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Sportsman GEN4000DF Instruction Manual

4000 surge watts / 3500 running watts dual fuel generator instruction manual
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DUAL FUEL GENERATOR INSTRUCTION MANUAL
READ ALL INSTRUCTIONS AND WARNINGS BEFORE USING THIS PRODUCT.
This manual provides important information on proper operation & maintenance. Every effort has been
made to ensure the accuracy of this manual. These instructions are not meant to cover every possible
condition and situation that may occur. We reserve the right to change this product at any time without
prior notice.
IF THERE IS ANY QUESTION ABOUT A CONDITION BEING SAFE OR UNSAFE,
DO NOT OPERATE THIS PRODUCT!
Visit our website for Troubleshooting / Frequently Asked Questions
DO NOT RETURN THIS GENERATOR TO THE RETAILER!
If you experience a problem, have questions or need parts for this product, call Customer Service at
1-866-460-9436, Monday-Friday, 8 AM - 4 PM Central Time. A copy of the sales receipt is required.
FOR CONSUMER USE ONLY – NOT FOR PROFESSIONAL USE.
KEEP THIS MANUAL, SALES RECEIPT & APPLICABLE WARRANTY FOR FUTURE
REFERENCE.
GEN4000DF
4000 Surge Watts / 3500 Running Watts
http://sportsmanseriesbrand.com/generators

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  Summary of Contents for Sportsman GEN4000DF

  • Page 1 GEN4000DF 4000 Surge Watts / 3500 Running Watts DUAL FUEL GENERATOR INSTRUCTION MANUAL READ ALL INSTRUCTIONS AND WARNINGS BEFORE USING THIS PRODUCT. This manual provides important information on proper operation & maintenance. Every effort has been made to ensure the accuracy of this manual. These instructions are not meant to cover every possible condition and situation that may occur.
  • Page 2 GEN4000DF Portable Dual Fuel Generator FEATURES: 4000 Surge Watts / 3500 Running Watts* • 4-Stroke OHV Engine 212cc • Recoil Start • 7.0 HP Dual Fuel Engine • (Propane Tank Not Included) • • 1 - 12V D/C Outlet • 4 - 120V A/C Outlets •...
  • Page 3: Table Of Contents

    Air Filter Maintenance ............................20 Changing Fuel Line ............................... 20 Spark Plug Maintenance ............................20 Emptying The Fuel Tank ............................20 STORAGE/TRANSPORT PROCEDURES ........................21 TROUBLESHOOTING ..............................22 PARTS DIAGRAM ................................24 EMISSION CONTROL SYSTEM WARRANTY ........................ 31 GEN4000DF Portable Dual Fuel Generator...
  • Page 4: Recognize Safety Symbols, Words And Labels

    Parts replaced during warranty repairs will be considered as part of the original product and will have the same warranty period as the original product. This warranty gives you specific legal rights, and you may have other rights that vary state to state. GEN4000DF Portable Dual Fuel Generator...
  • Page 5: Important Safety Instructions

    According to the State of California, the exhaust from this generator contains chemicals known to cause cancer, birth defects, or other reproductive harm. Chemicals: This product contains or emits chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. GEN4000DF Portable Dual Fuel Generator...
  • Page 6 Caution is necessary when near the engine’s recoil starter. Usage: Prolonged exposure to high noise levels can be hazardous to hearing. Always wear ANSI-approved hearing protection when operating or working around the generator when it is running. GEN4000DF Portable Dual Fuel Generator...
  • Page 7 • Do not operate an excessive number of electrical devices in excess of the wattage capacity of this generator. • Do not turn on electrical devices until after they are connected to this generator. • Turn off all connected electrical devices before stopping this generator. GEN4000DF Portable Dual Fuel Generator...
  • Page 8 In addition to the previously described safety information, familiarize yourself with all safety and hazard placards on this generator. GEN4000DF Portable Dual Fuel Generator...
  • Page 9: Package Contents

    GENERATOR TO THE RETAILER. Item List: Set of 2 DC connector wires for charging 12 Volt automotive-type batteries Spark plug wrench 5.9 Ft. Regulator Hose Kit (YOU MUST USE THE SUPPLIED REGULATOR FOR SAFE OPERATION) GEN4000DF Portable Dual Fuel Generator...
  • Page 10: Components

    8) AC Circuit Protector 9) Engine Switch 10) 120 Volt AC Outlet 11) DC Circuit Protector 12) 12 Volt DC Outlet 13) Grounding Terminal 14) 120 Volt RV Outlet 15) Voltmeter 16) LP gas inlet GEN4000DF Portable Dual Fuel Generator...
  • Page 11: Preparing The Generator For Use

    When the engine crankcase is full and almost overflowing, the oil level should reach the lower lip of the oil filling opening as shown in Figure 2. 4. Replace the oil filler/dipstick cap and close the oil access panel. Figure 1 – Unscrew the Dipstick Cap Figure 2 - Add Oil GEN4000DF Portable Dual Fuel Generator...
  • Page 12: Step 2 - Add Gasoline

    If using LPG, first connect the regulator that was included with the generator to the Propane Fuel Tank, then connect the other end to the Gas Inlet. Make sure the LPG cylinder is vertical and securely positioned. GEN4000DF Portable Dual Fuel Generator...
  • Page 13: Step 3 - Ground The Generator

    87 or higher according to “Step 2 - Add Gasoline” of the “Using this Generator for the First Time” section of this manual. Fuel Tank Capacity (gallons) Fuel Type Fresh, Unleaded Gasoline Octane Rating 87 or Higher GEN4000DF Portable Dual Fuel Generator...
  • Page 14: Step 3 - Ground The Generator

    No. 12 AWG (American Wire Gauge) stranded copper wire. The other end of this grounding wire should be connected to a copper or brass grounding rod that is driven into the earth. Grounding codes can vary by location. Contact a local electrician for information on grounding regulations for your area. GEN4000DF Portable Dual Fuel Generator...
  • Page 15: Starting The Generator

    The choke is used to provide an enriched fuel mixture when starting a cold engine. It can be opened and closed by operating the choke rod manually. Pull the rod out toward CLOSED to enrich the mixture for cold starting Figure 4 The Recoil Start is located on the left side of the generator. GEN4000DF Portable Dual Fuel Generator...
  • Page 16: Using The Generator

    120 Volt, single phase, 60 Hz loads to the 120 well water pump (1/3 HP) 1000 2000 Volt outlet. Connect 12 Volt, DC loads to the 12 Volt window air conditioner (10000 BTU) 1200 1800 outlet. window fan GEN4000DF Portable Dual Fuel Generator...
  • Page 17: Dc Usage

    Fuel Petcock to OFF position and let the engine continue to run until it burns off all remaining gasoline fuel in carburetor. Then turn the propane tank ON. If using propane and you want to switch to gasoline, turn the propane tank OFF and turn the gas Fuel Petcock ON. GEN4000DF Portable Dual Fuel Generator...
  • Page 18: Stopping The Generator

    Never clean this generator with a bucket of water and/or a hose as water can get inside and cause a short circuit or corrosion. Never use gasoline to clean parts of this generator. GEN4000DF Portable Dual Fuel Generator...
  • Page 19: Checking The Oil Level

    WILL NOT RUN IF THE OIL IS LOW. START WITH 20 OUNCES, THEN ADD MORE UNTIL ALMOST OVERFLOWING. TROUBLESHOOTING: IF THE GENERATOR WILL NOT START, DOUBLE CHECK THAT THE OIL LEVEL IS COMPLETELY FULL AND ALMOST OVERFLOWING. Figure 8 – Adding oil GEN4000DF Portable Dual Fuel Generator...
  • Page 20: Air Filter Maintenance

    To store this generator for extended time, the fuel needs to be drained from the carburetor. To drain the gasoline from the carburetor turn the fuel valve to the “off” position while the engine is running. The generator will shut down when all the gasoline in the carburetor has been used. GEN4000DF Portable Dual Fuel Generator...
  • Page 21: Storage/Transport Procedures

    2 months to 1 year Empty the fuel tank. (See “Emptying the Fuel Tank” in the “Maintenance/Care” section.) 1 year or more Empty the fuel tank. (See “Emptying the Fuel Tank” in the “Maintenance/Care” section.) Disconnect the spark plug. GEN4000DF Portable Dual Fuel Generator...
  • Page 22: Troubleshooting

    Generator runs but does not support all Short in one of the connected devices. Disconnect any faulty or short-circuited connected electrical devices. electrical loads. Air filter is dirty. Clean or replace air filter. GEN4000DF Portable Dual Fuel Generator...
  • Page 23 USING IT. IT COULD CAUSE DAMAGE TO PERSONAL PROPERTY. Turn it clockwise to turn volts up and kick the idle up. You may have to compensate for the increased idle from the governor screw with the idle screw. GEN4000DF Portable Dual Fuel Generator...
  • Page 24: Parts Diagram

    PARTS DIAGRAM GEN4000DF Portable Dual Fuel Generator...
  • Page 25 GEN4000DF Portable Dual Fuel Generator...
  • Page 26 (EPA Model Generator Doesn’t (EPA Model Generator Doesn’t Include These Parts) Include These Parts) GEN4000DF Portable Dual Fuel Generator...
  • Page 27 GEN4000DF Portable Dual Fuel Generator...
  • Page 28 GEN4000DF Portable Dual Fuel Generator...
  • Page 29 GEN4000DF Portable Dual Fuel Generator...
  • Page 30 GEN4000DF Portable Dual Fuel Generator...
  • Page 31: Emission Control System Warranty

    (2) Any warranty part that is scheduled only for regular inspection in your Owner’s Manual is warranted for warranty period stated above. Any such part repaired or replaced under warranty will be warranted for the remaining warranty period. GEN4000DF Portable Dual Fuel Generator...
  • Page 32 (a) Purge valves (b) Carbon canister (c) canister Mounting Brackets (d) Fuel Cap (e) Fuel Tank (7) Miscellaneous items used in above systems including: (a) Switches (b) Hoses, belts connectors, and assemblies (8) Air injection system (a) Pulse valve 2015/11 GEN4000DF Portable Dual Fuel Generator...