Tweco K4000 User Manual

ARCAIR

®

Cutting and Gouging Systems

VictorTechnologies.com/Arcair

K3000™, K4000

AIR CARBON-ARC
MANUAL GOUGING TORCHES

Operating

®

Manual

English

Canadien Français

Americas Español

Revision: AA Issue Date: September 23, 2013 Manual No.: 89250012

WE APPRECIATE YOUR BUSINESS!

Congratulations on receiving your new Victor Arcair® product. We are
proud to have you as our customer and will strive to provide you with the
best service and support in the industry. This product is backed by our
extensive warranty and world-wide service network.

We know you take pride in your work and we feel privileged to provide you
with this high performance product that will help you get the job done.

For more than 60 years Victor Arcair® has provided quality products you
can trust, when your reputation is on the line.

YOU ARE IN GOOD COMPANY!

Victor Arcair® is a Global Brand of Cutting Products for Victor
Technologies™ Inc. We distinguish ourselves from our competition
through market-leading innovation and truly dependable products that will
stand the test of time.

We strive to enhance your productivity, efficiency and welding
performance, enabling you to excel in your craft. We design products with
the welder in mind delivering- advanced features, durability, ease of use
and ergonomic comfort.

Above all, we are committed to a safer working environment within the
welding industry. Your satisfaction with this product and its safe operation
is our ultimate concern. Please take the time to read the entire manual,
especially the Safety Precautions.

If you have any questions or concerns regarding your new Victor Arcair®
product, please contact our friendly and knowledgeable Customer Service
Team at:

1-800-462-2782 (USA) and 1-905-827-4515 (Canada),
or visit us on the web at www.victortechnologies.com/arcair

!

WARNINGS

Read and understand this entire Manual and your employer’s safety practices
before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's
best judgement, the Manufacturer assumes no liability for its use.

Victor® Arcair® K3000™ & K4000® Air Carbon-Arc Manual Gouging Torches
Operating Manual
Operating Manual Guide Number: 89250012

Published by:
Victor Technologies, Inc.
2800 Airport Rd.
Denton, TX. 76208
940-566-2000
www.victortechnologies.com/arcair

Copyright © 2013 Victor Technologies, Inc. All rights reserved.

Reproduction of this work, in whole or in part, without written permission of
the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party
for any loss or damage caused by any error or omission in this Manual, whether
such error results from negligence, accident, or any other cause.

Publication Date: September 23, 2013

Table of Contents

SECTION 1: INTRODUCTION ............................................... 1-1

1.01 Air Carbon-Arc Cutting/Gouging ................................................. 1-1

1.02 History ........................................................................................ 1-1

1.03 Applications ................................................................................ 1-2

1.04 The "BEST" Just Got Better... ....................................................... 1-2

SECTION 2: SAFETY AND HEALTH ........................................ 2-1

2.01 Proper Installation, Use, and Maintenance .................................. 2-1

2.02 Electrodes ....................................................................................2-1

2.03 Ventilation Hazards ..................................................................... 2-2

2.04 Personal Protective Equipment and Clothing .............................. 2-3

2.05 Shielding Booths ......................................................................... 2-4

2.06 Fire and Burn Hazards ................................................................. 2-4

2.07 Safety and Operating References ................................................ 2-5

SECTION 3: HOW TO USE THIS MANUAL ................................ 3-1

3.01 Receipt of Equipment .................................................................. 3-1

SECTION 4: INSTALLATION .............................................. 4-1

4.01 Installing the DC Welding Power Cable and Air Hose to the

Power and Air Connector ............................................................ 4-1

4.02 Installing the DC Welding Power Cable with Twist Lock Power

Connection and Air Hose to the Torch Swivel Cable Assembly .... 4-4

4.03 Connecting to DC or AC Welding Power Supplies ....................... 4-5

SECTION 5: TROUBLESHOOTING ......................................... 5-1

SECTION 6: REPLACEMENT PARTS ...................................... 6-1

6.01 K3000™ & K4000® TORCH REPLACEMENT PARTS ...................6-1

6.02 K3000™ & K4000® SWIVEL CABLE REPLACEMENT PARTS ......6-2

6.03 POWER & AIR HOOK-UP KIT ...................................................... 6-3

STATEMENT OF WARRANTY ......................... INSIDE BACK COVER

SECTION 1: INTRODUCTION

1.01 Air Carbon-Arc Cutting/Gouging

The air carbon-arc process (CAC-A) removes metal physically, not chemically as in
oxy-fuel cutting (OFC). Gouging or cutting occurs when the intense heat of the arc
between the carbon electrode and the workpiece melts part of the workpiece. Simulta­neously, air passes through the arc quickly enough to blow the molten material away.

The air carbon-arc process does not require oxidation to maintain the cut, so it can
gouge or cut metals that the OFC process cannot. Most common metals (e.g., carbon
steel, stainless steel, many copper alloys and cast irons) can be cut using the air
carbon-arc process. The metal removal rate depends on the melting rate and how
efficiently the air jet removes molten metal. In the process, the air must lift the molten
metal clear of the arc before the metal solidifies.

1.02 History

Air carbon-arc gouging began in the 1940's, evolving from the existing carbon-arc cut­ting process. Myron Stepath, a welding engineer, developed air carbon-arc gouging to
remove several hundred feet of flat, cracked, stainless steel weld.

Previously, carbon-arc cutting removed overhead and vertical defective welds and rivet
heads. The carbon-arc melted the metal, then gravity moved the molten metal away.

Stepath reasoned that an air jet could provide the force to remove metal lying flat. So
he tried a direct-current, electrode-negative carbon-arc with a second operator direct­ing an air blast via air nozzle at the molten pool. However, this attempt was unsuc­cessful because the arc was less stable than a carbon-welding arc. So, Stepath tried a
direct-current, electrode-positive arc, and the result was air carbon-arc gouging.

In 1948, Myron Stepath introduced the first air carbon-arc torch to the welding
industry. In 1949, Stepath and two associates founded the Arcair® Company.

Two operators were no longer needed. The compressed air now passed through the
torch and exited beneath the electrode. This new tool saved time on weld backgouging,
crack removal, and weld defect repair on carbon, alloy, and stainless steel. Previously,
these tasks were performed by grinding or chipping.

Today, the basic principle remains the same, but with improved equipment and an
expanded number of applications.

1-1

1.03 Applications

The industry has enthusiastically adopted air carbon-arc gouging and found many
uses for the process in metal fabrication and casting finishing, chemical and petroleum
technology, construction, mining, general repair, and maintenance.

Victor® Arcair® Torches and Electrodes are used throughout the world, anywhere
metal is gouged, grooved, severed, or removed from a surface.

The air carbon-arc process is flexible, efficient, and cost effective on practically any
metal: carbon steel, stainless steel and other ferrous alloys; gray, malleable and ductile
iron; aluminum; nickel; copper alloys and other nonferrous metals.

1.04 The "BEST" Just Got Better...

Victor® Arcair® is changing the game when it comes to the power and air connection
design on their K-Series torch cable assemblies.

Since the invention of the air carbon-arc process in 1949, the torch and cable have
always used a molded rubber "boot" to provide electrical protection for the power
connection by preventing arcing against a grounded work surface. This boot design
incorporates a large open rectangular end that allows the power cable and air hose
space to connect to the torch cable. However, the boot can expose the power
connection to the grounded work surface if it is not properly installed and kept in place
over the connection.

Now, the improved boot design encapsulates the power/air connection, eliminating
the chance of accidental arcing. It can accept one 4/0 welding cable from the power
supply and one ¾” diameter air hose assembly that provides current and compressed
air.

This new boot design is molded from a hard nylon reinforced fiber material that can
withstand the abuse of everyday use in a fabrication shop.

1-2

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1-3

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1-4

SECTION 2: SAFETY AND HEALTH

Safe practices in welding and cutting processes, such as air carbon-arc, are covered
in ANSl Z49.1, “Safety in Welding and Cutting”, and ANSl 249.2, “Fire Prevention in
Use of Welding and Cutting Processes.” Air carbon-arc operators and their supervisors
should adhere to the safe practices discussed in these documents.

Other hazards in arc welding and cutting are briefly discussed in this section.

2.01 Proper Installation, Use, and Maintenance

Serious injury or death may result if gouging and cutting equipment is not properly
installed, used, and maintained. Misuse of this equipment and other unsafe practices
can be hazardous. The operator, supervisor, and helper must read and understand the
following safety warnings and instructions before installing or using any air carbon-arc
torch or equipment.

The gouging/cutting process is used in many potentially dangerous environments,
such as elevated heights, areas with limited ventilation, close quarters, areas around
water, hostile environments, etc. The operator must be aware of the dangers associ­ated with working in these types of conditions. The operator must be trained in safe
practices for his work environment and be under competent supervision.

It is essential that the operator, supervisor, and others in the work area be aware of the
dangers of the air carbon-arc process. Training and proper supervision are important
for a safe work place. Keep these instructions for future use. Additional recommended
safety and operating information is referenced in each section.

2.02 Electrodes

WARNING

ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH

Install and maintain equipment in accordance with the National Electrical
Code (NFPA 70) and local codes. Do not service or repair equipment with
power on. Do not operate equipment with protective insulators or covers
removed. Service or repair to equipment must be done by qualified and/or
trained personnel only

2-1

Keep carbon electrodes dry. If electrodes become damp, bake them for 10 hours at
300˚ F (176˚ C). Wet electrodes may shatter.

Do not touch electrically live parts. Do not touch an electrode with bare skin and
electrical ground at the same time. Always wear dry welding gloves that are in good
condition. Aluminized protective clothing can become part of the electrical path. Keep
oxygen cylinders, chains, wire ropes, cranes, hoists, and elevators away from any part
of the electrical circuit. Check all ground connections periodically to determine if they
are mechanically strong and electrically adequate for the required current.

If you are engaged in alternating current gouging/cutting under wet conditions or
warm surroundings where perspiration is a factor, use reliable automatic controls for
reducing no load voltage to reduce shock hazard. When the gouging/cutting process
requires values of open circuit voltages in alternating current machines higher than
80 volts, and direct current machines higher than 100 volts, take precautions, such as
using adequate insulation, to prevent the operator from making accidental contact with
the high voltage.

If you are going to suspend gouging for any substantial period of time, such as during
lunch or overnight, remove all electrodes from the torch and the put the torch in a safe
location so that accidental contact cannot occur. Disconnect the torch from the power
source when it is not in use. Never immerse air carbon-arc torches or electrodes in
water.

2.03 Ventilation Hazards

WARNING

SMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH

Keep smoke, fumes and gases from the breathing area. Fumes from the gouging
process are of various types and strengths, depending on the kind of base metal being
worked on. To ensure your safety, do not breathe these fumes. Ventilation must be
adequate to remove smoke, fumes and gases during the operation to protect gouging
operators and others in the area.

Vapors of chlorinated solvents can form the toxic gas phosgene when they are
exposed to ultraviolet radiation from an electric arc. Remove all solvents, degreasers,
and potential sources of these vapors from the operating area.

Fumes that are produced by cutting in particularly confined places can cause discom­fort and physical harm if inhaled over an extended period of time. Provide adequate
ventilation in the gouging/cutting area. Use air-supplied respirators if there is not
enough ventilation to remove all fumes and gases. Never ventilate with oxygen, be­cause oxygen supports and vigorously accelerates fire.

2-2

2.04 Personal Protective Equipment and Clothing

WARNING

NOISE CAN DAMAGE HEARING

Noise from the air carbon-arc process can damage your hearing. Operators and sur­rounding personnel must wear adequate protective hearing devices to ensure personal
protection against noise when noise levels exceed OSHA standards.

Duration Per Day (hours) Sound Level (dBA*) Slow Response

8 90
6 92
4 95
3 97
2 100

1-1/2 102

1 105

1/4 or less 115

* dBA = decibels

WARNING

ARC RAYS, HOT SLAG, AND SPARKS CAN INJURE EYES AND BURN SKIN

The gouging/cutting process produces extreme localized heat and strong ultraviolet
rays. Never attempt to gouge/cut without a welding helmet with the proper lens that
complies with federal guidelines.

A number 12 to 14 shade filter lens provides the best protection against arc radiation.
When in a confined area, prevent the reflected arc rays from entering around the hel­met. Make sure others are protected from arc rays and sparks. Use approved shielding
curtains and appropriate goggles to provide protection to others in the surrounding
area and operators of nearby equipment.

2-3

Skin should also be protected from arc rays, heat and molten metal. Always wear
protective gloves and clothing that will not allow skin to become exposed. Close all
pockets and sew shut all cuffs. Wear leather aprons, sleeves, leggings, etc. for out-of­position gouging/cutting, or for heavy metal-removal operations using large elec­trodes. High top work shoes provide adequate protection from foot burns. Use leather
spats for added protection. Do not use flammable hair preparations when gouging/
cutting. Wear ear plugs to protect ears from sparks.

2.05 Shielding Booths

Where the work permits, the arc welder should be enclosed in an individual booth
painted with a finish of low reflectivity—an important factor for absorbing ultraviolet
radiations—such as zinc oxide and lamp black. The welder may also be enclosed in
similarly painted noncombustible screens.

2.06 Fire and Burn Hazards

WARNING

WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS.

Causes of fire and explosion include combustibles reached by the arc, flame, flying
sparks, hot slag or heated materials. Remove combustibles from the work area and/or
provide a fire watch. Avoid oily or greasy clothing as a spark may ignite them. Keep a
fire extinguisher nearby, and know how to use it.

Be alert to the danger of conduction or radiation. For example, if you will be gouging/
cutting on a metal wall, partition, ceiling or roof, take precautions to prevent com­bustibles from igniting on the other side. Do not gouge/cut containers that have held
combustibles. Vent all hollow spaces, cavities and containers before gouging/cutting
to permit air or gases to escape. Purging with inert gas is recommended.

2-4

Table 2-1 - Recommended Minimum Air Requirements

Recommended Compressor Rating

Type of Torch

Air

Pressure¹

psi (kPA)

Air

Consumption

cfm (L/min.)

Intermittent

Use

hp (kW)

Continuous

Use

hp (kW)

ASME

Receiver

Size

gal (lit)

Light Duty² 40 (280) 8 (227) 0.5 (0.4) 1.5 (1.1) 60 (227)

General Duty²

80 (550)

25 (708) 5 (3.7) 7.5 (5.6)

80 (303)Multipurpose³ 33 (934) 7.5 (5.6) 10 (7.5)

Automatic460 (414) 46 (1303) N/A 15 (11.2)

¹ Pressure while torch is in operation.
² Accommodates flat electrodes.
³ Generally considered a foundry torch.

4

Requires some kind of mechanical manipulation.

Use only compressed air. Using combustible compressed gases can cause explosions
that may result in personal injury or death.

2.07 Safety and Operating References

1. Code of Federal Regulations. (OSHA) Section 29 Part 1910.95, 132, 133, 134, 139,

251, 252, 253, 254 AND, 1000. U.S. Government Printing Office, Washington, DC
20402

2. ANSl Z49.1 “Safety In Welding and Cutting”

3. ANSI Z87.1 “Practice for Occupational and Educational Eye and Face Protection.”

4. ANSl Z88.2 “Standard Practice for Respiratory Protection.” American National Stan-

dards Institute, 1430 Broadway, New York, NY 10018.

5. AWS C5.3 “Recommended Practices for Air Carbon-Arc Gouging and Cutting.”

6. AWS F4.1 “Recommended Safe Practices for Welding and Cutting Containers.”

The American Welding Society, 550 NW Lejeune RD., P.O. Box 351040, Miami FL.
33135

7. NFPA 51B “Fire Prevention in Cutting and Welding Processes” National Fire Protec-

tion Association, Battery Park. Quincy MA 02269

8. CSA Standard W117.2, “Safety in Welding. Cutting and Allied Processes” Canadian

Standards Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3

2-5

This Page Intentionally Blank

2-6

SECTION 3: HOW TO USE THIS MANUAL

To ensure safe operation, read the entire manual, including the chapters on safety
instructions and warnings.

Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay
particular attention to the information provided under these headings. These special
annotations are easily recognized as follows:

!

WARNING

A WARNING GIVES INFORMATION REGARDING POSSIBLE PERSONAL

INJURY.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

3.01 Receipt of Equipment

When you receive the equipment, check it against the invoice to make sure it is com­plete and inspect the equipment for possible damage due to shipping. If there is any
damage, notify the carrier immediately to file a claim. Furnish complete information
concerning damage claims or shipping errors to the location in your area listed in the
inside back cover of this manual. Include a full description of the parts in error.

3-1

This Page Intentionally Blank

3-2

SECTION 4: INSTALLATION

4.01 Installing the DC Welding Power Cable and Air Hose to the

Power and Air Connector

Models Part No. 61-065-006, 61-065-007, 61-082-008 and 61-082-009

Follow these instructions to connect the DC Welding Power Cable and Compressed Air
Line directly to the Power and Air Connector on the Torch Swivel Cable Assembly.

1. Remove the Torch and Cable Assembly from the carton and lay the assembly in a

straight and untwisted position on a workbench or floor.

2. Position the molded boot so that you have access to the four (4) screws as shown

in Figure 4-1.

Figure 4-1

3. Use a straight blade screwdriver to remove the four (4) screws. Lift the top half of

the molded boot away from the assembly.

Figure 4-2 Figure 4-3

4-1

4. Using a ½”-13 x 1” hex head bolt, position the bolt down so that its threads run

through the crimped lug of the DC Welding Power Cable and through the Power and
Air Connector on the Swivel Cable Assembly. The head of the bolt should be against
the flat side of the crimped lug as shown in Figure 4-4.

5. Place a ½” lock washer over the bolt threads and begin to thread a ½”-13 nut down

against the assembly.

Figure 4-4

6. Position the brass Power and Air Connector back into the bottom half of the boot.

Figure 4-5

7. Using your index finger to apply an upward force on the bolt, tighten the assembly

down.

Figure 4-6

4-2

8. Lift the assembly away from the bottom half of the boot to securely fasten. Do not

allow the crimped lug to move while doing this final tightening step.

Figure 4-7

9. Thread the incoming Compressed Air Line with a 3/8” pipe threaded fitting into the

Power and Air Connector. This connection should be wrench tight.

Figure 4-8

10. Reposition the Cable Assembly with the DC Welding Power Cable and Air Hose back

in place in the lower half of the boot.

Figure 4-9

4-3

10. Reposition the top half of the boot in place and secure with the four (4) screws that

were removed in step 3.

Figure 4-10

11. The assembly is now ready to be used in your metal removal application.

4.02 Installing the DC Welding Power Cable with Twist Lock Power

Connection and Air Hose to the Torch Swivel Cable Assembly

Models Part No. 61-065-002, 61-065-003, 61-082-006 and 61-082-007

1. Remove the Torch and Cable Assembly from the carton and lay the assembly in a

straight and untwisted position on a workbench or floor.

2. Remove the Twist Lock Connector attached to the Torch Swivel Cable Assembly.

Follow these steps to connect the brass female connector to the DC Power Cable:

a. Remove the cover screw holding the outer cover in place from the assembly.
b. Trim the rear of the connector cover to fit the cable being used. NOTE: Do not

over trim. The cover should fit snugly.
c. Slip the cover over the cable.
d. Trim the cable insulation back 1-7/8”, exposing the copper stranding.
e. Loosen the ball-point screws and insert the copper cable into the cable hole of

the brass connector half.
f. Tighten the ball-point screws securely (150 – 250 in./lbs.) The heads of the

screws should be flush with, or below, the connector body.
g. Slip the connector cover over the brass body and install/tighten the cover

screw. The screw fits into the second cover hole.

3. Thread the 3/8” pipe threaded fitting that is connected to the Air Hose coming out of
the Torch Swivel Cable, into your shop air line. This connection should be wrench
tight.

4-4

4.03 Connecting to DC or AC Welding Power Supplies

Gouging applications normally use three-phase welding power supplies with an open
circuit voltage higher than 60 volts, to allow for any voltage drop in the circuit.

1. Connect the Welding Power Cable that is connected to the Torch Swivel Cable to the
positive terminal on the power supply (DCEP or AC). Refer to Figure 4-11.

2. Connect the Welding Power Cable that is connected to the negative terminal on the
power supply to the workpiece.

COMPRESSED AIR

POWER SUPPLY

ELECTRODE LEAD

DCEP OR AC

CONCENTRIC

CABLE

WORKPIECE LEAD

CARBON ELECTRODE

TORCH

WORKPIECE

Figure 4-11

3. Turn on the power supply and air supply to the gouging torch and cable assembly.

4. Press down on the lever of the torch to insert the air carbon-arc electrode “carbon”
into the torch. When using copper coated carbons, the bare carbon end should be
down and away from the torch. This is where the arc will be struck between the carbon
and workpiece. Refer to Figure 4-12.

4-5

TORCH

STICKOUT 7" MAX

COPPER PEEL BACK

3/4" to 2"

AIR 80PSI

ALWAYS UNDER THE ELECTRODE

TRAVEL

WORKPIECE (-)

Figure 4-12

ELECTRODE

TORCH HEADS (+)

5. Hold the electrode as shown in Figure 4-12, so that a maximum of 7” (178 mm)
extends from the torch. This extension should be 3” (76.5 mm) for aluminum.

6. While the torch valve is open, adjust the air pressure at the torch to the normal pres­sures range between 80 psi (551.6 kPa) and 100 psi (690 kPa); higher pressures
may be used, but they do not remove metal more efficiently.

7. Adjust the welding current (Constant Current) or voltage (Constant Voltage), depend­ing on the type of power supply being used, to the suggested current range shown
for the carbon diameter being used. Refer to Table 4-1.

Table 4-1 - Suggested Current Ranges (AMP) for Commonly Used Electrode Types and Sizes

Electrode

DC Electrode DCEP AC Electrode ACAC Electrode DCEN

Diameter

in (mm) min - max min - max min - max

1/8 (3.2) 60 - 90

5/32 (4.0) 90 - 150

N/A

3/16 (4.8) 200 - 250 200 - 250 150 - 180

1/4 (6.4) 300 - 400 300 - 400 200 - 250

5/16 (7.9) 350 - 450 N/A

3/8 (9.5) 450 - 600 350 - 450 300 - 400
1/2 (12.7) 800 - 1000
5/8 (15.9) 1000 - 1250
3/4 (19.1) 1250 - 1600

1 (25.4) 1600 - 2200

N/A

3/8 (9.5) FLAT 250 - 450
5/8 (9.5) FLAT 300 - 500

4-6

8. Turn on the air jet before striking the arc. Hold the torch between a 45˚ - 60˚ work
angle, so that the electrode slopes back from the direction of travel. The air jet sweeps
between the electrode and workpiece, providing the force to remove all molten metal
from the groove.

9. Lightly touch the electrode to the workpiece to establish the arc. Do not draw back the
electrode once the arc is ignited. When the correct arc voltage is being maintained,
the sound of the arc and the compressed air is loud. When the sound is muffled,
the arc voltage is below the recommended operating conditions. Normal arc voltage
with a handheld gouging torch is measured between 35 to 50 volts.

10. The groove’s depth is controlled by travel speed. Grooves up to 1” (25 mm) deep may
be made. However, the deeper the groove, the more experienced the operator needs to
be. Slow travel speeds produce deep grooves, and fast travel speeds produce shallow
grooves. The width of the groove is determined by the size of the electrode used and
is typically about 1/8” (3.2 mm) wider than the electrode’s diameter. A wider groove
may be made with a small electrode by oscillating in a circular or weave motion.

4-7

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4-8

SECTION 5: TROUBLESHOOTING

Problem Cause Solution

Large free-carbon de­posit at the beginning of
the groove.

An unsteady arc, causing
the operator to use a
slow travel speed even
on shallow grooves.

Erratic groove with the
arc wandering from
side-to-side and with
the electrode heating up
rapidly.

Intermittent arc action
resulting in an irregular
groove surface.

1. The operator either ne­glected to turn on the
air jet before striking
the arc or the torch was
located improperly.

2. Carbon rod not posi­tioned properly in head
assembly.

1. Not enough amperage
for the electrode diam­eter used (see Table

2). While the lowest
recommended amper­age may be enough, it
requires greater opera­tor skill. A mid-range
amperage is better.

1. The process used with
DCEN (electrode nega­tive).

1. The travel speed was
too slow in manual
gouging. The opera­tor possibly set their
hand on other work for
balance, a tendency
in shielded metal-arc
welding. Since the
speed of air carbon-arc
gouging is much faster
than shielded metal-arc
welding, friction be­tween the gloved hand
and the workpiece may
cause a jerky forward
motion thus causing
the gap between the
electrode and work­piece to become too
large to maintain the
arc.

2. Poor ground connec­tion.

1. Turn on air before strik­ing the arc and air should
flow between the elec­trode and the workpiece.

2. Ensure carbon rod is
seated in groove in torch
head.

1. If the desired amper­age cannot be obtained
from the available
power source, use the
next smaller diameter
electrode or parallel two
or more welding power
supplies.

1. Gouging process should
be done with DCEP (Elec­trode positive) whenever
possible. Direct current
electrodes should be
used with DCEP (elec­trode positive) on all
metals, except for a few
copper alloys such as
Superston and Nialite.

1. The operator should
stand comfortably so
their arms move freely
and their gloves do not
drag on the workpiece. If
using mechanized equip­ment, check
Table 4 (Page 4-24) for
proper operating condi­tions.

2. Inspect ground clamps
and lead(s) to ensure
connection proper.

5-1

Problem Cause Solution

In gouging, free carbon
deposits at varying
groove intervals; in pad

-washing, free carbon
deposits at various spots
on the washed surface.

Irregular groove: too
deep, then too shallow.

Slag adhering to the
edges of the groove.

1. A shorted electrode
on the workpiece. In
manual gouging, this
is a result of excessive
travel speed for the
amperage used and for
the depth of the groove
being made. In mecha­nized operations, this
is a result of excessive
travel speed or using
a flat-curve, constant­voltage power source
for a small diameter
electrode 5/16" (7,9
mm). In padwashing,
this is caused by hold­ing the electrode at too
small a push angle.

1. The operator was
unsteady.

1. Slag ejection was
inadequate. To resolve,
keep a proper air
pressure and flow rate
(cfm). Air pressure be­tween 80 and 100 psi
(550-690 kPa) may not
effectively eject all of
the slag if the volume
is insufficient.

1. Use an electrode-to-work
angle of 15° to 70°. A
smaller angle increases
the arcing area,reducing
the current density; this
reduction in arc-current
density requires a great
decrease in arc length, to
the point of short circuit.
Keep a proper arc gap.

1. The operator should
assume a comfortable
position while gouging.

1. To deliver adequate
volume, the air hose
feeding the concentric
cable assembly needs
a minimum hose ID of
3/8" (9.5 mm) for manual
torches. For automatic
torches, the minimum
hose ID should be 1/2"
(12.7 mm). Direct the air
jet parallel to the gouge
area. Do not favor one
side unless operator
wants to minimize slag
from adhering to one
side of the cut.

5-2

SECTION 6: REPLACEMENT PARTS

14

4

5

6

8

3

7

12

1

10

2

1

9

13

11

11

K3000 and K4000 Torch

(K4000 Shown)

6.01 K3000™ & K4000® TORCH REPLACEMENT PARTS

TORCH REPLACEMENT PARTS LIST

Item Description K3000™ K4000

1 Insulators & Screws 94-433-193 94-433-183

2 Lever & Screw 94-476-080 94-476-066

3 Valve Bonnet 94-104-016 94-104-016

4 Bonnet Wrench 94-960-001 94-960-001

5 Bonnet Only 94-104-012 94-104-012

6 Spool & O-Rings 94-801-011 94-801-011

7 O-Ring 94-710-036 94-710-036

8 Spool Only 94-801-010 94-801-010

9 Upper Arm 94-048-120 94-048-088

10 Head & Screw 94-378-366 94-378-368

11 Torch Body 94-103-232 94-103-206

12 Hinge Pin 94-632-101 94-632-094

13 Spring 94-800-191 94-800-077

14 Handle 94-370-179 94-370-163

®

6-1

6.02 K3000™ & K4000® SWIVEL CABLE REPLACEMENT PARTS

9

6

8

6

10

7

5

4

3

2

1

6-2

CABLE REPLACEMENT PARTS LIST

Item Description K3000™ K4000

7ft. (2.1M) Swivel Cable 70-088-107 70-084-207

10ft. (3M) Swivel Cable 70-088-110 70-084-210

1 Retainer Screw 94-695-054

94-170-182 *2 O-Ring 94-710-027

3 Connector 94-170-178

4 Spring Washer 94-940-104 94-940-104

5 Flat Washer 94-940-103 94-940-103

6 Clamp (2 Required) 98-167-010 98-167-010

7

8

9 Molded Hard Boot with Screws 94-105-032 94-105-032

10 Female Connector 94-170-150 94-170-150

7ft. (2.1M) Conductor 96-130-314 96-130-263

10ft. (3M) Conductor 96-130-315 96-130-261

7ft. (2.1M) Cover 94-171-273 94-171-273

10ft. (3M) Cover 94-171-274 94-171-274

* Includes Retainer Screw, O-Ring, and Connector

®

6.03 POWER & AIR HOOK-UP KIT

3

1

4

2

HOOK-UP KIT & PARTS LIST

Item Description Cat No.

Complete Hook-Up Kit 94-463-046

1 Male Connector 94-170-184

2 Molded Hard Boot with Screws 94-105-031

3 4-WPC-R Connector 4WPC-R

4 Pigtail Air Supply Hose 94-396-205

6-3

This Page Intentionally Blank

STATEMENT OF WARRANTY

LIMITED WARRANTY: Victor Technologies, Inc. warrants that its products will be free of
defects in workmanship or material. Should any failure to conform to this warranty appear
within the time period applicable to the Victor Technologies products as stated below,
Victor Technologies shall, upon written notification thereof and substantiation that the
product has been stored, installed, operated, and maintained in accordance with Victor
Technologies’s specifications, instructions, recommendations and recognized standard
industry practice, and not been subject to misuse, repair, neglect, alteration, or accident,
correct such defects by suitable repair or replacement, at Victor Technologies’s sole op­tion, of any components or parts of the product determined by Victor Technologies to
be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Victor Technologies shall not under any circumstances be li-

able for special, indirect or consequential damages, such as, but not limited to, damage
or loss of purchased or replacement goods, business interruption or loss of profit, or
claims of customers of distributor (hereinafter the “Purchaser”) for service interruption.
The remedies of the Purchaser set forth herein are exclusive and the liability of Victor
Technologies with respect to any contract, or anything done in connection therewith such
as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or
use of any goods covered by or furnished by Victor Technologies whether arising out of
contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as
expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE
USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY VICTOR TECHNOLO­GIES PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

This warranty is effective for the time stated in the Warranty Schedule beginning on the
date that the authorized distributor delivers the products to the Purchaser.

Warranty repairs or replacement claims under this limited warranty must be submitted by
an authorized Victor Technologies repair facility within thirty (30) days of the repair. No
transportation costs of any kind will be paid under this warranty. Transportation charges
to send products to an authorized warranty repair facility shall be the responsibility of the
Purchaser. All returned goods shall be at the Purchaser’s risk and expense. This warranty
supersedes all previous Victor Technologies warranties.

THE AMERICAS

Denton, TX USA
U.S. Customer Care

Ph: 1-800-426-1888 (tollfree)
Fax: [phone] (tollfree)

International Customer Care

Ph: 1-940-381-1212
Fax: [phone]

Miami, FL USA
Sales Office, Latin America

Ph: 1-954-727-8371
Fax: [phone]

Oakville, Ontario, Canada
Canada Customer Care

Ph: 1-905-827-4515
Fax: [phone] (tollfree)

EUROPE

Chorley, United Kingdom
Customer Care

Ph: [phone]
Fax: [phone]

Milan, Italy
Customer Care

Ph: [phone]
Fax: [phone]

ASIA/PACIFIC

Cikarang, Indonesia
Customer Care

Ph: 6221-8990-6095
Fax: [phone]

Rawang, Malaysia
Customer Care

Ph: [phone]
Fax: [phone]

Melbourne, Australia
Australia Customer Care

Ph: 1300-654-674 (tollfree)
Ph: 61-3-9474-7400
Fax: [phone]

International

Ph: 61-3-9474-7508
Fax: [phone]

Shanghai, China
Sales Office

Ph: [phone]
Fax: [phone]

Singapore
Sales Office

Ph: [phone]
Fax: [phone]

INNOVATION TO SHAPE THE WORLD

U.S. Customer Care: 800-426-1888 / fax [phone]
Canada Customer Care: 905-827-4515 / fax [phone]
International Customer Care: 940-381-1212 / fax [phone]

© 2012 Victor Technologies International, Inc. www.victortechnologies.com/arcair Printed in Mexico

™