Harbor Freight Tools 96290 Product manual
Owner’s Manual & 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.
REV 15b
Visit our website at: http://www.harborfreight.com
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.
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Table of Contents
Safety ......................................................... 2
Specifications ............................................. 6
Setup .......................................................... 6
SAFETY OPERATION MAINTENANCESETUP
Operation ................................................... 10
Maintenance .............................................. 14
Parts List and Assembly Diagram.............. 15
Warranty .................................................... 16
WARNING SYMBOLS AND DEFINITIONS
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.
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.
Addresses practices not related to personal injury.
IMPORTANT SAFETY INSTRUCTIONS
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.
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.
Cluttered benches and dark areas invite accidents.
2. Keep bystanders, children, and visitors away
while operating. Distractions can cause you to
lose control. Protect others in the work area from
intense heat. Do not allow others close enough to
look at the flame as eye damage is a real possibility.
Provide barriers or shields as needed.
3. 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.
4. Enclose the work area with portable fire
resistant screens. Use a fire resistant
material to block all openings and protect
combustible walls, ceilings, floors, etc.
5. If working near/on a metal wall, ceiling, floor,
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 act as a fire watch
equipped with a fire extinguisher during the
cutting process and for at least one half hour
after the cutting project is completed.
6. Do not place the Torch on any material other
than bare concrete until it has cooled completely.
7. Do not cut any material that has a combustible
coating or a combustible internal structure,
such as drums or tanks, without an approved
method for eliminating the hazard.
8. Do not dispose of hot slag in containers
holding combustible materials.
Page 2 For technical questions, please call 1-888-866-5797. Item 96290
9. Keep a fully charged fire extinguisher close
by and know the proper way to use it.
10. After 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.
11. Do not cut in atmospheres containing
dangerously reactive or flammable
gases, vapors, liquids, or dust.
Personal Safety
12. 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 or cutting.
SAFETYOPERATIONMAINTENANCE SETUP
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.)
b. Fire-resistant leather leggings and work boots
c. Dry, insulating leather welding gloves
d. NIOSH-approved respirator
e. Shade 5 or higher welding goggles
f. Appropriate head covering to
protect head and neck
g. Fire-resistant ear plugs or ear muffs (if
cutting overhead or in confined spaces)
Keep clothing and safety equipment free of grease,
oil, solvents and any other flammable substances.
2. 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.
3. Do not overreach. Keep proper footing and
balance at all times. Proper footing and balance
enables better control in unexpected situations.
4. INHALATION HAZARD:
Welding and Cutting Produce
TOXIC FUMES.
Exposure to cutting exhaust fumes
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 cutting exhaust fumes are:
• Early onset of Parkinson’s Disease
• Heart disease • Ulcers
• Damage to the reproductive organs
• Inflammation of the small intestine or stomach
• Kidney damage
• 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.
5. 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 your
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 cutting situation.
6. 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
& Safety Code § 25249.5, et seq.)
7. 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
& Safety Code § 25249.5, et seq.)
8. WARNING: This product contains di (2-ethylhexyl)
phthalate (DEHP), a chemical known to the State
of California to cause cancer and birth defects
or other reproductive harm. (California Health
& Safety Code § 25249.5, et seq.)
Page 3For technical questions, please call 1-888-866-5797.Item 96290
Equipment Setup Safety
1. Make sure you are prepared to begin
work before opening gas supply.
2. To prevent explosion, use reverse-flow
SAFETY OPERATION MAINTENANCESETUP
check valves and flashback arrestors
(sold separately) on the base of the Torch.
3. Use with oxygen and acetylene only.
Do not modify this torch or use it for a
purpose for which it is not intended.
4. Set Acetylene Regulator no greater than 15 PSI.
Acetylene is unstable and can
explode if over-pressurized.
Cylinder Safety
1. Do not use dented or damaged cylinders.
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
temperatures 120° F or higher.
5. Do not use oil, grease or
thread seal tape on any connector.
6. 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 to
loss of control, fire and/or personal injury.
7. 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.
5. 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.
6. KEEP WRENCH ON
ACETYLENE CYLINDER’S VALVE
whenever cylinder is in use to allow
quick shutoff in case of emergency.
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;
see previous warning section.
2. Use only with proper ventilation.
3. Do not touch workpiece or tip until cool.
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 repaired.
6. Allow sufficient time for the Torch to
completely cool before storing.
7. 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.
4. Keep hoses away from hot parts,
from cut area, and from flame.
5. Never leave the Torch unattended when
it is attached to a gas supply.
Page 4 For technical questions, please call 1-888-866-5797. Item 96290
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,
or incorrect acetylene/oxygen pressure could 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.
10. 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.
11. Read and understand all instructions and safety
precautions as outlined in the manufacturer’s
manual for the material you will cut.
12. 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.
SAFETYOPERATIONMAINTENANCE SETUP
Service
1. Torch service must be performed only by
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 create a risk of fire or injury.
SAVE THESE INSTRUCTIONS.
Symbology
Canadian Standards Association
Underwriters Laboratories, Inc.
CGA
3
ft
PSI
CFH
OXY
Compressed Gas Association
Cubic Feet
Pounds per Square Inch
Cubic Feet per Hour flow
Oxygen related components
3. Maintain product labels and nameplates.
These carry important information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.
Fuel gas (acetylene)
GAS
related components
WARNING marking concerning Risk
of 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 5For technical questions, please call 1-888-866-5797.Item 96290
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