Forney 190 - Troubleshooting Common Problems

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roller make contact when the wire is in place between them, the wire feed roller must be
replaced.
• Check all cables periodically. They must be in good condition and not cracked.
This chart will assist you in resolving common problems you may encounter. These are not all the
possible solutions.
PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION
No “power” from welder. Input cable or plug malfunction.
Wrong size fuse.
Faulty on/off switch.
Check for proper input cable
connection.
Check fuse and replace as
necessary.
Replace on/off switch.
Fan operates normally, but
when gun trigger pulled,
there is no wire feed, weld
output or gas flow.
Faulty trigger gun.
Thermostat intervention.
Replace torch trigger.
Allow welder to cool. When the
pilot lamp/switch on the front panel
goes dark indicates the thermostat
has closed.
Feed motor operates but
wire will not feed.
Faulty wire feeding motor (rare).
Insufficient feed roller pressure.
Burr on end of wire.
Liner blocked or damaged.
Replace wire feeding motor.
Increase roller pressure.
Re-cut wire square with no burr.
Clear with compressed air or
replace liner.
Lack of penetration. Voltage or wire feed speed too low.
Loose connection inside the
machine (rare).
Worn or wrong size contact tip.
Loose gun connection or faulty gun
assembly.
Wrong size wire.
Torch moved too fast.
Re-adjust the welding parameters.
Clear with compressed air and
tighten all connections.
Replace the contact tip.
Tighten or replace torch.
Use correct size welding wire.
Move the gun smoothly and not too
fast.
Troubleshooting