Bug-O Systems STW-3000 Instructions And Parts Manual Download

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INSTRUCTIONS

AND

PARTS MANUAL

STW-3000

PROGRAMMABLE

STIFFENER

WELDER

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

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.

Summary of Contents for STW-3000

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

Page 2: ... before installing and using the equipment 1 Do not plug in the power cord without first verifying the equipment is OFF and the cord input voltage is the same as required by the machine or serious damage may result 2 Always verify both the pinion and wheels are fully engaged before applying power or equipment damage may occur 3 Do not leave the equipment unattended 4 Remove from the worksite and s...

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: ...Gun Hinge Left Exploded View Parts List 16 STW 2150 R Gun Hinge Right Exploded View Parts List 17 STW 2170 A CaptureWheelAssembly A Exploded View Parts List 18 STW 2170 B CaptureWheelAssembly B Exploded View Parts List 19 STW 2115 Drive Latch Exploded View Parts List 20 STW 2060 Flow Meter ValveAssembly Exploded View Parts List 21 STW 2120 Drive UnitAssembly Exploded View 22 STW 2120 Drive UnitAss...

Page 5: ...engage the Drive Latch and tighten to ensure constant pressure on the work piece between the Drive Assembly Work Piece and Capture Wheel Assemblies NOTE Move the unit forward and reverse using the Travel Manual Jog switch located on the front lower left of the control box to ensure proper tension has been applied by the Drive Latch to move the unit smoothly along the work piece 4 Align the left an...

Page 6: ...lenoid to purge welding gun and check the gas rate on the assigned regulators MAIN WELD CYCLE START Initiates automated weld cycle MAIN WELD CYCLE STOP Halts automated weld cycle TRAVEL MANUAL JOG Allows operator to move the unit forward or backward without welding EMERGENCY STOP When pressed causes all functions to stop PROGRAMMING CENTER See controls for programming center pg 7 Programming Cente...

Page 7: ...inuous mode Note It is possible to change from Continuous to Skip welding on the fly To change modes press the Continuous Skip Select button If the machine is making a continuous weld the backup function and postflow will occur immediately The machine will move the programmed skip distance and proceed to make the programmed skip welds If the machine is making a skip weld the machine will continue ...

Page 8: ...eed Preflow Time Increase Value Decrease Value Skip Weld Indicator Function Select Continuous Weld Indicator Continuous Skip Select Skip Length Postflow Time Backup Distance Digital Readout CONTROLS PROGRAMMING CENTER CONT D ...

Page 9: ...rse Drive Crater Fill 0 1 0 25mm Programmable Pre Weld Post Weld Gas Purge 0 10 seconds Net Weight 250 lbs 113 kg Stiffener Size Range Height 4 18 102 457mm Width 4 12 102 305mm Wire Spool Capacity 10 20 60 lbs each side DIMENSIONS 23 000 58 42 cm 48 657 123 6 m 25 470 64 7 cm 52 063 132 2 cm ...

Page 10: ...TW 2150 R Gun Hinge Right 8 1 STW 2170 A Capture Wheel Assy A 9 1 STW 2170 B Capture Wheel Assy B 10 4 STW 2142 3 Phenolic Caster 11 1 STW 2115 Drive Latch 12 2 STW 2060 Flow Meter Valve Assy 13 2 STW 2190 18 Leg 18 14 1 STW 2066 Left Leg Support 15 1 STW 2067 Right Leg Support 16 2 STW 2151 Wheel Mt Plt 17 1 STW 2054 Deck Plt 18 1 STW 2120 Drive Unit 19 1 STW 2195 Spool Support Bracket 20 1 STW 1...

Page 11: ...11 WIRING DETAIL See Electrical Component Chart pg 11 ...

Page 12: ...ECEPTACLE PANEL PM4 CON 06RP04F SHELL 18 RECEPTACLE PANEL PM5 CON 04RP03M SHELL 16S RECEPTACLE PANEL PM6 BUG 9856 PANEL CONNECTOR 2 T F SW1 SWT EPF3 ROUND FLUSH GREEN SWITCH SW2 SWT EPF4 ROUND FLUSH RED SWITCH SW3 BUG 2255 TOGGLE SWITCH DPDT ON OFF ON SW4 SWT 1111 NOR OPEN PUSH BUTTO BLACK SW5 SWT 1111 NOR OPEN PUSH BUTTO BLACK SW6 SWT 5225 TOGGLE SWITCH SW7 SWT 5225 TOGGLE SWITCH SW8 ARM 2279 TOG...

Page 13: ... 4 HDP 9 1 FAS 0535 Soc Hd Cap Scr 10 24 x 1 2 10 1 FAS 0557 Soc Hd Cap Scr 1 4 20 x 3 4 11 2 FAS 0654 Soc Hd Shd 5 16 x 3 8 x 1 4 20 12 2 FAS 0957 Flt Hd Soc 1 4 20 x 3 4 13 1 MUG 1515 Collar 14 1 PAN 1235 Slide Assy 15 1 PAN 2125 Mounting Arm Assy 16 1 PAN 2131 L Mounting Plate Left 17 1 PAN 2133 L Slide Plate 18 1 PAN 2134 Screw Retainer 19 1 PAN 2135 Screw Block 20 1 PAN 2136 Adjusting Screw 2...

Page 14: ...S 0557 Soc Hd Cap Scr 1 4 20 x 3 4 11 2 FAS 0654 Soc Hd Shd 5 16 x 3 8 x 1 4 20 12 2 FAS 0957 Flt Hd Soc 1 4 20 x 3 4 13 1 MUG 1515 Collar 14 1 PAN 1235 Slide Assy 15 1 PAN 2125 Mounting Arm Assy 16 1 PAN 2131 R Mounting Plate Left 17 1 PAN 2133 R Slide Plate 18 1 PAN 2134 Screw Retainer 19 1 PAN 2135 Screw Block 20 1 PAN 2136 Adjusting Screw 21 1 PAN 2137 External Retaining Ring 22 1 WAS 0230 10 ...

Page 15: ...2158 Vertical Mounting Rod 7 1 STW 2159 SS Pin 1 8 Diameter x 1 8 1 STW 2160 Clamp Block Round Square 9 1 STW 2168 Hinge Plate E 10 1 STW 2178 Knurled Knob Plunger 11 6 FAS 0559 Soc Hd Cap Scr 1 4 20 x 1 12 1 FAS 0599 Soc Hd Cap 3 8 16 x 1 13 2 FAS 2693 Soc Hd Shr 1 2 x 1 x 3 8 16 14 1 FAS 0999 Flt Hd Soc 3 8 16 x 1 15 1 FAS 1301 Hex Nut 1 2 13 16 1 STW 2165 Clamp Block LG Round Square 13 10 2 4 7...

Page 16: ...158 Vertical Mounting Rod 7 1 STW 2159 SS Pin 1 8 Diameter x 1 8 1 STW 2160 Clamp Block Round Square 9 1 STW 2167 Hinge Plate D 10 1 STW 2178 Knurled Knob Plunger 11 6 FAS 0559 Soc Hd Cap Scr 1 4 20 x 1 12 1 FAS 0599 Soc Hd Cap 3 8 16 x 1 13 2 FAS 2693 Soc Hd Shr 1 2 x 1 x 3 8 16 14 1 FAS 0999 Flt Hd Soc 3 8 16 x 1 15 1 FAS 1301 Hex Nut 1 2 13 16 1 STW 2165 Clamp Block LG Round Square 16 5 8 6 3 1...

Page 17: ...I D 3 1 STW 2173 Follower Hinge 4 1 STW 2174 Five Lobe Knob Insert 5 1 STW 2175 A Female Tube Weldment 6 1 STW 2179 2 Caster Iron Wheel 7 1 STW 2180 Male Tube Weldment 8 1 FAS 0454 Cone Set Scr 1 4 20 x 3 8 Cone Point 9 4 FAS 0555 Soc Hd Cap Scr 1 4 20 x 1 2 10 4 FAS 2554 Soc Hd Cap Scr 1 4 20 x 1 3 4 11 1 FAS 0455 HDP Set Scr 1 4 20 x 1 2 Half Dog 12 1 SPR 1001 LH Left Follower Spring ...

Page 18: ... D 3 1 STW 2173 Follower Hinge 4 1 STW 2174 Five Lobe Knob Insert 5 1 STW 2175 B Female Tube Weldment 6 1 STW 2179 2 Caster Iron Wheel 7 1 STW 2180 Male Tube Weldment 8 1 FAS 0454 Cone Set Scr 1 4 20 x 3 8 Cone Point 9 4 FAS 0555 Soc Hd Cap Scr 1 4 20 x 1 2 10 4 FAS 2554 Soc Hd Cap Scr 1 4 20 x 1 3 4 11 1 FAS 0455 HDP Set Scr 1 4 20 x 1 2 Half Dog 12 1 SPR 1001 RH Right Follower Spring ...

Page 19: ...EM QTY PART NUMBER DESCRIPTION 1 4 FAS 0557 Soc Hd Cap Scr 1 4 20 x 3 4 2 1 STW 2116 Drive Latch Weldment 3 1 STW 2118 Screw 1 2 13 x 3 1 2 4 1 STW 2119 Level Mount 5 1 STW 2174 Five Lobe Knob Insert 1 2 13 RT 6 4 WAS 0240 1 4 SAE Washer 1 6 5 3 4 2 6 1 ...

Page 20: ...en 4 1 CIR 1012 Hose Nut Oxygen Right Hand 5 1 CIR 1013 1 4 Hose Nipple 6 1 CIR 1016 Hose Clamp 9 16 Crimp Type 7 2 FAS 0545 Soc Hd Cap Scr 10 30 x 1 2 8 1 STW 2061 Argon Flowmeter 9 1 STW 2062 Modified Cord Grip 10 1 STW 2063 1 4 I D Hose Barb 11 1 STW 2064 Inert Gas Male RH 12 2 STW 2065 Clamp 2 Ear 8 11mm 13 1 CON PS04M Plug Straight 4 Pin Male NS 26 1000 4 002 1 4 I D x 3 8 O D Tube 3 2 9 8 10...

Page 21: ...21 STW 2120 DRIVEUNITASSEMBLY EXPLODEDVIEW 11 8 11 7 15 5 2 21 16 17 2 18 13 1 23 12 20 24 6 9 14 3 10 9 ...

Page 22: ...Cap Scr 8032 x 1 9 4 FAS 0559 Soc Hd Cap Scr 1 2 20 x 1 10 4 FAS 1305 Hex Nut 4 40 11 4 FAS 2553 Soc Hd Cap Scr 1 4 20 x 1 1 2 12 4 FAS 2554 Soc Hd Cap Scr 1 20 x 1 3 4 13 1 GOF 3014 Drive Pinion w Key Set Screw 14 1 STW 2121 Drive Unit Bottom Cover 15 1 STW 2122 Drive Unit Top Cover 16 1 STW 2123 Drive Shaft 17 1 STW 2124 Bushing 18 1 STW 2125 Drive Gear Assembly 19 1 STW 2128 Drive Unit Mounting...

Page 23: ... 4 2 ITEM QTY PART NUMBER DESCRIPTION 1 6 FAS 0557 Hex Hd Cap Scr 1 4 20 x 3 4 2 8 FAS 0579 Hex Hd Cap Scr 5 16 18 x 1 3 4 FAS 0599 Hex Hd Cap Scr 3 8 16 x 1 4 2 STW 2069 Spool Mount Plate 5 1 STW 2196 Mount Plate 6 1 STW 2197 Guage Mount Plate 7 1 STW 2198 Cable Mount ...

Page 24: ...mes in quantities of 1 30 lb Spool Kit The 30 lb spool kit accepts 30 lb spools of wire and mounts to the spool mounting bracket on the rear of the welding unit Order WFU 1041 Comes in quantities of 1 60 lb Spool Kit The 60 lb spool kit accepts 60 lb spools of wire and mounts to the spool mounting bracket on the rear of the welding unit Order BUG 3293 Comes in quantities of 1 ...

Page 25: ...rchantability 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 recoverable HOW TO OBTAIN SERVICE If you think this machine is not operating properly re read the instruction ...

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