Onan BF Series Instruction Manual

OPERATOR'S/SERVIwi

MANUAL

AND

PARTSCATALOG

FOR

SERIES

180AMP.AC

WELDER

MODELS

5.0

BF-341E/*

5.0

BF-343E/*

•SPECIFICATIONS5277AAND8474A

965-1003

9A73

Printed

inU.S.A.

180AMP.

WELDER

SERIES

RANTY

CARD

ATTACHED

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

IndicatesKilowattratingandfactorycodefor

generalidentification.

FactorycodeforACvoltageoutput:code341

indicates120volts,AC;343indicates120/240

volts,

AC.

3.Specifictype:E- Electricstartingatwelderonly.

Factorycodeforoptionalequipmentsupplied.

5.Specificationletteradvanceswithfactory

productionmodification.

SAFETY

PRECAUTIONS

ALWAYS

EMPLOY

PRECAUTIONARY

MEASURES

DURINGARCWELDING

OPERATIONS

TOEN-

SURE

MAXIMUM

PERSONAL

SAFETY

ANDTHE

SAFETY

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:

Flushthecontainerseveraltimeswithwater

anda wettingagent

(e.g.,

a lowpowered

detergent).Then,fillwithasmuchwaterasthe

workpermits.

Providea ventoropeninginthecontainerto

allowthereleaseofairpressure.

Whenthecontainerhashelda gasorliquidthat

doesnotreadilydissolveinwater,proceedas

follows:

Cleanthecontainerwithsteamora cleaning

agentandpurgeallairwitha gassuchascarbon

dioxideornitrogen.

Usesteamtocleanoutlightmaterial.

3.Tocleanoutheavygreaseoroil,usea strong

causticsodasolution.

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:

Adjustchokeaccordingtotemperature

con-

ditions.

2. Move ignition switch to ON.

3.PushSTARTswitch,locatedonrearsideof

controlbox,firmly.Ifunitdoesnotstartwithina

fewseconds,releasethe57>4^?rswitchandwaita

fewsecondsbeforereattemptingtostart.Ifunit

doesnotstartaftertwoattempts,openthechoke

andrepeatstartingsequence.

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

.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

POWER

Theweldersareavailablewitheither120-voltAC,

5KWauxiliarypoweror120/240-voltAC,5KWaux-

iliarypower.The120-voltmodelisequippedwithtwo

120-voltduplexreceptacleswitheachoutlet(4)rated

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.

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