Forney 125 FC Operating Manual

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125 FC FLUX CORED

WIRE WELDER

OPERATING MANUAL

FEATURES:

• 125A Output

• 120V Input

• Easy to use

• No gas required

• Portable

• Torch wrap

SPECIFICATIONS:

• Recommended Wire Diameter: Up to .030”

• Plate thickness range: 24 ga - 1/4”

• Weight: 32.6 Lbs. (14.8 Kg)

• Dimensions: 24.6” (411.48mm) X 12.6”

(205.74mm) X 18.5” (314.96mm)

• 6 month warranty

IDEAL FOR:

Do-It-Yourself, Maintenance &
Repair, Metal Fabrication,
Hobbyist

ENGLISH

REV 10.13.15

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STOP!

PLEASE DO NOT

RETURN TO THE STORE

If you have questions or problems with your new welder, please

call customer service at 1-800-521-6038

Monday through Friday from 7 a.m. - 5 p.m. (MST) or at

www.forneyind.com/customer_service.

Please take time to register your product at

www.forneyind.com/customer_service/register_your_product/

Thank you, enjoy your new welder.

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Forney Promise

We are committed to your success regardless of location, size or
needs. We understand it is your goal to get the job done right,
and we are ready to help you do just that.

President’s Message

We market the highest quality tools, equipment and accessories
for the do-it-yourselfer and professional. Our passion and
dedication in bringing new products to the industrial and retail
market, combined with our personal service, is unmatched in our
industry. Our ability to listen to our customers’ needs enables us to
create solutions to their problems.

Our dedication to the highest quality customer service within our
corporate headquarters and the service provided in the field is
unequaled. We are committed to creating the best solutions to our
customer’s needs. Above all, our employees will provide the same
respect and caring attitude within the organization as they are
expected to share with every Forney customer. Our goal will be to
exceed our customers’ expectations through empowered people,
guided by shared values and commitments.

We work hard so our customers trust us because of our integrity,
teamwork and innovation of Forney products, and Forney’s
80 years of unmatched product quality and an unwavering
commitment to our customers.

When our customers succeed we succeed.

STEVEN G. ANDERSON, President & CEO

Copyright© 2014 Forney Industries,
Inc. All rights reserved. Unauthorized
reproduction and/or distribution is
subject to US copyright laws.

U.S. Warehouses:

- Fort Collins, CO

- Tipp City, OH

FIVE WAYS TO ORDER

Web: www.forneyind.com
Phone: [phone]
Fax: [phone]
Mail: Forney Industries

2057 Vermont Drive
Fort Collins, CO 80525

Email: [e-mail]

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Forney 6 Month Warranty

Effective July 1, 2015

1) Limited Warranty: Subject to the terms and conditions below, Forney Industries, Inc., Fort Collins,
Colorado, warrants to its original retail purchaser that the new Forney equipment sold after the effective date
of this limited warranty is free of defects in material and workmanship at the time it is shipped by Forney. This
is in lieu of all other warranties, express or implied.

2) Notification: Please call 1-800-521-6038 with your warranty questions. You can also visit www.
forneyind.com for additional information about your new welder.

3) Length of Warranty: Within the 6 month warranty period Forney will repair or replace any warranted
parts or components that fail due to defects in material or workmanship. Warranty is effective from the date
of original retail purchase.

4) Non-Applicable Parts: Forney Industries limited warranty shall not apply to consumables such as contact
tips, cutting nozzles, felt wire cleaner, drive rollers, gas diffusers, plasma torch tips and electrodes, weld
cables, tips and parts that fail due to normal wear. In addition, this warranty does not extend to any damage
caused by the untimely replacement or maintenance of any of the previously listed consumable parts.

5) Warrantor:

Forney Industries
2057 Vermont Drive
Fort Collins, CO 80525
1-800-521-6038
www.forneyind.com

6) Purchaser / Warranty: The original purchaser of the Forney Industries product. The warranty is
not transferable. Forney Industries products are intended for purchase and use by persons trained and
experienced in the use and maintenance of welding equipment.

7) What is not covered under the warranty:

A) Implied warranties, including those of merchantability and fitness for a particular purpose are limited in

duration to this express warranty. After this period, all risks of loss, from whatever reason, shall be on the
purchaser.

B) Any incidental, indirect, or consequential loss, damage, or expense that may result from any defect,

failure or malfunction of the Forney product.

C) Any failure that results from accident, purchaser’s abuse, neglect or failure to operate products in

accordance with instructions provided in the owner’s manual(s) supplied with the product.

D) Pre-delivery service, i.e. assembly and adjustment.

8) Claim: In the event of a warranty claim under this warranty, the exclusive remedies shall be, at Forney
Industries sole option:
A) Repair; or
B) Replacement; or
C) Where authorized in writing by Forney Industries, the cost of repair or replacement at an authorized

Forney Industries Service Center; or

D) Payment of or credit for the purchase price less reasonable depreciation based on actual use upon the

return of the goods at the customer’s risk and expense.

9) Purchaser will:

A) Contact Forney Customer Service at 1-800-521-6038 within 30 days of the defect or failure.
B) Provide dated proof of purchase (typically a purchase receipt).
C) Provide the serial number. Registering your welder at www.forneyind.com/customer_service/

register_your_product/ will speed up this process.

D) Deliver or ship welder to a Forney authorized Service Center. Freight &/or packaging costs, if any, must

be borne by the purchaser.

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CAUTION!

BEFORE INSTALLING, OPERATING OR CARRYING OUT MAINTENANCE ON THE MACHINE, READ THE CONTENTS OF THIS MANUAL

CAREFULLY, PAYING PARTICULAR ATTENTION TO THE SAFETY RULES AND HAZARDS.

In the event of these instructions not being clear, please contact your

Forney Authorized Dealer or Forney Customer Service 1-800-521-6038

• Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society,
8669 Doral Boulevard, Suite 130, Doral, FL 33166 Safety and Health Standards, OSHA
29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402.

• Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That
Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from
American Welding Society, 8669 Doral Boulevard, Suite 130, Doral, FL 33166

• National Electrical Code, NFPA Standard 70, from National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.

• Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed
Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

• Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards
Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W
1R3.

• Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard
Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

• Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269

California Proposition 65 Warning

This product may contain chemicals known to the State of California to cause cancer, birth defects and
other reproductive harm (CA. Prop 65). Wash hands after use.

EMF Information

Welding or cutting current, as it flows through the welding or cutting cables, will cause electromagnetic
fields. There has been and still is some concern about such fields. However, after examination the
committee of the National Research Council concluded that: “The body of evidence, in the committee’s
judgment, has not demonstrated that exposure to power-frequency electric and a magnetic field is a
human health hazard.” However, studies are still going forth and evidence continues to be examined.
Until the final conclusions of the research are reached, you may wish to minimize your exposure to
electromagnetic fields when welding or cutting. To reduce magnetic fields in the workplace, use the
following procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding or cutting power source and cables as far away from operator as practical.

5. Connect work clamp to work piece as close to the cut or weld as possible.

ABOUT PACEMAKERS & HEARING AIDS:

Pacemaker & Hearing Aid wearers consult your doctor first. If cleared by your doctor, then following
the above procedures is recommended.

Principal Safety Standards

Safety Summary

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Personal Protection

Welding processes of any kind can be dangerous not only to the operator but to any person situated
near the equipment, if safety and operating rules are not strictly observed.

THE WELDING ARC PRODUCES VERY BRIGHT ULTRAVIOLET AND INFRARED

LIGHT. THESE ARC RAYS WILL DAMAGE YOUR EYES AND BURN YOUR SKIN IF
YOU ARE NOT PROPERLY PROTECTED. To reduce the risk of injury from arc rays, read,

understand, and follow the 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. Helmets and filter should conform to ANSI Z87.1 stan dards.

• 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, leav ing
a permanent dark spot in the field of vision. A shield or helmet with a #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.

• Do not wear a cracked or broken helmet and replace any cracked or bro ken filter lenses

immediately.

• Do not allow the uninsulated portion of the wire feed gun to touch the ground clamp or

grounded work to prevent an arc flash from being created on contact.

• Provide bystanders with shields or hel mets fitted with an appropriate 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 sur faces 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 and off the fil ter lens. It can
get inside your helmet or shield and 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.

• Flying sparks can injure. Wear proper safety equipment to protect eyes and face. Shape

tungsten electrode on grinder wearing proper protection and in a safe location. Keep
flammables away and prevent fire from flying sparks.

FUMES, GASSES, AND VAPORS CAN CAUSE DISCOMFORT, ILLNESS, AND

DEATH! To reduce the risk, read, understand, and follow the 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.

• Read and understand manufacturers SDS and MSDS.

• 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-sup plied respirators.

• Do not weld, cut or heat lead, zinc, cad mium, mercury, beryllium, antimony, cobalt,
manganese, selenium, arsenic, copper, silver, barium, chromium, vanadium, nickel, or similar
met als without seeking professional advice and inspection of the ventilation of the welding

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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 chlori nated
hydrocarbons, such as trichloroeth ylene and perchloroethylene, can be decomposed by the
heat of an electric arc or its ultraviolet radiation. These actions can cause phosgene, a high ly
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
pene trate 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 indi cates
inadequate ventilation. Stop work and take necessary steps to improve ventilation in the
welding area. Do not resume welding if physical discomfort persists.

Fire Prevention

FIRE OR EXPLOSION CAN CAUSE DEATH, INJURY, AND PROPERTY DAMAGE!

To reduce these risks, read, understand and follow the safety instructions. In addition, make
certain that anyone else that uses this welding equip ment, or is a bystander in the welding
area, understands and follows these safety instruc tions 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 touch the hot weld bead or weld puddle until fully cooled.

• Do not weld in an area until it is checked and cleared of combustible and/or flam mable

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 sepa rated 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 a flammable or toxic substance. The tech niques for removing flammable
sub stance and vapors, to make a used con tainer safe for welding or cutting, are quite
complex and require special educa tion and training.

• Do not strike an arc on a compressed gas or air cylinder. 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 pants, 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, pant 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 recom mended.

• Wear ear plugs when welding overhead to prevent spatter or slag from falling into ear.

• 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.

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• Check welding area to make sure it is free of sparks, glowing metal or slag, and flames
before leaving the welding area.

• Wear garments free of oil or other flammable substances such as leather gloves, thick cotton
shirts with no synthetic materials, cuffless trousers, closed toed shoes. Keep long hair pulled
back.

• Remove any combustibles such as lighters and matches before doing any welding.

• Follow requirements in OSHA and NFPA for hot work and have an extinguisher nearby.

• High Frequency (H.F) can interfere with radio navigation, safety services, computers and
communication equipment.

• It is the user’s responsibility to have a qualified electrician promptly correct any interference
problem resulting from the installation. Electrician should regularly check and maintain
installation.

• Stop using the equipment if notified by the FCC about interference.

• Keep H.F. source doors and panels tightly shut and keep spark gaps at correct setting.

• Computers and computer driven equipment can be harmed with electromagnetic energy.

• Be sure all equipment is compatible with electromagnetic energy.

• Keep welding cables short to reduce interference.

• Follow manual to install and ground machine.

• If interference continues, shield the work area or move the welding machine.

WARNING: ELECTRIC SHOCK CAN KILL! To reduce the risk of death or serious injury

from shock, read, understand, and follow the 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 OPERA TION of this welding equipment until you have read

and understand the following safety summary.

• Do not, in any manner, come into physi cal 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 gun.

• 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 gun, 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 cloth ing is
moist, or if you are in physical con tact 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

Electric Shock

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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 cannot 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.

• When not welding, cut wire back to contact tip or remove electrode from electrode holder.

Noise

Noise can cause permanent hearing loss. Welding processes can cause noise levels that exceed

safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.

• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs.

• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.

Additional Safety Information

For additional information concerning weld ing safety, refer to the following standards and comply with
them as applicable.

• ANSI Standard Z49.1 - SAFETY IN WELDING AND CUTTING - obtainable from the
American Welding Society, 550 NW Le Jeune Road, Miami, FL 33126 Telephone (800)
443-9353, Fax [phone] - www.amweld.org or www.aws.org

• ANSI Standard Z87.1 - SAFE PRAC TICE FOR OCCUPATION AND EDUCA TIONAL EYE
AND FACE PROTECTION - obtainable from the American National Standards Institute, 11
West 42nd St., New York, NY 10036 Telephone (212) 642A900, Fax [phone] ­www.ansi.org

• NFPA Standard 518 - CUTTING AND WELDING PROCESS - obtainable from the National
Fire Protection Association, 1 Batterymarch Park, P.O. Box 9101, Quincy, MA 02269-9101
Telephone [phone] Fax [phone] - www.nfpa.org

• OSHA Standard 29 CFR, Part 1910, Subpart Q., WELDING, CUTTING AND BRAZING

- obtainable from your state OSHA office or U.S. Dept. of Labor OSHA, Office of Public
Affairs, Room N3647, 200 Constitution Ave., Washington, DC 20210 - www.osha.gov

• CSA Standard W117.2 - Code for SAFE TY IN WELDING AND CUTTING. - obtainable
from Canadian Standards Association, 178 Rexdale Blvd., Etobicoke, Ontario M9W 1R3 ­www.csa.ca

• American Welding Society Standard A6.0. WELDING AND CUTTING CON TAINERS
WHICH HAVE HELD COM BUSTIBLES. - obtainable from the American Welding Society, 550
NW Le Jeune Road, Miami, FL 33126 Telephone [phone], Fax [phone] ­www.amweld.org or www.aws.org