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KDAR Company 

SAFETY PRECAUTIONS AND WARNINGS 

PLEASE READ BEFORE USING EQUIPMENT 

 

Keep children away from this equipment 

 

Protect your self and others from possible injury 

 

Pacemaker wearers should consult with their doctor before operating 

 

Read and follow all instructions in this manual before operating 

 

All installation, operation, and maintenance procedures should be per-
formed only by qualified individuals 

ELECTRIC SHOCK CAN KILL. 

 

Plasma cutting uses more voltage than welding, as high as 200 to 400 volts DC when output is oper-
ating. 

 

The input circuits are also live and hot when the power is on 

 

Do not touch live electrical parts 

 

Wear dry, hole free insulated work gloves and body protection when operating 

 

Do not touch torch components if in contact with the work piece or ground 

 

Always turn off power before cleaning, checking, or changing parts 

 

Properly ground this piece of equipment per state and federal requirements 

 

Inspect and replace any worn or damaged torch cables or leads 

 

Keep all panels and covers securely in place 

 

Keep away from the torch tip and pilot arc when trigger is pressed 

 

Ground the metal or work piece to the ground cable (Earth Clamp) 

 

Never dip the tip into water to cool or attempt to use cutter in or under water 

 

This DC equipment holds a lot of power in the off position, before touching, make sure voltage is 
near zero on input capacitors before touching any parts. 

ARC RAYS CAN BURN SKIN AND EYES 

 

Arc rays when cutting produce intense ultraviolet and infrared rays that can burn skin and eyes 

 

Where face protection, either helmet or shield when operating with ANSI Z49.1 approved shade #5 
recommended for all cutting currents less than 300 amperes. The lens should conform to ANSI 
Z87.1 standards for testing. 

 

Wear approved safety glasses with side shields under the face protection 

 

Warn others not to stare at the arc as it can cause damage to the eyes. Provide barriers to protect 
other workers in the area from the arc while operating 

 

Wear flame resistant gloves, clothing, and shoes when operating 

FUMES AND GASES CAN BE HAZARDOUS 

 

Plasma cutting produces fumes and gases and breathing these gases is hazardous to your health 

 

Keep your head out of the fumes and do not breath the fumes while cutting 

 

Work only in a confined area if it has sufficient ventilation, or while wearing an air supplied respira-
tor. Fumes from cutting deplete the oxygen supply and can be harmful. Always be sure there is am-
ple breathing air 

 

Read the MSDS sheets and the instructions from manufacturers for metals to be cut, coatings, and 
cleaners 

 

Do not use the Plasma cutter near hydrocarbon vapors coming from degreasing, cleaning, or spray-
ing operations. The heat and rays can react with solvent vapors to create the gas phosgene, a very 
toxic gas and other irritating gases 

 

Do not cut coated metals, such as galvanized, lead, or cadmium plated steel. Before cutting, all plat-
ing must be removed. The area must be well ventilated or an air supplied hood must be used. The 
coatings and chemicals when burned cause highly irritating and toxic fumes. 

 

Do not cut containers with toxic, flammable, or reactive elements stored in them. They must be 
emptied and properly prepared before cut. They must be cleaned and prepared to cut by the AWS 
F4.1 guidelines for cutting containers or tubes 

WARNING 

Summary of Contents for PL-40

Page 1: ...thout reading ALL of this manual and the safety precautions and warnings illustrated in this manual OPERATOR S MANUAL Model PL 40 Plasma Cutter KDAR Company Tel 636 493 9920 3671 New Town Blvd Fax 636...

Page 2: ...s Precautions 1 Specifications 4 Package Contents 4 Installation and Setup 5 Operation Safety 7 Operation Controls 8 Operation Design Features 9 Operation Job Setup and Control Settings 10 Operation C...

Page 3: ...either helmet or shield when operating with ANSI Z49 1 approved shade 5 recommended for all cutting currents less than 300 amperes The lens should conform to ANSI Z87 1 standards for testing Wear app...

Page 4: ...and CGA pub lication P 1 listed in the Safety Standards before using PLASMAARC CAN INJURE The heat from the plasma arc is very intense and forceful and can burn through protective clothing and pierce...

Page 5: ...S AMERICAN WELDING SOCIETY AWS C5 2 Recommended Practices for Plasma Arc Cutting AWS F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting OSHA STANDARDS OSHA 29 CFR 1910 Safety...

Page 6: ...2 Net Weight 27 Max Compressed Air Pressure psi 75 Min Compressed Air Pressure psi 60 Flow of Compressed Air CFM 3 5 Cutting Thickness Inches 0 02 5 Package Contents Plasma Cutter with gun ground clam...

Page 7: ...re dirt and dust around the unit should be kept to a minimum The PL 40 requires a supply of clean dry air Oil in the air will cause a problem with the PL 40 and must be removed The air supply pressure...

Page 8: ...er Be careful not to allow the cutting torch to touch the cylinder Always keep the cylinder clear of electrical parts Maximum pressure 80 psi KDAR Company 6 Assembly Instructions 1 Attached Brass fitt...

Page 9: ...e nozzle and plasma arc Operate the pilot arc with extreme care it can burn the operator or others and burne through safety clothing Fumes Gases Can Be Hazardous Plasma cutter should only be used in a...

Page 10: ...coincide with the unit shut ting down Do not turn off power when light is on fan is needed to cool the unit 4 Pressure Gauge 5 Output Control Used to set cutting output 6 Air Pressure Control Knob Pu...

Page 11: ...th LED power indicator LED warning light for thermal or pressure indi cator Fan cooled for long life No pre heat No distortion of metal Clean cuts Removes spot welds easily Severance cuts to 7 8 with...

Page 12: ...piece prior to cutting 4 Connect the unit to the power supply with 220 Plug as wired Do NOT use 110V Adapter Cord as the power supply will not work with this adapter even though it is included with t...

Page 13: ...he torch at a 30 angle away from the operator 3 Pull the trigger and the arc will start immediately 4 Slowly start moving the torch across the metal in suring that the sparks are going through the met...

Page 14: ...Gas Air Pressure Check the torch tip electrode air diffuser and outside nozzle Keep area around the machine clean and free of debris that could restrict the air flow of the cutter Every Three Months...

Page 15: ...Check the electrode 5 and replace if the center has a pit that is more then 1 16 deep or has worn down more than 1 16 Check Air Diffuser for cracks replace if cracked or chipped Electric Shock Can Kil...

Page 16: ...ts you may get repeated trips 2 Install or connect to a larger circuit or turn down output control 1 Check to insure input power is on 2 Check to insure power cord is properly connect ed to power supp...

Page 17: ...r on and allow the PL 40 to cool for at least 10 minutes The LED will turn off when the machine has cooled sufficiently 2 If the LED comes on continually prior to reaching the rated duty cycle check t...

Page 18: ...If warranty work is required DO NOT RE TURN THIS PLASMA CUTTER TO THE RETAILER Contact KDAR Company for instructions Visit www hotmaxtorches com or call KDAR Company M F 8AM 5PM CST to locate the near...

Page 19: ...nal Hot Max Products KDAR Company 17 Model 125WFG 125 Amp Wire Feed MIG Welder Model 135WFG 135 Amp Wire Feed MIG Welder Model 175WFG 175 Amp Wire Feed MIG Welder Model SPG Spool Gun Fits Hot Max MIG...

Page 20: ...Company 18 Additional Hot Max Products Model 500G Propane Torch Model WC100 Welding Plasma Cutter Cart The perfect cart for your Hot Max PL 40 Plasma Cutter 500G Now with new IDLE BOOST FUEL SAVER VA...

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