Bug-O Systems K-BUG 4000, K-BUG 4004, K-BUG 4002, K-BUG 1200, K-BUG 1202 Instructions And Parts Manual

INSTRUCTIONS

AND

PARTS MANUAL

COMPACT

WALL-FOLLOWING

FILLET WELDER

K-BUG 4000
K-BUG 4002
K-BUG 4004

Please record your equipment identication 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.

280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA

PHONE: [phone] http://www.bugo.com FAX: [phone]

A DIVISION OF WELD TOOLING CORPORATION

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.

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 equipment
when wet or standing in a wet location.

2) The unused connectors have power on
them. Always keep the unused connec­ tors covered with the supplied protective
panels. Operation of the machine without
the protective panels may result in injury.

3) Never open the equipment without rst
unplugging the power cord or serious
injury may result.

4) 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.

EQUIPMENT DAMAGE

POSSIBLE.

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) Always verity 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 work site and store in
a safe location when not in use.

FALLING EQUIPMENT
can cause serious
personal injury and
equipment damage.

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.

2

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.

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.

NEVER lay a plasma or welding cable across the controls of the machine.

2) Always physically separate the plasma or welding cable leads from the machine
cables. For example, the plasma or welding cable leads should NEVER be bundled
with a pendant cable or the machine power cord. Maximize the separation between
any machine cables and the plasma or welding cables.

3) Strictly follow the grounding procedures specied for the plasma or welding unit.
NOTE: Some plasma and welding units produce exceptionally large amounts 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 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 plasma or welding supply
remote contactor leads. Some plasma and welding sources can produce noise spikes
of up to several thousand volts. These sources are not compatible with automated
cutting and welding equipment. It is recommended that the remote contactor leads on
these plasma or welding sources not be connected to the machine. An alternate
solution is to purchase a separate remote contactor isolation box.

3

COMPACT WALL-FOLLOWING

FILLET WELDER

K-BUG 4000, K-BUG 4002

INSTRUCTIONS AND PARTS MANUAL

TABLE OF CONTENTS

PAGE

5 ..........Introduction

5 ..........Features

5 ..........Technical Data

5 ..........Dimensions

6 ..........User Interface

6 ..........Welding Modes

7 ..........Intermittent Welding

7 ..........Intermittent Welding Lock Out

7 ..........Stop Sensor Operation

8 ..........Time Settings

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 / Parts List

18 .........Accessories

19 .........SBG-450 Gun & Cable Assembly / Exploded View / Parts List

20 .........Warranty

4

INTRODUCTION

The K-BUG 4000 is a compact, light weight, wall-travelling unit designed to mechanize horizontal llet
welding. It is able to follow vertical or inclined walls of straight or curved (R > 1000 mm) prole. The
machine is capable of performing continuous and intermittent (stitch) welds.

FEATURES

• Compact - 14.6 x 8.9 x 11.3 in (370 x 226 x 288 mm)

• Lightweight - 14 lb (6.4 kg)

• Continuous 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-ll

• 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
Travel Speed 0.3 - 77 in/min (0.1 - 195 cm/min)
Torch Angle Adjustable
Running Angle 90°

DIMENSIONS

Max. 13.3" (337.8 mm)

Min. 9.7" (246.4 mm)

Min. 8.2" (208.3 mm)

Max. 10.8" (274.3 mm)

14.5" (368.3 mm)

5

USER INTERFACE

6

7

1. Cycle Start Button - Push button to initiate
weld cycle. Weld contact will close, according to
time settings, if the Weld Switch is set to Auto,
the carriage will travel in the direction selected
by the Travel Direction Switch.

2. Cycle Stop Button - Push button to stop
welding cycle.

3. Travel Direction Switch - Set switch to
determine direction of carriage travel.

4

4. Speed Adjustment Knob - Rotate knob to
adjust carriage travel speed. Turning clockwise

3

(right) will INCREASE speed.

NOTE: Travel Speed Adjustment Knob is also
used for setting the INTERMITTENT WELDING

5

function (pg.7) and the time settings.

5. Weld Auto / Off Contactor - When switched to
AUTO, weld contact will close with cycle start.
Switched to the right, weld contact will remain
open upon cycle start.

1 2

6. Digital Speed Display - Numerically displays

real-time travel speed in in/min (cm/min). Also
displays parameters during setup of intermittent
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 Dened
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. Continuous Welding

• No LED’s lit when Cycle Start button is pressed

• Displays speed while welding (0.1 in/min)

2. User Dened Intermittent Welding

• A or B LED lit when Cycle Start button is pressed

• User sets Welding Speed before pressing Cycle Start button

• Display will countdown each program parameter in order

- With A LED lit, the display will countdown Puddle Build-up timer, u, then Weld On
distance, A, then Crater Fill timer, n.

- With B LED lit, the display will countdown Weld Off distance, B
NOTE: Machine travels at higher speed during Non-Welding travel

• The intermittent cycle will repeat until the user presses Cycle Stop button or the Stop
tripped

S

ensor is

6

WELDING MODES, CONT’D.

3. Total Length Intermittent Welding

• C LED lit when Cycle Start button is pressed

• User sets Welding Speed before pressing Cycle Start button

• Display will countdown total distance remaining (1.0 in)

• A or B LED will light as appropriate for welding mode

NOTE: Machine travels at higher speed during Non-Welding travel

• The intermittent cycle will continue until the Total Length is satised or the Stop Sensor is
tripped

INTERMITTENT WELDING

The Travel Speed Adjustment Knob is used for entering the parameters for intermittent or stitch
welding. Follow the steps below to enter the welding parameters.

1. Press the Travel Speed Adjustment Knob. The A LED will illuminate.

2. Turn the Travel Speed Adjustment Knob (clockwise + / counterclockwise -) to set the WELD
LENGTH. The length adjusts.*

3. Press the Travel Speed Adjustment Knob again. The B LED will illuminate.

4. Turn the Travel Speed Adjustment Knob to set the NON-WELD LENGTH. The length adjusts.*

5. Press the Travel Speed Adjustment Knob again. The C LED will illuminate.

6. Turn the Travel Speed Adjustment Knob to set the TOTAL LENGTH. The length 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 Dened and Total Length. With User Dened
welding, user enters values for Weld Length and Non-Weld Length. Either A or B LED must be lit when
pressing Cycle Start Button. Intermittent Weld continues until user presses Cycle Stop Button.

For Total Length welding, user enters values for all three stitch parameters. C LED must be lit when
pressing Cycle Start Button. Intermittent welding ends when Total Length has been met.

INTERMITTENT WELDING LOCK OUT

To lock out the intermittent (stitch) welding controls, press and hold the Travel Speed Adjustment knob
for three (3) seconds. All of the LEDs will ash. To unlock the intermittent welding controls, press and
hold the Travel Speed Adjustment Knob for three (3) seconds. While in lockout, the machine will be
unable to perform 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
weld shutdown (crater ll).

7

TIME SETTINGS

The K-BUG 4000 offers three adjustable time settings - Puddle Build-Up, Pause Time and Crater Fill.
The Travel Speed Adjustment knob is used for setting each of the timers, as described below.

Puddle Build-up Time (u)

1. While pressing the Cycle Start button, connect the power cord to an appropriate power supply.

2. The Display will show “u0.0” ashing.

3. Turn the Travel Speed Adjustment knob until the desired build-up time is displayed.

4. Default setting is 1.0 seconds. Available range is 0.0 - 9.9 seconds.

Crater Fill Time (n)

1. Press Cycle Start button once more.

2. The Display will show “n0.0” ashing.

3. Turn the Travel Speed Adjustment knob until the desired crater ll time is displayed.

4. Default setting is 1.0 seconds. Available range is 0.0 -9.9 seconds.

Pause Time (E). After welding, a brief rest before Crater Fill.

1. Press the Cycle Start button once more.

2. The Display will show “E0.0” ashing.

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 nished setting times, press the Cycle Stop button to exit time setup mode. The machine is now
ready to be setup for welding.

Travel

Weld “On”

u E n

Travel

Weld “Off”

(time)

A graphic display of the user adjustable 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.

Table 1: Global Parameters

Display Description Default Range Units

n.0* Travel Speed Coefcient 1.0 0.1, 1.0, 2.0, 2.5,

5.0, 10.0
n.1 Motor Overload Stop Time 2 0.0 - 9.9 sec
n.2* Travel Motor Reduce Ratio 40 20 - 200 base g x 10 : 1
n.3* Diameter of Travel Wheel 50 0.0 - 99.9 mm
n.4 Show Mode off off / on
n.5 Operating Units U2 U1 / U2 U1 (cm/min), U2 (in/min)

* Indicates parameters NOT to be changed by the User. Changing these parameters can harm machine
performance.

cm/mn, in/min

8

GLOBAL PARAMETERS, CONT’D

ACCESS THE GLOBAL PARAMETER MENU

1. With machine unplugged from A/C power supply, remove the six (6) screws securing the Control
Interface (Legend Plate and Main PCB) to the Control Panel.

2. Remove the Control Interface and turn it over.

3. Locate DIP Switch 1 and 2 on the Main PCB, see
illustration at right.

4. Turn DIP Switch 1 to the “ON” position.

5. Turn over Control Interface. And secure to Control panel.

6. Plug in machine to A/C power supply of appropriate
voltage.

7. “0” should be shown in the Display.

8. Press and release Cycle Start button to cycle through
the six parameters (0, 1, 2, 3, 4, 5).

9. Use the Travel Speed Adjustment knob to change the
parameter setting.

10. When nished, 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.

Rear of Main PCB. Note DIP switch
placement on left hand side. Move
Switch 1 up to the ON position.

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. Use the Cycle Start button until “5” is shown on the
Display. Turn the Travel Speed Adjustment knob right or left to select the desired Units. Choose “U1”
for Metric (cm/min) or “U2” for English (in/min).

9

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 ow regulators and appropriate ttings

• Torch for gas shielded automated welding

• Basic Weld Prep Tools

2. Cable Connections

• Connect welding torch conduit cable to wire feeder

• Connect Weld Contactor lead from Torch to Main Cable Connector on machine body

• Connect Control Cable to the Control Box Connector on the machine body

• Connect Control Power Source Cable to the Welding Power Source

CAUTION: Carefully route power cable as it may become entangled during operation, resulting
in damage to people or equipment.

3. Welding Process

• Switch ON the Primary Side Distribution Board of the Welding Power Source

• Switch ON the Control Power Source on the front panel of the Welding Power Source

• Equip the Wire Feeder with wire

• Set the Carriage so the torch is at the weld starting point

• Install the Guide Arms offset in the direction of travel (leading 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 speed is > 0 and press Cycle Start button

• Press Cycle Stop button when welding is complete. Turn Welding Switch to OFF

• Conrm Welding End

MAINTENANCE

The K-BUG carriage should be periodically checked and cleaned to maximize service life.

Before use:

Check all screws in the torch clamp and guide rollers. Tighten as needed. Loose fasteners may
cause uneven travel or inconsistent weld quality.

During use:

Monitor wheels, motor and welding torch for abnormal noise or overheating.

After each use:

1. Clean control panel to remove dust and other debris.

2. Inspect carriage base, wheels, guide rollers, slide adjustment, magnets and torch for weld
spatter or other debris. Clean as needed.

3. Inspect power cable and torch cable for cracked, cut or damaged insulation. Replace as
needed.

4. Inspect connectors for damaged pins or loose connections. Replace as needed.

10

TROUBLESHOOTING

Symptom Cause Repair

Control panel
Display is not LIT
when machine is

plugged in

Disconnected Control Cable Connect control cable to machine

Faulty Control Cable Replace Cable

No Arc when
Welding Auto/Off
Switch turned to
AUTO

Carriage does not
travel when Cycle

Start Button is

pushed

Control Box Fuse Tripped or

Disconnected

Replace fuse. If problem persists,
contact service rep.

Weld Auto/Off Switch set to OFF Turn Weld Auto/Off Switch to AUTO

Loose contact of Welding Leads Check ground connections. Verify good

contact on clean, unpainted surface.

Faulty or incorrectly wired Welding
Auto/Off Switch

Stop Sensor does not detect work
piece.

Check Wiring. Replace Switch, if

needed

Reposition carriage so Stop Sensor is

over work piece.

Failed drive component Check Motor, Drive Chain and Gearbox.

Replace as needed

Faulty or incorrectly wired Cycle Start

Button

Check Wiring. Replace button , if

needed

Faulty MAIN PCB Replace MAIN PCB

Torch targets wrong

position

Slide is hard to

adjust

Carriage stops

during automatic

welding

Arc continues after
Welding Auto/Off
Switch is set to OFF

Unable to perform
Intermittent Welding

Loose fastener on Torch Clamp or
Slide Assembly

Check and tighten screws, replace if
needed.

Dust or other debris on slide parts Clean slide parts. Lubricate with light oil

Obstacle in carriage path Remove obstacles

Carriage is at end of work piece. Stop
Sensor doesn’t detect work piece.

Distance traveled exceeds Total
Length

The Welding Auto/Off Switch is still

Reposition carriage so Stop Sensor is

over work piece.

See “Intermittent Welding” on page 7 for
instructions to set Total Length

Turn Weld Auto/Off Switch to OFF

set to Auto

Faulty or incorrectly wired Welding
Auto/Off Switch

Check Wiring. Replace Switch, if
needed.

Intermittent Welding is locked Press and hold Travel Speed

Adjustment knob for 3 seconds.

11

TROUBLESHOOTING, CONT’D.

K-BUG ERROR LIST

NO. 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).

2. Replace motor or motor reducer

3. Replace main PCB

12

K-BUG 4000 ASSEMBLY VIEW

3

4

5

1

2

6

ITEM QTY PART NO. DESCRIPTION

1 1 KBUG-4010 Carriage Assembly
2 1 KBUG-4050 Control Panel Assembly
3 1 KBUG-4090 Torch Clamp Assembly
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.

13

K-BUG 4000 WIRING DIAGRAM

KBUG-1126

1234567

DISPLAY & SWITCH

J1

PA0

PA1

PA2

PA3

PA4

DA0

DA1

DA2

DA3

DA4

1234567

J1

PA5

PA6

DA5

DA6

PA7

DA7

1234567

8

J2

HEADER-S08

FND0

FND0

8

1234567

J2

HEADER-S08

FND1

FND1

FND2

FND3

EN_UP_SW

EN_DN_SW

FND2

FND3

EN_UP_SW

EN_DN_SW

8

HEADER-S08

EN_PUSH_SW

GND

EN_PUSH_SW

GND

8

HEADER-S08

TS11CS501

M1

12345

DC +24 V

CN2

KBUG-1049

P-GND

MA_CW/CCW

MA_PULSE

MA_PWM

MA_RUN/STOP

12345

6

6

MAIN PCB

123

CN1

AC+

EARTH

AC-

12345

CN6

WELD_COM

TORCH

TORCH

KBUG-1126

(STOP)

EXTERNAL SENSOR

120 VAC 50 - 60 Hz 1Ph

14

INPUT POWER

240 VAC 50 - 60 Hz 1Ph

KBUG-4010 CARRIAGE ASSEMBLY / EXPLODED VIEW

19

20

21

22

15

16

14

23

25

26

24

7

2

27

8

9

3

12

13

10

11

5

6

4

1

17

18

15

KBUG-4010 CARRIAGE ASSEMBLY / PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 1 KBUG-4011 Body, Rear
2 1 KBUG-4012 Body Side, Left
3 1 KBUG-4013 Body, Bottom
4 1 KBUG-4014 Body Side, Right
5 1 KBUG-4015 Body, Top
6 1 KBUG-4028 Body Cover
7 1 KBUG-4032 Handle
8 1 KBUG-4027 Magnet, Small
9 1 KBUG-4024 Magnet Bracket (1)
10 1 KBUG-4029 Sensor 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
24 4 KBUG-1036 Wheel, 50mm
25 2 KBUG-4018 Wheel Shaft Cover (2)
26 2 KBUG-4019 Wheel Shaft Bushing (1)

27 4 KBUG-4036 Roller Bearing

16

KBUG-1060 GUIDE ARMS / EXPLODED VIEW / PARTS LIST

1

6

2

4

3

ITEM QTY PART NO. DESCRIPTION

1 2 KBUG-1061 Guide Roller Bushing
2 2 KBUG-1062 Guide 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

5

KBUG-4090 TORCH CLAMP ASSEMBLY / PARTS LIST

2

3

1

ITEM QTY PART NO. DESCRIPTION
1 1 KBUG-2080 Torch Clamp Assembly

2 1 KBUG-4095 Slide Bar Clamp

4

3 1 KBUG-3076 Bushing

4 1 KBUG-4097 HDH-Torch Clamp Base

17

KBUG-4050 CONTROL PANEL ASSEMBLY / EXPLODED VIEW / PARTS LIST

10

12

11

3

9

2

7

4

8

5

6

1

ITEM QTY PART NO. DESCRIPTION

1 1 KBUG-4051 Panel
2 2 KBUG-1122 Toggle Switch Cover
3 1 KBUG-1123 Legend Plate
4 2 KBUG-1124 Push Button Cover (BS)
5 1 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 available for curved
or irregular seams.

18

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)

4

6

6

4

3

1

5

2

5

8

7

PARTS LIST WIRE SIZE

.035

ITEM QTY PART NO. DESCRIPTION

1 1 BUG-3159-35 16S-35 (.9 mm) Contact Tip X

1 1 BUG-3159-45 16S-45 (1.2 mm) Contact Tip X

1 1 BUG-3159-52 16S-52 (1.4 mm) Contact Tip X

1 1 BUG-3159-116 16S-116 (1.6 mm) Contact Tip X

1 1 BUG-3159-564 16S-564 (2.0 mm) Contact Tip X

1 1 PWS-4436-1.0 16S-40 (1.0 mm) Contact Tip X

2 1 PWS-4447 27S62 H.D. Nozzle ⅝" X X X X X X

3 1 PWS-4449 PX57HD Gas Diffuser X X X X X X

4 1 CWO-8017 Case w/ Binder Screws (Front) 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, ¾" 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 Clamps X X X X X X

** Not shown. Required only with standard Lincoln guns (SBG-450-L).

(.9 mm)

.040
(1.0)

.045
(1.2)

.052

(1.4)

1/16
(1.6)

5/64
(2.0)

19

WARRANTY

LIMITED WARRANTY

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.
THIS WARRANTY DOES NOT APPLY TO MACHINES, WHICH AFTER OUR INSPECTION, ARE DETERMINED TO HAVE
BEEN DAMAGED DUE TO NEGLECT, ABUSE, OVERLOADING, ACCIDENT OR IMPROPER USAGE. ALL SHIPPING AND
HANDLING CHARGES WILL BE PAID BY CUSTOMER.

BUG-O SYSTEMS MAKES NO WARRANTY OF MERCHANTABILITY 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 MANUAL CAREFULLY,
THEN CALL YOUR AUTHORIZED BUG-O DEALER/DISTRIBUTOR. IF HE CANNOT GIVE YOU THE NECESSARY SERVICE,
WRITE OR PHONE US TO TELL US EXACTLY WHAT DIFFICULTY YOU HAVE EXPERIENCED. BE SURE TO MENTION
THE MODEL AND SERIAL NUMBERS.

MODEL ____________________________
SERIAL NO. ________________________

DATE PURCHASED: _________________

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