Metal Man FC125X Owner's Manual
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Metal Man FC125X Owner's Manual

Gasless wire feed welder
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FC125X
Gasless Wire Feed Welder
OWNER'S MANUAL
07/2017
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.
www.MetalManGear.com
Toll Free Help 888-762-4045

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  • Page 1 FC125X Gasless Wire Feed Welder OWNER’S MANUAL 07/2017 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. www.MetalManGear.com Toll Free Help 888-762-4045...

  • Page 2: Warranty

    Limited to the warranty periods below, Metal Man Work Gear Co will repair or replace the item under warranty that fails due to defects in material and workmanship. Metal Man Work Gear must be notified within 30 days of the failure, so as to provide instructions on how to proceed with the repair of your welder and warranty claim processing.

  • Page 3: General Safety Rules

    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 unit until they have read this manual and have developed a thorough understanding of how this unit works. WARNING: The warnings, cautions, and instructions discussed in this instruction manual cannot cover all possible conditions or situations that could occur.
  • Page 4 -Do not allow the contact tip to make contact with the grounded material while the trigger is pulled. -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.
  • Page 5 -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.
  • Page 6 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 MIG gun and ground cable together whenever possible.

  • Page 7: Technical Specifications

    KNOW YOUR WELDER Description METAL MAN FC125X 115 volt input, 125 amp AC output flux core only wire feed welders is economical and easy to use. It requires no shielding gas and welds 18 gauge to 3/16" mild steel materials with .030" or .035" flux core wires on 4" or 8" spools. This unit features 2 voltage ranges, a set up chart, a cooling fan, trigger activated arc, overload protection, 6 ft MIG gun with Tweco style series 11 replacement parts and 6 ft ground cable and clamp.
  • Page 8 ON/OFF Switch In the “OFF” position no power is being supplied to the torch. In the “ON” position power is supplied to the main transformer and control circuit. Voltage Setting 1-2 switch is on the front panel of machine. There are two voltage settings. Refer to the “set up” chart inside the wire feed compartment for initial adjustment settings.

  • Page 9: Installation

    INSTALLATION 1. POWER REQUIREMENT - AC single phase 115V (110-120V) 60 HZ fused with a 20 amp time delayed fuse or circuit breaker is required. DO NOT OPERATE THIS UNIT if the ACTUAL power source voltage is less than 105 volts AC or greater than 132 volts AC. Electrical Shock ...
  • Page 10 the outside edge of the wire spool and bend it over to hold the wire in place. Remove the spool of wire from the drive compartment of the welder. 3.4 Rotate the Drive Roller Cap (3) counterclockwise and remove it from the Drive Roller. 3.5 Pull the Drive Roller off of the Drive Roller shaft.
  • Page 11 4.2.3 Remove the packaging from the spool of wire and then identify the leading end of the wire secured on the edge of the spool. DO NOT UNHOOK IT AT THIS TIME. 4.2.4 Place the spool on the spool hub so the wire will pull off the TOP of the spool. The welding wire should always come off the TOP of the spool into the drive mechanism.
  • Page 12 -Make certain that the welding wire is actually going into the torch liner. If not, the wire will jam up in the mechanism. 4.2.11 Line the wire up with the correct groove in the drive roller. Place the drive tension arm back above the drive roller.

  • Page 13: Operation

    OPERATION 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.
  • Page 14 6. DISTANCE FROM THE WORK PIECE - If the nozzle is held off the work piece, the distance between the nozzle and the work piece should be kept constant and should not exceed 1/4 inch or the arc may begin sputtering, signaling a loss in welding performance. 7.
  • Page 15 ELECTRIC SHOCK CAN KILL! To prevent ELECTRIC SHOCK, do not perform any welding while standing, kneeling, or lying directly on the grounded workpiece. 8.1 Moving the torch Torch travel refers to the movement of the torch along the weld joint and is broken into two elements: Direction and Speed.
  • Page 16 8.3 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. HORIZONTAL POSITION Is performed very much the same as the flat weld except that angle B (see HOLDING THE TORCH) is such that the wire, directed more toward the metal above the weld joint is to help prevent the weld puddle from running downward while still allowing slow enough travel speed.
  • Page 17 8.4 Multiple pass welding Butt Weld Joints When butt welding thicker materials, you will need to prepare the edges of the material to be joined by grinding a bevel on the edge of one or both pieces of the metal being joined. When this is done, a “V”...
  • Page 18 8.5 Spot welding There are three methods of spot welding: Burn-Through, Punch and Fill, and Lap. Each has advantages and disadvantages depending on the specific application as well as personal preference. 1. The BURN-THROUGH METHOD welds two overlapped pieces of metal together by burning through the top piece and into the bottom piece.

  • Page 19: Maintenance

    Maintain your FC125X. It is recommended that the general condition of any FC125X be examined before it is used. Keep your FC125X in good repair by adopting a program of conscientious repair and maintenance. Have necessary repairs made by qualified service personnel.

  • Page 20: Electrical Diagram

    ELECTRICAL DIAGRAM Page of 24...

  • Page 21: Diagram & Parts List

    DIAGRAM & PARTS LIST Page of 24...
  • Page 22 145200007 BACK PANEL 105200020 CABLE HOLDER 105200267 POWER CORD 105200208 VERTICAL MIDDLE PANEL 145200004 ENCLOSURE 105200041 MIG WARNING LABEL 145200001 METAL MAN NEED HELP LABEL 105200268 BOTTOM 105200024 FEET 105200025 THERMAL RELAY 105200205 MAIN TRANSFORMER 105500015 HANDLE 105200028 PCB BOARD...
  • Page 23 Reference # Part# Description Qty. 105200034 FLUX CORE NOZZLE 105200043 .030 CONTACT TIP 105200033 CONTACT TIP ADAPTER 105200104 TORCH INSULATOR 105200105 TORCH LINER 105200106 TORCH HEAD TUBE For replacement parts and technical questions contact the technical help line at 888-762-4045 Page of 24...
  • Page 24 METAL MAN WORK GEAR CO. 1760 Prospect Ct, Suite 120 Appleton, WI 54914 888-762-4045 www.metalmangear.com Made in China Page of 24...

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