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Clarke 6000670 CGW1 Welding Kit Instructions PDF

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Summary of Content for Clarke 6000670 CGW1 Welding Kit Instructions PDF

WELDING KIT MODEL CGW1

PART NO: 6000670

ORIGINAL INSTRUCTIONS GC0917 iSSUE 2

USER INSTRUCTIONS

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INTRODUCTION

Thank you for purchasing this CLARKE Welding Kit.

Before attempting to use this product, please read this manual thoroughly and follow the instructions carefully. In doing so you will ensure the safety of yourself and that of others around you, and you can look forward to your purchase giving you long and satisfactory service.

Please note, these instructions are designed to aid you in the basic principles of welding, flame cutting, brazing, silver soldering, heating and the safe use of gases, regulators and torches, they are NOT a definitive instruction manual. With practice, a beginner can become proficient in the art of gas welding and flame cutting. Once acquired, this skill will prove to be very useful and possibly profitable.

GUARANTEE

This product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase. Please keep your receipt which will be required as proof of purchase.

This guarantee is invalid if the product is found to have been abused or tampered with in any way, or not used for the purpose for which it was intended.

Faulty goods should be returned to their place of purchase, no product can be returned to us without prior permission. This guarantee does not effect your statutory rights.

GENERAL SAFETY PRECAUTIONS

IMPORTANT: In addition to the following precautions, you should read, and fully comply with, all instructions and safety precautions that were supplied with your TIG Welder. Please keep these instructions in a safe place for future reference.

1. NEVER point the torch at any person or animal.

2. NEVER touch the nozzle unless the welder is switched OFF and the nozzle has been allowed to cool off.

3. NEVER connect, disconnect, or attempt to service the torch, unless the welding machine is switched OFF and disconnected from the mains supply..

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4. When welding, users and bystanders must ALWAYS use a protective headshield fitted with the correct shade of lens. Failure to do so can cause serious damage to your eyes.

5. ALWAYS learn the product applications, limitations and the specific potential hazards peculiar to it. Read and become familiar with the entire operating manual.

6. ALWAYS check for damage. Before using the equipment, any damaged part should be checked to ensure that it will operate properly and perform its intended function. Any damage should be properly repaired or the part replaced. If in doubt, DO NOT use the product. Consult your local dealer.

7. ALWAYS wear safety goggles, manufactured to the latest European Safety Standards.

8. ALWAYS keep the work area clean. Cluttered areas and benches invite accidents.

9. ALWAYS ensure that adequate lighting is available. A minimum intensity of 300 lux should be provided. Ensure that lighting is placed so that you will not be working in your own shadow.

10. ALWAYS keep children away. All visitors should be kept a safe distance from the work area, especially whilst welding.

11. ALWAYS concentrate on the job in hand, no matter how trivial it may seem. Be aware that accidents are caused by carelessness due to familiarity.

12. ALWAYS keep your proper footing and balance at all times - dont overreach. For best footing, wear rubber soled footwear. Keep floor clear of oil, scrap wood, etc.

13. ALWAYS prepare the work area before welding/cutting, work in a well ventilated area.

14. ALWAYS wear the correct safety wear specified for welding, i.e. welding goggles, welding gloves, apron and safety shoes etc.

ADDITIONAL SAFETY PRECAUTIONS

ALWAYS handle gas cylinders with care, chain or otherwise secure cylinders to a permanent fixture. Take care when moving.

ALWAYS use acetylene cylinders in an upright position, NEVER lying down.

ALWAYS store gas cylinders and related equipment according to local regulations.

ALWAYS ensure all hoses and connections are tight and leak free. Test for leaking joints etc using soapy water, NEVER use an open flame. DO NOT overtighten connections.

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ALWAYS ensure the non return valves/flash back arrestors supplied are fitted to both lines.

ALWAYS use recommended pressure settings. Improper settings are wasteful. Extreme pressure build up in regulators is a warning to have them checked and repaired.

ALWAYS crack the oxygen cylinder valve before installing the regulator, this is carried out by briefly opening the valve and allowing the escaping oxygen to clear away any dust which could damage the regulator.

ALWAYS prime oxygen and acetylene lines separately before lighting up, this will help prevent incorrect mixing of gases.

NEVER use oxygen to blow off work or clothing. Pure oxygen supports combustion and a spark can ignite oxygen-saturated clothing.

NEVER use oil or grease on the equipment, oil and grease is easily ignited and burns violently in the presence of oxygen.

NEVER work with damaged/leaking hoses and equipment, check for leaks using soapy water, any defects must be rectified before continuing.

INVENTORY

The welding kit comprises the following items:

Item Qty

Moulded Carry Case 1

Oxygen Regulator 1

Acetylene Regulator 1

Welding Torch/Handle 1

Welding Nozzle Adapter 1

Cutting Torch 1

Welding Nozzles 3

Cutting Nozzles 3

Hoses 2

Non Return Valve/Flashback Arrestor (oxygen) 2

Non Return Valve/Flashback Arrestor (acetylene) 2

Spark Igniter 1

Tip Cleaners 1

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SETTING UP INSTRUCTIONS

ATTACHING THE REGULATORS (FIG 1) Open the oxygen cylinder valve (arrowed) briefly to blow out any dust etc, ensure the valve is fully closed before continuing.

Attach the oxygen regulator (Blue) and tighten the connector using 25mm open ended spanner.

DO NOT overtighten.

Repeat the above procedure for attaching the acetylene regulator (Red).

NOTE: The acetylene connections are all left handed whilst the oxygen connections are all right handed.

ATTACHING THE HOSES (FIG 2) Connect the hoses (complete with flashback arrestors on each one) to the regulator outlets, blue to the oxygen outlet marked OUT and red to the acetylene outlet marked OUT, again observing left and right handed threads.

Tighten both connectors using a 19mm open ended spanner.

DO NOT overtighten.

WARNING: ENSURE THERE ARE NO NAKED FLAMES OR SPARKS WHICH COULD IGNITE WHEN PRIMING OR PURGING THE HOSES ETC. ENSURE A FIRE EXTINGUISHER IS ALWAYS AT HAND IN CASE OF ACCIDENTS.

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ATTACHING THE TORCH (FIG 3) Attach the acetylene hose complete with flame arrestor (Red) to the torch inlet valve marked GAS and the oxygen hose complete with flame arrestor (Blue) to the torch inlet valve marked OX.

Tighten both connectors using a 19mm open ended spanner, DO NOT overtighten. Ensure both valves are closed fully before continuing.

OPENING THE VALVES (FIG 4) Ensure both regulator knobs are opened fully (turned anticlockwise), carefully using cylinder key, slowly open both cylinder valves in turn, starting with the oxygen one.

ADJUSTING THE OPERATING PRESSURE (FIG 5) When adjusting the operating pressures, refer to the relevant table on page 9, depending whether welding or cutting etc.

Adjust the operating pressure on both cylinders by turning the regulator valve knobs in a clockwise direction, observe the low pressure gauge (Right Hand Gauge) until the gauge reading is at the correct pressure setting.

NOTE: The left hand gauge shows the pressure in the cylinder and is not adjustable. This is an indication how much oxygen/acetylene remains inside the cylinder.

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INSTALLING THE CUTTING/WELDING NOZZLE (FIG 6, 7 & 8)

WELDING

Remove the cutting torch if fitted, attach the welding nozzle adapter to the welding torch/handle, tightening hand tight only.

Select the required welding nozzle and screw into the adapter. To prevent the adaptor from turning, hold in position with a 11mm open ended spanner. Adjust the nozzle position by turning to the desired position using an 11mm open ended spanner on the nozzle connector.

CUTTING

Remove the welding nozzle and nozzle adapter if fitted. Attach the cutting torch to the welding torch/ handle, tighten the securing collar by hand, ensuring the operating lever does not foul on the valve knobs etc.

Remove the cutting nozzle securing nut, select the required nozzle and place into the securing nut. Screw into the cutting torch and lock in place using a 23mm open ended spanner.

DO NOT overtighten.

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LIGHTING THE TORCH (FIG 9) Open the torch acetylene valve approximately one half turn and ignite using the supplied spark igniter.

Open the torch valve until the flame stops excessive smoking and leaves the end of the nozzle tip about 3mm, then reduce slightly to bring the flame back to the tip.

Open the torch oxygen valve until a bright inner cone appears in the flame.

The point at which the feathery edges of the flame disappear and a sharp inner cone is visible is called the Neutral Flame.

BASIC WELDING PROCEDURES

Gas welding is a method of joining similar metals by heating the adjacent surfaces to melting point with an oxyacetylene flame and allowing the two parts to fuse together with a filler metal being required on materials 5mm thick or more. The resulting weld is as strong as the parent metal.

All metal to be joined should be thoroughly cleaned before welding. Oil, grease, rust, scale or other impurities affect the weld quality and the tensile strength. Metal of 5mm and over should be bevelled before attempting to weld and when bevelled edges are to be joined. A filler rod of the same material must be used.

The table below is a guide only showing recommended, oxygen and acetylene pressures relating to the size of the material to be welded etc.

If a too larger tip is used and the flame is softened, the tip heats up unnecessarily and is often accompanied by a popping noise which splatters the weld puddle. Too hot a flame burns the steel and too small a flame is not big enough to get the job done.

WELDING ROD Welding rods are available in various sizes with the most common being 1.6mm, 2.4mm and 3.2mm. They are also available for welding mild steel, cast iron and aluminium.

The size of rod will be determined by the type of weld, the metal thickness and the amount of filler metal required.

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WELDING FLAME A neutral flame is used for almost all gas welding. The oxyacetylene flame consumes all oxygen in the welding area which leaves an uncontaminated weld area and a weld of maximum strength.

An oxidizing flame is rarely used.

A carbonizing flame is used mainly for flame hardening and brazing.

Metal Thickness

(mm)

Tip Size Rod Size Oxygen Pressure

(PSI)

Acety- lene Pres- sure (PSI)

Number of Passes

1.6mm 2 1.6mm 3 3 1

2.4mm 5 2.4mm 5 5 1

3.2mm 5 3.2mm 5 5 1

6.4mm 10 3.2mm 9 9 2

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WELDING - PRACTICES AND EXERCISES

Gas welding is not a difficult art. The following exercises of torch movement are good practice and make subsequent welding easy.

EXERCISE 1 Using a small welding nozzle and correct pressures (see table on page 9), point the flame directly onto the steel (3.2mm stock recommended) with the flame cone just above the metal surface. When a puddle begins to form, slowly move the torch back and forth to move the puddle across the steel. This action has to be done slowly as it is necessary to have good penetration, which comes from a deep puddle. When moving the puddle, it is helpful to lean the nozzle at an angle of approx 45 away from the direction you want the puddle to move.

EXERCISE 2

Place two pieces of 3.2mm steel together as shown. Make the puddle again with a back and forth torch motion, move the puddle along the seam. Move the torch slowly for a good penetration. This can be checked by turning the parts over. The penetration should be visible from the bottom side. Test the weld strength by attempting to pull the pieces apart.

EXERCISE 3

Repeat exercise 2, but add welding rod this time. While the flame is directed at the steel to form the puddle, put the rod into the flame. when it becomes red, maintain this temperature by moving it in and out of the flame. Once the weld is started dip the rod into the puddle, the rod will melt and build up the weld so that the top is rounded instead of concave. Remember, welding rod is

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necessary on all double joints and once the you become an experienced welder, you will prefer to use rod on all welds, regardless of how thin the steel to be welded.

Material of 5mm or thicker should be bevelled before welding. A 30 bevel on each piece is the recommended angle. This is necessary to obtain the best penetration possible through the entire thickness. A rod is necessary on all welds with bevelled edges. Once the torch movement and puddle control are mastered, you will be able to make vertical, horizontal and flat welds with confidence.

BRAZING

Brazing differs from welding because the two pieces of metal to be joined are not fused together. The brazing rod melts at a lower temperature than the parent metal and the braze strength comes from the surface overlay of the brazing rod.

The advantage of brazing over welding is that it is the best way to join dissimilar metals, or repair cast iron. Almost any two metals can be joined by brazing, excluding aluminium and magnesium.

Brazing is separated into two types, depending on the type of rod used, bronze or silver. Bronze is less expensive than silver and should be used when

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the fit between the two metals to be joined is not close. The metals must be cleaned thoroughly before attempting to braze, gently play the flame onto both parts until they become a dull reddish colour. Both pieces must be of equal temperature otherwise the braze will flow to the hottest piece. Heat the rod by placing it in the flame, then dip it into the flux (note the heat causes the flux to melt and stick to the rod). If a prefluxed rod is used, this heating and dipping step may be eliminated. Once the rod is fluxed, and the metals are heated to the correct temperature, touch the rod to the joint, the rod melts and flows over the heated area, depending on the size of the joint, it may be necessary to dip the rod into the flux again. Abundant flux must be used, otherwise the molten rod will not stick to the metals being joined.

Silver brazing is a little faster than bronze brazing. This is because silver melts at a much lower temperature and less heat is required. However, the joint must fit tightly together. Bronze bridges a gap much better than silver. Instead of putting flux on the silver rod, the joint should be painted with flux. The way to determine when the metals are at the correct temperature is to watch the flux as it starts to bubble; as it does so it is time to apply the silver. The silver melts as it touches the hot metal and the molten silver flows over the fluxed area.

FLAME CUTTING

Flame cutting is a simple process that can be quickly mastered. Only steel can be cut with the oxyacetylene method, since cast iron, stainless steel, aluminium, brass and other ferrous metals do not burn the way that steel does.

The way to cut steel is to heat it to its kindling temperature (a reddish colour), then burn it with pure oxygen. A cutting torch provides both the preheat

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flames and pure oxygen cutting stream. Acetylene and oxygen are combined in the torch head and burn at the torch tip with a 6000F flame; these are the preheat flames. The centre hole in the cutting tip is the cutting oxygen hole, through which, pure oxygen, which is not mixed with acetylene, flows to cut the steel after the metal is sufficiently preheated.

CUTTING NOZZLES Cutting nozzles are available in a wide range of sizes, the correct size being determined by the steel thickness. Refer to the table below for correct pressures and tip sizes.

Metal Thickness

Tip Size Oxygen Pressure

(P.S.I)

Acetylene Pressure

3.2 - 6.4mm

9.6mm

12.7 - 25.4mm

50.8mm

76.2 -101.6mm

127 - 152mm

00

0

1

2

3

4

25 - 35

25 - 35

35 - 45

45 - 50

45 - 55

55 - 65

6

6

6

6

6

6

Tip size and pressure may vary according to operator choice. The table is a guide only.

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Once the correct nozzle is tightly secured in the cutting torch, correct pressure set on the regulators and the flame is adjusted to a neutral one, follow these simple procedures to cut steel using oxyacetylene.

1. Before lighting, open the oxygen valve on torch handle, one full turn. Make all oxygen adjustments with valve on the cutting attachment.

2. Move the flame to the edge of the steel and position the preheat cone just above the metal.

3. When the steel becomes red, slowly depress the cutting lever to release the oxygen stream to cut through the steel.

4. Slowly move the torch in the direction of the cut. The correct speed is accompanied by a sputtering sound and a steady stream of sparks. This results in a clean, slag free cut with square top and bottom edges.

5. Too fast a movement does not allow time for the oxygen stream to cut all the way through the metal. Slag fills the kerf and the two pieces are not severed.

6. Too slow a movement leaves a rounded top edge with slag sticking to the bottom of the metal.

7. The size of the preheat flame determines how quickly the cut can be started. Often, a small preheat flame is desirable to conserve gases and prevent melting of the top edges.

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TROUBLESHOOTING

ACCESSORIES

A wide range of tools and accessories is available from your nearest CLARKE dealer, for further information, contact your nearest dealer, or telephone CLARKE International Sales department on 01992 565300.I

IMPORTANT: The use of parts other than CLARKE replacement parts may result in safety hazards, decreased tool performance and may invalidate your warranty.

Problem Probable Cause Remedy

Welding tip popping Tip is operated at too low heat.

Nozzle too large

Tip too close to work

Increase pressures, consult tip table (page 13).

Use next smallest size nozzle

Move tip further from the work area.

Flames not clearly defined, smooth or even.

Dirty tip Clean with tip cleaner or replace nozzle.

Regulator not holding constant pressure.

Defective seat. Return unit for replacement.

Cutting tip popping. Nozzle loose

Seat nicked

Tighten nozzle nut

Replace nozzle

Difficult to light. Too much pressure. Consult pressure table. (page 9).

Flame changes during cutting.

Oxygen needle valve on torch handle partly closed.

Oxygen cylinder almost empty.

Fully open oxygen valve.

Replace cyli

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