INSTRUCTIONS
AND
PARTS MANUAL
CON-O
Bug-O Systems is guided by honesty, integrity and ethics in service
to our customers and in all we do.
Please record your equipment identication 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-CONO-IPM-0515
A DIVISION OF WELD TOOLING CORPORATION
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA, USA 15317
PHONE: 412-331-1776 http://www.bugo.com FAX: 412-331-0383
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.
1.The equipment is not waterproof. Using
the unit in a wet environment may result
in serious injury. Do not touch the
equipment when wet or standing in a wet
location.
2.Never open the equipment without rst
unplugging the power cord or serious
injury may result.
3.Verify the customer-supplied power
connections are made in accordance
with all applicable local and national
electrical safety codes. If none exist, use
International Electric Code (IEC) 950.
4.Never remove or bypass the equipment
power cord ground. Verity the
equipment is grounded accordance
with all applicable local and national
electrical safety codes. If none exist, use
lnternational Electrical Code (IEC) 950.
READ INSTRUCTIONS
Read the instruction manual before installing
and using the equipment.
1. Do not plug in the power cord without
rst verifying the equipment is OFF
and the cord input voltage is the same
as required by the machine or serious
damage may result.
2. Do not leave the equipment unattended.
Remove from the worksite and store in
a safe location when not in use.
FALLING EQUIPMENT
can cause serious personal
injury and equipment
damage.
Faulty or careless user installation is
possible. As a result, never stand or
walk underneath equipment.
MOVING PARTS can cause
serious injury.
1. Never try to stop the pinion from moving
except by removing power or by using
the STOP control.
2. Do not remove any protective panels,
covers or guards and operate equipment.
POSSIBLE.
CAUTION
DO NOT LEAVE EQUIPMENT UNATTENDED
WHEN NOT IN USE!
Remove from work site and store in a safe location.
2
CON-O
INSTRUCTION AND PARTS MANUAL
TABLE OF CONTENTS
PAGE
4............TECHNICAL DATA
4............CON-O CAPACITIES AND SPEED RANGES
5-8 ........OPERATING INSTRUCTIONS
9............BUG-5100-F DC III DRIVE UNIT
10..........EXPLODED VIEW / CON-O
11 .......... PARTS LIST / CON-O
12..........EXPLODED VIEW / BUG-5100-F DC III DRIVE UNIT
13..........PARTS LIST / BUG-5100-F DC III DRIVE UNIT
14..........WIRING DIAGRAM / ELECTRICAL COMPONENT CHART
15..........VACUUM SUPPORT KIT
16..........EXPLODED VIEW / VACUUM PUMP
17..........PARTS LIST / VACUUM PUMP
18..........TROUBLESHOOTING GUIDE
19 ....... WARRANTY
THIS PRODUCT IS COVERED BY ONE OR
MORE PATENTS WORLD WIDE.
3
TECHNICAL DATA
CON-0 PRECISION CONTOUR-SADDLE CUTTER
Part Number: Power Requirement:
CON-3303 120 VAC/50-60/1
CON-3323 240 VAC/50-60/1
CON-3313 42 VAC/50-60/1
CON-4404 120 VAC/50-60/1
CON-4424 240 VAC/50-60/1
CON-4414 42 VAC/50-60/1
CON-5505 120 VAC/50-60/1
CON-5525 240 VAC/50-60/1
CON-5515 42 VAC/50-60/1
CON-3
CON-4
CON-5
24" (940 mm)
32" (813 mm)
40" (1016 mm)
Dimensions
25.50" (648 mm)
33.87" (860 mm)
42.25" (1073 mm)
19"
(483 mm)
CON-3
Net Weight:
CON-4
CON-5
CON-3303, 3323, 3313 65 lbs. (29.5 kg)
CON-4404, 4424, 4414 80 lbs. (36.3 kg)
CON-5505, 5525, 5515 105 lbs. (47.7 kg)
CAPACITIES AND SPEED RANGES
DIAMETER
DIAMETER
INCH IPM MM MM/MIN
3 .4-8 75 10-210
CON-3303 6 .8-16 150 20-420
10 1.4-28 250 35-700
14 2-39 350 50-1000
10 .9-18 250 23-460
CON-4404 14 1.3-26 350 32-650
18 1.7-33 450 42-840
22 2-40 550 50-1000
18 1.3-25 450 32-640
CON-5505 22 1.5-30 550 38-760
26 1.8-37 650 45-900
30 2-41 750 52-1050
37" (940 mm)
45" (1143 mm)
53" (1346 mm)
IMPORTANT NOTICE
SADDLE CUT DIAMETERS
SHOULD NOT EXCEED 2/3
THE DIAMETER OF THE
PIPE. 12" (304 mm) PIPE
IS THE SMALLEST SIZE
PRACTICAL, I.E. 8"(203 mm)
HOLE MAXIMUM ON A 12”
(304 mm) PIPE MAXIMUM DIAMETERS PRACTICAL WILL
BE REDUCED WHEN BEVEL
CUTS ARE MADE. CHART
SHOWS DIAMETERS FOR
STRAIGHT CUTS.
1.75"
(45 mm)
4
CON-O OPERATING INSTRUCTIONS
C
B
CC
BB
AA
A
X
DD
D
W
E H
V
U
G
R
S
J
I
K
L
T
M
N
Q
O
P
INTRODUCTION
The time required to read the following instructions will be reclaimed many
times by your becoming familiar with the operation and capacity of your new
CON-O precision contour saddle cutting machine.
The CON-O Carriage (X) should operate freely on the Ring Track (L), when
the Cam Clutch (D) is disengaged.
The Cam Clutch (D) engages the drive pinion to the Ring Gear (K) by
changing the position of the Drive Unit (CC). The Wing Nut (C) locks the
Cam Clutch (D) in position.
Turning the Potentiometer Knob (A) regulates speed. The Switch (B)
controls forward-off-reverse. Throw the Switch (B) in the direction you want
the carriage to travel.
5
CON-O OPERATING INSTRUCTIONS CONT’D.
LAYOUT AND SETUP
The only layout necessary is a centerline longitudinally [parallel to the axis
of the workpiece], a single center-punch mark, and a second punch mark
[along the longitudinal centerline a distance from the center-punch mark equal
to the radius [on the outside of the workpiece of the hole to be cut. If a bevel
hole is to be cut, layout a third punch mark [along the longitudinal centerline]
a distance from the center-punch mark equal to the radius [on the inside of
the workpiece] of the bevel hole to be cut.
RACK
TORCH
R
W
OUTSIDE
SURFACE
CENTER
PUNCH MARK
T
SMALL DIAMETER
LARGE DIAMETER
RIDING
WHEEL
INSIDE
SURFACE
OUTSIDE
RADIUS POINT
INSIDE
RADIUS POINT
LONGITUDINAL
CENTER LINE
W
The illustration shows you that the CON-O machine should be placed on the
work with the Center Pin (R) located in the center-punch mark and two sets
of Alignment Bars (W) straddling, equidistant, the longitudinal center-line.
The Outrigger Support Kits (Q) should be arranged with the Magnet Foot
Assemblies (O) and Legs (M) approximately perpendicular to the work
surface if possible. Clamp securely to level and stabilize the CON-O. The
Legs (U) are also symmetrically located so they will align the machine on
the layout line.
The Four Straight Legs (U) are symmetrically located so that they too may
be used in aligning the machine. The type and size of work being done will
determine which methods of attachment are most advantageous.
6
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