TOUGH GUN ThruArm G2 Series MIG Guns for FANUC Robots Owner's Manual
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TECHNICAL GUIDE TOUGH GUN™ ThruArm™ G2 Series Robotic MIG Guns for FANUC® Robots 100iC, 100iC-6L, 120iC, 120iC-10L  INSTALLATION  MAINTENANCE  TECHNICAL DATA  OPTIONS  EXPLODED VIEW & PARTS LIST  ORDERING INFORMATION Certified ISO 9001 : 2008 Please read instructions prior to use. Save this manual for fu

THANK YOU… …for selecting a Tregaskiss TOUGH GUN™ ThruArm™ G2 Series Robotic MIG Gun. Manufacturing operations demand extremely dependable robotic equipment. With this in mind, the TOUGH GUN MIG Gun was designed and engineered to be a reliable tool to support high production within a robotic cell. 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...

GENERAL SAFETY INFORMATION Before installation or operation of TOUGH GUN MIG Guns, please read the following safety precautions. 1. Do not touch live electrical parts. The following should be checked to prevent electrical shock:  Faulty or damaged equipment is repaired or replaced.  Equipment is off when not in use. 2. Ensure that all safety devices, guards, shields or barriers are properly in place and connected correctly before allowing operation of the equipment. 3. CSA Standard W117.2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Association, Standards...

1.0 – COMPLETE ASSEMBLY OVERVIEW For part numbers, see Section 6.0 – EXPLODED VIEW AND PARTS LIST. 2.0 – INSTALLATION STEP #1 – POSITIONING THE ROBOT  Position the robot with the wrist and top axis 180° parallel to each other (as shown) to properly complete the gun installation. WRIST

STEP #2 – INSTALLING INSULATING DISC   Begin by installing insulating disc, being sure to align dowel pin with associated hole on robot mounting face. NOTE: Dowel will be pressed into disc prior to shipping. Using the supplied tightening pattern in Figure 1, attach insulating disc using the provided M4X.7X12 cap screws (X4). Torque to 25 in.-lbs./2.8 Nm. IMPORTANT: Installing differently than as instructed can result in cracking or breaking of the insulating disc. Figure 1 M3 DOWEL (SHOWN EXPLODED FROM ASSEMBLY FOR CLARITY) ROBOT MOUNTING FACE STEP #3 – INSTALLING ALUMINUM SPACER  ...

STEP #4 – INSTALLING LSR UNICABLE  Feed the cable by bending it in a “U” shape. Insert the rear portion through the robot arm shroud and the front portion through the aluminum spacer. STEP #5 – INSTALLING FRONT HOUSING  Firmly grasp the unicable at the indicated location. Next bring the front end housing toward the unicable and insert fully onto the pin at the end of the unicable. Force the two components together until contact surfaces 1 and 2 are touching firmly. CONTACT SURFACE 2 GRASP HERE Fasten ThruArm Solid Mount to LSR Unicable by tightening front housing cap screw M6X1X12. Torque...

Next, fasten front housing and aluminum spacer together using M5X.8X16 cap screws (X4). Torque to 50 in.-lbs. / 5.5 Nm. CAP SCREWS M5X16 SHCS (50 in.-lbs. TORQUE) STEP #6 – INSTALLING FASTENER COVER  Slide fastener cover up and into place and then attach using flat head cap screws (X2). Torque to 12 in.-lbs./1.4Nm. BUTTON HEAD CAP SCREWS M4X8 SBHCS SOCKET HEAD CAP SCREW M3X12 SHCS STEP #7 – INSTALLING NECK / NECK REPLACEMENT IMPORTANT! Remove consumables (i.e. retaining head, nozzle and contact tip) before installing neck. Failure to do so will result in improper installation.  Twist the...

STEP #8 – INSTALLING POWER PIN TO THE LSR UNICABLE Option #1 of 2: Power Pins  Install power pin onto the LSR Unicable. NOTE: Power pins incorporate a taper to seat and lock the pin to the rear handle block. Make sure the power pin is tightened in the block with a wrench to insure the pin is secure and will not come loose. o Thread power pin into the adaptor of the LSR Unicable. o 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. o Torque to 18 ft.-lbs. / 24.4 Nm. POWER PIN (LINCOLN® SHOWN)...

STEP #10 – INSTALLING CONSUMABLES TOUGH LOCK CONTACT TIP RETAINING HEAD Thread the retaining head onto the neck. Use a 5/8” wrench and tighten to 80 in.-lbs. (or 9 Nm). Thread the contact tip into the retaining head. Torque to 30 in.-lbs. (3.5 Nm). Push the slip-on Tregaskiss Nozzle over the retaining head / contact tip combo until the nozzle is fully seated. IMPORTANT: Be sure all consumables are tightened properly and fully seated before welding to prevent overheating. STEP #11 – INSTALLING GUN LSR UNICABLE TO FEEDER      Ensure that the bolts clamping the feeder to the bracket on...

3.0 – MAINTENANCE 3.1 REPLACEMENT OF EURO CONNECTION CONDUIT HAND NUT   Remove M5 x 6 mm countersunk fasteners. Slide the hand nut over the Euro power pin body. Torque the power pin body to the threaded end of the unicable at 18 ft.-lbs. (24 Nm) using 7/8” & 13/16” wrenches. You may have to pull back on the outer conduit to achieve this. Once the power pin body is in place, pull the conduit down over it. Rotate the conduit so that the holes on the power pin line up with the holes on the plastic end of the conduit. Insert the two M5 x 6mm countersunk screws and torque to 12 in.-lbs. (1.35...

3.2 REPLACEMENT OF QUICK LOAD LINER POWER PIN (LINCOLN SHOWN) LINER RETAINER NOTE: One liner retainer can last for multiple liner replacements. Therefore this step is not required for every liner change. Remove the QUICK LOAD Liner retainer (#415-26) from the power pin and thread in new one. Torque to 30 in.-lbs. (3.5 Nm). Remove consumables (nozzle, contact tip, retaining head). Remove existing QUICK LOAD Liner. Insert new QUICK LOAD Liner through neck using the wire as a guide. Short strokes will prevent the wire from kinking. Once the liner stops feeding, give it an extra push to ensure...