Table of contents - Harbor Freight Tools

Table of contents
SAFETy
Safety ......................................................... 2
Setup .......................................................... 5
Specifications ............................................. 5
Operation .................................................... 8
Maintenance .............................................. 12
Troubleshooting ......................................... 13
Parts List and Diagrams ............................ 18
Warranty .................................................... 20
WARNING SyMBOLS AND DEFINITIONS
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.
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.
SETUp
Addresses practices not related to personal injury.
IMpORTANT SAFETy INSTRUcTIONS
Read all safety warnings and instructions.
Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
OpERATION
1.
2.
MAINTENANcE
3.
DANGER! people with pacemakers should
not use this plasma cutter or be nearby
during use. plasma cutters, such as this one,
produce strong, fluctuating electromagnetic
fields that can cause pacemaker interference
or pacemaker failure. people with pacemakers
should consult their physician(s) for advice.
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 flammable chemicals, dusts, and vapors.
Do not use in a damp or wet location.
Never 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.
Unplug the plasma cutter from its electrical
outlet before performing any inspection,
maintenance, or cleaning procedures,
including changing accessories.
Page 2
4.
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 Plasma Cutter.
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, fire resistant shoes or
boots should be worn when using this
product. Do not wear pants with cuffs, shirts
with open pockets, or any clothing that can
catch and hold molten metal or sparks.
• Keep clothing free of grease, oil, solvents,
or any flammable substances. Wear dry,
insulating gloves and protective clothing.
• Wear an approved head covering to protect
the head and neck. Use aprons, cape, sleeves,
shoulder covers, and bibs designed and
approved for welding and cutting procedures.
• When welding/cutting overhead or in confined
spaces, wear flame resistant ear plugs or
ear muffs to keep sparks out of ears.
For technical questions, please call 1-800-444-3353.
ITEM 60767
• When possible, move the work to a location well
away from combustible materials. If relocation
is not possible, protect the combustibles with
a cover made of fire resistant material.
• Remove or make safe all combustible
materials for a radius of 35 feet (10 meters)
around the work area. Use a fire resistant
material to cover or block all open doorways,
windows, cracks, and other openings.
• Enclose the work area with portable fire
resistant screens. Protect combustible
walls, ceilings, floors, etc., from sparks
and heat with fire resistant covers.
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.
• 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.
• 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.
• Do not dispose of hot slag in containers
holding combustible materials. Keep a fire
extinguisher nearby and know how to use it.
• Work in a confined area only if it
is well ventilated, or while wearing
an air-supplied respirator.
• 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 has
started. Do not weld or cut in atmospheres
containing dangerously reactive or flammable
gases, vapors, liquids, and dust.
• Follow OSHA guidelines for
Permissible Exposure Limits (PEL’s)
for various fumes and gases.
• 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.
• Only use compressed air to operate
the Plasma Cutter. Never use other
compressed gases. Don’t exceed
maximum PSI for this product as stated
on the specification table on page 6.
ITEM 60767
• 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.
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.
For technical questions, please call 1-800-444-3353.
SAFETy
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
• Inflammation 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.
Prevent accidental fires. Remove any
combustible material from the work area.
• 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.
INHALATION HAZARD:
Welding and cutting produce
TOXIc FUMES.
SETUp
8.
OpERATION
7.
Maintain labels and nameplates
on the plasma cutter.
These carry important information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.
Page 3
MAINTENANcE
6.
11.
SAFETy
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 plasma cutter.
Using components from other systems may cause
personal injury and damage components within.
14.
SETUp
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.)
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.
16.
This product requires a 3-prong, 240 V~,
twist-lock plug (not included). This plug must
be installed by a qualified electrician.
17.
KEEP CHILDREN AWAY. All visitors should
be kept safe distance from work area.
18.
MAKE WORKSHOP KID PROOF with padlocks,
master switches, or by removing starter keys.
19.
USE RIGHT Plasma Cutter. Don’t force
Plasma Cutter or attachment to do a
job for which it was not designed.
20.
SECURE WORK. Use clamps or a vise to hold
work. It’s safer than using your hand and it
frees both hands to operate Plasma Cutter.
21.
MAINTAIN PLASMA CUTTERS WITH CARE.
Keep Plasma Cutters clean for best and
safest performance.
Follow instructions for changing accessories.
22.
Inspect before every use;
do not use if parts loose or damaged.
OpERATION
Symbology
Double Insulated
Canadian Standards Association
Underwriters Laboratories, Inc.
V~
A
Volts Alternating Current
n0 xxxx/min.
No Load Revolutions per Minute (RPM)
Amperes
MAINTENANcE
Page 4
For technical questions, please call 1-800-444-3353.
ITEM 60767
Rated Input
240V~, 50/60Hz, 25A
Open Circuit Voltage (OCV)
240 V
Cutting Current
15-40 A DC
Rated Output Voltage
96 VDC
SAFETy
Specifications
60% @ 40 A
80% @ 34.6 A
100% @ 31 A
3/8″ Mild Steel @ 10 IPM (Rated)
5/8″ Mild Steel @ 5 IPM (Severance)
Maximum Cutting Thickness
1/4″ Stainless Steel, Aluminum, Galvanized Steel
1/8" Brass, Copper
Arc Striking System
3 second pilot arc
Gas Supply
Clean, dry, oil-free air, or nitrogen gas
Air Requirements
3.5 CFM @ 60-80 PSI
Air Inlet
1/4″ - 18 NPT
Unit Size
20″ L x 8-1/8″ W x 14-3/8″ H
Weight
49.6 lb.
SETUp
Rated Duty Cycle
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 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.
MAINTENANcE
OpERATION
cAUTION: Failure to follow the duty cycle limitations of this Plasma Cutter
can easily damage this equipment, and will void the warranty.
ITEM 60767
For technical questions, please call 1-800-444-3353.
Page 5
Setup
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.
SAFETy
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 Plasma Cutter may be shipped with a protective plug
covering the air inlet. Remove this plug before set up.
Grounding
2.
Connect the other end of the wire to an
appropriate ground, such as a steel workbench,
steel building member or grounding stake.
SETUp
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 Plasma Cutter case.
power plug
OpERATION
1.
A 6-50P plug is wired into this item,
rated to 250V~ and 50 A.
2.
If the receptacle does not match the plug,
make sure that it is a 230-250V~ receptacle
rated to at least 30 amps.
If the receptacle is rated properly, a qualified
electrician can cut the plug off of this machine
and install an different appropriate 250V~ plug.
MAINTENANcE
Page 6
For technical questions, please call 1-800-444-3353.
ITEM 60767
TO pREVENT SERIOUS INJURy AND DEATH FROM EXpLOSION:
Use only clean, dry, regulated, oil-free, compressed air or nitrogen gas with this plasma cutter.
Do not use oxygen, acetylene, carbon dioxide, combustible gases,
or any other bottled gas as a power source for this plasma cutter.
Note: Do not use an oiler system with this
plasma cutter. The oil will mix with the air
being propelled, causing poor results.
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 efficient, but are not required.
Handle
3.
Turn the Plasma Cutter’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 Plasma Cutter.
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 Plasma Cutter, but the output will not exceed
the Plasma Cutter’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.
8.
If the Plasma Cutter will not be used at
this time, turn off and detach the air supply,
safely discharge any residual air pressure, and
release the trigger and turn the switch to its
off position to prevent accidental operation.
Air Regulator
Air pressure gauge
1/4" Air inlet
MAINTENANcE
2.
Note: Air flow, and therefore Plasma Cutter
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.
SETUp
Incorporate a filter, regulator with pressure gauge,
dryer, in-line shutoff valve, and quick coupler for
best service. 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.
OpERATION
1.
SAFETy
Air Supply
ITEM 60767
For technical questions, please call 1-800-444-3353.
Page 7
Operation
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.
SAFETy
controls and Indicators
4
2
POWER
ON
1
POWER
WORKING
5
OFF
OVERHEAT
MIN
SETUp
OpERATION
2.
Digital Amp Meter.
Shows actual cutting current,
which will vary during operation.
Only displays current while cutting.
3.
Thermal Overload Indicator.
The Plasma Cutter will shut down if it overheats
and this light will come on. Stop using the
Plasma Cutter while leaving the power switch ON
to allow the cooling fan to operate.
The lamp will turn off automatically
when the Plasma Cutter cools down.
Continue use while paying attention to
Duty Cycle discussed on page 6.
4.
power ON Light.
5.
Working Indicator Light.
Will be on during cutting operation.
6.
Output current Dial.
Turn the Output Current Dial to the desired current
(15 to 40 amps). Lower currents reduce circuit
breaker tripping. Adjust as needed after test cuts.
Thicker material will use greater amperage.
Thinner material will use lower amperage.
7.
Mode Selector. This has two settings:
cUT: Used for normal operation.
SET: Produces constant air flow only for
air supply calibration. Not for operation.
3
MAX
CURRENT
AIR
with Digital Display
TORCH
power Switch & circuit Breaker.
Up is ON, down is OFF.
This switch also functions as a circuit breaker.
It will trip (disconnect power) if overcurrent occurs.
Turn OFF, then back to ON to reset it.
6
SET
CUT
240 VOLT INVERTER PLASMA CUTTER
1.
7
GROUND
Electrode
Swirl Ring
cutting Tip
Retaining cup
Air Flow calibration
WARNING! Make sure torch and
tip are completely cool.
Ball
MAINTENANcE
1.
Hold air flow meter firmly against end of cutting tip.
2.
Point Torch and air flow meter straight up.
3.
Set Mode Selector to SET to
start constant air flow.
Air Flow Meter
4.
Metal ball in air flow meter should start to float on
the flowing air. Proper air flow will cause the ball
to float in the marked area in the meter. Adjust
air flow as needed while observing the gauge.
Torch
5.
MAX
MIN
After adjustment, set Mode Selector
to cUT to allow normal operation.
THIS IS VERy IMpORTANT!
Page 8
For technical questions, please call 1-800-444-3353.
ITEM 60767
2.
Keep multiple appropriate fire
extinguishers readily available.
3.
Do not breathe arc fumes.
Use in area with proper ventilation.
Use forced air ventilation systems as needed.
5.
6.
7.
Use a sturdy metal work table that
is open below the cutting area.
Molten slag will be blown through the
work metal, and must be able to fall away freely.
Mount the metal to be cut to the work table so
that the cutting debris falls to the cement floor.
Place the Plasma Cutter on a sturdy, level surface
at least six feet from the work area.
Allow at least 18" around all sides of
the Plasma Cutter for air flow.
Connect an air hose and coupling (not supplied)
from the air supply tank to
the Air Input Coupling at the rear of the unit.
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, clean, and oil-free.
Install a moisture filter (not included) on
the compressor. Do not use an air oiler.
Verify that the Power Switch is in the Off (O)
position, then plug the Plasma Cutter
into an appropriate 240 V~ outlet
rated to at least 30 amps to limit
nuisance circuit breaker tripping.
Adjust air pressure by turning the Air Regulator
on top of the unit (see photo on page 6).
Read pressure on Pressure Gauge.
9.
pLASMA cUTTING TIpS:
Using a Plasma Cutter is a skill that
requires time and effort to do well.
Practice starting and maintaining an arc on
scrap work pieces before beginning work.
This will help determine the best settings for
the Plasma Cutter for the material at hand.
a. All metals that conduct electricity can be cut,
see Maximum cutting Thickness on page 5
for thickness capabilities of this Plasma Cutter.
Very thin or very thick metals are
more difficult to cut cleanly.
b. 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
– air pressure needs to increase as amperage
increases, however, low amperage cuts will
require less air pressure for a more stable cut.
c. 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 thicker and harder metals.
However, increased amperage will
reduce Duty Cycle time. (See page 5.)
d. 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.
Thicker Material
Thinner Material
High Amps
More Air pressure
Low Amps
Less Air pressure
MAINTENANcE
4.
8.
SETUp
The floor and surrounding area 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 all directions.
OpERATION
1.
SAFETy
preparation and Work Area
ITEM 60767
For technical questions, please call 1-800-444-3353.
Page 9
Basic Operation
SAFETy
pLASMA ARc cAN cAUSE SERIOUS INJURy,
INcLUDING SEVERE cUTS, BURNS, pERMANENT EyE DAMAGE AND BLINDNESS!
Once the trigger is squeezed, the arc will ignite IMMEDIATELy.
The torch does not need to contact the workpiece before the pilot arc ignites.
Do not look at the plasma Arc without an arc shaded full face shield.
1.
BEFORE EAcH USE, inspect the general
condition of the Plasma Cutter. Check for:
• loose hardware,
Note that most problems with plasma cutters aren’t
really problems. They’re simply torch consumables
that are worn or re-assembled improperly.
• damaged cord/electrical wiring,
• cooling fan operation,
• cracked or broken parts, and
• any other condition that may
affect its safe operation.
SETUp
Have a qualified technician correct
any problems before operation.
2.
check Torch components before every use.
Make sure torch is completely cool, then:
3.
Securely attach the Ground 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 planned
cut without exposing the clamp to damage.
4.
When everything is in place for cutting,
press the Power Switch UP to the ON position.
The green Power On Light will illuminate,
but the Torch is not yet energized.
5.
Orient yourself to one side of the cutting area,
and move the Welding Helmet (sold separately)
over your eyes, see warning 5 on page 2.
a. Unscrew and remove Retaining Cup.
b. Check condition of the O-ring.
c. Check condition of the Cutting Tip.
Replace if opening is deformed or 50% oversized.
Clean inside of tip as needed with steel wool,
(remove any pieces of steel wool afterwards).
OpERATION
d. Check condition of the Electrode.
A pit will develop in the center during use.
Once that pit is 1/16" deep,
replace the Electrode. (For greater accuracy,
replace when pit is only 1/32" deep.)
Electrode
Swirl Ring
cutting Tip
Retaining cup
MAINTENANcE
e. Replace parts as needed.
Replace Tip and Electrode at the same time.
keep
1/16" distance
from workpiece
6.
90º
Position torch near workpiece at start of cut.
Keep tip at a 90º angle to workpiece, and
at 1/16" distance from workpiece.
f. Make sure all other internal torch components
are undamaged, clean, and free of debris.
g. After replacing parts as needed,
reassemble parts and replace Retaining Cup.
DO NOT USE WITH WORN cOMpONENTS.
USING WORN cOMpONENTS
WILL VOID yOUR WARRANTy AND
DAMAGE THE pLASMA cUTTER.
Page 10
For technical questions, please call 1-800-444-3353.
ITEM 60767
Note: If the plasma cutter suddenly shuts off, check:
a. torch distance from workpiece,
b. poor workpiece grounding,
d. circuit Breaker & power Switch tripping, or
e. Thermal Overload tripping.
(See page 8 for details.)
8.
11.
Pause briefly at end of cut.
12.
Release the Trigger. The air will continue
to come out of the Torch Handle for a
few seconds once the Trigger is released
to cool off the torch components.
13.
When finished cutting:
SETUp
Do not squeeze Trigger until Torch
is in position to start cutting.
Squeeze and hold the Trigger to start the pilot arc.
When the Working Indicator Light comes on
start moving the torch along your cut line.
Start at the edge of the workpiece.
7.
SAFETy
c. dirty/painted workpiece,
Slowly move the Torch along the cutting
line with the Torch tip trailing.
if sparks do not pass
through workpiece
9.
If sparks start shooting up from the workpiece
instead of passing through, the torch is being
moved too quickly so the cut is not being
made completely. Move the torch along the
workpiece more slowly to cut completely.
a. Release the Torch handle trigger and lift
the Torch handle from the workpiece,
b. Wait 10 minutes for the Plasma Cutter
to cool down with the switch on so
the fan continues to operate,
c. Press the Power Switch to the Off (O) position,
SpEED Up
if sparks pass straight
down through bottom
of workpiece
d. Set the Torch handle down on
a cool part of the metal workbench,
e. Turn the air supply off and disconnect air lines,
f. Unplug the line cord from the electrical outlet.
10.
If sparks pass straight down through bottom of
workpiece instead of at a slight angle, the torch
is being moved too slowly. This could cause the
arc to extinguish. Move the torch a little faster.
ITEM 60767
For technical questions, please call 1-800-444-3353.
Page 11
MAINTENANcE
SLOW DOWN
OpERATION
Note: Keep the torch tip pointed straight (90º) into the
workpiece 1/16" from the surface. Consistent workpiece
distance and cutting speed are critical. Sparks should
pass through the workpiece at a slight angle.
Maintenance
Procedures not specifically explained in this manual
must be performed only by a qualified technician.
SAFETy
TO pREVENT SERIOUS INJURy FROM AccIDENTAL OpERATION OR ELEcTRIc SHOcK:
Make sure the power Switch of the plasma cutter is in its "OFF" position and that the plasma cutter is
unplugged from the electrical outlet before performing any inspection, maintenance, or cleaning procedures.
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.
SETUp
1.
Periodically recheck cutting tip
and electrode for tightness.
2.
Periodically blow the dust from the
cooling vents with compressed air.
3.
If the unit repeatedly shuts down
from thermal overload, stop all use.
Have the Plasma Cutter inspected and
repaired by a qualified service technician.
4.
Store the Plasma Cutter and accessories
in a clean and dry location.
5.
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 19.
6.
Opening the plasma cutter will void any
warranties, and may result in damage to
equipment or possible personal injury.
DO NOT OpEN THE HOUSING.
Any repairs must be completed
by a qualified technician.
7.
WARNING! If the supply cord of this
plasma cutter is damaged, it must be replaced
only by a qualified service technician.
OpERATION
MAINTENANcE
Page 12
For technical questions, please call 1-800-444-3353.
ITEM 60767
Troubleshooting
IMpORTANT!
SAFETy
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.
FAN RUNS WHEN SWITcHED ON BUT ARc WILL NOT IGNITE
AIR pRESSURE
TOO HIGH
Adjust the Air Regulator
to deliver only 60-80 pSI
to the plasma cutter.
AIR pRESSURE
cORREcT
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 conduct
electricity efficiently.
DIRTy OR
cOATED METAL
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.
AIR pRESSURE
TOO LOW
a. Verify that the compressor
is delivering at least
3.5 cFM @ 60 pSI.
b. Set Regulator on the
unit to at least 60 pSI.
METAL IS cLEAN IN
BOTH AREAS
Torch isn’t maintaining contact with the workpiece.
a. Maintain a 1/16" distance
from workpiece at all times.
b. Disassemble and inspect the torch assembly.
Replace worn or missing components
and reassemble carefully,
following the steps on page 10.
DO NOT OVERTIGHTEN.
c. Nozzle is moving too slowly across the metal
and cutting the material from underneath,
breaking contact. Move torch more quickly.
If the steps above do not solve the problem or if the repairs involved are too
complex, contact a qualified technician.
ITEM 60767
For technical questions, please call 1-800-444-3353.
Page 13
OpERATION
MODE SELEcTOR
IN "cUT"
Air pressure too high or too low.
check the Air pressure setting
on the regulator’s gauge.
MAINTENANcE
MODE SELEcTOR
IN "SET"
Switch Mode Selector
to "cut". "Set" is ONLy
used to check air flow.
It does not allow
normal operation.
SETUp
Air supply in check air flow mode.
Air Mode Selector switched to "Set".
Troubleshooting (cont.)
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.
SAFETy
ARc IGNITES FOR SEVERAL SEcONDS BUT THEN GOES OUT
Air pressure too high or too low.
check the Air pressure setting
on the regulator’s gauge.
AIR pRESSURE
TOO HIGH
SETUp
Adjust the Air Regulator
to deliver only 60-80 pSI
to the plasma cutter.
AIR pRESSURE
cORREcT
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 efficiently.
AIR pRESSURE
TOO LOW
a. Verify that the compressor
is delivering at least
3.5 cFM @ 80 pSI.
b. Set Regulator on the
unit to at least 60 pSI.
DIRTy OR
cOATED METAL
METAL IS cLEAN IN
BOTH AREAS
OpERATION
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.
Torch isn’t maintaining contact with the workpiece.
a. Maintain a 1/16" distance
from workpiece at all times.
b. Disassemble and inspect the torch assembly.
Replace worn or missing components
and reassemble carefully,
following the steps on page 10.
DO NOT OVERTIGHTEN.
c. Nozzle is moving too slowly across the metal
and cutting the material from underneath,
breaking contact. Move torch more quickly.
MAINTENANcE
If the steps above do not solve the problem or if the repairs involved are too
complex, contact a qualified technician.
Page 14
For technical questions, please call 1-800-444-3353.
ITEM 60767
Troubleshooting (cont.)
IMpORTANT!
SAFETy
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.
See Maximum cutting Thickness on page 5.
pROBLEM pERSISTS AT
MAXIMUM SETTING
Air pressure too low.
check the Air pressure setting
on the regulator’s gauge.
AIR pRESSURE
cORREcT
Disassemble and inspect
the torch assembly,
as explained on page 11.
AIR pRESSURE
TOO LOW
a. Verify that the compressor
is delivering at least
3.5 cFM @ 80 pSI.
b. Set Regulator on the
unit to 60 - 80 pSI.
TORcH IN GOOD
cONDITION
DAMAGED
cOMpONENTS FOUND
cut at a slower pace, the arc
may not have enough time to
cut through the workpiece.
Maximum cutting speeds:
Replace any damaged or
missing components and
reassemble carefully, following
the directions on pages 6-11.
3/8″ Mild Steel @ 10 IPM (Rated)
5/8″ Mild Steel @ 5 IPM (Severance)
If the steps above do not solve the problem or if the repairs involved are too
complex, contact a qualified technician.
ITEM 60767
For technical questions, please call 1-800-444-3353.
Page 15
SETUp
Use a more powerful
plasma cutter.
OpERATION
pROBLEM
cORREcTED
Take note of the
setting required for
this metal thickness.
MATERIAL
TOO THIcK
MAINTENANcE
WITHIN THIcKNESS
RANGE
Turn up the current
adjustment knob and try again
at a slower torch travel speed.
Troubleshooting (cont.)
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.
SAFETy
FAST NOZZLE WEAR
OR
EXcESSIVE SLAG FORMATION
These two problems have similar causes
and will often appear simultaneously.
The same diagnostic procedures
and remedies apply to both.
SETUp
Amperage setting too high;
cut at lowest setting possible
for the metal being cut.
pROBLEMS pERSIST AT
LOWEST pRAcTIcAL SETTING
pROBLEMS
REDUcED
Take into account the thickness
and type of metal to be cut before
starting. Thinner materials
require lower amp settings.
Disassemble and inspect
the torch assembly,
as explained on page 10.
OpERATION
TORcH IN GOOD
cONDITION
DAMAGED
cOMpONENTS FOUND
Air supply pressure may be inadequate:
a. Verify that the compressor is delivering
at least 3.5 cFM @ 80 pSI.
b. Set Regulator on the unit to at least 60 pSI.
Replace any damaged or
missing components and
reassemble carefully, following
the directions on page 10.
MAINTENANcE
Additional factors:
a. Maintain a 1/16" distance from workpiece at all times.
b. Move torch at proper rate. Maximum cutting speeds:
3/8″ Mild Steel @ 10 IPM (Rated)
5/8″ Mild Steel @ 5 IPM (Severance)
c. compare workpiece thickness
to Maximum cutting Thickness on page 5.
If the steps above do not solve the problem or if the repairs involved are too
complex, contact a qualified technician.
Page 16
For technical questions, please call 1-800-444-3353.
ITEM 60767
MAINTENANcE
OpERATION
SETUp
SAFETy
circuit Diagram
ITEM 60767
For technical questions, please call 1-800-444-3353.
Page 17
parts List and Diagrams
parts List
SAFETy
part
SETUp
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Description
Qty
Handle
Main Body Cover
Air Supply Solenoid
Control Transformer
Transfer Arc Circuit Board
Control Circuit Board
Chassis
Splitter
Current Check Coil
Reactor
Main Transformer
Digital Amp Meter
Working Indicator
Air Switch
Output Current Dial
Lower Cover
Torch Cable Connector
Ground Cable Connector
Air Pressure Relief Valve
Elbow Connector
Solenoid Holder
Timing Control PCB
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
part
OpERATION
1A
2A
3A
4A
5A
6A
part
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
Description
Drive Circuit Board
Diode
Reactor
Metal Resistor
Thermostat
Cement Resistor
Radiator
Power Switch
Switch Bracket
Air Regulator
Pressure gauge
Fitting
Gas Inlet Connector
Power Supply Circuit Board
Rectifier Bridge
Radiator
PCB Bracket
Inverter Circuit Board
Fan
Fan Grill
Power Cable Connector
Insulated Foot
Qty
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
4
Description
Body
Trigger
Electrode
Swirl Ring
Cutting Tip
Retaining Cup
pLEASE READ THE FOLLOWING cAREFULLy
MAINTENANcE
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL
AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR 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.
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.
Page 18
For technical questions, please call 1-800-444-3353.
ITEM 60767
Assembly Diagram
SAFETy
1A
2A
3A
4A
5A
MAINTENANcE
OpERATION
SETUp
6A
ITEM 60767
For technical questions, please call 1-800-444-3353.
Page 19
Limited 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 this product is free from defects in materials and workmanship for the
period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly,
to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper
installation, 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