DC Stick 4500K 130 Amp/9.5HP 4000 Watt Welder/Generator Owner’s Manual WARNING: Read carefully and understand all ASSEMBLY AND OPERATION INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety precautions may result in serious personal injury.
Thank you very much for choosing a Klutch™ product! For future reference, please complete the owner’s record below: Serial Number/Lot Date Code: ________________________________ Purchase Date: ____________________________________________ Save the receipt, warranty, and this manual. It is important that you read the entire manual to become familiar with this product before you begin using it. This 4500K is designed for certain applications only.
Table of Contents Intended Use .......................................................................................................................................... 4 Packaging Contents .............................................................................................................................. 4 Technical Specifications ...................................................................................................................... 4 Important Safety Information .................
Intended Use The 4500K Welder/Generator is a 4000 Watt (4500 Watt Peak) generator and DC only stick welder with an exceptionally smooth stick welding performance. It is intended for use for welding steel, stainless steel, cast iron, and hard surfacing using electrodes from 1/16 inch to 5/32 inch. Stick welding gives the operator the flexibility to use this welder for mobile applications, including outdoor applications. Stick electrodes contain a flux, making welding easy.
Property Specification Type 4 Stroke CC 277 Horse Power 9.5 HP RPM 3600 Fuel Type Gasoline Start Type Re-Coil Fuel Capacity 5 Gallon Dimensions 31.5" x 23.5" x 28.5" Weight 309 lb. Entire Unit Important Safety Information ⚠WARNING Read and understand all instructions. Failure to follow all instructions may result in serious injury or property damage. The warnings, cautions, and instructions in this manual cannot cover all possible conditions or situations that could occur.
Do not allow the product to come into contact with an electrical source. The tool is not insulated and contact will cause electrical shock. Keep children and bystanders away from the work area while operating the tool. Do not allow children to handle the product. Be aware of all power lines, electrical circuits, water pipes, and other mechanical hazards in your work area. Some of these hazards may be hidden from your view and may cause personal injury and/or property damage if contacted.
Specific Operation Warnings ⚠WARNING Your Welding Environment Keep the environment you will be welding in free from flammable materials. Always keep a fire extinguisher accessible to your welding environment. Always have a qualified person install and operate this equipment. Make sure the area is clean, dry, and ventilated. Do not operate the welder in humid, wet, or poorly ventilated areas.
glasses while welding. Wear proper gloves and protective clothing to prevent your skin from being exposed to hot metals, UV, and IR rays. Do not overuse or overheat your welder. Allow proper cooling time between duty cycles. Keep hands and fingers away from moving parts. Do not point the torch at a body part of yours or anyone else’s. Always use this welder in the rated duty cycle to prevent excessive heat and failure.
⚠WARNING Fumes and Gases Do not use unit in the presence of gasoline, diesel, propane, or other flammable liquids. Sparks created from this unit may ignite liquids or fumes, causing an explosion and serious injury or death. Fumes emitted from the welding process displace clean air and can result in injury or death. Do not breathe in fumes emitted by the welding process. Make sure your breathing air is clean and safe.
explosive materials. Do not operate any electric arc welder in areas where flammable or explosive materials are present. Remove all flammable materials within 35 feet of the welding arc. Take precautions to ensure that flying sparks do not cause fires or explosions in hidden areas, cracks, or areas you cannot see. Keep a fire extinguisher close in the case of fire. Wear garments that are oil-free with no pockets or cuffs that will collect sparks.
Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. ARC WELDING can cause interference! Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. Be sure all equipment in the welding area is electromagnetically compatible.
Main Parts of 4500K Reference 1 2 3 4 5 6 7 8 Subassembly 5 Gallon Fuel Tank Auxiliary Power Circuit Breaker 120V Duplex Receptacle 240V Receptacle Positive (+) Output Connection Negative (-) Output Connection Kohler CH395 Engine Weld Output Control Assembly Instructions Cart Assembly 1. Install the axle to the frame. a. Carefully lift main welder frame approximately 12 inches off the ground. Be careful to secure the unit to prevent it from falling.
b. Note the mounting holes on the axle flange and match it up with the mounting holes in the main unit frame. The axle gets mounted on the end of the welder controls. Use the supplied bolts, washers, lock washers, and nuts to secure axle bracket to the welder frame. 2. Install the wheels. a. Slide the wheel onto the axle. b. Slide the large supplied washer onto axle. c. Hold the wheel and washer on the axle by installing the large cotter pin into the hole at the end of the axle. d.
⚠CAUTION Make Tight Connections Improper connections, including loose connections, in the weld circuit leads to resistance causing excessive heat and may result in damage to your equipment. Insure all connections are snug and tight.
Engine Fueling And Lubrication Make certain that the engine has been properly fueled and lubricated prior to operation. Refer to the engine operator’s manual. Setting Amperage Turn the Amperage Control until the desired welding amperage. Approximate Amperage Ranges Electrode Diameter 3/32 in. (2.4 mm) 1/8 in. (3.2 mm) 5/32 in. (4.0 mm) 3/16 in. (4.
Operating Instructions ⚠WARNING High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle at the power source. This welder must be grounded while in use to protect the operator from electrical shock. If you are not sure if your outlet is properly grounded, have it checked by a qualified electrician. DC STICK OPERATION 1. SETTING UP THE WORK PIECE a. Welding Positions - There are two basic positions, for welding: Flat and Horizontal.
2. GROUND CLAMP CONNECTION Clear any dirt, rust, scale, oil, or paint on the ground clamp. Make certain you have a good solid ground connection. A poor connection at the ground clamp will waste power and heat. Make sure the ground clamp touches the metal. 3. ELECTRODE The welding electrode is a rod coated with a layer of flux. When welding, electrical current flows between the electrode (rod) and the grounded metal work piece.
ii. The bead will undercut the work. iii. The bead will be flat and porous. iv. The rod may be freeze or stick to work piece. Note: The rate of travel over the work also affects the weld. To ensure proper penetration and enough deposit of the rod, the arc must be moved slowly and evenly along the weld seam. 5. SETTING THE AMPERAGE CONTROL The welder has an infinite current control. It is capable of welding with electrodes up to 1/8” diameter.
It is important that the gap be maintained during the welding process without being too wide or too narrow. If it’s too narrow, the rod will stick to the work piece. If it’s too wide, the arc will be extinguished. Practice will be needed to maintain the gap. A beginner will usually have sticker or arc extinguishing. When the rod is stuck to the work piece, gently rock it back and forth to separate them. If not, a short circuit will occur and it will break the welder.
more toward the metal above the weld joint. This more direct angle helps prevent the weld puddle from running downward while still allowing slow enough travel speed to achieve good penetration. A good starting point for your electrode angle is about 30 degrees DOWN from being perpendicular to the work piece. e. Judging a good weld bead After you’ve learned to create and hold an arc, the next step is learning how to run a good bead.
After Each Use ⚠CAUTION Hot Materials - Welded materials are hot and can cause severe burns if handled improperly. Do not touch welded materials with bare hands. Do not touch the torch nozzle after welding until it has had time to cool down. 1. Turn OFF the engine when not using the equipment. 2. Inspect all cords and power cables. Replace any cords or power cables that are damaged or cracked. 3. Disconnect and organize welding cables so they are protected while not in use.
Maintenance Interval Maintenance Point Inspect all warning and caution labels affixed to this unit. If they are worn, torn or otherwise unreadable, replace the warning labels. Every 3 Months Inspect and clean and tighten all weld power connections. Maintain Your Engine Refer to the engine manual for routine maintenance on the engine. Troubleshooting ⚠WARNING ELECTRIC SHOCK CAN KILL! Touching live electrical parts can cause fatal shocks or severe burns. Do not touch live electrical parts.
Failure Possible Cause Corrective Action Weld cable connections are loose. Check to make certain weld cables are tight. Weld cable connections have corroded. Clean weld connections and reinstall. Poor welding performance, excessive spatter. Damp electrode. Use fresh and dry electrodes. Electrode sticks. The electrode is kept in contact with the work piece for too long while striking an arc. This will take practice. Keep trying. Welding bead is too thin. The welding travel speed is too fast.
Parts Diagram Page 24 of 27
Parts List Reference 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 ** ** 26 27 28 29 30 31 ** ** ** ** ** Part Number 105700001 105700002 105700003 105700004 105700005 105700006 105700007 105700008 105700009 105700010 105700011 105700012 105700013 105700014 105700015 105700016 105700017 105700018 105700019 105700020 105700021 105700022 105700023 105700024 125700001 105700025 105700026 105700027 105700028 105700029 105700030 105700031 105700032 125700002 105700033 105700034 105700035 105
Limited Warranty Northern Tool and Equipment Company, Inc. ("We'' or "Us'') warrants to the original purchaser only ("You'' or "Your") that the Klutch product purchased will be free from material defects in both materials and workmanship, normal wear and tear excepted, for a period of three years from date of purchase. The foregoing warranty is valid only if the installation and use of the product is strictly in accordance with product instructions.
Distributed by: Northern Tool & Equipment Company, Inc. Burnsville, Minnesota 55306 www.northerntool.
