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Chicago Electric 92496 - page 1
HEA VY DUTY OXY - ACETYLENE WELDING OUTFIT ASSEMBL Y AND OPERA TING INSTR UCTIONS 3491 Mission Oaks Blvd., Camar illo , CA 93011 Visit our W eb site at: http://www .harborfreight.com Cop yr ight © 2003 b y Harbor F reight T ools ® . All rights reserved. No portion of this manual or an y ar twork contained herein may be reproduced in an y shape or ...
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Chicago Electric 92496 - page 2
SKU 92496 PAGE 2 PRODUCT SPECIFICA TIONS SA VE THIS MANU AL Y ou will need this manual f or the safety warnings and precautions, assemb ly , operating, inspection, maintenance and c leaning pr ocedures, par ts list and assembl y dia gram. K eep y our in voice with this man ual. Write the in v oice number on the inside of the fr ont cover . K eep th ...
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Chicago Electric 92496 - page 3
SKU 92496 PAGE 3 3. Keep b ystander s, children, and visitor s away while operating a po wer tool. Distractions can cause y ou to lose control. Protect others in the work area from debris such as chips and spar ks . Pro vide barr iers or shields as needed. PERSONAL SAFETY 4. Stay alert. W atch what y ou are doing, and use common sense when oper - a ...
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Chicago Electric 92496 - page 4
SKU 92496 PAGE 4 T OOL USE AND CARE 14. Store idle tools out of reach of c hildren and other untrained persons. T ools are dangerous in the hands of untrained users. 15. Maintain tools with care . Keep cutting tools sharp and c lean. Proper l y maintained tools with a shar p cutting edge are less lik ely to bind and are easier to control. Do not us ...
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Chicago Electric 92496 - page 5
SKU 92496 PAGE 5 SPECIFIC SAFETY R ULES 1. Maintain labels and nameplates on the Heavy Duty W elding Kit. These carr y impor tant inf or mation. If unreadab le or missing, contact Harbor Freight T ools f or a replacement. 2. Maintain a saf e working en vir onment. K eep the wor k area w ell lit. Mak e sure there is adequate surrounding wor kspace . ...
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Chicago Electric 92496 - page 6
SKU 92496 PAGE 6 7. Read and understand all instructions and safety precautions as outlined in the manufacturer’ s manual for the material y ou will weld or cut. 6. Alwa ys keep the W elding Hoses (D1A, or D1B) a way fr om moving parts on the tool. Examine the Welding Hoses f or cuts , bur ns , or wor n areas bef ore each use . If an y damaged ar ...
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Chicago Electric 92496 - page 7
SKU 92496 PAGE 7 8. Proper cylinder care. Secure cylinders to a car t, wall, or post, to pre vent them from falling. All cylinders should be used and stored in an upright position. Ne v er drop or str ik e a cylinder. Do not use cylinders that ha ve been dented. Cylinder caps should be used when moving or storing cylinders . Empty cylinders should ...
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Chicago Electric 92496 - page 8
SKU 92496 PAGE 8 UNP ACKING When unpacking, chec k to make sure all the par ts shown on the P ar ts Lists on pa g es 15- 19 are included. If an y par ts are missing or brok en, please call Harbor F reight T ools at the number sho wn on the co v er of this manual as soon as possib le . ASSEMBL Y AND OPERA TING INSTRUCTIONS For additional inf ormatio ...
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Chicago Electric 92496 - page 9
SKU 92496 PAGE 9 5. IMPOR T ANT! The Pressure Adjusting Screw (18) on the Acetylene Regulator and the Pressure Adjusting Screw (A18) on the Oxygen Regulator should be opened slightly by t urning counterclockwise to relie ve pressure on the Regulator diaphragms before opening the cylinder v alv es. If this is not done , pressure from the cylinders m ...
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Chicago Electric 92496 - page 10
SKU 92496 PAGE 10 your gas supplier immediatel y . (See Figure F .) 7. Connect the Cutting Attachment (par ts C1-C27) to the T orch Handle (par ts B1- B10). Alw ays chec k the Connector (C23) and Coupling Nut (C22) f or damage or oil. If either are found, discontin ue use and contact your gas supplier . TORCH HANDLE (P ARTS B1-B10) RED (A C) WELDIN ...
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Chicago Electric 92496 - page 11
SKU 92496 PAGE 11 W ARNING! NEVER set the Acetylene Regulator (par ts 1-19) to a deliver y pressure abo ve 15 PSI. (See Figures I, J, and K.) Metal Thickness Tip Size Oxyg en Pressure P .S.I.G. Acetylene Pressure P .S.I.G. 1/64” - 3/64” 00 3 Min. Max. Min. Max. 5 3 5 1/32” - 5/64” 3/64” - 3/32” 1/16” - 1/8” 1/8” - 3/16” 3/16” ...
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Chicago Electric 92496 - page 12
SKU 92496 PAGE 12 9. T o determine the proper Acetylene Regulator (par ts 1-19) pressure and Oxygen Regulator (par ts A1-A20E) pressure f or neutral flame adjusting, ref er to Figures I, and K . PRE-HEA T O XYGEN CONTROL V AL V E (C26) O XYGEN CONTR OL V A L VE (B8 with O X Label (B9)) A CETYLENE CONTROL V A L V E (B8 with AC Label (B10)) FIGURE L ...
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Chicago Electric 92496 - page 13
SKU 92496 PAGE 13 14. Open the Acetylene Control V alv e (B8 with A C Label (B10)) about 1/4 tur n, and ignite the acetylene gas coming out of the Nozzle (par t D4). 15. Slo wly open the Acetylene Control V al v e (B8 with AC Label (B10)) fur ther until the smoke subsides and the flame jumps a wa y from the end of the Nozzle (par t D4) slightly . ( ...
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Chicago Electric 92496 - page 14
SKU 92496 PAGE 14 INSPECTION, MAINTENANCE, AND CLEANING 1. W ARNING! Make sure the W elding Kit is cool to the touc h and disconnected fr om its o xyg en and acetylene c ylinders bef ore performing an y inspection, maintenance , or cleaning pr ocedures. 2. BEFORE EA CH USE, inspect the general condition of the W elding Kit. Check f or loose scre ws ...
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Chicago Electric 92496 - page 15
SKU 92496 PAGE 15 P ARTS LIST AND DIA GRAM 1 - A CETYLENE REGULA T OR NO TE: Some par ts are listed and shown f or illustr ation pur poses only , and are not av ailabl e individually as replacement par ts . Note: When ordering parts from this par ts list and diagram always tak e the n umber from the No. column (on the left). For example: If you wis ...
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Chicago Electric 92496 - page 16
SKU 92496 PAGE 16 NO TE: Some par ts are listed and shown f or illustration purposes only , and are not av ailab le individually as replacement par ts. P ARTS LIST AND DIA GRAM 2 - OXYGEN REGULA T OR Note: When ordering par ts from this par ts list and diagram always tak e the n umber from the No. column (on the left) and add a suffix of A to the b ...
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Chicago Electric 92496 - page 17
SKU 92496 PAGE 17 NO TE: Some par ts are listed and shown f or illustration purposes only , and are not av ailab le individually as replacement par ts. P ARTS LIST AND DIA GRAM 3 - TORCH HANDLE Note: When ordering par ts from this par ts list and diag r am alw ays tak e the number from the No. column (on the left) and add a suffix of B to the begin ...
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Chicago Electric 92496 - page 18
SKU 92496 PAGE 18 NO TE: Some par ts are listed and shown f or illustration purposes only , and are not av ailab le individually as replacement par ts. P AR TS LIST AND DIA GRAM 4 - CUTTING ATT A CHMENT Note: When ordering par ts from this par ts list and diag ram alwa ys take the n umber from the No. column (on the left) and add a suffix of C to t ...
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Chicago Electric 92496 - page 19
SKU 92496 PAGE 19 NO TE: Some par ts are listed and shown f or illustration purposes only , and are not av ailab le individually as replacement par ts. P ARTS LIST AND DIA GRAM 5 - A CCESSOR Y P AR T S Note: When ordering par ts from this par ts list and diag r am alw ays tak e the number from the No. column (on the left) and add a suffix of D to t ...
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