Chicago Electric 92496 User Manual

HEAVY DUTY OXY - ACETYLENE

WELDING OUTFIT

Model 92496

ASSEMBLY AND OPERATING INSTRUCTIONS

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 Tools®.

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our website at: http://www.harborfreight.com

Read this material before using this product.

Failure to do so can result in serious injury.
SAVE THIS MANUAL.

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 or replacement parts, please call 1-800-444-3353.

PRODUCT SPECIFICATIONS

ITEM DESCRIPTION

Torch Handle, Oxygen Regulator and
Acetylene Regulator Construction

Cutting Nozzle Construction Brass and Steel. Chrome Plated oxygen lever. #1

Welding Nozzle and Heating Nozzle
Construction

Welding Hose Size and Construction 15 Ft. Long x 1/4” ID (each Hose)

Tip Cleaner Construction Steel files in an Anodized case

Safety Glasses Construction Plastic and Nylon, ANSI approved #10 Shade

Flint Lighter Construction Chrome plated steel with a Flint tip

Weight 19 Lbs.

Polished finish, all brass construction

Nozzle (For cutting material up to 3/4” thickness)

Brass base with a Copper tip. VH-W2, #2 Nozzle (For
welding material 1/16”-1/8”)

Rubber and brass fittings

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 RULES

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

3. 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

4. Stay alert. Watch what you are doing, and use common sense when

operating a power tool. Do not use a power tool while tired or under the
influence of drugs, alcohol, or medication. A moment of inattention while

operating power tools may result in serious personal injury.

5. 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.

6. 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 accidents.

7. 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.

8. 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.

9. 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

10. 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.

11. 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.

12. 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.

13. 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

TOOL USE AND CARE

14. Store idle tools out of reach of children and other untrained persons. Tools
are dangerous in the hands of untrained users.

15. Maintain 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

16. 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.

17. 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

18. Tool service must be performed only by qualified repair personnel. Service

or maintenance performed by unqualified personnel could result in a risk of injury.

19. 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
obstructions, 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 combustible 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 preheating, welding, or cutting.

SKU 92496 PAGE 5

5. Avoid overexposure to 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.

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.

7. 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