PROFAX AEC 4000-1 User manual

WARNING - Wear proper eye, ear, and body protection.
• Shut off all power before repairing or disconnecting
torch.
ELECTRIC SHOCK CAN KILL!!
• Arc gouging can burn eyes and skin, avoid smoke
inhalation.
It is dangerous to your health.
Noise can be harmful to your hearing.
USE WITH COMPRESSED AIR ONLY, NEVER
USE OXYGEN.
ARC GOUGING TORCHES
P.O. Box 898 • Pearland, TX 77588-0898
281-485-6258
Made in U.S.A.
00181OG031511
MADEINU.S.A.
MADEINU.S.A.
®
4000-1 Designed for 5/32” - 1/2”
Carbons
4500-1 Designed for 3/16” - 5/8”
Carbons
AEC 4000-1/AEC 4500-1
WARNING
This product, when used for welding or cutting,
produces fumes or gases which contain
chemicals known to the State of California to
cause birth defects and, in some cases, cancer.
(California Health & Safety Code 25249.5 et. seq.)

AEC-4000-1 Complete gouging torch with 7’ swivel cable assembly
AEC-4000-12-1 Complete gouging torch with 12’ swivel cable assembly
AEC-4001 Complete gouging torch less cable assembly
AEC-4500-1 Complete gouging torch with 7’ swivel cable assembly
AEC-4500-12-1 Complete gouging torch with 12’ swivel cable assembly
AEC-4501 Complete gouging torch less cable assembly
MODEL NO. DESCRIPTION
DC AMPS
5/32” 3/16” 1/4” 5/16” 3/8” 1/2” 5/8”
90 200 300 350 450 800
to to to to to to —
150 250 400 450 600 1000
AEC 4000-1/AEC 4500-1
Standard Features:
• 15° torch head • Unique valve design for easy field repair
• Special high impact, heat resistant material • 7’ 360° swivel cable assembly
• Special copper alloy forged body • Optional 12’ swivel cable assembly available
AEC 4000-1
5/32” - 1/2” Carbons
• Standard Swivel Cable Assembly
• Standard Swivel Head
AEC 4500-1
3/16” - 5/8” Carbons
• Heavy Duty Swivel Cable Assembly
• Heavy Duty Swivel Head
200 300 350 450 800 1000
— to to to to to to
250 400 450 600 1000 1250
AIR REQUIREMENTS
When using the AEC series arc gouging
torches 80 to 100 psi compressed air is
recommended.
ARC GOUGING TORCH PARTS BREAKDOWN
MADEINU.S.A.
MADEINU.S.A.
®
AEC 4000-1/AEC 4500-1
*7
8
10
6
3
4
5
16 17 18 19
12
*21
*22
14
9
11
13
3
15
20
1
*2
1 Swivel cable assembly 7’ AEC-302-1 AEC-502-1
*2 Swivel cable assembly 12’ AEC-312-1 AEC-512-1
3 Insulator assembly with screws AEC-403 AEC-403
4 Lower tong and valve body AEC-404 AEC-454
5 Pin AEC-410 AEC-410
6 Swivel head with screw AEC-305 AEC-505
*7 Flat swivel head with screw AEC-305F AEC-505F
8 Upper arm AEC-407 AEC-407
9 Lever assembly with screw AEC-408 AEC-408
10 Spring AEC-409 AEC-409
11 Handle AEC-450 AEC-450
12 Cable insulating boot AEC-311 AEC-511
13 Spool assembly AEC-316R AEC-316R
14 O-ring (package of 2) AEC-316-1R AEC-316-1R
15 Swivel joint assembly AEC-321 AEC-521
16 Swivel joint stem AEC-322 AEC-522
17 Swivel joint male nut AEC-323 AEC-523
18 Swivel joint spring AEC-326 AEC-526
19 Swivel joint bushing AEC-327 AEC-527
20 Female cable connector AEC-3-029 AEC-5-029
*21 Air hose extension with crow foot connection AEC-3-040 AEC-3-040
*22 Power cable extension 1/0 cable AEC-3-041-TW AEC-3-041-TW
*23 Power/Air insulation kit AEC-3-045CF AEC-3-045CF
*24 Power cable extension 2/0 cable w/male and female connections AEC-3-042 AEC-3-042
*25 Insulating block AEC-312 AEC-312
NO. DESCRIPTION AEC 4000-1 AEC 4500-1
*Items are optional
AEC-316T
o-ring installation
tool for no.13
A
A- When rebuilding Swivel Joint Assembly
®
in the field use LOCTITE 272 on the
threads of swivel joint stem (item #16).
*24
*21
*25
*23
AEC-40 Allows you to use the
PROFAX power cables
on the K-4000* torch
*K-4000 is a registered trademark of Tweco Products Inc.

AEC-4000-1 Complete gouging torch with 7’ swivel cable assembly
AEC-4000-12-1 Complete gouging torch with 12’ swivel cable assembly
AEC-4001 Complete gouging torch less cable assembly
AEC-4500-1 Complete gouging torch with 7’ swivel cable assembly
AEC-4500-12-1 Complete gouging torch with 12’ swivel cable assembly
AEC-4501 Complete gouging torch less cable assembly
MODEL NO. DESCRIPTION
DC AMPS
5/32” 3/16” 1/4” 5/16” 3/8” 1/2” 5/8”
90 200 300 350 450 800
to to to to to to —
150 250 400 450 600 1000
AEC 4000-1/AEC 4500-1
Standard Features:
• 15° torch head • Unique valve design for easy field repair
• Special high impact, heat resistant material • 7’ 360° swivel cable assembly
• Special copper alloy forged body • Optional 12’ swivel cable assembly available
AEC 4000-1
5/32” - 1/2” Carbons
• Standard Swivel Cable Assembly
• Standard Swivel Head
AEC 4500-1
3/16” - 5/8” Carbons
• Heavy Duty Swivel Cable Assembly
• Heavy Duty Swivel Head
200 300 350 450 800 1000
— to to to to to to
250 400 450 600 1000 1250
AIR REQUIREMENTS
When using the AEC series arc gouging
torches 80 to 100 psi compressed air is
recommended.
ARC GOUGING TORCH PARTS BREAKDOWN
MADEINU.S.A.
MADEINU.S.A.
®
AEC 4000-1/AEC 4500-1
*7
8
10
6
3
4
5
16 17 18 19
12
*21
*22
14
9
11
13
3
15
20
1
*2
1 Swivel cable assembly 7’ AEC-302-1 AEC-502-1
*2 Swivel cable assembly 12’ AEC-312-1 AEC-512-1
3 Insulator assembly with screws AEC-403 AEC-403
4 Lower tong and valve body AEC-404 AEC-454
5 Pin AEC-410 AEC-410
6 Swivel head with screw AEC-305 AEC-505
*7 Flat swivel head with screw AEC-305F AEC-505F
8 Upper arm AEC-407 AEC-407
9 Lever assembly with screw AEC-408 AEC-408
10 Spring AEC-409 AEC-409
11 Handle AEC-450 AEC-450
12 Cable insulating boot AEC-311 AEC-511
13 Spool assembly AEC-316R AEC-316R
14 O-ring (package of 2) AEC-316-1R AEC-316-1R
15 Swivel joint assembly AEC-321 AEC-521
16 Swivel joint stem AEC-322 AEC-522
17 Swivel joint male nut AEC-323 AEC-523
18 Swivel joint spring AEC-326 AEC-526
19 Swivel joint bushing AEC-327 AEC-527
20 Female cable connector AEC-3-029 AEC-5-029
*21 Air hose extension with crow foot connection AEC-3-040 AEC-3-040
*22 Power cable extension 1/0 cable AEC-3-041-TW AEC-3-041-TW
*23 Power/Air insulation kit AEC-3-045CF AEC-3-045CF
*24 Power cable extension 2/0 cable w/male and female connections AEC-3-042 AEC-3-042
*25 Insulating block AEC-312 AEC-312
NO. DESCRIPTION AEC 4000-1 AEC 4500-1
*Items are optional
AEC-316T
o-ring installation
tool for no.13
A
A- When rebuilding Swivel Joint Assembly
®
in the field use LOCTITE 272 on the
threads of swivel joint stem (item #16).
*24
*21
*25
*23
AEC-40 Allows you to use the
PROFAX power cables
on the K-4000* torch
*K-4000 is a registered trademark of Tweco Products Inc.

Operation and Use:
Air Carbon-Arc Cutting, by definition, is a method for cutting or gouging metal by melting it with an electric arc
and blowing away the molten metal with a high velocity jet of compressed air. This simple process reduces metal
removal time up to 75% over conventional flame cutting, grinding or chipping. The process is primarily physical
rather than chemical and is a proven way to cut, groove, bevel, scarf or pierce any metal. This process leaves a
bright, clean and slag free finish which usually requires no furthur preparation or cleanup.
Safety Warning:
Protect "yourself and others" read and understand all operation and safety instruction for the use of Arc Gouging
Torches. A red warning tag is attached to every PROFAX Arc Gouging Torch. The warning tag is to be removed by
the operator after the operator has read and understood all safety and operating information provided. The following
information is also provided on the warning tag.
READ AND UNDERSTAND
WARNING
"PROTECT YOURSELF AND OTHERS"
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
• Inspect equipment to make sure all safety features are in good working order
• Wear approved eye, ear, and body protection.
• Remove any and all combustible materials from the working area.
• 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. 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.
Equipment & Selection Charts:
PROFAX offers five series of Arc Gouging Torches for all manual use of air carbon arc electrodes applications.
PROFAX torches come complete with a 7' swivel or non-swivel cable assembly. An ordinary welding power source
of sufficient size to produce the current needed is usually used.
Available Through Your Welding Supply Distributor
MADEINU.S.A.
MADEINU.S.A.
®