Onan BF Series Instruction Manual

®
OPERATOR'S/SERVIwi
MANUAL
AND PARTSCATALOG
FOR
BF
SERIES
180AMP.AC WELDER
MODELS
5.0 BF-341E/*
5.0 BF-343E/*
•SPECIFICATIONS5277AAND8474A
965-1003
9A73
Printed inU.S.A.

180AMP. WELDER
BF
SERIES
RANTY CARD ATTACHED TO UNIT.
KEEPTHISMANUALHANDYSOITCANBEEASILYREFERREDTOWHENORDERING
PARTS, MAKINGADJUSTMENTS,ETC.

GENERAL INFORMATION
TheBFwelderisa completeenginedriven,alter-
natingcurrentarcweldingmachine.Itconsistsofa
two-cylindergasolineenginedirectlyconnectedto
anelectricgeneratorandmountedtoa sturdy
carryingframe.TheweldercontrolsandACoutput
receptaclesarelocatedinthecontrolboxthatis
mountedonthegeneratorendoftheunit.Anoptional
two-wheeleddollyisavailableiftheunitmustbe
movedfrequently.
WARNING Thissymbolisusedthroughoutthemanualto
warnofpossiblepersonalinjury.
[CAUTIONj Th'ssymbolreferstopossibleunitdamage.
Thewelderisrated180amperes,25volts,alternating
currentat50%dutycycle.Auxiliaryalternating
currentisavailableandoutputis120voltsor120/240
volts, rated5000watts,60hertzat100%dutycycle.
ACoutputisavailableatanytimealthoughatreduced
outputwhentheweldingcurrentisbeingused.This
ACoutputisconvenientforemergencylighting,
runningpowertools,etc.,whenworkingatlocations
awayfromACpowerlinesources.
Wheninstructionsinthismanualrefertoa specific
modelofwelder,identifythemodelbyreferringtothe
modelandspecificationdesignationasshownonthe
unitnameplate.
Howtointerpretmodelandspecificationnumber.
Beforeoperatinganywelder,becomethoroughly
familiarwiththesafetyprecautionsthatfollow!
5.0BF- 341E / 1 A
45
1. IndicatesKilowattratingandfactorycodefor
generalidentification.
2. FactorycodeforACvoltageoutput:code341
indicates120volts,AC;343indicates120/240
volts, AC.
3.Specifictype:E- Electricstartingatwelderonly.
4. Factorycodeforoptionalequipmentsupplied.
5.Specificationletteradvanceswithfactory
productionmodification.

SAFETY PRECAUTIONS
ALWAYS EMPLOY PRECAUTIONARY MEASURES
DURINGARCWELDING OPERATIONS TOEN-
SURE MAXIMUM PERSONAL SAFETY ANDTHE
SAFETY OF NEARBY PERSONNEL.
OperateAnd Maintain TheMachineAndIts
EquipmentProperly.
Donotoverloadthecables.Donotusewornor
poorlyconnectedcables.Donotallowthe
weldingcablestocontacthotmetal,water,oilor
grease.Preventcablesfrombecominga stumbl-
inghazardbykeepingtheminorderandoutofthe
way.
Useelectrodeholdersthatarecompletelyin-
sulated. Donotuseholderswithdefectivejaws.
Donotusethewelderwithoutgroundingthe
frameorthecase.Donotgroundtopipelines
carryinggasesofflammableliquids.Besurethe
conductorscansafelycarrythegrounding
current.
Keepallconnectionscleanandtight.
Donotuseanelectricwelderonanengineunless
boththeengine'sbatterycablesandalternator
wiresaredisconnected.
Take PrecautionsAgainst Electric Shock.
NEVERworkina dampareawithoutsuitable
insulationagainstshock.
NEVERstandinwaterorona wetfloororusewet
gloveswhenwelding.
ALWAYSdryouttheworkpiecesorbenchifthere
isanyevidenceofmoisture.
OPENpowercircuitsbeforeinspecting
machines.
ALWAYSturnoffthemachinewhenleavingthe
work.
*DoNotWeldNearInflammableMaterials.
NEVERweldinornearEXPLOSIVEAT-
MOSPHERES.
Cleananycontainerthathasheldcombustibleor
flammablematerialsbyapprovedorprescribed
methods.A verysmallamountofresidualgasor
liquidcancausea seriousexplosion.Whenthe
contentsofthecontainerisunknown,usean
explosimeter.
Usecarbondioxideornitrogentoventilatea
container.NEVERUSEOXYGEN.
Whenthecontainerhashelda gasorliquidthat
readilydissolvesinwater,performthefollowing:
1. Flushthecontainerseveraltimeswithwater
anda wettingagent (e.g., a lowpowered
detergent).Then,fillwithasmuchwaterasthe
workpermits.
2. Providea ventoropeninginthecontainerto
allowthereleaseofairpressure.
Whenthecontainerhashelda gasorliquidthat
doesnotreadilydissolveinwater,proceedas
follows:
1. Cleanthecontainerwithsteamora cleaning
agentandpurgeallairwitha gassuchascarbon
dioxideornitrogen.
2. Usesteamtocleanoutlightmaterial.
3.Tocleanoutheavygreaseoroil,usea strong
causticsodasolution.
4. Beforeweldingonthecontainer,PURGEALL
AIRwithagassuchascarbondioxideornitrogen.
Weargogglesandgloveswhencleaningwith
steamorcausticsoda.
Alwayscleanthecontainerina wellventilated
area, awayfromanyopenflame.
Whenscrapingorhammeringheavysludgeor
scale, usea WET,sparkresistant tool.
Alwayskeepheadandarmsasfarawayfromthe
workaspossible.
•NeverWeldOnHollow(Cored) Castings That
HaveNot Been ProperlyVented.
•Never Pick UpHot Metal With Bare Hands.
•DoNotWeldInConfined Areas Without Adequate
Ventilation.

NeverWear Frayed, FlammableOrOtherwise
InadequateClothingWhenWelding. Keep
ClothingDry.
Avoidwearinglightcoloredoropenshirtsthat
allowarcraystopenetrateandexposeparts'ofthe
bodytoultra-violetrays.Donotwearflammable
cottonfabricswhenarcwelding.Wearheavy
shoes,tightlylaced.
Topreventsevereburnsfromsplatterandmolten
metal, wearleatherorasbestosglovesatall
timesprotectingthehandsandwrists.When
weldinginverticalandoverheadpositions,wear
earshieldsunderhelmetandleathersleevelets,
apron, andleggings.
Use EyeProtectionAtAll Times.
ALWAYSwearsafetygogglesunderthewelding
helmet.Keepthehelmet,handshields,andface
shieldingoodcondition.Replacedefective
equipment.
Allarcweldingproducesintenseultra-violetand
infra-redradiation.Whenweldinginopenareas,
provideportablenon-reflectingscreensto
protectnearbypersonnelfromarcrays.

SPECIFICATIONS
NominalDimensions
Height29-1/2"
Width: : 22"
Length: 34"
WeightinPounds(approx.)
Skidmounted,electric....325
Fuel"Gasoline
NumberofCylinders•.2
CylinderBore: 3-1/8"
CylinderStroke2-5/8"
Displacement(cu.in.)40.3
MaximumBHP(at3600rpm)16
GovernorAdjustable,mechanicalflyball
FuelPumpPulseDesign
Ignition, ElectricStartBattery
MountedFuelTankCapacity(U.S.gallons)5.6
OilCapacity(U.S.quarts)2
Generator
WelderOutput- MaximumAmperes(50%dutycycle)180
ACAuxiliaryWattsOutput(120or120/240volts,
single-phase,100%dutycycle)5000
BatterySize
NominalBatteryVoltage12
NumberUsedOne
Ampere/HourSAE20Hr.Minimum32
Approx.BatteryDimensionsforBatteryRack7-3/4"L x 5-1/8"W x 7-3/8"H
*- Non-leadedorregulargrade.See OPERATIONsectionforspecialinstructions.
TUNE-UP SPECIFICATIONS
Tappets(Cold)Intakei 008*
Exhaust013*
BreakerPointGap(FullSeparation)025
SparkPlugGap.025
IgnitionTiming(EngineRunningorStatic)21°BTC(HOT)
25°BTC(COLD)
*- ± .001"

threads.Ifa torquewrenchisnotavailable,estimate
thedegreeoftightnessnecessaryforthe stud, nutor0ther5/16"CylinderBlock
screwbeinginstalledandtightenaccordingly.Donot
DIMENSIONSAND CLEARANCES
Alldimensionsandclearancesgivenatroomtemperatureof70°F.
Allvaluesininchesunlessotherwisespecified.
MinimumMaximum,
CAMSHAFTANDCRANKSHAFT
CrankshaftMainBearingJournaltoBearingClearance0.00250.00381
*CrankshaftEndPlay0.0060.012
CamshaftBearingtoCamshaft0.00150.0030
CamshaftEndPlay0.003
*CrankshaftRodJournaltoRodBearing0.00200.0033
ConnectingRodEndPlay0.0020.016'
TimingGearBacklash0.0020.003'
OilPumpGearBacklash0.0020.005
PISTONANDCYLINDER
PistonPininPiston0.00020.0004
PistonPininRod0.00020.0007
*PistonRingGapinCylinderr 0.0100.020
PistonClearanceinCylinder- Measured.10BelowOil
ControlRing,90°fromPin0.0010.003-
CylinderBore- StandardSize3.12453.1255'
CrankshaftMainBearingJournal- StandardSize 1.9992 2.0000
CrankshaftRodBearingJournal- StandardSize 1.6252 1.6260
TAPPETSANDVALVES
*ValveSeatWidth1/321/8
*ValveFaceAngle44°
*ValveSeatAngle45°
ValveStemtoGuide- Intake0.00100.0025
ValveStemtoGuide- Exhaust0.00350.0040
TappettoCylinderBlockClearance0.00150.0030
TappetAdjustment(Cold)
*Intake0.0070.009
*Exhaust0.0120.014
*- Frequentlyusedoverhaulvalues.
ASSEMBLY TORQUES
BOLTTORQUEFT.- LB.
GearcaseCover8-10
AOOCMDI v -rrmoiiccCylinderHeadStudNuts(Cold)14-16
ASSEMBLYTORQUESRearBearingp|ateScrews25_ 27
Assembly torques as given here require the use of a StarterMountingBo|ts18. 2Q
torquewrench.TheseassemblytorquesassureConnectinaRodBolt14-16
propertightnesswithoutdangerofstrippingtheconnectingHodBolt1416
FlywheelCapScrew35-40
StudandNuts8-10
stripthethreads.Checkallstuds,nutsandscrewsOilBase18-23
often. TightenasneededtopreventthemfromManifoldMountingStudNuts6-9
workingloose.OilPump7-9

INSTALLATION
Normally,theBFwelderisnotpermanentlymounted;
thusnoinstallationinstructionsarenecessary.
However,ifthewelderistobeusedina permanent
locationormountedina vehicle,usethefollowing
recommendationsasa guide.
VENTILATION
Weldersgenerateconsiderableheatduringopera-
tion. Therefore,whenoperatinginanysmall
enclosure,provideseparate,unobstructedairinlet
andoutletopenings(minimumareaof3-1/2square
feeteach).Positiontheopeningstopreventrecircula-
tionofheatedair:
•Locatetheinletopeningascloseaspossibleto
thefrontoftheengineblower.
•Provideanoutletopeningtowardthegenerator
end, somewhathigherthantheinletopening.
EXHAUST
Whenmountingextensionexhaustpipestothe
engine,usea pieceofflexibletubingbetweenthe
extensionsandtheengine.Fitthemufflerstothe
outerendoftheexhaustpipes.
WARNING EngineexhaustcanbedeadlylNeveroperate
thewelderinsidea buildingorconfinedarea
withoutpipingexhaustgasesoutsidetheenclosure.
MOBILE MOUNTING
Installingthewelderina vehiclerequiresspecial
attention. Roughroadsandsharpcornersproduce
considerablestrainontheweldermountingbolts.
Extravehiclefloorsupportmaybenecessaryto
preventtheboltsfromdisengaging.Usepipeclamps
oru-boltswhensecuringthewelderframetothe
floor.
Theweldercanoperateatamaximumtiltof15°sideways,30°front
torear.

OPERATION
PRE-START INFORMATION
Whentheunitistobeusedforwelding,always
connecttheweldingcablestothepowerterminalson
thepanelbeforestarting.Itisnotnecessaryto
observepolarityinmakinggroundconnections
betweenwelderandthework.Weldingcurrentselec-
tionmaybemadewiththeunitrunningbutnotunder
load.
IWARNINGI Donot'underanycircumstances,touchthe
Iw^^^^^^^Jterminalsofthewelderwhileitisoperating!
Althoughthevoltageisnothigh,itcancausesevereshockwith
possibleseriousconsequences!Stoptheunitbeforemaking
connections.
ELECTRIC STARTING:
1. Adjustchokeaccordingtotemperature con-
ditions.
2. Move ignition switch to ON.
3.PushSTARTswitch,locatedonrearsideof
controlbox,firmly.Ifunitdoesnotstartwithina
fewseconds,releasethe57>4^?rswitchandwaita
fewsecondsbeforereattemptingtostart.Ifunit
doesnotstartaftertwoattempts,openthechoke
andrepeatstartingsequence.
4. Afterunitstarts,adjustchoketobestrunning
position. Graduallyadjustchokecontrolasunit
warmsup.
INITIAL START
Checktheenginetomakesureithasbeenfilledwith
oiland fuel. Seetherecommendationsbelow.
CRANKCASE OIL:
BesurethecrankcasehasbeenfilledtotheFULL
markwithanAmericanPetroleumInstitute(API)
designationSEoiloftheviscosityrecommendedon
thenameplate.IftheSEoilisnotavailable,anSDor
SD/CCoilmaybeused.SeePERIODIC
MAINTENANCEsectionforcompletelubrication
recommendations.
Ifoilswiththesedesignationsarenotyetavailable,useanoilwith
theAPIdesignationMS,MS/DGorMS/DMwhichhaspassedall
theAutomotiveManufacturer'sSequenceTestsandtheMIL-L-
2104BTests.DonotuseanoilwiththeAPIdesignationMLorDS.
RecommendedFuel:Useclean,fresh,regulargrade,
automotivegasoline.Donotusehighlyleaded
premium fuel.
Fornewengines,themostsatisfactoryresultsare
obtainedbyusingnonleadedgasoline.Forolder
enginesthathavepreviouslyusedleadedgasoline,
headsmustbetakenoffandallleaddepositsremoved
fromenginebeforeswitchingtononleadedgasoline.
CAUTION Ifleaddepositsarenotremovedfromengine
beforeswitchingfromleadedtononleaded
gasoline,preignitioncouldoccurcausingseveredamagetothe
engine.
WARNINGI Neveraddfueltowelderwhileitisrunning.
Thebatterychargevoltageisregulatedtosupplyanominal 1 .Samp
chargeratealfullrpm.
APPLYING LOAD
Allowtheenginetowarmupthoroughlyatidlespeed
beforeapplyinga heavywelding load. Settheidle
leveratweldpositionbeforeapplyinga load. The
welderisthermallyprotectedandself-regulating.
Althoughtheweldercanbeloadedtofullnameplate
ratingforinitialoperation,itisrecommendeditbe
loadedonly80%ofratedcapacityforfirstfewhours.
Controlledbreak-inwiththeproperoilanda con-
scientiouslyappliedmaintenanceprogramhelps
assuresatisfactorywelderserviceforhundredsof
hours.
After25hoursofoperation,draintheinitialoilwhiletheengineis
stillhot.
STOPPING
MoveignitionswitchtoSTOPorOFFposition.If
ignitionswitchisleftintheOppositionwhenunitis
notrunning,batterywilldischarge.
WELDING CURRENT CONTROL
Thecontrolpanelcontainsa currentselectorhandle
thatcanbeturnedtoanyoneofthedialpositionsfor
therequiredweldingamperage(Figure1).Makesure
thehandlesnapsfirmlyintoplacewhenmakingthe
desiredamperageselection.Onsomemodels,an
optionalrheostatisprovidedforfinecurrentcontrol.
CAUTION
Oncoldstarts,settheidleleverintheidlepositiontotherightto
start.Theidleleverislocatedadjacenttothegovernoryokecontrol
shaft.Setmanualchokeasnecessaryforweatherconditions.
Considerableheatisgeneratedbythereactor
assemblyinsidetheweldercontrolbox.
Alwayskeepmeengineandcontrolcoverinstalledontheunitto
properiydirectairtothecontrolbox.NEVERWELDWITHTHE
ENGINEANDCONTROLCOVERREMOVED.

130v.nov.• «isn r
FIGURE1.CONTROLPANEL
WELDING CABLE SIZE
Keeptheweldingcablesasshortaspossible.Check
allconnectionsfortightness.Table1 listsJhecable
sizeforcurrentdrawandcablelength.
Whenweldingwithlongcables,avoidallowingthe
cablestoformcoils.A coilofcableproducesa
magneticfieldthatcanlowerthegeneratoroutput.If
youhaveexcesscableonthefloor,tapethecables
togetheratshortintervalsandarrangethemin
"snake"fashiontotakeuptheslack.
CAUTION Donotchangetheamperagetap(control
handle)whilethepowerisbeingusedfor
weldingorpipethawing.Thesuddenconnectionbreakcan
produceanarcwithinthecontrolboxandcauseseriousdamageto
theswitchingmembersorothercomponentsinthecontrolcircuit.
AUXILIARY AC POWER
Theweldersareavailablewitheither120-voltAC,
5KWauxiliarypoweror120/240-voltAC,5KWaux-
iliarypower.The120-voltmodelisequippedwithtwo
120-voltduplexreceptacleswitheachoutlet(4)rated
at 1 Samps. Althougha totalof42ampsisavailable,no
morethan15ampsmaybedrawnfromanyindividual
outlet.
Thethreeoutletsofthe120/240-voltmodelarerated
at20ampereseach.Drawnomorethan20ampsfrom
anyindividualoutlet.
TABLE1.RECOMMENDEDWELDINGCABLESIZE
ACPOWER
AMPERES TOTALCIRCUITLENGTHINFEETACPOWER AMPERES 100 150 200 250 300 400
75 6 4 3 3 2 1
100 4 3 3 2 1 1/0
150 3 2 1 1/0 2/0 3/0
200 2 1 1/0 2/0 3/0 4/0
Useofauxiliarypowerisnotrecommendedwhile
weldingcurrentisbeingused.Ifnecessary,however,
alowwattagetroublelightmaybeconnectedwithout
unduelossofweldingpower.Thegovernorcontrol
levermustbeintheWELDpositionforbothweldand
auxiliarypower.Onmodelswiththeoptionalrheostat
forfinecurrent,turnpointerknobtothe"10& AC"
position.
Usingauxiliarypowerduringweldingoperationcausesa voltage
dropwhenthearcisstruckandduringactualwelding.