Tregaskiss TOUGH GUN TT Series Quick start guide

TECHNICAL GUIDE
TOUGH GUN REAMER
TT Series
SAFETY & WARRANTY INFORMATION
INSTALLATION
MAINTENANCE GUIDE
TECHNICAL DATA
OPTIONS
EXPLODED VIEW & PARTS LIST
TROUBLESHOOTING
ORDERING INFORMATION
Certified QS 9000 TE.
Please read instructions prior to use.
Save this manual for future reference.

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TABLE OF CONTENTS
WARRANTY
1.0 - INSTALLATION
1.1 INSTALLING TOUGH GUN REAMER 4
1.2 AIR MOTOR LUBRICATION 4
1.3 WIRING INTERFACE CONNECTIONS 4
1.4 ACCESS TO ELECTRICAL AND PNEUMATIC CONTROLS 5
1.5 CIRCUIT BOARD LOGIC INVERSE 5
1.6 LED INDICATORS 5
2.0 - OPERATION
2.1 NOZZLE INSERTION HEIGHTS 6
2.2 PROGRAMMING EVENTS SEQUENCE 6
2.3 V-BLOCK SETUP 6
2.4 MANUAL REAMER SETUP 7
2.5 FLOW CONTROL VALVES 7
3.0 - MAINTENANCE
3.1 AIR MOTOR REPLACEMENT 7
3.2 REPLACEMENT OF PRINTED CIRCUIT BOARD 8
3.3 CUTTER REPLACEMENT 8
3.4 BELT REPLACEMENT 8
3.5 SOLENOID VALVE REPLACEMENT 9
3.6 SCHEDULED PROGRAM 9
4.0 - TECHNICAL DATA
4.1 PNEUMATIC DIAGRAM 9
4.2 ELECTRICAL SCHEMATIC 10
4.3 CUTTER AND V-BLOCK CHART 10
5.0 - EXPLODED VIEW & PARTS LIST 12
6.0 - TROUBLESHOOTING 13
7.0 - SPRAYER
7.1 OPTION (S): ANTI-SPATTER SPRAYER 13
7.2 OPERATION: PROGRAMMING EVENTS SEQUENCE 14
7.3 SPRAYER MAINTENANCE 14
7.4 SPRAYER TROUBLESHOOTING 14
7.5 SPRAYER PARTS LIST 15
8.0 - OPTIONS
8.1 REAMER STAND 15
8.2 MULTI-FEED READY 16
8.3 SPRAYER FLOW CONTROL 17
8.4 WIRE CUTTER 17
9.0 - TOUGH GUN ORDERING INFORMATION BACK COVER

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WARRANTY
Tregaskiss equipment and parts are warranted to be free of defects in material and/or workmanship as stated below.
If within that period, any Tregaskiss gun or part thereof is found to be defective under normal and recommended use,
Tregaskiss will at their option, repair, replace or issue credit for the value of the defective unit. All claims against this
warranty must be submitted through a factory-authorized distributor. Use of non-Tregaskiss parts and/or consumables
with these guns may damage or severely limit performance of the TOUGH GUN and may limit or void any warranties.
Tregaskiss will not assume responsibility for incidental damages or expenses by any defect whatsoever.
TOUGH GUN MIG guns and components - 120 days
TOUGH GUN handles and trigger switches - Lifetime
TOUGH GUN Reamer and components - 1 year
TOUGH GUN Robotic peripherals: Clutch, Sprayer,
Wire Cutter, Clutch Disc and Robotic Arms - 1 year
Customer Returns
Returned boxes must have a RA # and return address on boxes when received.
Torches returned under warranty must be complete including consumables.
Returned Trials must have bottom portion of Trial form completed and sent here before RA # is issued.
Products returned that were previously installed on torches cannot be put back into inventory (i.e. water-cooled
goosenecks).
No credit on returned specials
Any products left here for more than 30 days after contact with the customer will be shipped back at their expense.
If product is being returned for Warranty Repair or Replacement, a Return Authorization Number must be obtained
from the factory. No charge replacements or repaired products will be sent out once returned product has been
evaluated and warranty has been determined. If a replacement needs to be sent immediately, a purchase order
number is required and the goods will be billed until warranty is determined.
THANK YOU…
for selecting a TOUGH GUN REAMER. Manufacturing
operations demand extremely dependable robotic equipment.
With this in mind, the TOUGH GUN REAMER was designed
and engineered to be a reliable tool to support high production
within a robotic cell. As the name implies, the TOUGH GUN
REAEMR is made from durable materials and components
engineered to perform in a rugged, robotic welding
environment.
The instructions and illustrations in this technical guide make it
easy for you to maintain your TOUGH GUN REAMER. Please
read, understand, and follow all safety procedures. Keep this
Technical Guide booklet as a handy reference when ordering
complete guns, parts and special options.
For technical support and special applications, please
call the Tregaskiss Technical Service Department at
[phone] or fax [phone]. Our trained
technicians are available between 8:30 AM and 4:30 PM,
and will answer your application or repair questions.
Tregaskiss also manufactures complete robotic MIG gun
systems designed and engineered to perform as a team in
the high-volume robotic production environment.
Components include TOUGH GUN ROBOTIC air-cooled and
water-cooled MIG guns, TOUGH GUN CLUTCH and gun-
mount arms. Contact your Tregaskiss representative or
Tregaskiss Ltd. for further information.
GENERAL SAFETY
Before installation or operation of the TOUGH GUN REAMER, please read and understand all safety precautions listed below. Failure to follow
these instructions may result in personal injury or damage to the equipment.
1. Do not remove or deface warning and instruction labels from the unit.
2. Ensure that all equipment in the area is disabled and locked out before setting up, adjusting or conducting any work.
3. Ensure that electrical and pneumatic power to unit is off before setting up, adjusting, or conducting any work.
4. Check that electrical and pneumatic connections comply with the codes applicable to your country and state.
5. Keep hands away from unit while in operation.
6. For additional safety information, please refer to the following publications:
ANSI STANDARD Z49.1, SAFETY IN WELDING AND CUTTING,
American Welding Society, 550 LeJeune Rd. P.O> Box 351040, Miami, FL 33126
ANSI STANDARD, SAFETY OR ROBOTS AND ROBOT SYSTEMS,
American National Standards Institute, 1430 Broadway, New York, NY 10018
NFPA STANDARD 70-1978. NATIONAL ELECTRIC CODE,
National Fire Protection Association, 1470 Atlantic Avenue, Boston MA 02210

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1.0 - INSTALLATION
1.1 INSTALLING TOUGH GUN REAMER
Ensure power supply is off and disconnected before proceeding.
MOUNTING REAMER
The REAMER should be installed within the weld cell at a convenient location. Be sure to consider movable fixtures and the
confines of the robot.
Affix REAMER base to sturdy platform using four (4) 3/8" dia. bolts in the holes provided.
If using optional adaptor plate, first mount plate to stand using two (2) supplied 1/2" bolts. Then mount reamer to this plate.
CONNECTING AIR SUPPLY –WARNING –PUSH RESET BUTTON BEFORE CONNECTING AIR LINE.
Use only filtered, lubricated air.
REQUIREMENTS - IMPORTANT: 80 to 100 PSI at 16 CFM (5.0-7.0 BAR at 450 LPM) at the Reamer.
Use an air supply line with an inside diameter of 3/8" and connect to 1/4" female NPT inlet located on the side of the valve
base.
1.2 AIR MOTOR LUBRICATION
An air line lubricator (not supplied) must be mounted in the air line of the Reamer. The Lubricator should be set to feed one drop
of oil for every 50-75 CFM of air going through the motor. The lubricant can be air motor oil or light grade hydraulic oil with a
viscosity rating of 150 VC 15-20 (SAE 5W).
1.3 WIRING INTERFACE CONNECTIONS
WARNING: The following connections should only be performed by qualified technicians. Damage to equipment will occur if
connections are incorrect.
To interface the REAMER with the controller, 4 electrical connections are required.
ORANGE LEAD - CYCLE START INPUT (.25 AMP)
WHITE LEAD - 0 VDC SUPPLY .5 AMP
RED LEAD - 24 VDC SUPPLY .5 AMP
GREEN LEAD - JAWS UNCLAMPED OUTPUT (LOAD CAPACITY = .25 AMP)
BLACK LEAD –OPTION (INPUT)
NOTE: The pre-wired interface receptacle uses the above colour codes.
OPERATION NOTES:
Connection 2 - Red Lead. Operates the internal logic with 24 VDC supply
Connection 3 - Green Lead. Cycle complete output signal either +24 VDC for sourcing or 0-sinking logic (ref. Logic Inverse
pg. 5)
Connection 4 - Orange Lead. Cycle start input signal (pulse signal max. .5 seconds) either +24 VDC or 0 VDC for sinking
logic (ref. Logic Inverse pg.5).
NOTE The TOUGH GUN REAMER is capable of both sourcing or sinking (high or low) inputs and outputs:
TT Series
Mounting Hole Locations
and Footprint

5
1.4 ACCESS TO ELECTRICAL AND PNEUMATIC CONTROLS
WARNING!
Ensure power supply is off and disconnected before proceeding.
To access the electronic circuit board for installation or service of
the REAMER, simply loosen the 4 Allen head screws and
remove rear motor shroud for access to switches.
To reinstall the covers, place motor shroud into position and
tighten the 4 Allen screws.
1.5 CIRCUIT BOARD LOGIC INVERSE
1.6 L.E.D. INDICATORS
The L.E.D. indicators mounted on the front of the reamer supply visual information regarding cycle
status. This information may be used for both installation and maintenance to verify proper
operation. When REAMER is idle, L.E.D. status should be:
"Reamer Home" - ON
"Reamer Ahead" - Off
"Unclamped" - ON
"Reamer Home" - indicates that the lift cylinder has retracted, the cutter is at the bottom of its
stroke and the limit pin is activating the lower limit switch.
"Reamer Ahead" - indicates that the Reamer has reached full upper stroke and the limit pin is
activating the upper limit switch.
NOTE: Full stroke extension of the lift cylinder is 3/8" (9 mm) shorter in the automatic mode. Use
the insertion depth chart in section 2.1 for proper depth. If manual set-up is used (Section 2.4) for
insertion depth, cutter may not travel deep enough.
"Unclamped" - indicates that the clamp cylinder is fully retracted, releasing the clamp mechanism
and supplying an output signal that the cycle is complete (via the limit switch mounted next to the
clamp cylinder)
CAUTION! Before start-up ensure all connections are correct or damage to the TOUGH GUN REAMER
may occur.
NOTE: The TOUGH GUN® REAMER is factory set for sourcing inputs and outputs.
The control logic requirement for some installations may require an inverse of the logic provided. The inverse logic is 0 VDC
low (sinking) input or outputs.
To switch from sourcing to sinking, the switches located inside the motor shroud must be accessed. Refer to “Access to
Pneumatic and Electrical Controls (see above) for directions.
Although the circuit board is protected, Tregaskiss suggests disconnecting the power before moving the switches.
The switches are located on the bottom right hand corner of the circuit board.
The output signal (unclamped signal) can be altered to either sourcing (high) or sinking (low) by moving the switch (SW3) to
the position indicated on the diagram. (page 10)
The input signal (start signal) can be altered to either sourcing (high) or sinking (low) by moving the switch (SW2) to position
indicated on the diagram. (page 10)
The Option signal (sprayer) can be altered to either sourcing (high) or sinking (low) by moving the switch (SW1) to position
indicated on the diagram. (page 10)
REFER TO ELECTRICAL SCHEMATIC pg 10

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2.0 OPERATION
2.1 NOZZLE INSERTION HEIGHTS
TT Series Reamers
RETAINING HEAD
Cutter
Size
404-3
404-20/404-30
454-1
RC-06
3/8"
0.023 below
.025 below
.266
RC-12
3/4"
.110 below
.110 below
.466
RCT-01
5/8"
0.030
0.060
.716
RCT-04
1/2"
.219 below
.065
.065
DO NOT use manual overrides for setup. Use automatic
cycle. Cutter stroke will vary between manual and
automatic cycles. Measurements are based on new cutter
styles and a 14mm wire stickout.
2.2 PROGRAMMING EVENTS SEQUENCE
1. Verify Reamer input showing "Clamps Open".
2. Position the robot to place the MIG gun at a right angle to the unit and to insert the gun to the proper depth, centered and
pressed against the V-block (see Section 2.1 "Nozzle Insertion Parameters").
3. Cycle Start - Supply output signal from the robot controller. Pulse output for .5 seconds.
4. Wait and verify input from Reamer for cycle (clamps closed).
5. Reamer performs cleaning cycle.
6. Wait and verify input from Reamer for cycle complete (Clamps Open).
7. The robot can now be safely removed from the Reamer clamps to the next position.
If using anti-spatter sprayer:
1. After reaming, center the nozzle one (1) inch (25 mm) above the spray head.
2. Supply output signal from robot controller to the sprayer for about .5 seconds (increase or decrease spray time as required).
3. Move robot to next position.
2.3 V-BLOCK SETUP
WARNING! ENSURE POWER
SUPPLY IS OFF AND AIR IS
DISCONNECTED BEFORE
PROCEEDING.
Remove four cover
screws.
Lift clamp cover off.
Lift and rotate V-Block so
desired size faces jaws.
NOTE: Numbers are
stamped into the V-
Blocks. The number
refers to the outside
diameter of the nozzle
i.e.: 0938 =.938O.D..
V-BLOCK PART #
NOZZLE OUTSIDE DIAMETER
TR-2150
(4 sides)
TR-2151
TR-2152
TR-2153
TR-2154
TR-2155
TR-2156
TR-2157
TR-2158
0.850”, 0.938”
1.062” AND 1.106”
.938" AND .978"
1.062" AND 1.125"
.813" AND 1.00"
.078"
.830"
.875"
.591” (15mm)
.984” (25mm)
COVER SCREWS
V-BLOCK
JAWS
SEE
CHART

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2.4 MANUAL REAMER SETUP
NOTE:
The manual override valve screws allow confirmation
that the lift cylinder and jaw clamping air circuit is
operational. It should not be used for gauging the cutter
depth (see section 2.1 for insertion depths).
To manually start the TOUGH GUN ® REAMER, locate
the screws on the spindle air valve and clamp and motor
air valve. Rotate these screws clockwise and the
REAMER will function.
NOTE: The reset button should be pressed prior to
manual setup to reset all circuitry.
2.5 FLOW CONTROL VALVE(S)
OPERATING NOTES: The flow control valve(s) provide a smooth, constant feed of the cutting
tool. The feed rate is dependant on the amount of spatter accumulated. If a smaller amount of
spatter accumulates, the feed can be set faster. A feed rate that is set too fast may stall the
motor.
ADJUSTING THE FLOW CONTROL VALVE(S)
NOTE: Reamers prior to serial #TT-5338 utilized two flow controls for advancing and
retracting the feed unit.
There is a flow control valve for adjustment of the up speed of the feed head. The down
(retract) speed is fixed. The feed rate may require adjusting for different applications.
The valve controls the rate at which air is released on the exhaust side of the cylinder
To increase feed rate on the nozzle, the valve would have to be opened, which allows air to
flow out of the cylinder, thereby increasing speed.
To decrease feed rate into the nozzle, the valve would have to be closed, which slows air
flow out of the cylinder causing feed to slow down.
3.0 MAINTENANCE
3.1 AIR MOTOR REPLACEMENT
Loosen 4 screws and remove motor shroud
Remove tension lock screw.
Push motor in to release belt tension.
Remove belt
Release air lines from quick disconnect air
fittings.
Reverse order for reassembly.

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3.2 REPLACEMENT OF PRINTED CIRCUIT BOARD
Loosen 4 screws and remove motor shroud
Remove connectors from board being careful not to damage
wiring
Remove the fasteners which secure board to reamer body.
Board can now be carefully removed from the unit and a
new one installed.
Once located in the proper position, secure board by
tightening fasteners.
3.3 CUTTER REPLACEMENT
Remove cutter using 5/8" wrench and the supplied 9/16"
wrench.
The cutter is removed by turning counterclockwise when
viewed from above.
Considerable force may be required to loosen the cutter since
it tightens naturally as the reamer operates
INSTALLING CUTTER
The cutter is installed by threading it clockwise into the top of the
extension shaft.
NOTE: The application of anti-seize compound to the threads of
the REAMER cutter will assist in easy removal in the future.
3.4 BELT REPLACEMENT
Loosen 4 screws and remove motor shroud.
Remove tension lock screw.
Push motor in, to release belt tension.
Remove belt.
Reverse order for reassembly.
9/16 Wrench (supplied)

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3.5 SOLENOID VALVE REPLACEMENT
Shut off power to Reamer.
Shut off air supply to Reamer.
Remove motor shroud.
On Reamer circuit board, remove valve coil wires.
Loosen and remove (2) solenoid valve screws.
Remove solenoid valve and gasket.
NOTE: New gasket must be installed when replacing
valve.
Reinstall new gasket and valve and tighten screws to
12 in./lbs.
Reconnect valve coil wires to Reamer circuit board.
Reinstall the motor shroud.
3.6 SCHEDULED MAINTENANCE PROGRAM
The TOUGH GUN® REAMER will require a periodic maintenance program to ensure a reliable service life. The following
schedule is recommended.
DAILY
Ensure spindle cover area is clear of spatter.
Visually check oil level in lubricator reservoir
The life of the air motor is dependent on a consistent supply of oil.
Visually check air lines and interface cables for leaks and fraying.
Clean clamp jaw surfaces to ensure proper nozzle gripping.
WEEKLY
Visually check the REAMER cutter. The service life of the cutter is dependant on the type of application.
In lighter duties, the cutter may last indefinitely. However, it should be inspected for dullness, clogging and possible breakage.
Ensure belt tension lock screw is securely tightened.
YEARLY
Replace drive belt (reference "Belt Replacement" pg. 8).
4.0 TECHNICAL DATA
4.1 PNEUMATIC DIAGRAM
NOTE: UNITS PRIOR TO SERIAL #TT-5339
UTILIZED (2) TR-2234 FLOW CONTROL
VALVES TO ADVANCE AND RETRACT OF
THE LIFT CYLINDER

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4.2 ELECTRICAL SCHEMATIC
4.3 CUTTER AND V-BLOCK CHART
NOZZLE PART #
NOZZLE
OUTSIDE DIAMETER
REAMER MODEL
V-BLOCK PART #
CUTTER PART #
401-4-38
0.938"
TT-0938-06
TR-2150
RC-06
401-40-38
0.978"
TT-0978-06
TR-2151
RC-06
401-45-38
0.938"
TT-0938-06
TR-2150
RC-06
401-45-38
0.938"
TT-0938-06
TR-2150
RC-06
401-46-38
0.938"
TT-0938-06
TR-2150
RC-06
451-4-38
0.938"
TT-0938-06
TR-2150
RC-06
401-4-50
0.938"
TT-0938-04
TR-2150
RCT-04
401-6-50
1.062”
TT-1060-04
TR-2150
RCT-04
401-42-50
0.938"
TT-0938-04
TR-2150
RCT-04
401-44-50
0.938"
TT-0938-04
TR-2150
RCT-04
401-45-50
0.938"
TT-0938-04
TR-2150
RCT-04
401-46-50
0.938"
TT-0938-04
TR-2150
RCT-04
401-47-50
0.938"
TT-0938-04
TR-2150
RCT-04
401-48-50
0.938"
TT-0938-04
TR-2150
RCT-04
451-6-50
0.938"
TT-0938-04
TR-2150
RCT-04
401-4-62
0.938"
TT-0938-01
TR-2150
RCT-01
401-5-62
1.062”
TT-1060-01
TR-2150
RCT-01
SINKING
UNCLAMPED
SOURCING
SOURCING
START
SINKING
INPUT
SOURCING SINKING

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401-6-62
1.062”
TT-1060-01
TR-2150
RCT-01
401-7-62
1.106"
TT-1106-01
TR-2150
RCT-01
401-8-62
0.938"
TT-0938-01
TR-2150
RCT-01
401-9-62
0.938"
TT-0938-01
TR-2150
RCT-01
401-45-62
0.938"
TT-0938-01
TR-2150
RCT-01
401-46-62
0.938"
TT-0938-01
TR-2150
RCT-01
401-48-62
1.062”
TT-1060-01
TR-2150
RCT-01
401-72-62
1.062”
TT-1060-01
TR-2150
RCT-01
401-81-62
1.062”
TT-1060-01
TR-2150
RCT-01
401-87-62
1.062”
TT-1060-01
TR-2150
RCT-01
451-1-62
1.062”
TT-1060-01
TR-2150
RCT-01
451-5-62
0.938"
TT-0938-01
TR-2150
RCT-01
451-6-62
0.938"
TT-0938-01
TR-2150
RCT-01
451-8-62
0.938"
TT-0938-01
TR-2150
RCT-01
451-61-62
1.062”
TT-1060-01
TR-2150
RCT-01
451-81-62
1.062”
TT-1060-01
TR-2150
RCT-01
451-87-62
1.062”
TT-1060-01
TR-2150
RCT-01
650-5-62
1.062”
TT-1060-01
TR-2150
RCT-01
650-6-62
1.062”
TT-1060-01
TR-2150
RCT-01
651-5-62
1.062”
TT-1060-01
TR-2150
RCT-01
651-6-62
1.062”
TT-1060-01
TR-2150
RCT-01
401-4-75
.0938"
TT-0938-12
TR-2150
RC-12
401-5-75
1.062”
TT-1060-12
TR-2150
RC-12
401-6-75
1.062”
TT-1060-12
TR-2150
RC-12
401-7-75
1.106"
TT-1106-12
TR-2150
RC-12
451-1-75
1.062”
TT-1060-12
TR-2150
RC-12
451-5-75
0.938"
TT-0938-12
TR-2150
RC-12
451-6-75
0.938"
TT-0938-12
TR-2150
RC-12
650-5-75
1.062”
TT-1060-12
TR-2150
RC-12
650-6-75
1.062”
TT-1060-12
TR-2150
RC-12
651-5-75
1.062”
TT-1060-12
TR-2150
RC-12
651-6-75
1.062”
TT-1060-12
TR-2150
RC-12

12
5.0 EXPLODED VIEW & PARTS LIST
ITEM
PART#
DESCRIPTION
ITEM
PART #
DESCRIPTION
1
TR-2110
CLAMP COVER
22
TR-2500
AIR MOTOR ASSEMBLY w/pulley
2
TR-2120
JAW ASSEMBLY
23
TR-2520
MOTOR PULLEY
3
TR-2127
UPPER JAW SPACER (2req’d)
24
TR-2530
MUFFLER
4
TR-2128
LOWER JAW SPACER (3req’d)
25
TR-2660
SPINDLE CAP
5
TR-2130
CLAMP CYLINDER
26
TR-2661
SPINDLE CAP SEAL
5a
TR-2130R
CLAMP CYLINDER SEAL KIT (not shown)
27
TT-2670
SPINDLE SHROUD
6
XXX
V-BLOCK (refer to chart on page 10-11)
7
TR-2210
SOLENOID VALVE
28
TT-2680
MOTOR SHROUD
7A
TR-2210-2
VALVE SCREWS (M3X30mm SHS)
7B
TR-2215
GASKET (not shown)
29
TR-2690
ADAPTOR PLATE (OPTIONAL)
8
TR-2220
VALVE BASE (TR-2221 Vent not included)
N/S
TR-2234
FLOW CONTROL
9
TR-2235
AIR FITTINGS-MALE ELBOW (Spindle unit)
SERIAL #TT-5338 & EARLIER –2 EACH REQ.
10
TR-2236
AIR FITTINGS-MALE ELBOW (Motor)
SERIAL #TT-5339 & UP –1 REQUIRED
11
TR-2250
AIR LINE ¼”, 4FT. LENGTH (not shown)
N/S
TT-2412
FIXED FLOW CONTROL
12
TR-2260
AIR LINE 5/16”, 4FT. LENGTH (not shown)
SERIAL #TT-5339 & UP
13
TR-2310
P.C BOARD
31
RR-707-30
TCP LOCATOR PIN (optional –not shown)
13A
TR2310-S
STANDOFF SCREW KIT
32
TR-2910
CUTTER WRENCH
14
TT-2322
SPINDLE LIMIT SWITCH ASSEMBLY
33
RC-00
ALIGNMENT TOOL (not shown)
15
TR-2321
CLAMP SWITCH
34
RT-1000
TEST BOX (not shown)
16
TT-2330
RESET SWITCH (w/TT-2330-2 boot)
35
TT-2400RN
LIFT CYLINDER SEAL REPAIR KIT (not shown)
REPLACES TR-2330
36
TT-2400R
LIFT CYLINDER SEAL REPAIR KIT (not shown)
TR-2330-2
SWITCH BOOT
<For older generation blue cylinder>
17
TR-2340
INTERFACE RECEPTACLE
38
TR-2512
MOTOR TENSION SPRING
18
TR-2350
CONTROL CABLE - 20’ supplied standard
39
TR-2632
WASHER
TR-2350-30
CONTROL CABLE - 30’ optional (not shown)
40
TR-2239
RING WASHER (2)
TR-2350-50
CONTROL CABLE - 50’ optional (not shown)
41
TR-2231
AIR FITTING 5/16” SMC
19
TT-2400
SPINDLE UNIT ASSY’ w/pulley
42
TR-2232
AIR FITTING ¼” SMC
43
TR-2452
TOP MOUNT GROMMET
20
TR-2430
SPINDLE PULLEY
44
TR-2451
SIDE MOUNT GROMMET
21
TR-2440
DRIVE BELT
N/S
TR-2453
REAMER GROMMET & SEAL KIT
(INCLUDES ITEMS –15, 40, 43 & 44)

13
6.0 TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
SOLUTION
LED signals not activating
Power is off
Fuse is blown
REAMER station is not switched
on
Input voltage is incorrect
Turn power on
Install new fuse
Switch unit on
Check input voltage and make adjustments as
required.
Motor stops during
operation
Air supply is incorrect
Excessive spatter build up
Lubricator not installed or adjusted
properly
Set at 80-100 PSI at 16 CFM
Apply or increase quantity of anti-spatter
Increase frequency of torch cleaning or modify
welding parameters
Ensure lubricator is installed and adjusted (ref to
sec.1.2)
Pneumatic functions not
operative
Air line damaged or obstructed
Air supply incorrect
Faulty reset switch
Replace air line
Check air supply. Set at 80-100 PSI at 16 CFM
Repair or replace reset switch
Broken cutter
Improper cutter being used
Flow control valve set too low
Flow control valve shut
Repair or replace damage components
Adjust feed rate
Adjust flow control valve
Reamer stays in up
position
Cutter is jammed in torch
Faulty spindle unit
Faulty limit switch
Cycle start signal held on too long
Press or replace damage components
Repair or replace unit
Repair or replace limit switch
Revise program (.5 sec. pulse)
Cycle complete signal
does not activate
Faulty clamp unit
Faulty circuit board
Check or replace switch
Spindle (cutter) keeps
cycling up & down while
spinning
Interface receptacle or control
cable plug may be dirty.
Unplug control cable from reamer and clean both
connections thoroughly.
7.0 SPRAYER
7.1 OPTION (S): ANTI-SPATTER SPRAYER
SW1
The TOUGH GUN ®Sprayer is
factory set for “sourcing”. The wires
are connected to the P.C. board as
shown.
If you require the P.C. board
switches to be set to the “sinking”
position, the switch (SW1) must be
moved to sinking position (identified
on board)
To operate the sprayer, a timed 24
VDC signal must be applied to the
black lead (optional) of the interface
receptacle. Recommended spray
time .5sec. (refer to sprayer tech
guide).

14
7.2 PROGRAMMING EVENTS SEQUENCE
Program robot so that nozzle is centrally located.
X = 1.25” when using 5/8” Bore Nozzles
X = 1” when using 1/2" Bore Nozzles
X = 1.5” when using 3/4" Bore Nozzles
Energize timed output signal to initiate spray cycle.
Set timer at .5 seconds for initial set-up. Adjust
timer to increase or decrease quantity of anti-spatter
compound as required by process.
NOTE: If using Tregaskiss TOUGH GARD Anti-
Spatter compound, spray time can be as low as .2
seconds. Anti-spatter compound should be enough
to coat inside of nozzle with no drippage. Excessive
application of TOUGH GARD can decrease
performance and increase consumption.
IMPORTANT: If using the optional air-blast DO
NOT activate air blast when over the spray head.
Dirt/spatter may be blown into the spray head
orifice, which may hamper spray operation.
7.3 SPRAYER MAINTENANCE
DAILY
WEEKLY
QUARTERLY
YEARLY
Ensure fluid level in reservoir is maintained. Inspect spray operation to ensure adequate
anti-spatter compound is being applied.
Inspect unit for air leaks or damage supply and interface lines which may cause unit to
malfunction.
Inspect unit for build up of residue from anti spatter compound which could eventually
restrict fluid flow or cause unit to malfunction. Residue should be visible in reservoir or
nozzle assembly. If excessive, clean or flush with recommended solvent for anti-spatter
compound.
Inspect unit for damage or excessive wear of components. Replace if required.
7.4 SPRAYER TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
SOLUTION
No Air Flow
No Anti-spatter
Output to unit not functioning
Fuse blown
Loss of air supply
Faulty solenoid valve
Check output signal and cable
Install new fuse
Check air supply
Check air line and nozzle for blockage
Check solenoid valve and replace if required
Air Flow But No
Anti-Spatter
Vent closed on reservoir
Nozzle position incorrect on
spray head
Spool in valve block stuck
Fluid line blocked
Inadequate air pressure
Open vent
Adjust nozzle position on spray head
Repair or replace valve block
Clean or repair fluid line
Ensure 80 psi
Spray head
plugged
Clean spray head

15
7.5 SPRAYER PARTS LIST
ITEM
PART #
DESCRIPTION
1
TS-500-50
STEEL LINE KIT
2
TS-500-15
SPRAY HEAD
3
TS-500-1
SPRAY HEAD BRACKET
4
RR-1320
RESERVOIR
5
TS-500-20
CHECK VALVE
6
TS-500-28
SOLENOID VALVE
7
TS-500-29
MOUNTING PLATE
8
RS-500-20
BREATHER VENT
8.0 OPTIONS
8.1 Options ‘10’ or ’12’ – REAMER STAND with optional FRL (Filter
Regulator Lubricator)
PART #
DESCRIPTION
PART #
DESCRIPTION
RST-1000-A
ADJUSTABLE REAMER STAND
( 28” TO 43” )
RST-1200-A
ADJUSTABLE REAMER STAND
WITH FRL ( 28” TO 43” )
NOTE:Older sprayer units utilized plastic air lines and
can be updated using the TS-500-50 Steel line kit and
TS-500-15 spray head.
Option ‘10’
Option ‘12’
TENCHNICAL DATA
Electrical: 24 volts DC
2.5 watts
Pneumatic: 80-100 PSI
at 16 CFM
(Uses Reamer Air Supply)

16
8.2 Option ‘B’ – Multi-Feed Ready Reamer
`
RR-1320
(Removed)
Choosing Reamer option ‘B’ (Multi-feed
Ready Reamer), removes the Sprayer Reservoir
(RR-1320) from the bill of material, since it is
not needed with the Multi-feed System.
A diagram below shows one of many Multi-
feed configurations. Refer to our website or
your local Tregaskiss representative for more
information.
NOTE:
Multi-feed Systems are sold separately.
Multi-feed quick connects
thread into the sprayer at
this point.
Multi-Feed System

17
8.0 OPTIONS
8.3 Option ‘C’ – Flow Control
Note : Choosing Reamer option ‘C’ – Flow Control adds an adjustable check valve, giving users the ability to
control the amount of Tough Gard applied in each spray.
Also available the retro-fitable flow control kit. ( Part# TS-500-52).
8.4 Option ‘W’ – Wire Cutter
Reamer
with standard sprayer
Reamer
with optional flow control for the sprayer
Wire Cutter
(WC-100)
Choosing Reamer option ‘W’ – Wire
Cutter mounts to the top of the reamer.
Also available in the aftermarket add on
version to upgrade reamers (Part # WC-100).

18
9.0 - TOUGH GUN ORDERING INFORMATION
Distributed by:
2/26/07 REV C M061
Building a TOUGH GUN REAMER part number
TT –XXXX –XX –X –XX –XX
Order Number Examples:
TT –0938 –01 –3 –BCW –10 TT –1060 –01 –5 –SW –12
Optional Reamer Stand –‘10’ Stand only
–‘12’ Stand with FRL (filter-regulator-lubricator)
S –Sprayer
B –Multi-Feed Ready Sprayer (‘S’ not required)
C –Sprayer with Flow Control (‘S’ not required)
W –Wire Cutter
Optional Cordsets –20’ cord : blank
30’ cord : ‘3’
50’ cord : ‘5’
Cutter Style
Nozzle outside diameter
TT Series
Reamer Stand
Reamer Stand with FRL
Multi-Feed Ready
Sprayer (‘S’ not
required) with Flow-
Control option (BC).
Also, a Wire Cutter is
Installed (W).
Ant-Spatter Sprayer (S).
And Wire Cutter are
both installed (W).
30’ cord set
50’ cord set
RCT-01 Cutter
RCT-01 Cutter
0.938” Nozzle OD (V-block = TR-2150)
1.062” Nozzle OD (V-block = TR-2150)
TT Series Reamer
TT series Reamer