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.

GT200W PROFESSIONAL WELDER GENERATOR
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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

GT200W PROFESSIONAL WELDER GENERATOR
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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

GT200W PROFESSIONAL WELDER GENERATOR
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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.

GT200W PROFESSIONAL WELDER GENERATOR
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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