QJ Item # GEN4000DF-STW 4000 SURGE WATTS / 3500 RUNNING WATTS DUAL FUEL LPG LIQUID PROPANE & GASOLINE PORTABLE HIT WELDING GENERATOR + WELDER INSTRUCTION MANUAL d 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.
Item # GEN4000DF-STW 4000 Surge Watts / 3500 Running Watts This unit is a Dual Fuel LPG or Gasoline Fuel powered generator plus Stick/TIG welder. FEATURES: • 4000 Surge Output / 3500 Running Watts* • 7 HP Engine, 4 Stroke • Displacement (CC): 212cc • AVR Automatic Voltage Regulation • Low Oil Shut Off • UL Listed Electrical Components • Engine Shut Off Switch • Circuit Breaker & Power Outlets • Spark Plug Model F7RTC • 1-12V DC Outlet • 4-120V Outlets • 1-120V RV Outlet • 85A Welding Machine • 3.
TABLE OF CONTENTS RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS...............................................................................................4 PACKAGE CONTENTS PACKAGE CONTENTS .........................................................................................................................................10 COMPONENTS .....................................................................................................................................................
RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS What You Need to Know About Safety Instructions Warning and Important Safety Instructions appearing in this manual are not meant to cover all possible conditions and situations that may occur. Common sense, caution and care must be exercised when operating or cleaning tools and equipment. Always contact your dealer, distributor, service agent or manufacturer about problems or conditions you do not understand. This is the safety alert symbol.
Notice Regarding Emissions: Engines certified to comply with U.S. EPA emission regulations for SORE (Small Off Road Equipment) are certified to operate on regular unleaded gasoline and may include the following emission control systems: Three-Way Catalyst (TWC) (if equipped), and Engine Modifications (EM).
Usage: Misuse of this generator can damage it or shorten its life. • Use this generator only for its intended purpose. • Operate this generator only on a dry, level surface. • Allow this generator to run for several minutes before connecting any electrical devices. • Promptly turn off any malfunctioning devices and disconnect them. • Do not operate an excessive number of electrical devices in excess of the wattage capacity of this generator.
Usage: Welding is dangerous, and may cause damage to you and others, so take good protection when welding. For details, please refer to the operator safety guidelines in conformity with the accident prevention requirements of the manufacturer. Professional training is needed before operating the machine. l Wear protective flame-resistant gloves. l Clothing shall provide sufficient coverage and be made of suitable materials to minimize skin burns caused by sparks, spatter or radiation.
GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder 8
In addition to the previously described safety information, familiarize yourself with all safety and hazard notices on this generator.
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. Item List: Set of 2 DC connector wires for charging 12 Volt automotive-type batteries Spark plug wrench 5.9 Ft.
GENERATOR COMPONENTS Observe the locations and functions of the various components and controls of this generator.
PREPARING THE GENERATOR FOR USE Using this Generator for the First-Time STOP! The following section describes the required steps for preparing this generator for the first use. Failure to correctly perform these steps can damage this generator and/or shorten its life. If still unsure about how to perform any of these steps after reading this section, call 1-866-460-9436 Monday - Friday, 8 AM - 4 PM Central Time for customer service.
Step 2 – Connect Fuel Sulfur, water, dust, etc. are harmful for engine. If the gas supply source (LPG) contains these harmful elements, user must use filter to remove sulfur, water etc. and clean gas. Otherwise, the engine service lifetime will be shortened. Choose either LPG or Gasoline fuel. If using LPG, first connect the regulator that was included with the generator to Propane Fuel Tank, then connect the other end to the Gas Inlet.
Step 3 - Ground the Generator Failure to properly ground this generator can result in electrocution. Ground this generator by tightening the grounding nut against a grounding wire as illustrated in Figure 3. A No. 12 AWG (American Wire Gauge) stranded copper wire is generally an acceptable grounding 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.
Step 3 - Ground the Generator Failure to properly ground this generator can result in electrocution. Ground this generator by tightening the grounding nut against a grounding wire as previously illustrated in Figure 3. A generally acceptable grounding wire is a 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.
USING THE GENERATOR After the engine has been running for several minutes, electrical devices may be connected to this generator. AC Usage Electrical devices running on AC current may be connected according to their wattage requirements. The rated (running) and surge wattage: Model GEN4000DF-STW Rated (Running) Wattage Model GEN4000DF-STW Surge Wattage 3500 4000 The rated (running) wattage corresponds to the maximum wattage a generator can output on a continuous basis.
Connect electrical devices to this generator according to the following procedure: 1. Allow the engine to run for several minutes after it has been started. 2. Confirm that the electrical device is switched off prior to plugging it into this generator. Connect only electrical devices that are in good working order. Faulty devices or power cords present the risk of electrical shock. Immediately turn off and disconnect any device that commences to operate abnormally, sluggish or abruptly stops.
DC Usage The DC outlet is only for recharging 12 Volt automotive-type batteries. Do not connect any other device to this outlet. Use this generator only for recharging 12 Volt batteries. NEVER attempt to jumpstart a car with this generator. Failing to use the correct procedure can cause a battery to explode, seriously injuring anyone nearby. Keep heat, sparks, flame and smoking materials away from the battery. To connect 12 Volt batteries to the DC outlet: 1.
Recommended Maintenance Schedule Each Use Engine Oil Air Filter Fuel Filler Cap Spark Plug Check Level Replace Check Clean Clean Check/Clean Clean Every Month or Each 20 Hrs Every 3 Months or Each 50 Hrs Every 6 Months or Each 100 Hrs Every Year or Each 300 Hrs X X (First Use) X X X X X X Figure 10 - Recommended maintenance schedule Cleaning the Generator Always try to use this generator in a cool dry place.
To add oil to the engine crankcase: 1. Confirm that this generator is on a level surface. 2. Unscrew the oil filler/dipstick cap from the engine as illustrated in Figure 11 above. 3. Using a funnel, add high detergent motor oil to fill the engine crankcase to the correct quantity. SAE10W-30 oil is recommended for general use. When the engine crankcase is full, the oil level should reach the top of the oil filling opening as shown in Figure 13.
Spark Plug Maintenance The spark plug is essential for proper engine operation. The spark plug should be intact, free of deposits, and properly gapped. A bad or incorrectly installed spark plug can cause engine damage. To inspect the spark plug: 1. Remove the spark plug by pulling on the spark plug cap. 2. Unscrew the spark plug from this generator by using the included spark plug wrench. 3. Visually inspect the spark plug. If it is cracked and/or chipped, discard and install a new spark plug.
Fuel Tank Usage And Maintenance Instructions 1, Please pay attention to the cleanliness of the fuel tank inside when you add the fuel into the fuel tank at the first time, and use a small amount of diesel oil (kerosene) to flush fuel tank inside, after flushed fuel tank inside, and then start filling the fuel. 2, Please pay attention to the sundries will be went into the fuel tank inside when you are filling the fuel; and the fuel quality will affect the performance and safety of the equipment.
TROUBLESHOOTING IMPORTANT: If trouble persists, call our customer help line at 1-866-460-9436, Monday - Friday, 8 AM - 4 PM Central Time. Symptom Engine will not start. Generator runs but does not support all connected electrical devices. Cause Solution Fuel valve is turned to "closed." Choke is open. Propane Tank is out of fuel. Turn fuel valve to "open." Close the choke. Replace propane fuel tank. Spark plug is dirty. Clean spark plug. Generator is not on level surface.
Welder Troubleshooting: The following operation requires sufficient professional knowledge on electric aspect and comprehensive safety knowledge. Make sure the input cable of the machine is cut off from the electricity utility before uncovering the welding machine. Malfunction Cause and Solution Turn on the machine, the power LED is off, the fan doesn't work, and no welding output. (1) Check if the power switch is closed. (2) No input power.
SPECIFICATIONS Generator Type Brush, Revolving Magnetic Field, Self Exciting, 2-Pole, Single Phase AC Output Rated Wattage (W) 3500 Surge Wattage (W) 4000 Rated Voltage (V) 120 Rated Amperage 20A+20A+20A+20A at 120 V 30 A at 120 RV Rated Frequency (Hz) 60 Phase Single DC Output Voltage (V) 12 Circuit Breaker Amperage (A) 8 Engine Approvals EPA Engine Model (HP) 7 Engine Type 4-stroke single cylinder with forced air cooling system. Ignition System Non-contact transistor (T.C.I.
PARTS DIAGRAM GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder 26
GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder 27
GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder 28
GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder 29
GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder 30
GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder 31
WIRING DIAGRAM GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder 32
EMISSION CONTROL SYSTEM WARRANTY BUFFALO CORPORATION Your Warranty Rights and Obligations The California Air Resources Board, U.S. EPA and Buffalo Corp are pleased to explain the Emission Control System Warranty on your 2018 model year outdoor power equipment engine. California In California, new spark-ignited small off-stringent anti-smog standards. Other States, U.S. Territories In other areas of the United States, your engine must be designed, built and equipped to meet the U.S.
scheduled replacement date for that part. If the part fails before the first scheduled replacement, the part will be repaired or replaced by Buffalo Corp. according to the Subject (4) below. Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part. (4) Repair or replacement of any warranted part under the warranty provisions herein must be performed at a warranty station at no charge to the owner.
WELDER USAGE The Stick Welder is a DC only inverter stick welder with a smooth stick welding performance. It is intended for use for welding steel, stainless steel, cast iron and hard surfacing using electrodes from 1/16 inch to 3/32 inch. This unit can also perform lift start DC TIG welding on steel and stainless steel materials with the optional TIG Torch. (Argon shielding gas along with a regulator, gas hose, and TIG filler rod would also be required for TIG welding.
1.2 Your W elder’s Condition - Check ground cable, power cord and welding cable to be sure the insulation is not damaged. Always replace or repair damaged components before using the welder. - Check all components to ensure they are clean and in good operating condition before use. 1.3 Use of Your Welder Do not operate the welder if the output cable, electrode, torch, wire is wet. Do not immerse them in water. These components and the welder must be completely dry before use.
Fumes and Gases -Fumes emitted from the welding process displace clean air and can result in injury or death. -Do not breathe in fumes emitted by the welding process. Make sure your breathing air is clean and safe. -Work only in a well-ventilated area or use a ventilation device to remove welding fumes from the environment where you will be working. -Do not weld on coated materials (galvanized, cadmium plated or containing zinc, mercury or barium). They will emit harmful fumes that are dangerous to breathe.
Sparks/Flying Debris Welding creates hot sparks that can cause injury. Chipping slag off welds creates flying debris. -Wear protective apparel at all times: ANSI-approved safety glasses or shield, welder’s hat and ear plugs to keep sparks out of ears and hair. Electromagnetic Field -Electromagnetic fields can interfere with various electrical and electronic devices such as pacemakers.
USE AND CARE Do not modify the welder in any way. Unauthorized modification may impair the function and/or safety and could affect the life of the equipment. There are specific applications for which the welder was designed. Always check of damaged or worn out parts before using the welder. Broken parts will affect the operation. Replace or repair damaged or worn parts immediately. Store idle welder. When not in use, store it in a secure place out of the reach of children.
1. INSTALLATION OF OPTIONAL TIG TORCH (Call Customer Service for Optional TIG Torch purchase) 1.1 Remove the ground cable and the electrode holder from the weld output connections. Install the ground cable to the Positive (+) weld output connection. 1.2 Secure the ground clamp to the work piece 1.3 Connect a regulator to a bottle of ARGON gas. Then connect the gas connection from the TIG torch to the regulator. 1.4 Connect the TIG torch weld cable to the Negative (-) weld output connection. 1.
OPERATION High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle at the power source. This welder must be grounded while in use to protect the operator from electrical shock. If you are not sure if your outlet is properly grounded, have it checked by a qualified electrician. Do not cut off the grounding prong or alter the plug in any way and do not use any adapter between the welder's power cord and the power source receptacle.
Based on different welding position, there are different welding joint, see following image: 2. GROUND CLAMP CONNECTION Clear any dirt, rust, scale, oil or paint on the ground clamp. Make certain you have a good solid ground connection. A poor connection at the ground clamp will waste power and heat. Make sure the ground clamp touches the metal. 3. ELECTRODE The welding electrode is a rod coated with a layer of flux.
5. SETTING THE AMPERAGE CONTROL The welder has an infinite current control. It is capable of welding with electrodes up to 3/32” diameter. There is no golden rule that determines the exact amperage required for every situation. It is best to practice your welds on scrap metal which matches the metals you intend to work with to determine correct setting for your job. The electrode type and the thickness of the work piece metal determine the amount of heat needed in the welding process.
6.3 Types of weld bead The following paragraphs discuss the most commonly used arc welding beads. The stringer bead is formed by traveling with the electrode in a straight line while keeping the electrode centered over the weld joint. Stringer Bead Weave Bead The weave bead is used when you want to deposit metal over a wider space than would be possible with a stringer bead. It is made by weaving from side to side while moving with the electrode.
9.5 Judge the good weld bead When the trick of establishing and holding an arc has been learned, the next step is learning how to run a good bead. The first attempts in practice will probably fall short of acceptable weld beads. Too long of an arc will be held or the travel speed will vary from slow to fast (see following) A. B. A. Weld speed is too fast. B. Weld speed is too slow. C. C. Arc is too long. D. D. Ideal weld.
TROUBLESHOOTING SYMPTOM Unit Does Not Power Up Can Not Create An Arc POSSIBLE CAUSE Unit Is Not Plugged In Input Power Circuit Breaker Not On The Main Power Switch Is Not Working Work Piece is Painted Or Rusty Ground Clamp Is Connected Where There Is Paint Or Rust Ground Clamp Is Not Electrically Connected To The Work Piece Amperage Too Low for Electrode Overload Indicator Is On The internal temperature is too high. Electrode Holder or ground cable getting hot. Output Connections Getting Hot.