CAT Portable Generator GT950 User Manual

Commercial Duty Power Systems User's Guide  
(Model No. GT950)  
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Serial Number  
Date Purchased  
Fat CatProducts Made Exclusively for Aquatic Eco-Systems, Inc. • Phone: 407-886-3939 • Fax: 407-886-6787 • [email protected] • aquaticeco.com  
 
Dear Customer,  
Generator Hazards  
Read and understand the information provided in this manual before  
operating your generator.  
Thank you for your purchase of a Fat Cat™ commercial duty power  
system. We believe that the Fat Cat™ name represents the finest blend  
of quality, performance and price on the market.  
If you need assistance setting up or operating your generator, then give  
Aquatic Eco-Systems a call. AES has delivered outstanding products and  
service since 1978. We have the knowledge and experience to help you  
accomplish your goals.  
Operator Responsibility  
Know how to stop the generator quickly in case of an emergency.  
Understand the use of all generator controls, output receptacles  
and connections.  
Best regards,  
Ensure that anyone who operates the generator has proper instruction.  
Do not let children operate the generator.  
Robert C. Heideman  
Founder and President  
Carbon Monoxide Hazard  
Exhaust contains poisonous carbon monoxide, a colorless and odorless  
gas. Breathing exhaust may cause a loss of consciousness or even death.  
AES is open from 8 a.m. to 7 p.m. Monday-Thursday,  
8 a.m. to 5 p.m. Friday and 10 a.m. to 2 p.m. Saturday.  
For technical help call407-886-3939.  
Maintain adequate ventilation when operating the generator to keep a  
dangerous amount of exhaust gas from building up. Do not operate in  
a partially confined or enclosed area.  
This manual contains valuable information to help you get the best results  
from your generator and provides important safety guidelines for generator  
operation. Please read this manual carefully. Consider this manual a  
permanent part of the generator.  
Electric Shock Hazard  
A generator is a potential source of electrical shock that could cause  
electrocution. Do not expose the generator to moisture, rain or snow.  
Do not operate the generator with wet hands.  
Safety Messages  
If the generator is stored outdoors and unprotected from weather,  
check all electrical components on the control panel before each use.  
Moisture or ice can cause a malfunction or short circuit in electrical  
components, which can result in electrocution.  
Safety is important to us. We have included safety messages throughout  
this manual and on the generator for your protection. Please read and  
follow all directions.  
A safety message has a safety alert symbol  
followed by an explanation of what the hazard  
is, what can happen and what you should do  
to avoid injury. This is the safety alert symbol:  
Do not connect the generator to a building's electrical system unless  
an isolation switch has been installed by a qualified electrician.  
Fire and Burn Hazards  
The safety alert symbol and "WARNING" or "CAUTION" will precede  
all safety messages:  
The exhaust system gets hot enough to ignite some materials. Keep the  
generator at least three feet (one meter) away from buildings and other  
equipment. Do not enclose the generator in any structure. Keep flammable  
materials away from the generator.  
WARNING  
The generator's muffler becomes very hot during operation and remains  
hot for some time after stopping the engine. Be careful not to touch the  
muffler while it's hot. Allow the engine to cool before storing it indoors.  
You can be killed or seriously injured if you don't follow instructions.  
Gasoline is extremely flammable and is explosive under certain conditions.  
Do not smoke or allow flames or sparks during refueling or where gasoline  
is stored. Refuel in a well-ventilated area with the engine stopped.  
CAUTION  
You might be injured if you don't follow instructions.  
Fuel vapors are extremely flammable and may ignite after the engine starts.  
Wipe up any spilled fuel before starting the generator.  
Damage Prevention Messages  
A damage prevention message has "ATTENTION" with an explanation of  
what the equipment hazard is and what you should do to avoid damaging  
your generator:  
ATTENTION  
Your equipment may be damaged if you don't follow instructions.  
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Fat CatProducts Made Exclusively for Aquatic Eco-Systems, Inc. • Phone: 407-886-3939 • Fax: 407-886-6787 • [email protected] • aquaticeco.com  
 
FUEL TANK CAP  
ENGINE SWITCH  
ENGINE SERIAL NUMBER  
FUEL VALVE  
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RECOIL STARTER GRIP  
AC RECEPTACLES  
SPARK PLUG CAP  
RESET BUTTON  
AIR CLEANER  
CHOKE LEVER  
MUFFLER  
Before Starting  
System Ground  
You must connect the ground wire to a metal stake, spike or screw in the  
earth before using the generator.  
WARNING  
Improper connections to a building's electrical system can allow  
electrical current from the generator to backfeed into utility lines.  
This backfeed may electrocute utility company workers or others  
who contact the lines during a power outage. Consult the utility  
company or a qualified electrician.  
Follow any federal or state Occupational Safety and Health Administration  
(OSHA) regulations, local codes or ordinances that apply to the intended  
use of the generator. Consult a qualified electrician, electrical inspector or  
the local agency having jurisdiction.  
In some areas, you must register your generator with local utility companies.  
Generators used at construction sites may have additional regulations.  
CAUTION  
Fuel/Oil Mix  
Improper connections to a building's electrical system can allow  
electrical current from the utility company to backfeed into the  
generator. When utility power is restored, the generator may explode,  
burn or cause fires in the building's electrical system.  
Do not operate this generator using gasoline alone or the engine will  
overheat! Use a fuel/oil mix of 50 to 1. The oil must be 2-stroke oil.  
Make sure to pour the fuel/oil mix through the fuel tank filter to keep  
solid material out of the fuel tank. Do not fill the fuel tank above the  
fuel filter top. Shake the fuel tank before starting. Avoid repeated or  
prolonged contact with skin or breathing of fuel vapor.  
Use a ground fault circuit interrupter (GFCI) in any damp or highly  
conductive area, such as metal decking or steel work. Do not touch  
bare wires or receptacles. Do not use the generator with electrical cords  
that are worn, frayed, bare or damaged in any way. Do not operate the  
generator in the rain. Do not handle the generator or electrical cords  
while standing in water, while barefoot or while hands or feet are wet.  
Do not allow children or unqualified people to operate the generator.  
WARNING  
Gasoline and its vapors are extremely flammable and can be  
explosive in certain conditions. Fire or explosion can cause severe  
burns or death.  
If the engine has been running, allow it to cool before adding any fuel/oil  
mix. Refill the tank outdoors. Remove the gas cap slowly to relieve any  
pressure inside the tank. Keep sparks, flames, heat and other ignition  
sources away while adding or storing oil and fuel. Do not light a cigarette  
or smoke when refueling. Wipe up any fuel spills.  
4
Fat CatProducts Made Exclusively for Aquatic Eco-Systems, Inc. • Phone: 407-886-3939 • Fax: 407-886-6787 • [email protected] • aquaticeco.com  
 
Operation Guidelines  
CAUTION  
CAUTION  
Do not allow the starter cord to snap back. Return it slowly by hand.  
Exceeding the generator's wattage/amperage capacity may damage  
the generator and electrical devices connected to it.  
5. Move the choke lever back to the "open" position after the engine  
warms up.  
Do not connect any electrical loads before starting the engine and  
allowing it to warm up. Make sure electrical devices are "off" when  
you do connect them.  
High-Altitude Operation  
The standard carburetor air-fuel mixture will be too rich at high altitude  
(5,000 feet or 1,500 m and above), decreasing performance and increasing  
fuel consumption.  
Starting the Engine  
1. Place the generator on a level surface.  
2. Turn the fuel valve to the "on" position.  
FUEL VALVE LEVER  
Electrical Loads  
Before connecting an appliance or power cord to the generator,  
make sure the appliance or cord is in good working order. Do not  
overload the generator! The GT950's specifications are:  
ON  
OOFF  
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Rated Voltage (V)  
Rated Frequency (Hz)  
Rated Current (A)  
Rated Output (VA)  
120  
60  
7.3  
800  
ON  
To make sure that your generator can supply enough rated (running)  
and surge (starting) watts for the items you will power at the same time,  
follow these steps:  
3. Move the choke lever to the "closed" position.  
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CHOKE LEVER  
1. Select the items you will power at the same time.  
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2. Add up the rated (running) watts of these items. The generator must  
produce this total amount of power to keep your items running.  
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3. Estimate how many surge (starting) watts you will need; in other words,  
the short burst of power needed to start electric tools or appliances.  
Because not all motors start at the same time, total surge watts can  
be estimated by adding only the item with the highest additional surge  
watts to the total rated watts.  
CLOSED  
OPEN  
Example of determining the total output required:  
Tool/Appliance  
Refrigerator  
Television  
Rated (Running) Watts  
Surge (Starting) Watts  
4. Pull slowly on the starter cord until it engages, then pull sharply.  
800  
500  
1,600  
n/a  
Window AC  
1,200  
1,800  
STARTER GRIP  
Total Rated (Running) Watts = 2,500  
Highest Surge Watts = 1,800  
Total Generator Output Required = 4,300  
5
Fat CatProducts Made Exclusively for Aquatic Eco-Systems, Inc. • Phone: 407-886-3939 • Fax: 407-886-6787 • [email protected] • aquaticeco.com  
 
Take care when adding electrical loads to the generator. Never connect any  
load to the generator before starting the engine. The safe way to manage  
generator power is to sequentially add loads:  
Stopping the Engine  
Turn off all attached appliances and tools and unplug their cords. Move the  
AC switch, then the engine switch and finally the fuel lever to "off" positions.  
Transport  
1. Start the engine and allow it to warm up.  
Make sure the engine switch and fuel lever are in the "off" positions.  
Keep the generator level to prevent fuel spillage. Fuel vapor or spillage  
may ignite.  
2. Plug in the first load (turned off), which is preferably the largest load.  
3. Let the generator output stabilize (engine runs smoothly and device  
operates correctly).  
4. Plug in and turn on the next load.  
5. Let the generator stabilize again.  
WARNING  
Repeat steps 4 and 5 for each additional load.  
Contact with a hot engine or exhaust system can cause serious  
burns or fires. Let the engine cool before transporting the generator.  
If an appliance begins to operate abnormally, becomes sluggish  
or stops suddenly, then turn it off and disconnect it.  
Take care not to drop or strike the generator while transporting. Do not  
place heavy objects on the generator.  
Never operate a damaged or defective motor! When adjusting or making  
repairs to your generator disconnect the spark plug wire from the spark  
plug and place that wire where it cannot contact the spark plug. Do not  
use a garden hose to clean the generator because water can enter the fuel  
system and cause problems.  
ATTENTION  
Heavy overloading will trip the circuit breaker.  
Slight overloading may not trip the circuit breaker  
but will shorten the life of the generator.  
Wattage Reference Chart  
Tool/Appliance  
Light Bulb  
Rated (Running) Watts Surge (Starting) Watts  
Periodic Maintenance  
Spark Plug Inspection  
100  
625  
380  
100  
100  
300  
500  
600  
100  
400  
450  
100  
625  
380  
400  
200  
1. Remove the spark plug cap.  
Microwave Oven (625 W)  
Battery Charger (15 amps)  
Computer, Desktop  
Computer, Monitor  
AM/FM Clock Radio  
Small Hand Drill  
Jigsaw  
2. Remove the spark plug.  
3. Inspect the spark plug—it should be a tan color. Discard if the  
insulator is cracked or chipped.  
4. Clean the spark plug with a wire brush if it will be reused.  
5. Measure the plug gap with a feeler gauge. Make sure the plug gap  
is between .028 and .031 in (.7 and .8 mm).  
750  
80  
300  
.7 - .8 mm (.028 - .031 in.)  
Home Security System  
Small T.V.  
Slow Cooker  
*Wattages listed are for reference only. Check the appliance or tool for  
the actual wattage.  
6. Thread the spark plug back in by hand to prevent cross-threading.  
The correct torque to use is 14 ft-lbs (20 Nm).  
If the load exceeds the rated capacity of the generator, then the AC  
protector will trip, stopping the electricity flow to connected devices.  
Reduce the load to within the rated capacity and press the reset  
button to use the generator again.  
ATTENTION  
The spark plug must be securely tightened. An improperly tightened  
spark plug can become very hot and could damage the engine.  
RESET BUTTON  
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Fat CatProducts Made Exclusively for Aquatic Eco-Systems, Inc. • Phone: 407-886-3939 • Fax: 407-886-6787 • [email protected] • aquaticeco.com  
 
Air Filter Cleaning  
3. Pour a small amount of oil (foam-air-filter or SAW #20 motor oil  
recommended) into the filter element and gently squeeze out excess oil.  
Never wring out the filter element, as it may tear. The generator will  
smoke if too much oil remains in the filter element.  
A dirty air filter will restrict airflow to the carburetor. Service the air filter  
regularly to prevent carburetor malfunction (service more frequently in  
extremely dusty areas).  
4. Reinstall the filter element and air filter cover. Be sure both  
projections of the air filter cover fit the control box slots before  
tightening the mount screws.  
1. Unscrew the air filter cover.  
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Fuel Sediment Cup Cleaning  
1. Remove the cup at the bottom of the fuel valve using a small spanner.  
ON  
FUEL SEDIIMENT CUP  
AIR FILTER COVER  
2. Remove the filter element and wash well with an inflammable solvent  
or soap and water.  
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2. Clean with a scouring pad and brush, rinse with water and allow to air  
dry, then reinstall.  
Fuel Tank Filter Cleaning  
1. Remove the filter from below the fuel tank cap using your fingers.  
AIR FILTER  
FUEL TANKK FILTER  
WARNING  
Using gasoline or other flammable solvent to clean the filter element  
can cause a fire or explosion.  
ATTENTION  
Never run the generator without the air cleaner; this will cause rapid  
engine wear.  
2. Clean with a scouring pad and brush, rinse with water and allow  
to air dry, then reinstall.  
7
Fat CatProducts Made Exclusively for Aquatic Eco-Systems, Inc. • Phone: 407-886-3939 • Fax: 407-886-6787 • [email protected] • aquaticeco.com  
 
Maintenance Chart  
Daily  
(Preoperation  
Check)  
First Month Three Months Six Months Twelve Months  
Item  
Remarks  
(20 hrs)  
(50 hrs)  
(100 hrs)  
(300 hrs)  
Spark Plug  
Air Filter  
Check condition. Adjust gap and clean. Replace if necessary.  
Clean, replace if necessary.  
X
X
Fuel Filter  
Clean fuel valve and fuel tank filter. Replace if necessary.  
X
Check fuel hose for cracks or other damage.  
Replace if necessary.  
Fuel Line  
X
X
Check for leakage. Retighten or replace gasket if necessary.  
Check muffler screen. Clean or replace if necessary.  
Check choke operation.  
Exhaust System  
Carburetor  
X
X
X
X
Cooling System  
Starting System  
Check for rain damage.  
X
X
Check recoil starter operation.  
Remove carbon deposits in muffler, combustion chamber.  
Increase frequency if necessary.  
Decarbonization  
Fittings/Fasteners  
Check. Replace if necessary.  
X
Miscellaneous  
Do not expose the generator to excessive moisture, dust,  
dirt or corrosive vapors.  
Use a soft bristle brush to loosen caked-on dirt or oil.  
Use low-pressure air (less than 25 psi) to blow away dirt.  
Do not insert any objects through cooling slots. Cooling slots must not  
become clogged with snow, leaves or any other foreign material.  
8
Fat CatProducts Made Exclusively for Aquatic Eco-Systems, Inc. • Phone: 407-886-3939 • Fax: 407-886-6787 • [email protected] • aquaticeco.com  
 
Troubleshooting  
Generator Won't Start  
Generator Shuts Down While Running  
1. Check the fuel/oil mix level and add more if necessary.  
2. Make sure the engine switch and fuel valve are set to the "on" positions.  
3. Test the spark plug using the following procedure:  
1. Check the fuel/oil mix level and add more if necessary.  
Storage  
• Remove the spark plug cap and clean any dirt from around the  
spark plug.  
Your generator should be started at least once every seven days and  
allowed to run at least 30 minutes. If you must store the generator for  
longer periods of time, use the following guidelines:  
• Remove the spark plug and install the spark plug in the plug cap.  
• Set the plug side electrode on the bolt by the cylinder head.  
Storage Time Service Procedure  
Fill with fresh gasoline/oil mix and add fuel stabilizer.  
One to Two  
Months  
Run the engine for several minutes to circulate the  
additive through the carburetor.  
Fill with fresh gasoline/oil mix and add fuel stabilizer.  
Run the engine for several minutes to circulate the  
additive through the carburetor.  
Two Months  
to One Year  
Drain the carburetor bowl and carburetor.  
• Pull the starter cord gently; sparks should jump across the gap.  
Reinstall the spark plug or replace if necessary.  
Fill with fresh gasoline/oil mix and add fuel stabilizer.  
Run the engine for several minutes to circulate the  
additive through the carburetor*.  
WARNING  
Drain the carburetor bowl and carburetor.  
Over One  
Year  
Make sure no spilled fuel is near the spark plug when testing.  
The fuel may ignite.  
Remove the spark plug, pour in 1 spoonful of oil,  
pull the starter cord gently several times (engine switch  
in the "off" position!) and reinstall the spark plug.  
4. Make sure the fuel valve filter, fuel line and carburetor are not clogged.  
Pull the starter cord until you feel resistance and stop.  
5. Check cylinder heads for looseness and tighten the bolts that secure  
them if necessary.  
*After removal from storage, drain the stored gasoline/oil mix into a container  
and fill the fuel tank with fresh gasoline/oil mix before starting.  
6. Check the cylinder head gasket for damage and replace it if necessary.  
7. Contact AES if the generator still won't start.  
Place the generator in a dust-free, dry area and cover with a clean cloth.  
No AC Output  
1. Make sure the AC protector has not been not tripped. Press the reset  
button if necessary.  
Warning  
2. Check for poor connections or defective cords.  
3. Test the connected device(s) for proper operation.  
Storage covers can be flammable. Do not place a storage cover  
over a hot generator.  
Generator Falters Under Load  
1. The load is too heavy. Reduce the number of devices connected  
(see "Electrical Loads" on page 5).  
2. A connected device has a short circuit. Disconnect the shorted load.  
3. The generator has a short circuit. Contact AES.  
9
Fat CatProducts Made Exclusively for Aquatic Eco-Systems, Inc. • Phone: 407-886-3939 • Fax: 407-886-6787 • [email protected] • aquaticeco.com  
 
General Specifications  
12-Month Standard Warranty  
Aquatic Eco-Systems, Inc. (AES) products, when properly installed and  
operated under normal conditions of use, are warranted by AES to be free  
from defects in material and workmanship for a period of 12 months from  
the date of invoice from AES, unless otherwise stated. In order to obtain  
performance under this warranty, the buyer must promptly give verbal or  
written notice of the defect by calling the AES Returns Department at  
407-886-3939, sending a fax to 407-886-6787 or by e-mail to  
[email protected]. The buyer is responsible for freight charges,  
both to and from AES, in all cases.  
Model  
GT950  
12.5 x 12.5 x 14 in (32 x 32 x 36 cm)  
44 lbs (20 kg)  
L x W x H  
Weight (Empty)  
Engine Type  
AES warranties do not extend to any goods or parts which have been  
subjected to misuse, modification, lack of maintenance, neglect, transit  
damage or damage resulting from lightning, natural or accidental flooding,  
fire or accident. Operating use or circumstances outside normal conditions,  
such as high heat or high moisture, may also be excluded from this warranty.  
2-Stroke  
Fuel/Oil Mix  
Fuel/Oil Mix of 50 to 1  
63 cc  
THIS EXPRESS WARRANTY EXCLUDES ALL OTHER WARRANTIES OR  
REPRESENTATIONS EXPRESSED OR IMPLIED BY ANY LITERATURE,  
DATA OR PERSON. THE MAXIMUM LIABILITY OF AES UNDER THIS  
EXCLUSIVE REMEDY SHALL NEVER EXCEED THE COST OF THE  
SUBJECT PRODUCT AND AES RESERVES THE RIGHT, AT ITS SOLE  
DISCRETION, TO REFUND THE PURCHASE PRICE IN LIEU OF REPAIR  
OR REPLACEMENT.  
Displacement  
Operation Time  
Noise Level @ 25 ft (7 m)  
Cooling System  
Ignition System  
8 hrs  
64 dB  
AES WILL NOT BE RESPONSIBLE OR LIABLE FOR INDIRECT OR  
CONSEQUENTIAL DAMAGES OF ANY KIND, however arising,  
Forced Air  
including but not limited to those for use of any products, loss of time,  
inconvenience, lost profit, labor charges or other incidental or consequential  
damages with respect to persons, animals, business or property, whether  
as a result of breach of warranty, negligence or otherwise. Notwithstanding  
any other provision of this warranty, BUYER'S REMEDY AGAINST AES  
FOR GOODS SUPPLIED OR FOR NONDELIVERED GOODS OR FAILURE  
TO FURNISH GOODS, WHETHER OR NOT BASED ON NEGLIGENCE,  
STRICT LIABILITY OR BREACH OF EXPRESS OR IMPLIED WARRANTY IS  
LIMITED SOLELY, AT THE OPTION OF AES, TO REPLACEMENT OF OR  
CURE OF SUCH NONCONFORMING OR NONDELIVERED GOODS OR  
RETURN OF THE PURCHASE PRICE FOR SUCH GOODS AND, IN NO  
EVENT, SHALL EXCEED THE PRICE OR CHARGE FOR SUCH GOODS.  
AES EXPRESSLY DISCLAIMS ANY WARRANTY OF MERCHANTABILITY  
OR FITNESS FOR A PARTICULAR USE OR PURPOSE WITH RESPECT  
TO THE GOODS SOLD. THERE ARE NO WARRANTIES WHICH EXTEND  
BEYOND THE DESCRIPTIONS SET FORTH IN THIS WARRANTY,  
notwithstanding any knowledge of AES regarding the use or uses intended  
to be made of goods, proposed changes or additions to goods or any  
assistance or suggestions that may have been made by AES personnel.  
Transistor Control Ignition (T.C.I.)  
1.1 gal (4 liters)  
Fuel Tank  
Capacity  
BPR5ES (NGK)  
.028 to .031 in (.7 to .8 mm) Gap  
Spark Plug  
Unauthorized extensions of warranties by the customer shall remain the  
customer's responsibility.  
CUSTOMER IS RESPONSIBLE FOR DETERMINING THE SUITABILITY  
OF AES PRODUCTS FOR CUSTOMER'S USE OR RESALE OR FOR  
INCORPORATING THEM INTO OBJECTS OR APPLICATIONS THAT  
THE CUSTOMER DESIGNS, ASSEMBLES, CONSTRUCTS OR  
MANUFACTURES.  
This warranty can be modified only by AES personnel by signing a specific,  
written description of any modifications  
10  
6/17/05 db01  
Fat CatProducts Made Exclusively for Aquatic Eco-Systems, Inc. • Phone: 407-886-3939 • Fax: 407-886-6787 • [email protected] • aquaticeco.com  
 

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