7500K 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# 44451 Thank you very much for choosing a KLUTCH product! For future reference, please complete the owner’s record below: Model: _______________ Purchase Date: _______________ Save the receipt, warranty and these instructions. It is important that you read the entire manual to become familiar with this product before you begin using it. This machine is designed for certain applications only. The distributor cannot be responsible for issues arising from modification.
GENERAL SAFETY RULES WARNING: Read and understand all instructions. Failure to follow all instructions listed below may result in serious injury. CAUTION: Do not allow persons to operate or assemble this 7500K Welder/Generator until they have read this manual and have developed a thorough understanding of how the 7500K Welder/Generator works. WARNING: The warnings, cautions, and instructions discussed in this instruction manual cannot cover all possible conditions or situations that could occur.
1.3 Use of Your Welder Do not operate the welder if the output cable, electrode, torch, wire or wire feed system is wet. Do not immerse them in water. These components and the welder must be completely dry before attempting to use them. -Follow the instructions in this manual. -Keep welder in the off position when not in use. -Connect ground lead as close to the area being welded as possible to ensure a good ground.
Fumes and Gases -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. -Work only in a well-ventilated area or use a ventilation device to remove welding fumes from the environment where you will be working. -Do not weld on coated materials (galvanized, cadmium plated or containing zinc, mercury or barium). They will emit harmful fumes that are dangerous to breathe.
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 MIG gun nozzle after welding until it has had time to cool down. Sparks/Flying Debris Welding creates hot sparks that can cause injury. Chipping slag off welds creates flying debris. -Wear protective apparel at all times: ANSI-approved safety glasses or shield, welder’s hat and ear plugs to keep sparks out of ears and hair.
500K Welder/Generator USE AND CARE Do not modify the 7500K Welder/Generator in any way. Unauthorized modification may impair the function and/or safety and could affect the life of the equipment. There are specific applications for which the 7500K Welder/Generator was designed. Always check of damaged or worn out parts before using the 7500K Welder/Generator. Broken parts will affect the 7500K Welder/Generator operation. Replace or repair damaged or worn parts immediately.
Fuel Auxiliary Power Tank Circuit Breaker 120 Volt Duplex Receptacle 240 Volt Twist-Lock Current Receptacle Adjustment Kohler CH440 Engine Positive Output Connection Negative Output Connection Current Adjustment Current adjustment is on the front panel of the machine. It has infinite current output adjustment from 60 to 185 Amps DC. To provide auxiliary power WHILE NOT WELDING, this control must be turned all the way to maximum.
ASSEMBLY 1. Install Axle To Frame 1.1 Carefully lift main welder frame approximately 12 inches off the ground. Be careful to secure the unit to prevent it from falling. 1.2 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 Wheels 2.1 Slide wheel onto axle 2.
weld output connection on the front of the welder. 2.2.2 Connect the quick connector on the end of the ground clamp and cable to the positive (+) weld output connection on the front of the welder. EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN! Prolonged exposure to the welding arc can cause blindness and burns. Never strike an arc or begin welding until you are adequately protected.
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.
5.1.b. The base metal puddle will be as deep as the bead that rises above it 5.1.c. The welding operation will make a crackling sound similar to the sound of eggs frying 5.2. When a rod too small is used; 5.2. a. The bead will be high and irregular 5.2. b. The arc will be difficult to maintain 5.3. When the rod is too large 5.3. a. The arc will burn through light metals 5.3. b. The bead will undercut the work 5.3. c. The bead will be flat and porous 5.3. d.
It is important that the gap be maintained during the welding process and it should be neither too wide or too narrow. If too narrow, the rod will stick to the work piece. If too wide, the arc will be extinguished. It needs much practice to maintain the gap. The beginners may usually get sticker or arc extinguishing. When the rod is stuck to the work piece, gently rock it back and forth to make them separate. If not, a short circuit will occur and it will break the welder.
The horizontal position it is performed very much the same as the flat weld except that the angle is different such that the electrode, and therefore the arc force, is directed 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. 7.
MAINTENANCE • Maintain your KLUTCH 7500K Welder/Generator. It is recommended that the general condition of KLUTCH 7500K Welder/Generator be examined before it is used. Keep KLUTCH 7500K Welder/Generator in good repair by adopting a program of conscientious repair and maintenance. Have necessary repairs made by qualified service personnel. • • • Refer to the engine operator's manual for maintenance on the engine. Periodically clean dust, dirt, grease, etc. from your welder.
DIAGRAM & PARTS LIST 10 11 12 13 9 8 7 6 5 14 4 15 16 17 18 3 2 19 1 20 21 22 23 41 24 40 39 25 26 38 27 28 37 36 35 34 33 32 31 30 29 Page 16 of 18
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-L 25-R 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Part# 2.05.05.601 2.05.05.602 2.07.57.127 2.07.11.047 1.1.01.01.0317 1.1.04.03.1211 2.04.31.019 2.05.05.909 1.1.02.01.7862 2.07.57.923 2.07.73.1021 2.07.80.314 2.07.37.603 1.1.01.01.0317 2.07.80.302 2.07.04.804 2.07.99.691 1.1.04.01.1227 2.07.40.618 1.1.02.01.7975 2.07.62.1213 2.16.03.685 2.16.03.687 2.16.03.683 1.2.01.01.3243 1.2.01.01.3244 2.16.03.686 2.06.01.056 1.1.01.04.
WARRANTY EFFECTIVE JULY 1, 2014 LIMITED WARRANTY This warranty applies to the original purchaser and is subject to the terms and conditions listed below. This Limited Warranty is for new equipment sold after the above date, providing coverage for defects in material and workmanship at the time it is shipped from the factory. Limited to the warranty periods below, Northern Tool + Equipment will repair or replace the item under warranty that fails due to defects in material and workmanship.
