Tregaskiss TOUGH GUN ThruArm G2 Series Quick start guide

TECHNICAL GUIDE
TOUGH GUN™ThruArm™
G2 Series Robotic
MIG Guns
AVAILABLE PRODUCTS
EXPLODED VIEW & PARTS
LIST
ORDERING INFORMATION
Certified ISO 9001 : 2008
Please read instructions prior to use.
Save this manual for future reference

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TABLE OF CONENTS
THANK YOU…. .........................................................................................................................................................2
GENERAL SAFETY INFORMATION........................................................................................................................2
WARRANTY .............................................................................................................................................................. 3
1.0 –AVAILABLE THRUARM G2 PRODUCTS .......................................................................................................4
2.0 –EXPLODED VIEWS & PARTS LISTS..............................................................................................................5
2.1 CLUTCH SYSTEM..........................................................................................................................................5
2.1.1 CLUTCH SYSTEM EXPLODED VIEW ........................................................................................................5
2.1.2 CLUTCH SYSTEM PARTS LIST .................................................................................................................6
2.2 SOLID MOUNT SYSTEM................................................................................................................................7
2.2.1 SOLID MOUNT SYSTEM EXPLODED VIEW..............................................................................................7
3.0 –ORDERING INFORMATION ............................................................................................................................ 8
THANK YOU….
…for selecting a TOUGH GUN ThruArm™G2 Series Robotic MIG Gun from Tregaskiss. Manufacturing
operations demand extremely dependable robotic equipment. With this in mind, the TOUGH GUN™MIG Gun
was designed and engineered to be a reliable tool to support high production within a robotic cell. As the name
implies, the TOUGH GUN MIGGun is made from durable materials and components engineered to perform in a
rugged welding environment. Your TOUGH GUN MIG Gun is completely assembled and ready to weld, and has
undergone numerous quality checks to ensure high performance.
The instructions and illustrations in this technical guide make it easy for you to maintain your TOUGH GUN MIG
Gun. 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 1-855-MIGWELD (644-9353) or
fax [phone]. Our trained technicians are available between 8:00 a.m. and 5:00 p.m. EST and will answer
your application or repair questions.
Tregaskiss employees build TOUGH GUN MIG Guns for the world’s welding professionals. We are always
striving to improve our products and services, and would appreciate receiving your suggestions or comments.
Please contact us immediately if you experience any safety or operating problems.
GENERAL SAFETY INFORMATION
Before installation or operation of TOUGH GUN MIG Guns, please read the safety precautions listed below.
1. Do not touch live electrical parts. The following should be checked to prevent electrical shock:
Faulty or damaged equipment is repaired or replaced.
Equipment is off when not in use.
2. Ensure that all safety devices, guards, shields or barriers are properly in place and connected correctly before
allowing operation of the equipment.
3. CSA Standard W117.2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
ANSI Standard Z49.1 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the American
National Standards Institute, 1430 Broadway, New York, NY 10018.
CALIFORNIA PROPOSITION 65 WARNING

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This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the
State of California to cause birth defects and, in some cases, cancer.
This product contains chemicals, including lead, known to the State of California to cause cancer, and birth
defects or other reproductive harm. Wash hands after use.
(California Health & Safety Code Section 25249.5 at seq.)
WARRANTY
Product is warranted to be free from defects in material and workmanship for the period specified below after the
sale by an authorized Buyer. Should there be a defect please refer to our Return Merchandise Policy.
PRODUCT
WARRANTY PERIOD
TOUGH GUN™ MIG Guns and Components
180 days
TOUGH GUN Reamer
1 year
TOUGH GARD™Spatter Cleaner
1 year
TOUGH GUN Robotic Peripherals (Clutch, Sprayer, Wire Cutter, Mounting Arms)
1 year
Low-Stress Robotic Unicables (LSR Unicables)
2 years
Tregaskiss reserves the right to repair, replace or refund the purchase price of non-conforming product. Product
found not defective will be returned to the Buyer after notification by Customer Service.
Tregaskiss makes no other warranty of any kind, expressed or implied, including, but not limited to the warranties
of merchantability or fitness for any purpose. Tregaskiss shall not be liable under any circumstances to Buyer, or
to any person who shall purchase from Buyer, for damages of any kind, including, but not limited to any, direct,
indirect incidental or consequential damages or loss of production or loss of profits resulting from any cause
whatsoever, including, but not limited to, any delay, act, error or omission of Tregaskiss.
Genuine Tregaskiss parts must be used for safety and performance reasons or the warranty becomes invalid.
Warranty shall not apply if accident, abuse, or misuse damages a product, or if a product is modified in any way
except by authorized Tregaskiss personnel.

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1.0 –AVAILABLE THRUARM G2 PRODUCTS
TOUGH GUN ThruArm G2 is available for the following robot brands and models. Also available in the chart
below are part numbers to key components of the system. For additional parts, see Section 2.1.2 on page 5 and
Section 2.2.2 on page 7.
ROBOT BRAND
ROBOT MODEL
CLUTCH
SOLID MOUNT
LSR UNICABLE
CLUTCH
SOLID MOUNT
ABB
IRB1600ID
A58G2
A58G2S
58CA024
58SA024
ABB
IRB2600ID-15/1.85
A258G2
A258G2S
58CA028
58SA028
ABB
IRB2600ID-8/2.00
A258G2
A258G2S
58CA029
58SA029
KUKA
KR 5 ARC HW
K58G2
K58G2S
58CK023
58SK023
KUKA
KR 16 ARC HW
K258G2
K258G2S
58CK030
58SK030
KUKA
KR 16 L8 HW
K58G2
K58G2S
58CK027
58SK027
MOTOMAN
EA1400 XRC
58G2
58G2S
58CM016
58SM016
MOTOMAN
EA1900 XRC
58G2
58G2S
58CM017
58SM017
MOTOMAN
EA1400N
58G2
58G2S
58CM001
58SM001
MOTOMAN
EA1900N
58G2
58G2S
58CM002
58SM002
MOTOMAN
SSA2000
58G2
58G2S
58CM001
58SM001
MOTOMAN
MA1400
58G2
58G2S
58CM001
58SM001
MOTOMAN
VA1400
58G2
58G2S
58CM001
58SM001
OTC/DAIHEN
AII-B4
D58G2
D58G2S
58CD025
58SD025
OTC/DAIHEN
AII-B4L
D58G2
D58G2S
58CD026
58SD026
OTC/DAIHEN
AX-V4
D258G2
D258G2S
58CD003
58SD003
OTC/DAIHEN
AX-V4L
D258G2
D258G2S
58CD022
58SD022
PANASONIC*
TB-1800
P58G2
P58G2S
N/A
N/A
*An SG# is required for a Panasonic configuration.
Additional TOUGH GUN ThruArm G2 products will be released for other robot models as soon they become
available.
CLUTCH SYSTEM:
SOLID MOUNT SYSTEM:

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2.0 –EXPLODED VIEWS & PARTS LISTS
2.1 CLUTCH SYSTEM
2.1.1 CLUTCH SYSTEM EXPLODED VIEW

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2.1.2 CLUTCH SYSTEM PARTS LIST
PART #
DESCRIPTION
PART #
DESCRIPTION
1
401-X-XX
NOZZLE
15
AS-114-1
ABB INSULATING DISC
2
403-XX-XX
CONTACT TIP
AS-114-1
MOTOMAN INSULATING DISC
3
404-32
RETAINING HEAD
AS-116-1
OTC INSULATING DISC
4
59GI
G2 GOOSENECK INSULATOR
AS-114-6
KUKA INSULATING DISC
5
59G22
G2 GOOSENECK –22 DEG
AS-115-1
PANASONIC INSULATING DISC
59G22L
G2 GOOSENECK –22 DEG
16
AS-114-7
ABB TRANSITION FLANGE +
M6X1-16 LG. SHCS
59G22L1
G2 GOOSENECK –22 DEG
59G45
G2 GOOSENECK –45 DEG
AS-116-2
OTC TRANSITION FLANGE +
M5X0.8-10 LG. SHCS
59G45L
G2 GOOSENECK –45 DEG
59G45L1
G2 GOOSENECK –45 DEG
17
58CM001
MOTOMAN (MODEL EA1400N,
SSA2000, MA1400, VA1400)
LSR UNICABLE
59G45L2
G2 GOOSENECK –45 DEG
6
580-200
GOOSENECK CONNECTOR ASSY
7
580-4
SHUNT CABLE ASSEMBLY
58CM002
MOTOMAN (MODEL EA1900N)
LSR UNICABLE
N/A
M6X1.8mm LG. SBHCS
N/A
M6 WASHER
58CM016
MOTOMAN (MODEL EA1400
XRC) LSR UNICABLE
8
580-2-3
RUBBER WASHER
9
580-3
LOCK PIN AND SCREW
58CM017
MOTOMAN (MODEL EA1900
XRC) LSR UNICABLE
10
AS-714
CLUTCH ASSEMBLY
10A
AS-714-9
CLUTCH SWITCH ASSEMBLY
58CA024
ABB (MODEL IRB-1600ID) LSR
UNICABLE
10B
AS-714-7-3
HEX NUT
10C
AS-714-7-2
SWITCH BASE
58CA028
ABB (MODEL IRB-2600ID
15/1.85) LSR UNICABLE
10D
N/A
M3X0.5-6mm LG. SHCS
11
AS-114-3
COVER MOUNTING RING
58CA029
ABB (MODEL IRB-2600ID 8/2.00)
LSR UNICABLE
12
580-5A
OUTER COVER –AC KIT (INCLUDES
OUTER COVER, M4X0.7-8 LG.SBHCS,
M3X0.5-12 LG. SHCS)
58CD003
OTC (MODEL AX-V4) LSR
UNICABLE
13
AS-714-19
CONTROL CABLE
58CD022
OTC (MODEL AX-V4L) LSR
UNICABLE
14
580-19
MOTOMAN CABLE CONNECTOR KIT
(INCLUDES FLANGE CABLE
CONNECTOR, M4X0.7-12 LG. SHCS,
M4X0.7-25 LG, SHCS, M3X0.5-6 LG.
SBHCS)
58CD025
OTC (MODEL AII-B4) LSR
UNICABLE
58CD026
OTC (MODEL AII-B4L) LSR
UNICABLE
580-19
ABB CABLE CONNECTOR KIT
(INCLUDES FLANGE CABLE
CONNECTOR, M4X0.7-12 LG. SHCS,
M4X0.7-25 LG, SHCS, M3X0.5-6 LG.
SBHCS)
58CK023
KUKA (MODEL KR5 ARC HW)
LSR UNICABLE
58CK030
KUKA (MODEL KR 16 ARC HW)
LSR UNICABLE
58CK027
KUKA (MODEL KR 16 L8 HW)
580-19
OTC CABLE CONNECTOR KIT
(INCLUDES FLANGE CABLE
CONNECTOR, M4X0.7-12 LG. SHCS,
M4X0.7-25 LG, SHCS, M3X0.5-6 LG.
SBHCS)
LSR UNICABLE
580-20
KUKA CABLE CONNECTOR KIT
(INCLUDES FLANGE CABLE
CONNECTOR, M4X0.7-12 LG. SHCS,
M4X0.7-20 LG, SHCS, M3X0.5-6 LG.
SBHCS)
580-21
PANASONIC CABLE CONNECTOR
KIT (INCLUDES FLANGE CABLE
CONNECTOR, M4X0.7-12 LG. SHCS,
M5X0.8-25 LG, SHCS, M3X0.5-6 LG.
SBHCS)

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2.2 SOLID MOUNT SYSTEM
2.2.1 SOLID MOUNT SYSTEM EXPLODED VIEW

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2.2.2 SOLID MOUNT SYSTEM PARTS LIST
PART #
DESCRIPTION
PART #
DESCRIPTION
1
401-X-XX
NOZZLE
9
AS-114-1
ABB INSULATING DISC
2
403-XX-XX
CONTACT TIP
AS-114-1
MOTOMAN INSULATING DISC
3
404-32
RETAINING HEAD
AS-116-1
OTC INSULATING DISC
4
59GI
G2 GOOSENECK INSULATOR
AS-114-6
KUKA INSULATING DISC
5
59G22
G2 GOOSENECK –22 DEG
AS-115-1
PANASONIC INSULATING DISC
59G22L
G2 GOOSENECK –22 DEG
10
AS-114-7
ABB TRANSITION FLANGE +
M6X1-16 LG. SHCS
59G22L1
G2 GOOSENECK –22 DEG
59G35
G2 GOOSENECK –35 DEG
AS-116-2
OTC TRANSITION FLANGE +
M5X0.8-10 LG. SHCS
59G45
G2 GOOSENECK –45 DEG
59G45L
G2 GOOSENECK –45 DEG
11
58SM001
MOTOMAN (MODEL EA1400N,
SSA2000, MA1400, VA1400)
LSR UNICABLE
59G45L1
G2 GOOSENECK –45 DEG
59G45L2
G2 GOOSENECK –45 DEG
6
580-300-5
OUTER COVER –AC KIT (INCLUDES
OUTER COVER, M4X0.7-8 LG. SBHCS)
58SM002
MOTOMAN (MODEL EA1900N)
LSR UNICABLE
7
580-300
SOLID MOUNT CONNECTOR
58SM016
MOTOMAN (MODEL EA1400
XRC) LSR UNICABLE
8
580-19
MOTOMAN CABLE CONNECTOR KIT
(INCLUDES FLANGE CABLE
CONNECTOR, M4X0.7-12 LG. SHCS,
M4X0.7-25 LG, SHCS, M3X0.5-6 LG.
SBHCS)
58SM017
MOTOMAN (MODEL EA1900
XRC) LSR UNICABLE
58SA024
ABB (MODEL IRB-1600ID) LSR
UNICABLE
580-19
ABB CABLE CONNECTOR KIT (INCLUDES
FLANGE CABLE CONNECTOR,
M4X0.7-12 LG. SHCS, M4X0.7-25 LG,
SHCS, M3X0.5-6 LG. SBHCS)
58SA028
ABB (MODEL IRB-2600ID
15/1.85) LSR UNICABLE
58SA029
ABB (MODEL IRB-2600ID 8/2.00)
LSR UNICABLE
580-19
OTC CABLE CONNECTOR KIT (INCLUDES
FLANGE CABLE CONNECTOR,
M4X0.7-12 LG. SHCS, M4X0.7-25 LG,
SHCS, M3X0.5-6 LG. SBHCS)
58SD003
OTC (MODEL AX-V4) LSR
UNICABLE
58SD022
OTC (MODEL AX-V4L) LSR
UNICABLE
580-20
KUKA CABLE CONNECTOR KIT
(INCLUDES FLANGE CABLE
CONNECTOR, M4X0.7-12 LG. SHCS,
M4X0.7-20 LG, SHCS, M3X0.5-6 LG.
SBHCS)
58SD025
OTC (MODEL AII-B4) LSR
UNICABLE
58SD026
OTC (MODEL AII-B4L) LSR
UNICABLE
58SK023
KUKA (MODEL KR5 ARC HW)
580-21
PANASONIC CABLE CONNECTOR
KIT (INCLUDES FLANGE CABLE
CONNECTOR, M4X0.7-12 LG. SHCS,
M5X0.8-25 LG, SHCS, M3X0.5-6 LG.
SBHCS)
LSR UNICABLE
58SK030
KUKA (MODEL KR 16 ARC HW)
LSR UNICABLE
58SK027
KUKA (MODEL KR 16 L8 HW)
LSR UNICABLE
3.0 –ORDERING INFORMATION
To order replacement parts for your TOUGH GUN ThruArm G2 Series Robotic MIG Gun, please contact
Tregaskiss Customer Service via phone at 1-877-737-3111 (from Canada and USA) or [phone]
(international).
Distributed by:
04/12 REV D M080 .