Chicago Electric 92496 Welder User Manual
Contents
1. 17 18 19 20 21 Open the Acetylene Control Valve B8 with AC Label B10 about 1 4 turn and ignite the acetylene gas coming out of the Nozzle part D4 A WARNING Always point the Nozzle away from other people when lighting See Figures L and M Slowly open the Acetylene Control Valve B8 with AC Label B10 further until the smoke subsides and the flame jumps away from the end of the Nozzle part D4 slightly See Figure M Slowly open the Oxygen Control Valve B8 with OX Label B9 until a brilliant neutral flame is reached If the flame has a smooth inner cone the flame is called neutral See Figure N WARNING Always use appropriate welding goggles or welding helmet when welding or cutting at least a 10 shade lens rating OXYGEN CONTROL VALVE B8 with OX Label B9 ACETYLENE CONTROL VALVE B8 with AC Label B10 FIGURE N Once the welding or cutting job is competed turn off the Oxygen Control Valve B8 with OX Label B9 Then turn off the Acetylene Control Valve B8 with AC Label B10 NOTE Reversal of this procedure may cause damage to the Torch Handle parts B1 B10 See Figure N Shut off both cylinder valves See Figure E Drain the gas from the Oxygen Regulator parts A1 A20E by opening the Oxygen Control Valve B8 with OX Label B9 Complete this Step on the acetylene side See Figure N Release the pressure on the Acetylene and Oxygen Regulators2. cuca PEE ELECTRIC A Gae HEAVY DUTY OXY ACETYLENE WELDING OUTFIT Model 92496 ASSEMBLY AND OPERATING INSTRUCTIONS 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our Web site at http www harborfreight com Copyright 2003 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 For technical questions please call 1 800 444 3353 PRODUCT SPECIFICATIONS PF Describtion es Torch Handle e Regulator Polished finish all brass construction and Acetylene Regulator Construction Cutting Nozzle Construction Brass and Steel Chrome plated oxygen lever 1 Nozzle For cutting material up to 34 thickness Brass base with a Copper tip VH W2 2 Nozzle Construction Nozzle For welding material 1 16 1 8 Welding Hose Size and 15 Ft Long x 1 4 ID each Hose Rubber and brass fittings Flint Lighter Construction Chrome plated steel with a Flint tip Weight 19 Lbs SAVE THIS MANUAL You will need this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures parts list and assembly diagram Keep your invoice with this manual Write the invoice number on the inside of the front cover Keep this manual and invoice in a safe and dry place for future reference GENERAL SAFETY
3. correct directions normally clockwise for oxygen and counterclockwise for acetylene See Figure E next page SKU 92496 PAGE 8 IMPORTANT The Pressure Adjusting Screw 18 on the Acetylene Regulator and the Pressure Adjusting Screw A18 on the Oxygen Regulator should be opened slightly by turning counterclockwise to relieve pressure on the Regulator diaphragms before opening the cylinder valves If this is not done pressure from the cylinders may damage the diaphragms and render the Regulators inoperable RED OXYGEN REGULATOR PARTS A1 A20E WELDING NOZZLE D4 OR CUTTING NOZZLE D6 Kis CYLINDER VALVE CUTTING ATTACHMENT ADJUSTING PARTS C1 C27 SCREW or GREEN A18 ACETYLENE REGULATOR parts 1 19 TORCH i HANDLE l PARTS B1 B10 _ CYLINDER ial VALVE RED WELDING PRESSURE ADJUSTING SCREW 18 WELDING HOSE D1A peed ACETYLENE Se Le CYLINDER NOT INCLUDED OXYGEN CYLINDER NOT INCLUDED FIGURE E 6 Connect the GREEN and RED Welding Hoses D1A or D1B to the proper connec tions on the Torch Handle parts B1 B10 A WARNING SKU 92496 If any traces of oil or grease are found do not use Contact PAGE 9 your gas supplier immediately See Figure F TORCH HANDLE PARTS B1 B10 GREEN OX WELDING HOSE FIGURE F RED AC WELDING HOSE D1B 7 Connect the Cutting Attachment parts C1 C27 to the Torch Handle parts B1 B10 Alway
4. ACE 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 92496 PAGE 14 PARTS LIST AND DIAGRAM 1 ACETYLENE REGULATOR Note When ordering parts from this parts list and diagram always take the number from the No column on the left For example If you wish to order a Body for this regulator you d take the part number from the No column 1 So you d order part 1 Body Nut H P Gauge 2 1 x 400psi 2800kpa Diaphragm Plate L P Gauge 2 1 x 30psi 200kpa 12C Diaphragm Inlet Nut CGA 510 Centralizer Inlet Spigot Slip Ring Filter Adjusting Spring Valve Spring Spring Button Anti Vibrator Bonnet Valve Label Nozzle Adjusting Screw T Bar Plunger Outlet Adaptor Diaphragm Assembly NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts SKU 92496 PAGE 15 PARTS LIST AND DIAGRAM 2 OXYGEN REGULATOR Note When ordering parts from this parts list and diagram always take the number from the No column on the left and add a suffix of A to the beginning For exam
5. RULES Z WARNING READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed below may result in electric shock fire and or serious injury SAVE THESE INSTRUCTIONS WORK AREA 1 Keep your work area clean and well lit Cluttered benches and dark areas invite accidents 2 Do not operate power tools in explosive atmospheres such as in the presence of flammable liquids gases or dust Power tools create sparks which may ignite the dust or fumes SKU 92496 PAGE 2 10 11 12 13 Keep bystanders children and visitors away while operating a power tool Distractions can cause you to lose control Protect others in the work area from debris such as chips and sparks Provide barriers or shields as needed PERSONAL SAFETY Stay alert Watch what you are doing and use common sense when oper ating a power tool Do not use a power tool while tired or under the influ ence of drugs alcohol or medication A moment of inattention while operat ing power tools may result in serious personal injury Dress properly Do not wear loose clothing or jewelry Contain long hair Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts Avoid accidental starting Be sure the Power Switch is off before plugging in Carrying power tools with your finger on the Power Switch or plugging in power tools with the Power Switch on invites accid
6. Safety precautions such as using natural or forced air ventilation and wearing an ANSI approved respirator are ESSENTIAL to reduce the risk of developing the above illnesses 6 Always keep the Welding Hoses D1A or D1B away from moving parts on the tool Examine the Welding Hoses for cuts burns or worn areas before each use If any damaged areas are found replace the Welding Hoses immediately T Read and understand all instructions and safety precautions as outlined in the manufacturer s manual for the material you will weld or cut SKU 92496 PAGE 6 10 11 12 13 14 15 16 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 Never use oil or grease on any inlet connector outlet connector or cylinder valves Always use reverse flow check valves on the torch and regulator This greatly reduces the possibility of mixing gases in the regulator or hose Working pressure on the Acetylene Regulator should NEVER be set above 15 PSI There must be TWO O Rings C24 C25 on the Connector C23 end The absence of either O Ring can lead to flashback within the Torch Handle or C
7. ad a chemical known to the State of California to cause birth defects or other reproductive harm California Health amp Safety Code 25249 5 et seq SKU 92496 PAGE 7 UNPACKING When unpacking check to make sure all the parts shown on the Parts Lists on pages 15 19 are included 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 ASSEMBLY AND OPERATING INSTRUCTIONS For additional information regarding the parts listed in the following pages refer to the Parts Diagrams on pages 15 19 2 3 The following instructions are for acetylene gas use only Contact your gas supplier for instructions on the use of other fuel gases Make sure to secure the cylinders as noted in the Specific Safety Rules section While standing to one side crack each cylinder valve Cracking is to quickly open and close the valve allowing gas to escape and clearing the valve of any foreign material A WARNING If oil or grease is found discontinue using cylinder and immediate y contact your supplier See Figure D QUICKLY CYLINDER OPEN CLOSE VALVE VALVE TO HANDLE CRACK ACETYLENE OR OXYGEN CYLINDER NOT INCLUDED FIGURE D Attach the GREEN Oxygen Regulator parts A1 A20E to the oxygen cylinder Then attach the RED Acetylene Regulator parts 1 19 to the acetylene cylinder Make sure they are tightened in the
8. by turning their Pressure Adjusting Screws 18 A18 counterclockwise See Figure E SKU 92496 PAGE 13 INSPECTION MAINTENANCE AND CLEANING 1 WARNING Make sure the Welding Kit is cool to the touch and disconnected from its oxygen and acetylene cylinders before performing any inspection maintenance or cleaning procedures 2 BEFORE EACH USE inspect the general condition of the Welding Kit Check for loose screws misalignment or binding of moving parts cracked or broken parts damaged Welding Hoses D1A or D1B and any other condition that may affect its safe operation If a problem occurs have the problem corrected before further use Do not use damaged equipment 3 PERIODICALLY use the Tip Cleaner D7 to clean out dirt and debris from the Nozzle parts D4 Make sure to use the correct size Tip Cleaner for each individual Nozzle See Assy Diagram E 4 TO CLEAN use a clean cloth If necessary a mild detergent may be used Do not immerse any part of the Welding Kit in liquid Do not use solvents or other flammable agents to clean the Welding Kit PLEASE READ THE FOLLOWING CAREFULLY 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 REPL
9. e 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 welding process and for at least one half hour after the welding 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 hazard Do not dispose of hot slag in containers holding combustible materials Keep a fire extinguisher nearby and know how to use it 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 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 SKU opPy keating welding or cutting PAGE5 5 Avoid overexposure t
10. ents Remove adjusting keys or wrenches before turning the power tool on A wrench or a key that is left attached to a rotating part of the power tool may result in personal injury Do not overreach Keep proper footing and balance at all times Proper footing and balance enables better control of the power tool in unexpected situations Use safety equipment Always wear eye protection Dust mask non skid safety shoes hard hat or hearing protection must be used for appropriate conditions TOOL USE AND CARE Use clamps not included or other practical ways to secure and support the workpiece to a stable platform Holding the work by hand or against your body is unstable and may lead to loss of control Do not force the tool Use the correct tool for your application The correct tool will do the job better and safer at the rate for which it is designed Do not use the power tool if the Power Switch does not turn it on or off Any tool that cannot be controlled with the Power Switch is dangerous and must be replaced Disconnect the Power Cord Plug from the power source before making any adjustments changing accessories or storing the tool Such preventive safety measures reduce the risk of starting the tool accidentally SKU 92496 PAGE 3 14 15 16 17 18 19 TOOL USE AND CARE Store idle tools out of reach of children and other untrained persons Tools are dangerous in the hands of untrained users Maintai
11. n tools with care Keep cutting tools sharp and clean Properly maintained tools with a sharp cutting edge are less likely to bind and are easier to control Do not use a damaged tool Tag damaged tools Do not use until repaired Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the tool s operation If damaged have the tool serviced before using Many accidents are caused by poorly maintained tools Use only accessories that are recommended by the manufacturer for your model Accessories that may be suitable for one tool may become hazardous when used on another tool SERVICE Tool service must be performed only by qualified repair personnel Service or maintenance performed by unqualified personnel could result in a risk of injury When servicing a tool use only identical replacement parts Follow instructions in the Inspection Maintenance And Cleaning section of this manual Use of unauthorized parts or failure to follow maintenance instructions may create a risk of electric shock or injury SKU 92496 PAGE 4 SPECIFIC SAFETY RULES 1 Maintain labels and nameplates on the Heavy Duty Welding Kit These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement 2 Maintain a safe working environment Keep the work area well lit Make sure there is adequate surrounding workspace Always keep the work area free of obst
12. o 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 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 Work in a confined area only if it is well ventilated or while wearing an air supplied respirator 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 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 Inhalation Hazard Welding Produces TOXIC FUMES and GASSES Exposure to welding gasses 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 gasses or fumes are Early onset of Parkinson s Disease e Heart Disease Damage to the reproductive organs e Ulcers Inflammation of the small intestine or stomach Kidney damage Respiratory diseases such as emphysema bronchitis or pneumonia
13. ple If you wished to order a Filter for this regulator you d take the part number from the No column 6 and add an A to the beginning So you d order part A6 Body H P Gauge 2 1 x 4000psi 28000kpa L P Gauge 2 1 x 200psi 1400kpa Inlet Nut CGA 540 Inlet Spigot Filter Valve Spring Anti Vibrator Valve Nozzle Plunger Diaphragm Assembly Nut Diaphragm Plate Components Of 12 Diaphragm Centralizer Slip Ring Adjusting Spring Spring Button Bonnet Label Adjusting Screw T Bar Outlet Adaptor Safety Valve Safety Body Safety Rubber Safety Seat Safety Spring Safety Cap NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts SKU 92496 PAGE 16 PARTS LIST AND DIAGRAM 3 TORCH HANDLE Components Of 8 1 Note When ordering parts from this parts list and diagram always take the number from the No column on the left and add a suffix of B to the beginning For example If you wished to order a Tail for this handle you d take the part number from the No column 4 and add an B to the beginning So you d order part B4 eee le Torch Head Valve Stem Assembly Handle Valve Inner Tube Washer Tail Nut Oxygen Valve Body Adjusting Knob Gas Valve Body Label OX Cover Label AC NOTE Some parts are listed and shown for illustration purposes only and are not available individ
14. ructions grease oil trash and other debris 3 Prevent eye injury and burns Wearing and using personal safety clothing and safety devices reduce the risk for injury Wear ANSI approved welding goggles such as those included in this kit 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 or cutting overhead or in confined spaces wear flame resistant ear plugs or ear muffs to keep sparks out of ears 4 Prevent accidental fires Remove any combustible material from the work area 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 combustibl
15. s check the Connector C23 and Coupling Nut C22 for damage or oil If either are found discontinue use and contact your gas supplier Make sure the two O Rings C24 C25 are not damaged or missing otherwise gases will mix inside the Torch Handle parts B1 B10 and result in flashback or backfires See Figures G and H CUTTING ATTACHMENT PARTS C1 C27 CONNECTOR C23 O RING O RING C24 C25 GREEN OXYGEN WELDING HOSE D1A Fi Ts LEL SLE F TORCH HANDLE PARTS B1 Smeg D1B 8 Check connections for leaks Adjust the Acetylene Regulator parts 1 19 and Oxygen Regulator parts A1 A20E to their normal operating pressure Use an approved leak detection solution to check for leaks at the Welding Hoses D1A and D1B and cylinder valve connections If leaks are found tighten the nuts more SKU 92496 PAGE 10 securely If a leak still persists discontinue use and call your gas supplier A WARNING NEVER set the Acetylene Regulator parts 1 19 to a delivery pressure above 15 PSI See Figures I J and K WELDING TIP CHART Oxygen Pressure Acetylene Pressure Metal Thickness Tip Size P S I G P S I G EE s 3 5 1132 5 64 s gt 5 3 64 3 32 1 16 1 8 1 8 3 16 3 16 1 4 1 4 1 2 FIGURE OXY ACETYLENE MULTI FLAME HEATING CHART Acetylene Pressure Tip Size Range FIGURE J OXY ACETYLENE CUTTING NOZZLE CHART O
16. ually as replacement parts SKU 92496 PAGE 17 PARTS LIST AND DIAGRAM 4 CUTTING ATTACHMENT Note When ordering parts from this parts list and diagram always take the number from the No column on the left and add a suffix of C to the beginning For example If you wished to order a Head for this attachment you d take the part number from the No column 2 and add an C to the beginning So you d order part C2 el ee Tip Nut HP Spring Head Washer Oxygen Tube Valve Cap Nut Lever Ferrule Sprial Pin Nut Coupling Nut Fuel Tube Connector Inner Tube A O Ring Big Inner Tube B O Ring Small Spiro Valve Stem Assembly Inner Tube C Valve O Ring Washer Washer Teflon Nut Spring Adjusting Knob Body Label OX Valve OOnNDOBRWND NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts SKU 92496 PAGE 18 PARTS LIST AND DIAGRAM 5 ACCESSORY PARTS Note When ordering parts from this parts list and diagram always take the number from the No column on the left and add a suffix of D to the beginning For example If you wished to order a Welding nozzle you d take the part number from the No column 4 and add an D to the beginning So you d order part D4 So pesort eciton Green OX Welding Hose Safety Glasses Red AC Welding Hose Flint Lighter Welding Nozzle 2 10 Oxygen Check Valve C
17. utting Attachment For the Cutting Attachment inspect the tapered seating surfaces on the Tip and in the Torch Head Have a qualified technician resurface the seat area if it has dents burrs or is burned A poor seating surface may result in backfire or flashback Backfire and flashback When the flame goes out with a loud pop it is called a backfire Backfire can be caused by 1 operating the Torch at lower pressures than required for the Tip used 2 touching the Tip against the workpiece 3 overheating the Tip or 4 an obstruction in the Tip If backfire occurs shut off the Torch Handle Valves oxygen first and after remedying the cause relight the Torch A flashback is a condition that results when the flame flashes back into the Torch and burns inside with a shrill hissing or squealing noise If flashback occurs close the Torch Handle Valves oxygen first IMMEDIATELY Flashback generally indicates a problem that should be repaired A clogged Tip improper functioning of the Valves or incorrect acetylene oxygen pressure could lead to flashback Make sure to find the cause before relighting the Torch WARNING This product when used for welding and similar applica tions contains or produces a chemical known to the State of California to cause cancer and birth defects or other reproductive harm California Health amp Safety Code 25249 5 et seq WARNING The brass components of this product contain le
18. utting Nozzle 1 11 Acetylene Check Valve Tip Cleaner NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts SKU 92496 PAGE 19
19. xygen Acetylene Pressure Pressure Metal Thickness P S I G P S 1 G o e eee 5 O a d n eo as oes f oS FIGURE K SKU 92496 PAGE 11 9 To determine the proper Acetylene Regulator parts 1 19 pressure and Oxygen Regulator parts A1 A20E pressure for neutral flame adjusting refer to Figures I and K HIGH PRESSURE LEVER OXYGEN CONTROL VALVE B8 with OX Label B9 PRE HEAT OXYGEN CONTROL VALVE C26 CUTTING NOZZLE ACETYLENE CONTROL VALVE FIGURE L B8 with AC Label B10 l 10 Depending on use attach either a Cutting Nozzle 1 D6 or Welding Nozzle 2 D4 to the Cutting Attachment parts C1 C27 See Figure L 11 Open the Oxygen Control Valve B8 with label B9 on the Torch Handle Open the Pre Heat Oxygen Valve C26 on the Cutting Attachment Adjust the Oxygen Regulator parts A1 A20E to the desired working pressure Then close the Oxygen Control Valve on the Torch Handle See Figures E and L 12 Open the Acetylene Control Valve B8 with label B10 on the Torch Handle Adjust the Acetylene Regulator parts 1 19 to the desired working pressure Then close the Acetylene Control Valve on the Torch Handle See Figures E and L 13 Hold the Torch Handle parts B1 B10 in one hand and the Flint Lighter D9 in the other hand See Figure M FIGURE M ACETYLENE CONTROL VALVE AC Label B10 FLINT LIGHTER D9 88 with SKU 92496 PAGE 12 14 15 16
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