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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).
PowerMTS 400
3
1
8
9
5
7
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 chaffing of some of the accessories may be present, but this
is considered normal. Most notably, the MIG torch may appear to be
used or fired. 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 fit-
ment or for space saving, the unit may be used without the handle.
Setup Guide
Getting Started
2
4
6
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.
This unit includes an additional MIG contact tip, but does not contain
any other MIG consumables, including filler (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 fit
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.
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 configuration 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-
14
NOTICE:
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