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INSTRUCTIONS
PARTS MANUAL
WALL-FOLLOWING
FILLET WELDER
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.
280 TECHNOLOGY DRIVE
AND
COMPACT
K-BUG 4000
K-BUG 4002
K-BUG 4004
Bug-O Systems is guided by honesty, integrity and
ethics in service to our customers and in all we do.
A DIVISION OF WELD TOOLING CORPORATION
PHONE: 412-331-1776
CANONSBURG, PENNSYLVANIA 15317-9564
http://www.bugo.com
LIT-KBUG-4000-IPM-0916
USA
FAX: 412- 331- 0383
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Table of Contents
Related Manuals for Bug-O Systems K-BUG 4000
Summary of Contents for Bug-O Systems K-BUG 4000
- Page 1 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. A DIVISION OF WELD TOOLING CORPORATION...
- 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. EQUIPMENT DAMAGE ELECTRIC SHOCK can kill. POSSIBLE. 1) The equipment is not waterproof. Using the unit in a wet environment may result in serious injury.
- 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
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... -
Page 5: Introduction
INTRODUCTION The K-BUG 4000 is a compact, light weight, wall-travelling unit designed to mechanize horizontal fillet welding. It is able to follow vertical or inclined walls of straight or curved (R > 1000 mm) profile. The machine is capable of performing continuous and intermittent (stitch) welds. -
Page 6: User Interface
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 during Continuous welding 1. -
Page 7: Intermittent Welding
STOP SENSOR OPERATION The K-BUG 4000 is equipped with a magnetic proximity sensor, mounted internal to the carriage, on the non-torch side. When the sensor detects the end of the work piece, it stops carriage travel and initiates... -
Page 8: Time Settings
GLOBAL PARAMETERS A menu of Global Parameters is maintained in the K-BUG 4000. The menu consists of six (6) items as described in Table 1, below. Access to the menu is locked when DIP Switch #1 is in the OFF Position. -
Page 9: Converting Units
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 units (cm/min). If it is necessary to change units, follow the steps to access the Global Parameters Menu, above. -
Page 10: Installation And Operation
INSTALLATION AND OPERATION 1. Welding Preparation - Secure the necessary welding supplies • Welding Power Source (3 phase, 440/380/220V AC) • Wire Feeder • Tank of appropriate shielding gas, with pressure and flow regulators and appropriate fittings • Torch for gas shielded automated welding •... -
Page 11: Troubleshooting
TROUBLESHOOTING Symptom Cause Repair Control panel Disconnected Control Cable Connect control cable to machine Display is not LIT when machine is Faulty Control Cable Replace Cable plugged in Control Box Fuse Tripped or Replace fuse. If problem persists, Disconnected contact service rep. No Arc when Weld Auto/Off Switch set to OFF Turn Weld Auto/Off Switch to AUTO... - Page 12 TROUBLESHOOTING, CONT’D. K-BUG ERROR LIST SYMPTOM CAUSE SOLUTION E-03 Motion Stop Main PCB 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).
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Page 13: K-Bug 4000 Assembly View
K-BUG 4000 ASSEMBLY VIEW ITEM PART NO. DESCRIPTION KBUG-4010 Carriage Assembly KBUG-4050 Control Panel Assembly KBUG-4090 Torch Clamp Assembly KBUG-4070 Slide Assembly KBUG-1060 Guide Arm Assembly KBUG-4040 Cable Anchor KBUG-2274-XX 120 VAC Power Cord KBUG-2273-XX Weld Contact Cable KBUG-1003 Metric Hex Key Set... -
Page 14: K-Bug 4000 Wiring Diagram
K-BUG 4000 WIRING DIAGRAM... -
Page 15: Kbug-4010 Carriage Assembly / Exploded View
KBUG-4010 CARRIAGE ASSEMBLY / EXPLODED VIEW... -
Page 16: Kbug-4010 Carriage Assembly / Parts List
KBUG-4010 CARRIAGE ASSEMBLY / PARTS LIST ITEM PART NO. DESCRIPTION KBUG-4011 Body, Rear KBUG-4012 Body Side, Left KBUG-4013 Body, Bottom KBUG-4014 Body Side, Right KBUG-4015 Body, Top KBUG-4028 Body Cover KBUG-4032 Handle KBUG-4027 Magnet, Small KBUG-4024 Magnet Bracket (1) KBUG-4029 Sensor Cover KBUG-4031 Sensor... -
Page 17: Kbug-1060 Guide Arms / Exploded View / Parts List
KBUG-1060 GUIDE ARMS / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION KBUG-1061 Guide Roller Bushing KBUG-1062 Guide Roller KBUG-1063 Guide Roller Cover KBUG-1064 Guide Roller Slide Bracket KBUG-1065 Guide Arm KBUG-1068 Guide Roller Sleeve KBUG-4090 TORCH CLAMP ASSEMBLY / PARTS LIST ITEM PART NO. -
Page 18: Kbug-4050 Control Panel Assembly / Exploded View / Parts List
KBUG-4050 CONTROL PANEL ASSEMBLY / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION KBUG-4051 Panel KBUG-1122 Toggle Switch Cover KBUG-1123 Legend Plate KBUG-1124 Push Button Cover (BS) KBUG-1125 Display KBUG-1126 Main PCB KBUG-1127 Push Button Cover - 2 KBUG-1128 Push Button Cover -1 KBUG-1129 Volume Knob... - Page 19 SBG-450-_-___-__ GUN & CABLE ASSEMBLY / EXPLODED VIEW / PARTS LIST Whip Length: 15 (15 ft / 4.6 m) or 25 (25 ft / 7.6 m) Wire Size: 035, 040, 045, 052, 116, 564 Connector Type: E (Euro), L (Lincoln ¾"), M (Miller), T (Lincoln, small) PARTS LIST WIRE SIZE .035...
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Page 20: Warranty
SERIAL NO. ________________________ 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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