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Buffalo Tools GEN4000DF-STW, Instruction Manual

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     Item # GEN4000DF-STW 

       4000 SURGE WATTS / 3500 RUNNING WATTS 

DUAL FUEL LPG LIQUID PROPANE & GASOLINE  

PORTABLE HIT WELDING 

GEN 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. 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.  

Summary of Contents for GEN4000DF-STW

Page 1: ...t 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...

Page 2: ...s LP LPG and Propane Or Unleaded Gasoline Only 87 rating or higher This portable generator is not for use with gasoline ethanol blends with over 15 ethanol Do not use E85 fuel High Altitude Use This generator is not recommended for high altitude use above 3 000 feet If you are using a generator above sea level the generator may not function properly because of air flow getting through the mixer Pr...

Page 3: ...14 Step 1 Verify Oil Level 14 Step 3 Ground The Generator 15 STARTING THE GENERATOR 15 USING THE GENERATOR 16 AC Usage 16 DC Usage 18 STOPPING THE GENERATOR 18 MAINTENANCE CARE 18 Recommended Maintenance Schedule 19 Cleaning The Generator 19 Checking The Oil Level 19 Changing Adding Oil 19 Air Filter Maintenance 20 Spark Plug Maintenance 21 Spark Arrester 21 Changing Fuel Line 21 Fuel Tank Usage A...

Page 4: ...ng the states with high altitude areas identified in 40 CFR part 1068 Appendix III To exercise this warranty DO NOT RETURN TO RETAILER Instead call Customer Service toll free at 1 866 460 9436 email address info buffalotools com and you will be instructed on where to take the engine for warranty service Take the generator and proof of purchase your receipt to the repair facility recommended by the...

Page 5: ...ane fuel and generator outdoors Before transporting turn the fuel valve to the off position and disconnect the spark plug Powerful Voltage This generator produces powerful voltage which can result in electrocution ALWAYS ground this generator before using it See Ground the Generator section in this manual Only electrical devices should be plugged into this generator either directly or with an exte...

Page 6: ...ge and use areas Storage areas must meet national electric codes for class 1 hazardous areas Propane smells like rotten eggs a skunk s spray or a dead animal IF YOU SMELL GAS NO FLAMES OR SPARKS Immediately put out all smoking materials and other open flames Do not operate lights appliances telephones or cell phones Flames or sparks from these sources can trigger an explosion or a fire WHAT IS CAR...

Page 7: ... l Keep the head away from smoke and gas to avoid inhalation of exhaust gas from welding l Keep the working environment in good ventilation with exhaust or ventilation equipment when welding Arc radiation may damage eyes or burn skin l Wear suitable welding masks and protective clothing to protect your eyes and body l Use suitable masks or screens to protect spectators from harm Improper operation...

Page 8: ...GEN4000DF STW 4000 Surge Watt 3500 Running Watt Portable Dual Fuel Generator Welder 8 ...

Page 9: ...F STW 4000 Surge Watt 3500 Running Watt Portable Dual Fuel Generator Welder 9 In addition to the previously described safety information familiarize yourself with all safety and hazard notices on this generator ...

Page 10: ...tomotive type batteries Spark plug wrench 5 9 Ft Regulator Hose Kit YOU MUST USE THE SUPPLIED REGULATOR FOR SAFE OPERATION Electrode holder and Earth clamp Face mask with filter Brush Hammer ATTENTION The Air Fuel Mixer is not adjustable Tampering with the governor can damage your generator and electrical devices and will void your warranty WARNING To prevent electrical shock from faulty appliance...

Page 11: ...of this generator 9 5 7 11 12 13 1 Fuel Tank Cap 2 Control Panel 3 Oil Access 4 Recoil Starter 5 Engine Switch 6 120 Volt AC Outlet 7 12 Volt DC Outlet 8 120 Volt RV Outlet 9 Grounding Terminal 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 1 2 2 3 4 5 7 8 9 10 8 6 6 11 14 15 16 ...

Page 12: ...nd service life When new from the package this generator contains no oil in the engine crankcase Add the correct quantity of oil before operating this generator for the first time When replenishing oil for subsequent use of this generator always determine that this generator has the correct quantity of oil Model GEN4000DF STW Oil Capacity 18 5 ounces Model GEN4000DF STW Oil Type Recommended High D...

Page 13: ...der is vertical and securely positioned If using gasoline fuel add Unleaded gasoline only with an octane rating of 87 or higher Maximum Capacity 3 2 Gallons Pre Operation Check List Step 1 Check that the gas supply source is in good condition Check that the gas inlet connection is tightly fixed and not leaking Step 2 CHOKE VALVE GRIP is at CHOKE CLOSE position The generator may be hard to start if...

Page 14: ...ction titled Using the Generator for the First Time of this manual If not review this section now Step 1 Verify Oil Level Even though this generator is equipped with an automatic shutoff to protect it from damage due to low oil it is important to check the oil level in the engine crankcase before each use to ensure that there is sufficient quantity 1 Verify that this generator is on a level surfac...

Page 15: ...ure about how to perform any of these steps call 1 866 460 9436 Monday Friday 8 AM 4 PM Central Time for customer service Disconnect all electrical loads from this generator before attempting to start Step 1 If using Propane LPG fuel connect propane tank using included regulator hose and open fuel supply on the LP tank If using gasoline make sure unleaded gasoline fuel has been added to the tank a...

Page 16: ...ual to the rated wattage for the generator i e no more than 3500 for this generator This generator can run at its surge wattage capacity for only a short time Connect electrical devices requiring a rated running wattage equal to or less than the rated wattage of this generator Never connect devices requiring a rated wattage equal to the surge wattage of a generator A device s rated running wattage...

Page 17: ...amage this generator and void the warranty 3 Make sure AC Reset button is pressed in 4 Turn on the connected electrical devices beginning with the device with the highest rated wattage requirement and then each additional device with the next lower rated wattage requirement Do not connect 50Hz or 3 phase loads to this generator Figure 8 Outlets available on this generator from left to right 4 each...

Page 18: ...eyes flush with water and immediately call a physician If battery acid is swallowed drink large quantities of milk and immediately call a physician STOPPING THE GENERATOR To stop this generator 1 Turn off all connected electrical devices and then unplug them 2 Allow this generator to run for several more minutes with no electrical devices connected to help stabilize the temperature of this generat...

Page 19: ...pe the oil off of the dipstick that is located on the inside of the cap 4 Insert the dipstick as if replacing the cap and then remove again There should be oil on the dipstick If there is no oil on the dipstick or oil is visible only at the very end of the dipstick add oil until the engine crankcase is filled see Changing Adding Oil in this section of this manual 5 Confirm that the oil filler dips...

Page 20: ...13 Adding Oil Air Filter Maintenance Occasionally verify that the air filter is free of excessive dirt The air filter will require more frequent cleaning when operating this generator in extremely dusty areas 1 Unhinge the clasps at the top and bottom of the air filter cover as shown in Figure 14 2 Remove the sponge like elements from the casing 3 Wipe the dirt from inside the empty air filter cas...

Page 21: ...rk plug use a wire brush to clean any dirt from around the spark plug base and then re gap the spark plug 6 Screw the spark plug back into place on this generator by using the included spark plug wrench 7 Replace the spark plug cap Figure 16 Locating the Spark Plug Figure 17 Spark Plug Gap Spark Arrester 1 Allow the engine to cool completely before servicing the spark arrester 2 Remove the screws ...

Page 22: ... will cause an explosion 8 The fuel tank should be regularly checked if the rubber sealing has being aged or not if you find the components are damaged please immediately stop using and replace it STORAGE TRANSPORT PROCEDURES Never place any type of storage cover on this generator while it is still hot When transporting or storing this generator for extended time Allow generator to fully cool befo...

Page 23: ...nerator then check wiring behind control panel and at the end of generator for loose connection If wires are loose tighten the screws and or nuts Be certain the plug in connectors are pushed together all the way Engine runs but there is no electrical output Reset button s is are off Push reset button s to on Loose wiring harness connection Turn off generator then check wiring behind control panel ...

Page 24: ...by potentiometer when welding 1 The current potentiometer fails Replace it 2 Check if any loose contact exists inside the machine If any reconnect Turn on the machine the power LED is on the fan works but no welding output 1 Check if any loose contact exists inside the machine 2 Open circuit or loose contact occurs at the joint of output terminal 3 The overheating LED is on a The machine is under ...

Page 25: ...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 Starting System Recoil Continuous Operating Hours Run time 9 hrs 50 load Gasoline fuel Continuous Operating Hours Run time 12 hrs 50 load per 20 lbs of LPG fuel Oil Capacity SAE10W 30 18 5 ounces ...

Page 26: ...GEN4000DF STW 4000 Surge Watt 3500 Running Watt Portable Dual Fuel Generator Welder 26 PARTS DIAGRAM ...

Page 27: ...GEN4000DF STW 4000 Surge Watt 3500 Running Watt Portable Dual Fuel Generator Welder 27 ...

Page 28: ...GEN4000DF STW 4000 Surge Watt 3500 Running Watt Portable Dual Fuel Generator Welder 28 ...

Page 29: ...GEN4000DF STW 4000 Surge Watt 3500 Running Watt Portable Dual Fuel Generator Welder 29 ...

Page 30: ...GEN4000DF STW 4000 Surge Watt 3500 Running Watt Portable Dual Fuel Generator Welder 30 ...

Page 31: ...GEN4000DF STW 4000 Surge Watt 3500 Running Watt Portable Dual Fuel Generator Welder 31 ...

Page 32: ...GEN4000DF STW 4000 Surge Watt 3500 Running Watt Portable Dual Fuel Generator Welder 32 WIRING DIAGRAM ...

Page 33: ...he power equipment engine owner you should however be aware that Buffalo Corp may deny your warranty coverage if your power equipment engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your power equipment engine to distribution center or service center authorized by Buffalo Corp as soon as the problem exists The war...

Page 34: ...repairs and must be provided without charge to the owner Such use will not reduce the warranty obligations of Buffalo Corp 10 Add on or modified parts that are not exempted by the Air Resources Board may not be used The use of any non exempted add on or modified parts by the ultimate purchaser will be grounds for disallowing a warranty claims Buffalo Corp will not be liable to warrant failures of ...

Page 35: ...reventing the shielding gas from blowing away Use on a 20 amp 115V AC circuit without the use of an extension cord If an extension cord is necessary for your application use the appropriate size and length of extension cord to handle 20 amps the entire length of the extension Talk with a qualified electrician for cord sizerecommendations WELDER TECHNICAL SPECIFICATIONS Item Description Power Suppl...

Page 36: ... glasses while welding Wear proper gloves and protective clothing to prevent your skin from being exposed to hot metals UV and IR rays Do not overuse or overheat your welder Allow proper cooling time between duty cycles Keep hands and fingers away from moving parts and stay away from the drive rolls Do not point torch at any body part of yourself or anyone else Always use this welder in the rated ...

Page 37: ...the arc with protective clothing and shoes Flame retardant cloth or leather shirts coats pants or coveralls are available forprotection Use screens or other barriers to protect other people from the arc rays emitted from yourwelding Warn people in your welding area when you are going to strike an arc so they can protect themselves Fire Hazards Do not weld on containers or pipes that contain or hav...

Page 38: ... cable together whenever possible Keep welding holder and ground cables on the same side of your body Shielding Gas Cylinders Can Explode High pressure cylinders can explode if damaged so treat them carefully Never expose cylinders to high heat sparks open flames mechanical shocks or arcs Do not touch cylinder with welding holder Do not weld on the cylinder Keep cylinders away from welding or elec...

Page 39: ...ool down the internal components When the internal temperature had decreased the machine will automatically turn welding output back on Current Adjustment Current adjustment is on the front panel of the machine It has infinite current outputadjustment from 10 to 85 Amps Positive Output Connector This is the connector for the electrode holder and cable most often when STICK welding When this machin...

Page 40: ...nel of thewelder 1 6 Turn on the input power switch on the welder Be aware that the TIG torch will be electrically HOT when the Input Power Switch on the welder is turned on 1 7 Turn on the regulator on the bottle of shielding gas and adjust the regulator to approximately 20 CFH Then open the shielding gas valve on the torch to start the flow of shieldinggas EXPOSURE TO A WELDING ARC IS EXTREMELY ...

Page 41: ...ect your welder s power cord to a properly grounded 120 VAC 60 HZ single phase 20 amp power source 1 TURN ON POWER Turn on Generator and allow to run for several minutes Then turn on Welder power Insert electrode holders 1 1 Welding positions There are two basic positions for welding Flat and Horizontal Flat welding is generally easier faster and allows for better penetration If possible the work ...

Page 42: ...the work piece determine the electrode type and the amount of heat needed in the welding process Heavier and thicker metals required more amperage It is best to practice your welds on scrap metal which matches the metal you intend to work with to determine correct heat setting and electrode choice See the following helpful trouble shooting tips to determine if you are using a correct electrode 7 1...

Page 43: ...nitial arc it may be necessary to hold the electrode perpendicular to the work piece Once the arc is started the angle of the electrode in relation to the work piece should be between 10 and 30 degrees This will allow for good penetration with minimal spatter 6 2 Striking the arc EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN Prolonged exposure to the welding arc can cause bli...

Page 44: ...y at each side before weaving back the other way 9 4 Welding position Flat position It is easiest of the welding positions and is most commonly used It is best if you can weld in the flat position if at all possible as good results are easier to achieve Flat Position Horizontal Position The horizontal position it is performed very much the same as the flat weld except that the angle is different s...

Page 45: ...ng however forms slag The slag formation appears as an accumulation of dirty metal scale on the finished weld Slag should be removed by using a chipping hammer PEENING THE SLAG FROM A WELD JOINT CAUSES SMALL CHIPS OF METAL TO FLY THROUGH THE AIR Metallic chips flying through the air can cause eye injury or injury to other parts of the head hands or exposed portions of the body Wear goggles or safe...

Page 46: ...he electrode packaging for correct amperage settings Overload Indicator Is On The internal temperature is too high Leave power on and let the fan cool the unit Output will continue when the unit has cooled Electrode Holder or ground cable getting hot Output Connections Getting Hot Weld Cable Connections Loose Check to make certain weld cables are tight Weld Cable Connections have corroded Clean we...

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