Harbor Freight Tools Portable Torch Kit with Oxygen and Acetylene Tanks Product manual
Contents
1. lf Delivery Pressure decreases The leak is at the regulator outlet connection within the hose at the torch inlet connection or at the Torch Valve on the Torch Handle 1 Release pressure from the system 2 Tighten the regulator outlet connection 3 Tighten the Torch Handle Inlet connection 4 Repeat Gauge Leak Test a If the gauges do not change the test is completed and the system has no leaks b If the connections are still leaking have the regulator Torch Handle and hoses examined by a qualified technician If the hoses are leaking replace them do not attempt to repair the hoses No Leaks Found If the leak testing has been completed and the unit is found to be working properly open the cylinder valves turning counterclockwise and proceed to operation WARNING Only open Acetylene Cylinder Valve 1 4 to 1 2 turn to allow quick shutoff Acetylene Cylinder Oxygen Cylinder 13 Open Cylinder Valves Only After Testing Confirms There Are No Leaks WARNING KEEP WRENCH ON CYLINDER S VALVE whenever cylinder is in use to allow quick shutoff in case of emergency Page 9 Welding Tip Pressure Settings This Torch Handle is capable of welding metals from 1 32 up to 1 1 4 thick The included Welding Nozzle size 0 will weld metals up to 1 16 thick Check the thickness of the metals to be welded and use the chart below to choose the size nozzle for the job If welding metals other2. Note For additional information regarding the parts listed in the following pages refer to the Assembly Diagram near the end of this manual All instructions in this manual are for oxygen and acetylene gas only 1 Secure cylinders to a cart wall or post to prevent them from falling Do not place Acetylene Cylinder on its side Page 6 For technical questions please call 1 888 866 5797 Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product 3 The work area must have a fireproof floor 4 Secure loose workpieces using a vise or clamps not included to prevent movement while working Note Proper weld preparation can be complicated and is outside the scope of this manual Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product TO PREVENT SERIOUS INJURY FROM EXPLOSION Turn the Oxygen and Acetylene Torch Valves fully clockwise closed oxygen first and acetylene second before making any adjustments or performing any inspection or service to this Torch Kit WARNING TO PREVENT FIRE AND EXPLOSION Make sure there is no oil grease or ignition source such as a hot weld electric motor or another welding operation nearby before proceeding with the next step Item 65818 2 While standing to o
3. Eye Injury Wear ANSI approved safety goggles with side shields Read the manual before set up and or use WARNING marking concerning Risk of Explosion Do not use flame to detect leaks Handle cylinders properly WARNING marking concerning Risk of Inhalation Hazard Use in well ventilated area only Page 5 Specifications Regulators Oxygen CGA 540 Acetylene CGA 200 Welding Nozzle VM W Size 0 welds up to 1 16 Cutting Tip 3 101 Size 0 cuts up to 1 2 Cutting Tip f Replacement Victor Style Victor Style Tip Capable of welding from 1 32 up to 1 1 4 with the appropriate welding nozzle Capable of cutting from 1 2 up to 3 with the appropriate cutting tip 12 5 ft L x 3 16 inside diameter Color Coded Twin Hose Green oxygen hose w right hand fitting threads Red acetylene hose wileft hand fitting threads Shade 5 Goggles Striker Accessories 20 cu ft Oxygen Cylinder 10 cu ft Acetylene Cylinder Will cut up to 1 2 and weld up to 1 16 with the included welding and cutting tips Larger welding and cutting tips are sold separately Hose type A Workpiece and Work Area Setup 1 Designate a work area that is clean and well lit The work area must not allow access by children or pets to prevent distraction and injury 2 Remove all combustible material from area and or cover surfaces with fire resistant material Tool Set Up 1 of 3 Assembly A AWARNING
4. Torch Kit Check for loose hose connections cracked or worn hoses and any other condition that Maintenance Type Before After may affect its safe operation y Use Use If any abnormal condition occurs or is noticed have the problem corrected before further use Do not use damaged equipment Use tip cleaner to NO clean tip opening 2 Periodically use a tip cleaner to clean Wipe off with clean dry cloth out Cutting Tip and Welding Nozzle NEVER USE SOLVENTS TO WIPE DOWN THIS CUTTING ATTACHMENT Inspect tool for damage 3 To clean the outer body of the Cutting Attachment use a Clean dry cloth Do not immerse any part of the Cutting Attachment in ANY liquid Do not use solvents or other flammable agents to clean the Cutting Attachment Troubleshooting Possible Causes Likely Solutions Before turning 1 Hose connections loose 1 Tighten all connections on Torch gas 2 Crack in hose 2 Check hoses If any cracks are found replace entire hose odor is noticed DO NOT PATCH OR TAPE GAS HOSES 3 Cylinder leak at neck 3 Check neck area of cylinders If cracks or damage are found do not use Secure upright in a well ventilated area well away from sources of ignition Contact gas supplier IMMEDIATELY Replace cylinders before proceeding with work Flame is irregular 1 Cutting tip clogged or dirty 1 Close gas oxygen first then acetylene Let Torch cool completely Remove Tip check for dirt and debris U
5. 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 or cutting exhaust fumes are 7 e Early onset of Parkinson s Disease e Heart disease e Ulcers e Damage to the reproductive organs Item 65818 10 11 12 For technical questions please call 1 888 866 5797 After welding or cutting make a thorough check for evidence of fire and be aware the easily visible flame or smoke may not be present for some time after a fire has started Do not weld or cut in atmospheres containing dangerously reactive or flammable gases vapors liquids or dust SAFETY Clean and purge containers before applying heat 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 Vent closed containers including castings before preheating cutting or welding Inflammation of the small intestine or stomach e Kidney damage e Respiratory diseases such as emphysema bronchitis or pneumonia Use natural or forced air ventilation and wear a respirator approved by NIOSH to protect against the fumes produced to reduce the risk of developing the above illnesses Avoid overexposure to fumes and gases Keep your head out of the fumes Do not breathe fumes Use enough ventilation or exhaust or both to keep fumes and gases away from y
6. Bluish Colorless Orange Flame Flame Open Pre heat Close Pre heat A Oxygen Valve Slightly Oxygen Valve Slightly White Little or Acetylene oN Se als aaa Halo 4 4 Bluish Blue White Small Less Core Core Bright Core a Starting to Add Oxygen b Proper Oxygen Mix c Too Much Oxygen Cutting Step 8 Pre heat Flame Adjustment Page 16 For technical questions please call 1 888 866 5797 Item 65818 Cutting Shutdown Instructions 1 After work is complete first close the Oxygen Torch Valve clockwise then close the Acetylene Torch Valve clockwise Oxygen OXY _ Torch Valve Acetylene GAS Torch Valve Shutdown Step 1 Close Torch Valves 2 Fully close both cylinder valves turning clockwise Acetylene Cylinder Oxygen Shutdown Step 2 Close Cylinder Valves 3 Open the Acetylene Torch Valve counterclockwise to allow all the pressure to bleed out Note If the tank gauge still has pressure the Acetylene Regulator needs to be opened Bleed pressure on both gauges to 0 Acetylene GAS Torch Valve Shutdown Step 3 Open Acetylene Valve Item 65818 Cylinder For technical questions please call 1 888 866 5797 4 Open the Oxygen Torch Valve counterclockwise and open the Pre heat Oxygen Valve counterclockwise to allow all the pressure to bleed out Note If the tank gauge still has pressure the Oxygen Regulator needs to be opened Bleed pressure on both gauges to 0 Oxygen OXY
7. Owner s Manual amp Safety Instructions Save This Manual Keep this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures Write the product s serial number in the back of the manual near the assembly diagram or month and year of purchase if product has no number Keep this manual and the receipt in a safe and dry place for future reference eieae WELDING PORTABLE TORCH KIT WITH OXYGEN AND ACETYLENE TANKS Visit our website at http www harborfreight com ITEM 65818 Email our technical support at productsupport harborfreight com When unpacking make sure that the product is intact and undamaged If any parts are missing or broken please call 1 888 866 5797 as soon as possible Copyright 2011 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 Diagrams within this manual may not be drawn proportionally Due to continuing improvements actual product may differ slightly from the product described herein Tools required for assembly and service may not be included AWARNING Read this material before using this product Failure to do so can result in serious injury SAVE THIS MANUAL Table of Contents Safely i ea AA 2 Oi Uns ET EE T 14 Specifications cccccceceeceeeeeeeeeeseeeeeees 6 Maintenanc
8. R REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO MAINTENANCE Item 65818 For technical questions please call 1 888 866 5797 Page 19 Limited 90 Day Warranty Harbor Freight Tools Co makes every effort to assure that its products meet high quality and durability standards and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of 90 days from the date of purchase This warranty does not apply to damage due directly or indirectly to misuse abuse negligence or accidents repairs or alterations outside our facilities criminal activity improper installation normal wear and tear or to lack of maintenance We shall in no event be liable for death injuries to persons or property or for incidental contingent special or consequential damages arising from the use of our product Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation of exclusion may not apply to you THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS To take advantage of this warranty the product or part must be returned to us with transportation charges prepaid Proof of purchase date and an explanation of the complaint must accompany the merchandise If our inspe
9. Torch Valve Pre heat Oxygen Valve Shutdown Step 4 Open Oxygen Valves 5 After releasing pressure turn the Acetylene Pressure Adjusting Screw counterclockwise and remove it from its Regulator Then turn the Oxygen Pressure Adjusting Screw counterclockwise and remove it from its Regulator IMPORTANT Failure to release all pressure on the Regulators may permanently damage them Oxygen Regulator Acetylene Regulator Shutdown Step 5 Close Regulators Turn counterclockwise and remove Oo Z Fk gt 6 Lastly close the Acetylene Torch Valve clockwise and close the Oxygen Torch and Pre heat Oxygen Valves clockwise Oxygen OXY Torch Valve Acetylene GAS Torch Valve Pre heat Oxygen Valve Shutdown Step 6 Close Valves Page 17 2 Z par m Z gt Z 2 m Maintenance Instructions Procedures not specifically explained in this manual must be performed only by a qualified technician AWARNING TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION Close the oxygen then acetylene and allow the torch to cool completely then disconnect the hoses before performing any inspection maintenance or cleaning procedures TO PREVENT SERIOUS INJURY FROM TOOL FAILURE Do not use damaged equipment If abnormal noise vibration or leaking gas occurs have the problem corrected before further use 1 BEFORE EACH USE inspect the general condition MAINTENANCE CHART of the
10. ction verifies the defect we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement We will return repaired products at our expense but if we determine there is no defect or that the defect resulted from causes not within the scope of our warranty then you must bear the cost of returning the product This warranty gives you specific legal rights and you may also have other rights which vary from state to state Table C Heating Nozzle Flow Data Acetylene Pressure PSIG Oxygen Pressure PSIG Acetylene Oxygen CFH CFH 15 Note A heating nozzle may be used with this kit but is not included Chart provided for reference only CHICAGOG a WELDING 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 1 888 866 5797
11. e cccccceeceeeeeeeeeeeenteeeees 18 SOlUP eee eee etn AT 6 Parts List and Assembly Diagram 19 WeldInQvii ciad ie an 10 Waitranty A iden ati dates 20 wn gt mn m j lt WARNING SYMBOLS AND DEFINITIONS This is the safety alert symbol Itis used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A DANGER AWARNING Indicates a hazardous situation which if not avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury ACAUTION NOTICE CAUTION IMPORTANT SAFETY INSTRUCTIONS AWARNING Read all safety warnings and instructions Failure to follow the warnings and instructions may result in electric shock fire and or serious injury Save all warnings and instructions for future reference Addresses practices not related to personal injury The warnings precautions and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur It must be understood by the operator that common sense and caution are factors which cannot be built into this product but must be supplied by the operator Work Area Safety 1 Keep your work area clean and well lit Enclose the work a
12. e Oxygen Torch Valve slightly until you achieve the flame described in step b above _ Dm WARNING Wear appropriate welding goggles Welding Step 6 Slowly Open 8 After the flame is adjusted as explained Acetylene Torch Valve Until Flame Feathers and illustrated proceed with welding 6 Put the striker down on a fireproof surface Slowly open the Acetylene Torch Valve farther until the flame feathers at its edge slightly as shown below Note Oxygen acetylene welding is a two handed process one hand controls the torch while the other hand controls a filler rod sold separately Proper welding techniques and weld preparation are outside the scope of this manual Welding books and classes are recommended to teach proper methods and technique mi m Z Q 9 After welding follow shutdown instructions on facing page Nearly Colorless Flame Open Oxygen Torch Close Oxygen Torch White Valve Slightly Valve Slightly Little or Acetylene E A heor eee Halo gt Ses Bluish s N Blue White lt Small Less Core AK Core HAWG Bright Core a 1 a Starting to Add Oxygen b Proper Oxygen Mix c Too Much Oxygen Welding Step 7 Welding Flame Adjustment Page 12 For technical questions please call 1 888 866 5797 Item 65818 Welding Shutdown Instructions 1 After work is complete 4 Open the Oxygen Torch Valve counterclockwise first close the Oxygen Torch Valve clockwise to allow all the pressure to b
13. egulator 2 Open the cylinder valves turning counterclockwise 10 only until the gas starts flowing WARNING Only open Acetylene Cylinder Valve 1 4 to 1 2 turn emn Leak Test 1 Step 3 Set Testing Pressures 4 Check all connections for leaks using soapy water e If leaks are found tighten connections Acetylene Cylinder If a leak persists discontinue use and call gas supplier Oxygen Cylinder 13 If no leaks are found with this test move on to the Gauge Monitoring test Leak Test 1 Step 2 Open Cylinder Valves Tool Set Up 3 of 3 Second Leak Test Gauge Monitoring This test detects minor leaks 3 Monitor gauges on both regulators for five minutes Acetylene Acetylene Oxygen 1 Follow all steps in the Soapy Water test above Delivery Cylinder Delivery to prepare for the gauge monitoring test Pressure Pressure Pressure 2 Close both cylinder valves turning clockwise Acetylene Cylinder Acetylene Regulator Oxygen 10 Cylinder 13 Leak Test 2 Step 3 Monitor Gauges e If the readings do not change the test is completed and the system has no leaks Leak Test 2 Step 2 Close Cylinder Valves e If any reading changes there is a leak on that side of the system Follow Gauge Leak Analysis on the next page to diagnose Page 8 For technical questions please call 1 888 866 5797 Item 65818 Gauge Leak Analysis Oxygen shown If gauges move as shown Procedure a
14. l 1 888 866 5797 6a Welding Setu Connect the Welding Nozzle 8 to the Torch Handle Torch Handle 7 Welding Nozzle 8 Assembly Step 6a Welding Setup 6b Cutting Setu WARNING BEFORE CONNECTING iF make sure the two Cutting N Attachment 5 O Rings on the end of the Cutting Attachment 5 are not damaged or missing otherwise gases will mix inside the Torch Handle and result in flashback or backfires Connect the Cutting Attachment 5 to the Torch Handle Then connect the Cutting Tip 6 to the Cutting Attachment 5 Cutting Attachment 5 Torch Handle 7 Cutting Tip 6 Assembly Step 6b Cutting Setup 7 Before operation the leak tests on the following pages must be done after connection to check for leaks in the system Page 7 Tool Set Up 2 of 3 First Leak Test Soapy Water This test detects major leaks WARNING KEEP WRENCH ON no ACETYLENE CYLINDER S VALVE whenever cylinder 1 After everything is connected close both Torch is in use to allow quick shutoff in case of emergency Handle Valves turning clockwise Close regulators turning knobs counterclockwise until loose 3 Adjust the oxygen regulator to deliver 20 PSIG Adjust the acetylene regulator to deliver 10 PSIG DO NOT EXCEED 15 PSI ACETYLENE PRESSURE Oxygen Close Valves Close Regulators Turn clockwise i Turn counterclockwise until loose so a Leak Test 1 Step 1 Acetylene R
15. leed out then close the Acetylene Torch Valve clockwise Note If the tank gauge still has pressure the Oxygen Regulator needs to be opened Bleed pressure on both gauges to 0 Oxygen OXY Torch Valve Shutdown Step 1 Close Torch Valves 2 Fully close both cylinder valves turning clockwise Shutdown Step 4 Open Oxygen Valve 5 After releasing pressure turn the Acetylene Pressure Adjusting Screw counterclockwise and remove it from its Regulator Acetylene Then turn the Oxygen Pressure Adjusting Screw Cylinder counterclockwise and remove it from its Regulator Oxygen Cylinder IMPORTANT Failure to release all pressure on the Regulators may permanently damage them WELDING Shutdown Step 2 Close Cylinder Valves 3 Open the Acetylene Torch Valve counterclockwise Oxygen to allow all the pressure to bleed out Regulator Note If the tank gauge still has pressure Acetylene the Acetylene Regulator needs to be opened Regulator Bleed pressure on both gauges to 0 Shutdown Step 5 Close Regulators Turn counterclockwise and remove 6 Lastly close the Acetylene Torch Valve clockwise and close the Oxygen Torch Valve clockwise Acetylene GAS Torch Valve Shutdown Step 3 Open Acetylene Valve Shutdown Step 6 Close Torch Valves Item 65818 For technical questions please call 1 888 866 5797 Page 13 O Cc Z 0 Cutting Cutting Tip Press
16. llustration below center S c Too Much Oxygen Striker 3 114 E If you open the Pre heat Oxygen Valve too far Acetylene GAS the large section of the flame will be Torch Valve bluish orange and the inner core will be small as Cutting Step 5 Lighting Acetylene shown in Cutting Step 8 illustration below right Close the Pre heat Oxygen Valve slightly until 6 Put the striker down on a fireproof surface you achieve the flame described in step b above Slowly open the Acetylene Torch Valve farther until the flame feathers at its WARNING Wear appropriate welding goggles SAJE SNAHY aS SHOWN Delo 9 After the flame is adjusted as explained _ DE and illustrated proceed with cutting Cutting Step 6 Slowly Open 7 Pas ses S aia Acetylene Torch Valve Until Flame Feathers WARNING Start the cut at the edge of the 7 Do not squeeze the Oxygen Cutting Lever workpiece Open the Oxygen Torch Valve If done improperly attempting to start a cut in the middle of the workpiece will splash molten metal back at the operator Do not attempt to start a cut in the middle of a workpiece unless properly trained in safe methods of starting these cuts b After preheating press the Oxygen Cutting Lever and slowly guide the torch along the cut line to cut the metal Oxygen OXY Torch Valve 10 After cutting follow shutdown instructions on facing page Cutting Step 7 Open Oxygen Torch Valve O Cc Z 0 Nearly
17. lso applies to acetylene THEN If the Cylinder Pressure decreases and the Delivery Pressure increases There is a leak in the regulator seat Have the regulator repaired by a qualified technician If Cylinder gauge moves as shown and Delivery gauge stays still THEN Oxygen shown Procedure also applies to acetylene Ss ceo 2 os o O annast a If Cylinder Pressure decreases but the Delivery Pressure remains constant The leak is at cylinder valve or connection between regulator and cylinder valve DANGER To prevent serious injury and DEATH DO NOT TIGHTEN OR ADJUST ANY CONNECTION between the cylinder and cylinder valve or force the cylinder valve If the cylinder valve is leaking move the cylinder outside and notify your gas supplier immediately 1 Release pressure from the system 2 Tighten the connection between regulator and cylinder valve 3 Repeat Gauge Leak Test a If the gauges do not change the test is completed and the system has no leaks b If the connection still leaks try with a different cylinder c If the connection leaks with the different cylinder have the regulator examined by a qualified technician Item 65818 For technical questions please call 1 888 866 5797 Oxygen shown If Delivery gauge moves as shown Procedure also applies to acetylene THEN wee leak after regulator A a of aannnunuunt
18. ly For technical questions please call 1 888 866 5797 Do not use oil grease or thread seal tape on any connector 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 fire and or personal injury Use only accessories that are recommended by the manufacturer for your model Torch Accessories that may be suitable for one Torch may become hazardous when used on another Torch Only use proper gas hoses EMPTY CYLINDERS DO NOT DROP STRIKE PUNCTURE HEAT OR SET FIRE TO A CYLINDER EVEN IF IT IS EMPTY Keep empty cylinders in specified areas and clearly mark empty Contact local solid waste authorities for instructions on correct disposal or recycling of empty cylinders KEEP WRENCH ON ACETYLENE CYLINDER S VALVE whenever cylinder is in use to allow quick shutoff in case of emergency c Check for loose connections using soapy water solution Tighten or repair any leaks found d Do not use the Torch Kit if either gas does not turn off completely when the Oxygen Torch Valve and Acetylene Torch Valve are closed Leakage of gas from the tip is a substantial safety risk If gas cannot be turned off at the Torch Handle it is dangerous and must be replaced e Inspect for any other defects or damage Do not use any damaged parts Tag damaged parts Do not use until
19. ne side crack each cylinder valve Cracking is to quickly open and close the valve allowing a small amount of gas to escape and clearing the valve of any foreign material WARNING If oil or grease is found discontinue using cylinder and immediately contact your gas supplier Briefly open valve to clean then close valve yy gt Assembly Step 2 Crack Each Cylinder Valve WARNING KEEP WRENCH ON ACETYLENE CYLINDER S VALVE whenever cylinder is in use to allow quick shutoff in case of emergency NOTE Wrench not included 3 Attach the Green labeled Oxygen Regulator 9 to the Oxygen Cylinder 13 and the green oxygen hose to the regulator 4 Attach the Red labeled Acetylene Regulator 10 to the Acetylene Cylinder 14 and the red acetylene hose to the regulator tighten counterclockwise threads are reversed 5 To set up the Torch Handle 7 a Remove the plastic inlet covers b Make sure both check valves are in place on the torch handle c Connect the green oxygen hose to the oxygen Check Valve 11 on the Torch Handle d Connect the red acetylene hose to the acetylene Check Valve 12 on the Torch Handle tighten counterclockwise threads are reversed Check Valve OX 11 Oxygen Hose Torch green Handle 7 Check Valve AC 12 Acetylene Hose red Assembly Step 5 Torch Handle Setup Item 65818 For technical questions please cal
20. nks without an approved method for eliminating the hazard Do not dispose of hot slag in containers holding combustible materials Keep a fully charged fire extinguisher close by and know the proper way to use it Personal Safety 1 Wearing and using personal safety clothing and safety devices reduce the risk of injury Wear the following a Fire resistant clothing Do not wear pants with cuffs shirts with open pockets or any clothing that can catch and hold molten metal or sparks Fire resistant leather leggings and work boots Dry insulating leather welding gloves NIOSH approved respirator Shade 5 or higher welding goggles m 7 09 Q290 0 Appropriate head covering to protect head and neck g Fire resistant ear plugs or ear muffs if welding or cutting overhead or in confined spaces Keep clothing and safety equipment free of grease oil solvents and any other flammable substances Stay alert Watch what you are doing and use common sense when operating this Torch Do not use while tired or under the influence of drugs alcohol or medication A moment of inattention while operating may result in serious personal injury Do not overreach Keep proper footing and balance at all times Proper footing and balance enables better control in unexpected situations INHALATION HAZARD Welding and Cutting Produce 6 amp TOXIC FUMES Exposure to welding or cutting exhaust fumes can increase
21. o prevent explosion use reverse flow 6 check valves and flashback arrestors sold separately on the base of the Torch Use with oxygen and acetylene only Do not modify this torch or use it for a purpose for which it is not intended 7 Set Acetylene Regulator no greater than 15 PSI Acetylene is unstable and can explode if over pressurized Cylinder Safety 2 Secure cylinders to a cart wall or post to prevent them from falling Use and store cylinders in an upright position only 3 Use cylinder caps when moving or storing cylinders 4 Do not store cylinders in B temperatures 120 F or higher Equipment Inspection 1 DO NOT USE FLAME TO DETECT LEAKS 2 INSPECT BEFORE EVERY USE Look for the following and do not use kit if any damage is noted a Inspect the tapered seating surfaces on the Nozzles and the Tip Nut 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 b Examine all hoses for cuts cracks burns worn areas or other damage Do not use if damaged Operation Safety 1 Inspect before every use 6 see previous warning section 2 Use only with proper ventilation 7 3 Do not touch workpiece or tip until cool 4 Keep hoses away from hot parts from weld cut area and from flame 5 Never leave the Torch unattended when Page 4 Do not use dented or damaged cylinders 5 it is attached to a gas supp
22. orch Valve na Y Welding Step 2 Close Valves Acetylene Regulator 10 Welding Step 3 Set Welding Pressures See Table A on page 10 4 Hold the Torch Handle in one hand and the striker in the other hand WELDING Item 65818 For technical questions please call 1 888 866 5797 Page 11 5 Open the Acetylene Torch Valve about 1 4 turn 7 Flame Adjustment and quickly ignite the acetylene gas coming out of the Nozzle by squeezing the handle of the striker creating a spark a Starting to Add Oxygen Slowly open the Oxygen Torch Valve The flame will change to a carbonizing flame with WARNING Do not use matches or a a blue white inner core a white halo surrounding the core and a light orange flame as shown butane lighter to light the Torch i 4 t in Welding Step 7 illustration below left b Proper Oxygen Mix Continue slowly opening the Oxygen Torch Valve until the large light orange section of the flame becomes nearly colorless and the center of the flame has a white core with little or no halo This is the neutral flame needed for operation as shown in Welding Step 7 illustration below center Striker 3 Acetylene GAS Torch Valve i 7 Tes c Too Much Oxygen Welding Step 5 Lighting Acetylene If you open the Oxygen Torch Valve too far the large section of the flame will be bluish orange and the inner core will be small as shown in Welding Step 7 illustration below right Close th
23. our breathing area Where ventilation is questionable have a qualified technician take an air sampling to determine the need for corrective measures If necessary use mechanical ventilation to improve air quality If this is not possible use an approved respirator Do not work in confined areas unless they are well ventilated or you are wearing an air supplied ventilator Always follow OSHA guidelines for Permissible Exposure Limits PEL s for various fumes and gases Follow the American Conference of Governmental Industrial Hygienists recommendations for the 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 WARNING This product when used for welding plasma cutting soldering or similar applications produces chemicals 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 lead 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 Page 3 wn gt mn m j lt Equipment Setup Safety 1 Make sure you are prepared to begin 5 work before opening gas supply T
24. rea with portable fire Cluttered benches and dark areas invite accidents resistant screens Use a fire resistant material to block all openings and protect 2 Keep bystanders children and visitors away combustible walls ceilings floors etc while operating Distractions can cause you to lose control Protect others in the work area from If working near on a metal wall ceiling floor intense heat Do not allow others close enough to etc prevent ignition of combustibles on look at the flame as eye damage is a real possibility the other side by moving the combustibles Provide barriers or shields as needed to a safe location If relocation of combustibles is NOT possible 3 When possible move the work to a location well designate someone to act as a fire watch equipped Page 2 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 For technical questions please call 1 888 866 5797 with a fire extinguisher during the welding or cutting process and for at least one half hour after the welding or cutting project is completed Item 65818 Do not place the Torch on any material other than bare concrete until it has cooled completely Do not weld or cut any material that has a combustible coating or a combustible internal structure such as drums or ta
25. rely Oxygen Valve Oxygen OXY Torch Valve V S Acetylene GAS Q Torch Valve Cutting Step 2 Close Valves Item 65818 3 Adjust the Acetylene and Oxygen Regulators to their proper working pressures see Table B on page 14 DO NOT EXCEED 15 PSI ACETYLENE PRESSURE Oxygen Delivery Acetylene Delivery Pressure Pressure DO NOT EXCEED 15 PSI Oxygen Regulator 9 Acetylene Regulator 10 Cutting Step 3 Set Cutting Pressures See Table B on page 14 4 Hold the Torch Handle in one hand and the striker in the other hand CUTTING For technical questions please call 1 888 866 5797 Page 15 5 Open the Acetylene Torch Valve about 1 4 turn 8 Flame Adjustment and quickly ignite the acetylene gas coming out of the Nozzle by squeezing the handle of the striker creating a spark a Starting to Add Oxygen Slowly open the Pre heat Oxygen Valve The flame will change to a carbonizing flame WARNING Do not use matches or a with a blue white inner core a white halo butane lighter to light the Torch surrounding the core and a light orange flame as shown in Cutting Step 8 illustration below left b Proper Oxygen Mix Continue slowly turning the Pre heat Oxygen Valve until the large light orange section of the flame becomes nearly colorless and the center of the flame has a white core with little or no halo This is the neutral flame needed for operation as shown in Cutting Step 8 i
26. repaired Allow sufficient time for the Torch to completely cool before storing Any material discharged from the work area during use will be extremely hot Use care to not get burned by slag or other waste products Item 65818 8 BACKFIRE When the flame goes out with a loud pop it is called a backfire Backfire can be caused by a Operating the Torch at lower pressures than required for the Tip used b Touching the Tip against the workpiece c Overheating the Tip d An obstruction in the Tip If backfire occurs close the Torch Handle Valves oxygen first then acetylene and after remedying the cause relight the torch 9 FLASHBACK 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 then acetylene IMMEDIATELY Flashback generally indicates a problem that should be repaired before proceeding with the job at hand A clogged Tip improper functioning of the Valves Service 1 Torch service must be performed only by 3 qualified repair personnel Service or maintenance performed by unqualified personnel could result in a risk of injury 2 When servicing use only identical replacement parts Follow instructions in the Maintenance Instructions section of this manual Use of unauthorized parts or failure to follow maintenance instructions may crea
27. se tip cleaner to clean Tip or replace if necessary 2 Check gas level and refill if needed A Follow all safety precautions whenever diagnosing or servicing the tool Disconnect air supply before service Page 18 For technical questions please call 1 888 866 5797 Item 65818 Parts List and Assembly Diagram Part Description ___ Qty Part ___ Description _ s Qty 8 Welding Nozze __ o J 1 9 Oxygen Regulator CTC Striker Hose Assembl Cutting Attachment Cutting Tip Torch Handle 14 Acetylene Cylinder not shown Record Product s Serial Number Here Note Some parts are listed and shown for illustration purposes only and are not available Note If product has no serial number nee individually as replacement parts record month and year of purchase instead 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 REPLACE 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 BUYERASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HE
28. te a risk of fire or injury 10 11 12 or incorrect acetylene oxygen pressure could lead to flashback Find and correct the cause before relighting the Torch If the cause is not found have the kit serviced by a qualified technician before returning to your project Beware of leaking gas If you notice the odor of acetylene during use close the Torch Handle Valves oxygen first then acetylene IMMEDIATELY Extinguish all open flames and carefully check all hoses and connections for leaks using soapy water NEVER check for leaks using a flame If the odor continues do not use the Torch Call acetylene supplier for assistance SAFETY Read and understand all instructions and safety precautions as outlined in the manufacturer s manual for the material you will weld or cut After use bleed lines and store all components out of reach of children and other untrained persons Torches are dangerous in the hands of untrained users Maintain product labels and nameplates These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement A SAVE THESE INSTRUCTIONS Symbology GR Canadian Standards Association Underwriters Laboratories Inc C GA Compressed Gas Association ieee o LES eso Cubic Feet per Hour flow Item 65818 For technical questions please call 1 888 866 5797 Fuel gas acetylene related components WARNING marking concerning Risk of
29. than 1 32 to 1 16 thick a different welding nozzle will be needed Note Welding the thicker metals noted below will require special techniques such as edge chamfering that are outside the scope of this manual Table A Welding Nozzle Flow Data Metal NOSE Tip Orifice Oxygen Acetylene Aceviene Thickness Size Diameter Pressure Pressure CEH inches inches PSIG PSIG area o oos ss ss 153 ime o oo ss ss 1734 18 va e m2 e oon es se 1535 Torch Handle 7 mi m Z Q Oxygen OXY Torch Valve Welding Nozzle 8 Acetylene GAS Torch Valve Page 10 For technical questions please call 1 888 866 5797 Item 65818 Welding Instructions Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product Inspect tool before use looking for leaking damaged loose and missing parts If any problems are found do not use tool until repaired 1 Set up for welding according to 3 Adjust the Acetylene and Oxygen Regulators instructions on pages 6 9 to their proper working pressures see Table A on page 10 2 Close both valves on the Torch Handle securely DO NOT EXCEED 15 PSI ACETYLENE PRESSURE Oxygen Delivery Acetylene Delivery Pressure Pressure DO NOT EXCEED 15 PSI Oxygen OXY Torch Valve LNG e Acetylene GAS Q Oxygen T
30. ure Settings The Cutting Attachment is used to cut metal up to 3 thick The included tip size 0 cuts metal up to 1 2 thick Check the thickness of the metal to be cut and use the chart below to choose the appropriate size tip for the job If cutting metals over 1 2 thick a different tip will be needed Table B Cutting Tip Flow Data Cutting Standard Cutting Oxygen Acetylene Bed Thickness Nozzle Pressure Pressure E EEA BEN ESIC eee ee ae eee Gee ee eee ee The Cutting Attachment is attached to the Torch Handle and a Cutting Tip is attached to the end of the Cutting Attachment Pre heat Oxygen Valve Adjusts pre heat flame oxygen level Oxygen Cutting Lever Activates extra flow of oxygen for cutting Cutting Attachment 5 Oxygen Cutting Torch Handle 7 Oxygen OXY Cutting Torch Valve Tip 6 Pre heat Oxygen Valve Acetylene GAS Torch Valve Page 14 For technical questions please call 1 888 866 5797 Item 65818 Cutting Instructions Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product Inspect tool before use looking for leaking damaged loose and missing parts If any problems are found do not use tool until repaired 1 Set up for cutting according to instructions on pages 6 9 2 Close all valves on the Torch Handle and Cutting Attachment secu
Download Pdf Manuals
Related Search