Tregaskiss TOUGH GUN TT3 Reamer User manual

OM-TT3-1.1 April 2017
Processes
MIG (GMAW) Welding
Description
Robotic Nozzle Cleaning Station,
MIG (GMAW) Welding Peripheral
TOUGH GUN™
TT3 Reamer
For Analog and Tandem Models
OWNER’S MANUAL
Tregaskiss
2570 North Talbot Road
Windsor, Ontario N0R 1L0
Canada
Phone: 1-855-MIGWELD (644-9353) (US & Canada)
[phone] (International)
Fax: [phone]
For more information, visit us at Tregaskiss.com
For Serial#
TT-22000 and above

Thank You for Choosing Tregaskiss
Thank you for selecting a Tregaskiss product. The TOUGH GUN™ TT3 Reamer you have purchased has been designed and engineered
to be a reliable tool to support high production within a robotic cell. The TOUGH GUN TT3 Reamer is made from durable materials and
components engineered to perform in a demanding robotic welding environment. 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 le 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 TOUGH GUN TT3
Reamer. 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 email [email protected]
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.
For additional support materials such as spec sheets, troubleshooting information, how-to guides
and videos, animations, online congurators and much more, please visit Tregaskiss.com.
Scan this QR Code with your smart phone for immediate access to
Tregaskiss.com/TechnicalSupport
2

TABLE OF CONTENTS
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.
3
SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING ..................................................................... 4
1-1 Additional Safety Warnings for Installation, Operation and Maintenance ....................................................................................4
1-2 California Proposition 65 Warnings.............................................................................................................................................4
1-3 Principal Safety Standards ..........................................................................................................................................................4
1-4 Commercial Warranty..................................................................................................................................................................5
SECTION 2 – SPECIFICATIONS.......................................................................................................... 6
2-1 System Components ...................................................................................................................................................................6
SECTION 3 – INSTALLATION ........................................................................................................... 7
3-1 Installing TOUGH GUN™ TT3 Reamer .........................................................................................................................................7
3-2 Installing TOUGH GUN Wire Cutter..............................................................................................................................................8
3-3 Installing Nozzle Detect................................................................................................................................................................9
SECTION 4 – SETUP ...................................................................................................................... 9
4-1 Air Motor Lubricator....................................................................................................................................................................9
4-2 Accessing Electrical and Pneumatic Controls..............................................................................................................................9
4-3 Wiring Interface Connections ....................................................................................................................................................10
4-4 Inversing Circuit Board Logic ....................................................................................................................................................10
4-5 Setting Up V-Block ....................................................................................................................................................................11
4-6 Setting Nozzle Heights for Cutter Blade Insertion......................................................................................................................11
4-7 Nozzle Detect Setup...................................................................................................................................................................12
SECTION 5 – OPERATION .............................................................................................................. 14
5-1 Understanding L.E.D. Indicators................................................................................................................................................14
5-2 Programming Events Sequence ................................................................................................................................................14
5-3 Manual Operation ......................................................................................................................................................................15
5-4 Adjusting Flow Control Valves...................................................................................................................................................16
SECTION 6 – MAINTENANCE .......................................................................................................... 16
6-1 Replacing the Spindle Limit Switch ...........................................................................................................................................16
6-2 Replacing the Clamp Limit Switch.............................................................................................................................................16
6-3 Replacing the Air Motor.............................................................................................................................................................17
6-4 Replacing the Circuit Board.......................................................................................................................................................17
6-5 Replacing the Cutter Blade ........................................................................................................................................................17
6-6 Replacing the Drive Belt ............................................................................................................................................................18
6-7 Replacing the Solenoid Valves...................................................................................................................................................18
6-8 Scheduled Maintenance.............................................................................................................................................................19
SECTION 7 – TECHNICAL DATA ....................................................................................................... 20
7-1 Pneumatic Diagrams .................................................................................................................................................................20
7-2 Electrical Schematic ..................................................................................................................................................................21
SECTION 8 – PARTS LIST.............................................................................................................. 22
8-1 TOUGH GUN TT3 Reamer..........................................................................................................................................................22
8-2 Tandem SD Reamer – Top Assembly ........................................................................................................................................23
8-3 Tandem HD Reamer – Top Assembly........................................................................................................................................23
8-4 TOUGH GUN Sprayer Assembly ................................................................................................................................................24
8-5 TOUGH GUN Wire Cutter...........................................................................................................................................................25
SECTION 9 – TROUBLESHOOTING.................................................................................................... 26
9-1 TOUGH GUN TT3 Reamer..........................................................................................................................................................26
9-2 Lubricator..................................................................................................................................................................................27
9-3 Filter/Regulator..........................................................................................................................................................................27
9-4 Nozzle Detect.............................................................................................................................................................................28

4
SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING
1-1 Additional Safety Warnings for
Installation, Operation and Maintenance
READ INSTRUCTIONS
• Read and follow all labels and the
Owner’s Manual carefully before
installing, operating, or servicing the
unit. Read the safety information at
the beginning of the manual and each
section.
• Use only genuine replacement parts from the manufacturer.
• Perform maintenance and service according to the Owner’s
Manual, industry standards and national, state/provincial and
local codes.
MOVING PARTS can injure
• Keep away from moving parts such as
fans and blades.
• Keep all doors, panels, covers and
guards closed and securely in place.
• Have only qualied persons remove
doors, panels, covers or guards for
maintenance and troubleshooting as
necessary.
• Reinstall doors, panels, covers or
guards when maintenance is nished
and before reconnecting input power.
• Keep away from pinch points.
FIRE OR EXPLOSION hazard
• Do not install or place unit on, over or
near combustible surfaces.
• Do not install unit near ammables.
• Do not overload building wiring – be
sure power supply system is properly
sized, rated and protected to handle
this unit.
HOT PARTS can burn
• Do not touch hot parts barehanded.
• Allow cooling period before working
on equipment.
• To handle hot parts, use proper tools
and/or wear heavy, insulated welding
gloves and clothing to prevent burns.
NOISE can damage hearing
• Noise from some processes or
equipment can damage hearing.
• Wear approved ear protection if noise
level is high.
1-2 California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause birth
defects and in some cases, cancer. (California Health & Safety
Code Section 25249.5 et seq.)
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.
1-3 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 www.aws.org or purchased 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).
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: [phone], 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).
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 Ofce, Superintendent of Documents, P.O. Box 371954,
Pittsburg, PA 15250-7954 (phone: [phone]) (there are
10 OSHA Regional Ofces – 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 Road, Atlanta, GA 30333 (phone: [phone],
website: www.cdc.gov/NIOSH).

5
1-4 Commercial Warranty
Seller’s Products specied below shall be free from defects
in material and workmanship for the period specied below
from the delivery to an authorized Buyer provided the
Products are operated, maintained, and repaired properly
and pursuant to Product documentation provided by the
manufacturer. The Warranty against defects does not apply
to: (1) consumable components or ordinary wear items; or
(2) use of the Products with equipment, components or parts
not specied or supplied by Seller or contemplated under the
Product documentation.
Should there be a defect please refer to our Return Merchandise
Policy.
Seller reserves the right to inspect any allegedly defective
Product for the alleged deciencies and that the deciencies
were not caused by accident, misuse, neglect, improper
installment, unauthorized alteration or repair or improper
testing.
In the event of a defect covered by the above warranty, Seller
will, at its option, repair, replace or refund the purchase price
of the defective Product. Product found not defective will be
returned to Buyer at Buyer’s cost after notication by Seller’s
Customer Service Department. Any TOUGH GUN Reamer
component part replaced or repaired pursuant to the warranty
herein shall be further warranted for a period of six months
after delivery of the replacement.
EXCEPT AS SET FORTH ABOVE, SELLER MAKES NO
WARRANTY OF ANY KIND, EXPRESS OR IMPLIED,
INCLUDING, BUT NOT LIMITED TO, THE WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR ANY
PURPOSE. SELLER SHALL NOT BE LIABLE UNDER ANY
CIRCUMSTANCES FOR DAMAGES OF ANY KIND. INCLUDING,
BUT NOT LIMITED TO ANY, DIRECT, INDIRECT, SPECIAL,
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 SELLER.
Genuine Bernard and Tregaskiss parts must be used for
safety and performance reasons or the warranty above shall
not be valid. Warranty shall not apply if accident, abuse, or
misuse damages a product, or if a product is modied in any
way except properly and by authorized Seller personnel.
Product Warranty
Tregaskiss TOUGH GUN™ Robotic MIG
Guns and Components
Tregakiss TOUGH GUN™ Automatic
MIG Guns
1 year
1 year
Tregaskiss TOUGH GUN Reamer
• When factory-equipped with
Lubricator
• When both (i) factory-equipped
with Lubricator and (ii) used only
with Tregaskiss™ TOUGH GARD™
Anti-Spatter Liquid
1 year
2 years when factory
equipped with Lubricator
3 years when both (i)
and (ii)
Tregaskiss TOUGH GUN Robotic
Peripherals (Clutch, Sprayer, Wire
Cutter, Arms)
1 year
Tregaskiss Low-Stress Robotic
Unicables (LSR Unicables)
2 years

6
SECTION 2 – SPECIFICATIONS
2-1 System Components
Robotic Peripheral for GMAW Welding
Rated Voltage: 24 VDC
Operating Voltage: ±10% of rated voltage
Power Consumption: Max. wattage in operation 5.3 W
Air Requirements (minimum):
80 to 100 psi (5.5 to 7.0 bar) at 16 CFM (450 LPM)
Air Motor (at min. air requirement):
Stall torque at 80 psi (5.5 bar) = 83 in.-lbs. (9.4 Nm)
For a complete parts list, please see SECTION 8 - PARTS LIST page 22

7
SECTION 3 – INSTALLATION
3-1 Installing TOUGH GUN™ TT3 Reamer
Mounting Hole Locations and Footprint
7.13”
[181 mm]
2.49”
[63.2 mm]
0.50” [12.7 mm]
Front of Reamer
11.00”
[279.4 mm]
Dowel 4.00”
[101.6mm]
0.63” [15.9mm]
11.00”
[279.4 mm]
12.00”
[304.8 mm]
0.44”
[11.1 mm]
5.25”
[133.4 mm]
2x ø .382” [9.7 mm]
4x ø .41” [10.4 mm]
4x ø .41 [10.3 mm]
2.63”
[66.7 mm]
1.50” [38.1mm]
Dimensions
11.97”
[304 mm]
13.24”
[336.2 mm]
22.917”
[582.1 mm]
Tandem
23.31”
[591.1 mm]
WARNING: Ensure air and power supply is off and disconnected before proceeding.
Please follow your facility’s lockout/tagout procedures.
A. To Mount TOUGH GUN TT3 Reamer
The TOUGH GUN Reamer should be installed within the weld cell where it is clear of all tooling and convenient for the robot to
access the unit.
• Afx the reamer base to a sturdy platform using four (4) bolts (provided).
NOTE: The Reamer can be mounted
overhead or on an angle as long as
debris falls away from the clamp
housing.
B. To Connect Air Supply:
NOTE: Push the HOME POSITION
button before connecting air line.
1. Use only dry, ltered,
lubricated air.
IMPORTANT: Requirements –
80-100 psi at 16 CFM
(5.5-7.0 bar at 450 LPM) at the
Reamer during operation.
2. Use an air supply line with
an inside diameter of 3/8”.
Connect to a 1/4” NPT elbow
located on the side of the
TOUGH GUN Reamer.

8
WARNING: Ensure air and power supply is off and disconnected before proceeding.
Please follow your facility’s lockout / tagout procedures.
A. To Mount Wire Cutter:
1. The wire cutter should be installed within the weld cell where it is
clear of all tooling and convenient for the robot to access the unit.
The base plate has been designed for mounting on top of the TOUGH
GUN Reamer. Be sure to consider movable xtures and the connes
of the robot.
2. Attach the wire cutter base to the top of the Reamer, or other sturdy
platform using three (3) 10-24 x 3/4” bolts (for Reamer Serial
numbers up to 11,299) or three (3) M5 x 0.8 x 25 mm long Flat Head
Cap Screw (FHCS) (for Reamer Serial numbers 11,300 and up) in
the holes provided.
B. To Connect Air Supply:
1. Use only ltered lubricated air.
Use an air supply line with an inside diameter of 1/4” and connect to 1/8” female NPT inlet located on the side of the valve.
3-2 Installing TOUGH GUN Wire Cutter
4.75”
4.25”
3 x M5x0.8x25MM FHCS
Connect Air Supply

9
4-1 Air Motor Lubricator
SECTION 4 – SETUP
The TOUGH GUN Reamer must be operated with lubricated air using either the air motor lubricator option or a suitable alternative
system installed by the customer. The lubricator should be set to feed one drop of oil for every 50-75 CFM of air going through
the motor (approximately 1 drop every 5-10 cycles or 1 drop per minute of operation). The lubricant can be air motor oil or light
grade hydraulic oil with a viscosity rating of 150 VC 15-20 (SAE 5W).
4-2 Accessing Electrical and Pneumatic Controls
WARNING: Ensure power supply is off and disconnected before proceeding.
Please follow your facility’s lockout / tagout procedures.
To access the electronic circuit board for installation or service for the TOUGH GUN Reamer:
1. Remove reservoir (if equipped) and loosen the 2 Button Head Cap Screw (BHCS) using a 3 mm Allen wrench to open the
hinged rear access door.
2. The rear access door can be completely removed if accessibility is an issue. Using a 3 mm Allen wrench, remove the 3 BHCS
which fasten the hinge to the frame.
3-3 Installing Nozzle Detect
WARNING: Ensure air and power supply is off and disconnected before proceeding.
Please follow your facility’s lockout / tagout procedures.
This nozzle detect sensor has a sensing range of 5mm and can detect any metallic part that comes within this sensing range.
The accuracy is ± ≤2% (0.1mm). The circuit is normally open until the sensor detects a metallic part within its sensing range.
The green LED on the sensor will always be on if there is power to the sensor.
To Mount the Nozzle Detect:
1. Using the two M3x.5 - 16mm SHCS, attach the nozzle detect to the side of the clamp housing in the
two threaded holes (torque to 8 – 10 in-lbs).
2. Connect the supplied 4 Pin cable to the sensor and wire back to PLC / Robot Controller for monitoring.
M3x.5 - 16mm SHCS
Nozzle Detect Sensor

10
4-3 Wiring Interface Connections
WARNING: Before start-up, ensure that all connections are correct or damage to the TOUGH GUN Reamer may occur.
The TOUGH GUN Reamer is factory set for Sourcing inputs and outputs.
DEFINITIONS: Sinking = signal from PLC / controller is LOW (0 VDC)
Sourcing = signal from PLC / controller is HIGH (+24 VDC)
(see Section 7-2 Electrical Schematic)
The control logic requirement for some installations may require an inverse of the
logic provided.
To Switch from Sourcing to Sinking:
The switches located inside the rear access door must be accessed.
See Section 4-2 Accessing Electrical and Pneumatic Controls for directions.
NOTE: Although the circuit board is protected, Tregaskiss suggests disconnecting
the power before moving the switches.
The switches are located on the top left-hand corner of the circuit board:
SRC is Sourcing, SNK is Sinking
• Sprayer signal can be set to either SRC or SNK by moving the switch
(SW1 - Option) to the position indicated in the diagram
• Cycle Start signal can be set to either SRC or SNK by moving the switch
(SW2 - Start) to the position indicated in the diagram
• Reamer Home signal can be set to either SRC or SNK by moving the switch
(SW3 - Unclamped) to the position indicated in the diagram
SW1
SW2 SW3
4-4 Inversing Circuit Board Logic
WARNING: The following connection should only be performed by qualied technicians.
Damage to equipment will occur if connections are incorrect.
To interface the TOUGH GUN Reamer with the controller, ve (5) electrical connections are required
• ORANGE LEAD – Cycle Start output from PLC / controller (0.25 amp)
• WHITE LEAD – 0 VDC supply 0.5 amp constant
• RED LEAD – 24 VDC supply 0.5 amp constant
• GREEN LEAD – Home Signal Jaws Unclamped input to PLC / controller (0.25 amp)
• BLACK LEAD – Sprayer output from PLC / controller (0.25 amp)
NOTE: The pre-wired interface receptacle uses the above color codes.
The circuit board of the Reamer is capable of both sourcing or sinking inputs and outputs:
• Pin 1 - WHITE LEAD - 0 VDC
0 VDC operates the board for both Sourcing or Sinking settings
• Pin 2 - RED LEAD - +24 VDC
+24 VDC operates the board for both Sourcing or Sinking settings
• Pin 3 - GREEN LEAD - Reamer Home signal
Choose one of two settings:
1) Sourcing - When unit is in Home position, Reamer sends HIGH signal (+24 VDC) back to controller/PLC
2) Sinking - When unit is in Home position, Reamer sends LOW signal (0 VDC) singal back to controller/PLC
• Pin 4 - ORANGE LEAD - Cycle Start signal (signal should be a pulse with a maximum of 0.5 seconds in duration)
Choose one of two settings:
1) To intiate the Ream cycle, set board to Sourcing, controller sends HIGH signal (+24 VDC) to Reamer
2) To intiate the Ream cycle, set board to Sinking, controller sends LOW signal (0 VDC) to Reamer
• Pin 5 - BLACK LEAD - Sprayer Start signal
+24 VDC operates the sprayer for both Sourcing or Sinking settings
NOTE: Section 4-4 Inversing Circuit Board Logic for more information.

11
Jaws
V-Block
Cover Screws
Clamp
Cover
A. Setting Nozzle Heights:
See the chart below in order to nd the correct height to set your nozzle for proper
cutter blade insertion:
B. Setting Nozzle Heights for
Tandem Nozzles:
See the diagrams on the right in
order to nd the correct height to set
your nozzle for proper cutter blade
insertion.
V-Block
Part #
Nozzle Outside Diameter for each
side of V-Block
TR-2150 0.850” 0.938” *1.062” 1.106”
TR-2161 0.830” 0.978” 25 mm 1.125”
TR-2162 0.780” 0.813” 0.875” 1.000”
4-6 Setting Nozzle Heights for Cutter Blade Insertion
Retaining Head
Cutter
Blade Nozzle 404-3 404-20 / 404-26 / 404-30 / 404-32 454-1
RC-12 3/4”
(19.05 mm)
0.110”
Below
2.79 mm
Below 0.375” 9.53 mm 0.466” 11.84 mm
RCT-01 5/8”
(15.88 mm) 0.030” 0.762 mm 0.225” 5.72 mm 0.716” 18.19 mm
RCT-04 1/2”
(12.7 mm)
0.219”
Below
5.56 mm
Below 0.125” 3.18 mm 0.065” 1.65 mm
7.5°
0.428”
5.0°
2.239”
Tandem HD Tandem SD
4-5 Setting Up V-Block
*Part stamped as 1060, not according to it’s O.D. of 1.062”
TOUGH GUN TT3 Reamer
See Chart
Nozzle
Cutter Blade
Datum
Note: Using the top of the reamer as the datum, the base of the nozzle will either be above
or below this datum depending on the nozzle conguration.
WARNING: Ensure air and power supply are off and disconnected before proceeding.
Please follow your facility’s lockout / tagout procedures.
To Change V-Blocks:
1. Remove the four (4) cover screws at the top of the Reamer.
2. Lift the clamp cover off completely.
3. Lift and rotate the v-block so the desired size faces outward from
between the front jaws.
See below V-Block Size Chart.
Numbers are stamped into the v-blocks. The number refers to the outside diameter
of the nozzle (i.e. 0.938 = 0.938” O.D.)

12
4-7 Nozzle Detect Setup
WARNING: Please follow your facility’s lockout / tagout procedures.
IMPORTANT: In order for the system to operate properly, the sensor signal must be monitored.
A. Setup of Nozzle Detect
1. With a nozzle on the gun, move the robot into position beside the nozzle detect sensor.
2. Measure the distance from the tangent face of the nozzle to the face of the nozzle detect sensor ensuring that
it is 3mm ± 1mm
3. The ring crimp on the nozzle should be in line with the center of the sensor (yellow circle portion on the face of the
sensor). The vertical distance between the top of the reamer clamp housing and the base of the nozzle outer shell
should be approx. 0.10”
0.10” (2.54mm)
0.12” (3mm)
Nozzle
Detect
Sensor
Ring Crimp

13
B. Testing of Nozzle Detect
1. Move robot into position beside the nozzle detect sensor (with a nozzle on the torch) and the yellow LED should illuminate.
2. Move robot away from the nozzle detect sensor and remove the nozzle (keep the retaining head on).
3. Move robot back to the programmed position that was used in Step 1, and the yellow LED should not illuminate. This
indicates that there is no nozzle on the torch.
Note: Adjustments may be necessary if you are not using Tregaskiss consumables. The setup distances may change but the
procedure does not change.
Nozzle Detect LEDs
Cable Pin out Diagram
Nozzle Detect Wiring Diagram (with corresponding pin numbers)

14
The L.E.D. indicators mounted on the circuit board of the TOUGH GUN Reamer supply visual information regarding cycle status.
This information may be used for both installation and maintenance to verify proper operation. When the TOUGH GUN Reamer is
Home, L.E.D. status should appear as labeled in the chart and diagram below:
SECTION 5 – OPERATION
5-1 Understanding L.E.D. Indicators
5-2 Programming Events Sequence
REAMER HOME ON
indicates that the lift cylinder has retracted, the cutter
is at the bottom of its stroke, the limit pin is activating
the lower limit switch and the clamps are open and the
lower limit switch is working properly.
CLAMP / MOTOR
VALVE SHORT OFF indicates short with clamp or motor valve when ‘ON’.
REAMER AHEAD OFF
indicates that the TOUGH GUN Reamer has reached full
upper stroke and the limit pin is activating the upper
limit switch. Unless the Reamer gets stuck at the top,
this L.E.D. will only be ‘ON’ for a split second before the
unit begins to retract and the L.E.D. turns ‘OFF’.
SPRAYER VALVE
SHORT OFF indicates short with one of the sprayer valves when ‘ON’.
UNCLAMPED ON
indicates that the clamp cylinder is fully retracted,
releasing the clamp mechanism (via the clamp limit
switch).
FEED VALVE SHORT OFF indicates short with feed valve (also referred to as
“spindle valve”) when ‘ON’.
A. To Program Cutter Blade / Reamer Sequence:
1. Verify the TOUGH GUN Reamer L.E.D. is showing Unclamped and Reamer Home.
2. Position the robot to place the MIG gun nozzle so it is tangent to the two (2) angled faces of the v-block, at the proper
insertion depth and concentric with the cutter blade.
(See Section 4-6 Setting Nozzle Heights for Cutter Blade Insertion)
3. Cycle Start – Supply output signal from the robot controller / PLC. Pulse output for 0.5 seconds.
4. TOUGH GUN Reamer will perform cleaning cycle.
5. When the Cycle Start signal is supplied to the Reamer, Reamer Home and Unclamped L.E.D.s will turn off. There should be
no illuminated L.E.D.s on the board until the Reamer reaches the top of its stroke. At this point, the Reamer Ahead L.E.D. will
illuminate for a split second before the spindle begins to retract.
6. Once the Reamer reaches the bottom of the stroke again, the motor will stop spinning, the clamps will open to release the
nozzle and the Reamer Home and Unclamped L.E.D.s will be illuminated again. The PLC should check for the Home signal
before letting the robot move.
7. The gun can now be safely removed from the TOUGH GUN Reamer clamps and moved to its spray position.
Continued on page 12

15
B. To Program Sprayer Sequence:
After reaming, center the nozzle above the spray head as shown in Figure 1:
X = 1.0” (25.4mm) when using 1/2” bore nozzles
X = 1.25” (31.75mm) when using 5/8” bore nozzles
X = 1.5” (38.1mm) when using 3/4” bore nozzles
Supply output signal from robot controller for 0.5 seconds for initial setup.
Adjust timer to increase or decrease quantity of anti-spatter compound as
required by process.
NOTE: Set tandem nozzles 1.5” (38.1mm) above the spray head as shown
in Figure 2.
If using TOUGH GARD Anti-Spatter Liquid, there should be enough to coat inside of
nozzle with no drippage. Excessive application of TOUGH GARD Anti-Spatter Liquid
can decrease performance and increase consumption.
IMPORTANT: If gun is equipped with air blast, DO NOT activate air blast when over
the spray head. Dirt / spatter may be blown into the spray head orice, which may
hamper spray operation. Air blast can be activated during the reaming sequence.
The manual override switches allow conrmation that the lift cylinder, jaw clamping and sprayer air circuits are operational.
To Manually Operate the TOUGH GUN Reamer:
The HOME POSITION button should be pressed prior to
manual setup to reset all circuitry.
1. Locate the setup switches on the air supply side of the
Reamer (opposite the reservoir).
2. Operate the switches as required.
X
Figure 1
1.5”
Figure 2
5-3 Manual Operation

16
WARNING: Ensure air and power supply is off and disconnected before
proceeding. Please follow your facility’s lockout / tagout procedures.
1. Open the rear cover.
2. Remove the two (2) lower 3-pin circuit board connectors.
3. Remove the one fastener on the limit switch bracket.
4. Remove assembly and replace with new part. Ensure the actuator is clear of all
limit switches when the new assembly is installed.
5. Align the new bracket with the dowel holes on the Reamer frame face, then
reinstall fastener.
Plug in the tabbed 3-pin circuit board connectors.
(see Section 7-2 Electrical Schematic)
5-4 Adjusting Flow Control Valves
SECTION 6 – MAINTENANCE
6-1 Replacing the Spindle Limit Switch
3-Pin Connectors
Limit Switch
Bracket
Dowel Hole
Fastener
6-2 Replacing the Clamp Limit Switch
Clamp Limit Switch
Fastener
Rubber Grommet
WARNING: Ensure air and power supply is off and disconnected before proceeding.
Please follow your facility’s lockout / tagout procedures.
1. Remove the top plate of the Reamer.
2. Open the rear cover.
3. Disconnect the 3-pin connector from the lower right corner of the circuit board.
4. Loosen the screws and remove the wires from the circuit board connector.
Note the wire colors and their positions within the connector.
5. Remove the clamp limit switch fastener and remove assembly (pull the wires
through the grommet).
6. Slide the two wires through the grommet into the TOUGH GUN Reamer.
7. Fasten the new clamp limit switch into position.
8. Install the two wires into the new keyed circuit board connector
(see Section 7-2 Electrical Schematic)
9. Clip the circuit board connector into location on the circuit board.
10. Reinstall the top plate and close the rear cover.
NOTE: The ow control valve provides a smooth, constant feed of the cutting tool. The feed rate is dependent on the
amount of spatter accumulated. If a smaller amount of spatter accumulates, the feed rate can be set faster. A feed
rate that is set too fast may stall the motor or damage the cutter blade.
To Adjust the Flow Control Valve(s):
1. There is a ow control valve for adjusting up speed of the feed head
located behind the spindle shroud cover. The down (retract) speed is
xed. The feed rate may require adjustment for different applications.
2. To increase the feed rate of the cutter blade, the valve would have to be
opened. Turn counterclockwise.
3. To decrease the feed rate of the cutter blade, the valve would have to be
closed. Turn clockwise.
4. Tighten locking nut once desired setting is achieved.

17
6-3 Replacing the Air Motor
Belt
Air
Motor
Tension
Lock Screw
6-4 Replacing the Circuit Board
6-5 Replacing the Cutter Blade
Board
Standoffs
Board Mounting
Screws
Circuit Board
WARNING: Ensure power supply is off and disconnected before proceeding.
Please follow your facility’s lockout / tagout procedures.
1. Open the rear cover.
2. Being careful not to damage the wiring. Disconnect all
wiring and remove the connectors from the circuit board.
3. Remove the fasteners which secure the circuit board to
the standoffs.
IMPORTANT: Ensure all four (4) standoffs are still
attached to the frame.
4. Remove the board from the unit and install the
replacement in the same position.
5. Once located in the proper position, secure the circuit
board by tightening the four fasteners.
6. Reconnect all wiring and reset sink/source switches to
match the conguration of the board that was removed.
WARNING: Ensure power supply is off and disconnected before proceeding.
Please follow your facility’s lockout / tagout procedures.
1. Open the rear cover or remove it completely by removing the ve (5)
BHCS using a 3 mm Allen wrench.
2. Remove the tension lock screw located on the side of the Reamer
frame.
3. Push the motor in to release belt tension, and slide the belt off of the
front pulley at the same time.
4. Disengage belt from the rear pulley.
5. Release the air lines from the quick disconnect air ttings at the front
of motor.
6. Pull the motor out.
IMPORTANT: Be careful not to lose the belt tension spring.
7. Reverse the order of the steps above for reassembly.
Cutter
Blade
9/16” Wrench
(Supplied and secured on
the top of TOUGH GUN TT3
Reamer)
Washer
WARNING: Ensure power supply is off and disconnected before proceeding.
Please follow your facility’s lockout / tagout procedures.
A. To Remove the Cutter Blade
Remove the cutter blade using a 5/8” wrench and the supplied 9/16”
wrench.
• The cutter blade is removed by turning counterclockwise when
viewed from above.
NOTE: Considerable force may be required to loosen the cutter blade since
it tightens naturally as the Reamer operates. Resting the 9/16” at wrench
against the Reamer frame (below the air connection, and between the sprayer
braket and sprayer supply lines). This prevents slipping while trying to
remove the cutter blade.
B. To Install the Cutter Blade
• The cutter blade is installed by threading it clockwise into the top
of the spindle shaft. Reuse the old washer.
NOTE: The application of anti-seize compound to the threads of the TOUGH
GUN Reamer will assist in easy removal in the future.

18
6-6 Replacing the Drive Belt
6-7 Replacing the Solenoid Valves
Valve
Screws
WARNING: Ensure power supply is off and disconnected before proceeding.
Please follow your facility’s lockout / tagout procedures.
1. Open the rear cover.
2. Loosen the tension lock screw.
3. Push the motor in to release belt tension, and slide the belt off of the front pulley at the same time.
4. Remove the belt from the rear pulley.
5. Reverse the order of the steps above for reassembly.
WARNING: Ensure air and power supply is off and disconnected before proceeding.
Please follow your facility’s lockout / tagout procedures.
1. Shut off the power to the TOUGH GUN Reamer.
2. Shut off the air supply to the TOUGH GUN Reamer.
3. Open the rear cover.
4. Unplug the electrical connector directly from the bottom of the
solenoid valve.
5. Loosen and remove the two (2) solenoid valve screws.
6. Remove the solenoid valve and gasket.
NOTE: New gasket (included with new valve) must be installed
when replacing valve.
7. Install the new gasket and valve and tighten screws to 6 in.-lbs.
8. Reconnect the electrical connector to the bottom of the solenoid
valve.
9. Close the rear cover.

19
6-8 Scheduled Maintenance
The TOUGH GUN TT3 Reamer will require a periodic maintenance program to ensure a reliable service life. The following
schedule is recommended:
DAILY
CHECK The oil level in the lubricator reservoir. The life of the air motor is dependent on a consistent supply of oil.
CHECK The air lines and interface cable for leaks and fraying.
CHECK The alignment of the nozzle, retaining head and gun position.
CHECK The reservoir to ensure it is full of TOUGH GARD Anti-Spatter Liquid.
CLEAN The spindle cover shroud to ensure it is free of spatter.
CLEAN The Reamer clamp jaw and v-block surfaces to ensure proper nozzle alignment.
WEEKLY
CHECK The cutter blade. The service life of the cutter blade is dependent on the type of application. In lighter duties the
blade may last indenitely but should be inspected weekly for dullness, clogging and possible breakage.
CHECK The lubricator to ensure it is working and is set up properly (i.e. ll oil, clean / replace lter).
CHECK The LEDs to ensure Reamer and controller communication.
CHECK The Sprayer to ensure that the spray coming out of the spray head is normal.
CHECK The nozzle and retaining head/diffuser (remove from gun) for wear.
CLEAN The v-block, Reamer clamp jaw, and spindle seal with a brush or with compressed air to eliminate blockages.
CLEAN Wipe clean any debris from the Nozzle Detect Proximity Sensor
MONTHLY
CHECK That the belt tension lock screw is securely tightened.
CHECK That the belt tension bolt is tightened.
CHECK The spindle unit for wear.
CHECK The solenoids and spool them to ensure there are no leaks and that they are operating properly.
CLEAN The sprayer reservoir to eliminate contamination.
CLEAN The sprayer head and brush away excess spatter.
CLEAN Under the top cover.
YEARLY
INSPECT The drive belt for any signs of fraying and replace as necessary.
REPLACE The spindle cap seal and repair any damage to the spindle.
CLEAN Perform a complete clean-up of the Reamer and Sprayer.
The TOUGH GUN Wire Cutter will require a periodic maintenance program to ensure a reliable service life. The following
schedule is recommended:
DAILY
CHECK The air lines and interface cable for leaks and fraying.
WEEKLY
CHECK The cutter blade. The service life of the cutter blade is dependent on the type of application. In lighter duties
the blade may last indenitely but should be inspected weekly for dullness, looseness and possible breakage.
EMPTY The wire catcher basket.
QUARTERLY
LUBRICATE The sliding surfaces by applying general purpose grease (NLGI Grade 1-2) through the grease ttings located
on the sides of the main body.

20
SECTION 7 – TECHNICAL DATA
7-1 Pneumatic Diagrams
TOUGH GUN TT3 Reamer
TOUGH GUN TT3 Reamer with Lubricator