BUG-O HDT-1000 Instructions And Parts Manual Download Page 1

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INSTRUCTIONS

AND

PARTS MANUAL

Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.

Model Number

Serial Number

Date of Purchase

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above.

LIT-HDT-IPM-1207

A DIVISION OF WELD TOOLING CORPORATION

3001 WEST CARSON STREET PITTSBURGH, PENNSYLVANIA USA 15204-1899

PHONE: 1- 800-245-3186 http://www.bugo.com TELEFAX: 1- 412- 331- 0383

HEAVY-DUTY TRACTOR

HDT-1200

TRACTOR BASE PACKAGE

HDT-1250

TRACTOR BASE PACKAGE W/EQUIPMENT MOUNTS

HDT-1000

WITH FEEDER & FLUX RECOVERY

Summary of Contents for HDT-1000

Page 1: ...ou request replacement parts or information on this equipment always supply the information you have recorded above LIT HDT IPM 1207 A DIVISION OF WELD TOOLING CORPORATION 3001 WEST CARSON STREET PITTSBURGH PENNSYLVANIA USA 15204 1899 PHONE 1 800 245 3186 http www bugo com TELEFAX 1 412 331 0383 HEAVY DUTYTRACTOR HDT 1200 TRACTOR BASE PACKAGE HDT 1250 TRACTORBASEPACKAGEW EQUIPMENTMOUNTS HDT 1000 W...

Page 2: ...EC 950 5 Never remove or bypass the equipment power cord ground Verify the equipment is grounded in accordance with all applicable local and national electrical safety codes In none exist use International Electric Code IEC 950 READ INSTRUCTIONS Read the instruction manual before installing and using the equipment 1 Never try to stop the pinion from moving except by removing power or by using the ...

Page 3: ...ounts of high frequency noise They may require a grounding rod be driven into the earth within six feet 2 meters of the plasma or welding unit to become compatible with an automatic cutting or welding process 4 If the high frequency is produced using a spark gap adjust the points so the gap is as small as possible The larger the gap the higher the voltage and the higher the interference 5 Some pla...

Page 4: ... EXPLODED VIEW PARTS LIST 17 HDT 1060 MAST EXPLODED VIEW PARTS LIST 18 HDT 1270 WIRE REEL BRACKET EXPLODED VIEW PARTS LIST 19 HDT 1280 CONTROL BOX BRACKET EXPLODED VIEW PARTS LIST 20 HDT 1290 FLUX RECOVERY VACUUM MOUNT EXPLODED VIEW PARTS LIST HDT 1000 HEAVY DUTY TRACTOR WITH FEEDER AND FLUX RECOVERY 21 INTRODUCTION 22 SETUPAND OPERATION 23 HDT 1050 EXPLODED VIEW PARTS LIST 24 HDT 1070 WIRE REEL E...

Page 5: ... BASE PACKAGE For this model please see page 6 HDT 1250 1252 1254 HEAVY DUTYTRACTOR WITH EQUIPMENT MOUNTS For this model please see page 14 HDT 1000 1002 1004 HEAVY DUTYTRACTOR WITH FEEDER AND FLUX RECOVERY For this model please see page 21 ...

Page 6: ...rection The pendant also provides two separate weld contactor switches for the starting operation of two separate torches The LED display on the pendant shows the set travel speed for the tractor providing repeatable speed during system setup and operation The customer is responsible for the mounting of all welding equipment to the tractor base package WeldTooling Corporation can also provide cust...

Page 7: ...uides the front of the machine into the fillet member allowing the tractor to track a straight line 6 Install the desired feeder equipment onto the top plate of the tractor If assistance is required for this step contact Weld Tooling Corporation s sales department for application support 7 DRYRUN To ensure proper operation of the unit test by turning the main power on from the feeder control panel...

Page 8: ... 5 2 FAS 0124 8 32 X 3 8 PAN HD DI CHROME 6 3 MDS 1030 CABLE CLAMP NYLON BLACK 7 16 7 2 FAS 1320 HEXNUT10 24 8 2 WAS 0221 8 INTERNALSTAR LOCKWASHER 9 2 FAS 0126 8 32 x 5 8 PAN HD BLACK 10 1 HDT 1015 120 VAC HDT 1015 240 240 VAC HDT 1015 42 42 VAC 11 2 FAS 0115 6 32 X 1 2 PAN HEAD ZINC 12 1 HDT 1020 TRACTOR FRAME MECHANICALS 13 1 BUG 5355 5 5 M TO F 17 CONDUCTOR CABLEASSY 14 2 HDT 1190 FOLLOWERARM ...

Page 9: ...7 K RELAY BUG 1383 BUG 1551 BUG 9636 T TRANSFORMER BUG 9675 GOF 3112 BUG 1466 VT VOLT TRAP BUG 1393 BUG 1563 BUG 1393 F PRECISION SPEED CONTROL BUG 1725 C1 PANEL CONNECTOR BUG 9909 C2 PANEL CONNECTOR CON 07RP17M C3 PANEL CONNECTOR BUG 1034 M GEAR MOTOR NOT PART OF WIRING GRP P 10 BUG 1550 150 1 TB TERMINAL BLOCK CWO 6288 NA 3 version uses this with different TB configuration ELECTRICAL COMPONENT C...

Page 10: ...10 HDT 1020 TRACTOR EXPLODED VIEW 1 2 3 4 5 5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 31 22 30 32 ...

Page 11: ...3 1 HDT 1025 LEFT PLATE 14 1 HDT 1026 RIGHTPLATE 15 1 HDT 1027 MODIFIED SPUR DRIVE GEARASSY 16 1 HDT 1028 CLUTCH LOCK PLATEASSY 17 1 HDT 1029 CLUTCH LOCK STOPASSY 18 2 HDT 1031 AXLE 19 1 HDT 1033 CLUTCH LEVERASSY 20 1 HDT 1034 CLUTCH LEVER CAMSHAFT 21 1 HDT 1035 CLUTCH CAM SHAFT BEARING 22 1 HDT 1036 CLUTCH CAM HUBASSY 23 4 HDT 1037 RUBBERIZED METALWHEEL 24 1 HDT 1039 HTD8TIMINGBELT 25 1 HDT 1041 ...

Page 12: ...DS 1011 DISPLAY BEZEL 7 4 FAS 0115 6 32 X 1 2 PAN HEAD ZINC 8 1 HDT 1141 TOGGLE SWITCH DPDT ON OFF ON 9 1 HDT 1142 PENDANT LABEL 10 1 BUG 9677 POTENTIOMETER 11 1 BUG 2255 TOGGLE SWITCH DPDT ON OFF ON 12 1 BUG 1869 TOGGLE SWITCH SPST ON NONE ON 13 1 BUG 5527 PANEL CONNECTOR 14 4 FAS 0104 4 40 C 3 8 PAN HEAD BLACK SPEED READOUT SPEED CONTROL KNOB DIRECTION TOGGLE SWITCH SECONDARY WELD CONTACT SWITCH...

Page 13: ...RING DIAGRAM ITEM DESCRIPTION PART NUMBER C1 PANEL CONNECTOR BUG 5527 DM DIGITAL METER BUG 1764 P POTENTIOMETER CONTROL BUG 9677 SW1 SWITCH BUG 1869 SW2 SWITCH BUG 1869 SW3 SWITCH BUG 2255 ELECTRICAL COMPONENT CHART ...

Page 14: ...cerning the tractor The tractor control panel is located on the pendant for ease of use while in process The unit comes equipped with a mast and horizontal posts for mounting the preferred welding equipment The HEAVY DUTY TRACTOR is able to travel long distances at a constant speed Two methods for weld joint tracking are available The included follower arms can be used to track off of a vertical s...

Page 15: ... are supplied with the tractor It is the customer s responsibility to add the appropriate mounting holes to the mounting plates for their equipment If assistance is required contact WeldTooling Corporation s sales department for application assistance 7 DRY RUN To ensure proper operation of the unit test by turning the main power on from the feeder control panel if used in this configuration or by...

Page 16: ... 1260 EXPLODED VIEW PARTS LIST Item Qty Part Number Description 1 1 HDT 1060 MAST W FOOT PLATE 2 1 HDT 1280 FEEDER CONTROL MOUNT W O FEEDER 3 1 HDT 1270 WIRESPOOLBKTW OSPOOLKIT 4 1 HDT 1290 FLUX RECOVERYVACUUM MOUNT ...

Page 17: ... FAS 0959 1 4 20 X 1 FLAT HD SOCKET 3 1 HDT 1061 TOOLINGMAST 4 1 HDT 1062 TOOLING MASTFOOTPLATE 5 1 HDT 1063 TOOLINGMASTRETAINERRING 6 1 HDT 1064 TOOLING MASTRESTPLATE 7 1 HDT 1065 WELD HEAD MOUNT PLATE 8 1 HDT 1066 ACCESSORY MOUNT PLATE 9 1 HDT 1067 MAST CAP 10 2 HDT 1101 KIPP ADJUSTABLE HANDLES 11 2 HDT 1103 SHOULDER SCREW 1 4 20 X 1 2 ...

Page 18: ...T Item Qty Part Number Description 1 1 BUG 3274 INSULATOR 2 1 FAS 0308 1 2 13 X 1 1 2 HEX HD CAP SCR 3 1 FAS 0309 1 2 13 X 1 HEX HD CAP SCR 4 1 HDT 1073 WIRE CAPTURE BAR 5 1 HDT 1075 WIRE REEL MOUNT BRACKET 6 2 WAS 0280 1 2 SAE WASHER 7 2 WAS 0281 1 2 SPLIT LOCK WASHER ...

Page 19: ... SCR 10 24 X 5 8 2 2 FAS 0309 1 2 13 X 1 HEX HD CAP SCR 3 4 FAS 1330 HEX NUT 10 24 4 1 HDT 1083 NA 3MOUNTINGPLATE 5 1 HDT 1086 LINCOLN NA 3 WELDER 6 1 HDT 1087 NA 3MOUNT 7 2 HDT 1102 U BOLTW MOUNTINGPLATE 8 4 WAS 0230 10 FLAT WASHER 9 4 WAS 0232 10 SPLIT LOCK WASHER 10 2 WAS 0280 1 2 SAE WASHER 11 2 WAS 0281 1 2 SPLIT LOCK WASHER ...

Page 20: ...5 RND HD SCR 10 24 X 1 2 2 2 FAS 0309 HEX HD CAP SCR 1 2 13 X 1 3 2 FAS 1330 HEX NUT 10 24 4 1 HDT 1093 FLUX HOPPER VACUUM MOUNT PLATE 5 2 HDT 1102 U BOLTW MNTINGPLATE 6 1 HDT 1120 FLUX HOPPER VACUUM MOUNT 7 2 WAS 0230 10 SAE FLAT 8 2 WAS 0231 10 INTERNALSTAR LOCKWASHER 9 2 WAS 0280 1 2 SAE FLAT 10 2 WAS 0281 1 2 SPLITLOCKWASHER ...

Page 21: ...or re use of the submerged arc flux This allows for longer travel distances between fillings of the flux hopper as as well as reduced consumables cost The HEAVY DUTYTRACTOR is able to travel long distances at a constant speed Two methods for weld joint racking are available Follower arms can be used to rack off of a vertical surface located along the weld seam such as in fillet welding Amagnetic t...

Page 22: ...nstruction manual that ships with the HEAVY DUTYTRACTOR 6 Load the wire reel with the appropriate sized welding wire Again refer to the NA 3 instruction manual for proper installation of wire through the feeder and nozzle 7 DRY RUN To ensure proper operation of the unit test by turning the main power on from the feeder control panel Switch the tractor travel direction switch to the desired travel ...

Page 23: ...EW PARTS LIST Item Qty Part Number Description 1 1 HDT 1090 FLUX RECOVERY SYSTEM 2 1 HDT 1060 MAST 3 1 HDT 1080 NA 3WITHMOUNT 4 1 HDT 1070 WIREREELWITHMOUNT 5 1 HDT 1085 NA 3AUTOMATIC HEADASSEMBLY NOTE Refer to p 17 for HDT 1060 details ...

Page 24: ...art Number Description 1 1 BUG 3274 INSULATOR 2 1 BUG 3293 60 SPOOL KIT 3 1 FAS 0308 1 2 13 X 1 1 2 HEX HD CAP SCR 4 1 FAS 0309 1 2 13 X 1 HEX HD CAP SCR 5 1 HDT 1073 WIRE CAPTURE BAR 6 1 HDT 1075 WIRE REEL MOUNT BRACKET 7 2 WAS 0280 1 2 SAE WASHER 8 2 WAS 0281 1 2 SPLIT LOCK WASHER ...

Page 25: ...309 1 2 13 X 1 HEX HD CAP SCR 3 4 FAS 1330 HEX NUT 10 24 4 1 HDT 1083 NA 3MOUNTINGPLATE 5 1 HDT 1086 LINCOLN NA 3 WELDER 6 1 HDT 1087 NA 3MOUNT 7 2 HDT 1102 U BOLTW MOUNTINGPLATE 8 4 WAS 0230 10 FLAT WASHER 9 4 WAS 0232 10 SPLIT LOCK WASHER 10 2 WAS 0280 1 2 SAE WASHER 11 2 WAS 0281 1 2 SPLIT LOCK WASHER 1 8 9 2 10 11 3 4 7 5 6 ...

Page 26: ...26 CONTROL BOX WIRING DIAGRAM ITEM DESCRIPTION PART NUMBER C1 PANEL CONNECTOR BUG 5527 DM DIGITAL METER BUG 1764 SW SWITCH BUG 2255 P POTENTIOMETER CONTROL BUG 9677 ELECTRICAL COMPONENT CHART ...

Page 27: ... EXPLODED VIEW PARTS LIST Item Qty Part Number Description 1 1 CWO 1465 FINEADJ HORIZONTAL 2 1 CWO 1466 VERTICAL FINEADJUSTMENT 3 4 FAS 0309 HEX HD CAP SCR 1 2 13 X 1 4 1 LDC 0010 AUTOMATIC HEAD 5 4 WAS 0280 1 2 SAE FLAT 6 4 WAS 0281 1 2 SPLITLOCKWASHER ...

Page 28: ...HEX HD CAP SCR 1 4 20 X 3 4 3 2 FAS 0375 HEX HD CAP SCR 5 16 18 X 1 2 4 1 FRU 1000 FLH FLUXRECOVERYUNIT HOPPERONLY 5 1 HDT 1094 FLUXHOPPERMOUNTINGPLATE 6 2 HDT 1095 FLUXHOPPERMOUNTINGPLATE 7 1 HDT 1096 FLUXHOPPERMOUNTSTANDOFF HDT 1110 Flux Hopper W Mount 4 1 2 3 6 1 5 7 4 2 3 1 1 7 6 HDT 1110 Configuration for Fillet Welding Shown on HDT 1085 5 ...

Page 29: ... 2 13 X 1 3 2 FAS 1330 HEXNUT10 24 4 1 FRU 1000 VAC FLUXRECOVERYUNIT VACONLY 5 1 HDT 1093 FLUXHOPPERVACUUMMOUNTPLATE 6 2 HDT 1102 U BOLTW MNTINGPLATE 7 1 HDT 1120 FLUXHOPPERVACUUMMOUNT 8 2 WAS 0230 10 SAE FLAT 9 2 WAS 0231 10 INTERNALSTAR LOCKWASHER 10 2 WAS 0280 1 2 SAE FLAT 11 2 WAS 0281 1 2 SPLIT LOCKWASHER HDT 1115 Flux Vacuum W Mount 1 4 6 5 7 11 10 2 9 8 3 ...

Page 30: ...usage All shipping and handling charges will be paid by customer Bug o Systems makes no warranty of merchantability and makes no other warranty expressed or implied beyond the warranty expressly set forth above Buyer s remedy for breach of warranty hereunder shall be limited to repair or replacement of non conforming parts and machines Under no circumstances shall consequential damages be recovera...

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