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Item # GEN4000DF-STW
4000 SURGE WATTS / 3500 RUNNING WATTS
DUAL FUEL LPG LIQUID PROPANE & GASOLINE
PORTABLE HIT WELDING
GENERATOR + WELDER INSTRUCTION MANUAL
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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!
QUESTIONS? PROBLEMS? CALL US FIRST!
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.
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Summary of Contents for Buffalo Tools GEN4000DF-STW
- Page 1 Item # GEN4000DF-STW 4000 SURGE WATTS / 3500 RUNNING WATTS DUAL FUEL LPG LIQUID PROPANE & GASOLINE PORTABLE HIT WELDING GENERATOR + WELDER 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.
- Page 2 10-85 Duty Cycle Usable electrodes (mm) 1.6-2.5 Engine Engine Type 4-stroke single cylinder with forced air cooling system Ignition System Non-contact transistor (T.C.I.) Starting System Recoil GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
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Page 3: Table Of Contents
STORAGE/TRANSPORT PROCEDURES ........................22 TROUBLESHOOTING ..............................23 SPECIFICATIONS ................................25 PARTS DIAGRAM ................................26 WIRE DIAGRAM ................................32 EMISSION CONTROL SYSTEM WARRANTY ......................... 33 WELDER USAGE ................................35 GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... -
Page 4: Recognize Safety Symbols, Words And Labels
Consult a qualified electrician, electrical inspector, and/or the local agency having jurisdiction. Some areas require generators to be registered with local utility companies. Additional regulations may apply if this generator will be used at a construction site. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... - Page 5 Avoid the use of extension cords if possible. If you choose to use them, be sure they are sized adequately to handle the flow of electricity. An undersized cord can overheat, short out and cause a fire. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 6 Sensitive electronic equipment should be operated on approved inverter type generators or pure sine wave generators. For additional information consult the devices operation manual or call customer service at 1-866-460-9436 Monday - Friday, 8 AM - 4 PM Central Time. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 7 All doors, panels, covers and other protective devices should be closed during operation. Seek professional help when encountering machine failure. Contact customer service with questions. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 8 GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 9 In addition to the previously described safety information, familiarize yourself with all safety and hazard notices on this generator. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
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Page 10: Package Contents
PACKAGE CONTENTS The following items are supplied with this Model GEN4000DF-STW Dual Fuel Generator + Welder. Verify that all items are included. STOP! If there are missing items, call 1-866-460-9436, Monday - Friday, 8 AM - 4 PM Central Time for customer service. -
Page 11: Components
10) LP gas inlet 11) Welder Switch 12) AC Circuit Protector 13) DC Circuit Protector 14) Stick/TIG Welding Current Knob 15) “+” Output Terminal 16) “-“ Output Terminal GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... -
Page 12: Preparing The Generator For Use
When the engine crankcase is full, the oil level should reach all the way up to the threads as illustrated in Figure 2. 4. Replace the oil filler/dipstick cap. Figure 1 - Unscrew the Oil Cap Figure 2 - Add Oil To TOP Of Threads GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... -
Page 13: Step 2 - Connect Fuel
Disconnect all electrical loads from the generator set before starting the engine. The generator may be hard to start if a load is connected. Step 6 DC OUTPUT no load connected. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... -
Page 14: Step 3 - Ground The Generator
5. Confirm that the oil filler/dipstick cap is properly screwed in place when finished verifying the oil level. Model GEN4000DF-STW Oil Capacity 18.5 ounces Model GEN4000DF-STW Oil Type Recommended High Detergent Motor Oil, SAE10W-30 GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... -
Page 15: Step 3 - Ground 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 GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... -
Page 16: Using The Generator
(27 inch color) electric water heater (40 gallon) 4000 window air conditioner (10000 BTU) 1200 1800 window fan Figure 7 - Estimated wattage requirements for common electrical devices. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... - Page 17 1200 2400 1800 3600 2400 4800 3000 6000 3600 7200 4800 9600 NR = Not Recommended. Figure 9 - Maximum Extension Cord Lengths by Power Requirement GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
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Page 18: Dc Usage
Improper maintenance and/or failure to correct any problems prior to operating this generator can cause a malfunction which could cause death or serious injury. Always follow the inspection and maintenance recommendations and schedules in this manual. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... -
Page 19: Recommended Maintenance Schedule
NOTE: Never dispose of used motor oil in the trash, down a drain or on the ground. Put oil in a sealed container and contact your local recycling center or auto garage to arrange oil disposal. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... -
Page 20: Air Filter Maintenance
7. Replace the sponge-like elements in the air filter casing (the fine element first) and Figure 14 - Removing the Air Filter Casing. replace the cover. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... -
Page 21: Spark Plug Maintenance
Fuel line installation instruction ( include the carburetor and fuel tank, etc.) 1. Connect clamp (Ф7.5) to the fuel hose. 2. Slide fuel hose onto connection until it touches the bottom. 3. Then secure with clamp. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... -
Page 22: Fuel Tank Usage And Maintenance Instructions
7. Turn the fuel valve to the “off” position and replug the fuel hose to the carburetor. 8. Tighten the drain bolt of the carburetor. 9. Store the drained gasoline in a suitable place. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... -
Page 23: Troubleshooting
Look for the burn spots on the back side of the AVR. If there is burn spots, replace the AVR. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... - Page 24 The electrode holder becomes very hot. actual working current. Replace it with a bigger rated current. The output polarity connection is incorrect. Exchange the Excessive spatter in MMA welding. polarity. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
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Page 25: Specifications
Run time = 12 hrs @ 50% load per 20 lbs of LPG fuel Oil Capacity (SAE10W-30) 18.5 ounces Welder Power Voltage(V) Power Frequency(Hz) Max Input Power(KVA) Efficiency(%) Max No load voltage(V) Current range(A) 10-85 Duty cycle GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... -
Page 26: Parts Diagram
PARTS DIAGRAM GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... - Page 27 GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 28 GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 29 GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 30 GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 31 GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
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Page 32: Wire Diagram
WIRING DIAGRAM GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... -
Page 33: Emission Control System Warranty
(3) Any warranted part that is scheduled for replacement as required maintenance in your Owners Manual is warranted for the period of time before the first GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... - Page 34 (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 GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
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Page 35: Welder Usage
- Always be aware of your work environment. Be sure to keep other people, especially children, away from you while welding. - Keep harmful arc rays shielded from the view of others. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder... - Page 36 - Do not touch the welding wire and the ground or grounded work piece at the same time. - Do not use a welder to thaw frozen pipes. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 37 Welded materials are hot and can cause severe burns if handled improperly. -Do not touch welded materials with bare hands. -Do not touch MIG gun nozzle after welding until it has had time to cool down. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 38 - Do not touch or handle PC board without being properly grounded with a wrist strap. Put PC board in static proof bag to move or ship. - Do not put hands or fingers near moving parts such as drive rolls of fan GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 39 The power cord connects the welder to the 120V volt power supply. Plug the 15 amp plug into a 115V/20Amp receptacle to supply power to the welder. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 40 ANSI approved welding helmet. 1.8 Touch the tungsten that is installed in the TIG torch to the work piece, then quickly pull away approximately 1/4" to create an arc. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 41 If the base metal pieces to be joined are thick or heavy, it may be necessary to bevel the edges with a metal grinder, the correct bevel should be around 60 degree. See following picture: GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 42 Note: Rate of travel over the work also affects the weld. To ensure proper penetration and enough deposit of rod, the arc must be moved slowly and evenly along the weld seam. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 43 2 movements are required; downward (as the electrode is consumed) and in the direction the weld is to be laid, as in following figure: GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 44 A good starting point for your electrode angle is about 30 degrees DOWN from being perpendicular to the work piece. GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 45 Every six months, or as necessary, remove the cover panel from the welder and air-blow any dust and dirt • that may have accumulated inside the welder. Replace power cord, ground cable, ground clamp, or electrode assembly when damaged. • GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...
- Page 46 Reduce the welding travel speed. Maybe incorporate a slight weave over the joint. Welding Bead Is Too Thick The welding travel speed is to slow Increase the welding travel speed. 201810 GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder...