Buffalo Tools GEN4000DF-STW User manual

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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.

GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder
2
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
• 3.2 Gallons Max Capacity Gasoline Fuel Tank
• Complies with EPA emissions
• Decibel Rating < 69 db
• Mobility Kit: Not Available
• Run time =9 hrs @ 50% load Gasoline
• Run time =12 hrs @ 50% load LPG with 20 Gallon tank
• Fuel type - Liquid Propane Gas (also commonly referred to as 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.
• Propane Tank Not Included
• If you want to use a propane tank larger than 20 lbs, call Customer Service for details at 866-460-9436.
* SURGE WATTS / RUNNING WATTS MAY BE REDUCED BY 10% WHEN USING PROPANE FUEL VS USING GASOLINE.
AC Output
Rated Voltage (V)
120
Rated Watts (W)
3500
Rated Frequency (Hz)
60
Phase
Single
DC Output
Voltage (V)
12
Circuit Breaker Amperage (A)
8
Welding Machine
Max No load Voltage (V)
72
Current Range (A)
10-85
Duty Cycle
25%
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
3
TABLE OF CONTENTS
RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS...............................................................................................4
PACKAGE CONTENTS
PACKAGE CONTENTS .........................................................................................................................................10
COMPONENTS .....................................................................................................................................................11
PREPARING THE GENERATOR FOR USE ....................................................................................................................12
Using This Generator For The First Time...............................................................................................................12
Step 1 – Add Oil ............................................................................................................................................12
Step 2 – Connect Fuel...................................................................................................................................13
Step 3 – Ground The Generator....................................................................................................................14
Subsequent Use Of This Generator.......................................................................................................................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 And Maintenance Instructions…………………………………………………………………………22
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
4
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. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury or
death.
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which,
if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, may
result in property damage.
2 YEAR LIMITED EMISSION-RELATED WARRANTY
THIS ENGINE MEETS U.S. EPA EMISSION STANDARDS UNDER 40 CFR 1054.625 .The emission-related limited warranty is valid for two (2)
years. Keep the purchase receipt and mail in the product registration card for proof of purchase. Buffalo Corp limits emission-related warranty repairs
to authorized service centers for owners located within 100 miles of an authorized service center. For owners located more than 100 miles from an
authorized service center, Buffalo Corp will, in its sole discretion, either pay for shipping costs to and from an authorized service center, provide for a
service technician to come to the owner to make the warranty repair, or pay for the repair to be made at a local non-authorized service center. The
provisions of this paragraph apply only for the contiguous states, excluding 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
[e-mail]) 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 Customer Service Representative. The warranty does not extend to generators damaged or
affected by fuel contamination, accidents, neglect, misuse, unauthorized alterations, use in an application for which the product was not designed
and any other modifications or abuse.
1 YEAR LIMITED WARRANTY (30 Day Limited Warranty for Commercial and Rental Purpose)
Generators are warranted to be free from defects in materials and workmanship for a period of 1 YEAR from date of original purchase. Buffalo Corp.
is not liable for any indirect, incidental or consequential damages from the sale or use of this product. Any implied warranties are limited to 1 YEAR
as stated, or as otherwise stated, in this written limited warranty. Some states do not allow the exclusion or limitation of incidental or consequential
damages. Some states do not allow limitation on the length of an implied warranty. Buffalo Corp will repair or replace, at its discretion, any part that
is proven to be defective in materials or workmanship under normal use during the 1 YEAR warranty period. Warranty repairs or replacements will be
made without charge for parts or labor. 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
Legal Requirements:
Federal and/or State Occupational Safety and Health Administration (OSHA) regulations, local codes, and/or ordinances may apply to the intended
use of this generator. 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
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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).
IMPORTANT SAFETY INSTRUCTIONS – SAVE THESE INSTRUCTIONS
STOP!
Before using this generator and if you have any questions regarding the hazard and safety notices listed in this manual and/or on
this generator, call 1-866-460-9436, Monday - Friday, 8 AM - 4 PM Central Time.
Carbon Monoxide Gas: When in operation, the exhaust from this generator contains poisonous carbon monoxide gas. Carbon
monoxide gas is both odorless and colorless AND may be present even if you do not see or smell gas. Breathing this poison gas can
lead to headaches, dizziness, drowsiness, loss of consciousness and eventually death.
• Use this generator ONLY outdoors in non-confined areas.
• Keep at least several feet of clearance on all sides to allow proper ventilation for this generator.
Propane (LPG): This generator may emit highly flammable and explosive vapors, which can cause severe burns or even death. A
nearby open flame can lead to an explosion even if not directly in contact the fuel.
• Do not operate this generator near open flame.
• Always operate this generator on a firm, level surface.
This fuel is highly flammable and explosive. Handling fuel can result in serious injury or burns.
• Before starting the generator, inspect your LPG tank valve for damage or leaks, attach only approved tanks that have been properly filled by
an approved station. DO NOT light or smoke cigarettes.
• Replace the hose at the first sign of a leak or if age-cracking becomes apparent.
• Always handle propane 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 extension cord. NEVER connect a building electrical
system to this generator without a qualified electrician. Doing so voids your warranty. Such connections must isolate generator power from
utility power and comply with local electrical laws and codes. Failure to comply can create a back feed into utility lines creating an electrocution
hazard, which may result in serious injury or death to utility workers. Such a back feed may cause this generator to explode, burn and create
fires when utility power is restored.
• Do not use this generator in wet conditions (rain, snow, active sprinkler system, wet hands, etc.). Always keep this generator dry and operate it
with dry hands.
• Do not touch bare wires or outlets (receptacles).
• Do not allow children or non-qualified persons to operate this generator.
High Temperatures: This generator produces heat when in operation. Temperatures near the exhaust can exceed 150 Degrees
Fahrenheit (65 Degrees Celsius).
• Do not touch hot surfaces. Observe all warning placards on this generator denoting hot surfaces.
• Allow this generator to cool for several minutes after use before touching the engine, muffler or other areas that are hot during operation and
before storing indoors.
• Hot exhaust may ignite some materials. Keep flammable materials away from this generator.
• Keep at least several feet of clearance on all sides of this generator during operation. Do not enclose this generator in any structure.
Usage: 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
6
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.
• Do not turn on electrical devices until after they are connected to this generator.
• Turn off all connected electrical devices before stopping this generator.
Flammable liquid gas under pressure. Can form explosive mixtures with air. May cause frostbite. In Case Of Inhalation: Persons suffering from
lack of oxygen should be removed to fresh air. If victim is not breathing, administer artificial respiration. If breathing is difficult, administer
oxygen. Obtain prompt medical attention. In Case Of Eye Contact: Contact with liquid or cold vapor can cause freezing of tissue. Gently flush
eyes with lukewarm water. Obtain medical attention immediately. In Case Of Skin Contact: Contact with liquid or cold vapor can cause
frostbite. Immediately warm affected area with lukewarm water not to exceed 105°F (40°C). Fire And Explosion Hazards: Propane is easily
ignited. It is heavier than air, therefore, it may collect in low areas or travel along the ground where an ignition source may be present. Pressure
in a container can build up due to heat, and it may rupture if pressure relief devices should fail to function. Storage: Cylinders should be stored
upright with valve protection cap in place and firmly secured to prevent falling or being knocked over. Protect cylinders from physical damage;
do not drag, roll, slide or drop. Use a suitable hand truck for cylinder movement. Post "No Smoking or Open Flames" signs in the storage areas.
There should be no sources of ignition. All electrical equipment should be explosion proof in the storage 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 CARBON MONOXIDE (CO)?
You can’t taste or smell CO, but it is a very dangerous gas. High levels of CO can come from appliances that are not operating correctly, or from
a venting system or chimney that becomes blocked. CO CAN BE DEADLY! High levels of CO can make you dizzy or sick. In extreme cases,
CO can cause brain damage or death.
Symptoms of CO poisoning include: headache, dizziness, fatigue, shortness of breath,
and nausea.
IF YOU SUSPECT CO IS PRESENT, ACT IMMEDIATELY!
1. If you or a family member shows physical symptoms of CO poisoning, get everyone out of the building and call 911 or your local fire
department.
2. If it is safe to do so, open windows to allow entry of fresh air, and turn off any appliances you suspect may be releasing CO.
3. If no one has symptoms, but you suspect that CO is present, call your propane retailer or a qualified service technician to check CO levels
and your propane equipment.
Usage: Consult a physician(s) before using this generator if using a pacemaker. Electromagnetic fields in close proximity to a heart
pacemaker could cause a pacemaker to malfunction or fail. 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.
Usage: This generator is not intended to power sensitive electronic equipment such as TVs, DVD players, stereos, desktop
computers or laptop computers without the use of an appropriate line conditioner and/or surge protector (both not included).
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
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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.
!Wear protective flame-resistant gloves.
!Clothing shall provide sufficient coverage and be made of suitable materials to minimize skin burns
caused by sparks, spatter or radiation. Covering all parts of the body is recommended to protect
against ultraviolet and infrared ray flash burn.
!Wear protective eyewear and face mask.
Electric shock—may lead to serious injury or even death.
!Install earth device according to the application criteria.
!Make sure that you are insulated from the ground and work-piece.
!Make sure that your working position is safe.
!Cut off power before maintenance or repair.
Smoke & gas—may be harmful to health.
!Keep the head away from smoke and gas to avoid inhalation of exhaust gas from welding.
!Keep the working environment in good ventilation with exhaust or ventilation equipment when welding.
Arc radiation—may damage eyes or burn skin.
!Wear suitable welding masks and protective clothing to protect your eyes and body.
!Use suitable masks or screens to protect spectators from harm.
Improper operation may cause fire or explosion.
!Welding sparks may result in a fire, make sure no combustible materials are nearby.
!Have a fire extinguisher nearby, and have a trained person to use it.
!Airtight container welding is forbidden
!Do not use these machines for pipe thawing.
Hot workpiece may cause severe scalding.
!Do not contact hot workpiece with bare hands.
!Cooling is needed during continuous use of the welding torch.
Magnetic fields affect cardiac pacemaker.
!Pacemaker users should be away from the welding spot before medical consultation.
Moving parts may lead to personal injury.
!Keep yourself away from moving parts such as fan.
!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
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GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder
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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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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. 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 appliances, the generator should be grounded. Connect a length of heavy wire between the ground
terminal and the ground source.
Consult with a qualified electrician to ensure compliance with local electrical codes.

GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder
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GENERATOR COMPONENTS
Observe the locations and functions of the various components and controls 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
6
7
8
9
10
8
6
6
11
14
15
16

GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder
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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.
If this generator is being used for the first time, the following few steps are required to prepare it for operation:
Step 1 - Add Oil
This generator requires engine oil to function. Engine oil is a major factor affecting engine performance and 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 Detergent Motor Oil, SAE10W-30
To add oil:
1. Confirm that this generator is on a level surface.
2. Unscrew the oil filler/dipstick cap from the engine as illustrated in Figure 1.
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, all-
temperature 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
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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. (Fig A) Make sure the LPG cylinder 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 CHOKE VALVE GRIP is at RUN
(OPEN) position.
Step 3 Check if engine oil is full.
Step 4 Make sure GROUND TERMINAL is properly grounded.
Step 5 AC OUTPUT no load connected.
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
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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. Contact a local electrician for information on grounding regulations for your area.
Figure 3 - Attaching the Grounding Wire to this Generator
Subsequent Use of this Generator
For subsequent uses of this generator after the first use, certain steps still must be completed to prepare it for operation.
IMPORTANT: Be familiar with the procedures described in the previous section 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 surface.
2. Unscrew the oil filler/dipstick cap from the engine.
3. With a dry cloth, wipe the oil off of the dipstick that is located on the inside of the cap.
4. Fully insert the dipstick without screwing the filler/dipstick 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 the
“Maintenance/Care” section of this manual).
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
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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. Contact a local electrician for information on
grounding regulations for your area.
STARTING THE GENERATOR
STOP!
Before starting this generator, confirm that all the steps in the section titled, “Preparing the Generator for Use,” of this manual have been
correctly completed. If unsure 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 and turn fuel petcock to ON.
Step 2 Turn ENGINE SWITCH at ON position.
Step 3 Move Choke Lever to CHOKE position.
Step 4 Pull the STARTER GRIP slowly until resistance is felt and then pull rapidly. After the engine started, return the STARTER
GRIP gently to prevent damage to the starter or housing. DO NOT allow the starter grip to snap back. Return it slowly by hand.
Step 6 Turn the CHOKE LEVER to RUN position.
Choke Rod
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
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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
3500
Model GEN4000DF-STW Surge Wattage
4000
The rated (running) wattage corresponds to the maximum wattage a generator can output on a continuous basis.
The surge wattage corresponds to the maximum amount of power a generator can output for a short time. Many electrical devices, such as a
refrigerator, require short bursts of extra power for starting and stopping fan motors, etc., in addition to their listed rated wattage. Motorized devices
typically require more than their rated wattage for startup. The surge wattage ability of a generator allows for this extra power requirement.
The total running wattage requirement of the electrical devices connected to a generator should not exceed the rated wattage of the generator itself.
To calculate the total wattage requirement of the electrical devices to be connected, look up the rated (running) wattage of each device and add
these numbers together to find the total wattage that all of the devices together will draw from the generator. If the total wattage of the selected
devices exceeds the rated wattage of the generator, DO NOT connect all of the devices. Select a combination of the electrical devices that will have
a total wattage less than or equal 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 should be listed somewhere on the device itself and/or in its manual. If the wattage specification for a device is not
available, the wattage can be calculated by multiplying the Voltage requirement (120 or 240) by the Amperage drawn.
Watts = Volts x Amperes
Or, the wattage required by a device can be estimated by using the following chart (see Figure 7). The chart provides only estimates and it is better
to know the exact wattage of each electrical device to be powered by this generator.
Electrical Device
Rated (Running) Watts
Additional Surge Watts
air compressor (1 HP)
1500
3000
air compressor (1 - 1/2 HP)
2500
2500
airless sprayer (1/3 HP)
600
1200
box fan
300
600
clock radio AM/FM
300
0
coffee maker
1500
0
computer w/17 inch monitor
800
0
deep freezer
500
500
electric drill (1/2 HP)
1000
1000
DVD/CD player or VCR
100
0
furnace fan blower (1/2 HP)
800
1300
garage door opener (1/2 HP)
480
520
hot plate
2500
0
light bulb (75 watt)
75
0
microwave oven (1000 watt)
1000
0
quartz halogen work light
1000
0
refrigerator/freezer (18 Cu. Ft.)
800
1600
saw - circular (7 1/4 inch)
1500
1500
saw - miter (10 inch)
1800
1800
saw - reciprocating
960
1040
security system
180
0
electric stove - single element
1500
0
sump pump
800
1200
television (27 inch color)
500
0
electric water heater (40 gallon)
4000
0
window air conditioner (10000 BTU)
1200
1800
window fan
300
600
Figure 7 - Estimated wattage requirements for common electrical devices.

GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder
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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. Determine if the
problem was the device or the rated load capacity of this generator has been exceeded.
NOTE: Plug appliances into the correct outlet. Connect standard 120 Volt, single phase, 60 Hz loads to the 120 Volt outlet. See Figure 8 for an
illustration of these outlets.
Even though this Portable Generator has an overall rated wattage of 3500, do not attempt to draw more than 20 AMPS from any set of Two
receptacles of the 120 Volt outlets. Draws higher than 20 Amps will damage 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 120V AC, 120V AC RV and 12V DC.
SOME NOTES ABOUT POWER CORDS
Long or thin cords can require more wattage from a generator to power an electrical device. Figure 9 shows the recommended cords according to
the power requirement of the electrical device. When using cords that exceed these specifications, allow for the electrical device to have a slightly
higher rated wattage requirement.
Device Requirements
Max. Cord Length (ft) by Wire Gauge
Amps
Watts (120V)
Watts (240V)
#8 wire
#10 wire
#12 wire
#14 wire
#16 wire
2.5
300
600
NR
1000
600
375
250
5
600
1200
NR
500
300
200
125
7.5
900
1800
NR
350
200
125
100
10
1200
2400
NR
250
150
100
50
15
1800
3600
NR
150
100
65
NR
20
2400
4800
175
125
75
50
NR
25
3000
6000
150
100
60
NR
NR
30
3600
7200
125
65
NR
NR
NR
40
4800
9600
90
NR
NR
NR
NR
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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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. Connect the red charging wire to the positive terminal of the battery and the black charging wire to the negative terminal of the battery.
2. Connect the plug end of the wire to the 12V DC outlet on this generator.
3. Start this generator.
4. When disconnecting, always disconnect the wires from this generator first to avoid a spark.
Storage batteries emit highly explosive hydrogen gas when charged.
Batteries also contain acid, which can cause severe chemical burns.
• Do not allow open flames or cigarettes nearby for several minutes after charging a battery.
• Always wear protective goggles and rubber gloves when charging a battery.
• If battery acid gets on the skin, flush with water.
• If battery acid gets in the 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 generator.
3. Turn off the engine switch.
4. If using Propane, turn the propane tank fuel valve to the “off” position.
Allow this generator to cool down before touching areas that become hot during operation.
MAINTENANCE/CARE
Proper routine maintenance of this generator is essential for safe, economical, and trouble-free operation. It will help prolong the life of this generator
as well as help reduce air pollution. Perform maintenance checks and procedures according to the schedule in Figure 10.
STOP!
If you have questions about maintenance procedures described in this manual, call 1-866-460-9436 , Monday - Friday, 8 AM - 4 PM Central Time.
Never perform maintenance procedures while this generator is running. Allow this generator to cool before commencing any maintenance
procedures. Keep heat, sparks and flame away.
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
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Recommended Maintenance Schedule
Each Use
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
Engine Oil
Check Level
X
Replace
X (First Use)
X
Air Filter
Check
X
Clean
X
Fuel Filler Cap
Clean
X
Spark Plug
Check/Clean
X
Clean
X
Figure 10 - Recommended maintenance schedule
Cleaning the Generator
Always try to use this generator in a cool dry place. If this generator becomes dirty, the exterior can be cleaned with a damp cloth, soft brush,
vacuum and/or pressurized air.
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.
Checking the 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 a sufficient quantity.
To check the oil level:
1. Verify that this generator is shut down and on a level surface.
2. Unscrew the oil filler/dipstick cap from the engine as illustrated in Figure 11.
3. With a dry cloth, wipe 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/dipstick cap is properly in place when finished verifying the oil level.
Changing/Adding Oil
The oil level in this generator should be checked before each use. (See Figure 10.) When the oil level is low, add oil until the level is sufficient to
operate this generator.
To drain the oil from this generator:
The oil should be changed after the first 20 hours of operation. The oil should then be changed every 6 months, or for every 100 hours of use time,
or when it has become contaminated with water and/or dirt.
1. Place a bucket underneath this generator to catch oil as it drains.
2. Using a 12 mm hex wrench, unscrew the oil drain plug located on the crankcase underneath the oil filler/dipstick cap as illustrated in Figure 12.
3. Allow all the oil to drain from this generator.
4. Replace the oil drain plug and tighten with a 12 mm wrench.
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.
Figure 11 - Checking the Oil

GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder
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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.
Model GEN4000DF-STW Oil Capacity
18.5 ounces
Model GEN4000DF-STW Oil Type Recommended
High Detergent Motor Oil, SAE10W-30
Figure 12 - Draining Oil
Figure 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 casing.
4. Wash the sponge-like elements in household detergent and warm water. Do not
use gasoline or a flammable solvent.
5. Allow the sponge-like elements to dry thoroughly.
6. Soak the dry sponge-like elements in engine oil. Squeeze out any excess oil. The
engine will smoke during initial startup if too much oil is left in the air filter.
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.