Harbor Freight Tools 95136 User Manual
Table of Contents
Safety ......................................................... 2
Setup .......................................................... 5
SAFETY SERVICEOPERATION TECHNIQUESSETUP
Specications ............................................. 5
Operation ................................................... 10
Techniques ................................................ 12
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Maintenance .............................................. 13
Troubleshooting ......................................... 14
Parts List and Diagrams ............................ 18
Warranty .................................................... 22
WARNING SYMBOLS AND DEFINITIONS
Obey all safety messages that follow this symbol to avoid possible injury or death.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Addresses practices not related to personal injury.
IMPORTANT SAFETY INSTRUCTIONS
General Tool Safety Warnings
Read all safety warnings and instructions.
Failure to follow the warnings and instructions may result in electric shock, re and/or serious injury.
Save all warnings and instructions for future reference.
1. Maintain labels and nameplates on the tool.
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.
Keep the work area free of obstructions, grease,
oil, trash, and other debris. Do not use in areas
near ammable chemicals, dusts, and vapors.
Do not use in a damp or wet location.
3. Avoid unintentional starting. Make sure
switch is in off position before plugging in.
Make sure you are prepared to begin
work before turning on the tool.
4. 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. Unplug the tool from
its electrical outlet before performing
any inspection, maintenance, or cleaning
procedures, including changing accessories.
5. Prevent eye injury and burns. Wearing personal
protective equipment reduces the risk for injury.
• Wear an ANSI-approved welding helmet featuring
at least a number 10 shade lens rating.
• Leather leggings, re 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 ammable substances. Wear dry,
insulating gloves and protective clothing.
Page 2 For technical questions, please call 1-800-444-3353. SKU 95136
General Tool Safety Warnings (cont.)
• 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 conned
spaces, wear ame resistant ear plugs or
ear muffs to keep sparks out of ears.
8. Prevent accidental res. 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 re resistant material.
• Remove or make safe all combustible
materials for a radius of 35 feet (10 meters)
around the work area. Use a re resistant
material to cover or block all open doorways,
windows, cracks, and other openings.
• Enclose the work area with portable re
resistant screens. Protect combustible
walls, ceilings, oors, etc., from sparks
and heat with re 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 not
possible, designate someone to serve as a
re watch, equipped with a re extinguisher,
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 re
extinguisher nearby and know how to use it.
• After welding or cutting, make a thorough
examination for evidence of re. Be aware
that easily visible smoke or ame may not
be present for some time after the re has
started. Do not weld or cut in atmospheres
containing dangerously reactive or ammable
gases, vapors, liquids, and dust.
• Provide adequate ventilation in work areas
to prevent accumulation of ammable 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 ammable 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
on the specication table on page 6.
9. INHALATION HAZARD:
Welding and 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 cutting exhaust fumes are:
• Early onset of Parkinson’s Disease
• Heart disease • Ulcers
• Damage to the reproductive organs
• Inammation of the small intestine or
stomach • Kidney damage
• 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.
10. 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
qualied 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 conned 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
specic welding or cutting situation.
11. Keep hoses away from welding/cutting area.
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.
SAFETYSERVICE OPERATIONTECHNIQUES SETUP
Page 3For technical questions, please call 1-800-444-3353.SKU 95136
General Tool Safety Warnings (cont.)
12. Proper cylinder care. Secure cylinders to a
cart, wall, or post, to prevent them from falling.
SAFETY SERVICEOPERATION TECHNIQUESSETUP
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 specied areas and clearly marked “empty.”
13. Never use oil or grease on any inlet connector,
outlet connector, or cylinder valves.
14. Use only supplied Torch on this Inverter
Air Plasma Cutter. Using components
from other systems may cause personal
injury and damage components within.
15. This product, when used for cutting 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.)
16. People with pacemakers should consult
their physician(s) before using this product.
Electromagnetic elds in close proximity to
a heart pacemaker could cause interference
to, or failure of the pacemaker.
17. USE PROPER EXTENSION CORD. 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.
18. This product requires a 3-prong, 240 V~,
twist-lock plug (not included). This plug must
be installed by a qualied electrician.
19. KEEP CHILDREN AWAY. All visitors should
be kept safe distance from work area.
20. MAKE WORKSHOP KID PROOF with padlocks,
master switches, or by removing starter keys.
21. USE RIGHT TOOL. Don’t force tool or attachment
to do a job for which it was not designed.
22. SECURE WORK. Use clamps or a vise to
hold work. It’s safer than using your hand
and it frees both hands to operate tool.
23. MAINTAIN TOOLS WITH CARE.
Keep tools clean for best and safest performance.
Follow instructions for changing accessories.
Symbology
24. Inspect before every use;
do not use if parts loose or damaged.
Double Insulated
Canadian Standards Association
Underwriters Laboratories, Inc.
V~
A
n0 xxxx/min. No Load Revolutions per Minute (RPM)
Volts Alternating Current
Amperes
Page 4 For technical questions, please call 1-800-444-3353. SKU 95136
Specications
Rated Input 240V~, 50/60Hz, 19.2A
60%
@
40 A
Rated Duty Cycle
Air Requirements 3.5 CFM @ 60-80 PSI
Power Switch Rocker Type
Weight 49.6 lb.
Cutting Current 15-40 A
Cutting Thickness 1/2″ Mild Steel Maximum
Arc Striking System Pilot Arc
Unit Size 20″ L x 8-1/8″ W x 14-3/8″ H
Air Inlet 1/4″ - 18 NPT
Duty Cycle
Duty Cycle is the equipment specication which denes the number 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.
80%
100%
@
@
34.6 A
31 A
SAFETYSERVICE OPERATIONTECHNIQUES SETUP
CAUTION: Failure to observe the duty cycle limitations of this Plasma Cutter
can easily damage this equipment, and will void the warranty.
Page 5For technical questions, please call 1-800-444-3353.SKU 95136
Setup
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this
SAFETY SERVICEOPERATION TECHNIQUESSETUP
Note: For additional information regarding the parts listed in the following pages,
refer to the Assembly Diagram near the end of this manual.
Note: This air tool may be shipped with a protective plug covering the air inlet. Remove this plug before set up.
manual including all text under subheadings therein before set up or use of this product.
Grounding
1. 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.
2. Connect the other end of the wire to an
appropriate ground, such as a steel workbench,
steel building member or grounding stake.
Page 6 For technical questions, please call 1-800-444-3353. SKU 95136
Air Supply
TO PREVENT SERIOUS INJURY FROM EXPLOSION:
Use only clean, dry, regulated, compressed air with this tool.
Do not use oxygen, acetylene, carbon dioxide, combustible gases,
or any other bottled gas as a power source for this tool.
1. Incorporate a lter, regulator with pressure gauge,
dryer, in-line shutoff valve, and quick coupler for
best service, as shown on Figure A on page 8
and Figure B on page 9. An in-line shutoff
ball valve is an important safety device because
it controls the air supply even if the air hose
is ruptured. The shutoff valve should be a
ball valve because it can be closed quickly.
Note: An oiler system should not be used with
this tool. The oil will mix with the material
being propelled, causing poor results.
2. Attach an air hose to the compressor’s air outlet.
Connect the air hose to the air inlet on the back
of the Plasma Cutter. Other components, such
as a coupler plug and quick coupler, will make
operation more efcient, but are not required.
Handle
Air pressure
regulator knob
Note: Air ow, and therefore tool performance, can
be hindered by undersized air supply components.
The air hose must be long enough to reach
the work area with enough extra length to
allow free movement while working.
3. Turn the tool’s switch to the off position; refer to
Operation section for description of controls.
4. Close the in-line shutoff valve between
the compressor and the tool.
5. Turn on the air compressor according to
the manufacturer’s directions and allow it
to build up pressure until it cycles off.
6. Adjust the air compressor’s output regulator so
that the air output is enough to properly power
the tool, but the output will not exceed the tool’s
maximum air pressure at any time (60-80 PSI).
Adjust the pressure gradually, while checking the
air output gauge to set the right pressure range.
7. Inspect the air connections for leaks.
Repair any leaks found.
SAFETYSERVICE OPERATIONTECHNIQUES SETUP
Air pressure gauge
Air inlet
8. If the tool will not be used at this time, turn off
and detach the air supply, safely discharge
any residual air pressure, and release
the throttle and/or turn the switch to its off
position to prevent accidental operation.
Page 7For technical questions, please call 1-800-444-3353.SKU 95136
SAFETY SERVICEOPERATION TECHNIQUESSETUP
C
F
E H
E
A
A
C
D
Figure A: Portable Air Supply Setup
B
Lubricated
Tools
A
G
B
Non-lubricated
Tools
Description Function
A Air Hose Connects air to tool
B Filter Prevents dirt and condensation from damaging tool or work piece
C Regulator Adjusts air pressure to tool
F Leader Hose (optional) Increases coupler life
E Coupler and Plug Provides quick connection and release
D Lubricator (optional) For air tool lubrication
H Air Adjusting Valve (optional) For ne tuning airow at tool
G Air Cleaner / Dryer (optional) Prevents water vapor from damaging work piece
Page 8 For technical questions, please call 1-800-444-3353. SKU 95136
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