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Chicago Electric 92496 - page 1
HEA VY DUTY O XY - A CETYLENE WELDING OUTFIT ASSEMBL Y AND OPERA TING INSTR UCTIONS Model 92496 Diagrams within this manual may not be drawn proportionally . Due to continuing improvements, actual product may differ slightly from the product described herein. Distributed exclusively by Harbor Freight T ools ® . 3491 Mission Oaks Blvd., Camarillo, ...
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Chicago Electric 92496 - page 2
SKU 92496 P A GE 2 PR ODUCT SPECIFICA TIONS SA VE THIS MANU AL Y ou will need this manual f or the safety warnings and precautions, assembl y , ope rat in g, i nsp ect ion , m ain ten anc e and c lea nin g pr oc edu res , pa rts list a nd ass emb l y diag ram. K eep yo ur i n voic e wit h th is ma nual. Writ e the in v oice number on the inside of ...
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Chicago Electric 92496 - page 3
SKU 92496 P A GE 3 3. Keep b ystander s, children, and visitor s awa y 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 barriers or shields as needed. PERSONAL SAFETY 4. Stay alert. W atch what you are doing, and use common sense when operatin ...
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Chicago Electric 92496 - page 4
SKU 92496 P A GE 4 T OOL USE AND CARE 14. Store idle tools out of reach of children and other untrained per sons. T ools are dangerous in the hands of untrained users . 15. Maintain tools with care . Keep cutting tools sharp and c lean. Pr op er ly maintained tools with a shar p cutting edge are less likely to bind and are easier to control. Do not ...
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Chicago Electric 92496 - page 5
SKU 92496 P A GE 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 F reight T ools f or a replacement. 2. Maintain a safe w orking en vironment. K eep the work area well lit. Mak e sure there is adequate surrounding workspace. A ...
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Chicago Electric 92496 - page 6
SKU 92496 P A GE 6 7. Read and understand all instructions and saf ety precautions as outlined in the manufacturer’ s manual f or the material you will weld or cut. 6. Alwa ys keep the W elding Hoses (D1A, or D1B) a way from mo ving parts on the tool. Examine the W elding Hoses f or cuts, b ur ns , or worn areas bef ore each use . If any damaged ...
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Chicago Electric 92496 - page 7
SKU 92496 P A GE 7 8. Proper c ylinder care. Secure cylinders to a car t, wall, or post, to pre v ent them from f alling. All cylinders should be used and stored in an upright position. Ne v er drop or strike a cylinder . Do not use cylinders that ha v e been dented. Cylinder caps should be used when mo ving or stor ing cylinders . Empty cylinders ...
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Chicago Electric 92496 - page 8
SKU 92496 P A GE 8 UNP A CKING When unpac king, chec k to mak e sure all the par ts sho wn on the P ar ts Lists on pa ges 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 cov er of this manual as soon as possible . ASSEMBL Y AND OPERA TING INSTRUCTIONS For additional inf ormat ...
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Chicago Electric 92496 - page 9
SKU 92496 P A GE 9 5. IMPORT ANT! The Pressure Adjusting Scre w (18) on the Acetylene Regulator and the Pressure Adjusting Screw (A18) on the Oxygen Regulator should be opened slig htly b y turning co unte rclo c kwis e to re lie ve pr essu re on t he Regula tor diaphr ag ms bef ore opening the cylinder v alv es . If this is not done , pressure fro ...
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Chicago Electric 92496 - page 10
SKU 92496 P A GE 10 y our gas supplier immediately . (See Figure F .) 7. Connect the Cutting Attachment (par ts C1- C27) to the T orc h Han dle (par ts B1-B10 ). Alwa ys check the Connector (C23) and Coupling Nut (C22) f or damage or oil. If either are f ound, discontinue use and contact y our gas supplier . T ORCH HANDLE (P ARTS B1-B10) RED (A C) ...
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Chicago Electric 92496 - page 11
SKU 92496 P A GE 11 W ARNING! NEVER set the Acetylene Regulator (parts 1-19) to a deliver y pressure above 15 PSI. (See Figures I, J, and K.) Metal Thickness Tip Size Oxygen 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 P A GE 12 9. T o deter mine 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 VE (C26) O XYGEN CONTROL V AL VE (B8 with O X Label (B9)) A CETYLENE CONTR OL V AL VE (B8 with A C Label (B10)) FIGURE L ...
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Chicago Electric 92496 - page 13
SKU 92496 P A GE 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. Slowly open the Acetylene Control V alve (B8 with A C Label (B10)) fur ther until the smoke subsides and the flame jumps a w a y from the end of the Nozzle (par t D4) slightly . ...
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Chicago Electric 92496 - page 14
SKU 92496 P A GE 14 INSPECTION, MAINTENANCE, AND CLEANING 1. W ARNING! Make sure the W elding Kit is cool to the touc h and disconnected from its o xygen and acetylene cylinders bef ore perf orming any inspection, maintenance, or c leaning 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 P A GE 15 P ARTS LIST AND DIA GRAM 1 - A CETYLENE REGULA T OR NO TE: Some par ts are lis ted and sho wn f or illustra tion pur poses onl y , and are not a v ailab le individually as replacement par ts. Note: When ordering par ts from th is p ar ts l is t a nd d ia gra m alwa ys take the number from the No. column (on the left). For exampl ...
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Chicago Electric 92496 - page 16
SKU 92496 P A GE 16 NO TE: Some par ts are listed and sho wn f or illustration purposes only , and are not av ail- able individually as replacement parts. P ARTS LIST AND DIA GRAM 2 - O XYGEN REGULA T OR Note: When order ing par ts from this par ts list and diagram alwa ys take the number from the No. c ol umn (on the left) and add a suffix of A t ...
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Chicago Electric 92496 - page 17
SKU 92496 P A GE 17 NO TE: Some par ts are listed and sho wn f or illustration purposes only , and are not av ail- able individually as replacement parts. P ARTS LIST AND DIA GRAM 3 - T ORCH HANDLE Note: When order ing par ts from this par ts list and diagram alwa ys tak e the number from the No. column (on the left) and add a suffix of B to the b ...
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Chicago Electric 92496 - page 18
SKU 92496 P A GE 18 NO TE: Some par ts are listed and sho wn f or illustration purposes only , and are not av ail- able individually as replacement parts. P ARTS LIST AND DIA GRAM 4 - CUTTING A TT A CHMENT Note: When ordering par ts from this par ts list and diagram alw a ys take the number from the No. column (on the left) and add a suffix of C t ...
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Chicago Electric 92496 - page 19
SKU 92496 P A GE 19 NO TE: Some par ts are listed and sho wn f or illustration purposes only , and are not av ail- able individually as replacement parts. P ARTS LIST AND DIA GRAM 5 - A CCESSOR Y P AR TS Note: When order ing par ts from this par ts list and diagram alwa ys tak e the number from the No. column (on the left) and add a suffix of D to ...
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Chicago Electric 92496 - page 20
SKU 92496 P A GE 20 LIMITED 90 D A Y W ARRANTY Harbor F reight T ools Co . mak es e v er y eff or t to assure that its products meet high quality and dur ability standards, and warrants to the or iginal purchaser that this product is free from def ects in materials and w orkmanship f or the period of 90 da ys from the date of purchase . This warr a ...
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