Documentation Category: Automation2

IMPORTANT: The following instructions pertain to unicable replacement on TOUGH GUN CA3 MIG Guns manufactured on or after April 8, 2015 NOTE: Unicable replacement can be done while the gun is mounted to the robot. There is no need to uninstall the gun before proceeding. Remove nozzle, retaining head and liner.FOR CLUTCH MODELS ONLY: Disconnect […]

Remove the nozzle, retaining head and liner (parts not shown).Loosen the neck clamp SHCS using a 5 mm Allen wrench (see ‘A‘ in Figure 1).Remove the neck (see ‘B‘ in Figure 1). Loosen the 2x SHCS in the gun mount using a 5 mm Allen wrench (see ‘C‘ in Figure 2).Remove the old TOUGH GUN […]

Required Tools: 9/16″ wrench11/16″ wrench5 mm Allen key3 mm Allen key2.5 mm Allen keyPrecision flat head screwdriverWire strippers Installation Instructions Disconnect power and air. Identify your anti-spatter source (bulk-feed or Tregaskiss supplied reservoir). Disconnect the source from the bracket mounted on the side of your TOUGH GUN® TT3 Reamer. Remove the MALE fitting from the […]

WARNING: Ensure the power and air supplies to the TOUGH GUN® Reamer are disconnected or disabled prior to working with the Reamer.  ItemDescriptionPart NumberQty15/16″ x 1/18″ NPT QCTR-223122Bulkhead AdaptorLR-500-5123SpacerLR-500-50-514M6x1x20mm LG SHCS – Black OxideF1-M6X1-20B25Steel Line Kit – For LubricatorLR-500-5016Lubricator TT-LUB-SMC1 1. Remove lubricator kit from the box and inspect for any damage. 2. Remove the reservoir […]

Ensure that the bolts clamping the feeder to the bracket on the robot are loosened.Insert the power pin on the rear of the Low-Stress Robotic (LSR+) Unicable into the feeder.Slide the feeder toward the front of the robot. This will create a necessary curve in the cable to allow for proper operation. Reminder: The robot’s […]

The following images detail the installation of new motor PER-2510. This motor is not compatible with the existing mounting bracket on spatter cleaner units made before March 2012 and may also require new valve assembly ER-2700, serial number ER-1635 and lower. The new motor is assembled and marked inside the new mounting bracket for reference […]

NOTICE: This product is factory set for wire equal to or smaller than 0.045“. If you are using wire 0.052” and larger, please remove the wire guide within the neck housing and replace it with the larger size (part #598-116) that is supplied in the box with this product. Removal and Installation Instructions Follow the […]

Step 1: Insert the bronze jump liner (part #495-18-25) into the neck.Position the liner stop flush with the back of the neck copper.Cut the liner 1/2 inch from the consumable side of the neck. Step 2: Insert the Teflon liner into the torch until it stops.Measure from the end of the power pin to the […]

Wire Brake Tool #450-17 Instructions Remove Wire Brake.Slide the Wire Guide Holder out of the connector cone assembly.Clean any debris or residue on the Wire Guide Holder. To Reassemble the Wire Guide Holder Line up the Wire Brake Tool with the Wire Guide Holder as shown in the diagram.Slide the Wire Guide Holder back inside […]

Wire Brake Tool #450-17 Instructions Remove the neck and consumables (not shown in the diagram).Remove (unthread) the Wire Brake Pushing Unit.Using the Wire Brake Tool, slide the Wire Guide Holder out of the connector cone assembly.Clean any debris or residue on the Wire Guide Holder. To Reassemble the Wire Guide Holder Using the Wire Brake […]

AIR BLAST KIT 508-A (does not include housing)  Remove 408-200-9A using a standard screwdriver Remove 408-200-8A using a standard screwdriver Thread 410-45-2 into 408-200-8A using xx wrench Insert TR-2237 into push-lock connections of TR-2232 and 410-45-2. Insert TR-2232 into air supply, 60-80 psi air pressure 408-200-9A 408-200-8A (internal threads) 410-45-2

The sprayer should be installed within the weld cell at a convenient location. Be sure to consider movable fixtures and the confines of the robot. Each sprayer comes complete with all required installation hardware and mounting brackets.

The TOUGH GUN­® Reamer has all the necessary mounting holes for installation of the SR-500 spray unit. Remove the plug from the side of the frame detail and replace with the supplied bulkhead fitting.Attach the spray head bracket to the TOUGH GUN Reamer using the two (2) screws provided.Attach the spray head to the TOUGH […]

WARNING: Ensure the power supply is off and disconnected before proceeding! Mounting the Wire Cutter The Wire Cutter should be installed within the weld cell. The base plate has been designed for mounting on top of the TOUGH GUN™ Reamer. Be sure to consider movable fixtures and the confines of the robot. Attach the Wire Cutter […]

Step 1: It is best to start by establishing the pail/drum location. This way it will be easier to run the lines and permanently secure them.Start by removing the reservoir from the spray unit.NOTE: Shut the vent cap (if applicable) and turn the reservoir upside down when it comes off the spray unit to avoid […]

NOTE: The following instructions are for G-405. Other fixtures are similar. Step 1: Remove consumables; nozzle, retaining head and neck insulator (with the exception of TOUGH GUN I.C.E.® components).Install the gauge point into the neck. Step 2: Slide the neck completely into the datum block, aligning keys on the neck to the keyway in the […]

NOTE: There is a protective ring that must be rotated to expose the neck set screw.  Step 1: Using a 5 mm Allen wrench, loosen the screw 1/4 turn to remove the neck.Pull the neck directly out of the connector cone assembly. Step 2:  Insert the replacement neck into the gun housing, ensuring the key […]