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PARTS MANUAL
HEAVY-DUTY TRACTOR
TRACTOR BASE PACKAGE W/EQUIPMENT MOUNTS
WITH FEEDER & FLUX RECOVERY
Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above.
3001 WEST CARSON STREET
INSTRUCTIONS
HDT-1200
TRACTOR BASE PACKAGE
HDT-1250
HDT-1000
Model Number
Serial Number
Date of Purchase
A DIVISION OF WELD TOOLING CORPORATION
PHONE: 1- 800-245-3186 http://www.bugo.com TELEFAX: 1- 412-331- 0383
AND
PITTSBURGH, PENNSYLVANIA
LIT-HDT-IPM-1207
USA 15204-1899
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Table of Contents
Summary of Contents for BUG-O HDT-1200
- Page 1 INSTRUCTIONS PARTS MANUAL HEAVY-DUTY TRACTOR HDT-1200 TRACTOR BASE PACKAGE HDT-1250 TRACTOR BASE PACKAGE W/EQUIPMENT MOUNTS HDT-1000 WITH FEEDER & FLUX RECOVERY Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.
- Page 2 SAFETY PROTECT YOURSELF AND OTHERS FROM SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. MOVING PARTS can ELECTRIC SHOCK CAN KILL. cause serious injury. 1) Never try to stop the pinion from moving 1) The equipment is not waterproof.
- Page 3 HIGH FREQUENCY WARNINGS SPECIAL PRECAUTIONS ARE REQUIRED WHEN USING PLASMA, TIG OR ANY WELDING PROCESS THAT USES HIGH FREQUENCY TO STRIKE AN ARC. WARNING: HIGH FREQUENCY CAN EFFECT MACHINE OPERATION AND THEREFORE, WELD QUALITY. Read the precautions below before installing and using the equipment. PRECAUTIONS: 1) Some plasma or welding cables are strong sources of high frequency interference.
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Page 4: Table Of Contents
HEAVY-DUTY TRACTOR INSTRUCTIONS AND PARTS MANUAL TABLE OF CONTENTS HDT-1200/1202/1204 - HEAVY-DUTY TRACTOR BASE PACKAGE 6 ..INTRODUCTION 7 ..SETUP AND OPERATION 8 ..HDT-1010/1012/1014 TRACTOR / EXPLODED VIEW / PARTS LIST 9 ..HDT-1015 TRACTOR WIRING DIAGRAM 10 ..HDT-1020 TRACTOR / EXPLODED VIEW 11 .. - Page 5 HDT-1200/1202/1204 HEAVY-DUTY TRACTOR BASE PACKAGE For this model please see page 6. HDT-1250/1252/1254 HEAVY-DUTY TRACTOR WITH EQUIPMENT MOUNTS For this model please see page 14. HDT-1000/1002/1004 HEAVY-DUTY TRACTOR WITH FEEDER AND FLUX RECOVERY For this model please see page 21.
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Page 6: Introduction
HDT-1200/1202/1204 / INTRODUCTION The HEAVY-DUTY TRACTOR is a large tractor with over-sized wheels for submerged-arc welding on flat steel plate. The base package is available in 120, 240 or 42 VAC operation. The 120 VAC setup is HDT- 1200, 240 VAC setup is HDT-1202 and 42 VAC setup is HDT-1204. A control pendant is used to operate the tractor’s speed and direction. -
Page 7: Setup And Operation
NOTE: The tractor can easily be re-wired to draw 120VAC power from the wire-feeder or welding power supply outputs. The default configuration for the HDT-1200/HDT-1202/1204 is to get power from the AC lines through the supplied power cord. HOWEVER, HDT-1202/1204 (240, 42 VAC VERSIONS) CANNOT BE RE-WIRED FOR OPERATION WITH WELDING POWER SUPPLY OR FEEDER EQUIPMENT, ONLY HDT-1200 (120 VAC VERSION). -
Page 8: Hdt-1010/1012/1014 Tractor / Exploded View / Parts List
HDT-1010/1012/1014 TRACTOR / EXPLODED VIEW / PARTS LIST 2, 3 7, 8, 9 Item Part Number Description FAS-0112 PAN HD SLT 6-32 X 1/4 BLACK FAS-0104 #4-40 X 5/16 PAN HEAD, ZINC FAS-1305 HEX NUT 4-40 NYLON FAS-0722 FIL HD SCR 8-32 X 1/4 FAS-0124 8/32 X 3/8 PAN HD, DI-CHROME MDS-1030... -
Page 9: Hdt-1015 Tractor Wiring Diagram
HDT-1015 TRACTOR WIRING DIAGRAM ELECTRICAL COMPONENT CHART HDT-1015* HDT-1015-240 HDT-1015-42 ITEM DESCRIPTION 120 VAC 240 VAC 42 VAC CIRCUIT BREAKER BUG-2923 (.7A) BUG-2952 (.5A) BUG-2933 (2A) PILOT LIGHT BUG-1415 BUG-1428 BUG-1427 RELAY BUG-1383 BUG-1551 BUG-9636 TRANSFORMER BUG-9675 GOF-3112 BUG-1466 VOLT TRAP BUG-1393 BUG-1563 BUG-1393... -
Page 10: Hdt-1020 Tractor / Exploded View
HDT-1020 TRACTOR / EXPLODED VIEW... -
Page 11: Hdt-1020 Tractor Parts List
HDT-1020 TRACTOR / PARTS LIST Item Part Number Description BER-1001 FLANGE BEARING .502 X .627 X BUG-1550 GEAR MOTOR (150:1) BUG-1893 RETAINING RING 1/2'' EXTERNAL FAS-0525 SOC HD CAP 8-32 X 1/2 FAS-0835 FLT HD SLT SCR 10-24 X 1/2 FAS-0838 FLT HD SLT SCR 10-24 X 7/8 FAS-0957... -
Page 12: Hdt-1140 Tractor Pendant / Exploded View / Parts List
HDT-1140 TRACTOR PENDANT / EXPLODED VIEW / PARTS LIST SPEED READOUT SPEED CONTROL KNOB DIRECTION TOGGLE SWITCH SECONDARY WELD CONTACT SWITCH PRIMARY WELD CONTACT SWITCH Item Part Number Description FAS-1305-N HEX NUT 4-40 NYLON CBO-4168 PENDANT BOX BUG-1764 METER DISPLAY BOARD ASSY BUG-9621 KNOB, STRAIGHT MOLDED FAS-0104... -
Page 13: Pendant Wiring Diagram
PENDANT WIRING DIAGRAM ELECTRICAL COMPONENT CHART ITEM DESCRIPTION PART NUMBER PANEL CONNECTOR BUG-5527 DIGITAL METER BUG-1764 POTENTIOMETER CONTROL BUG-9677 SWITCH BUG-1869 SWITCH BUG-1869 SWITCH BUG-2255... -
Page 14: Introduction
(HDT-1200/1202/1204). The tractor comes set up for 120, 240 or 42 VAC operation. It comes with a power cord for use with AC line power. Refer to HDT-1200/1202/ 1204 for details concerning the tractor. The tractor control panel is located on the pendant for ease of use while in process. -
Page 15: Setup And Operation
HDT-1250/1252/1254 / SETUP AND OPERATION 1. Remove the machine from the shipping box. Be sure to account for all loose parts before discarding the box! 2. Locate the cords that ship with the machine. A power cord and control pendant cord should be included. -
Page 16: Hdt-1260 / Exploded View / Parts List
HDT-1260 / EXPLODED VIEW / PARTS LIST Item Part Number Description HDT-1060 MAST W/FOOT PLATE HDT-1280 FEEDER CONTROL MOUNT W/O FEEDER HDT-1270 WIRE SPOOL BKT W/O SPOOL KIT HDT-1290 FLUX RECOVERY VACUUM MOUNT... -
Page 17: Hdt-1060 Mast / Exploded View / Parts List
HDT-1060 MAST / EXPLODED VIEW / PARTS LIST Item Part Number Description CWO-4586 1-9/32'' I.D. EYE BOLT FAS-0959 1/4-20 X 1'' FLAT HD SOCKET HDT-1061 TOOLING MAST HDT-1062 TOOLING MAST FOOT PLATE HDT-1063 TOOLING MAST RETAINER RING HDT-1064 TOOLING MAST REST PLATE HDT-1065 WELD HEAD MOUNT PLATE HDT-1066... -
Page 18: Hdt-1270 Wire Reel Bracket / Exploded View / Parts List
HDT-1270 WIRE REEL BRACKET / EXPLODED VIEW / PARTS LIST Item Qty. Part Number Description BUG-3274 INSULATOR FAS-0308 1/2-13 X 1-1/2 HEX HD CAP SCR FAS-0309 1/2-13 X 1 HEX HD CAP SCR HDT-1073 WIRE CAPTURE BAR HDT-1075 WIRE REEL MOUNT BRACKET WAS-0280 1/2 SAE WASHER WAS-0281... -
Page 19: Hdt-1280 Control Box Bracket / Exploded View / Parts List
HDT-1280 CONTROL BOX BRACKET / EXPLODED VIEW / PARTS LIST Item Part Number Description FAS-0236 RND HD SCR 10-24 X 5/8 FAS-0309 1/2-13 X 1 HEX HD CAP SCR FAS-1330 HEX NUT 10-24 HDT-1083 NA-3 MOUNTING PLATE HDT-1086 LINCOLN NA-3 WELDER HDT-1087 NA-3 MOUNT HDT-1102... -
Page 20: Hdt-1290 Flux Recovery Vacuum Mount / Exploded View / Parts List
HDT-1290 FLUX RECOVERY VACUUM MOUNT / EXPLODED VIEW / PARTS LIST Item Part Number Description FAS-0235 RND HD SCR 10-24 X 1/2'' FAS-0309 HEX HD CAP SCR 1/2-13 X 1'' FAS-1330 HEX NUT 10-24 HDT-1093 FLUX HOPPER VACUUM MOUNT PLATE HDT-1102 U-BOLT W/MNTING PLATE HDT-1120... -
Page 21: Introduction
HDT-1000 / INTRODUCTION The HEAVY-DUTY TRACTOR is a large tractor with over-sized wheels for submerged-arc welding on flat steel plate. The unit is available with Lincoln NA-3S feeder and feeder controls. The tractor control panel is integrated into the NA-3S feeder control box for complete operation from the NA-3S panel. The unit is self- contained in that all tools and consumables for submerged-arc welding are located on the tractor. - Page 22 HDT-1000 / SET-UP & OPERATION 1. Remove the machine from the shipping box. Be sure to account for all loose parts before discarding the box! 2. Locate the cords that ship with the machine. A power cord and control pendant cord should be included.
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Page 23: Hdt-1050 / Exploded View / Parts List
HDT-1050 EXPLODED VIEW / PARTS LIST Item Part Number Description HDT-1090 FLUX RECOVERY SYSTEM HDT-1060 MAST HDT-1080 NA-3 WITH MOUNT HDT-1070 WIRE REEL WITH MOUNT HDT-1085 NA-3 AUTOMATIC HEAD ASSEMBLY NOTE: Refer to p.17 for HDT-1060 details. - Page 24 HDT-1070 WIRE REEL W/MOUNT / EXPLODED VIEW / PARTS LIST Item Qty. Part Number Description BUG-3274 INSULATOR BUG-3293 60# SPOOL KIT FAS-0308 1/2-13 X 1-1/2 HEX HD CAP SCR FAS-0309 1/2-13 X 1 HEX HD CAP SCR HDT-1073 WIRE CAPTURE BAR HDT-1075 WIRE REEL MOUNT BRACKET WAS-0280...
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Page 25: Hdt-1080 Na-3 W/Mount / Exploded View / Parts List
HDT-1080 NA-3 W/MOUNT / EXPLODED VIEW / PARTS LIST Item Part Number Description FAS-0236 RND HD SCR 10-24 X 5/8 FAS-0309 1/2-13 X 1 HEX HD CAP SCR FAS-1330 HEX NUT 10-24 HDT-1083 NA-3 MOUNTING PLATE HDT-1086 LINCOLN NA-3 WELDER HDT-1087 NA-3 MOUNT HDT-1102... -
Page 26: Control Box Wiring Diagram
CONTROL BOX WIRING DIAGRAM ELECTRICAL COMPONENT CHART ITEM DESCRIPTION PART NUMBER PANEL CONNECTOR BUG-5527 DIGITAL METER BUG-1764 SWITCH BUG-2255 POTENTIOMETER CONTROL BUG-9677... -
Page 27: Hdt-1085 Na-3 Automatic Head Mount / Exploded View / Parts List
HDT-1085 NA-3 AUTOMATIC HEAD MOUNT / EXPLODED VIEW / PARTS LIST Item Part Number Description CWO-1465 FINE ADJ. HORIZONTAL CWO-1466 VERTICAL-FINE ADJUSTMENT FAS-0309 HEX HD CAP SCR 1/2-13 X 1'' LDC-0010 AUTOMATIC HEAD WAS-0280 1/2'' SAE FLAT WAS-0281 1/2'' SPLIT LOCKWASHER... - Page 28 HDT-1090 FLUX RECOVERY UNIT W/MOUNT / EXPLODED VIEW / PARTS LIST HDT-1110 Flux Hopper W/Mount Item Part Number Description FAS-0155 PAN HD SCR 1/4-20X1/2 FAS-0357 HEX HD CAP SCR 1/4-20 X 3/4 FAS-0375 HEX HD CAP SCR 5/16-18 X 1/2 FRU-1000-FLH FLUX RECOVERY UNIT-HOPPER ONLY HDT-1094...
- Page 29 HDT-1090 FLUX RECOVERY UNIT W/MOUNT / EXPLODED VIEW / PARTS LIST HDT-1115 Flux Vacuum W/Mount Item Part Number Description FAS-0235 RND HD SCR 10-24 X 1/2'' FAS-0309 HEX HD CAP SCR 1/2-13 X 1'' FAS-1330 HEX NUT 10-24 FRU-1000-VAC FLUX RECOVERY UNIT-VAC ONLY HDT-1093 FLUX HOPPER VACUUM MOUNT PLATE HDT-1102...
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Page 30: Limited Warranty
Date Purchased: ___________________ For a period of twelve (12) months from delivery, Bug-O Systems warrants to the original purchaser (does not include authorized distributors), that a new machine is free from defects in material and workmanship and agrees to repair or replace, at its option, any defective parts or machine.
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