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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.

Item #62499

Summary of Contents for 62499

Page 1: ...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 prec...

Page 2: ...tant 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 Northern Tool Equipment is not responsible for...

Page 3: ...tions 4 Important Safety Information 5 Specific Operation Warnings 7 Main Parts of 4500K 12 Assembly Instructions 12 Before Each Use 15 Operating Instructions 16 After Each Use 21 Maintenance 21 Troub...

Page 4: ...s limited to areas inside or where wind can be controlled preventing the shielding gas from blowing away Since the 4500K Welder Generator is an engine powered welder it does NOT require a source of in...

Page 5: ...impair the function and or safety and could affect the life of the product There are specific applications for which the product was designed Use the right tool for the job DO NOT attempt to force sma...

Page 6: ...ant safety goggles not safety glasses with side shields or when needed a face shield Use a dust mask in dusty work conditions Also use non skid safety shoes hardhat gloves dust collection systems and...

Page 7: ...ing cable to be sure the insulation is not damaged Always replace or repair damaged components before using the welder Check all components to ensure they are clean and in good operating condition bef...

Page 8: ...oves and insulated footwear Insulate yourself from the work piece Avoid contacting the work piece or ground Do not attempt to repair or maintain the welder while the power is on Inspect all cables and...

Page 9: ...r materials that will emit toxic fumes when heated Vapors from cleaners sprays and degreasers can be highly toxic when heated WARNING UV and IR Arc Rays The welding arc produces ultraviolet UV and inf...

Page 10: ...lded materials with bare hands Do not touch the electrode or torch parts after welding until it has had time to cool down CAUTION Electromagnetic Field Electromagnetic fields can interfere with variou...

Page 11: ...sensitive electronic equipment Be sure this welding machine is grounded If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using l...

Page 12: ...ceptacle 4 240V Receptacle 5 Positive Output Connection 6 Negative Output Connection 7 Kohler CH395 Engine 8 Weld Output Control Assembly Instructions Cart Assembly 1 Install the axle to the frame a C...

Page 13: ...b Use supplied hardware to fasten the large flange with 4 mounting holes to the side of the frame c Use the supplied hardware to mount the tube leg to the bottom of the welder frame d Repeat for each...

Page 14: ...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 connection...

Page 15: ...ns Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Disconnect input power before installing maintaining or servicing this equipment Lockout tag out input po...

Page 16: ...lding Flat and Horizontal Flat welding is generally easier faster and allows for better penetration If possible the work piece should be positioned so that the bead will run on a flat surface b Prepar...

Page 17: ...ness of metal and the position of the work piece determine the electrode type and the amount of heat needed in the welding process Heavier and thicker metals require more amperage It is best to practi...

Page 18: ...als All practice welds should be done on scrap metal that can be discarded Do not attempt to make any repairs on valuable equipment until you are satisfied that your practice welds are of good appeara...

Page 19: ...s of weld bead The following content discusses the most commonly used arc welding beads The stringer bead is formed by traveling with the electrode in a straight line while keeping the electrode cente...

Page 20: ...not perform any welding while standing kneeling or lying directly on the grounded workpiece f Finish the bead As the coating on the outside of the electrode burns off it forms an envelope of protectiv...

Page 21: ...mponents Do not touch or handle the PC board without being properly grounded with a wrist strap Put the PC board in a static proof bag to move or ship Do not put hands or fingers near moving parts suc...

Page 22: ...ly HOT when the engine is running Failure Possible Cause Corrective Action Engine does not work See engine manual See the engine manual Auxiliary power does not work Auxiliary power switch or circuit...

Page 23: ...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...

Page 24: ...Page 24 of 27 Parts Diagram...

Page 25: ...E RECTIFIER 1 25 125700001 ENCLOSURE 1 105700025 WELDING WARNING DECAL 1 105700026 EXHAUSE WARENING DECAL 1 26 105700027 LEFT SIDE HANDLE 1 27 105700028 RUBBER HANDLE 2 28 105700029 GASOLINE TANK 1 29...

Page 26: ...claim contact Us at 1 800 222 5381 identify the product by make and model number and follow the claim instructions that will be provided The product and the purchase receipt must be provided to Us in...

Page 27: ...Page 27 of 27 Distributed by Northern Tool Equipment Company Inc Burnsville Minnesota 55306 www northerntool com Made in China...