GT POWER GT200W Operating Instructions Manual

200a welder / 5500w generator

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GT200W

PROFESSIONAL WELDER GENERATOR

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Page 1 GT200W PROFESSIONAL WELDER GENERATOR...
Page 2 GT200W PROFESSIONAL WELDER GENERATOR 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.
Page 3: Table Of Contents
GT200W PROFESSIONAL WELDER GENERATOR Contents Specifications..............5 General Operation ...............6 Features & Controls..............9 Installation................10 Generator Usage..............11 General Operation..............11 Welder / Generator Controls............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...
Page 4 GT200W 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 & muffler system - for cleaner quieter operation, superior quality alternator &...
Page 5: Specifications
GT200W PROFESSIONAL WELDER GENERATOR 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...
Page 6: General Operation
AC power. The machine is port- able. Welding Capability Recommended Applications The GT200W is rated at 180A, 26VDC at 60% duty cycle on a ten-minute basis. This WELDER: The GT200W provides excellent means that you can load the welder to 180A...
Page 7 They include important safety precau- The GT200W must be used outdoors. Do not tions, detailed engine starting, operat- set the machine in puddles or otherwise sub- ing and maintenance instructions, and merge it in water.
Page 8 5. Remove the spark plug and pour approx. (minimum 91) octane lead free gasoline. DO 1/2 ounce (15ml) of engine oil into the cyl- NOT MIX OIL WITH GAS. The GT200W capac- inder. Replace the spark plug and crank the ity is approximately 18L. DO NOT OVERFILL, engine slowly to distribute the oil.
Page 9: Features & Controls
GT200W PROFESSIONAL WELDER GENERATOR 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.
Page 10: Installation
Cable Installation b) be double insulated. Install the welding cables to your GT200W as When this welder is mounted on a truck or follows. See the previous page for the loca- trailer, the machine grounding stud must be tion of parts.
Page 11: Generator Usage
Premises Wiring CAUTION: The GT200W can be used for fixed installa- Never bypass the circuit breakers. tion or premises wiring. Please consult a reg- Without overload protection, the unit...
Page 12: Welder / Generator Controls
- Output current in amps (A) electrode holder or the work cable. (Because - Output power in watts (W) the GT200W is a DC output machine, either output terminal can be used for either cable.) - Output frequency in hertz (Hz) - Total operating hours (H) 4.
Page 13: Engine Operation
GT200W PROFESSIONAL WELDER GENERATOR remove the appliance(s) from the generator, reset CAUTION: the RCD switch and turn the appliance on again. DO NOT hold key in start position If this problem persists, please have an electrician for more than 5 seconds.
Page 14: Welding Operation
GT200W PROFESSIONAL WELDER GENERATOR FOR BEST ENGINE STARTING: CAUTION: In order to accomplish this break-in, the • Always use fresh gasoline and be sure Unit should be subjected to moderate the filter is clean and properly Loads, within the rating of the machine.
Page 15: Auxiliary Power Operation
GT200W PROFESSIONAL WELDER GENERATOR The GT200W can deliver from 50 to 200A of After Finishing the Weld welding output current. Output can be adjust- 1. Stop the gasoline engine. ed by setting the current control dial on the (See Engine Operation in this manual) output control panel.
Page 16: Electrode Selection Guide
5500 peak loads you can power with the GT200W Be watts or 5000 continuous watts. Be sure to sure to read the notes at the bottom of the start the largest loads first.
Page 17: Power Applications
GT200W PROFESSIONAL WELDER GENERATOR Power Applications SUGGESTED POWER APPLICATIONS RUNNING WATTS *START-UP WATTS (Peak) (Continuous) *Air Compressor - 2.5 HP 2000 4000 - 8000 *Air Compressor - 3/4 HP 1250 3100 - 5000 *Airless Sprayer - 1/3 HP 1500 - 2400...
Page 18: Basic Mma Welding Guide
GT200W PROFESSIONAL WELDER GENERATOR Basic MMA Welding Guide Joint Preparations Flat Position, Down Hand Butt Weld In many cases, it will be possible to weld steel (Fig 1-11) sections without any special preparation. For heav- ier sections and for repair work on castings, etc., it...
Page 19: Mma Welding Techniques
GT200W PROFESSIONAL WELDER GENERATOR MMA Welding Lap Joint (Fig 1-19e) Techniques A Word for Beginners For those who have not yet done any welding, the Fillet Joint (Fig 1-19f) simplest way to commence is to run beads on a piece of scrap plate.
Page 20 GT200W PROFESSIONAL WELDER GENERATOR by scratching the electrode along the plate surface The electrode is directed at the weld pool at about in the same way as a match is struck. As soon as 20º from the vertical. The rate of travel has to be the arc is established, maintain a 1.6mm to 3.2mm...
Page 21 GT200W PROFESSIONAL WELDER GENERATOR The electrode needs to be moved along fast A piece of angle iron is a suitable specimen with enough to prevent the slag pool from getting ahead which to begin, or two lengths of strip steel may of the arc.
Page 22: Other Knowledge And Resources
GT200W PROFESSIONAL WELDER GENERATOR 3. Overhead Welds Use a short arc, and do not attempt to weave on the first run. When the first run has been completed Apart from the rather awkward position necessary, de-slag the weld deposit and begin the second run overhead welding is not much more difficult that at the bottom.
Page 23: Mma Troubleshooting
GT200W PROFESSIONAL WELDER GENERATOR MMA Troubleshooting www.gtpower.co.nz...
Page 24: Accessories
(Incl. Alternator Back-End Alternator Cover and Stator Cover) 17737 Fuel Tank 17738 Rotor These accessories listed are available from your GT Power Distributor. See your GT Power Distributor or look online at www.gtpower.co.nz for other accessories and consumables available. www.gtpower.co.nz...
Page 25: Engine Maintenance
GT Power Dealer. Read the Safety Precautions at the end of this manual before working on the GT200W Keep all equipment safety guards, covers, and devices in position and in good repair. Keep your hands, hair, clothing, and tools...
Page 26 4. Use the wrench to remove the spark plug. Adjustments to the engine are to be made only by a GT Power Authorised Service Facility. 5. Visually inspect the spark plug. www.gtpower.co.nz...
Page 27: Troubleshooting
Engine Maintenance Parts malfunctions. The following options / accessories are Simply follow the three-step procedure listed available for your GT200W from your local below. Distributor: POWERDYNE 14HP 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled...
Page 28 PROFESSIONAL WELDER GENERATOR Output Problems RECOMMENDED PROBLEM (SYMPTOMS) POSSIBLE CAUSE COURSE OF ACTION 1. Contact your local GT Power Major physical or electrical Authorised Service Facility. damage is evident. 1. Check brushes for wear. See Maintenance section. 2. Check for loose or faulty connections at brush holders.
Page 29 GT200W PROFESSIONAL WELDER GENERATOR Engine Problems RECOMMENDED PROBLEM (SYMPTOMS) POSSIBLE CAUSE COURSE OF ACTION 1. Crankcase may be over-filled Recoil starter is hard to pull. with oil. - Check oil level. 1. Water in engine from rain and / or condensation. - Remove spark plug and dry it if wet.
Page 30: Wiring Diagram
GT200W PROFESSIONAL WELDER GENERATOR Wiring Diagram www.gtpower.co.nz...
Page 31: Safety Instructions
GT200W PROFESSIONAL WELDER GENERATOR Safety Instructions ARC RAYS can burn. WARNING: • Wear eye, ear and body protection. ELECTRIC SHOCK can kill. ENGINE EXHAUST can kill. • Do not touch electrically live parts or electrode with skin or wet clothing.
Page 32 USE ENOUGH VENTILATION or exhaust at Safety Depends On You the arc, or both, to keep the fumes and gases GT POWER welding and cutting equipment is from your breathing zone and the general designed and built with safety in mind.
Page 33: Warnings
GT200W PROFESSIONAL WELDER GENERATOR DO NOT WELD OR CUT painted or plated moving parts when starting, operating or parts unless special precautions with ventilation repairing equipment. have been taken. They can release highly toxic 1.e. In some cases it may be necessary to fumes or gases.
Page 34 GT200W PROFESSIONAL WELDER GENERATOR • Route the electrode and work cables welding head, nozzle or semi-automatic together. Secure them with tape when welding gun are also electrically “hot”. possible. 3.d. Always be sure the work cable makes • Never coil the electrode lead around a good electrical connection with the your body.
Page 35 GT200W PROFESSIONAL WELDER GENERATOR er’s instructions for this equipment and Fumes and Gases the consumables to be used, including can be Dangerous. the material safety data sheet (MSDS) 5.a. Welding may produce fumes and gases and follow your employer’s safety hazardous to health.
Page 36 GT200W PROFESSIONAL WELDER GENERATOR 7.c. Cylinders should be located: 6.e. Vent hollow castings or containers be- fore heating, cutting or welding. They • Away from areas where they may be may explode. struck or subjected to physical damage. • A safe distance from arc welding or 6.f.
Page 37: Warranty
Registered warranty period for the GT200W product. Commercial Use: 24 Months Should any issue be found to be a combination of...
Page 38 GT200W PROFESSIONAL WELDER GENERATOR Serial Number: ___________________________ Model:__________________________________ Date Purchased:__________________________ Retailer Purchased From:___________________ Scan here to register your product http://www.euroquip.co.nz/Contact+Us/ Product+Registration+Form.html Please attach your proof of purchase here. www.gtpower.co.nz...
Page 39 GT200W PROFESSIONAL WELDER GENERATOR www.gtpower.co.nz...
Page 40 Congratulations on your new GT POWER product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency visit www.gtpower.co.nz, or email...