Everlast POWER i-MIG 140E User manual

EVERLAST
POWER i-MIG 140E
MIG/GMAW WELDER
Rev. 1 0 1000722-14
everlastwelders.com
1-877-755-9353 Specicaons and Accessories subject to change without noce.
329 Lileeld Ave. South San Francisco, CA 94080 USA
Operator’s Manual for the
Power i-MIG 140E MIG Welder
General Use and Setup Guide
IGBT
DC
GMAW
CV

2
Table of contents
Section……………………………………………….Page
Letter to the Customer …………………....…………
Everlast Contact Information…………….………….
Safety Precautions……………………………………
Introduction and Specifications…..…………………
General Description, Purpose and Features………
Set Up Guide and Component Identification….…...
Suggested Settings…….…………………...………..
Installation of Filler Wire and Machine Setup……...
Front Panel View……………………...…………..….
Side View…...……………………..……….………….
Rear Panel View …...……………………....………..
Expanded View of MIG Torch……………………….
Trouble Shooting…...………………………………...
General Notes………………………………………...
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4
5
9
9
9
14
15
16
18
20
22
23
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3
Dear Customer,
THANKS! You had a choice, and you bought an Everlast Product. We appreciate you as a cus-
tomer and hope that you will enjoy years of use from your welder.
Please go directly to the Everlast website to register your unit and receive your warranty infor-
maon. Your unit registraon is important should any informaon such as product updates or re-
calls be issued. It is also important so that we may track your sasfacon with Everlast products
and services. If you are unable to register by website, contact Everlast directly through the sales
department at the main customer service number in your country. Your unit will be registered and
warranty will be issued and in full eect. Keep all informaon regarding your purchase. In the
event of a problem you must contact technical support before your welder can be a candidate for
warranty service and returned. An over-the-phone review/diagnosis must be performed BE-
FORE a RMA is issued or before the unit can be sent in for service.
Please read the warranty statement published online and other important informaon
found on the Everlast website of the division located in or nearest to your country. Print
it for your records and become familiar of its terms and condions. Guns, accessories and
torches are covered under a separate, shorter warranty. Please be sure you visit the web-
site and are familiar with all the warranty terms before you call for service.
Everlast oers full technical support, in several dierent forms. We have online support available
through email, and a welding support forum designed for customers and noncustomer interacon.
Technical advisors are acve on the forum daily. We also divide our support into two divisions:
technical and welding performance. Should you have an issue or queson concerning your unit,
please contact performance/technical support available through the main company headquarters
available in your country. This support is free to all Everlast customers. For best service call the
appropriate support line and follow up with an email, parcularly if o hours, or you cannot reach
a live person. In the event you do not reach a live person, leave a message and your call will nor-
mally be returned within 24 hours, except for weekends and holidays. Also for quick answers to
your basic quesons, join the company owned forum available through the website. You’ll nd
knowledgeable sta available to answer your quesons. You also may nd a topic that already
addresses your queson at hp://www.everlastgenerators.com/forums/. Should you need to call
or write, always know your model name, purchase date and welder manufacturing inspecon date.
This will assure the quick and accurate customer service. REMEMBER: Be as specic and informed
as possible. Technical and performance advisors rely upon you to carefully describe the condi-
ons and circumstances of your problem or queson. Take notes of any issues as best you can.
You may be asked many quesons by the advisors to clarify problems or issues that may seem
very basic. However, diagnosis procedures MUST be followed to begin the warranty process.
Advisors can’t assume anything, even with experienced users, and must cover all aspects to
properly diagnose the problem. Depending upon your issue, it is advisable to have basic tools
handy such as screwdrivers, wrenches, pliers, and even an inexpensive test meter with volt/ohm
funcons before you call.
Let us know how we may be of service to you should you have any quesons.
Sincerely,
Everlast Customer Service

4
Serial number: __________________________
Model number: ____________________________
Date of Purchase:___________________________
EVERLAST
Contact Information
Everlast US:
Everlast consumer satisfaction email: [e-mail]
Everlast Website: everlastwelders.com
Everlast Technical Support: [e-mail]
Everlast Support Forum: http://www.everlastgenerators.com/forums/index.php
Main toll free number: 1-877-755 WELD (9353) 9am—5pm PST M-F
11am-4pm PST Sat.
FAX: [phone]
Everlast Canada:
Everlast consumer satisfaction email: [e-mail]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [e-mail]
Telephone: [phone]am-4:30pm EST M-F
10am-1pm EST Sat.
FAX: [phone]
Everlast Australia:
Sydney: 5A Karloo Parade Newport NSW 2106
[phone]
Port Macquarie: 2B Pandorea Place Port Macquarie
[phone]
After hours support: 0410 661 334
Everlast Technical Support: [email protected]
OTHER (Please record here for your records):

5
Everlast is dedicated to providing you with the best possible equipment and
service to meet the demanding jobs that you have. We want to go beyond deliv-
ering a satisfactory product to you. That is the reason we offer technical sup-
port to assist you with your needs should an occasion occur. With proper use
and care your product should deliver years of trouble free service.
Safe operation and proper maintenance is your responsibility.
We have compiled this operator’s manual, to instruct you in basic safety, oper-
ation and maintenance of your Everlast product to give you the best possible
experience. Much of welding and cutting is based upon experience and com-
mon sense. As thorough as this welding manual may be, it is no substitute for
either. Exercise extreme caution and care in all activities related to welding or
cutting. Your safety, health and even life depends upon it. While accidents are
never planned, preventing an accident requires careful planning.
Please carefully read this manual before you operate your Everlast unit. This
manual is not only for the use of the machine, but to assist in obtaining the
best performance out of your unit. Do not operate the unit until you have read
this manual and you are thoroughly familiar with the safe operation of the unit.
If you feel you need more information please contact Everlast Support.
The warranty does not cover improper use, maintenance or consumables. Do
not attempt to alter or defeat any piece or part of your unit, particularly any
safety device. Keep all shields and covers in place during unit operation should
an unlikely failure of internal components result in the possible presence of
sparks and explosions. If a failure occurs, discontinue further use until mal-
functioning parts or accessories have been repaired or replaced by qualified
personnel.
Note on High Frequency electromagnetic disturbances:
Certain welding and cutting processes generate High Frequency (HF) waves.
These waves may disturb sensitive electronic equipment such as televisions,
radios, computers, cell phones, and related equipment. High Frequency may
also interfere with fluorescent lights. Consult with an electrician if disturb-
ance is noted. Sometimes, improper wire routing or poor shielding may be the
cause.
HF can interfere with pacemakers. See EMF warnings in following safety sec-
tion for further information. Always consult your physician before entering an
area known to have welding or cutting equipment if you have a pacemaker.
Safety Precautions

6
SAFETY PRECAUTIONS
These safety precautions are for protection of safety and health. Failure to
follow these guidelines may result in serious injury or death. Be careful to
read and follow all cautions and warnings. Protect yourself and others.
Welding and cutting processes produce high levels of ultraviolet (UV) radiation that
can cause severe skin burn and damage. There are other potential hazards involved
with welding such as severe burns and respiratory related illnesses. Therefore ob-
serve the following to minimize potential accidents and injury:
Use appropriate safety glasses with wrap around shields while in the work area, even
under welding helmets to protect your eyes from flying sparks and debris. When chip-
ping slag or grinding, goggles and face shields may be required.
When welding or cutting, always use an approved shielding device, with the correct
shade of filter installed. Always use a welding helmet in good condition. Discard any
broken or cracked filters or helmets. Using broken or cracked filters or helmets can
cause severe eye injury and burn. Filter shades of no less than shade 5 for cutting
and no less than shade 9 for welding are highly recommended. Shades greater than 9
may be required for high amperage welds. Keep filter lenses clean and clear for maxi-
mum visibility. It is also advisable to consult with your eye doctor should you wear
contacts for corrective vision before you wear them while welding.
Do not allow personnel to watch or observe the welding or cutting operation unless
fully protected by a filter screen, protective curtains or equivalent protective equip-
ment. If no protection is available, exclude them from the work area. Even brief expo-
sure to the rays from the welding arc can damage unprotected eyes.
Always wear hearing protection because welding and cutting can be extremely noisy.
Ear protection is necessary to prevent hearing loss. Even prolonged low levels of
noise has been known to create long term hearing damage. Hearing protection also
further protects against hot sparks and debris from entering the ear canal and doing
harm.
Always wear personal protective clothing. Flame proof clothing is required at all
times. Sparks and hot metal can lodge in pockets, hems and cuffs. Make sure loose
clothing is tucked in neatly. Leather aprons and jackets are recommended. Suitable
welding jackets and coats may be purchased made from fire proof material from
welding supply stores. Discard any burned or frayed clothing. Keep clothing away
from oil, grease and flammable liquids.
Leather boots or steel toed leather boots with rubber bottoms are required for ade-
quate foot protection. Canvas, polyester and other man made materials often found
in shoes will either burn or melt. Rubber or other non conductive soles are necessary
to help protect from electrical shock.
Flame proof and insulated gauntlet gloves are required whether welding or cutting or
handling metal. Simple work gloves for the garden or chore work are not sufficient.
Gauntlet type welding gloves are available from your local welding supply companies.
Never attempt to weld with out gloves. Welding with out gloves can result in serious
burns and electrical shock. If your hand or body parts comes into contact with the
arc of a plasma cutter or welder, instant and serious burns will occur. Proper hand
protection is required at all times when working with welding or cutting machines!

7
SAFETY PRECAUTIONS
WARNING! Persons with pacemakers should not weld, cut or be in the welding area
until they consult with their physician. Some pacemakers are sensitive to EMF radiation
and could severely malfunction while welding or while being in the vicinity of someone
welding. Serious injury or death may occur!
Welding and plasma cutting processes generate electro-magnetic fields and radiation.
While the effects of EMF radiation are not known, it is suspected that there may be
some harm from long term exposure to electromagnetic fields. Therefore, certain pre-
cautions should be taken to minimize exposure:
 Lay welding leads and lines neatly away from the body.
 Never coil cables around the body.
 Secure cables with tape if necessary to keep from the body.
 Keep all cables and leads on the same side the body.
 Never stand between cables or leads.
 Keep as far away from the power source (welder) as possible while welding.
 Never stand between the ground clamp and the torch.
 Keep the ground clamp grounded as close to the weld or cut as possible.
Welding and cutting processes pose certain inhalation risks. Be sure to follow any
guidelines from your chosen consumable and electrode suppliers regarding possible
need for respiratory equipment while welding or cutting. Always weld with adequate
ventilation. Never weld in closed rooms or confined spaces. Fumes and gases re-
leased while welding or cutting may be poisonous. Take precautions at all times.
Any burning of the eyes, nose or throat are signs that you need to increase ventilation.
 Stop immediately and relocate work if necessary until adequate ventilation is ob-
tained.
 Stop work completely and seek medical help if irritation and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, titanium, cop-
per, cadmium, lead or zinc without proper respiratory equipment and or ventilation.
WARNING! This product when used for welding or cutting produces fumes and gas-
es which contains chemicals known to the State of California to cause birth defects
and in some cases cancer. (California Safety and Health Code §25249.5 et seq .)
WARNING! Do not weld or cut around Chlorinated solvents or degreasing areas.
Release of Phosgene gas can be deadly. Consider all chemicals to have potential
deadly results if welded on or near metal containing residual amounts of chemicals.
Keep all cylinders upright and chained to a wall or appropriate holding pen. Certain
regulations regarding high pressure cylinders can be obtained from OSHA or local
regulatory agency. Consult also with your welding supply company in your area for
further recommendations. The regulatory changes are frequent so keep informed.
All cylinders have a potential explosion hazard. When not in use, keep capped and
closed. Store chained so that overturn is not likely. Transporting cylinders incorrectly
can lead to an explosion. Do not attempt to adapt regulators to fit cylinders. Do not
use faulty regulators. Do not allow cylinders to come into contact with work piece or
work. Do not weld or strike arcs on cylinders. Keep cylinders away from direct heat,
flame and sparks.

8
SAFETY PRECAUTIONS
WARNING! Electrical shock can kill. Make sure all electrical equipment is properly
grounded. Do not use frayed, cut or otherwise damaged cables and leads. Do not
stand, lean or rest on ground clamp. Do not stand in water or damp areas while weld-
ing or cutting. Keep work surface dry. Do not use welder or plasma cutter in the rain
or in extremely humid conditions. Use dry rubber soled shoes and dry gloves when
welding or cutting to insulate against electrical shock. Turn machine on or off only
with gloved hand. Keep all parts of the body insulated from work, and work tables.
Keep away from direct contact with skin against work. If tight or close quarters ne-
cessitates standing or resting on work piece, insulate with dry boards and rubber
mats designed to insulate the body from direct contact.
All work cables, leads, and hoses pose trip hazards. Be aware of their location and
make sure all personnel in area are advised of their location. Taping or securing ca-
bles with appropriate restraints can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cutting. Always keep
fire extinguishers close by and additionally a water hose or bucket of sand. Periodi-
cally check work area for smoldering embers or smoke. It is a good idea to have
someone help watch for possible fires while you are welding. Sparks and hot metal
may travel a long distance. They may go into cracks in walls and floors and start a fire
that would not be immediately visible. Here are some things you can do to reduce the
possibility of fire or explosion:
 Keep all combustible materials including rags and spare clothing away from area.
 Keep all flammable fuels and liquids stored separately from work area.
 Visually inspect work area when job is completed for the slightest traces of smoke
or embers.
 If welding or cutting outside, make sure you are in a cleared off area, free from
dry tender and debris that might start a forest or grass fire.
 Do not weld on tanks, drums or barrels that are closed, pressurized or anything
that held flammable liquid or material.
Metal is hot after welding or cutting! Always use gloves and or tongs when handling
hot pieces of metal. Remember to place hot metal on fire-proof surfaces after han-
dling. Serious burns and injury can result if material is improperly handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death. Prop-
er maintenance is your responsibility. Make sure all equipment is properly maintained
and serviced by qualified personnel. Do not abuse or misuse equipment.
Keep all covers in place. A faulty machine may shoot sparks or may have exploding
parts. Touching uncovered parts inside machine can cause discharge of high
amounts of electricity. Do not allow employees to operate poorly serviced equipment.
Always check condition of equipment thoroughly before start up. Disconnect unit
from power source before any service attempt is made and for long term storage or
electrical storms.
Further information can be obtained from The American Welding Society (AWS) that
relates directly to safe welding and plasma cutting. Additionally, your local welding
supply company may have additional pamphlets available concerning their products.
Do not operate machinery until your are comfortable with proper operation and are
able to assume inherent risks of cutting or welding.

9
Overview of Parameters and Features
Power i-MIG 140E
Section 1 Introduction and Specifications
Power i-MIG 140E Specification
Construction Type IGBT Inverter
Dimensions 17.5”L x 13.5”H x 8.5”W
Weight (Unit Only) 25 lbs.
Input Voltage/Phase/Hertz 115Volt (110-120V) 1 Phase/ 50/60Hz
Maximum Input Amps (I1MAX) 38.6V
Rated Input Amps (I1EFF) 19.5A
Duty Cycle at Rated Output 25% @ 140A/21V; 60% @ 90A/18.4V; 100% @ 70A/17.5V
Output Range (Amps/Volts): 25-140A/ 15.3-21V
Maximum Wire Speed 360 Inches Per Minute (IPM)
MIG Gun Type/Length 15 Series (Trafimet/Binzel Compatible)/6ft (2m)*
MIG Gun Connection Euro Quick Connect
Regulator Type Floating ball
Roll Size/Capacity 4” to 8” Diameter/ 1-12lbs
Wire Diameter (standard drive roll) Solid Wire: .023”-.035” (.6-.9mm) **
OCV: 60V
Fan: Continuous
Insulation: F
Water Ingress Protection Standard IP21S
NOTE: Environment, Maintenance and Safety.
Keep welder at least 10-12 inches away from all objects for proper cooling. Do not exceed 40° C in environment or
duty cycle will be reduced. Regularly inspect and clean the welder and circuitry on a quarterly basis with dry com-
pressed air. Remove the covers only aer the unit has been turned o and unplugged for 30 minutes to discharge the
capacitors to reduce the possibility of electrocuon. Do not grind or throw sparks near to the welder to prevent dam-
age to the panel face and internal components. Damage of this nature is not covered by the warranty.
* 2015 models feature 10 ft (3m) torches. **Recommend .023”-.030” for best results.

10
1.1 General Descripon, Purpose and Features.
The Power i-MIG 140E is a durable MIG (GMAW) welder
designed for light repair and fabricaon where 240V
service is limited or not praccal. The unit operates on
110/120V single phase input and comes equipped with
a standard 120V NEMA 15-5P plug for convenient use
in almost any standard 120V outlet. The Power i-MIG
140E’s IGBT inverter design is rated for 25% duty cycle
at 140 amps. It is designed to consume less power, pro-
vide beer arc stability and oer beer duty cycle over
transformer welders in the 120V input class. There are
no tapped sengs which prevent ne adjustment of
either voltage or wire speed. Both amps (wire speed)
and voltage are innitely adjustable within their ranges.
1.2 Basic Design and Construcon. The Power i-MIG
140E features an advanced IGBT inverter design, with
plug and play circuits and controls for maximum service-
ability and lifespan. The unit has a full me high speed
fan which maintains temperature levels providing in-
creased duty cycle and performance. A heavy duty
wire feeder mechanism features cast aluminum and
steel construcon for long life. The unit will accommo-
date 4” (1-2lb) and 8” (10-12lb) rolls of wire and fea-
tures rapid tool-free, wire spool installaon. Gun con-
necon is quick with the tool-free design of the Euro
quick connect ng. The Work clamp is equally easy to
install, and features a 25 series DINSE style connector.
For transport or storage both MIG gun and work clamp
can be disconnected in less than 15 seconds. The stand-
ard drive rolls included with the unit are designed for
use with .023”-.035” solid wire. The smaller groove
(.6mm) should be used with .023-.027” wire. The larger
groove (.8mm) should be used with .030 and .035 wire.
For general purpose use, Everlast recommends
that .030” ER70S-6 wire be used for most general pur-
pose welding. This diameter wire and class is designed
to work well with the amp output range that the Power
i-MIG 140E delivers. Special applicaons like aluminum
may be welded with the oponal spool gun. It is possi-
ble to weld aluminum with the main feeder and gun,
but a special gun liner must be purchased and a harder
wire such as 5356 should be used to prevent “bird’s
nesng” of the wire. Stainless can easily be welded
with either the spool gun or the standard gun. Using a
spool gun may be a more praccal choice if welding
smaller projects with stainless or aluminum since both
stainless and aluminum wires are expensive. Either
coated (copper or other coangs) or uncoated steel
wire may be used for welding steel as long as it re-
mains rust-free and clean.
NOTE: For ux core use, special drive rolls with a serrat-
ed design may be purchased from Everlast.
1.3 Installaon. The design of the Power i-MIG 140E is
compact and able to travel almost anywhere 120V service
is available. For maximum output capability, a 30 amp
circuit breaker is needed, with a minimum of a 20 amp
slow trip circuit breaker recommended. If operang on a
15 amp circuit near the maximum amp/volt sengs of
the welder the circuit breaker may trip. If this happens,
reduce the sengs on the welder.
Care and common sense should be taken to make sure
that the welder oers the safest and best performance.
Please note the following items regarding safe operaon:
1) Do not use the welder in damp or wet areas. Perspi-
raon and other forms of water in contact with the
body can increase the risk of electrocuon.
2) Do not use the welder in extremely corrosive environ-
ments. To maintain opmum power transfer, check
main connecons, clamps and cables frequently to
ensure that components are not corroded. Excessive
dirt, corrosion and oxidaon can result in an unstable
arc and excessive heat build-up.
3) Do not kink or ghtly coil the MIG gun or the wire
may not feed properly. Coiling ghtly may even dam-
age the liner or cable if the cable becomes kinked.
Always use the MIG gun with the cable running as
straight as possible. Gentle, natural curves are ac-
ceptable. Do not stand on or roll objects over the
welder cables. Pay close aenon if the welder is on a
rolling cart so that the cables are not accidentally
rolled over when moving it around.
4) Do not pull, hold, or suspend the welder by the gun
or cables. Pick up the welder from the handle only.
5) Due to the light weight and compact size, strap or e
the welder down (over the top) to prevent accidental
overturning while in use on a table or cart.
1.4 Duty Cycle. Duty Cycle is expressed as the percent-
age of me out of 10 minutes at the rated amps/volts that
the welder can weld without an interrupon or break.
Aer this the welder should be allowed to rest the re-
mainder of the 10 minutes. If the duty cycle light is trig-
gered, the welder will stop welding. If this happens, allow
the welder to connue to idle and cool for 15 minutes.
Aer giving the unit me to cool, cycle the power switch
o and back on to reset the welder and resume welding.
Lowering the welder output will increase the duty cycle
duty cycle. This welder has a rang of 25% @ 140 amps.
Lowering the amperage to 90 amps increases the duty
Introduction and Specifications
Section 1

11
cycle to 60%. Lowering it further to 70 amps increases
duty cycle to 100%. Keep in mind a 100% duty cycle
rang is not a connuous, innite rang. It is rated
100% only out of a consecuve 10 minute period of
me. Certain factors like ambient temperature, humidi-
ty, parcle/dust buildup inside of the welder, poor
quality power input etc, all can aect duty cycle. The
duty cycle interrupt cycle is governed by a temperature
sensor rather than a mer. This is a more eecve and
praccal way of determining duty cycle limit. Inter-
mient welding and many pracces involved in fabrica-
on and repair makes it hard to track usage so a tem-
perature limit is the best way to protect the welder if it
is overworked. Intenonally and consistently reaching
the duty cycle limit so the welding is regularly interrupt-
ed rapidly ages components and may cause premature
failure of the welder. The duty cycle interrupt feature is
not a fail safe against abuse and any heat related dam-
age. Never turn the unit o unl it has me to cool.
NOTE: If you are welding and the unit begins to feed
wire only without an arc when the trigger is pressed,
check the status of the duty-cycle light or the overcur-
rent light. When either an overcurrent or duty cycle
event has occurred, the unit will keep feeding wire but
not produce an arc when the trigger is held down.
1.5 Overcurrent. The unit is also equipped with an
overcurrent limiter. This feature detects when there is
either an over/under voltage or excessive amp draw.
If the overcurrent light is triggered, the unit will also
interrupt welding. When this is experienced, rst pow-
er the unit o. Then check to make sure the unit is
plugged into an appropriately rated outlet and that it is
being used with a correct sized extension cord rated for
a minimum of 20 amps. Do not use with undersized
extension cords or overheang, re or damage may
result. Check outlet voltage for a minimum of 110V and
not more than 125V. Cycle the power switch o and
back on to reset the unit. If the Overcurrent light does
not clear, then it is likely the power supply is poor or the
unit has developed an internal fault. Contact Everlast if
the overcurrent cannot be cleared or reoccurs repeat-
edly as the unit may have sustained internal damage.
NOTE: When using large diameter welding wire (.035”
or greater) at or near the maximum output of the ma-
chine, the welder may occasionally experience an
overcurrent. This can happen if the wire is not
trimmed to an appropriate length and the gun is
touched held too far away when starng the arc. Rem-
edy all other causes rst before assuming this is the
issue. This may also occur if the contact p is touched
to the metal when starng the arc. It can occur if the
gun nozzle has excess slag bridging inside of the nozzle
to the contact p and the nozzle is subsequently
touched to the metal when starng the arc. This cre-
ates a dead short and can trigger an overcurrent.
1.6 General operaon and setup.
1) Wire Tension. Always check wire tension before
use. Use no more wire tension than is necessary.
(See page 15 for adjustment.)
2) Work Clamp. MIG welders require good work
clamp (ground) contact. Rounely inspect work
clamp and cable and make sure they are in good
condion and that the cables are held ght in the
connectors and are free of corrosion. Always
grind a small clean spot where the work clamp is
to be aached. Always connect the work clamp
directly to the metal being welded if possible.
Hard starng or “machine gunning” at the start of
the weld may be a result of a poor ground.
3) MIG gun use and maintenance. Before use make
sure that collar on the Euro quick connect has been
fully ghtened by hand. Do not use tools. Grip the
gun rmly when starng the arc to prevent push-
o and spaering/popping at the start of the weld.
Trim the wire to 1/2” or less and hold the gun just
as close to the metal to start the weld. Use nozzle
dip or a an spaer spray to help keep the MIG
gun nozzle from becoming plugged with slag. Reg-
ularly check and clean the nozzle. Nozzle dip and
an spaer can be bought at almost any welding
supply store. It is an economical way to prevent
harmful accumulaon of slag in and on the nozzle
and can be used in the weld area to prevent
spaer from scking to the work-piece. Do not
apply too much to the nozzle or directly to the
weld area or porosity may occur. Only apply when
the protecve qualies begin to dissipate. Nozzle
dip and an spaer also provide some lubricity to
the contact p and increases the lifespan and ease
of feeding. Make sure to change contact p size
when changing the wire size. Using too large of a
contact p can cause errac arc behavior. Using
too small of a contact p can cause jamming.
When welding with aluminum, use a special alumi-
num contact p or at least one size larger regular
contact p to accommodate the wire as it expands
due to the heat. Over me, the gun liner may be-
come gradually fouled with dirt, metal lings from
the coang and other possible contaminants. To
Introduction and Specifications
Section 1

12
prevent this, regularly remove the wire from the
cable, and blow dry compressed air down the gun
neck with the contact p removed. If necessary
remove the liner and replace it if becomes worn
and irregular or dicult feeding or gas ow is ob-
served. NOTE: (Binzel/Tramet 15 series) When
removing the shielding gas nozzle, twist the nozzle
like a screw to install or remove as it grips the noz-
zle ghtly. There is a special retaining spring un-
der the nozzle that acts as a thread. This feature
allows you to posion the nozzle in order to vary
the depth of the contact p for dierent welding
applicaons.
4) Shielding gas selecon and use. For MIG opera-
on, selecon of the proper shielding gas is im-
portant. Remember, each shielding gas mixture
and ller metal thickness will require a dierent
seng of voltage and amps. A 75/25 (75% Ar-
gon/25%CO2) mixture is recommended for general
purpose steel welding. This yields the best results
in most circumstances. To reduce spaer further,
other blends of Ar/CO2 with higher percentages of
Argon (a true inert gas) may be used. The puddle
may be dicult to control and cold lap may occur if
the mix is over 85% Argon, especially if used in out
of posion welds. Generally, when there is a high-
er percentage of Argon present in the mix, the cost
of the mix will be greater. Though less desirable,
100% CO2 may also be used. Greater penetraon
with a narrower bead prole can be achieved with
100% CO2. However, extra spaer, smoke and
oxidaon will be noced. CO2 is not a a true inert
gas so it can impart a dull gray, and even aky ap-
pearance to the weld as it interacts with the molten
metal. If 100% CO2 is used, regularly check to en-
sure the regulator is not freezing up. CO2 oers a
cheaper opon but losses in transfer eciency
(amount of metal actually deposited versus total
amount consumed) and extra me spent for clean-
ing spaer may negate inial cost savings. For
Stainless, a commercial Tri-mix of gas is generally
used for short circuit transfer. This is usually a pro-
prietary % blend of Argon, Helium, and CO2. Con-
sult with your local welding supply store. For alu-
minum, 100% Argon must be used.
5) Regulator and shielding gas ow adjustment.
NOTE: Regulators may be supplied in LPM or CFH.
Please note which has been provided before
starng to weld for future reference. The regula-
tor should always be mounted nearly vercal if not
with a slight upturn (for safety) so that the ball may
oat free. Always stand to the opposite side of the
regulator and slowly open the regulator with the
front and top of the regulator facing away from
you. Gas ow requirements vary in MIG greatly
and a lot depends upon the environment. More
gas will be required in open/dray areas. To avoid
wasng shielding gas, perform some preliminary
test welds. To adjust, decrease gas ow unl the
weld begins to bubble and exhibit porosity. Gradu-
ally increase the gas ow unl the bubbles disap-
pears completely. Crack the adjustment on the
regulator an small addional amount to ensure full
gas coverage. This process will reduce waste and
help ensure you are not introducing oxygen into
the weld. As the pressure drops within the cylin-
der readjustment may be necessary.
6) MIG polarity. When using solid MIG wire, the
polarity should always be electrode posive. This
means the torch should always be connected to
the posive (+) terminal when welding with solid
wire. To check this, open the cover, and inspect
the heavy power cable that runs from the front
end of the wire feeder to the bolted terminals on
the center divider wall that are marked either with
a posive (+) sign or a negave (-) sign. The cable
should be screwed down to the terminal marked
with the (+) sign for solid wire. For ux core, most
(but not all) manufacturers of ux core wire specify
the use of negave (-) polarity. Consult the manu-
facturer’s recommendaons regarding ux core or
dual shield wire polarity before installaon. If neg-
ave polarity is required, swap the feeder cable to
the negave terminal. Always make sure the ter-
minal screw is fully ghtened. Do not over ghten
the terminal or it may strip out the terminal
threads. If, aer switching between solid and ux
core wire, an errac arc is noced, double check
the polarity. This is a commonly overlooked part
of the changeover procedure.
7) Volt and Amp adjustment. The welder features
innite adjustment of voltage and wire feed speed
within each range. Wire speed adjustment is di-
rectly related to amp output and the terms are
generally used interchangeably. As wire speed in-
creases so does amperage and vice versa. In many
welding charts and calculators, you may nd actual
amperage sengs rather than a wire speed seng.
Amperage output also depends upon the diameter
of the wire as well. Both volts and amps are cali-
brated in numbers ranging from 1-10 with innite
adjustment possibility between each number.
These are relave numbers and are used only as a
reference when repeang the same or similar set-
Introduction and Specifications
Section 1

13
up. If helpful for seng up the unit, the numbers 1
-10 can be thought of as represenng 10%-100% of
full output for either voltage or wire speed. For
each wire diameter, most users will nd 3 to 5
sengs that will t their welding style and applica-
ons but oen the ability to ne tune these sengs
for specic applicaons will be needed. At rst,
some experimentaon will be necessary. The fol-
lowing method of seng up wires peed and voltage
is commonly used by professionals in the industry
to setup almost any type MIG. When seng up
welding parameters, set the wire speed halfway
then begin to lower the voltage unl it begins to
cold feed into the metal (also referred to as stub-
bing). Note the point where it begins to do so.
Next, raise the voltage unl the puddle becomes
hot and the arc seems violent and irregular. Note
that point as well. Lower the voltage to a point
midway between the two extremes where the arc
seems to even out. Aer the voltage is set, gradu-
ally adjust the wire feed/amps unl the sound of
the arc is crisp. Listen to the arc. A steady sizzle, or
whine should be present. The weld puddle should
be weng out neatly on the edges of the weld.
This sound has oen been referred to as a “frying”
sound. The sound should be regular, and the arc
should be visually stable without signicant pop-
ping and snapping. The wire should be disappear-
ing easily into the puddle without the arc stopping.
If the wire speed is too high, violent popping with
bits of ying wire may be noced. If it is too low
the arc will appear to melt the wire before it reach-
es the puddle and may melt irregularly, even burn-
ing back into the p. Volts are responsible for how
at and wet the puddle appears. If too much volt-
age is used, the weld will appear wide and at with
the edges of the weld possibly exhibing undercut.
This will create weakness in the weld. If too lile is
used, the weld will appear rope like and may even
sit on top of the metal with irregular fusion. Am-
perage/Wire speed is responsible for penetraon.
If it is set too high for the thickness of metal being
used, burn through can occur, especially on thin
gauge material. If welding thin materials such as
used in exhaust systems or body work, make sure
the wire speed is adjusted to reduce penetraon
before aempng a voltage change. General g-
ures for both wire speed and amps can be easily
determined. To determine wire speed, simply
press the trigger (without welding) and hold it for
15 seconds. Measure the length of the wire that is
run from the torch in 15 seconds and mulply by 4.
This gure is your wire speed in inches per minute
(IPM). To roughly determine amps, which are
somemes used by manufacturers for recommend-
ed sengs, use the following formulas for the fol-
lowing wire thicknesses:
.023”: IPM/3.5 = Amps
.030”: IPM/2 = Amps
.035”: IPM/1.6 = Amps
The actual constant given in this formula represents
“inches per amp”. This formula is only a guide and is
only accurate in lower ranges as the funcon is not tru-
ly linear. But it usually will be within the overall range
specied by the manufacturer. For each manufacturer,
the ller wire diameter amp range may dier some-
what, though a general range can be established.
1.7 Spool Gun. The spool gun is an oponal, but use-
ful tool to have for welding small and medium projects
aluminum projects that are 3/32” and over in thickness.
The spool gun connects directly in place of the regular
MIG gun. The Spool gun picks up the gas and power at
the Euro connecon with a separate control connecon
for the trigger on the spool gun. Once the spool gun
panel switch is ipped, the trigger will control on and
o operaon of the gun. Wire speed and voltage are
sll controlled at the panel however. NOTE: Some
guns Everlast sells may have a separate control
mounted on the spool gun handle for wire speed, but
is inoperave and is not used with this unit. When
welding aluminum, the unit should be welded in the
spray arc mode. Typically spool guns are good for
welding 3/32” and thicker aluminum. Spray arc mode
is a mode where the voltage is increased to near maxi-
mum voltage for this unit, and wire speed is adjusted so
that the wire melts in a steady stream of consistently
sized droplets before the wire contacts the metal. A
slight hiss will be present if done correctly. There is a
threshold for spray arc, and it requires higher voltage
and increased wire speed to force it into this mode.
This is a quieter mode than regular short circuit with
quick wet in and fast forward travel. It’s recommended
that .030” wire be used to achieve the best results.
.023” wire may be used as well, but the unit may not
achieve true spray arc mode as it requires more wire
speed than the wire feeder can generate. In general,
the smaller the wire, the more wire speed is required
for spray arc. Larger diameter wire may cause overcur-
rents and may not feed well through the gun. More
informaon about spray arc welding with MIG can be
found in a variety of educaonal welding resources
online. Read over materials available and watch
demonstraon videos for more informaon.
Introduction and Specifications
Section 1

14
Setup Guide and component Identification
Section 2
PROCESS TORCH POLARITY WORK POLARITY
MIG (GMAW) +-
FLUX CORE (FCAW) - +
GENERAL POLARITY RECOMMENDATIONS*
*Consult manufacturer direcons of ller material. There are excepons.
Table 1
PROCESS GAS
MIG (GMAW) STEEL 80/20 Ar/CO2 or 75/25 Ar/CO2
MIG (GMAW) STAINLESS Tri-Mix (Ar/He/CO2)
MIG (GMAW) ALUMINUM 100% Argon
GAS SELECTION GUIDE
Table 2
WIRE DIAMETER WELDING AMPS (A) PLATE THICKNESS GAS FLOW RATE
.023” (0.6) 25-120 .040”-.125” 15-20 CFH /7-10 lpm
.030” (0.8) 35-200 .040”-.187” 20-25 CFH/ 10-14 lpm
.035” (0.9) 45-250 .063”-.250” 20-30 CFH/ 10-16 lpm
MIG (GMAW) CURRENT/WIRE/THICKNESS GENERAL SUGGESTIONS
Table 3
General Reference Information for Operation and Parameters
NOTES AND FAVORITE SETTINGS:

15
TO THREAD WIRE INTO FEEDER:
1. Loosen top idler tensioner, rotating counter-clockwise
2. Flip tensioner down, releasing top drive roll.
3. Raise top drive idler roller.
4. Inspect the drive roll to make sure that the groove size matches the wire diameter.
Reversal of the lower roller may be necessary. To reverse the roller, remove the
thumb screw securing the drive roll. Pull the drive roll off, and flip the drive roll
over. Reassemble and tighten roller. If a flux core roller is needed contact Everlast.
5. Thread straightened wire into coiled sheath and over grooves in lower drive roll.
Thread through until it threads into the gun section 3”-4”. Lower the upper drive roll
onto lower drive roll, keeping the wire securely fixed in the groove of the feed roller.
Make sure the wire has been engaged in the correct groove.
6. Raise tensioner back into place. Tighten slightly so wire will feed. Notice markings
on tensioner for future reference.
7. Hold torch straight out as possible. Press the gun trigger to feed wire until the wire
exits the end of the torch. Remove contact tip if necessary to feed out wire.
8. Adjust tensioner clockwise until drive rolls will not slip when the wire comes into
contact with a hard surface (a block of wood) and the wire will curl up on end. Re-
member to keep wire away from metal that is attached to the work clamp to pre-
vent the wire from accidentally arcing.
8
2
A
B
C
TO INSTALL MIG GUN/TORCH:
A. Align pins on the torch connector with the feeder receptacle.
B. Fully engage the connector into the receptacle.
C. Twist knurled nut on connector clockwise until it is snug.
4
5
1
3
4
5
TO LOAD WIRE SPOOL:
1. Loosen the oblong thumb nut (inside of cover) by turning it counter-clockwise.
2. Remove the spring, then the outer support collar.
3. Slide spool onto shaft. Make sure wire is unwrapping from bottom of the spool.
4. Turn support collar so shallow side of should faces “in” for 8” spools, out for 4” spools.
5. Reinsert spring then tighten the thumb nut clockwise.
6. Tension the roll with the thumb nut so that the roll doesn’t free wheel but turns easily.
7. Clip the end of the wire to feed the wire smoothly through drive mechanism.
Bottom Drive Roll (Standard)
.6mm=.023”-.025” .8mm=.030”-.035”
Setup Guide and component Identification
Section 2
INSTALLATION OF FILLER WIRE AND MACHINE SETUP

16
FRONT VIEW
Setup Guide and component Identification
Section 2
WIRE SPEED
3. EURO QUICK CONNECT FOR MIG/SPOOL GUN
1. LED Indicators: ON/TEMP/OVERCURRENT
5. SPOOL GUN CONTROL
4. SPOOL GUN SWITCH
3. WIRE SPEED/AMP ADJUSTMENT
2. VOLTAGE ADJUSTMENT
6. WORK CLAMP CONNECTOR

17
Front Panel:
1. LED Indicators. The LED’S indicate the exisng
status of the machine. The On indicator is lit any-
me the machine is turned on . The amber color
light will be lit when the duty cycle has been ex-
ceeded. When it is lit, welding will be interrupt-
ed. (The wire will connue to feed but will not arc
when the trigger is pressed.) If the duty cycle is
exceeded, allow the unit to cool for 15 minutes
before reseng the machine by powering it o
and back on. Do no turn the welder o unl the
unit has suciently cooled. If the red over-
current light is lit, welding will also be interrupt-
ed. If this light comes on, an overcurrent/
overvoltage or under voltage has occurred.
Check wiring such as extension cords and circuit
breakers for sucient current carrying capacity.
Also check to see if slag has bridged the space
between the contact p and the shielding gas
nozzle or if the wire sck out is too long. Occa-
sionally this may occur when using larger wire
(.035”) at or near maximum sengs with a long
sck out of the wire. Once the cause has been
remedied, turn the power o and back on to re-
set the welder. If the light does not clear aer
remedying the cause, contact Everlast technical
support for further diagnosis.
2. Voltage Selector. The voltage selector increases
and decreases the voltage incrementally through-
out the range. Increasing the voltage helps im-
prove wet in and puddle uidity. Too lile volt-
age results in a ropey, narrow weld with poor
fusion. Too much voltage results in an errac,
violent arc and undercung.
3. Wire Speed/Amp Selector. The wire speed se-
lector controls amperage throughout the range
by varying the speed of the wire. The relaon-
ship between wire feed speed and amps is a di-
rect one. Increasing one, increases the other.
Actual amp output at the same given wire speed
will vary with dierent diameter wires.
4. Spool Gun Switch. This switch changes the units
output to the spool gun. The spool gun connects
to the main Euro connecon, and wire speed/
voltage control is retained on the panel.
5. Spool Gun Connector. The spool gun control wire
is connected directly to this 2 pin connector.
This provides On/O control of spool gun feed-
ing. It does not provide welding power.
6. Work Clamp Connector. This is where the work
clamp connects to the welder. This is a DINSE 25
style connector. The work clamp cable can be
lengthened by removing the rubber cover. Firmly
grip the cover and slide it back. Under the con-
nector is a set screw that retains the cable. If arc
starng becomes irregular or dicult, check to
ensure the work clamp and cable are in good
repair that the cable is ght in the connector.
7. Euro Connector. The Euro connector provides
rapid and secure connecon of the MIG gun
without having to use tools. Use only hand pres-
sure to ghten the connector. Do not over-
ghten the plasc retainer collar. Both the MIG
gun and oponal spool gun connect to this point.
Both the spool gun and MIG gun cannot be con-
nected at the same me.
Setup Guide and component Identification
Section 2

18
Setup Guide and component Identification
Section 2
SIDE VIEW
+
-
+
+
+
+
+
+_
.
2. Polarity Connecon
1. Wire Spool Holder Assy.
4. Wire Feeder Assy.

19
Side Panel:
1. Wire Spool Carrier Assembly. The wire spool
holder is designed to accommodate 4” and 8” wire
spools. To install the wire, remove the thumb nut
and the pressure spring from the outer collar and
remove the collar. Note that the outer collar has
two possible ways to be installed. The hub on the
outer collar has a shallow and a deep side. The
deep side should be facing out when installing 8”
rolls. When installing 4” rolls, the shallow side
should be turned out. When installing 4” rolls, the
outer collar will serve to sandwich the smaller
spool on the steel sha prevenng side to side
movement. When installing an 8” roll, the wire
collar will serve as the carrier for the larger diame-
ter roll. When the outer hub is correctly inserted
into the 8” roll, the retaining lip on the collar will
be snug against the roll when the spring and
thumb nut are installed. If there is a gap between
the retaining lip on the collar and the wire roll,
then it is installed correctly. Flip the collar over.
Tension the wire roll with the thumb screw and
spring so that it does not connue to spool wire
when quickly turned. It should turn easily, but
connue to de-spool the wire more than a 1/4
turn when spun quickly by hand. NOTE: Make
sure the wire roll is installed with the wire rolling
o the boom of the spool and the spool is ro-
tang clockwise. Feeding problems will be encoun-
tered if the wire is fed o the top of the roll.
2. Polarity. Note the “+” and “-” symbols located on
the inside of the unit above the wire feed mecha-
nism. To change the polarity of the MIG torch,
simply loosen the screws and remove the cable
and install it on the other terminal. Standard po-
larity for MIG is (+) posive (DCEP) with the work
clamp serving as the (-) negave output terminal.
(Also known as reverse polarity). For ux core use
see the wire manufacturer’s direcon for polarity
recommendaon.
3. Wire Feed Assembly. Note the numbers on the
side of the tensioner. These numbers are a refer-
ence point to help properly tension the wire so
that the drive roller will not slip. Do not over-
tension the wire because it can create a condion
known as birds nesng, where the wire will tangle
around the feeder or jam in the gun. It may not slip
if wire burns back into p, stuck fast in weld or
other resistance is met. This will connue to wrap
the wire around the drive mechanism or jam wire
inside the gun liner unl trigger is released. Con-
siderable eort is usually needed to clear a bird’s
Setup Guide and component Identification
Section 2
nest condion. Too lile tension will result in wire
slippage and fast wear on the drive components.
Test the tension of the wire and inspect for proper
feeding before beginning a weld. Occasional
cleaning of the feeder mechanism is necessary to
prevent wear and damage to the feeder and to
the MIG gun liner. Regularly monitor any metal
aking and dirt build up that may occur around
the feeder. Clean it away gently with compressed
air as necessary. Use proper safety are while
doing this, i.e. glasses, gloves etc. to prevent inju-
ry. Do not use cleaners or solvents. Felt wire lu-
bricators may be bought and used to keep feeding
cleanly while using steel or stainless wire. You may
purchase addional drive rolls from Everlast for
ux core use.
NOTE: If errac feeding is experienced, check
wire feed tensioner, spool tension (rolling re-
sistance) and for correct size groove. Also
make sure the wire is riding in the groove and
not on the shoulder of the lower drive roll.
NOTE: The unit may connue to run for up to
5 seconds aer it is shut o while the capaci-
tors discharge. This is normal and not a defect.

20
Setup Guide and component IdentificationSection 2
.
REAR VIEW/BACK PANEL
3. Power Input Cable
1. Gas Connector (Barb Type)
2. Main Power Switch
4. Fan