Chicago Electric 97994 Operating instructions

Model 97994
Set up And Operating Instructions
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
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Read this material before using this product.
Failure to do so can result in serious injury.
Save this manual.
Copyright© 2008 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.
For technical questions or replacement parts, please call 1-800-444-3353.
Parts list and assembly
diagram���������������������������������� 17
Important SAFETY
Information���������������������������� 3 Limited 1 Year / 90 day
warranty������������������������������ 18
General Safety Rules�������������� 3
Specific Safety Rules��������������� 5
Specifications�������������������������� 8
Duty Cycle������������������������������������� 8
Unpacking���������������������������������� 9
Initial Set Up Instructions� 9
Assembly���������������������������������������� 9
Operating Instructions���� 10
Work Piece and Work Area
Set Up������������������������������������������ 11
General Operating
Instructions���������������������������� 11
WORK���������������������������������������� 13
Maintenance And
Servicing������������������������������� 14
Cleaning, Maintenance, and
Lubrication������������������������������� 14
Nozzle Care��������������������������������� 15
Troubleshooting����������������� 16
Cutting arc not stable.��� 16
Plasma Cutter does
not function when
switched on.����������������������� 16
Weak Arc strength������������ 16
Arc does not ignite.����������� 16
Gas does not flow.������������� 16
SKU 97994
For technical questions, please call 1-800-444-3353.
Page 2
NOTICE is used to
address practices
not related to personal injury.
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.
CAUTION, without
the safety alert
symbol, is used to address
practices not related to
personal injury.
General Safety Rules
WARNING! Read all instructions
Failure to follow all instructions
listed below may result in
electric shock, fire, and/or
serious injury.
Important SAFETY
In this manual, on the labeling,
and all other information provided with this product:
a.Keep work area clean and well lit.
Cluttered or dark areas invite accidents.
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.
indicates a
hazardous situation which, if
not avoided, could result in
death or serious injury.
with the safety
alert symbol, indicates a
hazardous situation which, if
not avoided, could result in
minor or moderate injury.
SKU 97994
Work area safety
b.Do not operate plasma cutters in
explosive atmospheres, such as in
the presence of flammable liquids,
gases or dust. Plasma cutters create sparks which may ignite the dust
or fumes.
c. Keep children and bystanders away
while operating a plasma cutter.
Distractions can cause you to lose
Electrical safety
a.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.
b.Do not expose plasma cutters to rain
or wet conditions. Water entering a
plasma cutter will increase the risk of
electric shock.
For technical questions, please call 1-800-444-3353.
Page 3
c. Do not abuse the Power Cord (32).
Never use the Cord for pulling or
unplugging the plasma cutter. Keep
Cord away from heat, oil, sharp
edges or moving parts. Damaged or
entangled Cords increase the risk of
electric shock.
d.When operating a plasma cutter outdoors, use an extension cord suitable for outdoor use. Use of a cord
suitable for outdoor use reduces the
risk of electric shock.
Personal safety
a.Stay alert, watch what you are doing
and use common sense when operating a plasma cutter. Do not use a
plasma cutter while you are tired or
under the influence of drugs, alcohol
or medication. A moment of inattention while operating plasma cutters
may result in serious personal injury.
b.Use safety equipment. Always wear
eye protection. Safety equipment
such as arc shaded, impact safety
full face shield, dust mask or respirator, heavy-duty work gloves, nonskid safety shoes, or hearing protection used for appropriate conditions
will reduce personal injuries.
c. Avoid accidental starting. Ensure
the Power Switch (11) is in the offposition before plugging in. Plugging in plasma cutters that have the
Switch on invites accidents.
d.Do not overreach. Keep proper footing and balance at all times. This
enables better control of the plasma
cutter in unexpected situations.
Plasma cutter use and care
cutter will do the job better and safer
at the rate for which it was designed.
b.Do not use the plasma cutter if the
Power Switch (11) does not turn it on
and off. Any plasma cutter that cannot be controlled with the Switch is
dangerous and must be repaired.
c. Disconnect the Power Cord (32)
from the power source before making any adjustments, changing accessories, or storing plasma cutters.
Such preventive safety measures
reduce the risk of starting the plasma
cutter accidentally.
d.Store idle plasma cutters out of the
reach of children and do not allow
persons unfamiliar with the plasma
cutter or these instructions to operate the plasma cutter. Plasma cutters are dangerous in the hands of
untrained users.
e.Maintain plasma cutters. Check for
misalignment or binding of moving
parts, breakage of parts and any
other condition that may affect the
plasma cutter’s operation. If damaged, have the plasma cutter repaired before use. Many accidents
are caused by poorly maintained
plasma cutters.
f. Use the plasma cutter and accessories in accordance with these instructions and in the manner intended for the particular type of plasma
cutter, taking into account the working conditions and the work to be
performed. Use of the plasma cutter
for operations different from those
intended could result in a hazardous
a.Use the correct plasma cutter for
your application. The correct plasma
SKU 97994
For technical questions, please call 1-800-444-3353.
Page 4
a.Have your plasma cutter serviced by
a qualified repair person using only
identical replacement parts. This will
ensure that the safety of the plasma
cutter is maintained.
Avoid unintentional starting. Prepare
to begin work before turning on the
Inverter Plasma Cutter.
Do not leave the Plasma Cutter unattended when it is plugged into an
electrical outlet. Turn off the plasma
cutter, and unplug it from its electrical
outlet before leaving.
Use clamps (not included) or other
practical ways to secure and support
the work piece to a stable platform.
Holding the work by hand or against
your body is unstable and may lead
to loss of control.
This product is not a toy. Keep it out
of reach of children.
Specific Safety Rules
Maintain labels and nameplates on
the Inverter Plasma Cutter. These
carry important safety information. If
unreadable or missing, contact Harbor Freight Tools for a replacement.
Avoid electric shock. Do not permit electrically live parts, cables, or
electrodes to contact skin, clothing, or
gloves. Wear ANSI-approved protective clothing. This unit draws enough
current to cause serious injury or
death. Do not use the Plasma Cutter unless you are insulated from the
ground and the work piece.
Avoid eye and body damage. Arc
rays and infrared radiation can injure
eyes and burn skin. Wear ANSI-approved eye and body protection. Do
not allow viewing by visitors without
proper eye and body protection. Use
a Face Shield with arc shaded filter
This Plasma cutter requires a dedicated 20 A circuit and NEMA type
5-20R receptacle.
Move flammable and explosive material at least 35 feet from the cutting
arc to prevent sparks or molten metal
from starting a fire. Keep a type ABC
fire extinguisher within easy reach.
Thoroughly clean the object being cut
of any paint, grease, or other foreign
SKU 97994
10. Industrial applications must follow
OSHA guidelines.
11. People with pacemakers should
consult their physician(s) before use.
Electromagnetic fields in close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure. In addition, people with
pacemakers should:
• Avoid operating alone.
• Do not use with Power Switch
locked on.
• Properly maintain and inspect to
avoid electrical shock.
• Any Power Cord must be properly grounded. Ground Fault Circuit
Interrupter (GFCI) should also be
implemented – it prevents sustained
electrical shock.
12. This product, when used for welding,
plasma cutting, soldering, or similar
applications, produces chemicals
known to the State of California to
cause cancer and birth defects (or
other reproductive harm).
For technical questions, please call 1-800-444-3353.
Page 5
(California Health & Safety Code §
25249.5, et seq.)
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 underneath welding
eye protection 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
• 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
• When welding/cutting overhead
or in confined spaces, wear flame
resistant ear plugs or ear muffs to
keep sparks out of ears.
Prevent accidental fires.
Remove any combustible
material from the work
• 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.
SKU 97994
• 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 not possible, designate someone
to serve as a fire watch, equipped
with a fire 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
• 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
accumulation of flammable gases,
For technical questions, please call 1-800-444-3353.
Page 6
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.
14. Do not touch live electrical parts.
Wear dry, insulating gloves. Do not
touch electrode or conductor tong
with bare hand. Do not wear wet or
damaged gloves.
15. Protect yourself from electric shock.
Do not use outdoors. Insulate yourself from the work piece and ground.
Use nonflammable, dry insulating
material if possible, or use dry rubber
mats, dry wood or plywood, or other
dry insulating material big enough to
cover your full area of contact with
the work or ground.
16. Ensure that the unit is placed on a
stable location before use. If this unit
falls while plugged in, severe injury,
electric shock, or fire may result.
17. Never remove the grounding prong
or modify the Power Cord Plug in any
way. Do not use adapter plugs with
this product.
18. 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
SKU 97994
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
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:
•Early onset of Parkinson’s Disease
•Heart disease
• Ulcers
•Damage to the reproductive organs
•Inflammation of the small intestine or
• 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
• 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
For technical questions, please call 1-800-444-3353.
Page 7
• 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.
19. Live torch when Trigger is pressed.
Keep Torch away from people and
flammables before touching Trigger.
20. Turn off, unplug, and discharge
electrode to ground before performing any inspection, maintenance, or
21. Use only compressed air at between
30 and 35 PSI. Never use oxygen,
carbon dioxide, combustible gases
or any bottled gas as an air source
for the Plasma Cutter. Such gases
are capable of explosion and serious
injury to people.
22. The brass components of this product
contain lead, a chemical known to
the State of California to cause birth
defects (or other reproductive harm).
(California Health & Safety code §
25249.5, et seq.)
23. The warnings, precautions, and instructions discussed in this instruction
manual cannot cover all possible conditions and situations that may occur.
It must be understood by the operator
that common sense and caution are
factors which cannot be built into this
product, but must be supplied by the
Save these
120 V~ / 60 Hz / 19 A
5-13 A
Duty Cycle
40% @ 13 A, 60% @ 10 A, 100% @ 8 A
Control Mode
IGBT Inverter
Air Pressure
30~35 PSI
Maximum Cutting
1/ ” Clean Cut Steel;
3/ ” Sever Cut Steel;
1/ ” Stainless Steel, Aluminum,
or Brass
Arc Striking System Pilot Start (5 Second Intervals)
LED Indicators
Power On: Green LED Light
Cutting in Process: Yellow LED Light
Unit Overheating: Red LED Light
Note: This Plasma cutter requires a dedicated 20 A circuit and NEMA type
5-20R receptacle.
Duty Cycle
Duty Cycle is the equipment specification which defines 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 10 Amps, which means that it
may be used only 6 minutes at 10 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 the equipment,
and will void the warranty.
When unpacking, check to make sure
that the item is intact and undamaged. If
any parts are missing or broken, please
call Harbor Freight Tools at the number
shown on the cover of this manual as soon
as possible.
REV 09a
SKU 97994
For technical questions, please call 1-800-444-3353.
Page 8
Initial Set Up
Read the entire Important
Safety Information section
at the beginning of this manual
including all text under
subheadings therein before set
up or use of this product.
To prevent
serious injury
from accidental
Turn the Power Switch (11) of
the Plasma Cutter to its “OFF”
position and unplug the
plasma cutter from its
electrical outlet before
assembling or making any
adjustments to the plasma
Slide the Regulator Body up through
the Loop on the back of the Cutter
and attach in place with the Regulator Nut as shown in the illustration
above. The Loop is keyed so that the
Regulator should only align in one
Note: For additional information regarding
the parts listed in the following pages,
refer to the Assembly Diagram near
the end of this manual.
Air Line
Remove the Regulator Nut from the
top of the Regulator Body.
Attach the Air Line to the connector
on the side of the Regulator Body.
The connector is designed to securely hold the line after inserting. Gently
pull on the line to ensure it is firmly
REV 09a
SKU 97994
For technical questions, please call 1-800-444-3353.
Page 9
A male Quick Release Adapter is
mounted on the Air Pressure Regulator (33) at the rear of the Plasma
Cutter. Attach your compressor’s air
supply hose to the Quick Release
Adapter. Then, adjust your compressor to deliver 30 to 35 PSI compressed air. (See Figure B.)
During operation, you can regulate air
pressure through the Plasma Cutter
by adjusting the Knob located on the
Air Pressure Regulator (33).
(See Figure B.)
SKU 97994
Power Switch (11): Up (I) is “ON”,
down (O) is “OFF”. (See Figure C.)
Potentiometer Knob (10): Allows
you to adjust the current from 5 to 13
Amps. (See Figure C.)
Green LED Light: When illuminated,
means the Plasma Cutter is on.
(See Figure C.)
Yellow LED Light: When illuminated,
means cutting is in process.
(See Figure C.)
Red LED Light: When illuminated,
means the Plasma Cutter has become overheated and the unit will
automatically shut down. Stop using
the Plasma Cutter while leaving the
Power Switch (11) ON to allow the
cooling Fan to operate. The LED
Light will turn off automatically when
the unit cools down and then you
may resume cutting. (See Figure C.)
For technical questions, please call 1-800-444-3353.
Page 10
Operating Instructions
General Operating Instructions
Protective gear
must be worn
when using the Plasma Cutter.
ANSI-approved, arc shaded,
eye protection, a full face
shield, heavy-duty work
gloves, a welding apron,
respirator, and heavy-duty
work clothes without pockets
should be worn when using
this product. Do not look at
the ignited arc without eye
protection. Light from the arc
can cause permanent damage
to the eyes. Light from the
arc can burn the skin. Do not
breathe arc fumes.
Read the entire Important
Safety Information section
at the beginning of this manual
including all text under
subheadings therein before set
up or use of this product.
To prevent
serious injury
from accidental
Turn the Power Switch (11) to
its “OFF” position before
performing any inspection,
maintenance, or cleaning
Work Piece and Work Area Set Up
Designate a work area that is clean
and well-lit. The work area must not
allow access by children or pets to
prevent injury and distraction.
Route the Power Cord (32) along a
safe route to reach the work area
without creating a tripping hazard
or exposing the Power Cord to possible damage. The Power Cord must
reach the work area with enough
extra length to allow free movement
while working.
There must not be hazardous objects, such as utility lines or foreign
objects, nearby that will present a
hazard while working.
A barrier, such as a welding curtain
or welding shroud should be put up
to protect others in the work area and
limit the spray of sparks.
SKU 97994
IMPORTANT: The duty cycle defines
the number of minutes, within a 10
minute period, during which a given
Plasma Cutter can safely produce a
particular current. For example, this
Plasma Cutter, with a 60% duty cycle
at 10 Amps (maximum setting), must
be allowed to rest for at least 4 minutes after every 6 minutes of continuous cutting at 10 Amps.
• Failure to carefully observe duty cycle limitations can stress a Plasma
Cutter’s power generation system,
contributing to premature plasma
cutter failure.
• This Plasma Cutter is equipped with
an internal thermal protection system to help prevent damage to the
unit. When the unit overheats; it automatically shuts down, then returns
to service when it cools down.
• Once the unit returns to service, follow a more conservative duty cycle
For technical questions, please call 1-800-444-3353.
Page 11
routine to help prevent excess wear
to the Plasma Cutter.
Mount the metal to be cut to the
metal welding/cutting table. It should
be mounted so that the cutting debris
falls to the cement floor.
Place the Plasma Cutter unit no
closer than 6 feet from the workpiece
to be cut.
Adjust the Knob on the Air Pressure
Regulator (33) to regulate the air
supply between 30 and 35 PSI as
indicated on the Air Pressure Gauge.
The air supply must be dry. It is recommended to install a moisture filter
(not included) on the compressor. Do
not use an air oiler. (See Figure B.)
Securely place the clamping end of
the Earth Clamp (14) 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.
Set the desired current (5~13 Amps)
for the type of metal being cut with
the Potentiometer Knob (10). Thin
metals use low current and heavy
metals use high current.
(See Figure C.)
Turn the Power Switch (11) OFF (O),
then plug the Plasma Cutter’s Power
Cord (32) into a dedicated, 120 V~,
20 A, electrical outlet with delayed action type circuit breaker or fuse.
(See Figure C.)
Hold the Cutting Torch (13) firmly.
WARNING! The Torch is “live” when
its Trigger is pressed. Keep the Torch
away from people and flammables
before touching Trigger.
When everything is in place for cutting, press the Power Switch up to its
“ON” position. The GREEN “Power
On” Light will illuminate.
(See Figure C.)
10. WARNING! To prevent serious injury, point torch away
from your body when squeezing trigger. Once the Trigger is
squeezed, the arc will ignite. This
unit provides a pilot arc, so allow you
to start an arc against the workpiece.
The pilot arc lasts only a few seconds.
11. Squeeze the Trigger to energize the
Cutting Torch (13), the YELLOW
“Cutting” LED will illuminate. Do not
to touch anything else with the Torch
except the workpiece to be cut.
(See Figure C.)
12. Maintain the tip of the torch within
1/16” from the workpiece. If the tip
is too far from the workpiece, the arc
will go out.
13. Slowly move the Cutting Torch (13)
at a slight angle 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 Potentiometer Knob (10) to a
higher level and/or increase air flow.
(See Figure C.)
Note: If too much current is drawn from
the Plasma Cutter, the thermal protector will activate and the RED
“Overheating” LED will illuminate.
The Plasma Cutter will automatically
shut down until it cools, then you may
resume cutting again.
REV 09a
SKU 97994
For technical questions, please call 1-800-444-3353.
Page 12
Note: If the input current is too high for the
Plasma Cutter, the overload protector
will activate and the cutter will stop
working. To reset, press the Circuit
Breaker (30) to begin cutting again.
(See Figure D.)
14. When finished cutting:
Set the air pressure between 30 and
35 PSI. Increased air pressure will
increase plasma speed and cutting
pressure. Air pressure and amperage should be adjusted in tandem.
Start with a mid-range amperage setting (10 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.
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
• Release the Trigger on the Cutting
Torch (13) and lift the Torch from
the workpiece.
Note: The air will continue to flow through
the end of the torch for about 20 seconds to allow it to cool.
• Press the Power Switch (11) to its
“OFF” position.
• Set the Cutting Torch (13) down on
the metal workbench.
• Turn off the air supply.
• Unplug the Power Cord (32) from its
electrical outlet.
• Allow all components of the Plasma
Cutter to completely cool. Then
store the unit indoors out of children’s reach.
Using a Plasma Cutter is a skill that
requires time and effort to do well.
Practice striking and maintaining
an arc on scrap workpieces 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 conduct electricity up to approximately
0.196” (5mm) thick mild steel or
equivalent. Very thin or very thick
metals are more difficult to cut cleanly.
SKU 97994
For technical questions, please call 1-800-444-3353.
REV 09a
Page 13
Maintenance And
WARNING! If the Power Cord (32) of
this Plasma Cutter is damaged, it
must be replaced only by a qualified
service technician.
Procedures not specifically
explained in this manual
must be performed only by a
qualified technician.
Nozzle Care
To prevent
serious injury
from accidental
Turn the Power Switch (11) of
the Plasma Cutter to its “OFF”
position and unplug the
plasma cutter from its
electrical outlet before
performing any inspection,
maintenance, or cleaning
To prevent serious
injury from plasma
cutter failure:
Do not use damaged
equipment. If abnormal noise
or vibration occurs, have the
problem corrected before
further use.
Cleaning, Maintenance, and
BEFORE EACH USE, inspect the
general condition of the Plasma Cutter. Check for loose screws, cracked
or broken parts, damaged electrical
wiring, and any other condition that
may affect its safe operation.
After Use, clean external surfaces
of the plasma cutter with clean cloth.
Periodically, using compressed
air, blow out all dust and debris from
the interior.
SKU 97994
Part Description
Insulating Diffuser
Nozzle Holder
Turn the Nozzle Holder (7A) counterclockwise while pulling to remove.
(See Figure E.)
Scrub the interior of the Nozzle Holder (7A) and Nozzle (6A) clean with a
wire brush. (See Figure E.)
Examine the end of the Nozzle (6A).
The end should be flat and even. If
the end is uneven, chipped, melted,
cracked, or otherwise damaged, the
Nozzle will adversely effect the weld
and should be replaced.
(See Figure E.)
Replace the Nozzle Holder (7A) after
inspecting, cleaning, and re-installing
the Nozzle (6A), Insulating Diffuser
(5A), and Electrode (4A).
(See Figure E.)
Check the Torch carefully for proper
For technical questions, please call 1-800-444-3353.
Page 14
To Prevent
serious injury:
Shut off the Welder,
disconnect it from power, and
discharge the torch to ground
before adjusting, cleaning, or
repairing the unit.
Cutting arc not stable.
• Possible Causes and Solutions:
• Loose Cutting Torch (13) cable or
Earth Clamp (14) cable:
Check to ensure that all connections are tight.
• Damaged Cutting Torch (13) or
loose connection within Torch:
Have a qualified technician inspect
and repair/replace as necessary.
Plasma Cutter does not function when
switched on.
• Possible Causes and Solutions
• Tripped thermal protection device:
Allow the unit to cool until the RED
“Overheating” LED goes off, then
resume use. Reduce duration or
frequency of cutting periods to help
reduce wear on the Plasma Cutter
and frequency of overheating.
• Faulty Power Switch (11): Have
a technician repair/replace Power
• Internal fuse blown: Have a qualified technician check/replace.
ficient, have a licensed electrician
remedy the situation.
Arc does not ignite.
• Possible Causes and Solutions:
• Improper ground connection:
Make certain that the work piece
is contacted properly by the Earth
Clamp (14) and that the work piece
is properly cleaned near the Earth
Clamp and the welding location.
• Improperly sized or excessively
worn Nozzle (6A):
Verify that Nozzle is the proper size
for the Cutting Torch used. Check
that the hole in the tip is not deformed, enlarged, or dirty. If needed, replace Nozzle with proper size
and type.
Air does not flow.
• Possible Causes and Solutions:
• Nozzle (6A) Plugged:
Clean Nozzle. If damaged, replace.
• Air Pressure Regulator (33) closed:
Make sure Regulator is adjusted
• Air supply hose blocked:
Check air supply hose, and hose
within Cutting Torch (13) cable.
Plasma Cutter continually overheats.
• Possible Causes and Solutions
• Input voltage too high or too low.
Have electrician inspect and service
building electrical circuit.
Weak Arc strength
• Possible Cause and Solution:
• Incorrect line voltage:
Check the line voltage and, if insufREV 09a
SKU 97994
For technical questions, please call 1-800-444-3353.
Page 15
Parts list and assembly diagram
Screw (M5x14) & Nut (M5)
Steel Cover
Tapping Screw (2.0x6)
Temperature Control
Panel Fixation
Electromagnetism Valve
Panel Fixation
PCB Support
Plastic Front Cover
Potentiometer Knob
Wind Pipe
Power Switch
Cutting Holder Jacket
Plastic Back Cover
Cutting Torch
Circuit Breaker
Earth Clamp
Cable Clip
Earth Clamp Connector (PG11)
Power Cord
Tapping Screw (4.2x9.5)
Air Pressure Regulator
Steel Base
Bolt (M5x12) & Nut (M5)
SKU 97994
For technical questions, please call 1-800-444-3353.
Page 16
Limited 1 Year / 90 day warranty
Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that for a period of ninety days from date of purchase that the torch, liner, wire feed mechanism (if applicable), welding clamps, electrode holders, cables
and accessories packed with the welder are free of defects in materials and workmanship. This Limited
90 Day/1 Year Warranty shall not apply to consumable parts such as tips, welding wire, and gas
nozzles. Harbor Freight Tools also warrants to the original purchaser, for a period of one year from date
of purchase, that the transformer and rectifier are free from defects in materials and workmanship (90
days if used by a professional contractor or if used as rental equipment). This warranty does not apply to
damage due directly or indirectly to misuse, abuse, negligence or accidents, repairs or alterations outside
our facilities, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or consequential damages arising from
the use of our product. Some states do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitation of exclusion may not apply to you. This warranty is expressly
in lieu of all other warranties, express or implied, including the warranties of
merchantability and fitness.
To take advantage of this warranty, the product or part must be returned to us with transportation
charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise. If our inspection verifies the defect, we will either repair or replace the product at our election
or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will return repaired products at our expense, but if we determine there is no defect, or that the
defect resulted from causes not within the scope of our warranty, then you must bear the cost of returning
the product.
This warranty gives you specific legal rights and you may also have other rights which vary from
state to state.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353
Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts.
The manufacturer and/or distributor has provided the parts list and assembly
diagram in this manual as a reference tool only. Neither the manufacturer or
distributor makes any representation or warranty of any kind to the buyer that
he or she is qualified to make any repairs to the product, or that he or she is
qualified to replace any parts of the product. In fact, the manufacturer and/
or distributor expressly states that all repairs and parts replacements should
be undertaken by certified and licensed technicians, and not by the buyer. The
buyer assumes all risk and liability arising out of his or her repairs to the
original product or replacement parts thereto, or arising out of his or her
installation of replacement parts thereto.
SKU 97994
For technical questions, please call 1-800-444-3353.
Page 17