GT POWER GT200W User manual

GT200W PROFESSIONAL WELDER GENERATOR

GT200W PROFESSIONAL WELDER GENERATOR
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Congratulations on your new GT Power product!
The GT Power range from Euroquip uses latest technology design and
engineering to produce generator products that combine market leading value
and features with durability. Designed for discerning operators who seek
professional results and product quality. Design emphasis is placed on simple,
functional design and operation. GT Power products are subject to stringent
quality control and designed and manufactured to NZ & Australian standards.
Euroquip is a market leading provider of innovative power equipment solutions
to a wide range of industries across New Zealand and Australia. Key product
categories are; welding equipment, air compressors, power generators and
cleaning equipment.
Euroquip’s slogan is ‘empowering industries’, nd out more about the advantage
Euroquip brings at www.euroquip.co.nz.
Providing exceptional product support is a key component of Euroquip’s market
leading customer advantage focus. As part of this program, it is required for all
products to be registered with Euroquip to qualify for product support. Products
not registered with Euroquip are supported by a base 12 month warranty only.
Spare parts and technical support will not be available for an unregistered
product outside of this base warranty period. If a Euroquip dealer has not
already registered your product, please register it online at www.euroquip.
co.nz. To request a physical registration form, please download one at www.
euroquip.co.nz under the ‘Contact Us’ tab.

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Contents
Specications.....................................................................5
General Operation ...............................................................6
Features & Controls................................................................9
Installation............................................................................10
Generator Usage...................................................................11
General Operation.................................................................11
Welder/GeneratorControls....................................................12
Engine Operation...................................................................13
Welding Operation.................................................................14
Auxiliary Power Operation......................................................15
Electrode Selection Guide......................................................16
Power Applications................................................................17
Basic MMA Welding Guide.....................................................18
MMA Welding Techniques......................................................19
Other Knowledge and Resources...........................................22
MMA Troubleshooting............................................................23
Accessories..........................................................................24
Engine Maintenance..............................................................25
Troubleshooting........................................................27
Wiring Diagram.....................................................................30
Safety Instructions.................................................................31
Warnings......................................................................33
Warranty................................................................................37

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The heavy duty 18L fuel tank and the industrial quality of
the GT200W will keep you welding all day. With all the
unique GT POWER features like industrial air cleaner &
muer system - for cleaner quieter operation, superior
quality alternator & automatic voltage regulator (AVR) - for
more stable power and welding output. Also features low
oil alert with automatic engine shutdown.
The GT200W features electric start with a recoil back-up,
this makes for a super reliable workhorse. With a dual
welding/generating function it will provide years of
exceptional performance in the eld or in the workshop
with a welding duty cycle of 60% @ 180 amps.
This machine is equipped standard with an industrial
fully-welded tube frame and wheel kit, making it robust
and portable - ready for any task.
• 200A,75VWeldingpower
 5000W(rated),5500W(max)Generatorpower
• Powerdyne4stroke,14HP,420CC,aircooled,OHV 
industrial engine
• Electricstartwithrecoilbackup
• 1x32AMonstersinglephaseoutletwithadaptercord
• 18Lfueltankforupto8hoursruntime
• Arcandearthleadsincluded(3&4m)
• Willrun1.6-5.0mmelectrodes
• 97dB
• 96kg
GT200W
5500W
200A 5000W 97 18L 196kg780 x 545 x 6328hrs
75V
OPEN CIRCUIT
VOLTAGE
WELDING GENERATING
9 Inch 1.6 - 5.0mm
Electrodes

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Specifications
INPUT - GASOLINE ENGINE
Make/Model: Powerdyne 14HP
Description: 1 Cylinder, 4 Cycle, Air-Cooled Gasoline
14HP @ 3600RPM, Aluminium Block
Speed: (RPM) 3000RPM
Displacement: 420CC
Ignition System: Recoil Start, Electric Start, Manual Choke,
Electronic Ignition
Capacities: Fuel: 18L, Oil: 1.1L
RATED OUTPUT - WELDER
Amps @ DC Constant Current: 200A
Duty Cycle: 60% @ 180A
Volts@ Rated Amperes: 26V Max. Output
OUTPUT - WELDER & GENERATOR
Welding Ranges: 50 - 200A DC
Welding Open Circuit Voltage: 75 V DC Max.
AC Auxiliary Power: 5500W Max.,5000W Continuous,
230V Single Phase
OTHER
Dimensions: 780 x 545 x 632mm
Weight: 96kg
Operating Temperature Range: -18oto 40oC
Storage Temperature Range: -40o to 55oC

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Safety
Read this entire installation section before
you start installation. More information on
safety procedures at the rear of this manual.
General Operation
The GT200W is designed for commercial use
welder/generator applications. As a welder
it provides 200A of DC constant current for
welding with DC stick electrodes. A single dial
lets you select a full range of welding output
from 50 to 200A.
As a generator it can supply up to 5500 surge
watts or 5000 continuous watts of 230 volt,
single-phase AC power. The machine is port-
able.
Recommended Applications
WELDER: The GT200W provides excellent
constant current DC welding output for stick
(SMAW) welding.
GENERATOR: The GT200W gives smooth
AC generator output for continuous auxiliary
power usage within the engine manufacturerʼs
required maintenance recommendations.
Operational Features & Controls
The GT200W was designed for simplicity.
Therefore, it has very few operating controls.
The welder/generator automatically senses
whether generator or welding function is re-
quired. No manual change is needed.
The gasoline engine controls include a recoil
starter, choke and stop switch. See the EN-
GINE OPERATION section of this manual for
details about starting, running, stopping, and
breaking in the gasoline engine.
Design Features & Advantages
• 200A DC constant current welding for
stick electrodes.
• Lightweight / portable.
• Full range, continuous welding output
control with a single knob.
• Five function hour meter.
• 5500 Surge Watts or 5000 Watts of
continuous 230V single phase AC
auxiliary power.
• Powerdyne 14HP overhead valve air-
cooled gasoline engine. Smooth running,
long life.
Welding Capability
The GT200W is rated at 180A, 26VDC at
60% duty cycle on a ten-minute basis. This
means that you can load the welder to 180A
for six-minutes out of every ten-minute pe-
riod. The machine is capable of higher duty
cycles at lower output currents.
The current is continuously variable from 50 to
200A DC. The GT200W can, therefore, weld
with 1.6, 2.5, 3.2, 4.0 and 5.0mm diameter
electrodes.
Limitations
• The GT200W is not recommended for
any processes besides those that are
normally performed using stick welding
(SMAW) procedures.
• The GT200W is not recommended for
pipe thawing.
• The generating function is never to be
used while welding is in process.

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WARNING: Do not attempt to use this
equipment until you have thoroughly
read all operating and maintenance
manuals supplied with your machine.
They include important safety precau-
tions, detailed engine starting, operat-
ing and maintenance instructions, and
parts lists.
Hazards of Electric Shock, Engine
Exhaust & Moving Parts
ELECTRIC SHOCK can kill.
• DO NOT touch electrically live parts
or electrode with skin or wet clothing.
• Insulate yourself from work and ground.
• Always wear dry insulating gloves.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or vent
exhaust outside.
• Do not stack anything on or near the
engine.
MOVING PARTS can injure.
• Do not operate with doors open or guards
off.
• Stop engine before servicing.
• Keep away from moving parts.
Only qualied personnel should install, use,
or service this equipment.
Location & Ventilation
Whenever you use the GT200W, be sure
that clean cooling air can ow around the
machineʼs gasoline engine and the genera-
tor. Avoid dusty, dirty areas. Also, keep the
machine away from heat sources. Do not
place the back end of the generator any-
where near hot engine exhaust from another
machine. And of course, make sure that en-
gine exhaust is ventilated to an open, outside
area.
The GT200W must be used outdoors. Do not
set the machine in puddles or otherwise sub-
merge it in water. Such practices pose safety
hazards and cause improper operation and
corrosion of parts.
Always operate the GT200W with the case
roof on and all machine components com-
pletely assembled. This will help to protect
you from the dangers of moving parts, hot
metal surfaces, and live electrical devices.
CAUTION:
GASOLINE FUEL ONLY - Use in well
ventilated areas or vent exhaust outside
Storage
1. Store the machine in a cool, dry place
when it is not in use. Protect it from dust
and dirt. Keep it where it can not be acci-
dentally damaged from construction activ-
ities, moving vehicles and other hazards.
2. If you will be storing the machine for over
30 days, you should drain the fuel to pro-
tect fuel system and carburetor parts from
gum deposits. Empty all fuel from the tank
and run the engine until it stops from lack
of fuel.
3. You can store the machine for up to 24
months if you use a stabilising additive in
the fuel system. GT Power endorses Fuel
Set™ as the recommended brand of fuel
stabiliser to use and it is available from
your local GT Power Dealer. Mix the ad-
ditive with the fuel in the tank and run the
engine for a short time to circulate the addi-
tive through the carburetor.

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4. While the engine is still warm, drain the oil
and rell with fresh 10W30 oil.
5. Remove the spark plug and pour approx.
1/2 ounce (15ml) of engine oil into the cyl-
inder. Replace the spark plug and crank the
engine slowly to distribute the oil.
6. Clean any dirt and debris from the cylinder
and cylinder head ns and housing, rotating
screen, and mufer areas.
7. Store in a clean, dry area.
8. GT200W machines CANNOT be stacked.
Tilting
Place the machine on a secure, level surface
whenever you use it or store it. Any surfaces you
place it on other than the ground must be rm,
non-skid, and structurally sound.The gasoline
engine is designed to run in a level position for
best performance. It can operate at an angle, but
this should never be more than 15 degrees in any
direction. If you do operate it at a slight angle, be
sure to check the oil regularly and keep the oil
level full. Also, fuel capacity will be a little less at
an angle.
Lifting
The GT200W should be lifted by two people.
Pre-Operation Engine Service
Read and understand the engine operating and
maintenance instructions supplied with this ma-
chine before you operate the GT200W
Oil
The GT200W is shipped without engine oil. ADD
OIL BEFORE YOU START THE ENGINE (Ap-
prox. 1100ml). Do not screw in dipstick when
checking oil level. DO NOT OVERFILL. Be sure
the ll plug is tight after servicing.
Fuel
Fill the fuel tank with clean, fresh, regular grade
(minimum 91) octane lead free gasoline. DO
NOT MIX OIL WITH GAS. The GT200W capac-
ity is approximately 18L. DO NOT OVERFILL,
allow room in the fuel tank for fuel expansion.
WARNING:
• Keep hands away from mufer or
HOT engine parts.
• Stop the engine when fueling.
• Do not leave unattended while fueling
• Do not smoke when fueling.
• Remove fuel cap slowly to release
pressure.
• Do not overll tank.
• Wipe up spilled fuel and allow fumes
to clear before starting engine.
• Keep sparks and ame away from
tank.
• Close fuel shut-off valve when
transporting or not operating machine.
Spark Arrester
Some state or local laws may require gasoline
engines to be equipped with exhaust spark
arresters when they are operated in certain lo-
cations where unarrested sparks may present
a re hazard.
The standard mufer included with this ma-
chine comes equipped with a spark arrester.
CAUTION:
An incorrect additional arrester may lead
to damage to the engine or adversely af-
fect performance.

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Features & Controls
Read this Operating Manual and the Safety Rules section before operating. Compare the
illustrations with your machine, to familiarise yourself with the locations of various controls
and adjustments. Save this manual for future reference.
1. Fuel Tank
2. Fuel Tank Cap
3. Wheel
4. Lead Acid Battery
5. Oil Filler Plug (Obscured)
6. Oil Drain Plug
7. Handle
8. 24A Circuit Breaker
9. Engine Ignition Switch
10. 5 Function Hour Meter
11. 32A Single Phase Receptacle
with 15A Adapter Cord
12. Anti-Vibration Rubber Feet
13. Welding Current Control 50 - 200A
14. Welding Output Terminals
15. Ground Terminals (Obscured)
16. Low Oil Warning Light
17. Fuel Tap
18. Air Filter (Obscured)
19. RCD (Residual Current Device)
2
4
3
7
12
110
5
8
14
9
15
6
13
16
17
11
18
19

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Installation
Cable Installation
Install the welding cables to your GT200W as
follows. See the previous page for the loca-
tion of parts.
1. The gasoline engine must be OFF to in-
stall welding cables.
2. Connect the electrode holder and work
cables to the weld output terminals. Nor-
mally, the electrode cable is connected to
the positive (+) output stud.
4. Push in and turn to secure welding cables
to welding sockets
5. Be certain that the metal piece you are
welding (the “work”) is securely connected
to the work clamp and cable.
6. Check the connections periodically.
CAUTION:
• Loose connections will cause the
output studs to overheat and the
studs may eventually melt.
• Do not cross welding cables at out
put stud connection. Keep isolated
and separate from one another.
For more information on welding, see WELD-
ING OPERATION in the OPERATION sec-
tion of this manual.
Machine Grounding
Because this portable engine driven welder
or generator creates its own power, it is not
necessary to connect its frame to an earth
ground, unless the machine is connected to
premises wiring (your home, shop, etc.).
To prevent dangerous electric shock, other
equipment to which this engine driven welder
supplies power, must:
a) be grounded to the frame of the welder
using a grounded type plug, or
b) be double insulated.
When this welder is mounted on a truck or
trailer, the machine grounding stud must be
securely connected to the metal frame of the
vehicle.
In general if the machine is to be grounded, it
should be connected with a #8 or larger cop-
per wire to a solid earth ground such as a
metal water pipe going into the ground for at
least ten feet and having no insulated
joints, or to the metal framework of a building
which has been effectively grounded.
A machine grounding stud marked with the
symbol is provided on the front of the welder.
WARNING:
Do not ground machine to a pipe which
carries explosive or combustible mate-
rial.
Plugs and Hand Held Equipment
For further protection against electric shock,
any electrical equipment connected to the
generator receptacles must use a three-
blade, grounded type plug or an approved
double insulated tool with a two blade plug.
WARNING:
Never operate this machine with dam-
aged or defective cords. All electrical
equipment must be in safe operating
condition.
Auxiliary Power Receptacles
The control panel of the GT200W features
a single “Monster” 32A single phase auxilliary
power outlet with a 15A adapter cord. This al-
lows maximum generator output (24A max.)
through a single plug and the ability to run
large powertools without tripping the circuit

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Circuit Breakers
Auxiliary power is protected by circuit break-
ers. When the machine is operated in high
temperature environments, the breakers may
tend to trip at lower loads than normally.
CAUTION:
Never bypass the circuit breakers.
Without overload protection, the unit
could overheat and/or cause damage
to the equipment being used.
breaker. Items could include a large angle
grinder or welding machine up to 180A. The
machine output voltages meet UL standards
and fall within ± 10% of the rated voltage.
Premises Wiring
The GT200W can be used for xed installa-
tion or premises wiring. Please consult a reg-
istered electrician for advice and refer to RCD
in the Welder/Generator Controls section in
this manual for more information.
Generator Usage
Euroquip is not responsible for any damage to electrical
components improperly connected to this product.
These devices require a large current
when starting. (See GENERATOR
POWER APPLICATIONS in this Opera-
tion section of this manual for required
starting wattages.)
Some synchronous motors may be fre-
quency sensitive to attain maximum out-
put torque, but they SHOULD BE SAFE
from any frequency induced failures.
Voltage spikes or high voltage regulation
can cause the capacitative elements to
fail. Surge protection, transient protec-
tion, and additional loading is recom-
mended for 100% fail-safe operation. DO
NOT RUN THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE TYPE LOADS.
Single-phase induction motors,
drills, well pumps, grinders, small
refrigerators, weed and hedge
trimmers.
TYPE:
Resistive
COMMON ELECTRICAL DEVICES: POSSIBLE CONCERNS:
NONE
Heaters, toasters, incandescent light
bulbs, electric range, hot pan, skillet,
coffee maker.
TV sets, radios, microwaves,
appliances with electrical control.
Computers, high resolution TV sets,
complicated electrical equipment.
An inductive type line conditioner along
with transient and surge protection is
required, and liabilities still exist.
DO NOT USE THESE DEVICES
WITH THIS PRODUCT.
Capacitive
Inductive
Capacitive /
Inductive

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Welder / Generator Controls
All welder/generator controls are located on the Output Control Panel.
1. CURRENT CONTROL DIAL:
Adjusts continuous current output. The amps
on the dial correspond to the approximate
amps needed for welding electrodes.
2. 24A CIRCUIT BREAKER:
Provides overload current protection for the
230V Receptacles
3. WELD POSITIVE OUTPUT TERMINAL:
Provides the connection point for either the
electrode holder or the work cable. (Because
the GT200W is a DC output machine, either
output terminal can be used for either cable.)
4. WELD NEGATIVE OUTPUT TERMINAL:
Provides the connection point for either the
electrode holder or the work cable. (Because
the GT200W is a DC output machine, either
output terminal can be used for either cable.)
5. GROUND STUD:
Provides a connection point for connecting the
machine case to earth ground for the safest
grounding procedure.
6. 32A SINGLE PHASE RECEPTACLE
WITH 15A ADAPTER CORD:
Connection point for supplying 230 volt
power to operate one electrical device.
7. 5 FUNCTION DIGITAL OUTPUT METER:
Displays important information when
operating generator. Press mode change
button to display different functions:
- Output voltage in volts (V)
- Output current in amps (A)
- Output power in watts (W)
- Output frequency in hertz (Hz)
- Total operating hours (H)
8. IGNITION SWITCH & KEY
9. RCD (RESIDUAL CURRENT DEVICE):
Disconnects power output when the RCD
detects leakage current in the load greater
than 30mA. 30mA is considered the ‘safe’
current level the human body can conduct
without serious injury if in contact with a live
conductor due to an electrical fault in an
appliance. If the RCD trips during operation,
1
2
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Engine Operation
Starting the Engine
Be sure all Pre-Operation Engine Service has
been performed. Also, Read owners manual
before starting for the rst time.
(See INSTALLATION section)
NOTE: Remove all loads connected to the
AC power receptacles before starting the
gasoline engine.
FOR A “COLD” ENGINE:
1. Put the “ON/OFF” Switch
in the “ON”(I) position.
2. Open the fuel shutoff valve.
3. Place the choke lever in the “CHOKE”
position.
4. Turn key around until engine res. Or
for manual starting pull the cord rapidly
then release tension until the engine
res.
CAUTION:
DO NOT hold key in start position
for more than 5 seconds.
If the engine does not start, open the
choke slightly and repeat the starting
process.
5. When the engine starts, gradually open
the choke to the “RUN” position.
To open the choke fully requires an engine
warm-up period of several seconds to sev-
eral minutes, depending on the temperature.
After starting the engine, rst open the choke
(toward RUN) until the engine just begins to
run smoothly. Then open the choke in small
steps, allowing the engine to accept small
changes in speed and load, until the choke is
fully open (in RUN). During engine warm-up
the equipment can be operated.
FOR A “HOT” ENGINE:
1. Open the fuel shutoff valve.
2. Place the choke lever in the
“RUN” position.
CAUTION:
Closing the choke of a hot engine will
ood the carburetor and prevent start-
ing.
3. Turn the key around to the start position
until engine starts. Or for manual
starting pull the cord rapidly then
release tension until the engine res.
If engine fails to start, use the choke
momentarily when starting generator.
remove the appliance(s) from the generator, reset
the RCD switch and turn the appliance on again.
If this problem persists, please have an electrician
check the appliance.
NOTE: When connecting the generator to a xed
installation or a large number of loads through a
multi box or similar, the total current leakage across
multiple loads and the power distribution system
may exceed 30AmA, which creates nuisance
tripping of the RCD.
For this reason, in most power distribution systems,
each power connection point is usually protected
by its own RCD, rather than a single RCD for the
complete system. To address this issue, it will
be required to bypass the RCD protector in the
generator control panel. Please have an electrician
check there is no earth leakage problem with
the connected load before bypassing the RCD
protection.

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CAUTION:
In order to accomplish this break-in, the
Unit should be subjected to moderate
Loads, within the rating of the machine.
Avoid long idle running periods. Remove
Loads and allow engine to cool several
Minutes at low idle before shutdown.
Low Oil Sensing
This engine has a built in sensor which
responds to low oil level (not pressure). When
activated, the system will shut the engine down.
The engine will not restart until sufcient oil is
added. Check oil level frequently and add oil as
required to the full mark on the dipstick. DO
NOT OVERFILL.
Break-in Period
It is normal for any engine to use larger
quantities of oil until break-in is accomplished.
Check the oil level twice a day during the break-
in period (about 50 running hours). Change the
oil after the rst 5 hours of operation.
The Fuel Valve is
located under the fuel
tank and above the
recoil starter.
FOR BEST ENGINE STARTING:
• Always use fresh gasoline and be sure
the lter is clean and properly
maintained.
• If you use an alternate fuel tank or
supply, be sure to install an in-line fuel
lter.
• Do not pull the recoil starter with the
choke in the “CHOKE” position more
than one time. Repeated attempts to
start will ood the engine. Do not turn
the key for more than 5 seconds.
• If the engine will not start, see the
Troubleshooting section in this manual.
Stopping the Engine
1. Remove all welding and auxiliary power
loads and allow engine to run for a few
minutes to cool the engine.
2. Stop the engine by placing the “ON/
OFF” switch in the “OFF”(O) position.
CAUTION:
Close the fuel valve when the machine
is transported to prevent fuel leakage
from the carburetor.
Welding Operation
WARNING:
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
or electrode with skin or wet clothing.
• Insulate yourself from work and ground.
• Always wear dry insulating gloves.
ENGINE EXHAUST can kill.
• Use in open, well ventilated
areas or vent exhaust outside.
• Do not stack anything on or near the engine.
MOVING PARTS can injure.
• Do not operate with doors
open or guards off.
• Stop engine before servicing.
• Keep away from moving parts.
Only qualied personnel should install, use,
or service this equipment.

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After Finishing the Weld
1. Stop the gasoline engine.
(See Engine Operation in this manual)
2. Allow the electrode and work to cool com-
pletely.
3. Remove the work clamp from the work.
4. Remove any remaining piece of electrode
from the electrode holder.
5. If you have nished using the GT200W
for welding, disconnect the welding ca-
bles from the weld output terminals.
For DC+ welding, the electrode cable is to be
connected to the “+” output socket and work
cable to the “-” output socket. (For DC- weld-
ing, reverse these connections.)
The GT200W can deliver from 50 to 200A of
welding output current. Output can be adjust-
ed by setting the current control dial on the
output control panel.
You can get maximum welding output by set-
ting the dial to 200A. At high current settings
like this, some output may decrease as the
machine is used. If you are welding for a long
time, you may need to turn the dial slightly
upward to maintain the same results.
The numbers on the dial correspond to the
approximate amps needed to weld using ge-
neric welding rods. The Electrode Selection
Guide in this manual gives the recommended
dial settings based on the thickness of the
work and the size and type of rod used.
To Use the GT200W for Welding
1. Insert, push and turn connectors on weld-
ing cables into the respective sockets on
the welding machine. Make sure they are
rmly locked in place. (There is no need
to switch the machine to “welding mode”
as the machine automatically detects
which process is being used.)
CAUTION:
DO NOT attempt to use welding pro-
cess and power generation process at
the same time.
2. Select the appropriate electrode. (See
Electrode Selection Guide Table in this
manual).
3. Attach the work clamp securely to the
work you are welding.
4. Insert the electrode into the electrode
holder.
5. Set the current control dial to the desired
output current.
6. Start the gasoline engine.
7. Strike an arc and begin welding.
Auxiliary Power
Operation
WARNING:
Be sure that any electrical equipment
plugged into the generator AC power
receptacles can withstand a ±10%
voltage and a ±5% frequency variation.
Some electronic devices cannot be
powered by the GT200W. (Refer to the
Generator Usage Table in this manual)
General Information
The GT200W is rated at 5500 peak watts or
5000 continuous watts. It provides 230V of sin-
gle phase power, up to 23.91A from the single
outlet/adapter cord. Rated continuous amper-
age use is 21.7A.
Electrical loads in watts are calculated by
multiplying the voltage rating of the load by
the number of amps it draws. (This informa-
tion is given on the load device name plate.)

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CAUTION:
Welder and Generator MUST NOT be in
use simultaneously.
NOTE: You can supply multiple loads as long
as the total load does not exceed 5500 peak
watts or 5000 continuous watts. Be sure to
start the largest loads rst.
AWS
CLASSIFICATION:
E6010
E6011
E6011
E6013
E7018
E7018
E7018-17 & E308L-17
ENi-CL
ELECTRODE
POLARITY:
CURRENT RANGE (AMPS):
2.5mm 3.2mm 4.0mm
DC+
DC+
DC+
DC±
DC+
DC+
DC+
DC+
50 - 75
50 - 75
50 - 80
70 - 95
70 - 100
65 - 85
50 - 80
50 - 80
75 - 135
70 - 110
55 - 110
100 - 135
90 - 125
90 - 125
75 - 110
80 - 110
-
80 - 125
105 - 125
-
125 - 145
-
80 - 125
-
SHEET THICKNESS: 3.2mm and thinner 3.2mm and thicker
Electrode
Selection Guide
For example, a device rated 230V, 10A will
need 2300W of power (230 x 10 = 2300).
You can use the Power Applications table on
the following page, to determine the wattage
requirements of the most common types of
loads you can power with the GT200W Be
sure to read the notes at the bottom of the
table.
Using the GT200W as an Auxiliary
Power Supply
1. Start the gasoline engine. (See Engine
Operation earlier in this manual)
2. Set the Welder / Generator mode to
Generator
3. Plug load(s) into the 230V power receptacle.
There is no need to switch the machine to
“welding mode” as the machine automatically
detects which process is being used.

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SUGGESTED POWER APPLICATIONS
*Air Compressor - 2.5 HP 2000 4000 - 8000
*Air Compressor - 3/4 HP 1250 3100 - 5000
*Airless Sprayer - 1/3 HP 600 1500 - 2400
Chain Saw 1200
Circular Saw 1200
Coffee Maker 1000
*Deep Freezer 500 750 - 2000
*Electric Motor - 1 HP 1000 2500 - 4000
Electric Range (1 element) 1500
Electric Skillet 1250
*Furnace Fan - 1/3 HP 1200 3000 - 4800
Portable Grinder (4 1/2”) 600
Portable Grinder (7”) 2000 4500
Halogen Work Light 500
Hand Drill - 1/4” 500
Hand Drill - 3/8” 700
1500 Watt Heater 1500
Hedge Trimmer 450
Light Bulb 100
Reciprocating Saw 900
Radial Arm Saw 2600
Radio 50
*Refrigerator/Freezer (small) 600 1500 - 2400
Slow Cooker 200
*Submersible Pump - 1 HP 1000 2500 - 4000
*Sump Pump 600 1500 - 2400
Toaster 1100
Weed Trimmer 500
RUNNING WATTS
(Continuous)
*START-UP WATTS
(Peak)
Power Applications
NOTES: Wattages listed are approximate. Check your equipment for actual wattage.
Equipment with unusually high *START-UP WATTS are listed. For start-up of other equipment that uses a
motor, listed in the table, multiply RUNNING WATTS by 2. Multiple loads can be used as long as the total
load does not exceed 5500 peak watts. Be sure to start the largest loads rst.

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Flat Position,
Down Hand Butt Weld
(Fig 1-11)
Flat Position,
Gravity Fillet Weld
(Fig 1-12)
Horizontal Position,
Butt Weld
(Fig 1-13)
Horizontal-Vertical
(HV) Position
(Fig 1-14)
Vertical Position,
Butt Weld
(Fig 1-15)
Vertical Position,
Fillet Weld
(Fig 1-16)
Overhead Position,
Butt Weld
(Fig 1-17)
Overhead Position,
Fillet Weld
(Fig 1-18)
Joint Preparations
In many cases, it will be possible to weld steel
sections without any special preparation. For heav-
ier sections and for repair work on castings, etc., it
will be necessary to cut or grind an angle between
the pieces being joined to ensure proper pen-
etration of the weld metal and to produce sound
joints.In general, surfaces being welded should be
clean and free of rust, scale, dirt, grease, etc. Slag
should be removed from oxy-cut surfaces. Typical
joint designs are shown in Figure 1-19.
Open Square Butt Joint
(Fig 1-19a)
Gap varies from1.6mm (1/16”)
to 4.8mm (3/16”) depending on plate thickness
Single Vee Butt Joint
(Fig 1-19b) Not less than 45°
Single Vee Butt Joint
(Fig 1-19c) Not less than 70°
1.6mm (1/16”) max.
1.6mm (1/16”)
Double Vee Butt Joint (Fig
1-19d) Not less than 70°
1.6mm (1/16”) max.
1.6mm (1/16”)
Basic MMA Welding Guide

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Lap Joint (Fig 1-19e)
Fillet Joint (Fig 1-19f)
Corner Weld
(Fig 1-19g)
Tee Joints
(Fig 1-19h)
Edge Joint
(Fig 1-19i)
Plug Welds
(Fig 1-19j)
MMA Welding
Techniques
A Word for Beginners
For those who have not yet done any welding, the
simplest way to commence is to run beads on a piece
of scrap plate. Use mild steel plate about 6.0mm thick
and a 3.2mm electrode.
Clean any paint, loose scale or grease off the plate
and set it rmly on the work bench so that welding
can be carried out in the down hand position. Make
sure that the Work Lead/Clamp is making good elec-
trical contact with the work, either directly or through
the work table. For light gauge material, always
clamp the work lead directly to the job, otherwise a
poor circuit will probably result.
The Welder
Place yourself in a comfortable position before be-
ginning to weld. Get a seat of suitable height and do
as much work as possible sitting down. Don’t hold
your body tense. A tense body will soon make you
feel tired. Relax and you will nd the job becomes
much easier. Wearing a leather apron and gauntlets
will stop you worrying about being burnt or sparks
setting alight to your clothes.
Place work so the direction of welding is across, rath-
er than to or from, your body. The electrode holder
lead should be clear of any obstruction so you can
move your arm freely along as the electrode burns
down. If the lead is slung over your shoulder, it al-
lows greater freedom of movement and takes a lot
of weight off your hand. Be sure insulation on your
cable and electrode holder is not faulty; as you may
risk electric shock.
Striking the Arc
Practice this on a piece of scrap plate before going
on to more exacting work. You may at rst experi-
ence difculty due to the tip of the electrode “stick-
ing” to the work piece. This is caused by making too
heavy a contact with the work and failing to withdraw
the electrode quickly enough. A low amperage will
accentuate it. This freezing-on of the tip may be over-
come

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20o
1.6mm (1/16”)
Striking an Arc
(Fig 1-20)
Arc Length
The securing of an arc length necessary to pro-
duce a neat weld soon becomes almost automatic.
You will nd that a long arc produces more heat.
A very long arc produces a crackling or splutter-
ing noise and the weld metal comes across in
large, irregular blobs. The weld bead is attened
and spatter increases. A short arc is essential if a
high quality weld is to be obtained although if it is
too short there is the danger of it being blanketed
by slag and the electrode tip being solidied in. If
this should happen, give the electrode a quick twist
back over the weld to detach it. Contact or “touch-
weld” electrodes such as E7014 Stick electrodes
do not stick in this way, and make welding much
easier.
Rate of Travel
After the arc is struck, your next concern is to main-
tain it, and this requires moving the electrode tip
towards the molten pool at the same rate as it is
melting away. At the same time, the electrode has
to move along the plate to form a bead.
Making Welded Joints
Having attained some skill in the handling of an
electrode, you will be ready to go on to make up
welded joints.
A. Butt Welds
Set up two plates with their edges parallel, as
shown in Figure 1-21, allowing 1.6mm to 2.4mm
gap between them and tack weld at both ends. This
is to prevent contraction stresses from the cooling
weld metal pulling the plates out of alignment.
Plates thicker than 6.0mm should have their mat-
ing edges bevelled to form a 70º to 90º included
angle. This allows full penetration of the weld metal
to the root. Using a 3.2mm E7014 Stick electrode
at 100 amps, deposit a run of weld metal on the
bottom of the joint.
Do not weave the electrode, but maintain a steady
rate of travel along the joint sufcient to produce a
well-formed bead. At rst you may notice a tenden-
cy for undercut to form, but keeping the arc length
short, the angle of the electrode at about 20º from
vertical, and the rate of travel not too fast, will help
eliminate this.
Tack Weld
Butt Weld
(Fig 1-21)
Electrode
20o- 30o
Tack Weld
by scratching the electrode along the plate surface
in the same way as a match is struck. As soon as
the arc is established, maintain a 1.6mm to 3.2mm
gap between the burning electrode end and the
parent metal. Draw the electrode slowly along as
it melts down.
Another difculty you may meet is the tendency,
after the arc is struck, to withdraw the electrode so
far that the arc is broken again. A little practice will
soon remedy both of these faults.
The electrode is directed at the weld pool at about
20º from the vertical. The rate of travel has to be
adjusted so that a well-formed bead is produced.
If the travel is too fast, the bead will be narrow and
strung out and may even be broken up into indi-
vidual globules. If the travel is too slow, the weld
metal piles up and the bead will be too large.