Buffalo Tools MMIG125 Assembly & Operating Instructions
MMIG125
Flux-cored 125 Amp Welder
Assembly & Operating Instructions
READ ALL INSTRUCTIONS AND WARNINGS BEFORE USING THIS PRODUCT.
This manual provides important information on proper operation & maintenance. Every effort has been
made to ensure the accuracy of this manual. These instructions are not meant to cover every possible
condition and situation that may occur. We reserve the right to change this product at any time
without prior notice.
IF THERE IS ANY QUESTION ABOUT A CONDITION BEING SAFE OR UNSAFE, DO
NOT OPERATE THIS PRODUCT!
HAVE QUESTIONS OR PROBLEMS? DO NOT RETURN THIS PRODUCT TO THE
RETAILER - CONTACT CUSTOMER SERVICE.
If you experience a problem or need parts for this product, visit our website http://www.buffalotools.com
or call our customer help line at 1-888-287-6981, Monday-Friday, 8 AM - 4 PM Central Time. A copy of
the sales receipt is required.
FOR CONSUMER USE ONLY – NOT FOR PROFESSIONAL USE.
KEEP THIS MANUAL, SALES RECEIPT & APPLICABLE WARRANTY FOR FUTURE
REFERENCE.
GENERAL PRODUCT SPECIFICATIONS
SPECIFICATIONS
• Thermal Overload Protection
• Output: 80A (rated current)@18V-20%, 125A (peak current)
• Input: 120V, 60Hz, 20A, 1Ph
• Duty Cycle 20%@80 AMPS
• Wire Size: .030 - .035 Inch
• Heat Settings: Two
• MAX Metal Thickness: 18 Gauge / 3/16"
FEATURES:
• Includes Ground Cable With Clamp, Welding Gun, Face Shield & Brush H a mmer
KEEP THIS MANUAL, SALES RECEIPT & APPLICA BLE WARRANTY FOR FUTURE
REFERENCE.
READ ALL INSTRUCTIONS AND WARNINGS BEFORE USING THIS PRODUCT.
When unpacking, check to make sure all parts listed are included. If any parts are missing or broken,
please call Customer Service at 1-888-287-6981.
FOR CONSUMER USE ONLY – NOT FOR PROFESSIONAL USE
2
TABLE OF CONTENTS
The warnings, cautions and instructions discussed in this instruction manual cannot
cover all possible conditions or situations that
could occur. It must be understood by the
operator that common sense and caution are
factors which cannot be built into this product, but must be supplied by the operator.
Reading this operator’s manual before using
the welder will enable you to do a better,
safer job. Learn the welder’s applications and
limitations as well as the specific potential
hazards peculiar to welding.
SAFETY SUMMARY
IMPORTANT SAFETY INFORMATION
The following safety information is provided
as guidelines to help you operate your new
welder under the safest possible conditions.
Any equipment that uses electrical power
can be potentially dangerous to use when
safety or safe handling instructions are not
known or not followed. The following safety
information is provided to give the user the
information necessary for safe use and operation.
A procedure step preceded by a WARNING
is an indication that the next step contains a
procedure that might be injurious to a person
if proper safety precautions are not heeded.
A procedure preceded by a CAUTION is an
indication that the next step contains a procedure that might damage the equipment
being used.
A NOTE may be used before or after a procedure step to highlight or explain something
in that step.
READ ALL SAFETY INSTRUCTIONS
CAREFULLY before attempting to install,
operate, or service this welder. Failure to
comply with these instructions could result in
personal injury and/or property damage.
RETAIN THESE INSTRUCTIONS FOR
FUTURE REFERENCE.
Note:
• The following safety alert symbols
identify important safety messages in this
manual.
• When you see one of the symbols shown
here, be alert to the possibility of personal injury and carefully read the message
that follows.
This symbol indicates that the
possibility of electric shock hazard
exists during the operation of the
step(s) that follow.
This symbol indicates that the
possibility of fire hazard exists
during the operation of the step(s)
that follow.
This symbol indicates that the
helmet must be worn during the
step(s) that follow to protect
against eye damage and burns
due to flash hazard.
This symbol indicates that the
possibility of toxic gas hazard
exists during operation of the
step(s) that follow.
This symbol indicates that the
possibility of being burned by hot
slag exists during operation of the
step(s) that follow.
This symbol indicates that the
eye protection should be worn to
protect against flying debris in the
following step(s).
• Published standards on safety are
available. They are listed in ADDITIONAL
SAFETY INFORMATION at the end of
this SAFETY SUMMARY.
The National Electrical Code, Occupation
Safety and Health Act regulations, local
industrial codes and local inspection requirements also provide a basis for equipment
installation, use, and service.
3
SHOCK HAZARDS
WARNING
ELECTRIC SHOCK CAN KILL! To reduce
the risk of death or serious injury from shock,
read, understand, and follow the following
safety instructions. In addition, make certain
that anyone else who uses this welding
equipment, or who is a bystander in the
welding area understands and follows these
safety instructions as well.
• IMPORTANT! TO REDUCE THE RISK
OF DEATH, INJURY, OR PROPERTY
DAMAGE, DO NOT ATTEMPT OPERATION of this welding equipment until you
have read and understand the following
safety summary.
• Do not, in any manner, come into physical
contact with any part of the welding current circuit. The welding current circuit
includes:
a. the work piece or any conductive
material in contact with it,
b. the ground clamp,
c. the electrode or welding wire,
d. any metal parts on the electrode
holder, or wire feed torch.
• Do not weld in a damp area or come in
contact with a moist or wet surface.
• Do not attempt to weld if any part of clothing or body is wet.
• Do not allow the welding equipment
to come in contact with water or moisture.
• Do not drag welding cables, wire feed
torch, or welder power cord through or
allow them to come into contact with
water or moisture.
• Do not touch welder, attempt to turn
welder on or off if any part of the body or
clothing is moist or if you are in physical
contact with water or moisture.
• Do not attempt to plug the welder into the
power source if any part of body or clothing is moist, or if you are in physical contact with water or moisture.
• Do not connect welder work piece clamp
to or weld on electrical conduit.
• Do not alter power cord or power cord
plug in any way.
• Do not attempt to plug the welder
into the power source if the ground prong
on power cord plug is bent over, broken
off, or missing.
• Do not allow the welder to be connected
to the power source or attempt to weld if
the welder, welding cables, welding site,
or welder power cord are exposed to any
form of atmospheric precipitation, or salt
water spray.
• Do not carry coiled welding cables around
shoulders, or any other part of the body,
when they are plugged into the welder.
• Do not modify any wiring, ground
connections, switches, or fuses in this
welding equipment.
• Wear welding gloves to help insulate
hands from welding circuit.
• Keep all liquid containers far enough
away from the welder and work area so
that if spilled, the liquid can not possibly
come in contact with any part of the
welder or electrical welding circuit.
• Replace any cracked or damaged parts
that are insulated or act as insulators
such as welding cables, power cord, or
electrode holder IMMEDIATELY.
FLASH HAZARDS
WARNING
ARC RAYS CAN INJURE EYES AND BURN
SKIN! To reduce the risk of injury from arc
rays, read, understand, and follow the following safety instructions. In addition, make certain that anyone else that uses this welding
equipment, or is a bystander in the welding
area understands and follows these safety
instructions as well. Headshields and filter
should conform to ANSI Z87.1 standards.
• Do not look at an electric arc without
proper protection. A welding arc is
extremely bright and intense and, with
inadequate or no eye protection, the retina can be burned, leaving a permanent
dark spot in the field of vision. A shield or
helmet with a number 10 shade filter lens
(minimum) must be used.
• Do not strike a welding arc until all
bystanders and you (the welder) have
welding shields and/or helmets in place.
4
• Do not wear a cracked or broken helmet
and replace any cracked or broken filter
lenses IMMEDIATELY.
• Do not allow the uninsulated portion of the
wire feed torch to touch the ground clamp
or grounded work to prevent an arc flash
from being created on contact.
• Provide bystanders with shields or helmets fitted with a #10 shade filter lens.
• Wear protective clothing. The intense light
of the welding arc can burn the skin in
much the same way as the sun, even
through light-weight clothing. Wear dark
clothing of heavy material. The shirt worn
should be long sleeved and the collar kept
buttoned to protect chest and neck.
• Protect against REFLECTED ARC RAYS.
Arc rays can be reflected off shiny surfaces such as a glossy painted surface,
aluminum, stainless steel, and glass. It is
possible for your eyes to be injured by
reflected arc rays even when wearing a
protective helmet or shield. If welding with
a reflective surface behind you, arc rays
can bounce off the surface, then off the filter lens on the inside of your helmet
or shield, then into your eyes. If a reflective background exists in your welding
area, either remove it or cover it with
something non-flammable and non-reflective. Reflective arc rays can also cause
skin burn in addition to eye injury.
FIRE HAZARDS
WARNING
FIRE OR EXPLOSION CAN CAUSE
DEATH, INJURY, AND PROPERTY DAMAGE! To reduce the risk of death, injury, or
property damage from fire or explosion, read,
understand, and follow the following safety
instructions. In addition, make certain that
anyone else that uses this welding equipment, or is a bystander in the welding area,
understands and follows these safety instructions as well. REMEMBER! Arc welding by
nature produces sparks, hot spatter, molten
metal drops, hot slag, and hot metal parts
that can start fires, burn skin, and damage
eyes.
• Do not wear gloves or other clothing that
contains oil, grease, or other flammable
substances.
• Do not wear flammable hair preparations.
• Do not weld in an area until it is checked
and cleared of combustible and/or flammable materials. BE AWARE that sparks
and slag can fly 35 feet and can pass
through small cracks and openings. If
work and combustibles cannot be separated by a minimum of 35 feet, protect
against ignition with suitable, snug-fitting,
fire resistant, covers or shields.
• Do not weld on walls until checking for
and removing combustibles touching the
other side of the walls.
• Do not weld, cut, or perform other such
work on used barrels, drums, tanks, or
other containers that had contained a
flammable or toxic substance. The techniques for removing flammable substance
and vapors, to make a used container
safe for welding or cutting, are quite complex and require special education and
training.
• Do not strike an arc on a compressed
gas or air cylinder or other pressure vessel. Doing so will create a brittle area that
can result in a violent rupture immediately
or at a later time as a result of rough
handling.
• Do not weld or cut in an area where the
air may contain flammable dust (such as
grain dust), gas, or liquid vapors (such as
gasoline).
• Do not handle hot metal, such as the work
piece or electrode stubs, with bare hands.
• Wear leather gloves, heavy long sleeve
shirt, cuffless trousers, high-topped
shoes, helmet, and cap. As necessary,
use additional protective clothing such as
leather jacket or sleeves, fire resistant
leggings, or apron. Hot sparks or metal
can lodge in rolled up sleeves, trouser
cuffs, or pockets. Sleeves and collars
should be kept buttoned and pockets
eliminated from the shirt front.
• Have fire extinguisher equipment handy
for immediate use! A portable chemical
fire extinguisher, type ABC, is recommended.
• Wear ear plugs when welding overhead
to prevent spatter or slag from falling into
ear.
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• Make sure welding area has a good,
solid, safe floor, preferably concrete or
masonry, not tiled, carpeted, or made of
any other flammable material.
• Protect flammable walls, ceilings, and
floors with heat resistant covers or
shields.
• Check welding area to make sure it is
free of sparks, glowing metal or slag, and
flames before leaving the welding area.
FUME HAZARDS
WARNING
FUMES, GASSES, AND VAPORS CAN
CAUSE DISCOMFORT, ILLNESS, AND
DEATH! To reduce the risk of discomfort, ill-
ness, or death, read, understand, and follow
the following safety instructions. In addition,
make certain that anyone else that uses this
welding equipment or is a bystander in the
welding area, understands and follows these
safety instructions as well.
• Do not weld in an area until it is checked
for adequate ventilation as described in
ANSI standard #Z49.1. If ventilation is not
adequate to exchange all fumes and
gasses generated during the welding
process with fresh air, do not weld unless
you (the welder) and all bystanders are
wearing air-supplied respirators.
• Do not heat metals coated with, or that
contain, materials that produce toxic
fumes (such as galvanized steel), unless
the coating is removed. Make certain the
area is well ventilated, and the operator
and all bystanders are wearing air-supplied respirators.
• Do not weld, cut, or heat lead, zinc, cadmium, mercury, beryllium, or similar metals without seeking professional advice
and inspection of the ventilation of the
welding area. These metals produce
EXTREMELY TOXIC fumes which can
cause discomfort, illness, and death.
• Do not weld or cut in areas that are near
chlorinated solvents. Vapors from chlorinated hydrocarbons, such as trichloroethylene and perchloroethylene, can be
decomposed by the heat of an electric
arc or its ultraviolet radiation. These
actions can cause PHOSGENE, a HIGHLY TOXIC gas to form, along with other
lung and eye-irritating gasses. Do not
weld or cut where these solvent vapors
can be drawn into the work area or where
the ultraviolet radiation can penetrate to
areas containing even very small
amounts of these vapors.
• Do not weld in a confined area unless it
is being ventilated or the operator (and
anyone else in the area) is wearing an
air-supplied respirator.
• Stop welding if you develop momentary
eye, nose, or throat irritation as this indicates inadequate ventilation. Stop work
and take necessary steps to improve
ventilation in the welding area. Do not
resume welding if physical discomfort
persists.
6
SERVICE
Tool service must be performed only by qualified repair personnel. Service or maintenance by unqualified
personnel could result in a risk of injury.
When servicing a tool, use only identical replacement parts and follow instructions in the manual. Use
of unauthorized parts or failure to follow Maintenance Instructions may create a risk of shock or injury.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.
This manual contains important information regarding safety, operation, maintenance and storage of this product.
Before use, read carefully and understand all warnings, cautions, instructions and labels. Failure to do so could result
in serious personal injury, property damage or even death.
IMPORTANT SAFETY INSTRUCTIONS
Before using this tool, you need to become familiar with its operation. If you are unsure about the
operation of the tool, or have any questions about its proper use, call the Customer Service Department at
1-888-287-6981. Follow these instructions for safe handling of the tool:
? Be sure your w ork area is clean and secure. Be sure the area is free from all foreign material, nails,
staples, or any other material.
? Always use the appropriate safety gear when operating. Including but not limited to, goggles, dust
mask or respirator.
MMIG125 MIG / Fluxcore Welder Instructions
7
KNOW YOUR WELDER
Figure 1. Model WE6482 Welder
Handle – Rugged, top mounted handle
allows for easy transport of your welder.
Wire Speed Control – Use this dial to adjust
the speed at which the welder feeds wire to
the torch. 1 is the slowest wire feed speed, 10
is the highest. You will need to adjust or “tunein” your wire speed for different welding conditions (thickness of metals, metal type, wire
size, etc.). When the wire speed is properly
“tuned-in” the welding wire will melt into the
material you are welding as quickly as it is fed
through the welding torch.
Voltage Selector – This two position switch
adjusts the voltage or “heat” of your welder.
Select MIN setting for lower voltage and
MAX setting for higher voltage. Different
materials and material thickness will require
different voltage settings. You will need to
adjust your voltage accordingly for different
welding conditions. By properly adjusting
your voltage settings and wire feed speed,
you will enable clean, precision welds.
Power Switch – This switch turns the welder
ON and OFF. (Make sure the power switch is
in the OFF position before performing any
maintenance on the welder.)
Power Cord – This is a standard, grounded
120 volt power cord. (Make sure you are
using a properly grounded 120 Vac, 60Hz,
single phase, 20 amp power source.)
Ground Clamp – Attaching the ground
clamp to your work piece “completes” the
welding current circuit. You must attach the
ground clamp to the metal you are welding. If
the ground clamp is not connected to the
metal work piece you intend to weld, the
welder will not have a completed circuit and
you will be unable to weld. A poor connection
at the ground clamp will waste power and
heat. Scrape away dirt, rust, scale, oil or
paint before attaching the ground clamp.
Ground Cable – The ground cable connects
the ground clamp to the internal workings of
the w elder.
Welding Torch and Cable – The welding
torch controls the delivery of the welding wire
to the material to be welded. The welding
wire is fed through the welding cable and
welding torch when the welding torch trigger
is pulled. You will need to install a contact tip
and welding nozzle to the end of the welding
torch, as described later in this manual, prior
to welding.
Circuit Breaker – This unit is equipped with
a circuit breaker switch which protects the
welder’s power supply from line voltage
surges. If circuit breaker is tripped, reset by
pressing the button located inside the access
panel on the dividing wall of the welder.
Welding Terms -Now that you are familiar
with the main parts of the welder, make note
of the following terms. You will see them
used throughout this manual.
weld puddle: The localized volume
of molten metal in a weld prior to its
solidification.
weld angle: The angle of the welding wire,
as it extends from the welding torch, in relation to the item being welded.
slag: The protective coating that forms on
the surface of molten metal.
arc: A sustained luminous discharge of electricity across a gap in a circuit.
welding bead: The extended build up of a
weld, made by pushing or pulling the weld
puddle.
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