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Maintenance & Servicing
General Maintenance
This welder has been engineered to give many years of trouble-free service providing that a few very
simple steps are taken to properly maintain it.
• Replace power cord, ground cable, ground clamp, or electrode assembly when damaged
or worn.
• Periodically clean dust, dirt, grease, etc. from your welder.
• Every six months, or as necessary, remove the cover panel from the welder and air-blow any
dust and dirt that may have accumulated inside the welder.
Troubleshooting
This chart will assist you in resolving common problems you may encounter. These are not all the possible
solutions.
PROBLEM
Welder does not hum
when turned on
Welder humbs but will not
weld
Welder gives shocks
Welder heat setting difficult
to adjust
Welder overheats/blows
fuses
Arc hard to strike
Bead too thin in places
All manuals and user guides at all-guides.com
POSSIBLE CAUSE
1. No power at receptacle
2. Broken or damaged power cord
3. Faulty switch
4. Faulty transformer
1. Inadequate power at the
receptacle
2. Inadequate current at the arc
3. Poor connections at the welder
1. Incorrect connections at power
cord or receptacle (hot wire
connected to ground terminal)
2. Welder wired to 3-phase current
Dust or dirt moving inside
transformer
1. Fan blade not turning or obstructed
2. Fan turning too slowly - misaligned
bearings
3. Wrong amperage fuse in fuse box
1. Wrong type of electrode or
electrode too large
2. Base metal not grounded
properly
3. Voltage from power line low due
to heavy loads
Uneven speed in moving electrode
across base metal
WWW.FORNEYIND.COM
POSSIBLE SOLUTION
1. Check circuit and fuses or circuit-
breakers back at meter
2. Replace power cord
3. Switch needs to be replaced
4. Transformer needs to be
replaced
1. Check power supplies
2. Check ground clamp cable and
connection to work piece; check
electrode cable and clamp at
electrode
1. Rewire power cord receptacle
2. Check power source
Clean shunt track
1. Clear blade of obstruction and/or
replace fan motor
2. Replace fan motor & bearings
3. Replace with 50 amp or breaker
1. Check electrode and verify size
and type of electrode for application
2. Verify grounding
3. Have power company verify
voltage and increase if possible
Slow down; try to maintain steady
rate of travel across the surface to
be welded.
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