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INSTRUCTIONS

AND

PARTS MANUAL

A DIVISION OF WELD TOOLING CORPORATION

280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA

PHONE: 412-331-1776 http://www.bugo.com FAX: 412-331- 0383

COMPACT

WALL-FOLLOWING

FILLET WELDER

K-BUG 4000

K-BUG 4002

K-BUG 4004

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-KBUG-4000-IPM-0916

Bug-O Systems is guided by honesty, integrity and

ethics in service to our customers and in all we do.

Содержание K-BUG 1200

Страница 1: ...K BUG 4004 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 KBUG 4000 IPM 0916 Bug O Systems is guided by honesty integrity and ethics i...

Страница 2: ...0 5 Never remove or bypass the equipment power cord ground Verify the equipment is grounded in accordance with all appli cable local and national electrical safety codes If none exist use International Electric Code IEC 950 READ INSTRUCTIONS Read the instruction manual before installing and using the equipment 1 Do not plug in the power cord without first verifying the equipment is OFF and the cor...

Страница 3: ...s as small as possible The larger the gap the higher the voltage and the higher the inter ference 5 Some plasma or welding units will inject high frequency interference into the AC power line Use separate power line branches whenever possible to power the plasma or welding source and the machine Do not plug them into the same outlet box 6 High frequency noise may enter the machine through the plas...

Страница 4: ...ttings 8 Global Parameters 9 Converting Units 10 Installation and Operation 10 Maintenance 11 12 Troubleshooting 13 K BUG 4000 Assembly View 14 K BUG 4000 Wiring Diagram 15 KBUG 4010 Carriage Assembly Exploded View 16 KBUG 4010 Carriage Assembly Parts List 17 KBUG 1060 Guide Arms Exploded View Parts List 17 KBUG 4090 Torch Clamp Assembly Parts List 18 KBUG 4050 Control Panel Assembly Exploded View...

Страница 5: ...ntinuous and intermittent welds Digital speed display Precision speed control for consistent weld quality User adjustable time settings for puddle build up pause time and crater fill Drive wheels rated to 400 F 204 C TECHNICAL DATA Power Input K BUG 4000 120VAC 50 60 Hz 1 Phase K BUG 4002 240VAC 50 60 Hz 1 Phase K BUG 4004 42VAC 50 60 Hz 1 Phase Weight 14 lb 6 4 kg Drive Motor 24 VDC 12 W 5000 RPM...

Страница 6: ...rmittent function and time settings 7 Indicator LED s Indicate active parameter during intermittent welding A Weld Length B Non Weld Length C Total Length WELDING MODES The K BUG 4000 offers three weld modes Continuous Total Length Intermittent and User Defined Intermittent The value shown in the speed display will vary based on what welding mode the machine is operating in Speed is displayed only...

Страница 7: ...adjusts 7 Press the travel Speed Adjustment Knob again All LEDs are unlit Note measurement is in inches or cm according to the unit setting refer to Converting Units on pg 9 Intermittent Welding is available in two forms User Defined and Total Length With User Defined welding user enters values for Weld Length and Non Weld Length Either A or B LED must be lit when pressing Cycle Start Button Inter...

Страница 8: ...lay will show E0 0 flashing 3 Turn the Travel Speed Adjustment knob until the desired stop time is displayed 4 Default setting is 0 5 seconds Available range is 0 0 9 9 seconds When finished setting times press the Cycle Stop button to exit time setup mode The machine is now ready to be setup for welding A graphic display of the user adjustable time settings GLOBAL PARAMETERS A menu of Global Para...

Страница 9: ...ob to change the parameter setting 10 When finished unplug machine remove Control Interface and turn it over 11 Turn DIP switch 1 to the OFF position to lock global parameter menu 12 Re assemble Control Panel and plug in machine to begin operation CONVERTING UNITS By default the K BUG 4000 will be factory set to operate in English units in min and the K BUG 4002 will be set to operate in Metric un...

Страница 10: ...ding arm slightly shorter than following arm for better positioning of the electrode in the joint Adjust the target angle and position of the Torch using the Torch Adjustment Slider Verify machine is in the proper welding mode Set stitch welding parameters if needed Verify adequate Shielding Gas Supply Start Welding Switch Welding Switch to AUTO verify desired travel direction is set and travel sp...

Страница 11: ...eeded Faulty or incorrectly wired Cycle Start Button Check Wiring Replace button if needed Faulty MAIN PCB Replace MAIN PCB Torch targets wrong position Loose fastener on Torch Clamp or Slide Assembly Check and tighten screws replace if needed Slide is hard to adjust Dust or other debris on slide parts Clean slide parts Lubricate with light oil Carriage stops during automatic welding Obstacle in c...

Страница 12: ...B EET ROM Error Main PCB Replacement E 05 Travelling Stop Auto Stop Travelling Motor Push and release Stop Button may be overloaded shorted IF UNRESOLVED 1 Check for loose wiring connec tion at drive motor and weave motor if equipped see below 2 Replace motor or motor reducer 3 Replace main PCB ...

Страница 13: ...embly 4 1 KBUG 4070 Slide Assembly 5 1 KBUG 1060 Guide Arm Assembly 6 1 KBUG 4040 Cable Anchor 1 KBUG 2274 XX 120 VAC Power Cord 1 KBUG 2273 XX Weld Contact Cable 1 KBUG 1003 Metric Hex Key Set Not shown Note 1 XX Cable length 15 25 50 ft 4 5 7 5 15 m 2 For KBUG 4002 Power Cord is KBUG 2272 15 K BUG 4000 ASSEMBLY VIEW 1 3 4 5 2 6 ...

Страница 14: ...S08 HEADER S08 HEADER S08 HEADER S08 1 2 3 4 5 1 2 3 1 2 3 4 5 6 FND0 FND1 FND2 FND3 EN_UP_SW EN_DN_SW EN_PUSH_SW GND 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 DC 24 V P GND MA_CW CCW MA_PULSE MA_PWM MA_RUN STOP DA0 DA1 DA2 DA3 DA4 DA5 DA6 DA7 PA0 PA1 PA2 PA3 PA4 PA5 PA6 PA7 FND0 FND1 FND2 FND3 EN_UP_SW EN_DN_SW EN_PUSH_SW GND AC EARTH AC WELD_COM TORCH KBUG 1126 ...

Страница 15: ...15 KBUG 4010 CARRIAGE ASSEMBLY EXPLODED VIEW 1 2 7 6 5 4 3 8 14 13 12 11 10 16 21 20 19 18 17 22 23 27 26 25 24 9 15 ...

Страница 16: ...nsor Cover 11 1 KBUG 4031 Sensor 12 1 KBUG 4034 Magnet Large 13 1 KBUG 4026 Magnet Plate 14 2 KBUG 4025 Magnet Bracket 2 15 1 KBUG 4023 Motor Bracket BD 16 1 KBUG 4037 Geared Motor 17 1 KBUG 4038 Motor Bracket BLDC 18 1 KBUG 1049 DC Brushless Motor 19 3 KBUG 4021 Wheel Shaft Bushing 2 20 3 KBUG 4035 Chain Sprocket 21 2 KBUG 4017 Wheel Shaft Cover 1 22 1 KBUG 4022 Chain 23 2 KBUG 4016 Wheel Shaft 2...

Страница 17: ...e Roller 3 2 KBUG 1063 Guide Roller Cover 4 2 KBUG 1064 Guide Roller Slide Bracket 5 2 KBUG 1065 Guide Arm 6 2 KBUG 1068 Guide Roller Sleeve 6 KBUG 4090 TORCH CLAMP ASSEMBLY PARTS LIST 1 3 ITEM QTY PART NO DESCRIPTION 1 1 KBUG 2080 Torch Clamp Assembly 2 1 KBUG 4095 Slide Bar Clamp 3 1 KBUG 3076 Bushing 4 1 KBUG 4097 HDH Torch Clamp Base 4 2 ...

Страница 18: ... KBUG 1125 Display 6 1 KBUG 1126 Main PCB 7 1 KBUG 1127 Push Button Cover 2 8 1 KBUG 1128 Push Button Cover 1 9 1 KBUG 1129 Volume Knob 10 1 KBUG 1131 Fuse Holder w Fuse 11 1 KBUG 1132 Power Connector 4T Female 12 1 KBUG 1133 Torch Connector 2T Female 1 KBUG 1173 Weld Contact Connector Male 1 KBUG 1174 Power Connector Male Not Shown ACCESSORIES KBUG 1067 Magwheel Add On Kit Magnetic guide wheels a...

Страница 19: ... X X X X X X 5 1 PWS 4411 Case w Binder Screws Back X X X X X X 6 1 STW 3044 450 Amp Cable X X X X X X 7 1 R174 T Connector Small Lincoln 7 1 R174 L Connector Lincoln 7 1 R174 M Connector Miller 7 1 R174 X Connector Euro 8 1 CWO 8009 44 3545 15 Cable Liner X X X 8 1 CWO 8011 44 116 15 Cable Liner X X 8 1 CWO 8012 44 564 15 Cable Liner X 1 SBG 1004 Gas Hose Assembly X X X X X X 2 SBG 1005 Gas Hose ...

Страница 20: ...CHANTABILITYAND 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 PARTSAND 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 MAN...

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