TREGASKISS TOUGH GUN Robotic Air Cooled Mig Gun Owner’s Manual

: September 12, 2024
: Tregaskiss

Table of Contents

TOUGH GUN Robotic Air Cooled Mig Gun
Specifications
Product Usage Instructions
Maintenance and Cable Guide
Mounting and Options
Air Blast and Wire Brake
Gun Configurations
- FAQ
What is the difference between clutch and solid mount
How do AccuLockTM R consumables benefit welding

TOUGH GUN Robotic Air Cooled Mig Gun

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Specifications

Product Name: Robotic Air-Cooled MIG Gun
Process: MIG (GMAW) Robotic Welding
Duty Cycle: 100% at 385 amp with Mixed Gases
Jacket: Outer layer resists ultraviolet radiation and abrasion,
inner layer resists thermal fatiguing
Unicable: Yes
Easy Maintenance with Minimal Downtime

Product Usage Instructions

Maintenance and Cable Guide

The robotic air-cooled MIG gun is designed for easy maintenance
with minimal downtime. The cable guide minimizes stress on the
cable connection as the robot articulates, reducing downtime
through faster repair and extended service life. Ensure to replace
the unicable when needed to maintain optimal performance.

Mounting and Options

The system components include various parts like solid mount
connector, clutch mount connector, cable guide, replaceable
unicable, and more. Choose between clutch and solid mount options
based on your needs. Clutch mounts trigger an emergency stop in
case of a collision, providing an additional safeguard.

Air Blast and Wire Brake

Utilize the air blast and wire brake features for efficient
welding operations. The AccuLockTM R consumables help eliminate
contact tip cross-threading issues, increasing tip life and
reducing replacement frequency, ultimately minimizing downtime.

Gun Configurations

There are different standard configurations available with
varying neck angles (22 degrees, 45 degrees, and 180 degrees) to
suit different welding requirements. Choose the appropriate
configuration based on your specific needs.

FAQ

What is the difference between clutch and solid mount

options?

A clutch mount triggers an emergency stop in case of a
collision, whereas a solid mount does not have this functionality.
The clutch option adds an extra layer of safety in robotic MIG gun
operations.

How do AccuLockTM R consumables benefit welding

operations?

AccuLockTM R consumables help eliminate contact tip
cross-threading issues, increase tip life, and reduce replacement
frequency, ultimately minimizing downtime during welding
processes.

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TOUGH GUN® CA3
ROBOTIC AIR-COOLED MIG GUN

MIG (GMAW) ROBOTIC WELDING

Issued August 2024 · Index No. CA3/4.2

DUTY CYCLE RATING PROCESSES ROBOTS

100%: 385 amp with Mixed Gases (Ratings are based on tests that comply with IEC 60974-7 standards)
MIG (GMAW) Welding
· ABB® · COMAU® · FANUC® · Kawasaki® · KUKA® · OTC Daihen® · Panasonic® · Reis® · Universal Robots · Yaskawa® Motoman®

· Extended unicable service life due to its dual layer outer
jacket: the outside layer resists ultraviolet radiation and abrasion while the inside layer resists thermal fatiguing
· Reduced costs and downtime due to new replaceable
unicable
· Clutch and solid mount models available
· Additional standard neck and mounting arm options
expand tool center point options and working envelopes
· Wire brake, air blast and TOUGH GUN I.C.E.® Technology
are available options

EASY MAINTENANCE WITH MINIMAL DOWNTIME

CABLE GUIDE
MINIMIZES STRESS ON CABLE CONNECTION AS
ROBOT ARTICULATES

REPLACEABLE UNICABLE
REDUCES DOWNTIME THROUGH FASTER REPAIR AND EXTENDED
SERVICE LIFE

Cable guide minimizes stress on the cable connection
Re-engineered neck clamp improves durability and
consistency of clamping force

Extended unicable service life
Replaceable unicable

Variety of standard neck and mounting arm options
Compatible with TOUGH LOCK® Consumables or AccuLockTM R Consumables
Designed for high-volume production environments, the TOUGH GUN® CA3 robotic air-cooled MIG gun combines the most valuable product features of our TOUGH GUN® G1 and G2 Series platforms, along with performance improvements in our unicable technology that extends service life.
Fully configurable, TOUGH GUN® CA3 MIG guns are engineered for precision, durability, accuracy, repeatability, minimal downtime and fast and easy maintenance.

2570 North Talbot Road Windsor, Ontario N0R 1L0, Canada

1-855-MIGWELD (644-9353) (US & Canada), +1-519-737-3000 (International), 519-737-1530 (Fax)

For more information, visit us at bernardtregaskiss.com

SYSTEM COMPONENTS

Solid Mount Connector

Connector

Clutch Mount Connector

Connector Housing

Cable Connector Cover

Cable Guide
Replaceable Unicable

Neck Neck Insulator

Retaining Head

QUICK LOAD® Liner
Contact Tip Nozzle

Insulating Disc
Not Provided
16 mm M6 SHCS
Mounting Arm

2

KNOW YOUR OPTIONS

WHAT’S THE DIFFERENCE BETWEEN CLUTCH AND SOLID MOUNT?
A clutch mount is designed to trigger an emergency stop in the event of a robotic collision, whereas a solid mount is not equipped with this functionality. Although many of today’s robots are equipped with independent collision detection software and may not require this functionality in a robotic MIG gun, the clutch option is sometimes selected during gun configuration as an additional safeguard.

AIR BLAST
Air blast utilizes compressed shop air to clear loose debris from front-end consumables thereby reducing the frequency of nozzle cleaning. 80-100 psi maximum air supply required for proper operation. This option is not available for TOUGH GUN® TA3 robotic air-cooled MIG guns for FANUC® robots equipped with TOUGH GUN I.C.E.® Technology.

WIRE BRAKE
Wire brake holds wire to a consistent stick out to allow a repeatable tool center point (TCP) for touch sensing / seam tracking while the torch articulates. Selecting the wire brake option when configuring a gun will impact TCP. 40-60 psi maximum air supply is required for proper operation. Wire brake is available for wire sizes between 0.030″ and 1/16″, and requires the use of a jump liner (for use with conventional liners). This option is not compatible with QUICK LOAD® Liners.

TOUGH GUN I.C.E.® TECHNOLOGY
This technology boosts the duty cycle of our already highly robust air-cooled TOUGH GUN® MIG guns by providing water-cooled benefits through our I.C.E.TM (Integrated Cooling Enhancer) component. This component circulates water at the nozzle, keeping front-end consumables running cooler and lasting longer. In the TOUGH GUN® TA3 robotic MIG gun series, this option is available only for select FANUC® and ABB® robots.

ACCULOCKTM R CONSUMABLES
Eliminate contact tip cross-threading issues with new AccuLockTM R consumables. These new consumables are designed for increased tip life, which can reduce replacement frequency and related downtime. AccuLockTM HDP contact tips can increase life by an additional 10x or more in pulse welding applications. And in most cases, your current tip and diffuser can be replaced with no impact to Tool Center Point (TCP), making this upgrade low effort, low risk, and high payoff.

QUICK LOAD® LINERS
The QUICK LOAD® liner system loads from the front of the MIG gun, and requires less than half the time and effort for replacement when compared with conventional liners. These liners interface with a QUICK LOAD® liner retainer that is seated within the power pin of the gun on first use. QUICK LOAD® liners come standard on TOUGH GUN® robotic MIG guns unless wire brake is a selected option. Available for wire sizes between 0.030″ and 3/32″ and in lengths of up to 15 feet for robotic applications.

3

GUN CONFIGURATIONS

NOTE: FOR CENTER OF MASS INFORMATION, PLEASE VISIT BERNARDTREGASKISS.COM/CA3

STANDARD CONFIGURATIONS — 22 DEGREE NECKS

316 mm (12.44″) TCP, Neck 405-22QC

350 mm (13.79″) TCP, Neck 405-22QCL

STANDARD CONFIGURATIONS — 45 DEGREE NECKS

400 mm (15.75″) TCP, Neck 405-22QCL

350 mm (13.78″) TCP, Neck 405-45QCL

400 mm (15.75″) TCP, Neck 405-45QCL1

4

GUN CONFIGURATIONS (CONTINUED) NOTE: FOR CENTER OF MASS INFORMATION, PLEASE VISIT BERNARDTREGASKISS.COM/CA3
STANDARD CONFIGURATIONS — 180 DEGREE NECKS

294 mm (11.57″) TCP, Neck 405-180QC

CONSUMABLE OPTIONS

ACCULOCKTM HEAVY DUTY (HD) COPPER CONTACT TIPS

T-A030CH T-A035CH T-A039CH T-A045CH T-A052CH*

for 0.030″ (0.8 mm) wire; qty. 10 for 0.035″ (0.9 mm) wire; qty. 10 for 0.039″ (1.0 mm) wire; qty. 10 for 0.045″ (1.2 mm) wire; qty. 10 for 0.052″ (1.3 mm) wire; qty. 10

T-A062CH T-A072CH T-A078CH T-A094CH

for 1/16″ (1.6 mm) wire; qty. 10 for 0.072″ (1.8 mm) wire; qty. 10 for 5/64″ (2.0 mm) wire; qty. 10 for 3/32″ (2.4 mm) wire; qty. 10

NOTE: ADD “-100” TO THE END OF THE ABOVE HD COPPER CONTACT TIP PART NUMBERS FOR QUANTITIES OF 100. *ADD “-1000″ TO THE END OF THE ABOVE PART NUMBERS FOR QUANTITIES OF 1000.

ACCULOCKTM HEAVY DUTY (HD) CHROME ZIRCONIUM CONTACT TIPS

T-A030ZH T-A035ZH T-A039ZH

for 0.030″ (0.8 mm) wire; qty. 10 for 0.035″ (0.9 mm) wire; qty. 10 for 0.039″ (1.0 mm) wire; qty. 10

T-A045ZH T-A052ZH T-A062ZH

for 0.045″ (1.2 mm) wire; qty. 10 for 0.052″ (1.3 mm) wire, qty. 10 for 1/16” (1.6 mm) wire, qty. 10

NOTE: ADD “-100″ TO THE END OF THE ABOVE HD CHROME ZIRCONIUM CONTACT TIP PART NUMBERS FOR QUANTITIES OF 100.

ACCULOCKTM HDP CONTACT TIPS

T-A035WH for 0.035″ (0.9 mm) wire; qty. 10 T-A039WH for 0.039″ (1.0 mm) wire; qty. 10

T-A045WH for 0.045″ (1.2 mm) wire; qty. 10 T-A052WH for 0.052” (1.3 mm) wire; qty. 10

NOTE: ADD “-100″ TO THE END OF THE ABOVE HDP CONTACT TIP PART NUMBERS FOR QUANTITIES OF 100.

ACCULOCKTM TEACH POINTERS (USED FOR ROBOTIC PROGRAMMING)

T-A001TP T-A050TP T-A062TP

Adjustable teach pointer Teach pointer, 1/2″ CTWD Teach pointer, 5/8″ CTWD

T-A075TP T-A10MTP T-A15MTP

Teach pointer, 3/4” CTWD Teach pointer, 10 mm CTWD Teach pointer, 15 mm CTWD

ACCULOCKTM R GAS DIFFUSERS

D-ATTH

Gas diffuser, thread-on, AccuLockTM R

D-ATSH

NOTE: ADD “-100″ TO THE END OF THE ABOVE GAS DIFFUSER PART NUMBERS FOR QUANTITIES OF 100.

Gas diffuser, slip-on, AccuLockTM R

TOUGH LOCK® HEAVY DUTY (HD) CONTACT TIPS

403-20-30 403-20-35 403-20-1.0 403-20-45 403-20-364 403-20-52

for 0.030″ (0.8 mm) wire for 0.035″ (0.9 mm) wire for 0.040″ (1.0 mm) wire for 0.045″ (1.2 mm) wire for 3/64″ (1.2 mm) wire for 0.052″ (1.3 mm) wire

403-20-1.4 403-20-116 403-20-1.8 403-20-78 403-20-564 403-20-332

for 0.055″ (1.4 mm) wire for 1/16″ (1.6 mm) wire for 0.072″ (1.8 mm) wire for 0.078″ (2.0 mm) wire for 5/64″ (2.0 mm) wire for 3/32″ (2.4 mm) wire

5

CONSUMABLE OPTIONS (CONTINUED)

TOUGH LOCK® HEAVY DUTY TAPERED CONTACT TIPS

403-21-30 403-21-35 403-21-1.0

for 0.030″ (0.8 mm) wire for 0.035″ (0.9 mm) wire for 0.040″ (1.0 mm) wire

403-21-45 403-21-52 403-21-116

for 0.045″ (1.2 mm) wire for 0.052″ (1.3 mm) wire for 1/16″ (1.6 mm) wire

TOUGH LOCK® EXTENDED LIFE HEAVY DUTY (EHD) CONTACT TIPS

403-27-30 403-27-35 403-27-1.0

for 0.030″ (0.8 mm) wire for 0.035″ (0.9 mm) wire for 0.040″ (1.0 mm) wire

403-27-45 for 0.045″ (1.2 mm) wire 403-27-364 for 3/64″ (1.2 mm) wire

TOUGH LOCK® STANDARD DUTY (SD) CONTACT TIPS

403-14-30 403-14-35

for 0.030″ (0.8 mm) wire for 0.035″ (0.9 mm) wire

403-14-45

for 0.045″ (1.2 mm) wire

TOUGH LOCK® STANDARD DUTY TAPERED CONTACT TIPS

403-12-30 403-12-35

for 0.030″ (0.8 mm) wire for 0.035″ (0.9 mm) wire

403-12-1.0 403-12-45

for 0.040″ (1.0 mm) wire for 0.045″ (1.2 mm) wire

TOUGH LOCK® TEACH POINTERS (USED FOR ROBOTIC PROGRAMMING)

403-20-01 403-20-05 403-20-062

Adjustable teach pointer Teach pointer, 1/2″ CTWD Teach pointer, 5/8″ CTWD

403-20-075 Teach pointer, 3/4″ CTWD 403-20-10mm Teach pointer, 10 mm CTWD 403-20-15mm Teach pointer, 15 mm CTWD

TOUGH LOCK® RETAINING HEADS

404-18

SD retaining head for slip-on nozzles

404-32 404-52

HD retaining head for slip-on nozzles HD retaining head for thread-on nozzles

NOZZLES

PART NUMBER 401-6-62 401-5-62 401-6-50 401-81-62 401-8-62 401-42-50 401-48-50 401-48-62 401-71-62 401-87-62 401-30-62 401-14-62 401-18-62 401-43-62 401-20-62 401-30-62T

DESCRIPTION
HD – 5/8″ bore, 1/8″ recess (copper) HD – 5/8″ bore, 1/4″ recess (copper) HD – 1/2″ bore, 1/8″ recess (copper) HD – 5/8″ bore, 1/8″ stick out (copper) SD – 5/8″ bore, 1/8″ stick out (copper) SD – 1/2″ bore, 1/8″ recess (bottleneck, brass) SD – 1/2″ bore, 1/8″ stick out (bottleneck, brass) HD – 5/8″ bore, flush tip (bottleneck, copper) HD – 5/8″ bore, 1/8″ recess (brass), straight bore HD – 5/8″ bore, 1/8″ stick out (brass) HD – 5/8″ bore, 1/8″ stick out (bottleneck, brass) HD – 5/8″ bore, 1/8″ recess (copper) SD – 5/8″ bore, 1/8″ stick out (copper) SD – 5/8″ bore, 1/8″ recess (copper) HD – 5/8″ bore, 1/8″ stick out (copper) SD – 5/8″ bore, 1/8″ stick out (bottleneck, brass)

STYLE
Slip-on Slip-on Slip-on Slip-on Slip-on Slip-on Slip-on Slip-on Slip-on Slip- on Slip-on Thread-on Thread-on Thread-on Thread-on Thread-on

SEE THE TOUGH LOCK® CONSUMABLES SPEC SHEET (SP-TLC) FOR MORE OPTIONS

COMPATIBLE CONSUMABLES SERIES TOUGH LOCK® ACCULOCKTM R

X

–

X

–

X

–

X

–

X

–

X

–

X

–

X

–

X

–

X

6

CONSUMABLE OPTIONS (CONTINUED)

QUICK LOAD® LINERS

415-26 415-24 415-30-6Q 415-30-15Q 415-35-6Q 415-35-10Q 415-35-15Q 415-116-6Q 415-116-10Q 415-116-15Q

QUICK LOAD® Liner Retainer QUICK LOAD® Liner Retainer (required for 3/32″ wire) QUICK LOAD® Liner for 0.030″ (0.8 mm) wire; 6′ (1.8 m) QUICK LOAD® Liner for 0.030″ (0.8 mm) wire; 15′ (4.5 m) QUICK LOAD® Liner for 0.035″ (0.9 mm) – 0.045″ (1.2 mm) wire; 6′ (1.8 m) QUICK LOAD® Liner for 0.035″ (0.9 mm) – 0.045″ (1.2 mm) wire; 10′ (3.05 m) QUICK LOAD® Liner for 0.035″ (0.9 mm) – 0.045″ (1.2 mm) wire; 15′ (4.5 m) QUICK LOAD® Liner for 0.052″ (1.3 mm) – 1/16″ (1.6 mm) wire; 6′ (1.8 m) QUICK LOAD® Liner for 0.052″ (1.3 mm) – 1/16″ (1.6 mm) wire; 10′ (3.05 m) QUICK LOAD® Liner for 0.052″ (1.3 mm) – 1/16″ (1.6 mm) wire; 15′ (4.5 m)

QUICK LOAD® E-Z FEEDTM LINERS

415-31 415-35-062Q 415-116-062Q

QUICK LOAD® Liner Retainer (required for 415-116-062Q liner) QUICK LOAD® Liner for 0.035″ (0.9 mm) – 0.045″ (1.2 mm) cored wire; 6′ (1.8 m) (requires 415-26 retainer) QUICK LOAD® Liner for 0.045″ (1.2 mm) – 1/16″ (1.6 mm) cored wire; 6′ (1.8 m) (requires 415-31 retainer)

CONVENTIONAL LINERS (REQUIRED FOR MIG GUNS EQUIPPED WITH WIRE BRAKE ONLY)

415-30-6 415-30-15 415-35-6 415-35-10 415-35-15 415-116-6 415-116-10 415-116-15 415-564-6 415-564-15 415-332-6 415-332-15

for 0.030″ (0.8 mm) wire; 6′ (1.8 m) round wound for 0.030″ (0.8 mm) wire; 15′ (4.5 m) round wound for 0.035″ (0.9 mm) – 0.045″ (1.2 mm) wire; 6′ (1.8 m) round wound for 0.035″ (0.9 mm) – 0.045″ (1.2 mm) wire; 10′ (3.05 m) round wound for 0.035″ (0.9 mm) – 0.045″ (1.2 mm) wire; 15′ (4.5 m) round wound for 0.052″ (1.3 mm) – 1/16″ (1.6 mm) wire; 6′ (1.8 m) round wound for 0.052″ (1.3 mm) – 1/16″ (1.6 mm) wire; 10′ (3.05 m) round wound for 0.052″ (1.3 mm) – 1/16″ (1.6 mm) wire; 15′ (4.5 m) round wound for 1/16″ (1.6 mm) – 5/64″ (2.0 mm) wire; 6′ (1.8 m) round wound for 1/16″ (1.6 mm) – 5/64″ (2.0 mm) wire; 15′ (4.5 m) flat wound for 0.078″ (2.0 mm) – 3/32″ (2.4 mm) wire; 6′ (1.8 m) flat wound for 0.078″ (2.0 mm) – 3/32″ (2.4 mm) wire; 15′ (4.5 m) flat wound

JUMP LINERS (required for MIG guns equipped with wire brake only; to be used with conventional liners)

495-18-35 495-18-116

for 0.035″ (0.9 mm) – 0.045″ (1.2 mm) wire; 26″ for 0.045″ (1.2 mm) – 1/16″ (1.6 mm) wire; 26″

7

COMPONENTS

AIR-COOLED NECKS

405-22QC 405-22QCL 405-45QC

22 degree neck, short length 22 degree neck, medium length 45 degree neck, short length

NON-CONFIGURABLE NECK OPTION

405-45QCL 405-45QCL1* 405-180QC

45 degree neck, medium length 45 degree neck, long length 180 degree neck, medium length

TOUGH GUN I.C.E.® NECKS

590-22-X.XXX 590-22L-X.XXX* 590-45-X.XXX

22 degree neck, short length 22 degree neck, medium length 45 degree neck, short length

590-45L-X.XXX 590-45L1-X.XXX 590-180-X.XXX*

45 degree neck, medium length 45 degree neck, long length 180 degree neck, medium length

NON-CONFIGURABLE NECK OPTION

NOTE: X.XXX IN THE PART NUMBERS ABOVE REPRESENT NOZZLE O.D.; I.E. 590-22-0.938 = 0.938″ O.D. , 590-45L1-1.106 = 1.106″ O.D. (REFER TO THE O.D. COLUMN IN THE TOUGH LOCK® CONSUMABLES SPEC SHEET (SP-TLC) FOR MORE INFORMATION)

UNICABLES
CA3UXX Replaceable Unicable, Clutch ECA3UXX Replaceable Unicable, Clutch (Euro)

CA3UXXS ECA3UXXS

Replaceable Unicable, Solid Mount Replaceable Unicable, Solid Mount (Euro)

NOTE: XX IN THE PART NUMBERS ABOVE REPRESENT CABLE LENGTH; I.E. CA3U04 = 4 FT, CA3U04.5 = 4.5 FT, CA3U10 = 10 FT, ETC. (REFER TO ORDERING INFORMATION ON THE LAST PAGE FOR AVAILABLE CABLE LENGTHS)

CONTROL CABLES

519-1 519-2 519-4 519-6 519-9 519-10

2 meter not terminated 5 meter not terminated 18″ 4-pin AMP® CPC Series connector (Motoman®/Miller®) 24″ 3-pin Amphenol® 97 Series connector 18″ 12-pin Burndy® UTG Series connector (ABB®) 24″ 5-pin Mini plug

FOR CLUTCH ONLY

AS-708-14 AS-708-14-1 AS-708-14-2

3-pin two Cable Cordset – complete length (includes both AS-708-14-1 & AS-708-14-2) Clutch Cord – coiled 0.3M; terminated both ends mini plug 3-pin female to male Cordset – main length 5.0M; 3-pin female to not terminated

8

MOUNTING OPTIONS

GUN MOUNTS

CACM

Clutch Mount

CASM

Solid Mount

MOUNTING ARMS (Please see Gun Configurations for dimensional information)

CA2201 CA2202 CA2203 CA4501 CA4502 CA1801

Mounting Arm for 22 degree short length neck (part #405-22QC); 316 mm TCP Mounting Arm for 22 degree medium length neck (part #405-22QCL); 350 mm TCP Mounting Arm for 22 degree medium length neck (part #405-22QCL); 400 mm TCP Mounting Arm for 45 degree medium length neck (part #405-45QCL); 350 mm TCP Mounting Arm for 45 degree long length neck (part #405-45QCL1); 400 mm TCP Mounting Arm for 180 degree neck (part #405-180QC); 294 mm TCP

INSULATING/TRANSITION DISCS

FOR ABB® ROBOTS

59D02 59D04 59DT-011

IRB6, IRB140, 1400, 1500, 1600, 2000, 4000, M97A, IRB2400L IRB2400-10, IRB2400-16, IRB2600, IRB440L, IRB4600-20/2.5 IRB1600ID (kit includes transition disc and 59D02 insulating disc)

FOR MILLER® ROBOTS 59D02 MRV-2

FOR OTC DAIHEN® ROBOTS

59D02

MRV-6, EX-V6, EX-V6L, NV25, EX-V16, DR-2000, DR-4400, DR-4200L, DR-4400

FOR COMAU® ROBOTS 59D01 Smart6 6-14

FOR FANUC® ROBOTS 59D02 100, 100i, 100iB, 120iB, S-6, M710-20L 59D05 ArcMate 50iB, 50iC 59DT-003 100iC, 100iC-12, 100iC-6L, 100iC-7L, 100iC-8L, 120iC,
120iC-10L, 120iC-12L, M710iC-12L (kit includes transition disc and 59D01 insulating disc) 59DT-010 100iD, 100iD-10L (kit includes transition disc and 59D01 insulating disc)

FOR KAWASAKI® ROBOTS 59DT-001 RS050N, RS30N, RS030N, RS80N
(kit includes transition disc and 59D02 Insulating disc)

FOR KUKA® ROBOTS 59D02 KR5 arc, KR6, KR6-2, KR6 arc, KR6 KS, KR16 L6, KR16
L6 arc, KR16 LS KS 59D05 KR5 R1400, KR6 R700 sixx, KR6 R900 sixx, KR10 R900
sixx, KR10 R1100 sixx, KR6 R1820, KR8R1620, KR10, R1420 59D06 KR16, KR16-2, KR16 S, KR16 KS, KR30 L16-2, KR20, R3100

59DT-006 59DT-012

KR30, KR60, KR60 L45, KR60 L30 (kit includes transition disc and 59D02 insulating disc) KR16 HW (kit includes transition disc and 59D02 insulating disc)

FOR PANASONIC® ROBOTS 59D03 VR-008A, VR-006A, VR-005C, VR-005LII, AW-010A,
AW-8010, AW-005A, AW-005C, AW-005CL, AW-006A, VR-006AL, TL-1800, TL-2000, TA-1600, TA-1800, TA-2000 59DT-005 TM-1100, TM-1400, TM-1600, TM-1800 (kit includes transition disc and 59D02 insulating disc)
FOR REIS® ROBOTS 59D06 RV4, RV6, RV6L, RV20-6
FOR UNIVERSAL ROBOTS 59D06 UR5, UR5e, UR10, UR10e
FOR YASKAWA® MOTOMAN® ROBOTS 59D02 K6A, K10S, SK6, SK16, SK16X, HP6, HP50-20,
MH50-20, MH6, SSF2000, UP6, UP20 59D05 K35, HP3, HP3C, HP3JC, MH5, MH5L, SV3 59D07 MH5, MH5L 59DT-001 MH50
(kit includes transition disc and 59D02 insulating disc) 59DT-002 EA Series
(kit includes transition disc and 59D03 insulating disc) 59DT-008 MA1440, AR1440, MH12, MA2010, AR2010, MA3210,
MH4, AR1730 (kit includes transition disc and 59D01 insulating disc) 59DT-013 HC10DT-XP (kit includes transition disc and 59D02 insulating disc)

9

POWER PINS

426 425-20E 214-17 425E

Bernard® Euro Fronius® L-Tec® Euro

214-7 214-40 214-1 214-39

Lincoln® Lincoln® (short) Miller® OTC Daihen®

214-30 214 214-12 214-18

Panasonic® Tweco® #4 Tweco® #5 Tweco® #5 (external gas line)

AUTOLENGTHTM PINS*

425-X20 214-X17 214-X40

Euro Fronius® Lincoln® (short)

214-X1 214-X39 214-X30

Miller® OTC Daihen® Panasonic®

214-X0 Tweco® #4 214-X12 Tweco® #5

*FOR USE WITH QUICK LOAD® LINERS ONLY. NOTE: FOR WIRE SIZES BETWEEN 0.030″ AND 0.045″, X=”8″; FOR WIRE SIZES BETWEEN 0.052″ AND 3/32″, X=”9”. AUTOLENGTHTM PIN NOT COMPATIBLE WITH WIRE SIZE SELECTIONS FOR ALUMINUM WIRE.

10

PERIPHERALS & ACCESSORIES

TOUGH GUN® TT4 REAMER

TOUGH GARD® MULTI-FEED SYSTEM

POWER THROUGH WELD SPATTER FOR INCREASED UPTIME AND WELD QUALITY
Automating spatter removal helps to extend the life of your robotic MIG guns and consumables, benefiting your bottom line, production uptime and throughput. Operates reliably in the harshest welding environments.
VISIT BERNARDTREGASKISS.COM/TT4 FOR ORDERING INFORMATION.

TG-103-05-2 TG-103-05-10 TG-103-55-10

Eliminate the need to frequently refill sprayer reservoirs with the TOUGH GARD multi-feed system from Tregaskiss®. Feed up to 10 TOUGH GUN® reamer units from a single 5-gallon or 55-gallon drum of TOUGH GARD anti-spatter liquid.
for 5-Gallon pail (up to 2 nozzle cleaning stations)
for 5-Gallon pail (up to 10 nozzle cleaning stations)
for 55-Gallon drum (up to 10 nozzle cleaning stations)

TOUGH GARD® ANTI-SPATTER LIQUID
This ready-to-use water-soluble, non-toxic product creates a sacrificial surface that reduces spatter adhesion. This prolongs the life of your consumables and minimizes downtime due to nozzle cleaning which can help reduce your operating and maintenance costs.

TG-101-05 TG-101-55 TG-101-01 TG-101-32SP TG-101-14S

5.28 U.S. Gallon / 20 L 55 U.S. Gallon / 208 L 1 U.S. Gallon / 3.78 L 32 fl. oz. / 946 mL (spray bottle) 16.9 fl. oz. / 500 mL

TOUGH GARD® MULTI-FEED SYSTEM HOSE
(SOLD SEPARATELY)

TG-103-100 TG-103-200

100′ Multi-Feed Hose 200′ Multi-Feed Hose

NECK CHECKING FIXTURE
The TOUGH GUN® neck checking fixture allows you to verify and remaster your tool center point (TCP). In the event of a collision, this fixture can be used to realign the neck.

G-405CA
G-405CA + G-495-8

Neck Checking Fixture for aircooled Neck assemblies Neck Checking Fixture for TOUGH GUN I.C.E.® Neck assemblies

11

ORDERING INFORMATION

STEP #1: TOUGH GUN® CA3 ROBOTIC MIG GUN

CA3 Series

Gun Style

Neck

Options

Contact Tip** + Diffuser

Cable Length

Nozzle

Control Cable

Wire Size***

Power Pin

RA 1

1

A

C

G

D

1

C

M

1 Clutch 2 Solid
mount··

AIR-COOLED
SHORT LENGTH A 22 degree
405-22QC B 45 degree
405-45QC C 180 degree
405-180QC

A No options
B Wire Brake
C Air Blast E Wire brake
+ air blast

MEDIUM LENGTH
D 22 degree 405-22QCL
E 45 degree 405-45QCL

TOUGH GUN I.C.E.® +
SHORT LENGTH
H 22 degree 590-22-X.XXX
J 45 degree 590-45-X.XXX

ACCULOCKTM FOR SLIP-ON
NOZZLES
A T-A0XXCH^ + D-ATSH
B T-A0XXZH + D-ATSH
C T-A0XXWH· + D-ATSH
FOR THREAD-ON NOZZLES
D T-A0XXCH^ + D-ATTH
E T-A0XXZH + D-ATTH
F T-A0XXWH· + D-ATTH
NO CONSUMABLES
0 No contact tip/ diffuser

A 3.0 ft B 3.5 ft C 4.0 ft D 4.5 ft E 5.0 ft F 5.5 ft G 6.0 ft H 6.5 ft J 7.0 ft K 7.5 ft L 8.0 ft M 8.5 ft N 9.0 ft P 9.5 ft R 10.0 ft S 12.0 ft T 15.0 ft

SLIP-ON A 401-6-62 D 401-81-62 G 401-8-62 K 401-48-62 N 401-71-62 P 401-87-62 3 401-30-62
THREAD-ON D 401-14-62 E 401-18-62 G 401-43-62 L 401-20-62 4 401-30-62T
NO CONSUMABLES
0 No nozzle

··CONTROL CABLE OPTION NOT AVAILABLE FOR SOLID MOUNT MODELS +X.XXX REPRESENTS NOZZLE O.D. XX = WIRE SIZE ^NOT AVAILABLE IN 0.055″ OR 0.078″ WIRE SIZES AVAILABLE IN 0.035″, 1.0 MM AND 0.045″ WIRE SIZES ·AVAILABLE IN 0.035″, 1.0 MM, 0.045″ AND 0.052″ WIRE SIZES WIRE SIZE OPTION DETERMINES CONTACT TIP AND LINER SIZE ++RECOMMENDED LINER PROVIDES SUPERIOR WIRE FEEDING; NOT AVAILABLE IN CABLE LENGTHS LONGER THAN 6 FEET; NOT COMPATIBLE WITH WIRE BRAKE SELECTION ···QUICK LOAD® LINER COMES STANDARD ON ALL CONFIGURATIONS UP TO 1/16″ WIRE SIZE EXCEPT IF EQUIPPED WITH WIRE BRAKE; CONVENTIONAL REAR-LOADING LINER COMES STANDARD ON ALL CONFIGURATIONS EQUIPPED WITH WIRE BRAKE IF CONFIGURING GUN WITHOUT CONSUMABLES, “0” MUST BE SELECTED FOR “CONTACT TIP + DIFFUSER”, “NOZZLE”, AND “WIRE SIZE” OPTIONS

0 No cable BARE END
1 5m 2 2m
4-Pin
3 18″ 3-Pin
4 24″ 12-Pin
5 18″ 5-Pin
7 24″

QUICK LOAD® PRO LINER++
A 0.035″ N 1.0 mm P 0.045″ W 0.052″ Y 1/16″ STANDARD
LINER···
B 0.030″
C 0.035″ D 1.0 mm E 0.045″ G 0.052″ J 1/16″ K 0.070″ L 0.078″ M 3/32″ TEFLON® LINER FOR ALUMINUM
R 0.035″ T 1/16″
U 0.045″ NO
CONSUMABLES
0 N/A

B Bernard® 426 D OTC Daihen®
214-39 E Euro
425-20E F Fronius®
214-17 L Lincoln®
214-7 M Miller® 214-1 C L-Tec® Euro
425E P Panasonic®
214-30 R Tweco® #5
(external gas line)
214-18
S Lincoln® (short) 214-40
T Tweco® #4 214
W Tweco® #5 214-12

STEP #2: INSULATING/TRANSITION DISC Select your insulating disc from page 9 and enter it here:

STEP #3: MOUNTING ARM Select your mounting arm from page 9 and enter it here:

BRAND AND PRODUCT NAMES SHOWN ABOVE ARE TRADEMARKS OF THEIR RESPECTIVE OWNERS. TREGASKISS®, TOUGH GUN®, TOUGH LOCK®, TOUGH ACCESSTM AND QUICK LOAD® ARE TRADEMARKS OF TREGASKISS®, A DIVISION OF ITW CANADA INC. SUBJECT TO CHANGE THE INFORMATION PRESENTED IN THIS SPEC SHEET IS ACCURATE TO THE BEST OF OUR KNOWLEDGE AT THE TIME OF PRINTING. PLEASE VISIT BERNARDTREGASKISS.COM FOR THE MOST UP-TO-DATE INFORMATION.
DISTRIBUTED BY: ©2024 Tregaskiss®