Tregaskiss TOUGH GUN Quick start guide

TECHNICAL GUIDE
TOUGH GUN™ Automatic
Air-Cooled MIG Guns
500 amp & 600 amp
TOUGH GUN™ Automatic
Water-Cooled MIG Guns
450 amp & 600 amp
SAFETY & WARRANTY
INFORMATION
INSTALLATION
MAINTENANCE GUIDE
TECHNICAL DATA
OPTIONS
EXPLODED VIEW & PARTS LIST
TROUBLESHOOTING
ORDERING INFORMATION
Certified ISO 9001 : 2008
Please read instructions prior to use.
Save this manual for future reference.
Air-Cooled
Water Cooled
Water-Cooled
Effective September 2010 –
QUICK LOAD™ Liners Standard on all
TOUGH GUN™Robotic Air-Cooled MIG Guns

2
TABLE OF CONTENTS
THANK YOU… .............................................................................................................................................2
WARRANTY ................................................................................................................................................3
GENERAL SAFETY ........................................................................................................................................3
1.0 –INSTALLATION....................................................................................................................................4
1.1 INSTALLING QUICK CONNECT BLOCK TO FEEDER ............................................................................................. 4
1.2 INSTALLING GUN TO QUICK CONNECT BLOCK.................................................................................................. 4
1.3 INSTALLING TOUGH GUN™ MIG GUNS EQUIPPED WITH “DIRECT PLUG-INS” .................................................... 5
2.0 –MAINTENANCE...................................................................................................................................5
2.1 NOZZLE AND CONTACT TIP SYSTEMS –AIR-COOLED GUNS .............................................................................. 5
2.2 NOZZLE AND CONTACT TIP SYSTEMS –WATER-COOLED GUNS ........................................................................ 6
2.3 NECK REPLACEMENT –AIR-COOLED GUNS ...................................................................................................... 6
2.4 NECK REPLACEMENT –WATER-COOLED GUNS ................................................................................................ 7
2.5 LINER REPLACEMENT...................................................................................................................................... 7
2.6 UNICABLE REPLACEMENT –AIR-COOLED GUNS............................................................................................... 8
2.7 CABLE BUNDLE REPLACEMENT –WATER-COOLED GUNS ................................................................................. 8
3.0 –TECHNICAL DATA.............................................................................................................................. 11
3.1 NECK DIMENSIONS –AIR-COOLED GUNS....................................................................................................... 11
3.2 NECK DIMENSIONS –WATER-COOLED GUNS................................................................................................. 11
3.3 RATINGS AND SPECIFICATIONS...................................................................................................................... 11
4.0 –OPTIONS .......................................................................................................................................... 12
4.1 DIRECT PLUG-INS.......................................................................................................................................... 12
4.2 CONNECTOR OPTIONS –AIR-COOLED GUNS.................................................................................................. 12
4.3 CONNECTOR OPTIONS –WATER-COOLED GUNS............................................................................................ 12
4.4 FEEDER ADAPTORS....................................................................................................................................... 13
5.0 –TROUBLESHOOTING ......................................................................................................................... 13
6.0 –EXPLODED VIEW AND PARTS LIST –AIR-COOLED GUNS..................................................................... 14
7.0 –EXPLODED VIEW AND PARTS LIST –WATER-COOLED GUNS............................................................... 15
8.0 –ORDERING INFORMATION................................................................................................................ 16
8.1 TOUGH GUN AUTOMATIC AIR-COOLED MIG GUN ORDERING INFORMATION................................................. 16
8.2 TOUGH GUN AUTOMATIC WATER-COOLED MIG GUN ORDERING INFORMATION............................................ 16
THANK YOU…
…for selecting a Tregaskiss™TOUGH GUN™ MIG Gun. Manufacturing operations demand extremely dependable robotic
equipment. As the name implies, the TOUGH GUN MIG Gun 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 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. Please contact us
immediately if you experience any safety or operating problems.

3
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™ Robotic 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.
GENERAL SAFETY
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.
a. Faulty or damaged equipment is repaired or replaced.
b. 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.
4. 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
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.)

4
1.0 –INSTALLATION
WARNING: Ensure water supply is on before operating gun.
1.1 INSTALLING QUICK CONNECT BLOCK TO FEEDER
STEP #1
Insert the correct feeder adaptor liner for desired wire diameter
(2 provided) flush with the threaded end of the feeder adaptor.
Tighten set screw.
Thread feeder adaptor into Quick Connect block and tighten.
STEP #2
Position assembly into feeder adaptor and trim liner within 1/16” (1.6 mm) of the
drive rolls and remove burrs if necessary.
Secure assembly into feeder.
Thread gas hose nipple into feeder gas fitting.
Connect power cable to 1/2” (13 mm) power bolt with appropriate lug.
Tighten all connections.
Feed welding wire through assembly by hand.
1.2 INSTALLING GUN TO QUICK CONNECT BLOCK
NOTE: Ensure correct liner and contact tip are utilized. Examine and replace power pin o-rings if necessary.
STEP #1
Guide welding wire into power
pin.
Insert power pin to shoulder.
Tighten thumbscrew securely.
Connect control plug lead to
control housing on gun.
Insert control plug into feeder.
STEP #2
If using a water-cooled gun, securely clamp blue hose on rear housing to “Water Out” on water cooler and
red hose on rear housing to “Water In” on water cooler.
WARNING: To prevent torch damage, it is highly advised that a Flow Sensor rated at 0.5 gpm
be used at all times (Part Number 659-50).
WARNING: Ensure water supply is on before
operation.
Water flow sensor should be used to ensure
water is on.
Recheck proper gas flow, drive roll pressure,
voltage, and wire feed speed.
WATER LINES
THUMB SCREW
POWER PIN
WELDING
WIRE
WATER
LINES
DRIVE
ROLLS
SET SCREW
FEEDER
ADAPTOR
QUICK CONNECT
BLOCK
FEEDER ADAPTOR LINER

5
1.3INSTALLING TOUGH GUN™ MIG GUNS EQUIPPED WITH “DIRECT PLUG-INS”
IMPORTANT: The thread-in two-piece power pin incorporates a taper to seat and lock in the power pin to the
rear handle block. Make sure power pin is tightened in the block with a wrench to insure pin is secure and will
not come loose.
NOTE: The rear handle and screws do not have to be removed when installing the two-piece power pins.
Thread power pin into the rear handle block.
Tighten the power pin into the rear block using a 1” (25 mm)
wrench on the rear block and a 5/8” (16 mm) or 3/4” (19 mm)
wrench on the power pin.
Install liner (See Section 2.5 LINER REPLACEMENT).
Install gun to feeder (See below).
Miller, Tweco#4 and #5, Lincolnand
HobartPower Pin
- Insert power pin to shoulder and secure.
- Insert control plug to control housing of gun.
- Insert control plug into feeder.
- Feed welding wire into power pin by hand
and tighten drive rolls.
- On Lincoln it is necessary to connect gas
hose to barbed fitting on power pin.
Bernard™Style and Euro-Connector
- Feed welding wire through female adaptor by
hand and tighten drive rolls.
- Guide welding wire into connector on gun,
carefully insert connector into female adaptor
and tighten Euro hand nut or Bernard style
locking collar.
ESABPower Pin (Non Euro Style)
- Insert power pin to shoulder and secure.
- Feed welding wire into power pin by hand and
tighten.
2.0 –MAINTENANCE
2.1 NOZZLE AND CONTACT TIP SYSTEMS –AIR-COOLED GUNS
IMPORTANT:
Neck insulator must be in place before welding to maintain insulation of neck armor.
Be sure all parts are tightened well before welding.
Replace nozzle retainer with deep counter bore toward the neck. Tighten until retainer and shock washer
are secure.
REMOVAL AND REPLACEMENT
Pull slip-on nozzles off with a clockwise twisting motion.
When installing nozzle, exposed insulator should nest inside shock washer to assure concentricity.
Neck insulators are positioned on the end of the neck with the large insulated counter bore facing
the nozzle.
THREAD-ON (OPTIONAL)
Thread-on nozzle system does not require nozzle retainer and cannot be used with heavy duty head.
Neck insulator must be in place.
External neck thread can be cleaned with a 9/16” - 18 die.
NOTE: Any of the above nozzle and contact tip systems can be used on the TOUGH GUN 350, 450, 550 or 650 amp models.
NECK
INSULATOR
STANDARD DUTY
NOZZLE (VARIOUS
SIZES AVAILABLE)
HEAVY DUTY
TOUGH LOCK
CONTACT TIP
HEAVY DUTY
TOUGH LOCK
RETAINING HEAD
HEAVY DUTY NOZZLE
(VARIOUS SIZES
AVAILABLE)
STANDARD DUTY
TOUGH LOCK
CONTACT TIP
STANDARD DUTY
TOUGH LOCK
RETAINING HEAD
NECK
INSULATOR

6
2.2 NOZZLE AND CONTACT TIP SYSTEMS –WATER-COOLED GUNS
IMPORTANT
Neck insulator must be in place before welding to maintain insulation of neck armor.
Be sure all parts are tightened well before welding.
When using the heavy duty retaining head make sure it is tightened with a 5/8” (16 mm) wrench to prevent overheating of
contact tip.
To prevent scoring on heavy duty retaining head do not use pliers.
REMOVAL AND REPLACEMENT
Pull slip-on nozzles off with a clockwise twisting motion.
When installing nozzle, exposed insulator should nest inside shock washer to assure concentricity.
Neck insulators are positioned on the end of the neck with the large insulated counter bore facing the nozzle.
Replace nozzle retainer with deep counter bore toward the neck. Tighten until retainer and shock washer are secure.
2.3 NECK REPLACEMENT –AIR-COOLED GUNS
STEP #1
Place neck in vise.
Remove all four housing mounting screws with 3
mm (3/32”) Allen wrench.
Slide handle back exposing connector cone and
crimp ring.
Loosen connector cone from neck using a 25 mm
(1") wrench.
Remove from vise and thread out neck by hand.
Cable connection between cone and crimp ring
should not be disturbed.
STEP #2
NOTE: The neck body is an integral part of the neck and the handle
screws are metric (MS). New handle screws must be used when
replacing the neck.
Thread neck into connector cone (hand-tighten).
Place neck in vise and tighten with 1" (25 mm) wrench to within 1/8"
(3.2 mm) spacing between the connector cone and body.
Slide housing forward and align with screw holes and body.
NECK
HOUSING
POWER CABLE
M5 FLATHEAD SCREWS
STANDARD DUTY NOZZLE
VARIOUS LENGTHS
AVAILABLE
HEAVY DUTY
CONTACT TIP
HEAVY DUTY
GAS
DIFFUSER
NECK
INSULATOR
TOUGH LOCK
CONTACT TIP
TOUGH LOCK
DIFFUSER
NOZZLE (THREAD ON)
600 AMP
450 AMP
CERAMIC
INSULATOR
NECK
1/8” (3.2 mm)
POWER
CABLE

7
2.4 NECK REPLACEMENT –WATER-COOLED GUNS
STEP #1
Remove liner from gun (See Section 2.5 LINER REPLACEMENT).
Remove two front housing screws.
STEP #2
Slide housing back.
Unthread power cable.
Cut off water line and conduit clamp and pull hoses off of barbed fittings.
STEP #3
Slide clamps on water line and conduit.
Thread power cable on and tighten.
Push water line and conduit on all the way to base of fittings and crimp.
2.5 LINER REPLACEMENT
NOTE: For guns equipped with “Direct Plug-Ins”, Bernard, or Euro-connector, the procedure is the same.
On Miller style guns, liner is held captive by a guide cap, which must be removed and replaced when
changing liner.
STEP #1
NOTE: Ensure power supply is off and gun is removed from feeder before proceeding.
Remove nozzle, tip and gas diffuser.
With gun straightened, unthread retainer and remove.
STEP #2
Feed replacement liner through gun
using short strokes to avoid kinking.
Twist liner clockwise if necessary.
Using a 10 mm wrench, turn thread-in liner retainer in a clockwise direction and tighten in power pin.
M5 SCREWS
NECK
WHITE CONDUIT LINE
FRONT HOUSING
WATER LINES (BLUE)
AND POWER LINE (RED)
NECK
FRONT HOUSING

8
STEP #3
Thread liner into power pin.
Trim conduit liner with 3/4” (19 mm) stick out for
Air Cooled (404-20 and 404-3 Retaining Heads)
and 1/2” (13 mm) for Water Cooled (454-1
Retaining Heads).
Remove any burr that may obstruct wire feed,
especially on flat wire type conduit liner.
Replace nozzle, tip and gas diffuser onto neck.
2.6 UNICABLE REPLACEMENT –AIR-COOLED GUNS
STEP #1
Remove liner from gun (See Section 2.5 LINER REPLACEMENT).
Mount neck in vise.
Remove housing screws and slide housing back (front and back).
Loosen connector cone from neck using 1” (25 mm) wrench.
Remove from vise and thread out neck by hand.
Cable connection between cone and crimp ring should not be disturbed.
Unthread power pin and remove using 1 1/4” (32 mm) on connector cone and a 5/8” (16 mm)
or 3/4” (19 mm) wrench on power pin. Install new power pin.
Retrieve front and rear housing. Slide housings onto new unicable assembly.
Repeat procedure in reverse to assemble remaining components.
2.7 CABLE BUNDLE REPLACEMENT –WATER-COOLED GUNS
STEP #1
Remove nozzle, tip and
retainer.
Take out rear housing
screws and remove liner.
NECK
CONDUIT LINER
3/4” (19 mm)
1/2" (13 mm)
450/600 AMP
MOUNTING SCREWS
REPLACEMENT
UNICABLE
USED UNICABLE

9
STEP #2
Pull the rear handle up the gun approximately 1 ft.
Unscrew power cable from rear power block.
Cut clamps off the water in (blue) line and gas line (white).
Pull gas and water line off of power block.
At this point, rear power block will be removed from gun.
Slide rear handle off gun.
STEP #3
On front of gun, release front handle from neck.
Remove outer jacket by pulling outer jacket only from rear of gun; all that remains are the inner hoses
attached to the neck.
STEP #4
Cut clamps off the water (blue) and gas line (white).
Unscrew power cable from neck.
Remove old cable bundle.
STEP #5
Slide rear handle and front
housing on to new cable
bundle.
Thread power cable (red) on
to neck.
Clamp water line (blue) and
gas line (white) onto neck.
2 PIECE
POWER PIN
REAR HANDLE
WHITE CONDUIT LINE
BLUE WATER LINE
POWER & RED
WATER LINE
450/600 AMP
450/600 AMP
NECK
WHITE CONDUIT LINE
FRONT HOUSING
WATER LINES (RED & BLUE)
& POWER LINE
OUTER JACKET
NECK
WHITE CONDUIT LINE
BLUE WATER LINE
USED RED WATER
LINE & POWER LINE
FRONT HOUSING
NECK
NEW CABLE BUNDLE

10
STEP #6
Slide outer jacket under front handle and bring front handle up to neck and secure.
STEP #7
At rear of gun, slide rear handle up over outer jacket.
Attach rear power block to power cable.
Attach the gas line and water line with new clamps and crimp to power block.
STEP #8
Slide rear handle to rear power block and secure housing with mounting screws.
Thread-on power pin
Put liner through gun and tighten.
Install liner (See Section 2.5 LINER REPLACEMENT).
NECK
FRONT HANDLE
OUTER JACKET
REAR HOUSING
WHITE CONDUIT LINE
POWER PIN
BLUE WATER LINE
POWER & RED
WATER LINE
REAR
HANDLE
POWER PIN
TERMINAL
HOUSING

11
3.0 –TECHNICAL DATA
3.1 NECK DIMENSIONS –AIR-COOLED GUNS
NECK
ANGLE
B
C
D
E
INCHES
mm
INCHES
mm
INCHES
mm
INCHES
mm
305-60
60°
4.10
105
4.00
103
2.00
51
1.90
48
405-22
22°
7.10
180
1.63
41
3.00
76
1.90
48
405-45
45°
5.19
132
3.55
90
3.00
76
1.90
48
405-60
60°
4.98
127
4.78
121
3.00
76
1.90
48
405-180
180°
7.38
187
---
---
---
---
1.90
48
505-22
22°
8.29
211
1.72
44
4.00
1.90
48
505-45
45°
7.23
184
3.87
98
4.00
102
1.90
48
505-60
60°
6.04
153
5.30
135
4.00
102
1.90
48
505-180
180°
8.63
219
---
---
---
---
1.90
48
3.2 NECK DIMENSIONS –WATER-COOLED GUNS
NECK
ANGLE
B
C
D
E
INCHES
mm
INCHES
mm
INCHES
mm
INCHES
mm
455-180
180°
7.44
189
--
--
--
--
1.48
38
455-22
22°
7.50
191
2.39
61
3.00
76
1.48
38
455-45
45°
6.32
161
4.12
105
3.00
76
1.48
38
455-60
60°
5.95
151
5.66
144
3.00
76
1.48
38
595-180
180°
7.89
200
--
--
--
--
1.78
45
595-22
22°
7.03
179
1.51
38
3.00
76
1.78
45
595-45
45°
6.00
152
3.80
97
3.00
76
1.78
45
595-60
60°
5.72
145
5.27
134
3.00
76
1.78
45
3.3 RATINGS AND SPECIFICATIONS
GUN MODEL
DESCRIPTION
MA15
MA16
46xx
64xx
Current Rating
350 amp, 100%
385 amp, 100%
450 amp, 60%
600 amp, 60%
Voltage Rating
≤ 141V
Min. Liquid Flow
N/A
0.5 L/min (0.13 G/min)
Min. Liquid Pressure
N/A
280 kPa (40 psi)
Max. Liquid Pressure
N/A
480 kPa (70 psi)
Min. Cooling Power
N/A
1000 W (3400 BTU/hr)
2600 W (8800 BTU/hr)
NOTE: Based on tests that comply with IEC 60974-7:2013, GB 15579.7:2013
E
E
.75 (19 mm) (Nominal size for all necks)
600 AMP W/C AUTO
595-XXX
455-XXX
450 AMP W/C AUTO

12
4.0 –OPTIONS
4.1 DIRECT PLUG-INS
PART #
DESCRIPTION
USE ON FEEDERS
214
TREGASKISS POWER PIN
TREGASKISS QUICK CONNECT BLOCK, HOBART®
2000 SERIES FEEDERS, TWECO® #4 RECEPTACLE
BODY PART #TAK-1, LINCOLN® POWER MIG 300
414-11-2
O-RING - FOR MILLER® POWER PINS
MILLERMATIC® 200 & 250, S21E & S22 SERIES, 52 & 54
SERIES, 60 SERIES
214-1
MILLER® POWER PIN
MILLERMATIC® 200 & 250, S21E & S22 SERIES, 52 & 54
SERIES, 60 SERIES
214-116
GUIDE CAP ONLY - FOR 414-11-116 (NEW STYLE)
214-332
GUIDE CAP ONLY - FOR 414-11-332 (NEW STYLE)
414-116
GUIDE CAP ONLY - FOR 414-11-116 (OLD STYLE)
414-332
GUIDE CAP ONLY - FOR 414-11-332 (OLD STYLE)
214-12
TWECO® #5 STYLE POWER PIN
ALL FEEDERS SET UP WITH TWECO® #5
414-12-2
O-RING - FOR TWECO® #5 STYLE POWER PIN
RECEPTACLE BODY PART #6TAK-1
214-2
LINCOLN® POWER PIN
LINCOLN® LN7, 8 & 9, LN25 SUITCASE, LN22, NA2
414-21
ESAB® (NON EURO)
A-10
214-13
PANASONIC®
4.2 CONNECTOR OPTIONS –AIR-COOLED GUNS
Euro Connector option - for European style feeders and
feeder adaptors for 500 and 600 amp MIG guns.
Bernard Style Connector Option - for Quick Connect
feeder adaptors for 500 and 600 amp MIG guns.
PART #
DESCRIPTION
PART #
DESCRIPTION
425
EURO CONNECTOR ASSEMBLY
426
BERNARD STYLE CONNECTOR ASSEMBLY
416-15
HOUSING ASSEMBLY - BLANK OLD STYLE ONLY
416-15
HOUSING ASSEMBLY - BLANK
425-10
POWER PIN - A/C EURO
426-1
POWER PIN - BERNARD
425-11
HAND NUT ASSEMBLY - EURO NEW STYLE
426-2
LOCKING COLLAR
425-6
SPACER - A/C EURO OLD STYLE ONLY
426-3
WASHER
425-8
EURO SPRING PIN
426-5
CONTROL PINS
425-9
O-RING - 4 x 1 mm - BUNA
426-6
O-RINGS - 009 - BUNA
666-10
REAR HOUSING - OLD STYLE ONLY
666-10
REAR HOUSING
4.3 CONNECTOR OPTIONS –WATER-COOLED GUNS
Euro Connector option - for European style feeders and feeder adaptors for 450 and 600 amp TOUGH GUN™MIG Guns.
PART #
DESCRIPTION
675-2
EURO HOUSING - W/C
675-10
EURO CONNECTION
425-5M
HOUSING SCREWS
425-2
EURO HAND NUT
675-10-4
RETAINING RING
675-4
EURO HOUSING BAND

13
4.4 FEEDER ADAPTORS
To be used with 417 (Tweco #4), 417-50 (Euro) or 417-60 (Tweco #5) Quick-Connect Block.
PART #
USE ON FEEDERS
418-1
AIRCO: AHF-E1, AHF-G, AHF-L1, AHF-N, AHF-R, AHF-SAHF-T, AHF-U, AHF-V, MOBILMATIC, LITTLE DIPPER, DIPSTIC-160, DIP-PAC-
200, DIP-COR-300
418-3
ESAB (NON EURO): A10, SMASH-WELD-180, MEC 30/44, MIGGY 125, OPTIMATIC 30/44
418-4
HOBART: 27, 27A, DUALMATIC 27/70, H3S, H4S, H6S, 44, 70, 70S, SP100
418-5
LINDE/L-TEC: EH-8, MIG-32, 160, V160, 3IN1, L-TEC 225, SWM-20, SWM-22, SWM-31, SWM-32, SWM-34, SWM-37
418-6
LINCOLN: LN7, LN8, LN9, LN22, LN25
418-7
LINDE/L-TEC: MM253, SWM14
418-8
LINDE/L-TEC: DIGIMIG & DIGIMIG DUAL, EH1, EH5, EH10, EH11, SHE-4, SHE-5, SWM11, SWM11B, SWM12, SWM13, SWM23, SWM24,
SWM25, SWM26, SWM35, VAM2, L-TEC35, MIG35, DIGIPULSE, SEH4/5
418-9
MILLER: 10A, 10E, 30A, 30B, 30E, 70A, 80A, SPOOLMATIC 150, MILLERMATIC 35 (OLD STYLE)
418-10
MILLER: INTELLIMATIC, SIDEKICK, D-51A, MILLERMATIC 90,120, 130, 150, 200, 250, MM-35 (NEW), NEW AUTOMATIC 1, PORTOMIG,
S-42GL, S-52A, S-54A, SWING ARC-DUAL, SWING ARC-SINGLE, S-32S, 52D, 54D, 52E, 54E, ALL 22 AND 60 SERIES FEEDERS
418-14
OTC: CM2321
418-21
GILLILAND, SAN DIEGO
418-25
LINCOLN: LN7 (SHORT)
418-27
PANASONIC
418-28
HOBART/TWECO #4: BETA-MIG (NEW STYLE) BETA-MIG 250 AND 251, DUAL FEEDER, DIGITAL 2000, DUAL DIGITAL, PORTA FEED 17,
ULTRA FEED 1000, 2000, 2400, HANDLER, OSCAWA, HEFTY CV/CC
5.0 –TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
POOR WIRE FEED
CONDUIT LINER IS CLOGGED OR KINKED
INCORRECT LINER SIZE OR CONTACT TIP
LINER CUT TOO SHORT AND NOT SEATING PROPERLY IN GAS DIFFUSER
DRIVE ROLLS TOO TIGHT, RESULTING IN SCORING OF WELDING WIRE
WELDING WIRE DIRTY, RUSTY, OR TOO MUCH CAST
SHORT TIP LIFE
DRIVE ROLLS TOO TIGHT, RESULTING IN SCORING OF WELDING WIRE
WELDING WIRE DIRTY, RUSTY, OR TOO MUCH CAST
UNCOATED WIRE BEING USED, INCREASING USAGE
WRONG WIRE SIZE
GUN BEING RUN BEYOND ITS AMPERAGE RANGE
LOOSE CONSUMABLES
GUN OVERHEATING
LOOSE RETAINING SCREW ON QUICK CONNECT BLOCK
INSUFFICIENT GAUGE POWER CABLE AND/OR GROUND CABLE
LOOSE CONNECTOR CONES AND/OR CONE NUTS
GUN BEING RUN BEYOND ITS AMPERAGE RANGE
ELECTRICAL MALFUNCTION IN POWER SOURCE
LOOSE CONSUMABLES
WELD POROSITY
SPATTER BUILT UP IN NOZZLE, BLOCKING GAS
LEAKS IN GAS HOSE OR IMPROPER CONNECTION
O-RINGS ON POWER PIN ARE CUT OR DAMAGED
INNER TUBE LOOSE FROM CONNECTOR CONE
POOR WIRE FEED (SEE ABOVE)
IMPROPER SHIELDING GAS OR WELDING WIRE
RUSTY OR POOR QUALITY WELDING WIRE
GAS FLOW IMPROPERLY SET

14
6.0 –EXPLODED VIEW AND PARTS LIST –AIR-COOLED GUNS
Air-Cooled Front-End
Air-Cooled Back-End
DESCRIPTION
1
STANDARD NOZZLES (Self Insulated)
401-40-38
SUPER TAPERED NOZZLE - 3/8" BORE (BRASS)
404-4-38
3/8" (10 mm) BORE - 1/8" (3 mm) TIP RECESS
401-4-50
1/2" (13 mm) BORE - 1/8” (3 mm) TIP RECESS
401-4--62
5/8" (16 mm) BORE - 1/8" (3 mm) TIP RECESS
401-4--75
3/4" (19 mm) BORE - 1/8" (3 mm)
SHORT ARC NOZZLE
401-8-62
1/8" (3 mm) TIP STICK OUT
HEAVY DUTY NOZZLES
401-5-62
5/8" (16 mm) BORE - 1/4" (6 mm) TIP RECESS
401-5-75
3/4" (19 mm) BORE - 1/4" (6 mm) TIP RECESS
401-6-60
1/2" (13 mm) BORE - 1/8" (3 mm) TIP RECESS
401-6-62
5/8" (16 mm) BORE - 1/8" (3 mm) TIP RECESS
401-6-75
3/4" (19 mm) BORE - 1/8" (3 mm) TIP RECESS
401-7-62
5/8" (16 mm) BORE - 1/4" (6 mm) TIP RECESS
2
HEAVY DUTY TOUGH LOCK™CONTACT TIPS
403-20-30
FOR .030” (0.6 mm) WIRE
403-20-30-25
FOR .030” (0.6 mm) WIRE
403-20-35
FOR .035”(0.9 mm) WIRE
403-20-35-25
FOR .035”(0.9 mm) WIRE
403-20-1.0
FOR 1 mm WIRE
403-20-1.0-25
FOR 1 mm WIRE
403-20-45
FOR .045”(1.2 mm) WIRE
403-20-5-25
FOR .045”(1.2 mm) WIRE
403-20-364
FOR .052”(1.3 mm) WIRE
403-20-364-25
FOR .052”(1.3 mm) WIRE
403-20-52
FOR 1/16" (16 mm) WIRE
403-20-52-25
FOR 1/16" (16 mm) WIRE
403-20-1.4
FOR 1.4” (1.4 mm) WIRE
403-20-1.4-25
FOR 1.4” (1.4 mm) WIRE
403-20-116
FOR 1/16" (16 mm) WIRE
403-20-116-25
FOR 1/16" (16 mm) WIRE
403-20-78
FOR .078” (1.8 mm) WIRE
403-20-564
FOR 5/64" (2.0 mm) WIRE
403-20-564-25
FOR 5/64" (2.0 mm) WIRE
403-20-332
FOR 3/32" (2.4 mm) WIRE
TOUGH LOCK™TAPERED CONTACT TIPS
403-21-30
FOR .030” (0.6 mm) WIRE
403-21-30-35
FOR .030” (0.6 mm) WIRE
403-21-35
FOR .035”(0.9 mm) WIRE
403-21-35-25
FOR .035”(0.9 mm) WIRE
403-21-1.0
FOR 1 mm WIRE
403-21-1.0-25
FOR 1 mm WIRE
403-21-45
FOR .045”(1.2 mm) W RE
403-21-45-25
FOR .045”(1.2 mm) WIRE
3
404-32
HEAVY DUTY RETAINING HEAD - TOUGH LOCK™
4
454-1-2
RETAINING RING ONLY
5
402-16
O-RING ONLY
6
402-11
NECK INSULATOR
7
405-180
NECK STRAIGHT
8
410-10
HOUSING - FRONT - 400 & 500 AMP
610-10
HOUSING - FRONT - 600 AMP
8a
410-12m
HOUSING SCREW - LOW PROFILE
PART #
DESCRIPTION
9
UNICABLE ASSEMBLY
513-104
4' (1.2 m) SERVICE - 500 AMP
513-106
6' (1.8 m) SERVICE - 500 AMP
513-108
8' (2.4 m) SERVICE - 500 AMP
513-110
10' (3.06 m) SERVICE - 500 AMP
613-104
4' (1.2 m) SERVICE - 600 AMP
613-106
6' (1.8 m) SERVICE - 600 AMP
613-108
8' (2.4 m) SERVICE - 600 AMP
613-110
10' (3.06 m) SERVICE - 600 AMP
10
666-10
HANDLE ASSEMBLY
11
416-15
HOUSING
13
414-400
POWER PIN BLOCK
14
214
TWECO® #4
214-6-116
MILLER ®
214-6-332
MILLER®
214-2
LINCOLN®
214-4
L-TEC MT SERIES®
214-12
TWECO® #5
214-13
PANASONIC®
214-14
PANASONIC® SHORT
16
QUICK LOAD™LINERS
415-26
LINER RETAINER (LINER DOES NOT COME WITH RETAINER)
415-35-6Q
FOR .035" - .045" (0.9 mm - 1.2 mm) WIRE - 6' (1.8m)
415-35-10Q
FOR .035" - .045" (0.9 mm - 1.2 mm) WIRE - 10' (3 m)
415-35-15Q
FOR .035" - .045" (0.9 mm - 1.2 mm) WIRE - 15' (5 m)
415-35-25Q
FOR .035" - .045" (0.9 mm - 1.2 mm) WIRE - 25' (8 m)
415-116-6Q
FOR .045" - 1/16" (1.2 mm - 1.6 mm) WIRE - 10' (1.8 m)
415-116-10Q
FOR .045" - 1/16" (1.2 mm - 1.6 mm) WIRE - 10' (3 m)
415-116-15Q
FOR .045" - 1/16" (1.2 mm - 1.6 mm) WIRE - 15' (5 m)
415-116-25Q
FOR .045" - 1/16" (1.2 mm - 1.6 mm) WIRE - 25' (8 m)
CONVENTIONAL LINERS
415-23-15
FOR .023” (0.6 mm) WIRE - 15’ (5 m)
415-30-15
FOR .030” (0.8 mm) WIRE - 15’ (5 m)
415-35-10
FOR .035” - .045” (0.9 mm - 1.2 mm) WIRE - 10’ (3 m)
415-35-15
FOR .035” - .045” (0.9 mm - 1.2 mm) WIRE - 15’ (5 m)
415-35-25
FOR .035” - .045” (0.9 mm - 1.2 mm) WIRE - 25’ (8 m)
415-35-2
FOR .035” (0.9 mm) WIRE - 15’ (5 m)
415-116-6
FOR .045” - 1/16” (1.2 mm - 1.6 mm) WIRE - 6’ (1.8 m)
415-116-10
FOR .045” - 1/16” (1.2 mm - 1.6 mm) WIRE - 10’ (3 m)
415-116-21
FOR .045” - 1/16” (1.2 mm - 1.6 mm) WIRE - 6’ (1.8 m)
415-116-22
FOR .045” - 1/16” (1.2 mm - 1.6 mm) WIRE - 10’ (3 m)
415-116-23
FOR .045” - 1/16” (1.2 mm - 1.6 mm) WIRE - 15’ (3 m)
415-116-25
FOR .045” - 1/16” (1.2 mm - 1.6 mm) WIRE - 25’ (8 m)
415-116-2
FOR 3/64” - 1/16” (1.2 mm - 2.4 mm) ALUMINUM WIRE - 15’ (5 m)
415-564-15
FOR ALL 5/64” (2.0 mm) WIRE & 1/16” (1.6 mm) FLUX CORE WIRE
415-1
LINER O-RING (NOT SHOWN)
17
FEEDER ADAPTOR REQUIREMENTS (SOLD SEPARATELY)
417
QUICK CONNECT BLOCK ASSEMBLY (TWECO #4)
Numbers in this column
correspond to the
exploded view images
above.

15
7.0 –EXPLODED VIEW AND PARTS LIST –WATER-COOLED GUNS
Water-Cooled Front-End Water-Cooled Back-End
PART #
DESCRIPTION
450 amp
600 amp
1
STANDARD NOZZLES
601 NOZZLES ARE THREAD ON
401-5-62
601-5-62
5/8” (16 mm) BORE - 1/4” (6 mm) TIP RECESS
401-5-75
601-5-75
3/4” (19 mm) BORE - 1/4” (6 mm) TIP RECESS
401-6-62
601-6-62
5/8” (16 mm) BORE - 1/8” (3 mm) TIP RECESS
401-6-75
601-6-75
3/4” (19 mm) BORE - 1/8” (3 mm) TIP RECESS
401-8-62
5/8” (16 mm) BORE - 1/8” (3 mm) TIP STICKOUT
2
HEAVY DUTY TOUGH LOCK™CONTACT TIPS –
5/16” (7.9 mm) O.D.
40-20-30
403-20-30
FOR .030" (0.8 mm) WIRE
403-20-35
403-20-35
FOR .035" (0.9 mm) WIRE
403-20-1.0
403-20-1.0
FOR 1 mm WIRE
403-20-45
403-20-45
FOR .045" (1.2 mm) WIRE
403-20-364
403-20-364
FOR 3/64" (1.2 mm) WIRE
403-20-1.4
403-20-1.4
FOR 1.4 mm WIRE
403-20-52
403-20-52
FOR .052" (1.3 mm) WIRE
403-20-116
403-20-116
FOR 1/16" (1.6 mm) WIRE
403-20-564
403-20-564
FOR 5/64" (2.0 mm) WIRE
3
454-1-2
O-RING ONLY
404-20
TOUGH LOCK™RETAINING HEAD –FOR HD TIPS
404-3
HEAVY DUTY RETAINING HEAD
404-38
TOUGH LOCK DIFFUSER
402-6
N/A
O-RING
4
601-5-75-3
CERAMIC INSULATOR
5
NECKS (INCL. (1) 656-1 AND (1) 657-1 CLAMP
455-45
595-45
NECK - 45°
455-60
595 60
NECK - 60°
455-180
595-180
NECK - STRAIGHT
6
452-1
NECK INSULATOR - USE WITH 454-1 HEAD
452-3
NECK INSULATOR - USE WITH 404-20 HEAD
7
INTERNAL WATER LINE (C/W (2) 656-1 CLAMPS)
656-15
656-15
15’ SERVICE
8
657-15
657-15
CONDUIT 15’
658
658
RED WATER LINE - OUT (C/W (1) 656-1 CLAMP)
658-1
658-1
BLUE WATER LINE - IN (C/W (1) 656-1 CLAMP)
(LOCATED AT QUICK CONNECT POWER BLOCK
ASSEMBLY)
9
POWER CABLE ASSEMBLY
659-10
659-10
10’ SERVICE (ACTUAL LENGTH - 9.5’)
659-12
659-12
12’ SERVICE (ACTUAL LENGTH - 11.5’)
659-15
659-15
15’ SERVICE (ACTUAL LENGTH - 14.5’)
10
CABLE BUNDLE (COMPLETE WITH CLAMPS)
661-10
661-10
10’ SERVICE (OUTER JACKET ONLY 663-1-10)
661-12
661-12
12’ SERVICE (OUTER JACKET ONLY 663-1-12)
661-15
661-15
15’ SERVICE (OUTER JACKET ONLY 663-1-15)
11
660-10
660-10
HOUSING FRONT
12
416-15
416-15
HOUSING
13
664-400
664-400
POWER PIN BLOCK
PART #
DESCRIPTION
450 amp
600 amp
14
214
214
TWECO® #4
214-2
214-2
LINCOLN®
214-4
214-4
L-TEC MT SERIES®
214-6-116
214-6-116
MILLER®1/16
214-6-332
214-6-332
MILLER®3/32
214-7
214-7
LINCOLN®SHORT
214-12
214-12
TWECO® #5
214-13
214-13
PANASONIC®
214-14
214-14
PANASONIC®SHORT
414-1
414-1
O-RING
414-2
414-2
LINER SET SCREW
414-11-2
414-11-2
O-RING FOR MILLER®POWER PIN
15
QUICK LOAD™LINERS
415-26
415-26
LINER RETAINER (LINER DOES NOT COME
WITH RETAINER)
415-35-6Q
415-35-6Q
FOR .035" - .045" (0.9 - 1.2 mm) WIRE - 6' (1.8
m)
415-35-10Q
415-35-10Q
FOR .035" - .045" (0.9 - 1.2 mm) WIRE - 10' (3 m)
415-35-15Q
415-35-15Q
FOR .035" - .045" (0.9 - 1.2 mm) WIRE - 15' (5 m)
415-35-25Q
415-35-25Q
FOR .035" - .045" (0.9 - 1.2 mm) WIRE - 25' (8 m)
415-116-6Q
415-116-6Q
FOR .045" - 1/16" (1.2 - 1.6 mm) WIRE - 6' (1.8m)
415-116-10Q
415-116-10Q
FOR .045" - 1/16" (1.2 - 1.6 mm) WIRE - 10' (3 m)
415-116-15Q
415-116-15Q
FOR .045" - 1/16" (1.2 - 1.6 mm) WIRE - 15' (5 m)
415-116-25Q
415-116-25Q
FOR .045" - 1/16" (1.2 - 1.6 mm) WIRE - 25' (8 m)
CONVENTIONAL LINERS
415-23-15
415-23-15
FOR .023" (0.6 mm) WIRE - 15' (5 m)
415-30-15
415-30-15
FOR .030" (0.8 mm) WIRE - 15' (5 m)
415-35-10
415-35-10
FOR .035" - .045" (0.9 - 1.2 mm) WIRE - 10' (3 m)
415-35-15
415-35-15
FOR .035" - .045" (0.9 - 1.2 mm) WIRE - 15' (5 m)
415-35-25
415-35-25
FOR .035" - .045" (0.9 - 1.2 mm) WIRE - 25' (8 m)
415-35-2
415-35-2
FOR .035" (0.9 mm) ALUMINUM WIRE - 15' (5 m)
415-116-10
415-116-10
FOR .045" - 1/16" (1.2 - 1.6 mm) WIRE - 10' (3 m)
415-116-15
415-116-15
FOR .045" - 1/16" (1.2 - 1.6 mm) WIRE - 15' (5 m)
415-116-25
415-116-25
FOR .045" - 1/16" (1.2 - 1.6 mm) WIRE - 25' (8 m)
415-116-2
415-116-2
FOR 3/64" - 1/16" (1.2 - 1.6 mm) ALUM. WIRE -
15' (5 m)
415-564-15
415-564-15
FOR ALL 5/64" (2.0 mm) WIRE & 1/16" (1.6 mm)
FLUX CORE WIRE
415-332-15
415-332-15
For .078” - 3/32”(2.24 mm) WIRE - 15’ (5 m)
FLAT WOUND
16
FEEDER ADAPTOR REQUIREMENTS (SOLD
SEPARATELY)
417
417
QUICK CONNECT BLOCK ASSEMBLY -
TWECO #4
417-50
417-50
QUICK CONNECT BLOCK ASSEMBLY - EURO
417-60
417-60
QUICK CONNECT BLOCK ASSEMBLY -
TWECO #5
17
FEEDER ADAPTORS (TO BE USED WITH
QUICK CONNECT BLOCK)
18
666-10
666-10
HANDLE ASSEMBLY

16
8.0 –ORDERING INFORMATION
8.1 TOUGH GUN AUTOMATIC AIR-COOLED MIG GUN ORDERING INFORMATION
M A 1
5500 amp 0No options 1TOUGH LOCK™ Heavy Duty A3.0’A401-6-62 0No Options B0.030”BBernard™
6* 600 amp 2HD Retaining Head B3.5’B401-5-62 C0.035”EEuro
A22 degrees 3HD Diffuser C4.0’C401-6-50 D1.0 mm FFronius®
405-22 4SD Diffuser D4.5’D401-42-50 E0.045”LLincoln®
B45 degrees E5.0’E401-7-62 F3/64”MMiller®
405-45 F5.5’F401-7-75 G0.052”CL-Tec®
C60 degrees G6.0’G401-4-38 H1.4 mm PPanasonic®
405-60 H6.5’H401-4-50 J1/16”TTweco #4
D180 degrees J7.0’J401-7-87 K1.8 mm WTweco #5
405-180NB K7.5’L5/64"
L8.0’M3/32”1Tweco #4
E22 degrees M8.5’2Lincoln
505-22 N9.0’R0.035”3Tweco #5
F45 degrees P9.5’S3/64”4Miller
505-45 R10’T1/16”6Panasonic
G60 degrees S12’U0.045”7Fronius
505-60 T15’V1.4 mm
H180 degrees W0.052"
505-180
J45 degrees
405-45LL
K60 degrees
405-60LL *TOUGH GUN I.C.E. Technology is not available with 600 amp model
**AutoLength™ Pins not compatible with wire sizes for aluminum wire
M22 degrees
591-22
N45 degrees
591-45
P60 degrees
591-60
Q180 degrees
591-180
5
K
Automatic Series
Amperage
Neck
Option 1
Retaining Head
Cable Length
Nozzle
Option 2
Wire Size
Power Pin
E
T
TOUGH GUN I.C.E.*
Aluminum
0
2
R
C
0
AutoLength™ Pin**
Air-Cooled
Short Length
Medium Length
Long Length
8.2 TOUGH GUN AUTOMATIC WATER-COOLED MIG GUN ORDERING INFORMATION
Distributed by:
01/31 REV J TG033