Everlast PowerMTS 400 User manual

Operator’s Manual
Publish Date: 8-25-2023
EVPMTS400 Rev. 1
USA/North America
©Everlast Power Equipment
240V 1Ph
480V 3Ph
Welders, Plasma Cutters, Multi-Process
Safety, Setup and General Use Guide For The
PowerMTS 400
FUNCTION: MIG/DC Stick/DC TIG Welder
PURCHASE DATE:
MODEL NAME:
SERIAL NUMBER:
OPTIONAL ACCESSORY SERIAL NUMBER:
DC
400/300A
DC
400/315A
DC
400/300A

2
TABLE OF CONTENTS
SPECIAL NOTICE AND CALIFORNIA PROPOSITION 65 WARNING 3
CUSTOMER GREETING AND EXPLANATION OF PROCEDURES 4
WARRANTY AND CONTACT INFORMATION 5
SAFETY DISCLAIMER AND HF WARNING 6
SAFETY WARNINGS, DANGERS, CAUTIONS AND INSTRUCTIONS 7
GENERATOR OPERATION INFORMATION / 240V 1 PHASE AND 480V 3 PHASE OPERATION 10
SPECIFICATIONS 11
DUTY CYCLE INFORMATION AND EXPLANATION 11
BREAKER AND WIRING REQUIREMENT INFORMATION 12
GENERAL OPERATING AND ELECTRICAL SPECIFICATIONS 13
GETTING STARTED, UNPACKING YOUR UNIT AND INSPECTION 14
CONNECTING YOUR UNIT TO THE POWER SOURCE AND WIRING INFORMATION 15
SHIELDING GAS,REGULATORS, AND TORCH INSTALLATION AND POLARITY INFORMATION 16
ASSEMBLING AND CONNECTING THE WIRE FEEDER TO THE UMBILICAL 17
INSTALLING MIG WIRE AND DRIVE ROLL SELECTION, MIG GUN DISASSEMBLY AND SETUP 20
DC TIG TUNGSTEN SELECTION 22
NEED TO KNOW CHARACTERISTICS OF THE WELDER 24
MIG GUN CARE, SELECTION AND LINER INFORMATION 25
FRONT PANEL VIEW OF THE POWER SOURCE 26
REAR PANEL VIEW OF THE POWER SOURCE 27
FCS 203 WIRE FEEDER VIEW 28
CONTROL PANEL LAYOUT INFORMATION AND OPERATION DETAILS 29
EXPLANATION OF MIG AND TIG OPERATION 31
STICK WELDING INFORMATION 36
MIG TORCH COMPONENT BREAKDOWN 37
COMMON WELDING ISSUES 39

3
NOTICE:
Product Specications and features are subject to change without notice. While
every attempt has been made to provide the most accurate and current infor-
mation possible at the time of publication, this manual is intended to be a general
guide and not intended to be exhaustive in its content regarding safety, welding,
or the operation/maintenance of this unit. Due to multiple variables that exist in
the welding eld and the changing nature of it and of the Everlast product line,
Everlast Power Equipment INC. does not guarantee the accuracy, completeness,
authority or authenticity of the information contained within this manual or of any
information offered during the course of conversation or business by any Everlast
employee or subsidiary. The owner of this product assumes all liability for its use
and maintenance. Everlast Power Equipment INC. does not warrant this product
or this document for tness for any particular purpose, for performance/accuracy
or for suitability of application. Furthermore, Everlast Power Equipment INC. does
not accept liability for injury or damages, consequential or incidental, resulting
from the use of this product or resulting from the content found in this document
or accept claims by a third party of such liability.
WARNING!
California Proposition 65 Warning:
This product, when used for welding or cutting, produces fumes or gases which
contain chemicals known to the State of California to cause birth defects and, in
some cases, cancer. (California Health & Safety Code § 25249.5 et seq.)
Warning: Cancer and/or Reproductive Harm
www.P65warnings.ca.gov

4
THANK YOU! We appreciate you as a valued customer and hope that you will enjoy years of use from your welder. We work to please the customer by
providing a well supported, quality product. To make sure that you receive the best quality ownership experience, please see below for important infor-
mation and time sensitive details.
What to do right now:
1. Print your receipt from your conrmation email that should have been sent to you after your purchase and put it up for safe keeping. If you do not
have one, contact us at 1-877-755-9353 (US customers) or 1-905-570-1818 (Canadian Customers). You will need this if anything should ever
happen for original owner verication (if bought as a gift, original receipt will still be needed, or explanation sent to Everlast).
2. Read this manual! A large number of tech and service calls are a result of not reading the manual from start to nish. Do not just scan or casually
peruse this manual. There are different features and functions that you may not be familiar with, or that may operate differently than you expect.
Even if you have expertise in the eld of welding, you should not assume this unit operates like other brands or models you have used.
3. Carefully unpack and inspect all items immediately. Look for missing or damaged items. Please report any issues within 48 hours (72 hours on
weekend or holidays) of receiving your product,. Take pictures if you are able and contact us at 1-877-755-9353, ext. 207 if any issue is discov-
ered between 9 am and 5 pm Eastern Time M-F (US customers) or at 1-905-570-1818 (Canadian Customers) between 9am and 4 pm weekdays
except on Fridays when hours are from 9 am to 12pm Eastern. If outside of the US or Canada, contact your in-country/or regional distributor di-
rect at their service number.
What to do within the next 2-3 days:
1. Make sure your electrical system is up to date and capable of handling the inrush and rated current of the unit. Consult and use a licensed and
knowledgeable electrician. If you have downloaded this manual in expectation of delivery, get started now.
2. Make sure this machine is plugged in, turned on, and tested with every process and major feature, checking for proper function. You have a 30
day period to test and thoroughly check out the operation of this unit under our 30 day satisfaction period. If something is wrong, this policy co-
vers shipping on the unit (30 day satisfaction policy applies to the USA only for the 48 lower states and D.C., territories and provinces are exclud-
ed) or any incidental parts that may be needed to resolve any issue. After this 30 day period, if you nd something wrong with the unit, you will not
receive the benet of free shipping back and forth to resolve this issue. Your unit is still covered under the 5 year parts/labor warranty, but ship-
ping is covered by the customer after the 30 day period is over. The rst 30 days of operation with any electronic item is the most critical and if
any issue will happen, it will often happen during this time. This is why it is very important that you put this unit to work as soon as possible. Any
issue should be reported within 48 hours (72 if on the weekend or holiday). Everlast will not be liable for any shipping after that time.
What to do within the next 30 days:
Visit our website (US customers). Go to www.everlastwelders.com. Navigate to the resources tab and to the “product registration” page to register
your product. While keeping your receipt/proof of purpose is still required for verication of ownership, registering will help us keep your details
straight and establish a chain of ownership. Don’t worry, though, your warranty is still valid if you can’t do this. Remember: Always keep your receipt
even if you register. You may want to staple a copy to your manual.
What to do if you have a warranty issue or problem with the unit:
1. Unplug the unit. (Also do this before any maintenance or cleaning is done.)
2. Do not attempt a self-repair until authorized by an Everlast representative. This does not include performing routine maintenance such as point gap
adjustments or regular internal cleaning. Any third party repairs are not covered under warranty, and can further damage your unit.
3. Within 24-48hours, (or by the next working business day) you must contact U.S. tech support at 1-877-755-9353 ext 207(U.S. hours are 9 am to
5pm Eastern for tech support and 9 am to 5 pm Pacic for the business/sales ofce). If you are in Canada contact 1-905-570-1818 (Canada hours
are 9am to 4pm M-Th, 9am to 12pm Fri). Although phone contact is preferred to establish a warranty claim, you may send an email to
[e-mail] (US) or [e-mail] (Canada) along with your contact information and brief explanation of the issue and
ask for a follow up call. If you contact us via phone, and you do not reach a live person, please leave a brief message with the nature of your prob-
lem and your contact information. You should expect a call back within 24 hours. It is also a good idea to follow up the message with an email.
4. Be prepared with as much information as possible when you talk with a tech advisor, including a details of the failure, settings, and application of
the unit. NOTE: A Proof-Of-Purchase (receipt) is required before returning the unit for warranty or before warranty parts can be sent to you.
5. Keep in mind that, you may be asked to check a few basic things. Before you call, having a screwdriver and volt/ohm meter at hand is a good idea
and will save time. Many issues can be resolved over the phone. If the issue cannot be resolved over the phone/email, you may be given an op-
tion to return the unit, or have a part shipped to you, at Everlast’s discretion. Keep in mind, you may be asked questions that seem basic, or ele-
mentary to your knowledge base. These are not meant to question your knowledge, but rather to make sure nothing is overlooked. However the
tech chooses to proceed, please cooperate with the process, even if you think you know what the cause or issue is. You may be asked to check
something or open the unit during the diagnosis. This does not void the warranty! Opening the unit is a part of routine maintenance and cleaning.
This is an important step. The willingness of the customer to work with tech support can save lots of time and accelerate the warranty process. For

5
warranty to be honored, you will need to make sure that you follow these guidelines. Units that are returned without an RMA (issued by the tech
support department) may not be repaired under the warranty agreement and you may be charged for the repair and can result in a delayed repair
as well.
What to do if you need setup help, guidance, weld issue diagnosis or have general product compatibility questions.
Call us at 877-755-9353 ext. 204 for welding guidance and general welding issue diagnosis. Or email [e-mail] with the basic
issue you are having, along with your specic settings, and welding application.
Hey...wait, what is my warranty?
Warranties and service policies and procedures vary from country to country and are maintained and supported by the region-
al or in country distributor of Everlast welding equipment.
USA Customers Only: For full details on the 5 year parts and labor warranty, 30 day satisfaction policy, terms of sale, and how to proceed with a war-
ranty claim, please visit: https://www.everlastgenerators.com/standard-warranty. Accessories are covered by a separate warranty and detailed infor-
mation can also be found at the link above.
Canada Customers Only: For full details on the 3 year parts and labor warranty, terms of sale, and related policies and procedures, please visit: https://
www.everlastwelders.ca/terms.php.
Who do I contact?
USA Technical Support:
Email: [e-mail]
1-877-755-9353 ext. 207
9am-5pm Eastern (Closed holidays)
Monday-Friday
USA Welding Support and General Product Information:
Email: [e-mail]
1-877-755-9353 ext 204
9am-6:30 pm Eastern (Closed holidays)
Monday-Friday
USA Sales and Main Ofce:
Email: [e-mail]
1-877-755-9353 ext 201
9am-5pm Pacic (Closed holidays)
Monday-Friday
Canada Technical Support:
Email: [e-mail]
905-570-1818
9am-4pm Eastern Monday-Thursday
9am-12pm Eastern Friday
Canada Sales and Main Ofce:
Email: [e-mail]
905-570-1818
9am-4pm Eastern Monday-Thursday
9am-12pm Eastern Friday
Other Countries and Regions:
Visit the U.S. Website @ www.everlastwelders.com and click on the flag of the country or region represented that is closest to you. If your country or
region is not found, call the U.S. ofce at 1-650-588-8588 between the hours of 9am to 5pm Pacic, Monday through Friday.

6
Safe operation and proper maintenance is your responsibility.
Everlast is dedicated to keeping safety a top priority. While we have compiled this operator’s manual to instruct you in basic safe operation and
maintenance of your Everlast product, it is no substitute for observing safe welding practices and behavior. Safe welding and related cutting
operations require basic knowledge, experience and ultimately the exercise of common sense. Welding does signicant hazards to your health
and life! Exercise extreme caution and care in all activities related to welding or cutting. Your safety, health and even life depends upon it.
WARNING! If you do not have proper knowledge or capability to safely operate this machine, do not use this machine until proper
training has been received!
While accidents are never planned, preventing an accident requires careful planning. Stay alert!
Please carefully read this manual before you operate your Everlast unit.
The warranty does not cover damage or harm created by improper use. neglect of the machine or failure to follow safe operating practices.
NOTICE:
Welding and cutting operations may generate undesirable High Frequency (HF) and EMF
energy. This can interfere with surrounding electronic equipment such as computers,
routers, CNC equipment, televisions, radios, fluorescent lighting etc. If disturbance in sur-
rounding electrical and electronic equipment is noted, consult a licensed electrician to help
properly ground surrounding equipment to limit the interference. This machine may cause
GCFI and ground fault outlets to malfunction. This unit is designed to be operated on a
dedicated, properly grounded circuit.

7
Safety Warnings, Dangers, Cautions and Instructions
NOTICE. This unit manual is intended for users with basic knowledge and skillset in weld-
ing. It is your responsibility to make certain that the use of this welder is restricted to per-
sons who have read, understand and follow the warnings and instructions in this manual. If
you or the operator needs further instruction, contact Everlast welding support at 1-877 755
-9353 ext. 204 or seek qualied professional advice and training.
WARNING! High Frequency (HF) energy can interfere with the operation of pacemakers and
can damage pacemakers. Consult with your physician and pacemaker manufacturer before
entering an area where welding and cutting equipment is in operation and before using this
welder. Some pacemakers have limited shielding. Alert any users or customers of this po-
tential problem.
WARNING! Use approved safety glasses with wrap around shields and sides while welding
and working in the weld area or serious eye damage or loss of vision may result. Use a
grinding shield in addition to the safety glasses during chipping and grinding operations.
WARNING! When welding always use an approved welding helmet or shielding device
equipped with at least an equivalent of a shade 9 or greater. Increase the shade number
rating as amperage increase over 100 amps. Inspect helmet for cracks in lenses and in the
helmet. Keep lens covers in good condition and replace as necessary.
WARNING! Welding/cutting operations carry inherent risks which include but not limited to
possible cuts burns, electrical shocks, lung damage, eye damage and even death. Take all
appropriate measures to use proper Personal Protective Equipment (PPE). Always use
leather welding gloves, closed toe (preferably reinforced or steel toe leather shoes, and long
-sleeved flame resistant clothing (i.e. denim). Do not wear Poly/Nylon blend materials.
DANGER! Welding/cutting poses shock and electrocution risks. Keep this welding equip-
ment dry. Do not weld in the rain or where moisture accumulates. Use dry, rubber soled
shoes, gloves and clothing when welding. Do not rest or contact work clamp (ground) when
welding. Keep all parts of the body insulated from the part being welded when possible. Do
not touch terminals or connections while the unit is on. Consider all parts to be “live” at all
times even if no live work is being performed. Do not use frayed welding cables.
CAUTION! Fires are possible but also preventable while welding. Always remove flammable
rags, papers, and other materials from the weld area. Keep rags stored in an approved flame
proof canister. Keep a fully charged re extinguisher at hand. Remove any fuels, oils,
paint, pressurized spray cans, and chemicals from the weld area. Make sure any smoke/re
detectors are function properly. Do not weld on tanks, drums or barrels, especially if pres-
surized or sealed. Do not weld on any container that previously held fuel or chemicals.
Make sure the weld area is clear of flammable materials such as grass or wood shavings
solvents and fuels. Do not wear frayed or loose clothing. Visually inspect and recheck the
work area after welding looking for smoldering debris or flames.
WARNING! Welding gas cylinders are under high pressure. Keep all gas cylinders upright
and chained to a cart or held safely in a safety holding pen. Never transport gas cylinders
in an enclosed car van or other vehicle. Transport gas cylinders securely. Keep all cylin-
ders capped while not in use or during transport. Replace the cap on the cylinder when it
is going to be more than 24 hours before use. Do not use or attempt to repair faulty regu-
lators. Never weld on gas cylinders. Keep gas cylinders away from direct sparks.

8
Safety Warnings, Dangers, Cautions and Instructions
DANGER! Welding and cutting operations pose serious inhalation hazards. Some of these
hazards are immediate while others are cumulative in their effect. Do not weld in enclosed
spaces or in areas without adequate ventilation. Fumes and gases released in the welding
and cutting operations can be toxic. Use fans or respiration equipment to insure adequate
ventilation if you are welding in a shop or garage area. Do not weld on galvanized metal
under any circumstance. You may develop metal fume fever. Symptoms are similar to lu-
like symptoms. Seek medical advice and treatment if you are exposed to galvanized weld-
ing fumes.
If you experience any eye burning, nose or throat irritation while welding, these are signs
that you need more ventilation.
If you feel these symptoms:
• Stop work immediately and relocate work area with better ventilation.
• Wash and clean your face and hands.
• Stop work completely and seek medical help if irritation persists
DANGER! Never use brake cleaner or any chlorinated solvent to clean or degrease metal
scheduled to be welded or other related equipment in the area being welded. The heating
of this cleaner and its residue will create highly toxic phosgene gas. Small amounts of
this vapor are harmful and can lead to organ failure and death. If degreasing of a part is
necessary, use Acetone or an approved pre-weld cleaner. Use the proper personal protec-
tive equipment (PPE) when handling any cleaners/solvents.
DANGER! People with pacemakers should consult a physician and pacemaker manufactur-
er before welding. There is a potential for damage or serious malfunction resulting in
death. High Frequency energy (HF)/Electromagnetic Fields generated during welding can
interfere with pacemaker signals, even permanently damaging it. Some pacemakers offer
some shielding, but restrictions regarding amperage and HF starting of welding arcs may
be placed upon the individual. Warn all potential bystanders that they should exit the work
area if they have a pacemaker or similar medical equipment before welding. In adverse
conditions, severe electrical shock leading to injury or death may occur while using the
welder if the user becomes part of the circuit path. Consult with a Physician if a pacemaker
is expected to be implanted.
DANGER! Never defeat or modify any safety guards or shields. Keep all safety covers and
shields in place.
Never place your ngers in or near a fan shroud or insert any object into the fan(s).
DANGER! Do not weld on the gas cylinder. Do not weld near fuel, cleaners, solvents or
other flammable materials. Remove these items from the premises before welding. Se-
vere injury or death may result from explosions or res may occur.

9
Safety Warnings, Dangers, Cautions and Instructions
CAUTION! Trip Hazards exist around this unit. Cords, cables, welding leads and hoses
pose a trip hazard. Be aware of their location and inform others of their location. Tape and
secure them so they will stay out of high trafc areas.
CAUTION! Welded metal can stay hot long after welding is completed. Burns may occur.
Always wear gloves or use tongs/pliers when handling welded or cut metal. Remember
the heat from the metal may catch other material on re. Always have a re-proof area
ready to place welded components until they fully cool. Use soap stone or a metal marking
marker to label the metal as “HOT” to serve as a reminder to all present in the area.
CAUTION! Welding and cutting operations generate high levels of ultraviolet (UV) radiation
which can burn and damage skin and eyes. The intensity is so high that exposed skin and
eyes can burn in a few minutes of exposure. Minimize direct skin and eye exposure to this
intense form of radiation by using proper PPE and sun screen where appropriate.
CAUTION! Do not allow bystanders. Do not allow others without proper Personal Protec-
tion Equipment (PPE) suitable for welding to stand in the welding area or to observe weld-
ing and welding related activities. If protection is not readily available, use a welding
screen to separate the welding area from the rest of the area. If no protection or screen is
available, physically exclude them from the welding area by a wall or other solid divider.
Keep all pets and young children away from the welding area.
CAUTION! Electromagnetic Fields can be generated by this unit and radiate into the work
place. The effect of EMF is not fully known. Exercise caution when welding by: NOT drap-
ing welding leads (guns/cables) over your shoulders or arms, NOT coiling them around
your body, NOT inserting yourself directly between the cables, and by NOT contacting the
unit while welding. DO keep the work clamp connected as close as possible to the area of
the weld and directly to the object being welded whenever possible.

10
IMPORTANT: Operating this unit with a generator or other off-grid service.
MINIMUM REQUIRED SURGE WATT RATING: 15,000W
MINIMUM REQUIRED THD: 5% or Less
This welder unit should only be operated on a generator certied by its manufacturer to produce clean power. Clean power is equivalent
to the quality of household or shop/garage type power. This means the generator must have 5% or less total harmonic distortion (THD)
of the Sine wave. If you are unsure of the power output type of the generator, contact the manufacturer of the generator for verication.
Do not operate on square wave or modied square wave generators or converters/inverters or damage or malfunction may occur. Dam-
age caused by running this unit off of “dirty” power or modied sine waves may not be readily apparent and can be cumulative in nature.
However, damage may present itself immediately. The damage caused by running this unit on “dirty” power usually leaves internal tell-tale
signs and damages specic parts.
NOTICE! Operation of this unit with generators not rated by its manufacturer as providing clean power (5% or less THD) is prohibited and
will void the warranty. Operation with modied sine wave, or square wave generators and inverters/converters/UPS that do not produce
“sine wave” output is prohibited and doing so will also void the warranty. Use only with generators/inverters/converters that produce an
equivalent type of sine wave used in shops, homes and “shore” type systems. The generator manufacturer determines the THD rating, not
Everlast. Do not assume that a name brand generator, or a “new” generator automatically provides clean power. Price paid does not
guarantee a clean power output either. There are multiple brands at various price points capable of producing clean power. Investigate
this before purchasing a generator. The manufacturer will usually state that a unit is clean power in the advertising information and will
state actual THD. If the manufacturer does not state it, contact the manufacturer directly for a statement concerning actual THD.
WARNING! Do not start or stop the generator with the unit switched on. Never use the generator in ECO mode or an auto-idle mode.
Even with a clean power rated generator, this action can damage the unit. Turn the unit on only after full generator R.P.M. has been
achieved and the engine is sufciently warmed up. Closely monitor generator fuel level so that the engine R.P.M doesn’t drop or com-
pletely shut down with the unit plugged in. For best practice: do not start or stop the generator with this unit plugged in, even if it is
turned off. Unplug the unit before shutting down the generator.
If using with a welder/generator, make sure the manufacturer has determined that the generator portion produces a clean sine wave.
Many older models do not. Some newer models use “divided” power between welding and generating and cannot supply the full power
to the unit unless the ne current control knob is turned to maximum. Do not use this unit with such welder/generators unless the Power/
ne current control is turned to 100%. Some welder generators do have a separate alternator for generating power. If this is the case, be
sure not to weld or load the machine while this unit is in use.
WARNING! Always make sure any generator or welder generator is properly wired and grounded, according to local and national code.
Ground the machine per the generator manufacturers instructions to meet code requirements. Improperly grounded generators may dam-
age the machine and more importantly may cause severe injury or death.
240V 1 Phase, 480V 3 Phase Operation
This unit is designed for 240V 50/60Hz single phase operation or 480V 50/60Hz three phase operation. This unit is shipped without a
plug and must be wired for the voltage you supply. If your single phase voltage is derived from 208V 3 phase Wye Type power (or your
local power company provides measured voltage 216V or less across each hot leg of power), then it is recommended that you install a
buck-boost type transformer to provide 240V output. It cannot be operated using all 3 phases of 208, 220 or 240V power. It must be
congured for single phase operation. If operating on 480V input, the welder must use all 3 phases of 480V power.
WARNING: Before connecting the unit to the power source make sure the correct voltage has been selected
with the rear input voltage selector switch. Failure to do so may damage the welder.

11
Specifications
DUTY CYCLE
Duty Cycle is simply the amount of time out of a 10 minute period in which the unit can operate. For example, if this unit has a duty cycle of 60% at
maximum output (400 A while operating on 480V 3 phase and 315A while operating on 250V 1phase) means that the unit can be operated for 6
minutes out of 10 minutes at the maximum setting. The unit may be operated be continuously, or intermittently for 6 minutes during the 10 minute
period of time while the machine is MIG welding at maximum output. This rating standard (United States) is based on a maximum ambient temperature
of 40 C (104°F). Operating at or above this rated operation temperature point, or even at slightly lower temperatures with high humidity readings ex-
pect a reduction in duty cycle. In most cases, the duty cycle will increase somewhat as ambient temperature drops. Lowering the operating Amperage
to will cause a rise in duty cycle. MIG welding at 315A (480V 3 phase)/250A (240V 1 phase) will increase the duty cycle to 100%. Duty cycle is im-
portant to determining what type of work welder is suitable for. However at 35% duty cycle while welding at maximum output, it is rare that manual
welding will exceed the duty cycle of the machine, since there is a lot of “in between” work such as grinding, repositioning, cleaning etc. that is often
needed between welds.
Even though the machine has a 100% duty cycle rating level of 315A/250A on this machine, this does not mean that the welder will operate continu-
ously at this level beyond the 10 minute mark. This is not an innite rating. Don’t forget that the 100% rating is a rating based off a dened 10 minute
period of time. Depending upon the circumstances, the welder could go into overheat mode at the 11 or 12 minute mark even though it is rated for
100% at 10 minutes.
Regardless of the duty cycle rating, this unit’s duty cycle is not controlled by a timer. Rather, this unit is equipped with a heat sensor located on a heat
sink near the critical power components of the welder. If the operating temperature of the unit is exceeded, welding output will stop and an over-
temperature warning light/error code will be displayed on the panel. If a duty cycle event is registered, do not turn the unit off! Allow the welder to
continue to run at idle for at least 10-15 minutes until the temperature has fallen enough to reset the sensor and over-temperature warning light. Even
if the unit resets, allow the unit to cool for a full 15 minutes, or the duty cycle will be more quickly triggered since the unit resets just below the heat
threshold. The fan(s) must continue to run for a full 15 minutes to cool the unit properly after the duty cycle shut down has occurred. After 15 minutes
of cooling, you may switch the unit off if you are nished welding. If the unit does not automatically reset after 15 minutes, turn the unit off. Wait for
15 seconds before turning the machine back on. If the unit does not reset, contact technical support for further advice and assistance. As a best prac-
tice, when you have completed welding and have been welding continuously for extended periods of time, keep your unit on for 10 additional minutes
without welding to allow it to cool.
Keeping the unit clean will help maintain the duty cycle of the welder. Removing the cover and blowing it out with dry compressed air, every 3 to 6
months will help maintain air flow and cooling surfaces and will allow the unit to operate at maximum efciency.
The intentional and/or repeated triggering of the duty cycle protection feature on this unit will shorten the lifespan of the unit’s electronics and can
weaken internal components. The effect of overheating your unit repeatedly takes a cumulative toll on the unit.
NOTICE: These units are tested by an international and independent certifying agency for their ability to sustain the claims of duty cycle, under lab in-
duced conditions which are typically more stringently controlled than average shop conditions.

12
Specifications
BREAKER SIZING AND WIRING REQUIREMENTS
Before installation of this unit in any facility, always consult a licensed local electrician familiar with the requirements of properly wiring a welder into
the electrical supply. Refer to the National Electric Code (NEC) and local codes. If needed, refer the electrician to Article 630 of the NEC during consul-
tation to determine proper application and wiring needs. Use the I1MAX and the I1EFF ratings listed above to determine the proper breaker and con-
ductor (wire) sizing required. Everlast welders are designed around use in industrial wiring applications and are intended to be used with modern elec-
trical systems. Household wiring may need to be upgraded before this welder may be installed. Additional HF protection and isolation may be needed
if this welder interferes with the operation of electrical/electronic equipment. This unit should be operated only on a dedicated branch circuit.
IMPORTANT: Do not modify this unit’s wiring, power plug or conductors. This unit meets the standards for conductor sizing on the power cable and
takes into account power cable length, duty cycle and rated current.
NOTICE: POSSIBLE HF INTERFERANCE FROM THE INVERTER AND WHAT TO DO IF IT OCCURS
If any electrical disturbance is noticed as a result of the high frequency interference that is possible with the operation of the inverter switching and
operation, the HF service bolt should be connected directly to a 12 gauge wire that is bonded directly to an outside copper ground rod driven into
moist soil. Additionally, all metal items including any metal frame or sheeting of the building should be connected and grounded to separate copper
ground rods driven into the ground at 10 foot intervals around the perimeter of the building. This includes items such as tables, carts, rack material,
metal surrounds, etc. that may act as “antenna” to radiate/absorb HF energy. Additionally, all cords and welding leads should be twisted together and
run directly to the work without coils or excess cabling. Normally, this will not be required, but it is supplied in the case of any interference that may be
observed. This is usually observed in older or non standard installations where grounding and ground isolation is a problem. Normally this is not
needed, but if interference is observed, rst try relocating the welder and affected objects, and re-route welding cables. If operation is not improved,
contact an electrician to wire the ground and make proper ground connections to all metal objects.
NOTICE:
The unit is designed with several features and functions in common between processes. The principles of setup and operation carry over from one
process to another. In this case, information may not be repeated in detail in this manual if it has been discussed previously in another process.
NOTICE:
The unit is designed with several features and functions in common between processes. The principles of setup and operation carry over from one
process to another. In this case, information may not be repeated in detail in this manual if it has been discussed previously in another process.
WARNING!
Before turning the machine on for the rst time, make sure the voltage selector switch on the rear is set to the correct voltage or permanent damage
may occur. Correct voltage selection and wiring is the customer’s responsibility. Damage occurring from incorrect wiring or wrong voltage selection is

13
Specifications
PowerMTS Product Specications
Construction Type Inverter (IGBT based, Digital Control)
Input Voltage 240 V 1 Phase, 480V 3 Phase 50/60 Hz (Switched at rear.)
I1MAX Current Rating (Inrush Amps) 240V 1 ph / 480V 3ph 60A / 24A
I1EFF Current Rating (Rated Amps) 240V 1 ph / 480V 3ph 46A / 20A
OCV 70V
MIG Duty Cycle @ Rated Outputs (Rated at 40° C/104 F) 240V 1 ph: 60% @ 315A/29.8V, 100% @ 250A/26.6V
480V 3 ph: 60% @ 400A/34V 100% @ 315A/30V
TIG Duty Cycle @ Rated Outputs (Rated at 40° C/104 F) 240V 1 ph: 60% @ 300A/22V, 100% @ 250A/20V
480V 3 ph: 60% @ 400A/26V, 100% @ 310A/22.6V
Stick Duty Cycle @ Rated Outputs (Rated at 40° C/104 F ) 240V 1 ph: 60% @ 300A/32V, 100% @ 250A/30V
480V 3 ph: 60% @ 400A/36V, 100% @ 310A/32.4V
MIG Output Range V/A (DC Output Only) 240V 1 ph / 480V 3 ph 17-29.8V/60-315A / 17-34V/60-400A
TIG Output Range V/A (DC Output Only) 240V 1 ph / 480V 3 ph 10.8-22V/20-300A / 11.2-26V/30-400A
Stick Output Range V/A (DC Output Only) 240V 1 ph / 480V 3 ph 20.8-30V/20-300A / 21.2-36V/30-400A
MIG Wire Feeder Series (Detachable Type) FCS 203 (Non-water Cooled)
Spool and Push Pull Gun Capable Spool Gun Only. Use Parker DSP 360,
MIG Wire Feed Speed (No load) 240 1 phase/480 3 phase: 60-600/60-750 IPM , Set on machine as a percent 0-100%.
MIG 2T/4T Function Yes
MIG/ Stick Inductance (Arc Force) 0-10 (0-100% of range)
MIG Burn Back Time 0-2 Seconds
MIG Wire Size Handling Capability .030”-.062” (Recommend to add 24 gun option and blue
liner for .030-.035” wire.)
MIG Spool Size 12” (Up to 44 lbs.)
MIG Drive Roll Sizes Included .045”-.062” V-Groove (Installed). .030”-.035” V-Groove
Crater Voltage (Fill Voltage) 0-10 (0-100% of Available Voltage)
Crater Current (Fill Wire Feed Speed) 0-10 (0-100% of Available Voltage)
Pre/Post Flow Time Auto
Burn Back Voltage 0-10 (0-100% of Available Voltage)
Stick Arc Force 0-100% above set Amperage
Stick 6010 Capable Yes
TIG Start/ Torch Type Scratch Start with 26V (gas-valve) rigid neck torch
TIG Foot Pedal Capable No
MIG Gun Type/Length/ Connector Type North Series 36KD Series 10ft/ 3m w/ Euro Quick Connect
400A Work Clamp with Cable Length 10 ft (3m) DINSE 35/50 (1/2 nom. dia.)
400A Stick Electrode Holder Length 10 ft (3m) DINSE 35/50 (1/2” nom. dia.)
Power Output Adapter/Connectors DINSE 35 series (35/50mm2 or 35/70mm2)
Power Cable Length 6.5 ft (2m)
Power Plug Type for Single Phase Operation 240V Customer Supplied according to voltage input.
Cooling Type Full Time, High Volume Fan(s)
Dimensions (Approximate) 20” H X 11.25” W X 26” L (Power Source, not mounted)
Weight (Bare Power Source) 105 lbs.
Ingress Protection Rating IP21S
Duty Cycle
Duty Cycle is simply the amount of time out
of a 10 minute period in which the unit can
operate. For example, this unit has a duty
cycle of 60% at maximum output, that
means that the unit can be operated for 60
minutes out of 10 minutes. This is rated for
continuous or intermittent use during the
10 minute period of time. This rating stand-
ard (United States) is based on a maximum
ambient temperature of 40 C. Operating
above this point, or at lower temperatures
with high humidity may reduce the duty
cycle rating. Of course, the duty cycle will
increase somewhat as ambient temperature
and output Amps drops as well. Regardless,
the duty cycle is not controlled by a timer.
Rather, a heat sensor located on a heat sink
near the critical power components of the
welder signals overheat. If the operating
temperature of the unit is exceeded, weld-
ing output will stop and an over-
temperature warning light/error code will be
displayed on the screen. If a duty cycle
event occurs, do not turn the unit off!
Allow the welder to continue to run at idle
for at least 10-15 minutes until the temper-
ature has fallen enough to reset the sensor
and over-temperature warning light. Even if
the unit resets, allow the unit to cool for a
full 15 minutes, or the duty cycle will be
more quickly triggered since the unit resets
just below the heat threshold. The fan(s)
should be allowed to continue to cool for a
full 15 minutes without welding/cutting
activity after a duty cycle shut down has
occurred. After 15 minutes of cooling, you
may switch the unit off if you are nished
welding. If the unit does not automatically
reset after 15 minutes, turn the unit off.
Wait for 15 seconds before turning the
machine back on. If the unit does not reset,
contact technical support for further advice
and assistance. As a best practice, before
shut down, if you have been welding con-
tinuously for extended periods of time, keep
your unit on for 10 additional minutes to
allow it to cool down. The intentional and/or
repeated triggering of the duty cycle protec-
tion feature on this unit will shorten the
lifespan of the unit’s electronics and can
weaken internal components. Overheating
your unit repeatedly takes a cumulative toll
NOTICE:
The maximum output of the machine is reduced to when operating on 240V 1phase input power. For full power, use 480V 3 phase input power. See
above specications for more information.

14
Setup Guide
Getting Started
UNPACK YOUR UNIT.
Upon arrival, you will need to completely unpack your unit, and check
things over. This is a time sensitive matter. Do not delay or hold the
welder unopened in the box. Make sure the unit is opened from the
top. Be careful with using knives and sharp objects so you won’t cut
cords and cables inside the boxes. Lay all items out and inspect them.
The complete welder package arrives in separate boxes. Make sure no
boxes or parts are missing.
You should have the following in your box:
1. DC MIG/DC TIG/DC Stick Power Source (bare unit).
2. Wire Feeder (FCS 203) with gas/power umbilical (15ft).
3. PowerCart 400.
4. Floating Ball Regulator for MIG. (hose included but not pictured).
5. 36 Series MIG Gun/Torch. (MB36KD style).
6. 250A Work Clamp (approx. 9.5 ft with cable).
7. 250A Stick Electrode Holder (approx. 9.5 ft with cable).
8. Drive Rolls: .045” and .062” (1.2mm and 1.6mm)
9. 26V Gas Valve Torch (12.5 ft with cable).
INSPECT AND ASSEMBLE YOUR UNIT.
When you receive your package, inspect the unit for damage. Check for
the presence and general condition of the accessories. Some slight
rubbing or chafng of some of the accessories may be present, but this
is considered normal. Most notably, the MIG torch may appear to be
used or red. This is because it has been live tested in the factory for
proper operation before putting into the box. If any item is damaged or
missing, please inform Everlast within 72 hours of product receipt. See
pages 4 and 5 for more details.
First, assemble the cart with the main axle, casters, fasteners, washers
and cotter pins provided in the package. Use the separate cart manua
lfor assembly guidance. You will need to carefully lay the cart on its
side for assembly. Use a soft cloth or foam pad under the cart to pre-
vent scratching during assembly. The thumb screws in the cart pack-
age secure the welder to the cart from the bottom of the cart. The wire
feeder is secured via the swivel post on the top grab bar of the cart.
IMPORTANT! Do not overtighten the screws. If desired for proper t-
ment or for space saving, the unit may be used without the handle.
However, install the screws and tighten them to the panel anyway. Do
not leave them out. After 8 hours of use, check and retighten back plate
assembly, casters and axle assembly. Check and inspect the cart peri-
odically to ensure the undercarriage is tight and secure to the welder
and the wire feeder. A good time to check is during routine cleaning of
the unit.
POWER UP AND TEST YOUR UNIT.
You will need to fully assemble (install cart and wire feeder) and test the
unit as soon as possible. Within 72 hours after receipt of the unit, be
sure to have every thing you need at hand to test the unit. Make sure
the correct input power, wiring, and plug conguration is being used for
your input voltage. Make sure you have the regulator is installed (See
following section). Then, power up your machine without any accesso-
ries installed. Allow the unit to idle for 15 minutes. Check and observe
operation of knobs, controls and buttons, cycling through each as re-
quired. Make sure the fan is running at full speed. After the static run-
NOTICE:
This unit includes an additional MIG contact tip, but does not contain
any other MIG consumables, including ller (MIG or Flux-Cored) wire.
Additional sizes of contact tips, nozzles and basic gun parts are availa-
ble direct from Everlast’s website, from other online sources and from
select local welding supply stores that carry parts for similar MB36KD
styled MIG guns. Some miscellaneous parts like a contact tip wrench
may be found in the box, depending upon your region. Filler (MIG
and Flux-Cored) wire should be purchased locally or direct from other
online sources. Other drive roll sizes and types should be purchased
direct from Everlast. The included drive roll is a V groove drive roll,
designed for solid steel wire. Depending upon the region/country
where purchased, drive rolls for flux core or aluminum use, must be
purchased separately. Flux-Cored wire will have a serrated or zippered
appearance in the groove. The Flux-Cored Drive rolls are indicated by
an X or K letter after the size. Aluminum drive rolls will have a U-
groove shape. Make sure you are ordering 4 roll kits designed to t
the FCS 203 feeder. They differ from other 4 roll kits used in self-
contained wire feeder units where the feeder is located in the housing
of the welder itself.
If you are considering using .030” or .035” wire, you should purchase
the 24 series gun in addition to the supplied 36 series. You will need
to order a blue liner to go with the 24 gun as well. This will feed wire
better and arc performance will be much improved and will provide
good performance up to 240A for short circuit or light spray arc use.
The 36 gun, as supplied, is designed primarily for heavy weldments
that require spray arc welding. A different combination of consumables
will be required to improve short arc performance with the 36 gun.
NOTE: If you think you are missing a needed part, check the consum-
able kit bag and related packaging before calling Everlast for replace-
ment. If you are missing parts, call 1-877-755-9353 ext. 206 for help.
1
2
5
3
PowerMTS 400
4
6
8
7
9

15
ning test is completed, turn the unit off, connect the torches and
cables. Then, conduct live testing of all the functions and features of
the machine. For testing make sure work clamp is connected directly
to the part being welded (work). Check for arc starting and stability. If
any welding problems are observed and persist, contact Everlast.
However, before you contact Everlast double check that polarity is
correct for the process being used. Improper polarity will result in
poor welding performance, and in some cases, can result in no arc at
all. See page 5 for more contact information. NOTICE: Cosmetic
damage claims after 30 days will not be accepted, unless Everlast is
contacted and informed of such delay and reason for such a required
delay (i.e. Overseas, or while on deployment with the armed services
etc.).
GIVE YOUR UNIT SOME SPACE TO COOL.
This unit needs room to cool itself and maintain proper duty cycle.
Place the unit in a place that will allow 18” from all sides to allow for
proper cooling. This welder pulls air in from the rear, and pushes it
through the unit’s heat sinks to cool the electronics. The air is then
exhausted through the front panel and side louvers of the unit. If any
of sides is blocked or restricted, the duty cycle will be reduced, and
overheating will occur, leading to possible damage if the restriction is
severe enough. Never attempt to restrict air flow by attaching lters
to the vents or by modifying your fans for “on demand” service. If the
sound from the welder fans diminish or become non existent, check
fans for proper operation. If, over time, you suspect one or more of
the fans are not working, discontinue use until the unit can be re-
paired to prevent damage to the machine. One fan not working will
cause duty cycle to drop drastically. If your duty cycle warning ap-
pears unexpectedly, and continues to do so, contact Everlast tech
support for help on checking fan operation and diagnosing the cause.
CONNECT YOUR UNIT TO POWER.
WARNING: Before connecting your unit to power, be sure to select
the appropriate power input via the switch on the rear of the welder.
This unit is designed only to operate on either 1 phase 240V or 3
phase 480V. It can be operated on a 3 phase 240V system, however,
if you only use two of the balanced power legs and do not use the
high (wild leg) of power. Single phase use will cause a higher Amp
draw however.
Your unit has been shipped without a power plug. This is because it
is both single 240V and three phase 480V capable. For 240V 1 phase
use, we suggest that you select the NEMA 6-50P. This is the standard
plug used for 240V 1 Phase welders in North America. The red wire
will not be used. It should be taped up and stored out of the way. It
is also important to understand that welders do not require or need a
neutral by code. However, the welder does always need to be
properly grounded via the green wire. Black and white wires in a 1
phase 240V welder circuit are always used as the “Hot” wires, which
measure 120V to ground and 240V phase to phase. Always consult a
licensed electrician before making any electrical connection on this
unit. Never modify or attempt to rewire this unit in any way.
If you are using on 480V 3 phase, all wires will be used, including the
red wire. Use the red wire for the “High leg” input. Since there is no
standard for 480V 3 phase welder plugs and design, amp rating and
Setup Guide
Getting Started
Standard Plug Conguration 1 Phase 240V
Selecting A Breaker and Wire Size
Select a breaker based off of the I1MAX rating of this unit. This is the
maximum inrush current of the unit. The inrush is not a sustained
current. The I1EFF rating of the unit is the maximum “rated” current
of the machine. When combined with the length of the run from the
main panel, this determines the conductor size. Refer your licensed,
local electrician to Article 630 of the NEC and the specication page
of this manual (or the specication grid printed on your unit) to select
the correct breaker and wire size. A delayed trip breaker, or slow
blow fuse should be used with this unit.
conguration can vary, consult with a licensed electrician before mak-
ing any attempt to wire or connect your unit.
The unit should be used on a dedicated circuit and should not share
operation of another device on the same breaker.
.
NEMA 6-50P
Standard Wire Conguration 3 Phase 480V
IMPORTANT!
Select input voltage via the switch located on the lower rear
of the welder before connecng the power or damage may
occur to the unit.

16
Setup Guide
Getting Started
CONNECT YOUR UNIT TO THE CORRECT SHIELDING GAS
Carefully lift and install the gas cylinder onto the welder back deck
plate while safety cap is still on. Use the supplied safety chain to
secure the cylinder to the cart as tightly as possible. Once the cylinder
is installed, it may be uncapped when ready for use. Before connect-
ing any cylinder, stand to the side of the cylinder valve, making sure
you are away from the discharge side opening. Then, quickly open
and shut the cylinder valve giving it a quick blast. This will dislodge
any dirt or particles stuck in the valve or the connection seat. This will
help reduce the chance of dirt particles making its way into the sole-
noid valve, causing sticking issues later on in service.
Connecting your cylinder will require a cylinder wrench (1 1/16”)to
connect the regulator to the cylinder (North American Cylinders with a
What Shielding Gas Should Be Used?
The following gases should be used and are the best choices in the
gas selection during initial setup after powering the unit up:
MIG Steel Short Circuit: 75%/25% Ar/CO2 (75/25 or C25) OR 100%
CO2 (C100)
MIG Steel Axial Spray: 90%/10% Ar/CO2 (90/10 or C10) or similar
less than 20% CO2 with balance being Argon.
MIG Stainless (Inox): Short Circuit OR Spray 98%/2% Ar/CO2
(98/2 )
MIG Stainless Short Circuit Only: He/Ar/CO2 ((Stainless TriMix)
MIG: Aluminum or Brazing: 100% Ar ( Argon)
All TIG: 100% Ar (Argon)
Notice that Steel has a couple of gas choices. In the North American
Market, 75/25 is the standard gas choice for short circuit MIG and
Gas Shieled Flux-cored welding. It provides less spatter than CO2
and a cleaner, less oxidized weld in general. 100% CO2 is cheaper,
but can require more cleanup and descaling after the weld is com-
pleted. In other markets, 100% CO2 is more commonly available, or
may offer slightly different combinations. If 75/25 gas mix is not
available for use and 80/20 is an option, then this gas may be used
on the 75/25 setting. Any gas less than or equal to 20% CO2 is
generally considered suitable for Axial Spray welding.
Stainless gas mixes can range throughout the industry. However, in
the industry. this unit is designed to be used with 98/2 Ar/CO2 blend
when welding Stainless Steel. While there are other gas choices,
such as “TriMix” with He, Ar and CO2, this is typically the most wide-
ly available and economic one for welding Stainless Steel (Inox).
MIG Aluminum and MIG Brazing will always require the use of pure
Argon (100% Ar) shielding gas while welding in MIG mode. This is
a widely available and a standard gas throughout the world.
TIG uses Argon for all metals. Never accept any other gas for DC
TIG welding.
580 CGA valve). If you do not have a cylinder wrench, an adjustable
type wrench will work, but make sure it is properly adjusted to pre-
vent rounding of the tting shoulders. Do not use pliers, or a serrated
-jawed wrench such as a pipe wrench to tighten the tting. The de-
sign of the tting means that no thread sealing tape or compound
needs to be used.
Connect the supplied tubing to the regulator. Tighten with two
3/4” (19mm) wrenches to hold both the regulator and the tubing
connection at the same time. Hold counter pressure on the regulator
connector while tightening the hose tting to prevent damage to the
regulator. After connecting the tubing to the regulator, connect the
other end of the tubing to the 5/8” CGA tting on the welder. Hold
the tting on the unit with one 3/4” (19mm) wrench rmly while
tightening the hose tting with another 3/4”(19mm) wrench. NOTE:
Some regulators use an 11/16” (17mm) tting.
Important: Do not use thread tape or pipe sealant on any cylinder,
regulator or unit connection. The residue and debris may get into the
gas solenoid and cause operational issues.
Connect Regulator To Cylinder And Unit.
CAUTION!
Do not tighten the rear unit connection without holding the female
5/8 CGA tting located on the back of the welder with a wrench, or
damage may occur to the solenoid, housing or tting as the tting
may turn in the housing while the hose tting is being tightened.
WARNING!
Always wear safety glasses and gloves when changing a gas cylin-
der. Always use safety chains to secure the cylinder to the welder.

17
CONNECT THE UMBILICAL TO THE WIRE FEEDER .
The wire feeder controls all wire feed operations and is connected to the
unit via the umbilical cable which is provided which provides separate
connections for the gas (#1), control (#2) and power connections (#3).
The umbilical is connected directly to the connections on the front of the
power source and to the rear of the wire feeder. The main power cable
connects via the DINSE type connector on the front and is bolted to the
copper lug on the rear (#3). The copper lug identies which in should be
connected. It should be fully tightened, but not over torqued to prevent
stripping of the connection bolt. Make sure the strain relief (#4) is installed
properly to secure the umbilical to the feeder. Only use hand tools to com-
plete the connection of both the power cable and the gas line. Use two
wrenches when tightening the gas line to the wire feeder. Use only nger
pressure to tighten the control cable to the wire feeder and the welding
power source. NOTICE: The power connection can be placed in either the
positive (+) or the negative (-) DINSE type terminal on the front of the
machine. The exact location is determined by process and recommended
polarity. See next page for general wire feed polarity recommendations.
Use the guide below to make the proper connections before using with the
wire feeder. The wire feeder may be used or mounted separately without
the cart. Longer cables are available up to 50 ft as an option if the wire
feeder needs to be detached from the cart. If the feeder is being used but
is not mounted to the cart, secure the feeder so it cannot be turned over.
Be sure to inspect the gas line portion of the umbilical upon installation for
leaks and tighten all ttings. Periodically recheck for leaks caused by abra-
sions caused by moving the welder and for holes created by welding.
CONNECTING THE WIRE FEEDER TO THE POWER UNIT.
Setup Guide
Getting Started
12
3
OR
3
1
2
4

18
SELECT THE CORRECT TORCH SETUP AND POLARITY.
The polarity of the welder is controlled on the main unit via the DINSE type
connectors. These connectors that can be used are the DINSE 35/50mm2
or the DINSE 35/70mm2 style connectors. The both have the same diame-
ter connecting pin, but the cable size that the connector is capable of ac-
cepting are different.
To change the welder’s polarity, simply swap the cables on the main pow-
er source. This includes the wire feeder cable when switching from MIG to
Gasless Flux-Cored wire.
NOTICE: For MIG and wire feed applications the wire feeder will connect
directly to the power source via an umbilical cable (provided) and the gun
will connect to the wire feeder. The work clamp will connect directly to the
power source. The wire feeder is designed to be mounted directly to the
PowerCart 400. However it may be used independently from the cart if
precautions are taken to secure the feeder from overturn and moving. For
all other applications the torch cables and the work clamp will connect
directly to the power source.
See the general torch polarity recommendations below. These are the
normal congurations for each process. But with wire feed operations and
with stick, polarities may vary from what is listed. Conrm the recom-
mended torch polarity with the maker of the ller metals (consult packag-
ing paper work or box of ller metals or manufacturer’s website for more
information) as occasionally there are exceptions based off of application.
GMAW (MIG, INCLUDING SPOOL GUN/ALUMINUM): Connect wire feeder
to Positive (+), Work Clamp is connected to Negative (-). The Spool gun
uses the same conguration when being used for welding Aluminum,
Stainless and other solid wire metals.
FCAW (Self Shielded Flux-cored): Connect wire feeder to Negative (-),
Work Clamp is connected to Posititve (+). For gasless, self shielded flux
cored wire use, purchase a flux-cored gun. Do not attempt to use the
standard gun unless operating briefly. Performance with the stock gun will
be limited Everlast does not offer a flux-cored gun. This must be pur-
chased aftermarket. The use of aftermarket guns does not affect warranty.
FCAW-G (Gas Shieled Flux-cored): Connect Flux-Cored Gun to Positive
(+), Work Clamp is connected to Negative (-). The standard gun provided
with the welder may be used with this unit with Gas shielded Flux Cored
wire (also called “Dual-Shielded” wire).
GTAW (TIG): Connect the gas-valve TIG torch to Negative (-), Work Clamp
is connected to Positive (+). The gas valve TIG torch is operated direct
from the Regulator.
SMAW/MMA (Stick): Connect the stick electrode holder to Positive (+),
Work Clamp is connected to Negative
CAC-A (Air Carbon Arc Gouging): Connect gouging torch to Positive (+),
Setup Guide
Getting Started
POLARITY FOR SOLID WIRE MIG / GAS SHIELDED FLUX-CORED WIRE
WORK CLAMP
WORK
MIG GUN
POLARITY FOR GASLESS FLUX-CORED WIRE
WORK CLAMP
WORK
FLUX-CORED GUN

19
Setup Guide
Getting Started
POLARITY FOR STICK/MMA
WORK CLAMP
WORK
STICK ELECTRODE HOLDER
WARNING!
Do not leave MIG/Wire Feed gun connected while welding other pro-
cesses and remove all torches and accessories while welding wire feed
processes. Disconnect all ttings and connections relating to the other
welding processes. The power source terminals remain live while weld-
ing other processes. This can lead to accidental arcing and damage to
the components and machine. It can also lead to accidental arc flashing
of the eyes and burns, shock and injuries to the body. Damage done to
the welder from leaving the other accessories and torches connected
while welding that are not required for use with the selected process
will not be covered under warranty!
POLARITY FOR CARBON ARC GOUGING
WORK CLAMP
WORK
CARBON ARC TORCH
TO AIR COMPRESSOR
POLARITY FOR TIG
WORK CLAMP
WORK
GAS VALVE TIG TORCH
TO REGULATOR
NOTE: Carbon arc gouging torch, and
necessary connections are supplied by
customer. It is not sold by Everlast.
NOTE: TIG torch connects direct to the
regulator. Fittings to connect TIG torch
directly to the Regulator are not included.
Customer should purchase fittings sepa-
rately at time of purchase, or source
locally. Some adaptation of the gas fitting
may be required.
NOTE: Some electrodes are able to be
run with electrode negative polarity,
but this is typical configuration of
most all rods. Some specialty rods
may only be run electrode negative.
Check with electrode manufacturer.

20
Setup Guide
Getting Started
CHECK AND CHANGE YOUR DRIVE ROLL.
The unit comes with a pair of .045” and .062” drive rolls installed. Re-
member, if you change wire size or type, you will need to either flip both
of the lower drive rolls over for the opposing size or completely change
both of the drive rolls out with the ones of correct size and type that are
sold as options (The change of wire diameter will also require change of
gun and/or liner). When not in use, keep these “spares” put up where
moisture and dust cannot get to them. They will rust if not used and
stored properly.
The top drive rolls are actually idler rolls used to hold tension and keep
the wire in the groove. These are not changeable. Only the bottom drive
rolls needs to be changed. Each of the bottom drive rolls have two small
grooves that are sized for .045” (1.2mm) and .062” (1.6mm) solid wire.
Additional sizes and types of drive rolls are available as options. The
standard installed drive roll is meant to feed hard (solid) steel wire. The
groove on this drive roll has a “V” shape designed for the solid wire. A
Flux-Cored drive roll has a serrated edge to the groove, which grips the
softer, cored wire. Viewing a flux-core drive roll from the top, you will see
a “zipper” like pattern. It will be designated by either an “X” or a “K” stamp.
This should never be used to feed hard steel, stainless or aluminum wire.
This will result in damage to the wire, metal flaking and possible plugging
of the MIG gun liner. To determine the exact size of wire and type you
have, look at the side of the drive roll. The size of the drive roll groove is
stamped on the side of the drive roll. The size of wire is on the opposite
side from the groove. This means the size faces out toward the user for
quick I.D. The type of the drive roll will also be stamped with a “V” if it is
for solid, hard wire. If it is stamped with an “U”, this is a special drive roll
for feeding aluminum wire. Aluminum wire is best fed with a spool gun.
The drive rolls are held in place by thumb screws. Use a nger pressure
to gently remove the screws to expose and change the drive roll. The
drive rolls are mounted with a key and keyway. When removing the drive
rolls, make sure that the square locating key are not dismounted. Keep on
nger on the key to prevent it from sliding out with the drive roll. If the key
falls out of the keyway, replace it before replacing the drive roll. If it does
not stay in place use a small amount of grease on the key to hold the key
in place. When the drive roll is reinstalled, just lightly snug the thumb-
screws with ngertip pressure. Wipe off excess grease before using.
INSTALLING THE WIRE SPOOLS.
The wire feeder is designed to accept up to 12” diameter rolls, normally
up to 44 lbs. For heavier rolls, install and test for free rotation without
sagging or bowing of the support arm and carrier bolt . To remove or
install a wire spool: Open clamshell (#1). Remove the spool retaining nut
(#2). Flip down both tensioners so that upper drive roll arms raise (#3).
Install wire spool on carrier with wire feeding from the bottom and rotating
counter clockwise(#5). Replace spool retaining nut (#2). Feed wire
through drive roll grooves and 6 inches into gun connector (#4). Lower
drive roll arms and return tensioners to the upright position (#3). See MIG
gun consumable and parts below: Remove gas nozzle and contact tip.
Using inching button or gun trigger, feed wire until it exits the end of the
gun about 4 inches (#6). Reinstall tip and nozzle over wire.
DRIVE ROLL SIZE AND LOCATION
4
5
4
5
INSTALLING THE WIRE SPOOL
MIG GUN CONSUMABLES AND PARTS
M8
Contact Tip Diffusor
Gas Nozzle Contact Tip
Holder
Gun Neck
Size
Tensioners
Drive Roll (X 2)
Wire Grooves
NOTE: Illustration immediately below is simplied for clarity and detail.
Wire
4
5
4
5
23
5
1
5
5
2
3
4
6