Chicago Electric 95136 Installation manual

INVERTER AIR PLASMA CUTTER
Model 95136
SET UP AND OPERATING INSTRUCTIONS
Visit our website at: http://www.harborfreight.com
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Copyright©2006 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. Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein. Tools required for
assembly and service may not be included.
For technical questions or replacement parts, please call 1-800-444-3353.
Manual Revised 10e

Page 2 For technical questions, please call 1-800-444-3353. SKU 95136
SAVE THIS MANUAL
Keep this manual for the safety warnings
and precautions, assembly, operating,
inspection, maintenance and cleaning
procedures. Write the product’s serial number
in the back of the manual near the assembly
diagram (or month and year of purchase if
product has no number). Keep this manual
and the receipt in a safe and dry place for
future reference.
IMPORTANT SAFETY
INFORMATION
In this manual, on the labeling, and
all other information provided with
this product:
This is the safety alert
symbol. It is used to alert
you to potential personal
injury hazards. Obey all
safety messages that follow
this symbol to avoid possible
injury or death.
DANGER indicates a
hazardous situation
which, if not avoided, will result
in death or serious injury.
WARNING indicates a
hazardous situation
which, if not avoided, could
result in death or serious injury.
CAUTION, used with
the safety alert
symbol, indicates a hazardous
situation which, if not avoided,
could result in minor or moderate
injury.
NOTICE is used to
address practices not
related to personal injury.
CAUTION, without the
safety alert symbol, is
used to address practices not
related to personal injury.
SAFETY WARNINGS AND
PRECAUTIONS
WARNING: When using tool, basic safety
precautions should always be followed
to reduce the risk of personal injury and
damage to equipment.
Read all instructions before using this
tool!
WARNING!
READ AND UNDERSTAND ALL
INSTRUCTIONS
Failure to follow all instructions listed
below may result in electric shock,
re, and/or serious injury.
SAVE THESE INSTRUCTIONS
Work Area Precautions
Keep your work area clean and well1.
lit. Cluttered benches and dark areas
invite accidents.
Do not operate power tools in2.
explosive atmospheres, such as in the
presence of ammable liquids, gases,
or dust. Power tools create sparks
which may ignite the dust or fumes.
Keep bystanders, children, and3.
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.

Page 3For technical questions, please call 1-800-444-3353.SKU 95136
Electrical Safety
Grounded tools must be plugged1.
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 qualied
electrician if you are in doubt whether
the outlet is properly grounded. If the
tool should electrically malfunction or
break down, grounding provides a low
resistance path to carry electricity away
from the user.
Double insulated tools are equipped2.
with a polarized plug (one blade is
wider than the other). This plug will
t in a polarized outlet only one way.
If the plug does not t fully in the
outlet, reverse the plug. If it still does
not t, contact a qualied 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.
Avoid body contact with grounded3.
surfaces such as pipes, radiators,
ranges, and refrigerators. There is an
increased risk of electric shock if your
body is grounded.
Do not expose power tools to rain or4.
wet conditions. Water entering a power
tool will increase the risk of electric
shock.
Do not abuse the Power Cord.5. Never
use the Power Cord to carry the tool
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.
When operating a power tool6.
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
Stay alert. Watch what you are1.
doing, and use common sense when
operating a power tool. Do not use
a power tool while tired or under
the inuence of drugs, alcohol, or
medication. A moment of inattention
while operating power tools may result in
serious personal injury.
Dress properly. Do not wear loose2.
clothing or jewelry. Contain long hair.
Keep your hair, clothing, and gloves
away from moving parts. Loose
clothes, jewelry, or long hair can be
caught in moving parts.
Avoid accidental starting.3. Be sure the
Power Switch is off before plugging
in. 
on the Power Switch, or plugging in
power tools with the Power Switch on,
invites accidents.
Remove adjusting keys or wrenches4.
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.
Do not overreach. Keep proper5.
footing and balance at all times.
Proper footing and balance enables
better control of the power tool in
unexpected situations.
Use safety equipment. Always wear6.
eye protection. Dust mask, non-skid
safety shoes, hard hat, or hearing

Page 4 For technical questions, please call 1-800-444-3353. SKU 95136
protection must be used for appropriate
conditions.
Tool Use and Care
Use clamps (not included) or other1.
practical ways to secure and support
the workpiece to a stable platform.
Holding the work piece by hand or
against your body is unstable and may
lead to loss of control.
Do not force the tool. Use the correct2.
tool for your application. The correct
tool will do the job better and safer at the
rate for which it is designed.
Do not use the power tool if the Power3.
Switch does not turn it on or off. Any
tool that cannot be controlled with the
Power Switch is dangerous and must be
replaced.
Disconnect the Power Cord Plug from4.
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.
Store idle tools out of reach of5.
children and other untrained persons.
Tools are dangerous in the hands of
untrained users.
Maintain tools with care. Keep cutting6.
tools maintained and clean. Properly
maintained tools are less likely to bind
and are easier to control. Do not use a
damaged tool. Tag damaged tools “Do
not use” until repaired.
Check for misalignment or binding of7.
moving parts, 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.
Use only accessories that are8.
recommended by the manufacturer
for your model. Accessories that may
be suitable for one tool may become
hazardous when used on another tool.
Service
Tool service must be performed only1.
by qualied repair personnel. Service

personnel could result in a risk of injury.
When servicing a tool, use only2.
identical replacement parts. Use of
unauthorized parts or failure to follow
maintenance instructions may create a
risk of electric shock or injury.
SPECIFIC SAFETY RULES
Maintain labels and nameplates on the1.
tool. These carry important information.
If unreadable or missing, contact Harbor
Freight Tools for a replacement.
Always wear ANSI approved safety2.
impact eye goggles and heavy work
gloves when using the tool. Using
personal safety devices reduce the risk
for injury. Safety impact eye goggles and
heavy work gloves are available from
Harbor Freight Tools.
Maintain a safe working environment.3.
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

dusts, and vapors. Do not use this
product in a damp or wet location.
Avoid unintentional starting.4. Make
sure you are prepared to begin work
before turning on the tool.

Page 5For technical questions, please call 1-800-444-3353.SKU 95136
Never leave the tool unattended when5.
it is plugged into an electrical outlet.
Turn off the tool, and unplug it from its
electrical outlet before leaving.
Always unplug the tool from its6.
electrical outlet before performing and
inspection, maintenance, or cleaning
procedures.
Prevent eye injury and burns.7. 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.

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,

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 welding/cutting overhead or in

ear plugs or ear muffs to keep sparks
out of ears.
Prevent accidental res. 8. 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

Remove or make safe all combustible
materials for a radius of 35 feet (10
meters) around the work area. Use a

all open doorways, windows, cracks,
and other openings.

resistant screens. Protect combustible


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 not possible, designate


during the cutting process and for at
least one half hour after the cutting is
completed.
Do not weld or 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

to use it.
After welding or cutting, make a
thorough examination for evidence of



weld or cut in atmospheres containing

gases, vapors, liquids, and dust.
Provide adequate ventilation in work
areas to prevent accumulation of

Do not apply heat to a container that
has held an unknown substance or a
combustible material whose contents,


Page 6 For technical questions, please call 1-800-444-3353. SKU 95136
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 Welder/Cutter. Never use
other compressed gases. Don’t exceed
maximum PSI for this product as stated

WARNING
INHALATION HAZARD:
Welding and Plasma Cutting Produce
TOXIC FUMES.
Exposure to welding or cutting exhaust
fumes 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 or
plasma cutting exhaust fumes are:

  


  

bronchitis, or pneumonia
Use natural or forced air ventilation and
wear a respirator approved by NIOSH to
protect against the fumes produced to
reduce the risk of developing the above
illnesses.
Avoid overexposure to fumes and9.
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,

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.

ventilated, or while wearing an air-
supplied respirator.
Follow OSHA guidelines for
Permissible Exposure Limits (PEL’s) for
various fumes and gases.
Follow the American Conference of
Governmental Industrial Hygienists
recommendations 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

Always keep hoses away from welding/10.
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.
Read and understand all instructions11.
and safety precautions as outlined
in the manufacturer’s manual for the
material you will weld or cut.
Proper cylinder care.12. 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

areas and clearly marked “empty.”

Page 7For technical questions, please call 1-800-444-3353.SKU 95136
Never use oil or grease on any inlet13.
connector, outlet connector, or
cylinder valves.
Use only supplied Torch on this14.
Inverter Air Plasma Cutter. Using
components from other systems may
cause personal injury and damage
components within.
This product, when used for cutting15.
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.)
People with pacemakers should consult16.
their physician(s) before using this

proximity to a heart pacemaker could
cause interference to, or failure of the
pacemaker.
USE PROPER EXTENSION CORD.17.
Make sure your extension cord is in good
condition. When using an extension cord,
be sure to use one heavy enough to
carry the current your product will draw.
An undersized cord will cause a drop in
line voltage resulting in loss of power
and overheating. A 50 foot extension
cord must be at least 12 gauge in
diameter, and an 100 foot extension cord
must be at least 10 gauge in diameter.
If in doubt, use the next heavier gauge.
The smaller the gauge number, the
heavier the cord.
This product requires a 3-prong, 24018.
V~, twist-lock plug (not included). This

electrician.
Symbology
Double Insulated
Canadian Standards Association
Underwriters Laboratories, Inc.
V~ Volts Alternating Current
AAmperes
n0xxxx/min. No Load Revolutions per Minute
(RPM)
REV 09j

Page 8 For technical questions, please call 1-800-444-3353. SKU 95136
SPECIFICATIONS
Rated Input 240 V~, 50/60 Hz, 19.2 A
Rated Duty Cycle
60% @ 40 A;
80% @ 34.6 A;
100% @ 31 A
Air Requirement 60-80 PSI @ 3.5 CFM
Power Switch Rocker Type
Weight 49.6 lb.
Cutting Current 15 - 40 Amps
Cutting Thickness ½” mild steel Maximum
Arc Striking System Pilot Arc
Unit Size 20” L x 8-1/8” W x 14-3/8” H
Duty Cycle
Duty Cycle is the equipment

of minutes within a 10 minute period that
a piece of equipment can safely operate.
This plasma cutter has a 60% duty
cycle at 40 Amps, which means that it
may be used only 6 minutes at 40 Amps
out of any 10 minute period, and must be
rested the remaining 4 minutes.
CAUTION: Failure to observe the duty cycle
limitations of this Plasma Cutter can
easily damage this equipment, and will
void the warranty.
UNPACKING
When unpacking, check to make sure the
following parts are included.
Inverter Plasma Cutter tool with
Cutting Torch with Power Cord
Ground Cable with Clamp
If any parts are missing or broken, please call
Harbor Freight Tools at the number on the cover
of this manual.
Preparing Your Work Area
You must have a sturdy work table that1.
is open below the area you are cutting.
Molten slag will be blown through the
work metal, and must be able to fall
away freely.
Your work table must allow the work2.

accidentally falling or moving.
3.


cutting process will eject molten metal

8-10 feet or more in any direction. Have

needed.

Page 9For technical questions, please call 1-800-444-3353.SKU 95136
ASSEMBLY
Attaching the Electric Plug (not supplied):
1. 
the 240 V~ power cable. CAUTION:
This operation must only be done by a

2.
and White wires are both ‘HOT’ 120 V~
conductors.
Use the plug appropriate to your 2403.

is protected with an appropriate circuit
breaker.
Grounding the Tool:
Attach a ground wire of at least 14 Ga.
thickness (not supplied) to the screw
on the lower left of the back of the tool
case. Connect the other end of the wire
to an appropriate ground, such as a steel
workbench, steel building member or
grounding electrode.
Attaching the Air Supply:
WARNING: Only use dry air as the gas in
this tool. Use of any other gas, such
as oxygen, acetylene, etc. may cause
explosion.
Handle
Air pressure
regulator knob
Air input couplingAir pressure gauge
1. A male quick release adapter is mounted
on the rear of the tool. Attach your
pressurized air supply using your female
quick release adapter. Adjust your air
supply to deliver 60-80 PSI at 3.5 CFM.
During operation, you can regulate air2.
pressure through the Plasma Cutter by
adjusting the knob located on top of the
tool.
If the tool becomes over pressurized,3.
there is a pressure relief valve on the top
of the unit.

Page 10 For technical questions, please call 1-800-444-3353. SKU 95136
CONTROLS AND INDICATORS
POWER
WORKING
1 2
3
4
5
6
7
Torch Connector Ground Connector
1. Power Switch. Up is ON, down is OFF.
Digital Amps Meter.2. Shows actual
cutting current, which will vary during
operation.
Thermal Overload Indicator Lamp.3.
This light will come on, and the device
will shut down if the tool becomes
overheated. Stop trying to use the
cutter while leaving the power switch
ON to allow the cooling fan to operate,
and the lamp will turn off automatically
when the machine cools down. Please
pay attention to the Rated Duty Cycle
discussed on page 2.
Power ON Light.4.
Power Supply Controller.5.
Mode Selector.6. Turns the air supply ON
prior to cutting.
Working Indicator Light.7. Will be on
during cutting operation.
OPERATION
Note: Before beginning, please read and
understand all the safety precautions
starting on page 2, and especially
the section “Specic Safety Rules”
starting on page 4.
Mount the metal to be cut to the metal1.
welding-cutting table. It should be
mounted so that the cutting debris falls to

Place the Air Plasma Cutter unit no2.
closer than six feet from the workpiece to
be cut.
Connect an air hose and coupling (not3.
supplied) from the air supply tank to the
Air Input Coupling at the rear of the unit.
See photo on page 9, 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

(not included) on the compressor. Do not
use an air oiler.
Connect the Torch Cable plug into the4.
twist-lock connector on the lower left unit
front. Twist to lock.
Plug in the Grounding Cable into the5.
Ground Connector on the lower right of
the unit front. Twist to lock.
Securely place the clamping end of the6.
Grounding Cable Clamp to a part of the
workpiece or metal table that is clean
of paint, oil, or dirt. Clamp as close
as possible to the workpiece without
damaging the cable during cutting.
Verify that the Power Switch is in the Off7.
(O) position, then plug the 240 V~ line
cord plug into an appropriate 240 V~
outlet.

Page 11For technical questions, please call 1-800-444-3353.SKU 95136
Turn the Power Supply Controller to the8.
desired current (15 to 40 amps).
Adjust air pressure by turning the9.
Pressure Regulator Knob on top of
the unit (see photo on page 9). Read
pressure on Pressure Gauge.
When everything is in place for cutting,10.
press the Power Switch UP to the ON
position. The green Power On Light
will illuminate, but the Torch is not yet
energized.
Orient yourself to one side of the area11.
to be cut, and move the Welding Helmet
Face Shield (not included, see page 5
item 7) over your eyes.
BE CAREFUL! PILOT PLASMA ARC12.
CAN SEVERELY INJURE. Once the
trigger is squeezed, the arc will ignite.
This unit provides a pilot arc, so the
torch does not need to contact the
workpiece before the cutting arc
ignites.
2A
1A
3A
4A
5A
6A
7A
Part Description
1A Handle
2A Trigger
3A 
4A Electrode
5A Insulating Diffuser
6A Nozzle
7A Nozzle Holder
13. (Refer to parts diagram above for Torch
Handle components.) Direct torch away
from people and ammables while you
squeeze (and hold) the Torch Handle
Trigger (2A) to energize the Torch
Electrode (4A). The air output is delayed
a few seconds to enable a proper arc to
begin.
Caution: The Torch handle is now energized.

the Torch except the workpiece to be cut.
Warning: Never look at the ignited arc
without ANSI-approved, arc shaded,
eye protection in a full face shield.
Permanent eye damage or blindness
can occur. Skin burns can occur.
Never breathe arc fumes.
14.
close to the starting point of the cut. The
Working Indicator Light will come on.
Slowly move the Torch at a slight angle15.
along the cutting line with the Torch tip
trailing.
The air causes the molten metal to fall
away from the workpiece being cut. If
proper cutting is not achieved, adjust
the Power Supply Controller to a higher


to the Off (O) position, then adjust the air
pressure at the Air Pressure Regulator.
The air will continue to come out of the
Torch Handle for a few seconds once the
trigger is released.
Note: If too much current is drawn from the
Plasma Cutter (i.e., short circuit), the
Thermal Switch, an overload protector,
will activate and the red Thermal
Overload Indicator Light will light. The
Plasma Cutter will turn off until it cools
down. To reset you must turn the power
OFF then back ON. Press the Trigger to
begin cutting again.
When nished cutting:16.
Release the Torch handle trigger and lifta.
the Torch handle from the workpiece,
Press the Power Switch to the Off (O)b.
position,

Page 12 For technical questions, please call 1-800-444-3353. SKU 95136
Set the Torch handle down on the metalc.
workbench,
Turn the air supply off,d.
Unplug the line cord from the electricale.
outlet.
Plasma Cutting Technique
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.
You can cut any metal that will conduct1.
electricity up to approximately ½” thick
mild steel or equivalent. Very thin or

cleanly.
Generally set the air pressure between2.
60 and 80 psi. Increased air pressure
will increase plasma speed and cutting
pressure. Air pressure and amperage
should be adjusted in tandem.
Generally start with a mid-range3.
amperage setting (32-33 amps) and
adjust up or down from there. Increased
amperage will increase cutting heat.
This is needed with heavier and harder
metals. However, increased amperage
will reduce Duty Cycle time. (See page
2.)
Move the cutting head more slowly for4.
thicker and harder metals, and more
quickly for thin or soft metals. Keep the
cutting head moving while cutting.How
Plasma Cutters Work
Plasma cutters work by feeding an inert
gas (air) through an electric arc. The air is
then heated to an extremely high temperature
which converts the gas to plasma which cuts
the metal.
High temperature and pressure are
required to create a plasma. The electric arc
provides the temperature, and by exhausting

pressure is increased far beyond the 60-80
PSI operating pressure of the air supply.
What is Plasma?
Materials in Nature exist in one of four
different states: Solid, Liquid, Gas or Plasma.
Plasma is very rare on Earth because of its
very high temperature, however most of the
matter in the universe is plasma. The Sun,
stars and galaxies are made of plasma. On


lights contain low-temperature plasma when
lighted.
The difference between water ice, liquid
water and water vapor is temperature. In
each of these states, temperature energy
pushes the molecules of water away from
each other to change the state the water is
in. At very high temperature and pressure
the water molecules themselves break apart,
and the atoms begin to ionize. Normal atoms
are made up of protons and neutrons in the
nucleus, surrounded by a cloud of electrons.
In plasma, the electrons separate from
the nucleus. The electrons are negatively
charged, and they leave behind their
positively charged nuclei which are known as
ions. When the fast-moving electrons collide
with other electrons and ions, they release
vast amounts of energy. This energy is what
gives plasma its unusual status and great
cutting power.
How do Plasma Cutters Work?
Plasma cutters work by sending a
pressurized gas through a small channel.
In the center of this channel, there is a
negatively charged electrode. When power
is supplied to the negative electrode, and
REV 10e

Page 13For technical questions, please call 1-800-444-3353.SKU 95136
the tip of the nozzle contacts the work metal,
the connection creates a circuit. When the
nozzle is lifted away, the arc will continue. As
the inert gas passes through the channel, the
arc heats the gas until it becomes ionized.
This reaction creates a stream of directed
plasma, approximately 30,000° F (16,649° C)
and moving at approximately 20,000 feet per
second (6,096 m/sec), that reduces metal to
molten slag.
The plasma itself conducts electrical
current. The cycle of creating the arc is
continuous as long as power is supplied to the
electrode and the plasma stays in contact with
the metal that is being cut. In order to ensure
this contact, protect the cut from oxidation,
and regulate the unpredictable nature of
plasma, the cutter nozzle has a second set of
channels. These channels release a constant


controls the radius of the plasma beam.
Maintenance
WARNING! 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.
1. inspect the general
condition of the Air Plasma Cutter.
Check for loose cable connections,
misalignment or binding of the fan,
cracked or broken parts, damaged
electrical wiring, and any other condition
that may affect its safe operation. If
abnormal noise or vibration occurs, have
the problem corrected before further use.
Do not use damaged equipment.
Periodically recheck all nuts, bolts, and2.
screws for tightness.
Periodically blow the dust from the3.
cooling vents with compressed air.
Verify that the cooling fan is operational4.
before cutting.
If the unit repeatedly shuts down from5.
thermal overload, stop all use. Have the
Air Plasma Cutter inspected and repaired

Store the welder and accessories in a6.
clean and dry location.
Periodically disassemble and clean7.
the Torch Head components with steel
wool. Replace burnt, cracked, distorted,
or coated components. Refer to the
assembly drawing on page 16.
To gain access to the internal8.
components of the unit, remove screws

strongly advised not to remove the tool
covers and not to attempt any electronic
repairs. Any repairs must be completed

the tool will void any warranties, and
may result in damage to equipment or
possible personal injury. Don’t do it.
On a daily basis check for any of the9.
following problems: if any are found, take

Abnormal vibration, sound or smell.a.
Abnormal heating at any cableb.
connection.
The fan does not work properly.c.
Any switch or control does not workd.
properly.
Any damage to cables.e.
REV 10e

Page 14 For technical questions, please call 1-800-444-3353. SKU 95136
PARTS LIST
Part Description Q’ty
1 Handle 1
2 1
3 1
4 Control Transformer 1
5 1
6 Chassis 1
7 1
8 Transformer 1
9 Reactor 1
10 Radiator 4
11  1
12  1
13 Metal Resistor 2
14  1
15 Working Indicator 1
16 Mode Selector 1
17 Overheat Indicator 1
18 Power Supply Controller 1
19 Power Indicator 1
Part Description Q’ty
20 Torch Cable Connector 1
21 Coil 1
22 Ground Cable Connector 1
23 Lower Cover 1
24 Cement Resistor 3
25  1
26  1
27 Air Pressure Relief Valve 1
28 Air Pressure Gauge 1
29 Fan 1
30 Fan Grill 1
31 Splitter 1
32 Air Supply Solenoid 1
33 Insulated Foot 4
34  1
35 Power Cord 1
36 Digital Display 1
37 Reactor 1
PLEASE READ THE FOLLOWING CAREFULLY



              
           
          

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.
REV 10e

Page 15For technical questions, please call 1-800-444-3353.SKU 95136
ASSEMBLY DIAGRAM
NOTE: Some parts are listed and shown for illustration purposes only and are not available
individually as replacement parts.
REV 10e

Page 16 For technical questions, please call 1-800-444-3353. SKU 95136
WIRING DIAGRAM
REV 10e
P1
32A/ 50 0V
FAN1
QA17050HA2BL/230V
BD1
MDQ1 00 -1 6
11 31 32 30 11 34 35
11 28
28
11
10
12
11
11 22 20 24 11 25
13
14
15
16
17
11
27
19
51 52
Iout 11 22v
11 31 32 30 11 34 35
11 28
28
11
10
12
11
11 22 20 24 11 25
13
14
15
16
17
11
27
19
51 52
Iout 11 22v
FHP0 6060 506-3
ZT1
BK1
t
TH1
LED1 YL/D5
LED3 RED/D5
15V
22V
22V
11 31 32 11 30
37 36 40 43 42 39 41 38
11 31 32 11 30
37 36 40 43 42 39 41 38
FHP0 6650 604-1
CN4 CN3
DC-
37 36
DC+
41 40 43 42 39 38
CN4 CN3
DC-
37 36
DC+
41 40 43 42 39 38
FHP0 6640604-1
CT1
t
TH2
S1
32A/ 50 0V
230V-AC INPUT
11 20
FHP06070509
CN3
CN4
CN5-1
CN1CN2
CN5-2
104/28 0V
104/630V
100k/3 w
5K/2W
1130
DF1
24V/DC
S4
S4
FHP06320608-3
C N5 -4
C N2 -1 C N2 -2
CN6-2
CN6-3
C N5 -1
C N1 -1
C N1 -3 C N4 -1
C N4 -3
C N4 -4 C N4 -5
C N9 -1
C N9 -2
S1 S2
CN8-2 CN8-3 CN8-1
14
FH P0 606050 6-3
LED2 RED/D5
CN4-1
CN4-2
CN2-3CN7-2
CN2-1
CN2-6
CN3-1
CN3-2
CN1-1 CN1-2
BK1
FHP06930703-2
22V
CN7-3CN2-5

Page 17For technical questions, please call 1-800-444-3353.SKU 95136
WIRING DIAGRAM (CONTINUED)
REV 07i, 10e
C4
103/3KV
C3
103/3KV
C5
103/3KV
ZK1
12
FL1
50A/ 75 MV
400R/60W
LGK-40-cpu
L1
10 ×20
1KV/20D
10R/50 W
10R/50 W
1KV/20D
2*102/2KV
2*102/2KV
R1
400R/60W
1KV/20D
DA2F75P1 2SA
+
_
L=2mH
S2
AC
11
IN
+5VDC
GND
IN
PCB6
FHP0 6110 508
AC
11
IN
+5VDC
GND
IN
+5VDC
GND
IN
PCB7
LED
+5VDC
GND
IN
R2
L2
L3

Page 18 For technical questions, please call 1-800-444-3353. SKU 95136
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.
TROUBLESHOOTING
The Air pressure may be too high or too
low. Check the Air Pressure setting on
the regulator’s gauge.
Adjust the Air Regulator to
deliver only 60-80 PSI to
the Cutter.
FAN RUNS WHEN SWITCHED ON BUT ARC WILL NOT IGNITE
AIR PRESSURE
TOO HIGH
AIR PRESSURE
TOO LOW
a. Verify that the compres-
sor is delivering at least
3.5 CFM @ 60 PSI to the
tool.
b. The Regulator on the
unit must be set to at
least 60 PSI.
Make sure that all air and
electrical connections are
tight.
Shut off switch, if not off already, and
tighten connections.
If connections do not tighten properly,
contact a qualied technician.
LOOSE
CONNECTIONS
Disconnect the Torch Cables.
Disassemble the torch assembly and in-
spect all internal components.
Replace any damaged or missing compo-
nents and reassemble carefully, following
the directions on page 9.
TIGHT
CONNECTIONS
AIR PRESSURE
CORRECT
If the steps above do not solve the problem or if the repairs involved are
too complex, contact a qualied technician.
REV 07h

Page 19For technical questions, please call 1-800-444-3353.SKU 95136
If the steps above do not solve the problem or if the repairs involved are too
complex, contact a qualied technician.
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.
TROUBLESHOOTING (CONTINUED)
Check that the grounding
point and the metal being
cut are both clean, dry,
and free from all coatings
and paint. These sections
need to be able to conduct
electricity efciently.
The Air pressure may be too high or too
low. Check the Air Pressure setting on
the regulator’s gauge.
Adjust the Air Regulator to
deliver only 60-80 PSI to
the Cutter.
ARC IGNITES FOR SEVERAL SECONDS BUT THEN GOES OUT
AIR PRESSURE
TOO HIGH
AIR PRESSURE
TOO LOW
a. Verify that the compres-
sor is delivering at least
3.5 CFM @ 80 PSI to the
tool.
b. The Regulator on the
unit must be set to at
least 60 PSI.
Use a wire wheel brush or sander (not
included) to thoroughly clean both the
grounding point and the area that will be
cut. If any cleaners are used, allow them
to dry thoroughly before continuing.
DIRTY OR COATED
METAL
Make sure that all air and electrical con-
nections are tight.
METAL IS CLEAN IN
BOTH AREAS
Shut off switch, if not off
already, and tighten con-
nections.
If connections do not
tighten properly, contact
a qualied technician.
LOOSE
CONNECTIONS
Torch isn’t maintaining contact with the workpiece.
a. Make certain that you don’t lose workpiece contact after
an arc is struck.
b. Make sure that the Torch can function correctly.
Disconnect the Torch Cables.
Disassemble the torch assembly and inspect all internal
components.
Replace any damaged or missing components and reas-
semble carefully, following the steps on page 9.
DO NOT OVERTIGHTEN.
c. Nozzle is moving too slowly across the metal and cutting
the material from underneath, breaking contact.
AIR PRESSURE
CORRECT
TIGHT
CONNECTIONS
REV 07h

Page 20 For technical questions, please call 1-800-444-3353. SKU 95136
If the steps above do not solve the problem or if the repairs involved are too
complex, contact a qualied technician.
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.
TROUBLESHOOTING (CONTINUED)
You may wish to take note
of the setting required for
this metal thickness.
CUT GOES ONLY PARTIALLY THROUGH THE WORKPIECE
The Air pressure may be too low.
Check the Air Pressure setting on the
regulator’s gauge.
Turn up the current adjustment knob and
try again.
Material being cut is too thick. Maximum
thickness for steel is 1/2”.
You may wish to cut the
object along one side and
then cut along the other.
If this is not practical, use
a more powerful Cutter.
WITHIN THICKNESS
RANGE
MATERIAL
TOO THICK
a. Verify that the compres-
sor is delivering at least
3.5 CFM @ 80 PSI to the
tool.
b. The Regulator on the
unit must be set to at
least 60 PSI.
AIR PRESSURE
CORRECT
AIR PRESSURE
TOO LOW
PROBLEM
CORRECTED
PROBLEM PERSISTS AT
MAXIMUM SETTING
Disconnect the Torch Cables.
Disassemble the torch assembly and
inspect all internal components, as ex-
plained on page 11.
Replace any damaged or missing compo-
nents and reassemble carefully, following
the directions on pages 9-11.
TORCH IN GOOD
CONDITION
DAMAGED
COMPONENTS FOUND
Try cutting at a slower pace, the arc may
not have enough time to cut through the
workpiece.
REV 07h