Toolex 597078 User manual

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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.
IMPROTANT 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: WARNING indicates a
hazardous situation which, if not
avoided, could result in death or
serious injury.
CAUTION: CAUTION, used with
the safety alert symbol, indicates a
hazardous situation which, if not
avoided, could result in minor or
moderate injury.
NOTICE:NOTICE 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!
Work Area Precautions
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 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.
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

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Electrical Safety
1. 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 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.
2. 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.
3. 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.
4. Do not expose power tools to rain
or wet conditions. Water entering a
power tool will increase the risk of
electric shock.
5. Do not abuse the Power Cord.
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.
6. When operating a power tool
outside, sue an outdoor extension
cord marker “W-A” or “W”. These
extension cords are rated for outdoor
use, and reduce the risk of electric
shock.
Personal Safety
1. 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.
2. Dress properly. Do not wear loose
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.
3. Avoid accidental staring. 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.
4. 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.
5. 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.
6. Use safety equipment. Always wear
eye protection. Dust mask, non-skid

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safety shoes, hard hat, or hearing
protection must be used for
appropriate conditions.
Tool Use and Care
1. Use clamps (not included) or other
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.
2. 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.
3. 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.
4. 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.
5. Store idle tools out of reach of
children and other untrained
persons. Tools are dangerous in the
hands of untrained users.
6. Maintain tools with care. Keep
cutting 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
7. Check for misalignment or binding
of 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.
8. 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
1. Tool service must be performed only
by qualified repair personnel. Service
or maintenance performed by
unqualified personnel could result in a
risk of injury.
2. When servicing a tool, use only
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
1. Maintain labels and nameplates on
the tool. These carry important
information. If unreadable or missing,
contact TOOLEX INDUSTRIAL for a
replacement.
2. Always wear the approved safety
impact eye goggles and heavy work
gloves when suing 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.
3. 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

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damp or wet location.
4. Avoid unintentional starting. Make
sure you are prepared to begin work
before turning on the tool.
5. Never leave the tool unattended
when it is plugged into an electrical
outlet. Turn off the tool, and unplug it
from its electrical outlet before leaving.
6. Always unplug the tool from its
electrical outlet before performing
and inspection, maintenance, or
cleaning procedures.
7. Prevent eye injury and burns.
Wearing and using the approved
personal safety clothing and safety
devices reduce the risk for injury.
a. Wear the approved safety impact
eye goggles with a welding helmet
featuring at least a number 10
shade lens rating.
b. 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.
c. Keep clothing free of grease, oil,
solvents, or any flammable
substances. Wear dry, insulating
gloves and protective clothing.
d. 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.
e. When welding/cutting overhead or
in confined spaces, wear flame
resistant ear plugs or ear muffs to
keep sparks out of ears.
8. Prevent accidental fires. Remove
any combustible material from the
work area.
a. When possible, move the work to
a location well away from
combustible; protect the
combustibles with a cover made of
fire resistant material.
b. 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.
c. Enclose the work area with
portable fire resistant screens.
Protect combustible walls, ceilings,
floors, etc., from sparks and heat
with fire resistant covers.
d. If working on a metal wall, ceiling,
etc., prevent ignition of
combustibles on the other side by
mobbing the combustibles to a
safe location. If relocation of
combustibles is not possible,
designate someone to serve as a
fire watch, equipped with a fire
extinguisher, during the cutting or
welding process and for at least
one half hour after the cutting or
welding is completed.
e. 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.
f. Do not dispose of hot slag in
containers holding combustible
materials. Keep a fire extinguisher
nearby and know how to use it.
g. After welding or 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

6
has started. Do not weld or cut in atmospheres containing
h. Dangerously reactive or
flammable gases, vapors, liquids,
and dust.
i. Provide adequate ventilation in
work areas to prevent
accumulation 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.
j. Only use compressed air to
operate the Plasma Welder/Cutter.
Never use other compressed
gases.
9. 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.
!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 the
specific welding or cutting
situation.
10. Always keep hoses away from
welding/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.
11. Read and understand all
instructions and safety precautions
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:
a. Early onset of Parkinson’s Disease
b. Heart disease
c. Ulcers
d. Damage to the reproductive organs
e. Inflammation of the small intestine or stomach
f. Kidney damage
g. Respiratory diseases such as emphysema,
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.

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as outlined in the manufacturer’s
Manual for the material you will
weld or cut. 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.
13. Use only supplied Torch on this
Inverter Air Plasma Cutter. Using
components from other systems may
cause personal injury and damage
components within.
14. People with pacemakers should
consult their physician(s) before using
this product. Electromagnetic fields in
close proximity to a heart pacemaker
could cause interference to, or failure
of the pacemaker.
15. USE PROPER EXTENSION
CORD.
Make sure your extension cord is in
good condition. When using an
extension cord, be sure to sue 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 gauges in diameter,
and a 100 foot extension cord must be
at least 10 gauges in diameter. If in
doubt, use the next heavier gauge.
The smaller the gauge number, the
heavier the cord.

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Nameplate and Serial Number/Rating Label
Model
Rated input
voltage(V）
Rated
input
current(A)
Rated
input
power
(KVA)
Rated
output
voltage(V)
Cutting
current
(A)
Rated
duty
cycle (%)
No-load
voltage
(V)
Cutting
thickness
(mm)
Dimension
(mm)
Weight
(kg)
ECO CUT
20
1ph ~
115V±15%
(50/60HZ)
19.8
1.7
100V
20
60%/20A
300
≦10mm(Steel
plate)
≦6mm
（Aluminum)
450x145x225
12.5
ECO CUT
20
1ph ~
220V±15%
(50/60HZ)
12
2.1
100V
20
60%/20A
300
≦10mm(Steel
plate)
≦6mm
（Aluminum)
430*155*300
12.5
Preparing Your Work Area
A
Amperes
Plasma Arc Cutting
( PAC)
Adjust Air/Gas
Pressure
Low Air Pressure
Light
V
Volts
Increase
No - Do Not Do This
^ Temperature
Protective Earth
(Ground)
Single Phase
Constant Current
-®
Voltage Input
On
〇
Off
Percent
Rated No Load
Voltage (Average)
U1
Primary Voltage
Conventional Load
Voltage
Line Connection
Rated Maximum
Supply Current
Rated Welding
Current
Duty Cycle
Single Phase Static
Frequency
Transformer-
Rectifier-Converter
Degree Of
Protection
Loose Shield Cup
Input
Hz
Hertz
Maximum Effective
Supply Current
power factor
Suitable for Some
Hazardous
Locations
S1
Power Rating,
Product Of Voltage
And Current (KVA)
Duty Cycle is the equipment specifications which defines the number of minutes within a 10 minute period
that a piece of equipment can safely operate.
This plasma cutter 20 has a 60% duty cycle at 20 Amps, which means that it may be used only 6
minutes at 20 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 warranty.

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1. You must have a sturdy work table
that 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
2. Your work table must allow the work
metal to be firmly clamped to prevent it
accidentally falling or moving.
3. The floor and surrounding area of your
work site must not be flammable. A
clean cement floor is recommended.
The cutting process will eject molten
metal slag onto the floor, and it will
scatter for 8-10 feet or more in any
direction. Have an adequate fire
extinguisher available if needed.
ASSEMBLY
Grounding the tool:
Attach a ground wire of at least 14 Ga.
thicknesses (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 biding member or
grounding electrode.
CONTROLS AND INCICAROURS
1. Power Switch. Up is ON, down is
OFF.
2. Thermal Overload Indicator
Lamp. 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 onto 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 8.
3. Power supply indicator.
4. Abnormal indicator
5. Air pressure gauge: It indicates
the air pressure of the machine.
6. Plasma cutting torch
7. Grounding cable
8. Air pressure regulator knob: For
adjusting the air pressure of the
machine.
OPERATION
Note: Before beginning, please read
and understand all the safety
precautions staring on page 2 and
3
1
2
5
4

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especially the section “Specific Safety
Rules” starting on page 3.
1. Mount the metal to be cut to the metal
weeding-cutting table. It should be
mounted so that the cutting debris falls
to the cement floor.
2. Place the Air Plasma Cutter unit no
closer than six feet from the
workpicece to be cut.
3. Securely place the clamping end of
the 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.
4. Verify that the Power Switch is in the
Off (O) position, then plug the
120V~line cord plug into an
appropriate 120V~outlet.
5. When everything is in place for cutting,
press the Power Switch UP to the ON
position. The Power Light” WILL
illuminate, but the Torch is not yet
energized.
6. Orient yourself to one side of the area
to be cut, and move the Welding
Helmet Face Shield (not included,)
over your eyes.
7. BE CAREFUL! PILOT PLASMA ARC
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 work piece before the
cutting arc ignites.
8. (Refer to parts diagram above for
Torch Handle components.)Direct
torch away from people and
flammables 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. Be careful not touch anything
else with the Torch except the work piece
to be cut.
Warning: Never look at the ignited arc
without the approved, arc shaded, eye
protection in a full face shield. Permanent
eye damage or blindness can occur, also
Skin burns can occur. Never breathe arc
fumes.
The pilot arc starts immediately
when trigger is pressed.

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"丨\\
Pause briefly at
end of cut before
releasing trigger.
//l\\
Adjust speed so
sparks go thru metal
and out bottom of cut.
"丨\\
Pause briefly at
end of cut before
releasing trigger.
//l\\
Adjust speed so
sparks go thru metal
and out bottom of cut.
Maintain approximately a 90° angle to the
work piece
If sparks flare back from surface,
this usually is an indication that
travel speed is too fast.
Pulling rather than pushing the
torch makes cutting easier. Use a
proper guide or template for
accurate cutting operations.
DO NOT put pressure on shield
when drag cutting; instead, slide
shield along the surface for
proper cutting results.
Sparks should pass through
the work piece surface for
proper cutting results. and out the bottom when cutting
Move torch to upright
position 90° to surface.
Start cutting when arc
pierces work piece.
Maintain torch position
and continue cutting.
Release trigger. Post flow cooling
Continues after releasing trigger
Post flow must finish before
Trigger will restart pilot
arc.
Place tip near work.
Keep tip 1/16 in.
From work
For max cutting
Speed and tip
life.
Torch air cooling (post flow) continues after
releasing trigger.
Post flow must finish before trigger will
restart pilot arc.
"丨\\
Pause briefly
at end of cut
before
releasing
trigger.
//l\\
Adjust speed so sparks go thru
metal and out bottom of cut.

12
9. Bring the Electrode (4A) of the Torch close to the starting point of the cut. The
Working Indicator Light will come on.
10. Slowly move the Torch at a slight angle along the cutting line with the Torch tip trailing.
The air causes the molten metal to fall away from the work piece being cut. If proper
cutting is not achieved, adjust the Power Supply Controller to a higher level, and/or
increase air flow. To increase air flow, press the Power Switch to the Off (O) position,
then adjust the air pressure at the Air Pressure Regulator. The air will continue 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
Switchman 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.
11. When finished cutting:
a. Release the Torch handle trigger and lift the Torch handle from the work piece,
b. Press the Power Switch to the Off (O) position.
c. Set the Torch handle down on the metal workbench,
d. Turn the air supply off,
e. Unplug the line cord from the electrical 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.
1. You can cut metal that will conduct electricity up to approximately 1/2” thick mild steel
or equivalent. Very thin or very thick metals are more difficult to cut cleanly.
2. Generally set the air pressure between 60 and 80 psi. Increased air pressure will
increase plasma speed and cutting pressure. Air pressure and amperage should be
adjusted in tandem.
3. Generally start with a mid-range 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 8.)
4. Move the cutting head more slowly for thicker and harder metals, and more quickly for
thin or soft metals. Keep the cutting head moving while cutting.
How do 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 the air through a very small orifice, the
pressure is increased far beyond the 60-80 PSI operating pressure of the air supply.

13
Bring the Electrode (4A) of the Torch close to the starting point of the cut. The Working
Indicator Light will come on.
12. Slowly move the Torch at a slight angle along the cutting line with the Torch tip trailing.
The air causes the molten metal to fall away from the work piece being cut. If proper
cutting is not achieved, adjust the Power Supply Controller to a higher level, and/or
increase air flow. To increase air flow, press the Power Switch to the Off (O) position,
then adjust the air pressure at the Air Pressure Regulator. The air will continue 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
Switchman 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.
13. When finished cutting:
a. Release the Torch handle trigger and lift the Torch handle from the work piece,
b. Press the Power Switch to the Off (O) position.
c. Set the Torch handle down on the metal workbench,
d. Turn the air supply off,
e. Unplug the line cord from the electrical 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.
5. You can cut metal that will conduct electricity up to approximately 1/2” thick mild steel
or equivalent. Very thin or very thick metals are more difficult to cut cleanly.
6. Generally set the air pressure between 60 and 80 psi. Increased air pressure will
increase plasma speed and cutting pressure. Air pressure and amperage should be
adjusted in tandem.
7. Output cutting current :13A
8. Move the cutting head more slowly for thicker and harder metals, and more quickly for
thin or soft metals. Keep the cutting head moving while cutting.
How do 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 the air through a very small orifice, the
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

14
matter in the universe is plasma. The Sun, stars and galaxies are made of plasma. On
Earth, you will find plasma in lightening and a few other places. Neon tubes and florescent
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 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 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°(16,649) 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 flow of shielding gas around
the cutting area. The pressure of this gas flow effectively 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. Before each use, 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.
2. Periodically recheck all nuts, bolts, and screws for tightness.
3. Periodically blow the dust from the cooling vents with compressed air.
4. Verify that the cooling fan is operational before cutting.

15
5. If the unit repeatedly shuts down from thermal overload, stop all use. Have the Air
Plasma Cutter inspected and repaired by a qualified service technician.
6. Store the welder and accessories in a clean and dry location.
7. Periodically disassemble and clean the Torch Head components with steel wool.
Replace burnt, cracked, distorted, or coated components, Refer to the assembly
drawing on page 11.
8. To gain access to the internal components of the unit, remove screws from Main Body
Cover. The home user is strongly advised not to remove the tool covers and not to
attempt any electronic repairs. Any repairs must be completed by a qualified
technician. Opening the tool will void any warranties, and may result in damage to
equipment or possible personal injury. Don’t do it.
9. On a daily basis check for any of the following problems: If any are found, take the tool
to a qualified repair technician.
a. Abnormal vibration, sound or smell.
b. Abnormal heating at any cable connection.
c. Then fan does not work properly.
d. Any switch or control does not work properly.
e. Any damage to cables.

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ASSEMBLY STRUCTURE

17
PARTS LIST
1
205012929
middle septum
LGK-20 no air pump/use for Italy
customer/black 825
PCS
1
2
202000371
LGK-16 main
control board
FHP06910612-5
PCS
1
3
301008322
header with
frame
4-40
PCS
1
4
303022001
indicating lamp
5R4HD（red）/long feet 20mm
PCS
1
4
303022002
indicating lamp
5R4HD（green）/long feet 20mm
PCS
1
4
303022003
indicating lamp
5R4HD（yellow ）/long feet 20mm
PCS
1
5
303017131
R5 series the
ship switches
R515KKFTOFH
PCS
1
6
301009137
filter
AR2000
PCS
1
7
305006027
king protection
PG cable card
PG-21（black）
PCS
1
8
2050131586
base
EASY CUT 40E1 no air
pump/slop/black825/1-240V/MAX-3
PCS
1
9
305007016
spray head
6＃
PCS
4
10
202000372
LGK-16 timing
board
FHP06990901-1
PCS
1
11
301009140
solenoid valve
G1/8〃internal crest（mid）
ZCT-3/AC240V/English version
PCS
1
12
301008315
PL speed plug
6-02
PCS
1
13
303023055
fan
G12038HA2BL（120*120）
/AC240V/install M5 thread fixed
orifice(with fan net)/power cable and
VH terminal
PCS
1
14
301008263
copper speed
plug
G1/4″air intake LGK-40I/use in
non-USA machine
PCS
1
14
301008186
internal and
external tooth
joint
2″shift 1″LGK-40I（G1/4″*1/8″）
PCS
1
15
305006028
king protection
PG cable card
PG-13.5（black）
PCS
1

18
Wiring Diagram

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TROUBULESHOOTING (CONTINUED)
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.
CUT GOES ONLY PARTIALLY THROUGH THE WORKPIECE
Material being cut is too thick. Maximum thickness for steel is
10MM.
WITHIN THICKNESS RANGE
Turn up the current adjustment knob
and try again.
MATERIAL TOO THICK
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.
PROBLEM CORRECTED
You may wish to take note of the
setting required for this metal
thickness
PROBLEM PERSISTS AT MAXIMUM
SETTING
The Air pressure may be too low. Check
the Air Pressure setting on the regulator’s
gauge.
AIR PRESSURE CORRECT
Disassemble the torch assembly and
inspect all internal components, as
explained on page 11.
AIR PRESSURE TOO LOW
a. Verify that the compressor 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.
TORCH IN GOOD CONDITION
Try cutting at a slower pace, the arc
may not have enough time to cut
through the work piece.
DAMAGED COMPONENTS FOUND
Replace any damaged or missing
components and reassemble carefully,

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