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HALANSM® Shield Z4025 Swirl Gas Cap .11.835.201.1581 for Kjellberg Plasma Cutting Torch Consumables Replacement
O2 / Air / N2 / ArH2 (select to match nozzle and electrode)
OD / Height / Thread
Confirm exact specs with us.
HALANSM®
SILVER CUTTING
HLN-Z4030
HALANSM® HLN-Z4025 Kjellberg Z4025 Swirl Gas Cap .11.835.201.1581
Aftermarket Shield / Swirl Gas Cap, 2.5 mm bore, copper alloy, for Kjellberg HiFocus 80i-160i and PerCut 160/170 torches
HALANSM® HLN-Z4025 is an aftermarket plasma swirl gas cap (Shield) with a 2.5 mm bore and copper alloy body, built for Kjellberg HiFocus 80i, 100, 130i, 160i and PerCut 160 / 170 torches to deliver stable vortex gas flow, a focused arc, and clean, dross-free cuts.
Product Overview
The HALANSM® HLN-Z4025 mounts at the front of the PerCut torch, immediately behind the nozzle and protection cap. Its internal swirl geometry spins the plasma gas into a tight vortex around the arc column, which concentrates energy, narrows the kerf, and pushes molten slag away from the cut face.
Precision-machined from copper alloy, the cap also acts as a heat shield and locating seat for the nozzle and retaining components. A worn or incorrectly sized swirl gas cap is one of the most common causes of arc instability, poor edge squareness, and accelerated nozzle wear.
Key Advantages
2.5 mm Bore, Optimized Vortex
The 2.5 mm center bore is sized for the mid-range nozzle family (1.0-1.4 mm nozzles, 80-160 A). It produces a balanced vortex that stabilizes the arc without over-constricting gas flow.
Copper Alloy Thermal Mass
Copper construction pulls heat away from the torch front end and resists deformation under sustained cutting loads, helping maintain bore geometry over the full service interval.
Exact Seat Geometry
Machined to match the OEM Z4025 profile, including the locating step and retaining-cap contact surfaces. Drops in without modification to the torch body or surrounding consumables.
Batch-Controlled Consistency
Each production lot is dimensionally checked for bore, seat, and thread tolerances. Consistent parts mean predictable cut quality from the first piece to the last.
Specifications
Part Type
Shield / Swirl Gas Cap
OEM Reference
Z4025 / .11.835.201.1581
Bore Size
2.5 mm
Material
Copper alloy (rose-copper finish)
OD / Height / Thread
Confirm exact specs with us
Vent / Cooling
Based on product image; confirm venting detail with us
O2 / Air / N2 / ArH2 (select to match nozzle and electrode)
Position in Torch
Front consumable stack, between nozzle and protection / retaining cap
Selection Guide: Match Bore to Nozzle and Current
The Z-series swirl gas caps share the same seat family but differ in center bore. Fitting the wrong bore disrupts gas vortex and sealing, even if the part physically seats. The bore values below are verified by product image and supplier listing:
Swirl Gas Cap
Bore
Typical Current Range
Z4015
1.5 mm
25-50 A
Z4020
2.0 mm
50-80 A
Z4022
2.2 mm
80-100 A
Z4025
2.5 mm
100-160 A (this part)
Z4030
3.0 mm
160-200 A
Z4140
4.0 mm
HiFocus 280-440 A (.11.835.401.xxx body)
For the Z4025 (2.5 mm): pair with 1.0-1.4 mm nozzles (S2010X through S2016X / S2112X-S2116X family) and the correct SilverLine electrode. Provide your torch model and original part number for fitment check if you are outside the HiFocus 130i / 160i / PerCut 160 / 170 range.
Compatible Equipment and Application
Compatible with Kjellberg HiFocus 80i, HiFocus 100, HiFocus 130i, HiFocus 160i plasma systems using PerCut 160 and PerCut 170 torches. Broader supplier listings also reference HiFocus 280i / 360i / 440i and PerCut 370.1 / 450M; for those systems the higher-current Z4140 / Z4530 / Z4540 family is generally specified - confirm exact specs with us before ordering.
Applications: CNC plasma cutting of mild steel, carbon steel, stainless steel, and aluminum. Provide your torch model and original part number for fitment check when in doubt.
Installation and Handling
· Power down the plasma power supply and fully depressurize all gas lines before opening the torch.
· Remove the retaining cap, protection cap, worn swirl gas cap, nozzle, and electrode in order.
· Clean the torch seat and gas channels with compressed air. Inspect O-rings for dryness or damage.
· Install the electrode and nozzle first, then the swirl ring / gas guide (Z101 / Z102 / Z111 family).
· Seat the HALANSM® HLN-Z4025 swirl gas cap squarely against the locating step. Do not force it past a mismatch.
· Hand-tighten the retaining and protection caps. Over-tightening brass and copper parts damages seats and threads.
· Run a low-current test cut on scrap and verify arc stability, gas flow, and cut edge squareness.
Frequently Asked Questions
What Kjellberg torches fit the Z4025 swirl gas cap?
The Z4025 fits HiFocus 80i, 100, 130i, 160i with PerCut 160 / 170 torches. Provide your torch model and original part number for fitment check.
What does the 2.5 mm bore mean for cutting?
Bore controls vortex gas velocity around the arc. At 2.5 mm it is matched to 100-160 A nozzles; the correct bore keeps the arc focused and the cut edge square.
Can I use a 3.0 mm Z4030 instead of the Z4025?
No. A 3.0 mm bore is too large for the 100-160 A nozzle family and breaks the vortex. Stay within the same Z-series bore whenever you change current range.
Why does my cut quality drop after changing the cap?
Usually wrong bore size, dirty seat, or mixed current-range parts. Clean the seat, confirm Z4025 versus Z4030 / Z4140, and re-run a low-current test cut.
Is the HALANSM® Z4025 an original Kjellberg part?
No. It is an aftermarket compatible replacement. Kjellberg and all referenced model names are trademarks of their respective owners; this product is not OEM-authorized.
How should I store spare swirl gas caps?
Keep them in a dry, clean environment, separated by bore size. Lightly lubricate O-rings if applicable and avoid contamination of the seating surfaces.
Related Products
From the official HALANSM® Kjellberg consumables catalog:
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