Chicago Electric 91814 User manual

PLASMA AIR CUTTER
220 VOLT - 36 AMP
INVERTER TECHNOLOGY
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 MISSION OAKS BLVD., CAMARILLO, CA 93011
VISIT OUR WEB SITE AT HTTP://WWW.HARBORFREIGHT.COM
Copyright©2004 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-
91814
MANUAL REVISED 02/05; 06/06

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
SKU 91814 PAGE 2
Contents
SPECIFICATIONS............................................................................3
GENERAL SAFETY RULES............................................................3
SPECIFIC SAFETY RULES.............................................................6
UNPACKING ...................................................................................10
ASSEMBLY INSTRUCTIONS .........................................................10
CONTROLS AND INDICATORS.....................................................11
OPERATING INSTRUCTIONS........................................................11
SETUP.....................................................................................................11
CUTTING TECHNIQUE ...........................................................................12
INSPECTION, MAINTENANCE, AND CLEANING.........................14
CIRCUIT DIAGRAM........................................................................15
PARTS LIST ....................................................................................16
TORCH DIAGRAM..........................................................................16
ASSEMBLY DIAGRAM ...................................................................17
TROUBLESHOOTING ....................................................................18
REV 07/05

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SKU 91814 PAGE 3
SPECIFICATIONS
Cutting Depth 3/8 inch on steel
Cutting Current 5 to 36 Amps listed
Rated Load Voltage 100 VDC
No-load Voltage 200 VDC (maximum)
Power Consumption 220 VAC, 15 Amps, 50/60 Hz, single phase
Line Cord 6’ - 9” long (without 220 VAC twist plug); 14 AWG x 3-C
Arc Torch Cable 16’ - 3” long
Ground Cable 9’ long, 1 AWG x 6 mm2
Air Requirement 60-65 PSI, dry compressed air; 3.5 CFM @ 65 PSI
Arc Striking System Pilot arc feature with two second delay
Power Switch Rocker type, lighted
Overall Dimensions 16-3/4” (L) x 14-3/4” (H) x 8-1/8” (W)
Weight 26.5 lb.
Accessories Inlet air regulator (1/4” - 18 NPT), Shoulder strap, Electrode, Tip, Ceramic Ring
Rated Duty Cycle 40% at 36 amps, 60% at 28 amps
DUTY CYCLE is a welding or cutting, equipment specification, which defines the number of
minutes, within a 10-minute period, that a given piece of equipment can safely weld or cut
at its rated load without overheating.
For example, if a welder or cutting type piece of equipment is rated at a 40% duty cycle at
36 amps, that particular piece of equipment must be “rested” for at least 6 minutes after 4
minutes of continuous welding or cutting.
Failure to carefully observe duty cycle limitations can easily over stress the power generation systems
of a piece of equipment contributing to the premature failure of that piece of equipment and the
voiding of the warranty.
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 in-
voice in a safe and dry place for future reference.
GENERAL SAFETY RULES
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS.Failure to follow all instructions
listed below may result in electric shock, fire, and/or serious injury.
SAVE THESE INSTRUCTIONS
WORK AREA
1. Keep your work area clean and well lit. Cluttered benches and dark areas invite
accidents.
2. Do not operate power tools in explosive atmospheres, such as in the presence

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Troubleshooting section at end of manual.
SKU 91814 PAGE 4
of flammable liquids, gases, or dust. Power tools create sparks which may ignite the
dust or fumes.
3. Keep bystanders, children, and visitors away while operating a power tool.
Distractions can cause you to lose control. Protect others in the work area from debris
such as chips and sparks. Provide barriers or shields as needed.
ELECTRICAL SAFETY
4. Avoid body contact with grounded surfaces such as pipes, radiators, ranges, and
refrigerators. There is an increased risk of electric shock if your body is grounded.
5. Do not expose power tools to rain or wet conditions. Water entering a power tool
will increase the risk of electric shock.
6. Grounded tools must be plugged into an outlet properly installed and grounded in
accordance with all codes and ordinances. Never remove the grounding prong or
modify the plug in any way. Do not use any adapter plugs. Check with a qualified
electrician if you are in doubt as to whether the outlet is properly grounded. If the
tools should electrically malfunction or break down, grounding provides a low resistance
path to carry electricity away from the user.
7. Double insulated tools are equipped with a polarized plug (one blade is wider than
the other). This plug will fit in a polarized outlet only one way. If the plug does
not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified
electrician to install a polarized outlet. Do not change the plug in any way. Double
insulation eliminates the need for the three wire grounded power cord and grounded
power supply system.
8. Do not abuse the Power Cord. Never use the Power Cord to carry the tools or pull
the Plug from an outlet. Keep the Power Cord away from heat, oil, sharp edges, or
moving parts. Replace damaged Power Cords immediately. Damaged Power Cords
increase the risk of electric shock.
9. When operating a power tool outside, use an outdoor extension cord marked“W-A”
or “W”. These extension cords are rated for outdoor use, and reduce the risk of electric
shock.
PERSONAL SAFETY
10. Stay alert. Watch what you are doing, and use common sense when operating a
power tool. Do not use a power tool while tired or under the influence of drugs,
alcohol, or medication. A moment of inattention while operating power tools may result
in serious personal injury.
11. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep
your hair, clothing, and gloves away from arc. Loose clothes, jewelry, or long hair
can catch fire.
12. Avoid accidental starting. Be sure the Power Switch is off before plugging in.
Carrying power tools with your finger on the Power Switch, or plugging in power tools
with the Power Switch on, invites accidents.

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SKU 91814 PAGE 5
13. Remove adjusting keys or wrenches before turning the power tool on. A wrench
or a key that is left attached to a rotating part of the power tool may result in personal
injury.
14. Do not overreach. Keep proper footing and balance at all times. Proper footing and
balance enables better control of the power tool in unexpected situations.
15. Use safety equipment. Always wear eye protection. Dust mask, nonskid safety shoes,
hard hat, or hearing protection must be used for appropriate conditions.
TOOL USE AND CARE
16. Use clamps (not included) or other practical ways to secure and support the
workpiece to a stable platform. Holding the work by hand or against your body is
unstable and may lead to loss of control.
17. Do not force the tool. Use the correct tool for your application. The correct tool will
do the job better and safer at the rate for which it is designed.
18. Do not use the power tool if the Power Switch does not turn it on or off. Any tool
that cannot be controlled with the Power Switch is dangerous and must be replaced.
19. Disconnect the Power Cord Plug from the power source before making any
adjustments, changing accessories, or storing the tool. Such preventive safety
measures reduce the risk of starting the tool accidentally.
20. Store idle tools out of reach of children and other untrained persons. Tools are
dangerous in the hands of untrained users.
21. Maintain tools with care. Keep tools in good repair. Properly maintained tools will
get the job done better. Do not use a damaged tool. Tag damaged tools “Do not use”
until repaired.
22. Check for breakage of parts, and any other condition that may affect the tool’s
operation. If damaged, have the tool serviced before using. Many accidents are
caused by poorly maintained tools.
23. Use only accessories that are recommended by the manufacturer for your model.
Accessories that may be suitable for one tool may become hazardous when used on
another tool.
SERVICE
24. Tool service must be performed only by qualified repair personnel. Service or
maintenance performed by unqualified personnel could result in a risk of injury.
25. When servicing a tool, use only identical replacement parts. Follow instructions
in the “Inspection, Maintenance, And Cleaning” section of this manual. Use of
unauthorized parts or failure to follow maintenance instructions may create a risk of
electric shock or injury.

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
SKU 91814 PAGE 6
SPECIFIC SAFETY RULES
1. Maintain labels and nameplates on the Air Plasma Cutter. These carry important
information. If unreadable or missing, contact Harbor Freight Tools for a replacement.
2. Maintain a safe working environment. Keep the work area well lit. Make sure there
is adequate surrounding workspace. Always keep the work area free of obstructions,
grease, oil, trash, and other debris. Do not use a power tool in areas near flammable
chemicals, dusts, and vapors. Do not use this product in a damp or wet location.
3. Avoid unintentional starting. Make sure you are prepared to begin work before turning
on the Air Plasma Cutter.
4. Unplug before performing maintenance. Always unplug the Plasma Cutter from
its electrical outlet before performing and inspection, maintenance, or cleaning
procedures.
5. Never leave the Plasma Cutter unattended while energized. Turn power off if you
have to leave the Air Plasma Cutter.
6. Prevent eye injury and burns. Wearing and using ANSI-approved personal safety
clothing and safety devices reduce the risk for injury.
• Wear ANSI-approved safety impact eye goggles with a welding helmet featuring at
least a number 10 shade lens rating.
• Leather leggings, fire resistant shoes or boots should be worn when using this product.
Do not wear pants with cuffs, shirts with open pockets, or any clothing that can catch
and hold molten metal or sparks.
• Keep clothing free of grease, oil, solvents, or any flammable substances. Wear dry,
insulating gloves and protective clothing.
• Wear an approved head covering to protect the head and neck. Use aprons, cape,
sleeves, shoulder covers, and bibs designed and approved for welding and cutting
procedures.
• When cutting overhead or in confined spaces, wear flame resistant ear plugs or ear
muffs to keep sparks out of ears.
7. Prevent accidental fires. Remove any combustible material from the work area.
• When possible, move the work to a location well away from combustible materials. If
relocation is not possible, protect the combustibles with a cover made of fire resistant
material.
• Remove or make safe all combustible materials for a radius of 35 feet (10 meters)
around the work area. Use a fire resistant material to cover or block all open doorways,
windows, cracks, and other openings.
• Enclose the work area with portable fire resistant screens. Protect combustible walls,
ceilings, floors, etc., from sparks and heat with fire resistant covers.
• If working on a metal wall, ceiling, etc., prevent ignition of combustibles on the other
side by moving the combustibles to a safe location. If relocation of combustibles is

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
SKU 91814 PAGE 7
not possible, designate someone to serve as a fire watch, equipped with a fire extin-
guisher, during the cutting process and for at least one half hour after the cutting is
completed.
• Do not cut on materials having a combustible coating or combustible internal structure,
as in walls or ceilings, without an approved method for eliminating the hazard.
• Do not dispose of hot slag in containers holding combustible materials. Keep a fire
extinguisher nearby and know how to use it.
• After cutting, make a thorough examination for evidence of fire. Be aware that easily
visible smoke or flame may not be present for some time after the fire has started. Do
not weld or cut in atmospheres containing dangerously reactive or flammable gases,
vapors, liquids, and dust. Provide adequate ventilation in work areas to prevent ac-
cumulation of flammable gases, vapors, and dust. Do not apply heat to a container
that has held an unknown substance or a combustible material whose contents, when
heated, can produce flammable or explosive vapors. Clean and purge containers
before applying heat. Vent closed containers, including castings, before preheating,
welding, or cutting.
• Only use compressed air to operate the Plasma Cutter. Never use other compressed
gases.
8.
Inhalation Hazard
Welding Produces TOXIC FUMES and GASSES.
Exposure to welding gasses can increase the risk of developing
certain cancers, such as cancer of the larynx and lung cancer.
Also, some diseases that may be linked to exposure to welding gasses
or fumes are:
• Early onset of Parkinson’s Disease • Heart Disease
• Damage to the reproductive organs • Ulcers
• Inflammation of the small intestine or stomach • Kidney damage
• Respiratory diseases such as emphysema, bronchitis or pneumonia
Safety precautions, such as using natural or forced air ventilation and
wearing an ANSI-approved respirator, are ESSENTIAL to reduce the risk
of developing the above illnesses.
Avoid overexposure to fumes and gases. Always keep your head out of the fumes.
Do not breathe the fumes. Use enough ventilation or exhaust, or both, to keep fumes
and gases from your breathing zone and general area.
• Where ventilation is questionable, have a qualified technician take an air sampling to
determine the need for corrective measures. Use mechanical ventilation to improve
air quality. If engineering controls are not feasible, use an approved respirator.
• Work in a confined area only if it is well ventilated, or while wearing an air-supplied
respirator.

For technical questions, please call 1-800-444-3353;
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SKU 91814 PAGE 8
• Follow OSHA guidelines for Permissible Exposure Limits (PEL’s) for various fumes
and gases.
• Follow the American Conference of Governmental Industrial Hygienists recommenda-
tions for Threshold Limit Values (TLV’s) for fumes and gases.
• Have a recognized specialist in Industrial Hygiene or Environmental Services check
the operation and air quality and make recommendations for the specific welding or
cutting situation.
9. Always keep hoses away from cutting spot. Examine all hoses and cables for cuts,
burns, or worn areas before each use. If any damaged areas are found, replace the hoses
or cables immediately.
10. Read and understand all instructions and safety precautions as outlined in the
manufacturer’s manual for the material you will weld or cut.
11. 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.”
12. Never use oil or grease on any inlet connector, outlet connector, or cylinder
valves.
WARNING! This product, when used for welding and similar applications, contains
or produces a chemical known to the State of California to cause cancer and birth defects
(or other reproductive harm). (California Health & Safety Code § 25249.5, et seq.)
WARNING! People with pacemakers should consult their physician(s) before us-
ing this product. Electromagnetic fields in close proximity to a heart pacemaker could
cause interference to, or failure of the pacemaker.

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
SKU 91814 PAGE 9
GROUNDING
This Air Plasma Cutter requires a 3-prong, 220 VAC, polarized, twistlock plug (not sup-
plied). This plug must be installed by a qualified electrician.
WARNING!
Improperly connecting the grounding wire can result in the risk of electric
shock. Check with a qualified electrician if you are in doubt as to whether the
outlet is properly grounded. Do not modify the power cord provided with the
tool or product. Never remove the grounding prong from the plug. Do not use
the tool if the power cord or plug is damaged. If damaged, have it repaired by
a service facility before use. If the plug will not fit the outlet, have a proper
outlet installed by a qualified electrician.
EXTENSION CORDS
If an extension cord is to be used with this product, it must be rated to handle 220 VAC,
single phase at 20 amps (minimum), and have a twistlock plug.
1. Grounded, 220 VAC tools require a three wire extension cord.
2. As the distance from the supply outlet increases, you must use a heavier gauge extension
cord. Using extension cords with inadequately sized wire causes a serious drop in voltage,
resulting in loss of power and possible tool damage.
3. The smaller the gauge number of the wire, the greater the capacity of the cord. For
example, a 14 gauge cord can carry a higher current than a 16 gauge cord.
4. When using more than one extension cord to make up the total length, make sure each
cord contains at least the minimum wire size required.
5. If you are using one extension cord for more than one tool, add the nameplate amperes
and use the sum to determine the required minimum cord size.
6. If you are using an extension cord outdoors, make sure it is marked with the suffix “W-A”
(“W” in Canada) to indicate it is acceptable for outdoor use.
7. Make sure your extension cord is properly wired and in good electrical condition. Always
replace a damaged extension cord or have it repaired by a qualified electrician before
using it.
8. Protect your extension cords from sharp objects, excessive heat, and damp or wet
areas.

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
SKU 91814 PAGE 10
SYMBOLOGY
Table B
UNPACKING
When unpacking, check to make sure that all the parts are included. Refer to the Assembly
section, and the Assembly Diagrams and Parts List on pages 15 & 16.
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.
Air Plasma Cutter
Grounding Clamp/Cable (54)
220 VAC
Line Cord
Cutting Torch with Cable (53)
Carrying Strap
Air Inlet (8)