Klutch 62499 User manual

READ & SAVE THESE INSTRUCTIONS
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

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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. Northern Tool &
Equipment is not responsible for issues arising from modification or
improper use of this product such as an application for which it was not
designed. We strongly recommend that this product not be modified
and/or used for any application other than that for which it was designed.
For technical questions, please call 1-800-222-5381.

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Table of Contents
Intended Use..........................................................................................................................................4
Packaging Contents..............................................................................................................................4
Technical Specifications......................................................................................................................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
Troubleshooting..................................................................................................................................22
Parts Diagram......................................................................................................................................24
Parts List..............................................................................................................................................25
Replacement Parts..............................................................................................................................25
Limited Warranty.................................................................................................................................26

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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. It does not require the
use of a separate shielding gas which can be blown away by the wind in outdoor applications.
Since this welder does not use shielding gas, the operator will not be required to have or maintain
shielding gas bottles, a regulator, or a gas hose. TIG welding does require the use of Argon
shielding gas. The shielding gas replaces the flux that is used in stick welding, providing a more
controlled and cosmetic weld. However, TIG welding is 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
input power. The generator provides the required input electrical power needed to operate the
welder. This generator also provides auxiliary power that may be needed to perform other tasks
such as lighting, grinding, or power tool operation. A total of 4000 watts of auxiliary power is
available while not welding.
Packaging Contents
4500K Welder/Generator
18 ft. Electrode Holder
and Cable
12 ft. Ground Cable with
Clamp
5 Gallon Fuel Tank
Running Gear Set-Up
with Gears and Handle
Owner’s Manual
Technical Specifications
Property
Specification
Generator Specifications
Output Frequency
60 HZ
Output Voltage
120V AC / 240V AC
Peak Output
4500 Watts
Rated Output
4000 Watts
Output Phase
Single Phase
Operational Time
10 Hours
Welder Specifications
No Load Voltage
75V DC
Output Range
40 to 130 Amp DC
Duty Cycle
30% @ 130 Amp DC
Electrode Diameters
1/16 inch to 5/32 inch
Engine Specifications
Engine Model
Kohler CH395
Cooling Method
Air Cooled

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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
Entire Unit
Dimensions
31.5" x 23.5" x 28.5"
Weight
309 lb.
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. Exercise common sense and caution when using this tool. Always be
aware of the environment and ensure that the tool is used in a safe and responsible manner.
Do not allow persons to operate or assemble the product until they have read this manual and
have developed a thorough understanding of how it works.
Do not modify this product in any way. Unauthorized modification may 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 small equipment to do the work of larger
industrial equipment. There are certain applications for which this equipment was designed. It will
be a safer experience and do the job better at the capacity for which it was intended. DO NOT use
this equipment for a purpose for which it was not intended.
Industrial or commercial applications must follow OSHA requirements.
⚠WARNING
WORK AREA SAFETY
Inspect the work area before each use. Keep work area clean, dry, free of clutter, and well-lit.
Cluttered, wet, or dark work areas can result in injury. Using the product in confined work areas
may put you dangerously close to cutting tools and rotating parts.
Do not use the product where there is a risk of causing a fire or an explosion; e.g., in the presence
of flammable liquids, gases, or dust. The product can create sparks, which may ignite the
flammable liquids, gases, or dust.

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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.
⚠WARNING
PERSONAL SAFETY
Stay alert, watch what you are doing, and use common sense when operating the tool. Do not use
the tool while you are tired or under the influence of drugs, alcohol, or medication. A moment of
inattention while operating the tool may result in serious personal injury.
Dress properly. Do not wear loose clothing, dangling objects, or jewelry. Keep your hair, clothing
and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving
parts. Air vents on the tool often cover moving parts and should be avoided.
Wear the proper personal protective equipment when necessary. Use ANSI Z87.1 compliant 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 hearing protection when appropriate. This applies to all persons in the work area.
Do not overreach. Keep proper footing and balance at all times.
⚠CAUTION
PRODUCT USE AND CARE
Do not force the product. Products are safer and do a better job when used in the manner for
which they are designed. Plan your work, and use the correct product for the job.
Check for damaged parts before each use. Carefully check that the product will operate properly
and perform its intended function. Replace damaged or worn parts immediately. Never operate the
product with a damaged part.
Store the product when it is not in use. Store it in a dry, secure place out of the reach of children.
Inspect the tool for good working condition prior to storage and before re-use.
Use only accessories that are recommended by the manufacturer for use with your product.
Accessories that may be suitable for one product may create a risk of injury when used with
another tool. Never use an accessory that has a lower operating speed or operating pressure than
the tool itself.
Keep guards in place and in working order. Never operate the product without the guards in place.

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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.
Always have your welder maintained by a qualified technician in accordance with local, state and
national codes.
Always be aware of your work environment. Be sure to keep other people, especially children,
away from you while welding.
Keep harmful arc rays shielded from the view of others.
Mount the welder on a secure bench or cart that will keep the welder secure and prevent it from
tipping over or falling.
⚠WARNING
Your Welder’s Condition
Check the ground cable, power cord, and welding 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 before use.
⚠CAUTION
During Operation
Do not operate the welder if the output cable, electrode, torch, or any accessories are 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 the 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.
Do not allow any body part to come in contact with the welding electrode if you are in contact with
the material being welded, ground, or electrode from another welder.
Do not weld if you are in an awkward position. Always have a secure stance while welding to
prevent accidents. Wear a safety harness if working above ground.
Do not drape cables over or around your body.
Wear a full coverage helmet with appropriate shade (see ANSI Z87.1 safety standard) and safety

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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
Electrical Shock
Electric arc welders can produce a shock that can cause injury or death. Touching electrically live
parts can cause fatal shocks and severe burns. While welding, all metal components connected to the
electrode are electrically hot. Poor ground connections are a hazard, so secure the ground lead before
welding.
Wear dry protective apparel: coat, shirt, gloves 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 cords for any exposed wire and replace immediately if found.
Use only recommended replacement cables and cords.
Always attach the ground clamp to the work piece or work table as close to the weld area as
possible.
Do not touch the electrode and the ground or grounded work piece at the same time.
Do not use a welder to thaw frozen pipes.
⚠WARNING
Battery explosion may cause blindness even death!
Always power down this unit prior to any repair work.
Keep battery away from open flames.
Wear a protective mask and rubber gloves when working with the battery.
⚠WARNING
Engine exhaust is hazardous to your health!
Work only in a well-ventilated area or use a ventilation device to remove exhaust fumes from the
environment where you will be working.
Exhaust gas may cause serious nausea, dizziness and even death.

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⚠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.
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. If necessary use a ventilator,
respirator with air supply, or remove the coating from the material in the weld area.
The fumes emitted from some metals when heated are extremely toxic. Refer to the material
safety data sheet for the manufacturer’s instructions.
Do not weld near 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 infrared (IR) rays that can cause injury to your
eyes and skin. Do not look at the welding arc without proper eye protection.
Always use a helmet that covers your full face from the neck to top of head and to the back of
each ear.
Use a lens that meets ANSI standards and safety glasses. For welders under 160 amps output,
use a shade 10 lens; for above 160 amps, use a shade 12. Refer to the ANSI standard Z87.1 for
more information.
Cover all bare skin areas exposed to the arc with protective clothing and shoes. Flame-retardant
cloth or leather shirts, coats, pants, or coveralls are available for protection.
Use screens or other barriers to protect other people from the arc rays emitted from your welding.
Warn people in your welding area when you are going to strike an arc, so they can protect
themselves.
⚠WARNING
Fire Hazards
Do not weld on containers or pipes that contain or have had flammable, gaseous, or liquid
combustibles in them. Welding creates sparks and heat that can ignite flammable and

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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.
Do not have on your person any items that are combustible, such as lighters or matches.
Keep work lead connected as close to the weld area as possible to prevent any unknown,
unintended paths of electrical current from causing electrical shock and fire hazards.
Be careful to prevent any unintended arcs.
⚠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 electrode or torch parts after welding until it has had time to cool down.
⚠CAUTION
Electromagnetic Field
Electromagnetic fields can interfere with various electrical and electronic devices such as
pacemakers.
Consult your doctor before using any electric arc welder or cutting device.
Keep people with pacemakers away from your welding area when welding.
Do not wrap cable around your body while welding.
Wrap the torch and ground cable together whenever possible.
Keep the torch and ground cables on the same side of your body.
H.F. RADIATION can cause interference!
High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem
resulting from the installation.
If notified by the FCC about interference, stop using the equipment at once.
Have the installation regularly checked and maintained.

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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.
To reduce possible interference, keep weld cables as short as possible, close together, and down
low, such as on the floor.
Locate welding operation 100 yards from any 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 line filters, or shielding the work area.
⚠WARNING
Shielding Gas Cylinders Can Explode!
High pressure cylinders can explode if damaged; treat them carefully.
Never expose cylinders to high heat, sparks, open flames, mechanical shocks or arcs.
Do not touch the cylinder with the electrode.
Do not weld on the cylinder.
Always secure cylinder upright to a cart or stationary object.
Keep cylinders away from welding or electrical circuits.
Use the proper regulators, gas hose, and fittings for the specific application.
Do not look into the valve when opening it.
Use a protective cylinder cap whenever possible.

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Main Parts of 4500K
Reference
Subassembly
1
5 Gallon Fuel Tank
2
Auxiliary Power Circuit Breaker
3
120V Duplex Receptacle
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. Carefully lift main welder frame approximately 12 inches off the ground. Be careful to
secure the unit to prevent it from falling.

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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. Repeat for the other wheel.
3. Install the handles.
a. Identify which handle goes on each side.
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 side.
Weld Cable Connections
⚠CAUTION
Be aware that the ELECTRODE HOLDER will be electrically HOT when the welder is running.
Most DC Stick Welding is performed using DC Electrode Positive (DCEP) welding current. This
means that the electrode holder and welding cable is connected to the Positive (+) Weld Output
Terminal. The Ground Cable and Clamp is then connected to the Negative (-) Weld Output Terminal.
The connectors are twist-lock style connectors. Completely insert the connector into the proper weld
output receptacle and then turn the connector clockwise until it’s snug and tight.

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⚠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.

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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
Amperage
3/32 in. (2.4 mm)
40 –150
1/8 in. (3.2 mm)
75 - 180
5/32 in. (4.0 mm)
80 –250
3/16 in. (4.8 mm)
110 - 330
Before Each Use
⚠WARNING
ELECTRIC SHOCK CAN KILL!
Touching live electrical parts can cause fatal shocks or severe burns. 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 power according to OSHA 29 CFR 1910.147.
1. Review the contents of this manual and follow all safety warnings and cautions.
2. Inspect all cords and power cables. Replace any cords or power cables that are damaged or
cracked.
3. Make certain your equipment is in good working order.
4. Make sure the area is clean, dry, and ventilated. Do not operate the welder in humid, wet, or
poorly ventilated areas.
5. Always be aware of your work environment. Be sure to keep other people, especially children,
away from you while welding.

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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.
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. Preparing the Joint- Before Welding - The surface of the work piece needs to be free
of dirt, rust, scale, oil, or paint or it will create brittle and porous welds. If the base
metal pieces to be joined are thick or heavy, it may be necessary to bevel the edges
with a metal grinder; the correct bevel should be around 60 degrees. See the
following illustration:
Based on different welding positions, there are different welding joints. See the following illustrations
for reference.

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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. The intense heat of the
arc between the rod and the grounded metal melts the electrode and the flux.
4. SELECTING THE PROPER ELECTRODE
There is no golden rule that determines the exact rod or heat setting required for every
situation. The type and thickness 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 practice your welds on scrap metal which
matches the metal you intend to work with to determine the correct heat setting and electrode
choice. See the following troubleshooting tips to determine if you are using a correct
electrode.
a. When the proper rod is used:
i. The bead will lay smoothly over the work without ragged edges.
ii. The base metal puddle will be as deep as the bead that rises above it.
iii. The welding operation will make a crackling sound similar to the sound of
eggs frying.
b. When a rod that is too small is used:
i. The bead will be high and irregular.
ii. The arc will be difficult to maintain.
c. When a rod that is too large is used:
i. The arc will burn through light metals.

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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 best to practice your welds on scrap metal which matches the metals you
intend to work with to determine the correct setting for your job. The electrode type and the
thickness of the work piece metal determine the amount of heat needed in the welding
process. Heavier and thicker metals require more voltage (amperage), whereas lighter and
thinner metals require less voltage (amperage). Consult the welding electrode packaging for
recommended welding amperage range.
6. WELDING TECHNIQUES
The best way to teach yourself how to weld is with short periods of practice at regular
intervals. 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 appearance and free of slag or gas inclusions.
a. Holding the electrode
The best way to grip the electrode holder is the way that feels most comfortable to
you. Position the electrode to the work piece when striking the initial arc. It may be
necessary to hold the electrode perpendicular to the work piece. Once the arc is
started, the angle of the electrode in relation to the work piece should be between 10
and 30 degrees. This will allow for good penetration and minimal spatter.
⚠WARNING
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. Wear flame-proof welding gloves, a heavy long-
sleeved shirt, trousers without cuffs, high topped shoes, and an ANSI approved welding helmet.
b. Striking the arc
Scratch the work piece with the end of the electrode to start an arc and then raise it
quickly to create a 1/8 inch gap between the rod and the work piece. See the
following illustration:

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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. A good arc
is accompanied by a crisp, cracking sound (similar to eggs frying). To lay a weld bead, only
two movements are required: downward (as the electrode is consumed) and in the direction
the weld is to be laid, as in the following illustration:
c. Types 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 centered over the weld joint.
The weave bead is used when you want to deposit metal over a wider space than
would be possible with a stringer bead. It is made by weaving from side to side while
moving with the electrode. It is best to pause momentarily at each side before
weaving back the other way.
d. Welding position
Flat position is easiest of the welding positions and is most commonly used. It is best
if you can weld in the flat position if at all possible as good results are easier to
achieve.
The horizontal position 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
Stringer Bead
Weave Bead
Flat Position
Horizontal Position

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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. The first attempts in practice will probably fall short of acceptable weld
beads. Too long of an arc will be held or the travel speed will vary from slow to fast
(illustrated below).
A. Weld speed is too fast.
B. Weld speed is too slow.
C. Arc is too long.
D. Ideal weld.
A solid weld bead requires that the electrode be moved slowly and steadily along the
weld seam. Moving the electrode rapidly or erratically will prevent proper fusion or
create a lumpy, uneven bead.
⚠WARNING
ELECTRIC SHOCK CAN KILL!
To prevent ELECTRIC SHOCK, do 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
protective gases around the weld. This prevents air from reaching the molten metal
and creating an undesirable chemical reaction. The burning coating, however, forms
slag. The slag formation appears as an accumulation of dirty metal scale on the
finished weld. Slag should be removed by using a chipping hammer.
⚠WARNING
PEENING THE SLAG FROM A WELD JOINT CAUSES SMALL CHIPS OF METAL TO FLY
THROUGH THE AIR!
Metallic chips flying through the air can cause eye injury or injury to other parts of the head, hands
or exposed portions of the body. Wear goggles or safety glasses with side shields and protect the
hands and other exposed parts of the body with protective garments, or if possible, work with a
shield between the body and the work piece.
Strain is created in the metal due to the intense heat the arc produces while welding.
Peening the weld not only removes the scale left behind in the welding but relieves
the internal strains developed by the heating and cooling process.