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INSTRUCTIONS
PaRTS MaNUaL
SIdE BEaM SYSTEM
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-SBC-4555-IPM-0713
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
280 TECHNOLOGY dRIVE CaNONSBURG, PENNSYLVaNIa 15317-9564 USa
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.
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 first
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.
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.
EQUIPMENT daMaGE
POSSIBLE.
1) Do not plug in the power cord without first
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 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.
REad INSTRUCTIONS.
1) Never try to stop the pinion from moving
except by removing power or by using the
STOP control.
before installing and using the equipment.
2) Do not remove any protective panels,
covers or guards and operate equipment.
2
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 specified 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
4
SIdE BEaM SYSTEM
INSTRUCTIONS aNd PaRTS MaNUaL
TaBLE OF CONTENTS
PaGES
5.......Introduction / Mounting
6.......SBC-4555 Motorized Carriage / Exploded View
7.......SBC-4555 Motorized Carriage / Parts List
8.......CWO-3918-MH Carriage Assembly Motorized Horizontal / Exploded View
9.......CWO-3918-MH Carriage Assembly Motorized Horizontal / Parts List
10.....SBC-1065 Floating Car w/ Follower / Exploded View / Parts List
11 .....SBC-1020-DS Dual Side ABR 62"
12.....MUG-1145 Carriage Spotter Sub Assy. / Exploded View / Parts List
13.....MUG-1145 Carriage Spotter Sub Assy. / Exploded View / Parts List
14.....CWO-1690 Large Horizontal Racker / Exploded View / Parts List
15.....SBC-6110 M-14 Rotational Control / Wiring Diagram
16.....SBC-5997 Bodine Motor w/ Connector / Wiring Diagram
16.....SBC-1635-10-2 Remote Weld Starter (Two Guns) / Wiring Diagram
INTROdUCTION
Bug-O Side Beam Systems are custom designed assemblies that are used in a variety of applications such as automated seam welding, beam and stiffener fabrication as well as cutting applications such as stripping and edge preparation. A wide range of gantry and side beam carriage designs are available and can be used to suite a specific application. Systems are available in programmable or manually operated versions. Consult your Bug-O distributor for more information.
MOUNTING
You will need the following:
• Standard allen keys
• Standard wrench set
• Large C clamps 8-10 inch range
1) Loosen bolts (1). There are two bolts per carriage. The slide bolts to the back of the carriage towards the U slot of the motor mount.
2) Install the carriage onto the monorail. Using the large C clamps, tighten the carriage to the monorail. Tighten the
C clamps which will bring the face of the carriage toward the monorail, this will bring the face of the carriage into place. These wheels are (2) on the drawing.
3) Bring the bolts (1) to the monorail and tighten. This will secure the carriage to the monorail. Loosen clamps and slide carriage. This should move easily on the beam.
Repeat process for the second carriage.
Side View
2
1
5
6
SBC-4555 MOTORIZEd CaRRIaGE / EXPLOdEd VIEW
3
15
14
23
13
19
2
6
12
4
5
9
11
27
26
25
20
24
22
8
28
1
17
16
21
18
7
10
SBC-4555 MOTORIZEd CaRRIaGE / PaRTS LIST
16
17
18
19
20
21
22
23
8*
9
10
11
12
13
14
15
ITEM
1
2
3
4
5
6
7
24
25
26
27
28
1
2
1
1
1
1
1
2
QTY
1
1
1
1
1
1
1
4
1
1
2
2
2
2
2
1
1
2
2
1
PaRT NO.
CWO-3918-MH
CWO-5997
CWO-4884
CWO-5768
SBC-4551
CWO-5802
CWO-5804
SBC-6110
CWO-9006
FAS-0357
FAS-0359
FAS-0455
FAS-0558
FAS-0593
FAS-0679
FAS-0955
FAS-0957
FAS-0999
FAS-1350
FAS-2556
SBC-1014
SBC-4540
SBC-4547
SBC-4548
SBC-4549
WAS-0240
WAS-0243
SBC-1635-10-2
* 240 VAC requires SBC-6110-240 Rotation Control
dESCRIPTION
Carriage Assy. Motorized Horiz.
Bodine Motor 156 w/connector
McGill Cyr 1/45
Pinion Gear w/ Key
Shaft Extender
Motor Mount Plate
Guard
Rotation Control Modified
Wheel & Clamp Mount (left)
Hex Hd Cap Scr 1/4-20 x 3/4"
Hex Hd Cap Scr 1/4-20 x 1"
Set Scr 1/4-20 x 1/2" Cup Point
Soc Hd Cap Scr 1/4-20 x 7/8
Soc Hd Cap Scr 3/8-16 x 1-1/2
Soc Hd Shr 3/8" x 1" x 5/16-18
Flt Hd Soc Scr 1/4-20 x 1/2"
Flt Hd Soc Scr 1/4-20 x 3/4"
Flt Hd Soc Scr 3/8-16 x 1"
Hex Jam Nut 1/4-20
Soc Hd Cap Scr 1/4-20 x 2-1/2
Control Mount Angle
Side Beam Clutch Assembly
Cot Extension Spring
Stabilizer Block
Stabilizer / Stop Block
1/4" SAE Washer
1/4" Split Lockwasher
Pendant Control (2 guns) (Part of SBC-6110)
7
8
CWO-3918-MH CaRRIaGE aSSEMBLY MOTORIZEd HORIZONTaL /
EXPLOdEd VIEW
CWO-3918-MH CaRRIaGE aSSEMBLY MOTORIZEd HORIZONTaL /
PaRTS LIST
16
17
18
19
20
21
*
8
9
10
11
12
13
14
15
ITEM
1
2
3
4
5
6
7
* Not Shown
2
6
19
22
4
1
1
9
QTY
1
1
1
1
1
1
3
11
3
4
7
7
2
2
PaRT NO.
CWO-9001
CWO-9002-MT
CWO-9003
CWO-9004
CWO-9005
CWO-9006
CWO-9007
CWO-9008
CWO-9011
CWO-9194
CWO-4884
FAS-0557
FAS-0679
FAS-0959
FAS-0999
FAS-1390
FAS-2397
FAS-2399-FT
WAS-0260
WAS-0262
CWO-9490
CWO-9492
dESCRIPTION
Carriage Front Plate
Carriage Top Plate Motorized
Carriage End Plate (L.H.)
Carriage Reinforcement Bar
Wheel & Clamp Mounting Block, Right
Wheel & Clamp Mounting Block, Left
Cam Roller Spacer
Wheel Mount Block
Carriage Back-up Bar
Carriage End Plate (R.H.)
Cam Roller Spacer
Soc Hd Cap Scr 1/4-20 x 3/4"
Soc Hd Cap Scr 3/8 x 1 x 5/16-18
Flt Hd Soc Scr 1/4-20 x 1"
Flt Hd Soc Scr 3/8-16 x 1"
Hex Nut 3/8-16
Hex Hd Cap Scr 3/8-16 x 2-1/2"
Hex Hd Cap Scr 3/8-16 x 3-1/2" full Thread
3/8" Washer
3/8" Split Lockwasher
Lower Cam Roller Assembly
Metric Spacer Plate
9
SBC-1065 FLOaTING CaR W/ FOLLOWER / EXPLOdEd VIEW / PaRTS LIST
10
ITEM
1
2
3
QTY
1
1
1
PaRT NO.
CWO-1690
MUG-1145
ABR-1060
dESCRIPTION
Large Horizontal Racker
Carriage Spotter Sub-Assy
V-Guide Ways 33"
SBC-1020-dS dUaL SIdE aBR 62"
ITEM
1
2
2
3
4
5
6
6
7
8
8
QTY
1
2
2
4
1
2
10
10
44
22
22
PaRT NO.
SBC-1021-DS
SBC-1022
SBC-1023
SBC-1024
SBC-1025
SBC-1029
FAS-0399-SS
WAS-0260-SS
FAS-0535-SS
FAS-0545-SS
WAS-0232-SS
dESCRIPTION
Dual Side Abr Box 65"
Rack 62"
Spacer 62"
T-3 Guide Way 62"
Gusset Assembly
Mtg. Angle
Hex Hd Cap Scr 3/8-16 x 1"
3/8 Washer
Soc Hd Cap Scr #10-24 x 1/2"
Soc Hd Cap Scr #10-32 x 1/2"
#10 Split Lock Washer
11
MUG-1145 CaRRIaGE SPOTTER SUB aSSY. / EXPLOdEd VIEW / PaRTS
LIST
12
ITEM
1
2
3
4
5
6
7
8
9
QTY
1
1
1
1
1
1
1
1
1
PaRT NO.
BUG-2032
FAS-0357
FAS-0557
FAS-1307
MUG-1141
MUG-1142
MUG-1143
MUG-1502
MUG-1579
dESCRIPTION
Knob, Black w/ Set Scr 1/4-20 x 3/8" (FAS-0454)
Hex Hd Cap Scr 1/4-20 x 3/4"
Soc Hd Cap Scr 1/4-20 x 3/4"
Hex Jam Nut 3/4-16
Bearing, Collet
Knob, Locking
Positioning Plate
Gear Assembly
Retaining Ring For 3/4" Shaft
MUG-1145 CaRRIaGE SPOTTER SUB aSSY. / EXPLOdEd VIEW / PaRTS
LIST
ITEM
1
2
3
4
5
6
7
8
9
QTY
1
1
1
1
1
1
1
1
1
NOTE: WHEN USED FOR MUG-1148 (TORCH SPOTTER),
CUT MUG-1143 (POSITIONING PLATE) TO 2.5" LONG AND
INVERT IN ASSEMBLY AS SHOWN.
PaRT NO.
BUG-2032
FAS-0357
FAS-0557
FAS-1307
MUG-1141
MUG-1142
MUG-1143
MUG-1502
MUG-1579
dESCRIPTION
Knob, Black w/ Set Scr 1/4-20 x 3/8" (FAS-0454)
Hex Hd Cap Scr 1/4-20 x 3/4"
Soc Hd Cap Scr 1/4-20 x 3/4"
Hex Jam Nut 3/4-16
Bearing, Collet
Knob, Locking
Positioning Plate
Gear Assembly
Retaining Ring For 3/4" Shaft
13
CWO-1690 LaRGE HORIZONTaL RaCKER / EXPLOdEd VIEW / PaRTS LIST
F = FIXED WHEEL PLACEMENT
A = ADJUSTABLE WHEEL PLACEMENT
14
8
9
10
11
12
13
14
15
ITEM
1
2
3
4
5
6
7
16
17
18
1
1
2
1
2
2
1
1
QTY
1
1
1
2
2
1
2
3
1
2
PaRT NO.
BUG-2032
CWO-1678
CWO-1679
CWO-1680
CWO-1681
CWO-1687
CWO-4326
CWO-4327
FAS-0557
FAS-1307
MUG-1141
MUG-1142
MUG-1144
MUG-1453
MUG-1579
WAS-0240
CWO-1671
FAS-0559
dESCRIPTION
Knob, black w/ Set Scr 1/4-20 x 3/8" (FAS-0454)
Racker Plate
Pinion 11T
W2 Fixed Leg & Wheel Assy.
W2 Adj. Leg & Wheel Assy.
Mount Plate (Large Racker)
Fixed Leg & Wheel Assy.
Adj. Leg & Wheel Assy.
Soc Hd Cap Scr 1/4-20 x 3/4"
Hex Jam Nut 3/4-16
Bearing Collet
Knob, Locking
Shaft
Stand-off
Retaining Ring
1/4" SAE Washer
Racker Shield
Soc Hd Cap Scr 1/4-20 x 1"
SBC-6110 M-14 ROTaTIONaL CONTROL / WIRING dIaGRaM
ITEM PaRT NO.
CB CWO-6525
CORD BUG-9445
dESCRIPTION
0-90Dc Speed Control W/Reset
Power Cord 16/3 Type, So, 10 Amp
GOF-3115 Line Cord 240Vac
FH1 FHO-0188
FUS-0257
FH2 FHO-0188
Fuse Holder
3 Amp
Fuse Holder
FUS WTE 0190 1.5 Amp
LMP CWO-6206 Red Neon Lamp 125V
BUG-1428 Pilot Light 240V
PC1 BUG-1034
PC2 BUG-5527
PC3 MUG-1156
PC4 BUG-9902
CBC1 BUG-9906
SW ARM-2279
K1 BUG-1383
Panel Connector 4-T, M
Panel Connector 17-T, F
Panel Connector 4-T, F
Panel Connector 6-T, F
Cable Connector 6-T, M
Toggle Switch
Relay, 4Pdt, 3A 120V Plug In
120V 240V
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
15
SBC-5997 BOdINE MOTOR W/ CONNECTOR / WIRING dIaGRaM
QTY
1
PaRT NO.
MUG-1616
dESCRIPTION
Cable Connector 4-T, M
SBC-1635-10-2 REMOTE WELd STaRTER (TWO GUNS) / WIRING dIaGRaM
16
ITEM
CC
SW1
SW2
SW3
SW4
R1
QTY
1
1
1
1
1
1
PaRT NO.
BUG-5552
ABP-1069
ABP-1069
CWO-6525
MUG-1258-1
CWO-6213
dESCRIPTION
Cable Connector 17-T, M
Toggle Switch, ON-NONE-ON
Toggle Switch, ON-NONE-ON
0-90 VDC Speed Control w/ Reset, Pot Only
Rotary Switch Assembly
50 OHMS, 10W, 5% Wire Wound
WaRRaNTY
LIMITEd WaRRaNTY
MOdEL ____________________________
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.
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 dISTRIBuTOR/ dEAlER. 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.
17
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