Harbor Freight OLSEN Medium Duty Oxygen/Acetylene Welding Kit User Manual

Medium Duty
OXYGEN/ACETYLENE WELDING KIT
64408 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 the product has no number).
Keep this manual and the receipt in a safe and dry place for future reference.
21e
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© Copyright 2020 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, the actual product may differ slightly from the product described herein.
Tools required for assembly and service may not be included.
WARNING
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.

SAFETY

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.
DANGER
** Indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
NOTICE
CAUTION
Addresses practices not related to personal injury.
IMPORTANT SAFETY INSTRUCTIONS
WARNING
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 that 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 welding or cutting process and for at least one-half hour after the welding or 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 weld or 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.
   

9. Keep a fully charged fire extinguisher close by and know the proper way to use it.
   

10. 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.

11. do not weld or cut in atmospheres containing dangerously reactive or flammable gases, vapors, liquids, or dust.
    

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, cutting, or welding.

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.)
   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 welding or 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 enable better control in unexpected situations.

4. INSTALLATION HAZARD
   Welding and Cutting produce TOXIC FUMES
   Exposure to welding or 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 welding or 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 welding or cutting situation.

Equipment Setup Safety

1. Make sure you are prepared to begin work before opening the gas supply.

2. to prevent explosion, use reverse-flow 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.

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 lead 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.

Cylinder Safety

1. does 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. 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 the 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 the 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 a backfire or flashback.
   b. Examine all hoses for cuts, cracks, burns, worn areas, or other damage. Do not use if damaged.
   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

Operation Safety

1. Inspect before every use; see previous warning section.

2. Use only with proper ventilation.

3. Do not touch the 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 it is attached to a gas supply.
   

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.

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 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.

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 weld or 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.
    

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.

3. Maintain product labels and nameplates.
   These carry important information.
   If unreadable or missing, contact
   Harbor Freight Tools for a replacement.

SAVE THIS INSTRUCTION.
Symbology

CGA

| Compressed Gas Association
---|---

ft³

| Cubic Feet

PSI

| Pounds per Square Inch

CFH

| Cubic Feet per Hour flow

OXY

| Oxygen related components

GAS

| Fuel gas (acetylene) 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 a flame to detect leaks.
Handle cylinders properly.
| WARNING marking concerning Risk of Inhalation Hazard.
Use in well-ventilated areas only.

Specifications

Color-Coded Twin Hose
Green oxygen hose w/right-hand fitting threads
Red acetylene hose w/left-hand fitting threads
Accessories| Shaded Goggles, Striker, Tip Cleaner

Setup
Read the ENTER IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product.
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 the area and/or cover surfaces with fire-resistant material.

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.

Tool Set Up 1 of 3 – Assembly
Read the ENTER IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product.
WARNING
TO PREVENT SERIOUS INJURY FROM EXPLOSION
Turn the Oxygen and acetylene torch Valves fully clockwise to close (oxygen first and acetylene second) before making any adjustments or performing any inspection or service to this product.
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.
   WARRING!
   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.
   

2. While standing to one 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
   TO PREVENT SERIOUS INJURY: if oil or grease is found, discontinue using the cylinder and immediately contact your gas supplier.

3. Attach the Green labeled Oxygen Regulator to the Oxygen Cylinder and the green oxygen hose to the Regulator.

4. Attach the Red labeled Acetylene Regulator to the Acetylene Cylinder and the red acetylene hose to the Regulator, tighten counterclockwise-threads are reversed.
   

5. torch Handle Setup:
   a. Remove the 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 on the Torch Handle.
   d. Connect the red-acetylene hose to the acetylene Check Valve on the Torch Handle,
   tighten counterclockwise-threads are reversed.
   

6. Welding nozzle Setup:
   Connect the Welding Nozzle to the Torch Handle.
   6a. Cutting attachment Setup:
   WARNING!
   TO PREVENT SERIOUS INJURY
   BEFORE CONNECTING
   make sure the two O-Rings on the end of the Cutting attachment are not damaged or missing, otherwise, gases will mix inside the torch Handle and result in flashbacks or backfires.
   Connect the Cutting Attachment to the Torch Handle.
   Then, connect the Cutting Tip to the Cutting Attachment.
   

7. Before the operation, the leak tests on the following pages must be done after connection to check for leaks in the system.

SETUP

Tool Set up 2 of 3 – First leak test: Soapy Water
This test detects major leaks.

1. After everything is connected, close both Torch
   Handle Valves, turning clockwise. Close Regulators, turning knobs counterclockwise until loose.
   

2. Open the cylinder valves turning counterclockwise only until the gas starts flowing.
   CAUTION! Only open acetylene Cylinder Valve
   

3. Open the Oxygen cylinder valve completely, turning it counterclockwise.

4. Adjust the Oxygen Regulator to deliver 20 pSi.
   Adjust the acetylene Regulator to deliver 10 pSi.
   DO NOT EXCEED 15 PSI
   ACETYLENE PRESSURE
   
   

5. Check all connections for leaks using soapy water:
   • If leaks are found, tighten connections.
   • If a leak persists, discontinue use and call a gas supplier.
   • If no leaks are found with this test, move on to the Gauge Monitoring test.

Tool Set Up 3 of 3 – Second Leak Test: Gauge Monitoring
This test detects minor leaks.

1. Follow all steps in the Soapy Water test above to prepare for the Gauge Monitoring test.

2. Close both cylinder valves, turning clockwise.
   

3. Monitor gauges on both Regulators for five minutes.
   • if the readings do not change, the test is completed and the system has no leaks.
   • if any reading changes, there is a leak on that side of the system. Follow Gauge Leak Analysis on the next page to diagnose.

Gauge Leak Analysis
Oxygen shown.
(procedure also applies to acetylene.)

If the Cylinder pressure decreases
and the delivery pressure increases –
There is a leak in the Regulator seat.
Has the Regulator been repaired by a qualified technician?
Oxygen shown.
(procedure also applies to acetylene.)

If Cylinder pressure decreases
but the delivery pressure remains constant –The leak is at the 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.

Oxygen shown.
(procedure also applies to acetylene.)

if 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, turn counterclockwise, and proceed to operation.
WARNING!
TO PREVENT SERIOUS INJURY
Only open acetylene Cylinder Valve 1/4 to 1/2 turn to allow quick shutoff.

Welding

Welding tip pressure Settings
Check the thickness of the metals to be welded and use the chart below to choose the size nozzle for the job.
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 Thickness (inches)| Nozzle Size| Tip Orifice Diameter (inches)| Oxygen Pressure
(PSI)| Acetylene Pressure (PSI)|

Acetylene
(CFH)

---|---|---|---|---|---
1/32| 000| 0.024| 3-5| 3-5| 1-2
3/64| 00| 0.028| 3-5| 3-5| 1.5-3
1/16| 0| 0.031| 3-5| 3-5| 1.7-3.4
5/64| 1| 0.035| 3-5| 3-5| 2-4
3/32| 2| 0.039| 3-5| 3-5| 3-6
1/8| 3| 0.051| 3-6| 3-6| 5-10.5
1/4| 4| 0.067| 4-6| 4-6| 8.5-19
3/8| 5| 0.079| 5-7| 5-7| 11.5-26
1/2| 6| 0.091| 6-8| 5-8| 15-35
1-1/4| 7| 0.126| 8-10| 8-10| 30-60

Welding instructions
Read the ENTER 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 the tool until repaired.

1. Set up for welding according to instructions on pages 6-9.

2. Close both valves on the Torch Handle securely.
   

3. Adjust the Acetylene and Oxygen Regulators to their proper working pressures. See Table A on page 10.
   DO NOT EXCEED 15 PSI
   ACETYLENE PRESSURE
   

4. Hold the Torch Handle in one hand and the Striker in the other hand.

5. Open the Acetylene Torch Valve about 1/4 turn, and quickly ignite the acetylene gas coming out of the Nozzle by squeezing the handle of the striker, creating a spark.
   WARNING!
   TO PREVENT SERIOUS INJURY
   not use matches or a butane lighter to light the Torch.
   

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.
   

7. Flame adjustment:
   a. Starting to add Oxygen:
   Slowly open the Oxygen Torch Valve.
   The flame will change to a carbonizing flame with a blue/white inner core, a white halo surrounding the core, and a light orange flame as shown 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.
   c. too Much Oxygen:
   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 the Oxygen Torch Valve slightly until you achieve the flame described in step b above.
   WARNING!
   TO PREVENT SERIOUS INJURY
   Wear appropriate welding goggles.

8. After the flame is adjusted as explained and illustrated, proceed with welding.
   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 techniques.

9. After welding, follow shutdown instructions on the facing page.

Welding Shutdown instructions

1. After work is complete, first close the Oxygen Torch Valve clockwise, then close the Acetylene Torch Valve clockwise.
   

2. Fully close both cylinder valves, turning clockwise.
   

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.

4. Open the Oxygen Torch 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.
   

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.
   

6. Lastly, close the Acetylene Torch Valve clockwise, and close the Oxygen Torch Valve clockwise.

Cutting

Cutting tip pressure Settings
The Cutting Attachment is used to cut metal up to 3 thick.
The included tip, size 0, cuts metal up to 1/2
Check the thickness of the metal to be cut and use the chart below to choose the appropriate size tip for the job.
table B: Cutting tip Flow data

Cutting Thickness (inches)

| Standard Nozzle Size| Cutting Oxygen Pressure (PSI)| Acetylene Pressure (PSI)|

Speed (IPM)

---|---|---|---|---
1/2| 0| 30-35| 3-5| 20-24
3/4| 1| 30-35| 3-5| 17-21
1-1/2| 2| 40-45| 3-7| 13-17
2-1/2| 3| 45-50| 4-10| 10-13
3| 4| 45-50| 5-10| 9-12

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 instructions
Read the ENTER 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 the 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 securely.
   

3. Adjust the Acetylene and Oxygen Regulators to their proper working pressures, see Table B on page 14.
   DO NOT EXTEND 15 PSI
   ACETYLENE PRESSURE
   

4. Hold the Torch Handle in one hand and the striker in the other hand.

5. Open the Acetylene Torch Valve about 1/4 turn, and quickly ignite the acetylene gas coming out of the Nozzle by squeezing the handle of the striker, creating a spark.
   WARNING!
   TO PREVENT SERIOUS INJURY: Do not use matches or a butane lighter to light the Torch.
   

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.
   

7. do not squeeze the Oxygen Cutting lever.
   Open the Oxygen Torch Valve.
   

8. Flame adjustment:
   a. Starting to add Oxygen:
   Slowly open the Pre-heat Oxygen Valve.
   The flame will change to a carbonizing flame with a blue/white inner core, a white halo 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 the Cutting Step 8 illustration, below center.
   c. too Much Oxygen:
   If you open the Pre-heat Oxygen Valve too far, the large section of the flame will be bluish-orange and the inner core will be small as shown in the Cutting Step 8 illustration, below right. Close the Pre-heat Oxygen Valve slightly until you achieve the flame described in step b above.
   WARNING!
   TO PREVENT SERIOUS INJURY
   Wear appropriate welding goggles.

9. After the flame is adjusted as explained and illustrated, proceed with cutting:
   a. Heat the edge were starting the cut until it is red hot.
   WARNING!
   TO PREVENT SERIOUS INJURY
   Start the cut at the edge of the workpiece.
   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.

10. After cutting, follow shutdown instructions on the facing page.

Cutting Shutdown instructions

1. After work is complete, first close the Oxygen Torch Valve clockwise, then close the Acetylene Torch Valve clockwise.

2. Fully close both cylinder valves, turning clockwise.

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.
   

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.
   

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.
   

6. Lastly, close the Acetylene Torch Valve clockwise, and close the Oxygen Torch and Pre-heat Oxygen Valves clockwise.

Maintenance instructions

procedures not specifically explained in this manual must be performed only by a qualified technician.
DANGER
TO PREVENT SERIOUS INJURY AND DEATH FROM FIRE OR EXPLOSION:
Close the oxygen cylinder valve, then the acetylene cylinder valve, and allow the torch to cool completely, then disconnect the hoses before performing any inspection, maintenance, or cleaning procedures.
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 of the Torch Kit. Check for loose hose connections, cracked or worn hoses, and any other condition that may affect its safe operation.
   If any abnormal condition occurs or is noticed, have the problem corrected before further use.
   do not use damaged equipment.

2. Periodically use a tip cleaner to clean out Cutting Tip and Welding Nozzle.

3. To clean the outer body of the Torch, use a clean, dry, cloth. Do not immerse any part of the Torch in ANY liquid. do not use solvents or other flammable agents to clean the torch.

MAINTENANCE CHART

Maintenance type| Before use|

after use

Inspect tool for damage.| X|

X

Use tip cleaner to clean tip opening.|

X

|

X

Wipe off with a clean, dry cloth.
NEVER USE SOLVENTS TO WIPE DOWN THIS TORCH.| |

X

Troubleshooting

Problem

| Possible Causes|

Likely Solutions

---|---|---
Before turning on Torch, an odor is noticed.|

1. Hose connections lose.
2. Crack in hose.
3. Cylinder leak at the neck.

|

1. Tighten all connections.

2. Check hoses. If any cracks are found, replace the entire hose.
   DO NOT PATCH OR TAPE GAS HOSES.

3. Check the neck area of cylinders.

If cracks or damage are found, do not use them.
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. Tip clogged or dirty.
2. Gas low.

|

1. Close gas, acetylene first, then oxygen.
   Let Torch cool completely.
   Remove Tip, check for dirt and debris.
   Use tip cleaner to clean Tip or replace if necessary.

2. Check gas level and refill if needed.

Follow all safety precautions whenever diagnosing or servicing the tool.
Disconnect air supply before service.

parts lists and assembly diagrams
Accessory Parts List and Diagram

Record product’s Serial number Here:
Note: if the product has no serial number, record the month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. Specify UPC 792363644082 when ordering parts.
PLEASE READ  THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM THIS MANUAL IS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR 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 BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.
parts list and diagram O – Oxygen Regulator

part| description| Order Code| part| description| Order Code
---|---|---|---|---|---
ASM O| Oxygen Regulator| OR-VM| O12C| Diaphragm| VMA10A
O1| Body| VMA01| O12D| Centralizer| 101A77
O2| HP Gauge| 25A52AD| O13| Gasket| VMA09
O3| LP Gauge| 25A52BD| O14| Adjusting Spring| 76A69
O4| Inlet Nut| 76A09AB| O15| Spring Button| 101A68
O5| Inlet Spigot| 25A04| O16| Bonnet| VMA08
O6| Filter| 25A22| O17| Label| VMA14
O7| Valve Spring| 101A83| O18| Adjusting T-Screw| VMA24
O8| Damper| 101A82| O19| Outlet Adapter| 25A76
O9| Valve| 101A81C| O20| Safety Valve| VHA19C
O10| Nozzle| 101A80| O20A| Safety Body| VHA19B
O11| Plunger| 76A74| O20B| Safety Rubber| 56A29
O12| Diaphragm Asm.| VMA18A| O20C| Safety Seat| VHA22A
O12A| Nut| 101A73| O20D| Safety Spring| VHA24
O12B| Diaphragm Plate| 101A74| O20E| Safety Cap| VHA25A

parts list and diagram H – torch Handle

part| description| Order Code| part| description| Order Code
---|---|---|---|---|---
ASM H| Torch Handle| VM-221| H8| Valve Stem Asm| VMCWA21E
H1| Cover| VMCWA49| H8A| Valve Stem| VMCWA16
H2| Torch Head| VMCWA30| H8B| Washer| VMCWA17
H3| Handle| VMCWA31| H8C| Nut| VMCWA18
H4| Inner Tube| VMCWA32| H8D| Adjusting Knob| VMCWA19A
H5| Tail| VMCWA33| H9| Label (OX)| VMCWA19B
H6| Oxygen Valve Body| VMCWA34| H10| Label (AC)| VMCWA19C
H7| Gas Valve Body| VMCWA35|

parts list and diagram C – Cutting attachment

part| description| Order Code| part| description| Order Code
---|---|---|---|---|---
ASM C| Cutting Attachment| VM-222| C16| Valve| VMCWA20
C1| Tip Nut| VMCWA02| C17| HP Spring| VMCWA21
C2| Head| VMCWA01| C18| Washer| VMCWA22
C3| Oxygen Tube| VMCWA03| C19| Valve Cap| VMCWA23
C4| Nut| VMCWA05| C20| Lever| VMCWA24
C5| Ferrule| VMCWA04| C21| Spiral Pin| VMCWA25
C6| Nut| VMCWA08| C22| Coupling Nut| VMCWA27
C7| Fuel Tube| VMCWA06A| C23| Cone End| VMCWA26
C8| Inner Tube (A)| VMCWA10| C24| O-ring (Big)| VMCWA28
C9| Inner Tube (B)| VMCWA11| C25| O-ring (Small)| VMCWA29
C10| Spiral| VMCWA13| C26| Valve Stem Asm| VMCWA16C
C11| Inner Tube (C)| VMCWA12| C26A| Valve Stem| VMCWA16
C12| O-ring| CMA17D| C26B| Washer| VMCWA17
C13| PTFE Washer| VMCWA09| C26C| Nut| VMCWA18
C14| Spring| VMCWA14| C26D| Adjusting Knob| VMCWA19A
C15| Body| VMCWA15| C27| Label (OX)| VMCWA19B

parts list and diagram a – acetylene Regulator

part| description| Order Code| part| description| Order Code
---|---|---|---|---|---
ASM A| Acetylene Regulator| AR-VM| A12| Diaphragm Asm.| VMA18A
A1| Body| VMA02| A12A| Nut| 101A73
A2| HP Gauge| 25A52CD| A12B| Diaphragm Plate| 101A74
A3| LP Gauge| 25A52DD| A12C| Diaphragm| VMA10A
A4| Inlet Nut| 25A16AB| A12D| Centralizer| 101A77
A5| Inlet Spigot| 25A06| A13| Gasket| VMA09
A6| Filter| 25A22| A14| Adjusting Spring| 76A70A
A7| Valve Spring| 101A83| A15| Spring Button| 101A67
A8| Damper| 101A82| A16| Bonnet| VMA08
A9| Valve| 101A81| A17| Label| VMA15
A10| Nozzle| 101A80| A18| Adjusting T-Screw| VMA24
A11| Plunger| 76A74| A19| Outlet Adapter| 25A76

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 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 or 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 inspection 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.

26541 Agoura Road
Calabasas, Ca 91302
1-888-866-5797

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