CAT GT950 User Manual

Commercial Duty Power Systems User's Guide

AC

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(Model No. GT950)

Serial Number Date Purchased

Fat Cat™Products Made Exclusively for Aquatic Eco-Systems, Inc. • Phone: [phone] • Fax: [phone] • [e-mail] • aquaticeco.com

Table of Contents

Page

Safety and Damage Prevention Message Explanation

Generator Hazards

Before Starting

ystem Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

S

Engine Fuel/Oil Mix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Operation Guidelines

Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

High-Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Electrical Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Wattage Reference Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Periodic Maintenance

Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Air Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fuel Sediment Cup Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fuel Tank Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

. . . . . . . . . . . 3

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Troubleshooting

Generator Won't Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

No AC Output

Generator Falters Under Load . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Generator Shuts Down While Running

Storage

General Specifications

12-Month Standard Warranty

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

. . . . . . . . . . . . . . . . . . . . 9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2

Fat Cat™Products Made Exclusively for Aquatic Eco-Systems, Inc. • Phone: [phone] • Fax: [phone] • [e-mail] • aquaticeco.com

ear Customer,

D

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

quatic Eco-Systems a call. AES has delivered outstanding products and

A
service since 1978. We have the knowledge and experience to help you
accomplish your goals.

Best regards,

Generator Hazards

Read and understand the information provided in this manual before
operating your generator.

perator Responsibility

O

Know how to stop the generator quickly in case of an emergency.

Understand the use of all generator controls, output receptacles

nd connections.

a

Ensure that anyone who operates the generator has proper instruction.
Do not let children operate the generator.

Robert C. Heideman
Founder and President

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.

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.

Safety Messages

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:

The safety alert symbol and "WARNING" or "CAUTION" will precede
all safety messages:

WARNING

You can be killed or seriously injured if you don't follow instructions.

CAUTION

ou might be injured if you don't follow instructions.

Y

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:

Carbon Monoxide Hazard

Exhaust contains poisonous carbon monoxide, a colorless and odorless
gas. Breathing exhaust may cause a loss of consciousness or even death.

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.

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.

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.

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 exhaust system gets hot enough to ignite some materials. Keep the
generator at least thr
equipment. Do not enclose the generator in any structur
materials away fr

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.

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.

Fuel vapors are extremely flammable and may ignite after the engine starts.
Wipe up any spilled fuel before starting the generator.

ee feet (one meter) away from buildings and other

e. Keep flammable

om the generator.

ATTENTION

Your equipment may be damaged if you don't follow instructions.

3

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Before Starting

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ENGINE SWITCH

FUEL TANK CAP

A

C RECEPTACLES

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ESET BUTTON

AIR CLEANER

FUEL VALVE

E

NGINE SERIAL NUMBER

C

HOKE LEVER

MUFFLER

RECOIL STARTER GRIP

S

PARK PLUG CAP

System Ground

You must connect the ground wire to a metal stake, spike or screw in the
earth before using the generator.

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.

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 compan
who contact the lines during a power outage. Consult the utility
company or a qualified electrician.

y workers or others

Fuel/Oil Mix

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.

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.

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 childr

en or unqualified people to operate the generator.

WARNING

CAUTION

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

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Operation Guidelines

ONONON

F

UEL VALVE LEVER

OFF

OFFOFF

OFF

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CHOKE LEVERCHOKE LEVERCHOKE LEVER

OPENOPENOPEN

CLOSEDCLOSEDCLOSED

OFF

ON

STARTER GRIPSTARTER GRIPSTARTER GRIP

CAUTION

Exceeding the generator's wattage/amperage capacity may damage

he generator and electrical devices connected to it.

t

Do not connect any electrical loads before starting the engine and

llowing it to warm up. Make sure electrical devices are "off" when

a
you do connect them.

Starting the Engine

1. Place the generator on a level surface.

2. Turn the fuel valve to the "on" position.

CAUTION

Do not allow the starter cord to snap back. Return it slowly by hand.

5. Move the choke lever back to the "open" position after the engine
arms up.

w

High-Altitude Operation

The standar
(5,000 feet or 1,500 m and above), decr

d carburetor air-fuel mixture will be too rich at high altitude

easing performance and increasing

fuel consumption.

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:

Rated V

oltage (V)

120

3. Move the choke lever to the "closed" position.

4. Pull slowly on the starter cord until it engages, then pull sharply.

Rated Frequency (Hz)

Rated Current (A)

Rated Output (VA)

60

7.3

800

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:

1. Select the items you will power at the same time.

2. Add up the rated (running) watts of these items. The generator must

oduce this total amount of power to keep your items running.

pr

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.

Example of determining the total output required:

Tool/Appliance Rated (Running) Watts Surge (Starting) Watts

Refrigerator

800 1,600

Television 500 n/a

Window AC 1,200 1,800

Total Rated (Running) Watts = 2,500

Highest Surge W

atts = 1,800

Total Generator Output Required = 4,300

Fat Cat™Products Made Exclusively for Aquatic Eco-Systems, Inc. • Phone: [phone] • Fax: [phone] • [e-mail] • aquaticeco.com

5

ake care when adding electrical loads to the generator. Never connect any

AC

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RESET BUTTON

.7 - .8 mm (.028 - .031 in.)

T
load to the generator before starting the engine. The safe way to manage
generator power is to sequentially add loads:

1. Start the engine and allow it to warm up.

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
perates correctly).

o

4. Plug in and turn on the next load.

. Let the generator stabilize again.

5

Repeat steps 4 and 5 for each additional load.

If an appliance begins to operate abnormally, becomes sluggish
or stops suddenly, then turn it off and disconnect it.

ATTENTION

Heavy overloading will trip the circuit breaker.
Slight overloading may not trip the circuit breaker
but will shorten the life of the generator.

W

attage Reference Chart

Tool/Appliance Rated (Running) Watts Surge (Starting) Watts

Light Bulb 100 100

Microwave Oven (625 W) 625 625

Battery Charger (15 amps) 380 380

Computer, Desktop 100 400

Computer, Monitor 100 200

AM/FM Clock Radio 300

Small Hand Drill 500 750

Jigsaw 600 80

Home Security System 100 300

Small T.V. 400 —

Slow Cooker 450 —

—

topping the Engine

S

Turn off all attached appliances and tools and unplug their cords. Move the

C switch, then the engine switch and finally the fuel lever to "off" positions.

A

Transport

Make sure the engine switch and fuel lever are in the "off" positions.

eep the generator level to prevent fuel spillage. Fuel vapor or spillage

K
may ignite.

WARNING

ontact with a hot engine or exhaust system can cause serious

C
burns or fires. Let the engine cool before transporting the generator.

ake care not to drop or strike the generator while transporting. Do not

T
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.

Periodic Maintenance

Spark Plug Inspection

1. Remove the spark plug cap.

2. Remove the spark plug.

Inspect the spark plug—it should be a tan color. Discard if the

3.
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).

*Wattages listed are for reference only. Check the appliance or tool for

the actual wattage.

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.

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6. Thread the spark plug back in by hand to prevent cross-threading.
The correct torque to use is 14 ft-lbs (20 Nm).

ATTENTION

The spark plug must be securely tightened. An improperly tightened
spark plug can become very hot and could damage the engine.

6

ir Filter Cleaning

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AIR FILTER COVER

AC

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ET

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AIR FILTER

OFF

ON

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UEL SEDIMENT CUPFUEL SEDIMENT CUPFUEL SEDIMENT CUP

FUEL TANK FILTERFUEL TANK FILTERFUEL TANK FILTER

A

A dirty air filter will restrict airflow to the carburetor. Service the air filter

egularly to prevent carburetor malfunction (service more frequently in

r
extremely dusty areas).

. Unscrew the air filter cover.

1

2. Remove the filter element and wash well with an inflammable solvent
or soap and water.

. Pour a small amount of oil (foam-air-filter or SAW #20 motor oil

3

recommended) into the filter element and gently squeeze out excess oil.
Never wring out the filter element, as it may tear. The generator will

moke if too much oil remains in the filter element.

s

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.

Fuel Sediment Cup Cleaning

1. Remove the cup at the bottom of the fuel valve using a small spanner.

2. Clean with a scouring pad and brush, rinse with water and allow to air
dry, then reinstall.

WARNING

Using gasoline or other flammable solvent to c
can cause a fire or e

xplosion.

lean the filter element

ATTENTION

Never run the generator without the air cleaner; this will cause rapid
engine wear.

Fuel Tank Filter Cleaning

1. Remove the filter from below the fuel tank cap using your fingers.

2. Clean with a scouring pad and brush, rinse with water and allow
to air dry, then reinstall.

7

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Maintenance Chart

Item Remarks

Spark Plug

ir Filter

A

Fuel Filter

Fuel Line

Exhaust System

Carburetor

Cooling System

Check condition. Adjust gap and clean. Replace if necessary.

Clean, replace if necessary.

Clean fuel valve and fuel tank filter

Check fuel hose for cracks or other damage.

Replace if necessary.

Check for leakage. Retighten or replace gasket if necessary.

Check muffler screen. Clean or replace if necessary.

Check choke operation.

Check for rain damage.

. Replace if necessary.

Daily

(Preoperation

Check)

First Month

(20 hrs)

Three Months

(50 hrs)

X

X

X

X

X X

Six Months

(100 hrs)

X

X

Twelve Months

(300 hrs)

X

Starting System

Decarbonization

Fittings/Fasteners

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-pr

Do not insert any objects through cooling slots. Cooling slots must not
become clogged with snow, leaves or any other foreign material.

essure air (less than 25 psi) to blow away dirt.

Remove carbon deposits in muffler, combustion chamber.

Check recoil starter operation.

Increase frequency if necessary.

Check. Replace if necessary.

X

X

X

8

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Troubleshooting

Generator Won't Start

1. Check the fuel/oil mix level and add more if necessary.

. Make sure the engine switch and fuel valve are set to the "on" positions.

2

3. Test the spark plug using the following procedure:

• Remove the spark plug cap and clean any dirt from around the
spark plug.

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.

Generator Shuts Down While Running

1. Check the fuel/oil mix level and add more if necessary.

Storage

our generator should be started at least once every seven days and

Y
allowed to run at least 30 minutes. If you must store the generator for
longer periods of time, use the following guidelines:

torage TimeService Procedure

S

• Pull the starter cord gently; sparks should jump across the gap.
Reinstall the spark plug or replace if necessary.

WARNING

Make sure no spilled fuel is near the spark plug when testing.
The fuel may ignite.

4. Make sure the fuel valve filter, fuel line and carburetor are not clogged.

5. Check cylinder heads for looseness and tighten the bolts that secure
them if necessary.

Check the cylinder head gasket for damage and replace it if necessary.

6.

7. Contact AES if the generator still won't start.

No AC Output

1. Make sure the AC protector has not been not tripped. Press the reset
button if necessary.

2. Check for poor connections or defective cords.

3. Test the connected device(s) for proper operation.

One to Two
Months

Two Months
to One Year

Over One
Year

*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.

Place the generator in a dust-free, dry area and cover with a clean cloth.

Fill with fresh gasoline/oil mix and add fuel stabilizer.

Run the engine for several minutes to circulate the

dditive through the carburetor.

a

Fill with fresh gasoline/oil mix and add fuel stabilizer.

Run the engine for several minutes to circulate the
additive through the carburetor.

Drain the carburetor bowl and carburetor.

Fill with fresh gasoline/oil mix and add fuel stabilizer.

Run the engine for several minutes to circulate the
additive through the carburetor*.

Drain the carburetor bowl and carburetor.

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.

Pull the starter cord until you feel resistance and stop.

Warning

Storage co

ver a hot generator.

o

vers can be flammable. Do not place a storage cover

Generator Falters Under Load

The load is too heavy. Reduce the number of devices connected

1.
(see "Electrical Loads" on page 5).

2. A connected device has a short circuit. Disconnect the shorted load.

The generator has a short circuit. Contact AES.

3.

9

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General Specifications 12-Month Standard Warranty

Aquatic Eco-Systems, Inc. (AES) products, when properly installed and

Model GT950

L x W x H

Weight (Empty)

Engine Type

Fuel/Oil Mix

Displacement

Operation Time

Noise Level @ 25 ft (7 m)

Cooling System

Ignition System

Fuel Tank

Capacity

Spark Plug

12.5 x 12.5 x 14 in (32 x 32 x 36 cm)

44 lbs (20 kg)

-Stroke

2

Fuel/Oil Mix of 50 to 1

63 cc

8 hrs

64 dB

Forced Air

ransistor Control Ignition (T.C.I.)

T

1.1 gal (4 liters)

BPR5ES (NGK)

.028 to .031 in (.7 to .8 mm) Gap

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
[e-mail]. The buyer is responsible for freight charges,
both to and from AES, in all cases.

AES warranties do not extend to any goods or parts which have been

ubjected to misuse, modification, lack of maintenance, neglect, transit

s
damage or damage resulting from lightning, natural or accidental flooding,
fire or accident. Operating use or circumstances outside normal conditions,

uch as high heat or high moisture, may also be excluded from this warranty.

s

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.

AES WILL NOT BE RESPONSIBLE OR LIABLE FOR INDIRECT OR
CONSEQUENTIAL DAMAGES OF ANY KIND, however arising,
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.

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

6/17/05 db01

10

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