TECHNICAL GUIDE

TOUGH GUN™
TT REAMER
For Serial #TT-11300 and higher

 SAFETY & WARRANTY

 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.
TABLE OF CONTENTS
WARRANTY ................................................................................................................................ 2
THANK YOU… ............................................................................................................................ 3
GENERAL SAFETY ..................................................................................................................... 3
1.0 – INSTALLATION / SETUP .................................................................................................... 4
1.1 INSTALLING TOUGH GUN REAMER ............................................................................................................ 4
1.2 AIR MOTOR LUBRICATION ........................................................................................................................... 5
1.3 WIRING INTERFACE CONNECTIONS .......................................................................................................... 5
1.4 ACCESS TO ELECTRICAL AND PNEUMATIC CONTROLS ........................................................................ 5
1.5 CIRCUIT BOARD LOGIC INVERSE ............................................................................................................... 5
1.6 L.E.D. INDICATORS ....................................................................................................................................... 6
1.7 NOZZLE HEIGHTS FOR CUTTER BLADE INSERTION ............................................................................... 6
1.8 PROGRAMMING EVENTS SEQUENCE ........................................................................................................ 7
1.9 V-BLOCK SETUP ............................................................................................................................................ 7
1.10 MANUAL REAMER SETUP .......................................................................................................................... 7
1.11 FLOW CONTROL VALVE(S) ........................................................................................................................ 7
2.0 – MAINTENANCE.................................................................................................................. 8
2.1 AIR MOTOR REPLACEMENT ........................................................................................................................ 8
2.2 REPLACEMENT OF PRINTED CIRCUIT BOARD ......................................................................................... 8
2.3 CUTTER BLADE REPLACEMENT ................................................................................................................. 9
2.4 BELT REPLACEMENT .................................................................................................................................... 9
2.5 SOLENOID VALVE REPLACEMENT ............................................................................................................. 9
2.6 SCHEDULED MAINTENANCE PROGRAM ................................................................................................. 10
3.0 – TECHNICAL DATA ........................................................................................................... 10
3.1 PNEUMATIC DIAGRAM................................................................................................................................ 10
3.2 ELECTRICAL SCHEMATIC .......................................................................................................................... 11
3.3 CUTTER BLADE AND V-BLOCK CHART .................................................................................................... 12
4.0 – EXPLODED VIEW AND PARTS LIST ................................................................................ 13
5.0 – TROUBLESHOOTING ....................................................................................................... 14
6.0 – SPRAYER (OPTION) ........................................................................................................ 14
6.1 ANTI-SPATTER SPRAYER .......................................................................................................................... 14
6.2 SPRAYER PROGRAMMING EVENTS SEQUENCE.................................................................................... 15
6.3 SPRAYER MAINTENANCE .......................................................................................................................... 15
6.4 SPRAYER TROUBLESHOOTING ................................................................................................................ 15
6.5 SPRAYER PARTS LIST – SR-500 ............................................................................................................... 16
7.0 – ADDITIONAL OPTIONS .................................................................................................... 16
7.1 REAMER STAND WITH OPTIONAL SMC FRL (FILTER REGULATOR LUBRICATOR) ............................ 16
7.2 FLOW CONTROL .......................................................................................................................................... 17
7.3 WIRE CUTTER .............................................................................................................................................. 17
8.0 – MULTI-FEED READY REAMER ......................................................................................... 18
9.0 – ORDERING INFORMATION .............................................................................................. 19

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

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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.

THANK YOU…
…for selecting a TOUGH GUN™ Reamer. Manufacturing operations demand extremely dependable robotic
equipment. With this in mind, the TOUGH GUN Reamer was designed and engineered to be a reliable tool to
support high production within a robotic cell. As the name implies, the TOUGH GUN Reamer is made from
durable materials and components engineered to perform in a rugged robotic welding environment.

The instructions and illustrations in this Technical Guide make it easy for you to maintain your TOUGH GUN
Reamer. Please read, understand, and follow all safety procedures. Keep this Technical Guide booklet as a
handy reference when ordering complete guns, parts and special options.

For technical support and special applications, please call the Tregaskiss Technical Service Department
at 1-877-737-3111 or fax 1-877-737-2111. Our trained technicians are available between 8:30 AM and 4:30 PM
EST, and will answer your application or repair questions.

Tregaskiss also manufactures complete robotic MIG gun systems designed and engineered to perform as a team
in the high-volume robotic production environment. Components include TOUGH GUN Robotic Air-Cooled and
Water-Cooled MIG Guns, TOUGH GUN Clutch and Mounting Arms. Contact your Tregaskiss representative or
Tregaskiss for further information.

GENERAL SAFETY
Before installation or operation of the TOUGH GUN Reamer, please read and understand all safety precautions
listed below. Failure to follow these instructions may result in personal injury or damage to the equipment.

1. Do not remove or deface warning and instruction labels from the unit.
2. Ensure that all equipment in the area is disabled and locked out before setting up, adjusting or conducting
any work.
3. Ensure that electrical and pneumatic power to unit is off before performing maintenance or
troubleshooting.
4. Ensure reset button is pressed to reset circuit board logic before doing any maintenance or
troubleshooting with electrical power and/or pneumatic power on.
5. Check that electrical and pneumatic connections comply with the codes applicable to your country and
state.
6. Keep hands away from unit while in operation.
7. For additional safety information, please refer to the following publications:

ANSI STANDARD Z49.1, SAFETY IN WELDING AND CUTTING,

American Welding Society, 550 LeJeune Rd. P.O. Box 351040, Miami, FL 33126

ANSI STANDARD, SAFETY FOR ROBOTS AND ROBOT SYSTEMS,

American National Standards Institute, 1430 Broadway, New York, NY 10018

NFPA STANDARD 70-1978, NATIONAL ELECTRIC CODE,

National Fire Protection Association, 1470 Atlantic Avenue, Boston, MA 02210

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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.)

1.0 – INSTALLATION / SETUP

1.1 INSTALLING TOUGH GUN™ REAMER

WARNING: ENSURE POWER SUPPLY IS OFF AND DISCONNECTED BEFORE PROCEEDING.

Mounting Hole Locations and Footprint

Dimensions
MOUNTING REAMER
 The TOUGH GUN Reamer should be
installed within the weld cell at a convenient
location. Be sure to consider movable
fixtures and the working envelope of the
robot.
 Affix Reamer base to sturdy platform using
four (4) bolts (provided).

CONNECTING AIR SUPPLY

WARNING: PUSH RESET BUTTON BEFORE
CONNECTING AIR LINE.
 Use only filtered, lubricated air.
 REQUIREMENTS - IMPORTANT: 80 to
100 psi at 16 CFM (5.0 - 7.0 BAR at 450
LPM) at the Reamer during operation.
 Use an air supply line with an inside
diameter of 3/8". Connect to 1/4" female
NPT inlet located on the side of the reamer.

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1.2 AIR MOTOR LUBRICATION
An air line lubricator (not supplied) must be mounted in the air line of the TOUGH GUN Reamer. The Lubricator
should be set to feed one drop of oil for every 50-75 CFM of air going through the motor (approximately every 3-5
cycles). The lubricant can be air motor oil or light grade hydraulic oil with a viscosity rating of 150 VC 15-20 (SAE
5W).

1.3 WIRING INTERFACE CONNECTIONS

WARNING: THE FOLLOWING CONNECTIONS SHOULD ONLY BE PERFORMED BY QUALIFIED
TECHNICIANS. DAMAGE TO EQUIPMENT WILL OCCUR IF CONNECTIONS ARE INCORRECT.

To interface the TOUGH GUN Reamer with the controller, 4 electrical connections are required (5 if using
Sprayer):
 ORANGE LEAD - CYCLE START INPUT (0.25 AMP)
 WHITE LEAD - 0 VDC SUPPLY 0.5 AMP
 RED LEAD - 24 VDC SUPPLY 0.5 AMP
 GREEN LEAD - JAWS UNCLAMPED OUTPUT (LOAD CAPACITY = 0.25 AMP)
 BLACK LEAD - OPTION / SPRAYER (INPUT)
NOTE: The pre-wired interface receptacle uses the above color codes.

OPERATION NOTES:
NOTE: The circuit board of the TOUGH GUN Reamer is capable of both sourcing or sinking inputs and outputs:
 Connection 2 - RED LEAD. 24 VDC supply that operates the board.
 Connection 3 - GREEN LEAD. Cycle Complete Signal has one of two settings: 1) Sourcing, OR 2) Sinking.
 Connection 4 - ORANGE LEAD. Cycle Start Signal (Start Signal should be a pulse with a maximum of 0.5
seconds in duration) has one of two settings: 1) Board set to “Sourcing” (Robot sends “high” signal or +24
VDC), or 2) Board set to “Sinking” (Robot sends “low” signal or 0 VDC). See Section 1.5 LOGIC INVERSE for
more information.

1.4 ACCESS TO ELECTRICAL AND PNEUMATIC CONTROLS

WARNING: ENSURE POWER SUPPLY IS OFF AND DISCONNECTED BEFORE PROCEEDING.

 To access the electronic circuit board for

installation or service of the TOUGH GUN
Reamer, simply loosen the 2 Metric screws
using a 3 mm Allen wrench to open the a.
hinged access door.
 The shroud can be completely removed if
accessibility is an issue. Simply loosen the 3
Metric screws using a 3 mm Allen wrench
and remove shroud. M5 x 0.8 x 16 mm
SBHCS SCREWS

b.

1.5 CIRCUIT BOARD LOGIC INVERSE

CAUTION! BEFORE START-UP, ENSURE THAT ALL CONNECTIONS ARE CORRECT OR DAMAGE TO THE
TOUGH GUN REAMER MAY OCCUR.

NOTE: The TOUGH GUN Reamer is factory set for sourcing inputs and outputs.

DEFINITIONS: SINKING = signal from robot is LOW SOURCING = signal from robot is HIGH

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 See Section 3.2 ELECTRICAL SCHEMATIC.
 The control logic requirement for some installations may require an inverse of the logic provided. The inverse
logic is 0 VDC low (sinking) input or outputs.
 To switch from sourcing to sinking, the switches located inside the motor shroud must be accessed. See
Section 1.4 ACCESS TO ELECTRICAL AND PNEUMATIC CONTROLS above for directions.
 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.
 The Output signal (unclamped signal) can be altered to either sourcing or sinking by moving the switch (SW3)
to the position indicated in the diagram.
 The Input signal (start signal) can be altered to either sourcing or sinking by moving the switch (SW2) to the
position indicated in the diagram.
 The Option signal (sprayer) can be altered to either sourcing or sinking by moving the switch (SW1) to the
position indicated in the diagram.

1.6 LED INDICATORS

The LED indicators mounted on the front 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 idle, LED status should be:
“Reamer Home” - ON
“Clamp / Motor Valve Short” - OFF
“Reamer Ahead” - OFF
“Sprayer Valve Short” - OFF
“Unclamped” - ON
“Feed Valve Short” - OFF (Feed Valve = Spindle Valve)
“Reamer Home” - indicates that the lift cylinder has retracted, the cutter is at the bottom
of its stroke and the limit pin is activating the lower limit switch.
“Clamp / Motor Valve Short” - indicates short with clamp or motor valve.
“Reamer Ahead” - indicates that the Reamer has reached full upper stroke and the limit
pin is activating the upper limit switch.
“Sprayer Valve Short” - indicates short with sprayer / option valve.
“Unclamped” - indicates that the clamp cylinder is fully retracted, releasing the clamp
mechanism and supplying an output signal that the cycle is complete (via the limit switch
mounted next to the clamp cylinder).
“Feed Valve Short” - indicates short with feed valve (also referred to as “spindle valve”).

1.7 NOZZLE HEIGHTS FOR CUTTER BLADE INSERTION

RETAINING HEAD
404-14 / 404-20 /
CUTTER SEE
NOZZLE 404-3 / 404 404-26 / 404-30 / 454-1
BLADE CHART
404-32
3/8” .023” .564 mm .025” .635 mm
RC-06 -- --
(9.53 mm) BELOW BELOW BELOW BELOW
3/4" 11.84
RC-12 FLUSH FLUSH FLUSH FLUSH .466” NOZZLE
(19.05 mm) mm
5/8” 18.19
RCT-01 .200” 5.08 mm .200” 5.08 mm .716”
(15.88 mm) mm
1/2"
RCT-04 FLUSH FLUSH .165” 4.19 mm .085” 2.16 mm
(12.7 mm)

CUTTER
BLADE

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1.8 PROGRAMMING EVENTS SEQUENCE
1. Verify the TOUGH GUN Reamer input showing “Clamps Open”.
2. Position the robot to place the MIG gun at a right angle to the unit and to insert the gun to the proper depth,
centered and pressed against the v-block (See Section 1.7 NOZZLE INSERTION HEIGHTS).
3. Cycle Start - Supply output signal from the robot controller. Pulse output for 0.5 seconds.
4. TOUGH GUN Reamer performs cleaning cycle.
5. Wait and verify input from TOUGH GUN Reamer for cycle (Clamps Closed).
6. Wait and verify input from TOUGH GUN Reamer for Cycle Complete (Clamps Open).
7. The robot can now be safely removed from the TOUGH GUN Reamer clamps to the next position.
8. If using anti-spatter sprayer - See Section 6.0 SPRAYER.
9. After reaming, center the nozzle above the spray head (See Section 6.2 SPRAYER PROGRAMMING
EVENTS SEQUENCE for details).
10. Supply output signal from robot controller to the sprayer for about 0.5 seconds (increase or decrease spray
time as required).
11. Move robot to next position.

1.9 V-BLOCK SETUP

WARNING: ENSURE POWER SUPPLY IS OFF AND AIR IS DISCONNECTED BEFORE PROCEEDING.

 Remove four cover COVER SCREWS V-BLOCK NOZZLE OUTSIDE DIAMETER

PART # FOR EACH SIDE OF V-BLOCK
screws.
 Lift clamp cover off. TR-2150
0.850” 0.938” 1.062” 1.106”
 Lift and rotate v-block so (4 SIDES)
desired size faces jaws.
 NOTE: Numbers are JAWS V-BLOCK
TR-2161 25
stamped into the v- 0.830” 0.978” 1.125”
(4 SIDES) mm
blocks. The number
refers to the outside
TR-2162
diameter of the nozzle 0.780” 0.813” 0.875” 1.000”
(4 SIDES)
(i.e. 0.938 = 0.938 O.D.)

1.10 MANUAL REAMER SETUP

NOTE:
 The manual override switches allow confirmation that the lift cylinder and jaw clamping air circuit is
operational.
 To manually operate the TOUGH GUN Reamer, locate the switches on the air supply side of the Reamer as
shown.
NOTE: The RESET button should be pressed prior to manual setup to reset all circuitry.

1.11 FLOW CONTROL VALVE(S)

OPERATING NOTES: The flow control valve(s) provide a smooth, constant RESET
BUTTON
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 can be set
faster. A feed rate that is set too fast may stall the motor or damage the cutter
blade.

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ADJUSTING THE FLOW CONTROL VALVE(S)
 There is a flow control valve for adjustment of the up speed of the feed head. The
down (retract) speed is fixed. The feed rate may require adjusting for different
applications.
 The valve controls the rate at which air is released on the exhaust side of the
cylinder.
 To increase feed rate on the nozzle, the valve would have to be opened, which
allows air to flow out of the cylinder thereby increasing speed.
 To decrease feed rate into the nozzle, the valve would have to be closed, which
slows air flow out of the cylinder causing feed to slow down.

2.0 – MAINTENANCE

2.1 AIR MOTOR REPLACEMENT

 Open motor shroud or remove completely by removing

2 screws using a 3 mm Allen wrench.
 Remove tension lock screw.
 Push motor in to release belt tension.
 Disengage belt.
 Release air lines from quick disconnect air fittings at
front of motor.
 Pull out motor. BE CAREFUL NOT TO LOSE THE
MOTOR SPRING.
TENSION
 Reverse order for reassembly. SCREW DRIVE
BELT

2.2 REPLACEMENT OF PRINTED CIRCUIT BOARD

BOARD
 Open rear shroud. STANDOFFS
 Remove connectors from
board being careful not to
damage wiring.
 Remove the fasteners which secure
board to standoffs.
 IMPORTANT: Check to ensure all
4 standoffs are still attached to the frame.
 Board can now be carefully removed
from the unit and a new one installed.
 Once located in the proper
position, secure board by BOARD
tightening fasteners. MOUNTING
REAMER BOARD
SCREWS

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2.3 CUTTER BLADE REPLACEMENT
 Remove 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. CUTTER
 Considerable force may be required to loosen the BLADE
cutter since it tightens naturally as the Reamer
operates.

INSTALLING CUTTER BLADE

The cutter blade is installed by threading it clockwise
into the top of the extensions shaft.
9/16”
WRENCH
NOTE: The application of anti-seize compound to the (SUPPLIED)
threads of the TOUGH GUN Reamer cutter will assist in
easy removal in the future.

2.4 BELT REPLACEMENT

 Open rear cover.

 Loosen tension lock screw.
 Push motor in to release belt tension.
 Remove belt. TENSION
LOCK
 Reverse order for reassembly. SCREW
BELT

2.5 SOLENOID VALVE REPLACEMENT

 Shut off power to TOUGH GUN Reamer.

 Shut off air supply to TOUGH GUN Reamer.
 Open motor shroud.
 Unplug wires directly from bottom of solenoid valve.
 Loosen and remove (2) solenoid valve screws.
 Remove solenoid valve and gasket.
NOTE: New gasket (included with new valve) must be installed when
replacing valve.
 Reinstall new gasket and valve and tighten screws to 6 in.-lbs.
 Reconnect wires to bottom of solenoid valve.
 Close the motor shroud.

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2.6 SCHEDULED MAINTENANCE PROGRAM
The TOUGH GUN Reamer will require a periodic maintenance program to ensure a reliable service life. The
following schedule is recommended.

DAILY
 Ensure spindle cover area is clear of spatter.
 Visually check oil level in lubricator reservoir.
 The life of the air motor is dependent on a consistent supply of oil.
 Visually check air lines and interface cable for leaks and fraying.
 Clean clamp jaw surfaces to ensure proper nozzle gripping.
WEEKLY
 Visually check the TOUGH GUN Reamer cutter blade. The service life of the cutter blade is dependent on the
type of application.
 In lighter duties, the blade may last indefinitely. However, it should be inspected for dullness, clogging and
possible breakage.
 Ensure belt tension lock screw is securely tightened.
YEARLY
 Replace drive belt (See Section 2.4 BELT REPLACEMENT).

3.0 – TECHNICAL DATA

3.1 PNEUMATIC DIAGRAM

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3.2 ELECTRICAL SCHEMATIC

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3.3 CUTTER BLADE AND V-BLOCK CHART
NOZZLE OUTSIDE CUTTER BLADE
NOZZLE PART # REAMER MODEL V-BLOCK PART #
DIAMETER PART #
401-4-38 0.938” TT-0938-06 TR-2150 RC-06
401-45-38 0.938” TT-0938-06 TR-2150 RC-06
401-45-38 0.938” TT-0938-06 TR-2150 RC-06
401-46-38 0.938” TT-0938-06 TR-2150 RC-06
401-4-50 0.938” TT-0938-04 TR-2150 RCT-04
401-6-50 1.060” TT-1060-04 TR-2150 RCT-04
401-42-50 0.938” TT-0938-04 TR-2150 RCT-04
401-44-50 0.938” TT-0938-04 TR-2150 RCT-04
401-45-50 0.938” TT-0938-04 TR-2150 RCT-04
401-46-50 0.938” TT-0938-04 TR-2150 RCT-04
401-47-50 0.938” TT-0938-04 TR-2150 RCT-04
401-48-50 0.938” TT-0938-04 TR-2150 RCT-04
451-6-50 0.938” TT-0938-04 TR-2150 RCT-04
401-4-62 0.938” TT-0938-01 TR-2150 RCT-01
401-5-62 1.060” TT-1060-01 TR-2150 RCT-01
401-6-62 1.060” TT-1060-01 TR-2150 RCT-01
401-7-62 1.106” TT-1106-01 TR-2150 RCT-01
401-8-62 0.938” TT-0938-01 TR-2150 RCT-01
401-9-62 0.938” TT-0938-01 TR-2150 RCT-01
401-45-62 0.938” TT-0938-01 TR-2150 RCT-01
401-46-62 0.938” TT-0938-01 TR-2150 RCT-01
401-48-62 1.060” TT-1060-01 TR-2150 RCT-01
401-72-62 1.060” TT-1060-01 TR-2150 RCT-01
401-81-62 1.060” TT-1060-01 TR-2150 RCT-01
401-87-62 1.060” TT-1060-01 TR-2150 RCT-01
451-1-62 1.060” TT-1060-01 TR-2150 RCT-01
451-5-62 0.938” TT-0938-01 TR-2150 RCT-01
451-6-62 0.938” TT-0938-01 TR-2150 RCT-01
451-8-62 0.938” TT-0938-01 TR-2150 RCT-01
451-61-62 1.060” TT-1060-01 TR-2150 RCT-01
451-81-62 1.060” TT-1060-01 TR-2150 RCT-01
451-87-62 1.060” TT-1060-01 TR-2150 RCT-01
650-5-62 1.060” TT-1060-01 TR-2150 RCT-01
650-6-62 1.060” TT-1060-01 TR-2150 RCT-01
651-5-62 1.060” TT-1060-01 TR-2150 RCT-01
651-6-62 1.060” TT-1060-01 TR-2150 RCT-01
401-4-75 0.938” TT-0938-12 TR-2150 RC-12
401-5-75 1.060” TT-1060-12 TR-2150 RC-12
401-6-75 1.060” TT-1060-12 TR-2150 RC-12
401-7-75 1.106” TT-1106-12 TR-2150 RC-12
451-1-75 1.060” TT-1060-12 TR-2150 RC-12
451-5-75 0.938” TT-0938-12 TR-2150 RC-12
451-6-75 0.938” TT-0938-12 TR-2150 RC-12
650-5-75 1.060” TT-1060-12 TR-2150 RC-12
650-6-75 1.060” TT-1060-12 TR-2150 RC-12
651-5-75 1.060” TT-1060-12 TR-2150 RC-12
651-6-75 1.060” TT-1060-12 TR-2150 RC-12

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4.0 – EXPLODED VIEW AND PARTS LIST

COMMON COMMON
WITH WITH
PART # DESCRIPTION PART # DESCRIPTION
PREVIOUS PREVIOUS
MODEL MODEL
1 R-2110 CLAMP COVER N 19 TR-2530 MUFFLER Y
2 TR-2120 JAW ASSEMBLY Y 20 TR-2632 TENSION LOCK WASHER Y
3 TR-2130 CLAMP CYLINDER Y 21 TR-2662 RUBBER GASKET Y
4 V-BLOCK SEE PAGES 12 FOR CHART N 22 TR-2661 SPINDLE CAP SEAL Y
CLAMP LIMIT SWITCH
5 TR-2321 Y 23 TR-2660 SPINDLE CAP Y
ASSEMBLY
6 TR-2232 AIR FITTING 1/4" SMC (2) Y 24 TT-2400 SPINDLE ASSEMBLY Y
7 TR-2239 RING GASKET - .062” THICK Y 25 TR-2411 SPINDLE SWITCH - ACTUATOR Y
NON- SCREWS SCHCS M5 X .8 X 16
8 N 26 TR-2234 FLOW CONTROL Y
SELLABLE LONG
9 TR-2452 GROMMET (2) Y 27 TT-2670 REAMER SPINDLE SHROUD Y
10 412-5 FEMALE SPADE CONNECTOR N 28 TR-2440 REAMER DRIVE BELT Y
11 411-12-6 ROCKER SWITCH N 29 TT-2322 LIMIT SWITCH ASSEMBLY Y
12 TR-2500 AIR MOTOR ASSEMBLY Y 30 R-2247 SPRAYER VALVE WITH PLUG N
13 R-2680 REAR COVER ASSEMBLY N 31 R-2248 MOTOR VALVE WITH PLUG N
REAMER SWITCH COVER FRONT JAW SPACER - 2
14 R-2601 N 32 TR-2127 Y
ASSEMBLY REQUIRED
REAR JAW SPACE - 1
15 TT-2330 RESET SWITCH ASSEMBLY Y 33 TR-2128 Y
REQUIRED
1/8” NPT 3” LG. NIPPLE,
16 R-2245 N 34 TR-2310 REAMER CIRCUIT BOARD Y
GALVANIZED
17 TR-2340 INTERFACE RECEPTACLE Y 35 R-2241 CLAMP / SPINDLE VALVE N
CUTTER BLADE (SEE Section 3.3 CUTTER
5/16” X 1/8” NPT PUSH-TO-
18 TR-2231 Y 36 BLADE AND V-BLOCK CHART FOR Y
CONNECT FITTING
COMPLETE LIST)

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5.0 – TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
LED SIGNALS  CIRCUIT BOARD DAMAGED  REPLACE BOARD
NOT  LIMIT SWITCH MALFUNCTIONING  REPLACE SWITCH
ACTIVATING  INPUT VOLTAGE IS INCORRECT  CHECK INPUT VOLTAGE AND MAKE ADJUSTMENTS AS
REQUIRED
MOTOR STOPS  AIR SUPPLY IS INCORRECT  SET AT 80-100 PSI AT 16 CFM
DURING  EXCESSIVE SPATTER BUILD-UP  APPLY OR INCREASE QUANTITY OF ANTI-SPATTER
OPERATION  LUBRICATOR NOT INSTALLED OR  INCREASE FREQUENCY OF TORCH CLEANING OR
ADJUSTED PROPERLY MODIFY WELDING PARAMETERS
 ENSURE LUBRICATOR IS INSTALLED AND ADJUSTED
(SEE Section 1.2 AIR MOTOR LUBRICATION)
PNEUMATIC  AIR LINE DAMAGED OR OBSTRUCTED  REPLACE AIR LINE
FUNCTIONS  AIR SUPPLY INCORRECT  CHECK AIR SUPPLY. SET AT 80-100 PSI AT 16 CFM
NOT  FAULTY RESET SWITCH  REPAIR OR REPLACE RESET SWITCH
OPERATIVE  MANUAL SWITCHES ENGAGED  TURN OFF MANUAL SWITCHES
BROKEN  IMPROPER CUTTER BEING USED  REPAIR OR REPLACE DAMAGED COMPONENTS
CUTTER  FLOW CONTROL VALVE SET TOO FAST  ADJUST FEED RATE
 GUN IMPROPERLY ALIGNED IN REAMER  ADJUST FLOW CONTROL VALVE
TOUGH GUN  CUTTER IS JAMMED IN GUN  PRESS OR REPLACE DAMAGED COMPONENTS
REAMER  FAULTY SPINDLE UNIT  REPAIR OR REPLACE UNIT
STAYS IN UP  FAULTY LIMIT SWITCH  REPAIR OR REPLACE LIMIT SWITCH
POSITION  CYCLE START SIGNAL HELD ON TOO  REVISE PROGRAM (0.5 SEC. PULSE).
LONG
CYCLE  FAULTY CLAMP SWITCH  CHECK OR REPLACE SWITCH
COMPLETE  FAULTY CIRCUIT BOARD
SIGNAL DOES
NOT ACTIVATE

6.0 – SPRAYER (OPTION)

6.1 ANTI-SPATTER SPRAYER

● The TOUGH GUN Sprayer is factory
set for “Sourcing”. The wires are
connected to the P.C. board as shown.
● If you require the P.C. board switches
to be set to the “Sinking” position, the
SPRAYER OPTION switch (SW1) must be moved to the
“Sinking” position (identified on board).
● To operate the sprayer, a timed +24
VDC signal must be applied to the
black lead (sprayer option) of the
interface receptacle. Recommended
spray time 0.5 seconds (Refer to
Sprayer Tech Guide).

14
6.2 SPRAYER PROGRAMMING EVENTS SEQUENCE
● Program robot so that nozzle is centrally located.
X = 1.25” when using 5/8” Bore Nozzles.
X = 1.0” when using 1/2" Bore Nozzles.
X = 1.5” when using 3/4" Bore Nozzles.
● Energize timed output signal to initiate spray
cycle. Set timer at 0.5 seconds for initial set-up.
Adjust timer to increase or decrease quantity of
anti-spatter compound as required by process.
● NOTE: If using Tregaskiss TOUGH GARD™ Anti-
Spatter Compound, spray time can be as low as
0.2 seconds. Anti-spatter compound should be
enough to coat inside of nozzle with no drippage.
Excessive application of TOUGH GARD Anti-
Spatter can decrease performance and increase
consumption.
● IMPORTANT: If using the optional air-blast, DO
NOT activate air blast when over the spray head.
Dirt / spatter may be blown into the spray head
orifice, which may hamper spray operation.

6.3 SPRAYER MAINTENANCE

DAILY
 Ensure fluid level in reservoir is maintained. Inspect spray operation to ensure adequate anti-spatter
compound is being applied.
WEEKLY
 Inspect unit for air leaks or damaged supply and interface lines which may cause unit to malfunction.
QUARTERLY
 Inspect unit for buildup of residue from anti-spatter compound which could eventually restrict fluid flow or
cause unit to malfunction. Residue should be visible in reservoir or nozzle assembly. If excessive, clean or
flush with recommended solvent or anti-spatter compound.
YEARLY
 Inspect unit for damage or excessive wear of components. Replace if required.

6.4 SPRAYER TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE SOLUTION
NO AIR FLOW  OUTPUT TO UNIT NOT  CHECK OUTPUT SIGNAL AND CABLE
NO ANTI-SPATTER FUNCTIONING  CHECK AIR SUPPLY
 LOSS OF AIR SUPPLY  CHECK AIR LINE AND NOZZLE FOR
 FAULTY SOLENOID VALVE BLOCKAGE
 SINK / SOURCE  CHECK SOLENOID VALVE AND REPLACE IF
REQUIRED
 ADJUST SINK / SOURCE SWITCH FOR SPRAY
OPTION (FIG. 6.1)
AIR FLOW BUT NO  VENT CLOSED ON RESERVOIR  OPEN VENT
ANTI-SPATTER  SPOOL IN CHECK VALVE STUCK  REPAIR OR REPLACE CHECK VALVE
 FLUID LINE BLOCKED  CLEAN OR REPAIR FLUID LINE
SPRAY HEAD  DEBRIS IN SPRAY HEAD  CLEAN SPRAY HEAD
PLUGGED

15
6.5 SPRAYER PARTS LIST – SR-500

TECHNICAL DATA
Electrical: 24 volts DC 2.5 watts
Pneumatic: 80-100 psi at 16 CFM
(Uses Reamer Air Supply)

ITEM PART # DESCRIPTION

1 SR-500-1 SPRAY HEAD BRACKET
2 TS-500-15 SPRAY HEAD
3 SR-500-20 CHECK VALVE - SMC
4 RR-1320 RESERVOIR
5 SR-500-50 SPRAYER STEEL LINE KIT
6 TS-500-40-1 FEMALE QUICK CONNECT
7 TS-500-40-2 MALE QUICK CONNECT
TS-500-40 QUICK CONNECT ASSEMBLY (INCLUDES MALE & FEMALE)
9 TR-2237 1/4” TUBING - 8” LONG

7.0 – ADDITIONAL OPTIONS

7.1 REAMER STAND WITH OPTIONAL SMC FRL (FILTER REGULATOR LUBRICATOR)

Option ‘10’ Option ‘12’

PART # DESCRIPTION PART # DESCRIPTION

ADJUSTABLE REAMER STAND ADJUSTABLE REAMER STAND
RST-1000-A RST-1200-A
(28” TO 43”) WITH SMC FRL (28” TO 43”)

16
7.2 FLOW CONTROL

Reamer Reamer
with standard sprayer with optional flow control for the sprayer

NOTE: Choosing Reamer option ‘C’ - Flow Control adds an adjustable check valve, giving users the ability to
control the amount of TOUGH GARD Anti-Spatter applied in each spray.
Also available: the retrofitable flow control kit (Part #SR-500-55).

7.3 WIRE CUTTER

WIRE
CUTTER
(WC-100)

17
8.0 – MULTI-FEED READY REAMER

All Reamers are multi-feed ready by removing the

sprayer reservoir (RR-1320) since it is not needed with
the Multi-Feed System.

RR-1320 A diagram below shows one of many Multi-Feed

configurations. Refer to our website or your local
(REMOVED)
Tregaskiss representative for more information.

NOTE:
Multi-Feed Systems are sold separately.

MULTI-FEED MALE QUICK

CONNECT IS INCLUDED WITH
ALL REAMERS.

TOUGH GARD MULTI-FEED SYSTEM

PART # DESCRIPTION
CHOOSE 1
TG-103-05-2 5 GALLON PAIL (UP TO 2 REAMERS)
TG-105-05-10 5 GALLON PAIL (UP TO 10 REAMERS)
TG-103-55-2 55 GALLON DRUM (UP TO 2 REAMERS)
TG-103-55-10 55 GALLON PAIL (UP TO 10 REAMERS)
HOSE (SOLD SEPARATELY)
TG-103-50 50’ MULTI-FEED HOSE (UV RATED)
TG-103-100 100’ MULTI-FEED HOSE (UV RATED)
TG-103-200 200’ MULTI-FEED HOSE (UV RATED)
REPLACEMENT PARTS SEE M055 TECH GUIDE

18
9.0 – ORDERING INFORMATION
Building a TOUGH GUN Reamer part number

TT – XXXX – XX –XX – XX
Optional Reamer Stand – ‘10’ Stand only
– ‘12’ Stand with FRL (filter-regulator-lubricator)
S – Sprayer
C – Sprayer with Flow Control (‘S’ not required)
W – Wire Cutter

Cutter Style

Nozzle outside diameter

TT Series

Order Number Examples:

TT – 0938 – 01 – 3 – W – 10 TT – 1060 – 01 – 5 – SW – 12
Reamer Stand with FRL
Reamer
Stand Anti-Spatter Sprayer
(S) is installed and Wire
Wire Cutter Cutter (W) is included.
included (W).
50’ cord set
30’ cord set
RCT-01 Cutter
RCT-01 Cutter

0.938” Nozzle OD 1.060” Nozzle OD (V-block = TR-2150)

(v-block = TR-2150)

TT Series Reamer TT series

Reamer

19
NOTES

TREGASKISS is an industry leader in the development and

manufacture of semi-automatic and robotic MIG welding
guns and robotic peripherals.

TREGASKISS™, TOUGH GUN™, TOUGH LOCK™, and

other names are trademarks of Tregaskiss, a division of
ITW Canada Inc.

M064 REV I 06/13

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