HOOK-UP & INSTALLATION
The hook-up and installation of your new Arc Gouging Torch is very similar to connecting a manual electrode holder, with the exception of the
shop air connection. The Arc Gouging Torch is easily installed by the following four descriptive steps:
STEP 1- Shop Air Connection:
Shop Air Connection (Never Use Oxygen) is completed by using an
air supply hose with 3/8” NPT connection (shown in expanded view).
The shop air hose is connected to the air/power fitting on the Arc
Gouging Torch. The air valve on the torch will allow the operator to
control the air as required (refer to the air pressure and flow settings
chart on page 2.)
STEP 3- Welding DC Machine Connection (Positive (+) Lead):
The work lead can now be attached to the positive (+) terminal of your
DC welding machine. This is the most common connection which is
also referred to as Direct Current Electrode Positive (DCEP).
STEP 2- Torch Connection (Positive (+) Lead):
The work lead is now attached to the Arc Gouging torch, air/power
connector, using a ½”(12mm) bolt and nut. This work lead is attached
to the positive terminal of the power source.
STEP 4- Connection (Negative (-) Cable):
The negative (-) work lead is connected to the work piece by the most
common clamp method shown in figure 1. The cable must be connect-
ed to the negative (-) terminal of the welding machine.
Please review all the warnings and safety information on page 1 of this document.
After completion of hook-up, you are now ready to review the operation procedures (page 4) and begin using your arc gouging torch.
Welding Machine
Electrode
Work
Work Lead -
Stud
Terminal
Use Shop
Air Only
NEVER USE OXYGEN
Gouging Torch
Work Piece
Carbon
Electrode
Torch Lead +
-
+
USE
AIR ONLY
Shop Air In
3/8” NPT
Torch Lead +
To Torch
Direction Of
Travel
SPECIFICATIONS
G3000
G4000
Amperage:
Maximum 600 Amps
Amperage:
Maximum 1000 Amps
Compressed Air:
Pressure - 80 PSI (5.6 kg/cm²)
Flow Rate - 21 - 28 cfm
Compressed Air:
Pressure - 80 PSI (5.6 kg/cm²)
Flow Rate - 28 cfm
Torch & Cube Weight:
4.0 lbs (1.8 kg)
Torch & Cube Weight:
5.4 lbs (2.4 kg)
Accepts Carbons:
Pointed - 1/8” (3mm) to 3/8” (10mm)
Flat - 3/8” (10mm) to 5/8” (16mm)
Accepts Carbons:
Pointed - 5/32” (4mm) to 1/2” (13mm)
Flat - 3/8” (10mm) to 5/8” (16mm)
Figure 1: Torch Hook-up
Electric shock can cause injury or death. Breathing air carbon arc gouging fumes can harm your health and can lead to disability.
Arc rays and hot sparks can injure eyes, and skin. Noise can damage hearing
BEFORE OPERATING THIS EQUIPMENT
• Do not service or repair equipment with power on.
• Do not touch exposed or frayed wires with power on.
• Do not service or repair equipment unless you are trained and qualified to do so.
“OBSERVE ALL SAFETY RULES.”
• Be sure equipment is turned off when not in use.
• See ANSI 749.1 “Safety in Welding and Cutting” published by The American Welding Society,
550 Lejeune Road, Miami Florida 33135 or contact your employer,
welding distributor, or manufacturer of this product.
• Inspect equipment to make sure all safety features are in good working order.
• Wear approved eye, ear, and body protection.
• Use enough ventilation and/or exhaust to keep fumes from the breathing zone.
Keep your head out of the fumes.
• Use only compressed air—
NEVER USE OXYGEN.
• Be sure all other persons are clear of work area.
• Do not operate equipment with protective covers removed.
READ AND UNDERSTAND
“PROTECT YOURSELF AND OTHERS”
LIT.9206 (5-09)
ABICOR BINZEL CORP. • 650 Medimmune Ct., Suite 110, Frederick, MD 21703 • 301-846-4196 • FAX: 301-846-4407 • 800-542-4867 • www.abicorusa.com
