Get started with the Forney Easy Weld 140 FC-i! This is a breakdown of the Quick Start Guide that is included with your new machine.
FIRST STEPS
1. 
Read User Manual
2. Install wire spool
a. 0.030” (0.8mm) diameter
3. Set drive roll
a. Face the side marked 0.030” away from the machine
4. Feed wire and set pressure
a. For proper tension align the tops of the screw and nut together
5. Connect to Input Power 
a. Generator OK with continuous output ≥ 4,000 W
b. Extension cord: #12 AWG or larger; 25’ (8m) or shorter
6. Remove consumables and depress trigger until wire comes out. Replace consumables.
7. Adjust wire feed speed (
) and voltage (
). See chart on welder for correct settings.
8. With contact tip 1/4″ from metal, depress trigger completely to initiate arc.
MIG Troubleshooting Tips
Both LED lights off
- Verify machine is plugged in and on. See manual.
Both LED lights on
- Duty cycle exceeded or insufficient air flow. Allow machine to cool. Ensure vents are clear of obstacles. See manual.
Aluminum welding
- Welding aluminum requires shielding gas. This machine is only for gas-less flux-cored welding.
- This machine cannot connect to a spool gun, which is recommended for aluminum.
Workpiece grounding
- Connect ground clamp to clean, bare metal. No rust, paint or other coatings. Attach the ground clamp directly to the work piece if you are experiencing issues.
Frequently tripping circuit breaker or exceeding duty cycle
Use wire with a diameter of 0.030” (0.8mm). Larger diameters draw too much amperage. 
Trying to weld single pass on material larger than ¼” (6mm) thick is not possible with this machine. Multi-pass recommended for thicker materials. 
Welder should be the only thing plugged into the circuit.
Low weld output or poor fusion
- Usually due to low input power.
- Welder should be only thing plugged into circuit.
- Avoid using extension cords. If one must be used, it must be #12 AWG or larger; 25’ (8m) or shorter.
- Generators must be 4,000 W continuous output and not have a low-idle function (or have it disabled).
Improper wire spool installation
- Can cause feed issues and inconsistent weld quality.
- Verify all parts are in the proper place. Refer to manual.
Too much spool tension
- Wire from spool to drive should relax with a slight curve after feeding.
Incorrect drive roll pressure
- Too little pressure = Roll can slip and feed can be erratic
- Too much pressure = can crush wire, causing wire feeding problems and welder damage
No arc start on contact
- Trigger must be pulled to initiate the arc. This will initiate the arc and begin feeding the wire.
- DEPRESS THE TRIGGER COMPLETELY
Mismatched drive roll, liner, or contact tip size
- Can cause feed and weld issues and arc instability.
- Each component must be sized for wire diameter used.
This welder has been a workhorse. I love. This afternoon it doesn’t come on and there are two lights flashing on the front. It isn’t overheated. It has been shutoff for hours. What can I do?
Hello Scotty! Our Expert-Techs can assist you with this problem- you can reach them at 1-800-521-6038 ext. 2. Thanks for reaching out!
There is definitely a problem with this welder, when I first bought this fc-140i I notice the the wire dive was not pushing the flux core wire out fast enough to accommodate a smooth weld, I contact the Forney company and they sent me a wire drive motor replacement to repair the problem, I installed the drive motor assembly and completed the set up. The drive motor still is very slow with the wire spool connected and with no wire spool attach to it. The drive roller just doesn’t turn fast to have a descent weld. What can you do to help me fix this problem.
Hi Rocco, we’re sorry to hear you’re still experiencing problems with your welder. Our Expert-Techs will definitely be able to assist you with this problem, they even offer an option to video call in so they can see exactly what issues you’re experiencing. You can reach them at 1-800-521-6038 ext. 2!
Try a different wire. My Forney dislikes Forney wire. It feeds Firepower like a champ.
Hello Rocco! Give our Expert-Techs a call, they should be able to assist you with this problem. 1-800-521-6038 ext. 2. Thanks for reaching out!
Wire fed for 10 mins and quit. 20 amp circuit is good all lites and come on. Checked spool tension all ok. Why won’t it feed wire
Hi David! You can reach out to our Expert-Techs, they will be able to assist you with this question. Give them a call at 1-800-521-6038 ext. 2!