do not leave the powered Plasma Cutter unattended.
10. Significant DC voltage exists after turning off and unplugging the unit. Discharge the
electrode to ground before handling.
Wear Protective Clothing

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1. Welding and cutting operations are a source of radiation, noise, hear, and noxious
fumes; for this reason, the protection of the operator and any spectators must be
guaranteed with suitable safety devices and precautions. Never approach arc rays or
hot metal without protection. Failure to observe these standards during operation could
lead to serious health risks.
2. Wear fire-resistant work gloves, a heavy, long-sleeved shirt, trousers without cuffs,
shoes with high insteps to protect skin from arc rays and metal sparks, and a welder’s
helmet to protect hair and face.
3. Always wear safety glasses with side shields under the welding helmet. High
temperature slag may be thrown to great distances. Pay attention to fellow workers in
the vicinity.
Fire and Explosion Safety
1. Position a fire-resistant screen around the Plasma Cutting area to protect persons in
the vicinity from arc rays, sparks, and slag.
2. Clear away or protect flammable objects such as wood, saw dust, clothing, paints,
solvents, petroleum products, natural gas, acetylene, propane, and other substances
with fireproof material.
3. Keep an ABC type fire extinguisher near the work area.
4. Never perform welding or cutting operations on closed pipes or containers as the
possible internal fumes may cause an explosion.
5. Never perform welding or cutting operations on open pipes or containers that may
have come in contact with moisture, chemicals, or flammable materials. Always clean
and dry the areas first.
Fumes and Gases Hazards
1. Welding and cutting fumes and gases may be hazardous if inhaled for long periods of
time.
2. Install a natural or forced-air ventilation system in the work area. If the ventilation
system is inadequate, use an air respirator.
3. Use a forced-air ventilation system when welding or cutting lead, beryllium, cadmium,
zinc, zinc-coated or painted materials. Always wear a protective breathing mask.
4. When welding or cutting in small areas, the operator should be externally
accompanied by another person to observe accident prevention procedures.
5. Do not perform welding operations near chlorinated hydrocarbon vapors produced by
degreasing or painting; the heat generated by arc rays can react to form phosgene, a
highly toxic gas.
6. Irritation of the eyes, nose, and throat are symptoms of inadequate ventilation. Take
immediate steps to improve ventilation. Do not continue operations if symptoms
persist.

Page 6SKU 45949
Transporting the Plasma Cutter
1. When moving the Plasma Cutter, the power must be shut off and disconnected.
2. Pull the Plasma Cutter by its handle and roll on its wheels.
3. Do not drag, pull, or lift the Plasma Cutter by it’s cables.
High Frequency Radiation
1. When cutting or welding, be aware that high frequency radiation may be produced
which can interfere with radio navigation, safety services, computers, and
communications equipment. Before operations, have a qualified electronics technician
check out that possibility.
2. Keep high frequency source doors and panels tightly shut. Keep spark gaps at the
correct settings. Use proper grounding and shielding to minimize the possibility of
interference. Keep all cables close together and close to the ground. Locate the
welding or cutting operation as far as possible from sensitive electronic equipment; or
have the electronic equipment shut down temporarily.
Electrical Shock Hazard
1. Electric shock could be fatal. Never touch exposed electrical parts.
2. Switch off and disconnect the power source before installing or opening the Plasma
Cutter.
3. Installation must be performed by a qualified technician.
4. Installation procedures must comply with the National Electric Code, and all other
relevant regulations.
Unpacking
When unpacking, check to make sure the following parts are included.
If any parts are missing or broken, please call Harbor Freight Tools at the number on the
cover of this manual as soon as possible.
3 - Electrodes (not shown)
3 - Nozzles (not shown)

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Assembly
1. Assembly the platform stand and attach the wheels using the supplied hardware.
2. Place the Plasma Cutter on the Platform Stand and secure with the supplied
hardware.
3. Attach the Pull Handle to the Plasma Cutter with the supplied hardware.
4. Install a 3-prong, 220 VAC power connector with at least a 35 amp capacity. This
should only be done by a licensed electrician.
Operation
WARNING: This product, when used for welding and similar applications, produces
chemicals known to the State of California to cause cancer and birth defects (or other
reproductive harm). (California Health & Safety Code 25249.5, et seq.)
Front Panel Controls and Indicators
 
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
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 




 
 
 
Cutting Operation
1. Connect the air supply hose to the manometer located on the back panel, and set the
air pressure to 60 PSI. The air supply should have an in-line moisture filter.
2. Check the Plasma Torch. Replace or clean the nozzle and electrode if worn or dirty.
3. Clamp the Plasma Cutter Ground Cable Clamp to the bare metal workpiece.
4. With the On/Off switch set to “O”, plug the power cord into the 220 VAC (35 amp
capacity) electrical outlet.
5. Place your protective clothing, gloves, and welding helmet.
6. While holding the Torch handle away from the workpiece, set the On/Off switch to 20A
or 35A depending on the hardness of the metal being cut.
It is recommended to do a test cut on a piece of scrap metal of the same type as the
work piece to determine the correct amperage and air pressure for a clean cut.

Page 8SKU 45949
7. Adjust the air pressure from the Control Filter Knob on the back panel.
Caution: Verify that no wires, cables, or other obstructions are below the cutting area.
8. Place the Torch Head on the metal to be cut and press the Start button on the Torch
handle.
Start to cut slowly, then increase the speed to obtain the desired cut quality. Regulate
the speed to obtain a good cut. See illustration “A” below. Air plasma will create a
straight arc with stainless steel or aluminum, or a 5” arc with softer steel. The arc varies
depending on speed, material, and thickness.
In some cutting operations, it may be necessary to start the cut from a point away from
the edge. See illustration “B” above. The backfire from this operation could shorten the
life of the torch components, so it is recommended to do this cut as fast as possible.
Slightly incline the Torch so that the backfire particles are blown away by the nozzle
(and by the operator), instead of bouncing back into the Torch. Clean away slag and
incrustations from the Torch Head. Spraying or immersing the Torch Head in an anti-
slag substance, minimizes the quantity of incrustation that would stick to it.
9. When the cutting process is complete, release the Start button on the Torch handle,
place the Torch handle in a safe place, and wait 5 minutes before turning the On/Off
switch to “O” to allow proper cooling. The pilot arc is automatic, not manually
controlled. Handle the torch components with care and protect them from damage.
10. Unplug the line cord from the electrical outlet.
Troubleshooting
 
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


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 


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
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AB
REV 06/03

Page 9SKU 45949
Maintenance
Warning: Before performing any maintenance you must disconnect power to the Plasma
Cutter and discharge it’s electrode to ground.
1. Regularly clean the Control Filter Receptacle on the rear panel.
2. Clean or replace the nozzle and electrode when they become dirty or worn.
3. Store the Plasma Cutter in a clean and dry location.
Main Parts List
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
NOTE: Some parts are listed and shown
for illustration purposes only and are not
available individually as replacement
parts.

Page 10SKU 45949
Main Assembly Drawing
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS
MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBU-
TOR 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. IN FACT, THE MANUFACTURER
AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS
SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE
BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER
REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING
OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.
41
70
09
14
21
18
26
69
24
84
84.1
08
46
46.1
02
47
23
01
31
30
72
42
29
72.1