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CUTTING SPARKS CAN CAUSE INJURY, FIRE, OR EXPLOSION 

 

Remove all flammable materials from the plasma cutting and gouging area 

 

Always have a charged fire extinguisher available in the cutting area 

 

When not cutting make sure the cutting tip is not grounded, this causes a heat build up and possible 
fire 

 

Avoid cutting or gouging near hydraulic lines, fuel lines, electrical cords, air hoses, or welding guns 
and cables 

 

Sparks and hot metal fly out from the arc when cutting, wear approved safety glasses with side 
shields under approved helmets, wear proper body and hand protection, and wear flame resistant ear 
plugs to keep sparks from entering the ears 

CYLINDERS CAN EXPLODE IF DAMAGED 

 

Gas cylinders contain gas under very high pressure. If damaged they can result in that cylinder ex-
ploding. Gas cylinders are a major part of metalworking and must be treated with care. 

 

Protect gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs 

 

Always keep cylinders in an upright position securely fastened to a fixed support 

 

Valve protection caps should always be in place and hand tight except when the cylinder is in use 

 

Keep all cylinders away from any cutting or electrical circuits 

 

Never allow the arc from a plasma cutter to contact a cylinder 

 

Never cut any type of pressurized cylinder, an explosion could result 

 

Always turn your face away from the valve when opening the cylinder 

 

Read and follow all instructions on compressed gas cylinders, associated equipment, and CGA pub-
lication P-1 listed in the Safety Standards before using 

PLASMA ARC CAN INJURE 

 

The heat from the plasma arc is very intense and forceful and can burn through protective clothing 
and pierce skin causing serious burns 

 

The pilot arc can cause severe burns, keep body away from the cutting tip when the trigger is de-
pressed 

 

Always point the cutting tip away from your body when trigger is pressed, the pilot arc comes on 
immediately 

 

Do not hold or grip the material being cut close to the cutting tip 

 

Always wear protective clothing when operating the cutter, cover all exposed body areas 

 

Turn off power source and unplug unit when dis-assembling torch handle or replacing components 
of gun 

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS 

 

Electric current used in Plasma cutting and welding create Electric and Magnetic Fields (EMF) 

 

Magnetic fields can affect pacemakers and wearers should avoid proximity to EMF. Wearers need to 
contact their doctors before operating this type of equipment 

 

Exposure to EMF during operation of this equipment may have other health effects which are not 
yet known 

 

Route the work and torch cables together and not around your body 

 

Do not place your body between the torch cable and the work cable. They both need to be on the 
same side of your body when operating 

 

Do not work next to the cutting or welding machine 

ELECTRICALLY POWERED EQUIPMENT 

 

Disconnect power source or disconnect the switch at the fuse box before working on any equipment 

 

Only install equipment using the US National Electrical Code, all local codes, and the manufactur-
er’s recommendations 

 

Ground the equipment in accordance with the US National Electrical Code 

KDAR Company 

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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