Tregaskiss TOUGH GUN CA3 Series User manual

Robotic, Air-Cooled, Conventional MIG
(GMAW) Welding Gun
Tregaskiss.com/TechnicalSupport
1-855-MIGWELD (644-9353) (US&Canada)
[phone] (International)
August 2020 OM-CA3-1.9
TOUGH GUN®CA3 Robotic
Air-Cooled MIG Gun
OWNER'S MANUAL

Thank You for Choosing Tregaskiss
Thank you for selecting a Tregaskiss product. The MIG gun you have purchased has been carefully assembled and is ready to weld
and factory tested prior to shipment to ensure high performance. Before installing, compare the equipment received against the
invoice to verify that the shipment is complete and undamaged. It is the responsibility of the purchaser to file all claims of damage or
loss that may have occurred during transit with the carrier.
The owner’s manual contains general information, instructions and maintenance to help better maintain your MIG gun. Please read,
understand and follow all safety precautions.
While every precaution has been taken to assure the accuracy of this owner’s manual, Tregaskiss assumes no responsibility for
errors or omissions. Tregaskiss assumes no liability for damages resulting from the use of information contained herein. The
information presented in this owner’s manual is accurate to the best of our knowledge at the time of printing. Please reference
Tregaskiss.com for updated material.
For customer support and special applications, please call the Tregaskiss Customer Service Department at 1-855-MIGWELD (644-
9353) (US & Canada) or [phone] (International) or fax [phone]. Our trained Customer Service Team is available
between 8:00 a.m. and 5:30 p.m. EST, and will answer your product application or repair questions.
Tregaskiss manufactures premium robotic MIG (GMAW) welding guns, peripherals and consumables. For more information on other
premium Tregaskiss products, contact your local Tregaskiss distributor or visit us on the web at Tregaskiss.com.
Subject to Change – The information presented in this manual is accurate to the best of our knowledge at the time
of printing. Please visit Tregaskiss.com for the most up-to-date information.
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TABLE OF CONTENTS
DECLARATION OF CONFORMITY IV
SECTION 1 — SAFETY PRECAUTIONS — READ BEFORE USING 1
1-1 Symbol Usage 1
1-2 Arc Welding Hazards 1
1-3 Additional Symbols For Installation, Operation, And Maintenance 4
1-4 California Proposition 65 Warnings 6
1-5 EMF Information 6
1-6 Principal Safety Standards 6
1-7 Commercial Warranty 7
SECTION 2 — SPECIFICATIONS 8
2-1 System Components 8
SECTION 3 — INSTALLATION 9
3-1 Installing Gun to Robot 9
3-2 Installing Gun to Wire Feeder 11
3-3 Installing Clutch Cable to Gun 12
3-4 Connecting Wire Brake and/or Air Blast 12
SECTION 4 — REPLACEMENT 13
4-1 Changing Consumables 13
4-2 Changing the Neck 14
4-3 Changing TOUGH GUN I.C.E.™ Components 14
4-4 Changing the Liner 16
4-5 Changing the Power Pin or AutoLength™ Pin 17
4-6 Changing the Replaceable Unicable 18
4-7 Replacing the Wire Brake 19
SECTION 5 — TECHNICAL DATA 21
5-1 Wiring Diagram 21
5-2 Center of Mass Coordinates 22
SECTION 6 — PARTS LIST 23
SECTION 7 — TROUBLESHOOTING 24
7-1 Troubleshooting Table 24
ADDITIONAL SUPPORT MATERIALS 26
OM-CA3-1.9 iii

DECLARATION OF CONFORMITY
for European Community (CE marked) products
Tregaskiss, 2570 North Talbot Rd., Oldcastle, Ontario N0R 1L0 Canada declares that the product(s) identified in this
declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product Stock Number
Tregaskiss TOUGH GUN CA3 Series RA1XXXXXXXXX (Configurable #)
Council Directives:
l2006/95/EC Low Voltage
l2011/65/EU Restriction of the use of certain hazardous substances in electrical and
Electronic equipment standards:
lIEC 60974-7:2013 Arc welding equipment – Part 7: Torches
Signatory:
March 22, 2017
David A. Werba
MANAGER, PRODUCT DESIGN COMPLIANCE
Date of Declaration
iv OM-CA3-1.9

Protect yourself and others from injury – read,
follow, and save these important safety precautions
and operating instructions.
1-1 Symbol Usage
DANGER! – Indicates a hazardous situation which, if
not avoided, will result in death or serious injury.
The possible hazards are shown in the adjoining
symbols or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible haz-
ards are shown in the adjoining symbols or explained in
the text.
NOTICE – Indicates statements not related to personal injury.
– Indicates special instructions.
This group of symbols means Warning!Watch Out!
ELECTRICSHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary
actions to avoid the hazards.
1-2 Arc Welding Hazards
The symbols shown below are used throughout this
manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and
follow the related instructions to avoid the hazard. The safety
information given below is only a summary of the more complete
safety information found in the Principal Safety Standards
section. Read and follow all Safety Standards.
Only qualified persons should install, operate, maintain,
and repair this equipment. A qualified person is defined
as one who, by possession of a recognized degree,
certificate, or professional standing, or who by extensive
knowledge, training and experience, has successfully
demonstrated ability to solve or resolve problems relating to the
subject matter, the work, or the project and has received safety
training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children,
away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine internal
circuits are also live when power is on. In semi-
automatic or automatic wire welding, the wire, wire
reel, drive roll housing, and all metal parts
touching the welding wire are electrically live.
Incorrectly installed or improperly grounded equipment is a
hazard.
lDo not touch live electrical parts.
lWear dry, hole-free insulating gloves and body protection.
lInsulate yourself from work and ground using dry insulating
mats or covers big enough to prevent any physical contact
with the work or ground.
lDo not use ACweld output in damp, wet, or confined
spaces, or if there is a danger of falling.
lUse ACoutput ONLY if required for the welding process.
lIf AC output is required, use remote output control if present
on unit.
lAdditional safety precautions are required when any of the
following electrically hazardous conditions are present: in
damp locations or while wearing wet clothing; on metal
structures such as floors, gratings, or scaffolds; when in
cramped positions such as sitting, kneeling, or lying; or
when there is a high risk of unavoidable or accidental
contact with the workpiece or ground. For these conditions,
use the following equipment in order presented: 1) a semi-
automatic DCconstant voltage (wire) welder, 2) a DCmanual
(stick) welder, or 3) an ACwelder with reduced open-circuit
voltage. In most situations, use of a DC, constant voltage
wire welder is recommended. And, do not work alone!
lDisconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power
according to OSHA 29 CFR 1910.147 (see Principal Safety
Standards).
lProperly install, ground, and operate this equipments
according to its Owner's Manual and national, state, and
local codes.
lAlways verify the supply ground – check and be sure that
input power cord ground wire is properly connected to
ground terminal in disconnect box or that cord plug is
connected to a properly grounded receptacle outlet.
lWhen making input connections, attach proper grounding
conductor first – double-check connections.
lKeep cords dry, free of oil and grease, and protected from
hot metal and sparks.
lFrequently inspect input power cord and ground conductor
for damage or bare wiring – replace immediately if damaged
– bare wiring can kill.
OM-CA3-1.9 1
SECTION 1 — SAFETY PRECAUTIONS — READ BEFORE USING

lTurn off all equipment when not in use.
lDo not use worn, damaged, undersized, or repaired cables.
lDo not drape cables over your body.
lIf earth grounding of the workpiece is required, ground it
directly with a separate cable.
lDo not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.
lDo not touch electrode holders connected to two welding
machines at the same time since double open-circuit voltage
will be present.
lUse only well-maintained equipment. Repair or replace
damaged parts at once. Maintain unit according to Manual.
lWear a safety harness if working above floor level.
lKeep all panels and covers securely in place.
lClamp work cable with good metal-to-metal contact to
workpiece or worktable as near the weld as practical.
lInsulate work clamp when not connected to workpiece to
prevent contact with any metal object.
lDo not connect more than one electrode or work cable to
any single weld output terminal. Disconnect cable for
process not in use.
lUse GFCI protection when operating auxiliary equipment in
damp or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding
power sources AFTERremoval of input power.
lTurn off unit, disconnect input power, and discharge input
capacitors according to instructions in Manual before
touching any parts.
HOT PARTS can burn.
lDo not touch hot parts bare handed.
lAllow cooling period before working on
equipment.
lTo handle hot parts, use proper tools and/or wear heavy,
insulated welding gloves and clothing to prevent burns.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
lKeep your head out of the fumes. Do not breathe the fumes.
lVentilate the work area and/or use local forced ventilation at
the arc to remove welding fumes and gases. The
recommended way to determine adequate ventilation is to
sample for the composition and quantity of fumes and
gases to which personnel are exposed.
lIf ventilation is poor, wear an approved air-supplied
respirator.
lRead and understand the Safety Data Sheets (SDSs) and the
manufacturer's instructions for adhesives, coatings,
cleaners, consumables, coolants, degreasers, fluxes, and
metals.
lWork in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained
watch-person nearby. Welding fumes and gases can
displace air and lower the oxygen level causing injury or
death. Be sure the breathing air is safe.
lDo not weld in locations near degreasing, cleaning, or
spraying operations. The heat and the rays of the arc can
react with vapors to form highly toxic and irritating gases.
lDo not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from
the weld area, the area is well ventilated, and while wearing
an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if
welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
lWear an approved welding helmet fitted with a proper shade
of filter lenses to protect your face and eyes from arc rays
and sparks when welding or watching (see ANSI Z49.1 and
Z87.1 listed in Principal Safety Standards).
lWear approved safety glasses with side shields under your
helmet.
lUse protective screens or barriers to protect others from
flash, glare and sparks; warn others not to watch the arc.
lWear body protection made from durable, flame-resistant
material (leather, heavy cotton, wool). Body protection
includes oil-free clothing such as leather gloves, heavy shirt,
cuffless trousers, high shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up.
Sparks can fly off from the welding arc. The flying
sparks, hot workpiece, and hot equipment can
cause fires and burns. Accidental contact of
electrode to metal objects can cause sparks, explosion,
overheating, or fire. Check and be sure the area is safe before
doing any welding.
lRemove all flammables within 35 ft (10.7 m) of the welding
arc. If this is not possible, tightly cover them with approved
covers.
lDo not weld where flying sparks can strike flammable
material.
lProtect yourself and others from flying sparks and hot metal.
2 OM-CA3-1.9

lBe alert that welding sparks and hot materials from welding
can easily go through small cracks and openings to adjacent
areas.
lWatch for fire, and keep a fire extinguisher nearby.
lBe aware that welding on a ceiling, floor, bulkhead, or
partition can cause fire on the hidden side.
lDo not cut or weld on tire rims or wheels. Tires can explode
if heated. Repaired rims and wheels can fail. See OSHA 29
CFR 1910.177 listed in Principal Safety Standards.
lDo not weld on containers that have held combustibles, or
on closed containers such as tanks, drums, or pipes unless
they are properly prepared according to AWS F4.1 and AWS
A6.0 (see Principal Safety Standards).
lDo not weld where the atmosphere can contain flammable
dust, has, or liquid vapors (such as gasoline).
lConnect work cable to the work as close to the welding area
as practical to prevent welding current from traveling long,
possibly unknown paths and causing electric shock, sparks,
and fire hazards.
lDo not use welder to thaw frozen pipes.
lRemove stick electrode from holder or cut off welding wire
at contact tip when not in use.
lWear body protection made from durable, flame-resistant
material (leather, heavy cotton, wool). Body protection
includes oil-free clothing such as leather gloves, heavy shirt,
cuffless trousers, high shoes, and a cap.
lRemove any combustibles, such as a butane lighter or
matches, from your person before doing any welding.
lAfter completion of work, inspect area to ensure it is free of
sparks, glowing embers, and flames.
lUse only correct fuses or circuit breakers. Do not oversize or
bypass them.
lFollow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA
51B for hot work and have a fire watcher and extinguisher
nearby.
lRead and understand the Safety Data Sheets (SDSs) and the
manufacturer's instructions for adhesives, coatings,
cleaners, consumables, coolants, degreasers, fluxes, and
metals.
FLYING METAL or DIRT can injure eyes.
lWelding, chipping, wire brushing, and
grinding cause sparks and flying metal. As
welds cool, they can throw off slag.
lWear approved safety glasses with side shields even under
your welding helmet.
BUILDUP OF GAS can injure or kill.
lShut off compressed gas supply when not in
use.
lAlways ventilate confined spaces or use approved air-
supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF) can
affect Implanted Medical Devices.
lWearers of Pacemakers and other Implanted
Medical Devices should keep away.
lImplanted Medical Device wearers should consult their
doctor and the device manufacturer before going near arc
welding, spot welding, gouging, plasma arc cutting, or
induction heating operations.
NOISEcan damage hearing.
Noise from some processes or equipment can
damage hearing.
lWear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the
welding process, be sure to treat them carefully.
lProtect compressed gas cylinders from excessive heat,
mechanical shocks, physical damage, slag, open flames,
sparks, and arcs.
lInstall cylinders in an upright position by securing to a
stationary support or cylinder rack to prevent falling or
tipping.
lKeep cylinders away from any welding or other electrical
circuits.
lNever drape a welding torch over a gas cylinder.
lNever allow a welding electrode to touch any cylinder.
lNever weld on a pressurized cylinder – explosion will result.
lUse only correct compressed gas cylinders, regulators,
hoses, and fittings designed for the specific application;
maintain them and associated parts in good condition.
lTurn face away from valve outlet when opening cylinder
valve. Do not stand in front of or behind the regulator when
opening the valve.
lKeep protective cap in place over valve except when cylinder
is in use or connected for use.
lUse the proper equipment, correct procedures, and
sufficient number of persons to lift, move, and transport
cylinders.
lRead and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association
(CGA) publication P-1 listed in Principal Safety Standards.
OM-CA3-1.9 3

1-3 Additional Symbols For Installation,
Operation, And Maintenance
FIRE OR EXPLOSION hazard.
lDo not install or place unit on, over, or near
combustible surfaces.
lDo not install unit near flammables.
lDo not overload building wiring – be sure power supply
system is properly sized, rated, and protected to handle this
unit.
FALLING EQUIPMENT can injure.
lUse lifting eye to lift unit only, NOTrunning
gear, gas cylinders, or any other accessories.
lUse correct procedures and equipment of
adequate capacity to lift and support unit.
lIf using fork lifts to move unit, be sure forks are long
enough to extend beyond the opposite side of unit.
lKeep equipment (cables and cords)away from moving
vehicles when working from an aerial location.
lFollow the guidelines in the Applications Manual for the
Revised NIOSH Lifting Equation (Publication No. 94-
110)when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING.
lAllow cooling period; follow rated duty cycle.
lReduce current or reduce duty cycle before
starting to weld again.
lDo not block or filter airflow to unit.
FLYING SPARKS can injure.
lWear a face shield to protect eyes and face.
lShape tungsten electrode only on grinder
with proper guards in a safe location wearing
proper face, hand, and body protection.
lSparks can cause fires – keep flammables away.
STATIC (ESD)can damage PCboards.
lPut on grounded wrist strap BEFORE
handling boards or parts.
lUse proper static-proof bags and boxes to store, move, or
ship PCboards.
MOVING PARTS can injure.
lKeep away from moving parts.
lKeep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
lDo not press gun trigger until instructed to
do so.
lDo not point gun toward any part of the body, other people,
or any metal when threading welding wire.
BATTERY EXPLOSION can injure.
lDo not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
MOVING PARTS can injure.
lKeep away from moving parts such as fans.
lKeep all doors, panels, covers, and guards
closed and securely in place.
lHave only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
lReinstall doors, panels, covers, or guards when maintenance
is finished and before reconnecting input power.
COMPRESSED AIR can injure or kill.
lBefore working on compressed air system,
turn off and lockout/tagout unit, release
pressure, and be sure air pressure cannot be
accidentally applied.
lRelieve pressure before disconnecting or
connecting air lines.
lCheck compressed air system components and all
connections and hoses for damage, leaks, and wear before
operating unit.
lDo not direct air stream toward self or others.
lWear protective equipment such as safety glasses, hearing
protection, leather gloves, heavy shirt and trousers, high
shoes, and a cap when working on compressed air system.
lUse soapy water or an ultrasonic detector to search for leaks
– never use bare hands. Do not use equipment if leaks are
found.
lReinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
lIf ANY air is injected into the skin or body, seek medical help
immediately.
4 OM-CA3-1.9

READ INSTRUCTIONS.
lRead and follow all labels and the Owner's
Manual carefully before installing, operating,
or servicing unit. Read the safety information
at the beginning of the Manual and in each section.
lUse only genuine replacement parts from the manufacturer.
lPerform installation, maintenance, and service according to
the Owner's Manuals, industry standards, and national,
state, and local codes.
H.F. RADIATION can cause interference.
lHigh-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
lHave only qualified persons familiar with electronic
equipment perform this installation.
lThe user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
lIf notified by the FCCabout interference, stop using the
equipment at once.
lHave the installation regularly checked and maintained.
lKeep high-frequency source doors and panels tightly shut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
ARC WELDING can cause interference.
lElectromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
lBe sure all equipment in the welding area is
electromagnetically compatible.
lTo reduce possible interference, keep weld cables as short
as possible, close together, and down low, such as on the
floor.
lLocate welding operation 100 meters from any sensitive
electronic equipment.
lBe sure the welding machine is installed and grounded
according to the Manual.
lIf interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-CA3-1.9 5

1-4 California Proposition 65 Warnings
WARNING: This product can expose you to chemicals including
lead, which are known to the state of California to cause cancer
and birth defects or other reproductive harm.
For more information, go to www.P65Warnings.ca.gov.
1-5 EMF Information
Electric current flowing through any conductor causes localized
electric and magnetic fields (EMF). The current from arc welding
(and allied processes including spot welding, gouging, plasma arc
cutting, and induction heating operations) creates an EMF field
around the welding circuit. EMF fields may interfere with some
medical implants, e.g. Pacemakers. Protective measures for
persons wearing medical implants have to be taken. For example,
restrict access for passersby or conduct individual risk assessment
for welders. All welders should use the following procedures in
order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or
using a cable cover.
2. Do not place your body between welding cables. Arrange
cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld while carrying the welding power source wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and
the device manufacturer before performing or going near arc
welding, spot welding, gouging, plasma arc cutting, or induction
heating operations. If cleared by your doctor, then following the
above procedures is recommended.
1-6 Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard
Z49.1, is available as a free download from the American Welding
Society at http://www.aws.org or purchased from Global
Engineering Documents (phone: [phone], website:
www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for
Welding and Cutting, American Welding Society Standard AWS
F4.1, from Global Engineering Documents (phone: [phone]-
5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers That Have Held
Combustibles, American Welding Society Standard A6.0, from
Global Engineering Documents (phone: [phone],
website:www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Quincy, MA 02269 (phone: [phone]-
3555, website: www.nfpa.org and www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-
1, from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: [phone], website:
www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales,
5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
1-800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National
Standards Institute, 25 West 43rd Street, New York, NY 10036
(phone: [phone], website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other
Hot Work, NFPA Standard 51B, from National Fire Protection As-
sociation, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General
Industry, Title 29, Code of Federal Regulations (CFR), Part 1910,
Subpart Q, and Part 1926, Subpart J, from U.S. Government
Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburg, PA 15250-7954 (phone: [phone])
(there are 10 OSHA Regional Offices – phone for Region 5,
Chicago, is 312-353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The
National Institute for Occupational Safety and Health (NIOSH),
1600 Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone]-
4636, website:www.cdc.gov/NIOSH).
6 OM-CA3-1.9

1-7 Commercial 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.
lRobotic MIG Guns and Components: 1 year
lAutomatic MIG Guns 1 year
lReamer: 1 year
lReamer when factory-equipped with Lubricator: 2 years
lReamer when factory-equipped with Lubricator and used only
with Tregaskiss®TOUGH GARD®Anti-Spatter Liquid: 3 years
lRobotic Peripherals (Clutch, Sprayer, Wire Cutter, Mounting
Arms): 1 year
lLow-Stress Robotic (LSR) Unicables: 2 years
Through-Arm Robot Articulation Limits for LSRUnicable
Axis Articulation Limit
5 +/- 90°
4+6 +/- 270°
NOTE:Any articulation beyond these limits is considered abuse of
the cable and will accelerate LSR Unicable wear.
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 of a
product, or if a product is modified in any way except by
authorized Tregaskiss personnel. Use as directed.
OM-CA3-1.9 7

SECTION 2 — SPECIFICATIONS
2-1 System Components
Robotic MIGGun for GMAW Welding
Duty Cycle Rating: 100%: 385 amps with Mixed Gases
For complete parts list, please see Section 6 — Parts List on page 23.
8 OM-CA3-1.9

SECTION 3 — INSTALLATION
3-1 Installing Gun to Robot
A. Installing Disc to Robot
1. Bring robot to service position.
2. Align the dowel in the wrist with the dowel hole in the insulating disc
and fully seat the disc on the robot wrist.
NOTE:Dowel not provided.
3. Install the disc to the robot with fasteners using the supplied
tightening pattern (see Figure 3-A). IMPORTANT: Do not use the
fasteners to pull the face of the insulating disc to the face of the robot
wrist, as damage will occur.
NOTE:Fasteners are not provided since the size varies by robot.
4. Torque to 45 in-lbs (5 Nm).
Figure 3-A Figure 3-B
B. Installing Mounting Arm to Disc
1. Align dowel on mounting arm with the dowel hole in
insulating disc and seat it by hand.
2. Install the mounting arm to the disc on the robot with 6 mm
SHCS (provided) using the supplied tightening pattern (see
Figure 3-A). IMPORTANT: Do not use fasteners to pull the
mounting arm to the face of the insulating disc, as damage
will occur.
3. Torque to 45 in-lbs (5 Nm).
Figure 3-C
OM-CA3-1.9 9

C. Installing Clutch or Solid Mount Clamp to
Mounting Arm
1. Remove the fastener and the locking pin from the mounting
arm.
2. Insert the clutch / solid mount stud into the mounting arm on
the robot until it bottoms out.
3. Once the stud is fully seated in the mounting arm, reinstall
the fastener and locking pin. IMPORTANT: The flat feature of
the locking pin must interface with the flat feature on the
clutch or solid mount stud to achieve proper locking and
orientation as shown below in Figure 3-G, Figure 3-H and
Figure 3-I (solid mount shown).
4. Insert the 6 mm SHCS on the opposite side of the arm and
screw it into the locking pin.
5. Torque 6 mm SHCS to 60 in-lbs (7 Nm).
Figure 3-D Figure 3-E
Solid Mount Shown Clutch Mount Shown
Figure 3-F
For Solid Mount Models Only:
6. Insert 5 mm SHCS through solid mount clamp assembly and screw into the mounting arm as shown in Figure 3-H.
7. Torque 5 mm SHCS to 45 in-lbs (5 Nm).
Figure 3-G Figure 3-H Figure 3-I
10 OM-CA3-1.9

D. Installing Gun to Gun Mount
1. Loosen clamp screws in mounting clamp.
2. Fully insert gun into the clamp, aligning the key on the gun
with the keyway on the clamp.
3. Tighten the 6 mm SHCS using a 5 mm Allen wrench to secure
the gun in place.
Figure 3-J
3-2 Installing Gun to Wire Feeder
1. Plug gun into feeder and lock in place (see your feeder
manual for details). Connect external gas if required.
2. OPTIONAL: Connect voltage sense lead (see your feeder
manual for details) on the replaceable unicable with the male
connector on the power jumper cable.
3. FOR CLUTCH INSTALLATIONS: Connect clutch cable with
either the provided connections (cut and splice required) or
one of our jumper cables (sold separately and available only
for select robot models).
NOTE:Be sure to align any features to allow for proper
installation.
Figure 3-K
OM-CA3-1.9 11

3-3 Installing Clutch Cable to Gun
1. Connect cable supplied with clutch mount to the receptacle on the
gun body.
2. Tighten securely by hand.
Figure 3-L
3-4 Connecting Wire Brake and/or Air Blast
A. Wire Brake
1. Route wire brake air line to designated control valve in your facility (not provided).
2. 40-60 psi air supply required for proper operation.
B. Air Blast
1. Route air blast air line to designated control valve in your facility (not provided).
2. 80-100 psi air supply required for proper operation.
12 OM-CA3-1.9

SECTION 4 — REPLACEMENT
4-1 Changing Consumables
Figure 4-A
IMPORTANT NOTES:
lNeck insulator MUST be in place before welding to properly insulate gun.
lCheck all parts to ensure that connections are tight before welding.
lThe retaining head / diffuser MUST be tightened with a 5/8” (16 mm) wrench to prevent the contact tip from overheating.
lDO NOT use pliers to remove or tighten the retaining head / diffuser or scoring may result.
A. Changing the Nozzle
1. Pull slip-on nozzles off with a twisting motion.
2. When installing the nozzle, ensure that it is fully seated.
B. Changing the Contact Tip
1. Thread the contact tip into the retaining head / diffuser.
2. Torque to 30 in-lbs (3.5 Nm).
3. The Tregaskiss Tip Tool (part #450-18 for TOUGH LOCK
heavy duty tips, or part # T-ALTOOL for AccuLock tips) or a
pair of weld pliers are the optimal tools for contact tip
installation.
C. Changing the Retaining Head / Diffuser
1. Thread the retaining head / diffuser onto neck with a 5/8” (16
mm) wrench.
2. Torque to 80 in-lbs (9 Nm).
IMPORTANT: DO NOT use pliers to remove or tighten the
heavy duty retaining head / diffuser or scoring may result.
D. Changing the Neck Insulator
1. Remove front-end consumables.
2. The neck insulator is pressed onto the neck by hand with the
aluminum side towards the neck and the black insulation
towards the nozzle.
3. Reinstall front-end consumables.
OM-CA3-1.9 13

4-2 Changing the Neck
1. Remove front-end consumables (see section 4-1 Changing
Consumables on page 13).
2. Remove liner (see section 4-4 Changing the Liner on page
16).
3. Using a 5 mm Allen wrench, loosen screw 1/4 turn to remove
the neck.
4. Pull neck directly out of the connector housing.
5. Insert replacement neck into the connector housing, ensuring
the key on the neck is lined up with the keyway on the gun.
6. Tighten screw to 60 in-lbs (7 Nm) using a 5 mm Allen wrench.
7. Install and trim liner if required.
8. Reinstall consumables.
Figure 4-B
4-3 Changing TOUGH GUN I.C.E.™ Components
1. Remove front-end consumables (see section 4-1 Changing
Consumables on page 13).
2. Remove screw and remove water line bracket.
3. Disconnect both water lines at quick connect couplers.
Figure 4-C
14 OM-CA3-1.9

4. Loosen neck bolt (4-2 Changing the Neck on page 14).
5. Remove TOUGH GUN I.C.E. components / neck assembly.
NOTE: If existing clamping device on arm has 2 bolts, remove
only the front bolt and snug the rear bolt.
Figure 4-D
6. Reinstall TOUGH GUN I.C.E. components / neck assembly.
7. Tighten neck bolt to torque specification of 60 in-lbs (7 Nm).
Figure 4-E
8. Connect water lines with quick connect couplers.
9. Fasten water line bracket with bolt (bracket and bolt included
with TOUGH GUN I.C.E. assembly).
NOTE: Ensure both bolts are tightened on the mounting
clamp.
10. Reinstall front-end consumables.
Figure 4-F
OM-CA3-1.9 15

4-4 Changing the Liner
A. Changing QUICK LOAD®Liner
NOTE: Ensure power supply is off before proceeding.
1. Remove consumables (nozzle, contact tip and retaining head /
diffuser) (see section 4-1 Changing Consumables on page
13).
Figure 4-G
2. Remove existing QUICK LOAD Liner by pulling it out from the
neck.
3. Insert the new QUICK LOAD Liner through the neck using the
welding wire as a guide (short strokes will prevent kinking).
4. Once liner stops feeding, give it an extra push until it bottoms
out in the liner retainer in the power pin to ensure it is
inserted completely.
Figure 4-H
5. Push liner back into gun and hold in place. Using liner gauge,
trim liner to a 1/2" stick-out for gun lengths 6 feet and shorter,
or 3/4” stick-out for gun lengths longer than 6 feet. HELPFUL
HINT: Before cutting the liner with wire inside, mark the liner
using the gauge and then pull the liner out beyond the end of
the welding wire; then cut the liner and push it back into place
securely. This will help with feeding the wire through the
contact tip afterward.
6. Remove any burr that may obstruct wire feed.
7. Reinstall consumables onto neck.
Figure 4-I
16 OM-CA3-1.9