TOUGH GUN CA3 Robotic Air-Cooled MIG Guns

Maximize Throughput. Minimize Costs.

Learn more about AccuLock R consumables and how they reduce downtime, offer longer service life, and provide better weld quality

Designed for high-volume production environments, TOUGH GUN® CA3 robotic air-cooled MIG guns are engineered for precision, durability, accuracy, repeatability, minimal downtime and fast and easy maintenance.

Configure My Gun Reverse Lookup

  • Replaceable conventional unicable design offers extended service life and ease of serviceability
  • Dual layer cable outer jacket, re-engineered cable guide and increased copper content contribute to extended service life
    • Reduced costs and downtime due to simplified unicable replacement process
    • New wiring connections simplify unicable replacement
    • Connector and neck remain in mounting arm during cable replacement, mitigating the need for tool center point (TCP) touch-ups
  • Re-engineered neck clamp improves durability and consistency of clamping force
  • Additional standard neck and mounting arm options
    • Expands the range of tool center points and variety of working envelopes
    • Reduces costs and lead times for necks and arms that were previously specials
    • Simplifies transition from standard TOUGH GUN® G2 series configurations while maintaining TCP
  • Compatible with legacy product
    • Compatible with existing TOUGH GUN G1 series necks, gun mounts, power pins and consumables
    • Replacement for TOUGH GUN G1 series with no effect on TCP*
    • Gun part numbers are unaffected by these changes
    • New black gun body simplifies identification of upgraded vs. legacy guns
  • Clutch and solid mount models available
  • Wire brake, air blast and TOUGH GUN I.C.E.® technology are available options

*An increase to the length of the gun housing was necessary to accommodate the added features and benefits. Verification of tooling or fixture clearance may be required.

Infographic explaining cable guide on the product minimizes stress on cable connection as robot articulates
Infographic explaining new product features provide increased durability
Infographic explaining product offers easy maintenance with minimal downtime
Infographic explaining product features replaceable unicable that reduces downtime through faster repair and extended service life

Processes

  • MIG (GMAW) welding

Duty Cycle Rating

  • 100%: 385 amp with mixed gases
    Gun performance unchanged. Ratings are based on tests that comply with the new 2013 IEC 60974-7 standards.

Configurations available for

  • ABB®, COMAU®, FANUC®, KUKA®, Kawasaki®, Motoman®, Miller®, OTC Daihen®, Panasonic®, Reis®

Customize your TOUGH GUN CA3 robotic air-cooled MIG gun online

Configure your entire system or just the gun part number you need, or reverse lookup your existing gun part number – plus get access to additional resources and an expanded replacement parts list with diagram.

This new mobile-friendly online configurator provides downloadable exploded view diagrams and other valuable takeaways that you can print, save in PDF format for later, or share via email.

Check it out today!

Please note that the following additional components are required when configuring a complete robotic system and are sold separately:

Configure a TOUGH GUN CA3 robotic air-cooled MIG gun online
Find the replacement parts list and other details for the TOUGH GUN CA3 robotic air-cooled MIG gun you already have

Gun Part Number Conversion Tool

Click here to convert your legacy TOUGH GUN G1 series MIG gun part number to a new TOUGH GUN CA3 robotic air-cooled MIG gun part number!


Consumables Systems

NOTE: There is no impact to Tool Center Point (TCP) when upgrading to AccuLock R consumables from TOUGH LOCK or many other consumables.

AccuLock Contact Tips; Copper

Part NumberDescription
T-A030CH*^for 0.030″ (1.8 mm) wire, copper; qty. 10
T-A035CH*^for 0.035″ (1.9 mm) wire, copper; qty. 10
T-A039CH*^for 0.039″ (1.0 mm) wire, copper; qty. 10
T-A045CH*^for 0.045″ (1.2 mm) wire, copper; qty. 10
T-A052CH*^for 0.052″ (1.3 mm) wire, copper; qty. 10
T-A055CH*for 0.055″ (1.4 mm) wire, copper; qty. 10
T-A062CH*for 1/16″ (1.6 mm) wire, copper; qty. 10
T-A072CH*for 0.070″ (1.8 mm) wire, copper; qty. 10
T-A078CH*for 5/64″ (2.0 mm) wire, copper; qty. 10
T-A094CH*for 3/32″ (2.4 mm) wire, copper; qty. 10

*add “-100” to end of the above part numbers for quantities of 100.
^add “-1000” to end of the above part numbers for quantities of 1000.

AccuLock Contact Tips; Chrome Zirconium

Part NumberDescription
T-A030ZH*for 0.030″ (1.8 mm) wire, chrome zirconium; qty. 10
T-A035ZH*for 0.035″ (1.9 mm) wire, chrome zirconium; qty. 10
T-A039ZH*for 0.039″ (1.0 mm) wire, chrome zirconium; qty. 10
T-A045ZH*for 0.045″ (1.2 mm) wire, chrome zirconium; qty. 10

*add “-100” to end of the above part numbers for quantities of 100.

AccuLock Contact Tips; HDP

Part NumberDescription
T-A035WH*for 0.035″ (1.9 mm) wire, HDP; qty. 10
T-A039WH*for 0.039″ (1.0 mm) wire, HDP; qty. 10
T-A045WH*for 0.045″ (1.2 mm) wire, HDP; qty. 10
T-A052WH*for 0.052″ (1.3 mm) wire, HDP; qty. 10

*add “-100” to end of the above part numbers for quantities of 100.

Part NumberDescription
D-ATSH*Gas diffuser, slip-on; qty. 10
D-ATTH*Gas diffuser, thread-on; qty. 10

*add “-100” to end of the above part numbers for quantities of 100.

Tregaskiss® Nozzles; Slip-On

Part NumberDescription
401-6-62HD – 5/8″ bore, 1/8″ recess (copper); qty. 10
401-8-62SD – 5/8” bore, 1/8” stick out (copper); qty. 10
401-4-62SD – 5/8″ bore, 1/8” recess (copper); qty. 10
401-5-62HD – 5/8″ bore, 1/4” recess (copper); qty. 10
401-48-62HD – 5/8” bore, flush tip (bottleneck, copper); qty. 10
401-81-62HD – 5/8” bore, 1/8” stick out (copper); qty. 10
401-7-62HD – 5/8” bore, 1/4″ recess (brass); qty. 10
401-71-62HD – 5/8” bore, 1/8” recess (brass); qty. 10
401-87-62HD – 5/8” bore, 1/8” stick out (brass); qty. 10

Tregaskiss Nozzles; Thread-On

Part NumberDescription
401-14-62HD – 5/8″ bore, 1/8″ recess (copper); qty. 10
401-43-62SD – 5/8″ bore, 1/8″ recess (copper); qty. 10
401-18-62SD – 5/8″ bore, 1/8″ stick out (copper); qty. 10
401-20-62HD – 5/8″ bore, 1/8″ stick out (copper); qty. 10

Contact Tips; Standard Duty (SD)

(use with 404-18 or 404-54 retaining heads)

Part NumberDescription
403-14-30for 0.030″ (0.8 mm) wire
403-14-35for 0.035″ (0.9 mm) wire
403-14-1.0for 1.0 mm wire
403-14-45for 0.045″ (1.2 mm) wire

Contact Tips; Standard Duty Tapered

(use with 404-18 or 404-54 retaining heads)

Part NumberDescription
403-12-30for 0.030″ (0.8 mm) wire
403-12-35for 0.035″ (0.9 mm) wire
403-12-45for 0.045″ (1.2 mm) wire
403-12-52for 0.052″ (1.3 mm) wire

Contact Tips Heavy Duty (HD)

(use with 404-32, 404-52 or 404-50 retaining heads)

Part NumberDescription
403-20-30for 0.030″ (0.8 mm) wire
403-20-35for 0.035″ (0.9 mm) wire
403-20-1.0for 1.0 mm wire
403-20-45for 0.045″ (1.2 mm) wire
403-20-364for 3/64″ (1.2 mm) wire
403-20-52for 0.052″ (1.3 mm) wire
403-20-1.4for 1.4 mm wire
403-20-116for 1/16″ (1.6 mm) wire
403-20-1.8for 1.8 mm wire
403-20-78for 0.078″ (2.0 mm) wire
403-20-564for 5/64″ (2.0 mm) wire
403-20-332for 3/32″ (2.4 mm) wire

Contact Tips; Extended Life Heavy Duty (EHD)

(use with 404-32, 404-52 or 404-50 retaining heads)

Part NumberDescription
403-27-30for 0.030″ (0.8 mm) wire
403-27-35for 0.035″ (0.9 mm) wire
403-27-1.0for 1.0 mm wire
403-27-45for 0.045″ (1.2 mm) wire
403-27-364for 3/64″ (1.2 mm) wire
403-27-116for 1/16″ (1.6 mm) wire

Contact Tips; Heavy Duty Tapered

(use with 404-32, 404-52 or 404-50 retaining heads)

Part NumberDescription
401-21-30for 0.030″ (0.8 mm) wire
401-21-35for 0.035″ (0.9 mm) wire
401-21-1.0for 1.0 mm wire
401-21-45for 0.045″ (1.2 mm) wire

Teach Tips

(used for robotic programming)

Part NumberDescription
403-20-01Adjustable teach tip
403-20-05Teach tip 1/2″ CTWD
403-20-062Teach tip 5/8″ CTWD
403-20-075Teach tip 3/4″ CTWD
403-20-10mmTeach tip 10 mm CTWD
403-20-15mmTeach tip 15 mm CTWD
Part NumberDescription
404-32-25for robotic applications; heavy duty, qty: 25
404-32for robotic applications; heavy duty, qty: 100
404-32-250for robotic applications; heavy duty, qty: 250
404-18-25for robotic applications; standard duty, qty: 25
404-18for robotic applications; standard duty, qty: 100
404-52-25for robotic applications; heavy duty, qty: 25
404-52for robotic applications; heavy duty, qty: 10

Nozzles; Slip-On

(use with 404-18 or 404-32 retaining heads)

Part NumberDescription
401-6-62HD – 5/8″ bore, 1/8″ recess (copper)
401-5-62HD – 5/8” bore, 1/4″ recess (copper)
401-6-50HD – 1/2″ bore, 1/8” recess (copper)
401-81-62HD – 5/8” bore, 1/8” stick out (copper)
401-7-62HD – 5/8” bore, 1/4″ recess (brass)
401-7-75HD – 3/4″ bore, 1/8” recess (brass)
401-8-62SD – 5/8” bore, 1/8” stick out (copper)
401-42-50SD – 1/2″ bore, 1/8” stick out (bottleneck, brass)
401-48-50SD – 1/2″ bore, 1/8” stick out (bottleneck, brass)
401-48-62HD – 5/8” bore, flush tip (bottleneck, copper)
401-44-50SD – 1/2″ bore, 1/4″ stick out (bottleneck, brass)
401-49-50HD – 1/2″ bore, flush tip (bottleneck, brass)
401-71-62HD – 5/8” bore, 1/8” recess (brass), straight bore
401-87-62HD – 5/8” bore, 1/8” stick out (brass)
401-91-62HD – 5/8” bore, 1/8” stick out (brass), straight bore
401-72-62HD – 5/8” bore, 1/8” recess (brass)
401-51-62HD – 5/8” bore, flush tip (bottleneck, brass)

Nozzles; Thread-On

(use with 404-52 retaining heads)

Part NumberDescription
401-8-62BRTSD – 5/8″ bore, 1/8″ stick out (brass)
401-47-51
SD – 1/2″ bore, 1/8″ recess (copper)

Nozzles; TOUGH ACCESS*

(use with 404-54 retaining heads)

Part NumberDescription
401-55-501/2″ bore, flush tip (bottleneck)
401-56-501/2″ bore, 1/8” stick out (bottleneck)
401-57-501/2″ bore, 1/4″ stick out (bottleneck)
*TCP will be different from TOUGH LOCK consumables (verify X, Y, Z offset)

Nozzles; TOUGH ACCESS*

(use with 404-50 or 404-54 retaining heads)

Part NumberDescription
401-54-625/8” bore, 1/8” recess, straight bore
401-56-625/8” bore, 1/8” stick out, straight bore
*TCP will be different from TOUGH LOCK consumables (verify X, Y, Z offset)

MIG Gun Liners

Part NumberDescription
415-30-6QQUICK LOAD liner for 0.030″ (0.8 mm) wire; 6′ (1.8 m)
415-30-15QQUICK LOAD liner for 0.030″ (0.8 mm) wire; 15′ (5.0 m)
415-35-6QQUICK LOAD liner for 0.035″ (0.9 mm) – 0.045″ (1.2 mm) wire; 6′ (1.8 m)
415-35-10QQUICK LOAD liner for 0.035″ (0.9 mm) – 0.045″ (1.2 mm) wire; 10′ (3.05 m)
415-35-15QQUICK LOAD liner for 0.035″ (0.9 mm) – 0.045″ (1.2 mm) wire; 15′ (5.0 m)
415-116-6QQUICK LOAD liner for 0.052″ (1.3 mm) – 1/16 (1.6 mm) wire; 6′ (1.8 m)
415-116-10QQUICK LOAD liner for 0.052″ (1.3 mm) – 1/16″ (1.6 mm) wire; 10′ (3.05 m)
415-116-15QQUICK LOAD liner for 0.052″ (1.3 mm) – 1/16″ (1.6 mm) wire; 15′ (5.0 m)
415-564-6QQUICK LOAD liner for 1/16″ (1.6 mm) – 5/64″ (2.0 mm) wire; 6′ (1.8 m)
415-564-15QQUICK LOAD liner for 1/16″ (1.6 mm) – 5/64″ (2.0 mm) wire; 15′ (5.0 m)
415-332-6QQUICK LOAD liner for 0.078″ (2.0 mm) – 3/32″ (2.4 mm) wire; 6′ (1.8 m) (requires 415-24 retainer)
415-332-15QQUICK LOAD liner for 0.078″ (2.0 mm) – 3/32″ (2.4 mm) wire; 15′ (5.0 m) (requires 415-24 retainer)

QUICK LOAD Liners for Cored Wire

Part NumberDescription
415-35-062QQUICK LOAD liner for 0.035″ (0.9 mm) – 0.045″ (1.2 mm) cored wire; 6′ (1.8 m)
415-116-062QQUICK LOAD liner for 0.045″ (1.2 mm) – 1/16″ (1.6 mm) cored wire; 6′ (1.8 m)

QUICK LOAD Liner Retainers

Required for initial installation only (sold separately)

Part NumberDescription
415-26QUICK LOAD liner retainer (required for 0.030″-5/64″ wire)
415-24QUICK LOAD liner retainer (required for 0.078″-3/32″ wire)
415-31QUICK LOAD liner retainer (required for QUICK LOAD Liners for cored wire)
Part NumberDescription
415-30-6for 0.030″ (0.8 mm) wire; 6′ (1.8 m) – round wound
415-30-15for 0.030″ (0.8 mm) wire; 15′ (5.0 m) – round wound
415-35-6for 0.035″ (0.9 mm) – 0.045″ (1.2 mm) wire; 6′ (1.8 m) – round wound
415-35-10for 0.035″ (0.9 mm) – 0.045″ (1.2 mm) wire; 10′ (3.05 m) – round wound
415-35-15for 0.035″ (0.9 mm) – 0.045″ (1.2 mm) wire; 15′ (5.0 m) – round wound
415-116-6for 0.052″ (1.3 mm) – 1/16″ (1.6 mm) wire; 6′ (1.8 m) – round wound
415-116-10for 0.052″ (1.3 mm) – 1/16″ (1.6 mm) wire; 10′ (3.05 m) – round wound
415-116-15for 0.052″ (1.3 mm) – 1/16″ (1.6 mm) wire; 15′ (5.0 m) – round wound
415-564-6for 1/16″ (1.6 mm) – 5/64″ (2.0 mm) wire; 6′ (1.8 m) – round wound
415-564-15for 1/16″ (1.6 mm) – 5/64″ (2.0 mm) wire; 15′ (5.0 m) – flat wound
415-332-6for 0.078″ (2.0 mm) – 3/32″ (2.4 mm) wire; 6′ (1.8 m) – flat wound
415-332-15for 0.078″ (2.0 mm) – 3/32″ (2.4 mm) wire; 15′ (5.0 m) – flat wound

Jump Liners

(to be used with conventional liners on MIG guns equipped with wire brake)

Part NumberDescription
495-18-35for 0.035″ (0.9 mm) – 0.045″ (1.2 mm) wire; 26″
495-18-116for 0.045″ (1.2 mm) – 1/16″ (1.6 mm) wire; 26″
TOUGH GUN TT4 Reamer - front view

TOUGH GUN® TT4 Reamer

The TOUGH GUN TT4 reamer robotic nozzle cleaning station — now available in both analog and Ethernet models — is TOUGH on spatter and operates reliably in even the harshest welding environments. Automating spatter removal will help to extend the life of your robotic MIG guns and consumables, benefiting both your bottom line and your production uptime and throughput. Learn more about the TOUGH GUN TT4A reamer or the TOUGH GUN TT4E reamer.


TOUGH GUN TT4 Reamer on a TOUGH GUN Multi-Feed System

TOUGH GARD® Anti-Spatter Multi-Feed System

Interested in the ultimate solution to refilling the reservoirs on your nozzle cleaning stations? Feed up to 10 TOUGH GUN reamer units from a single 5-gallon or 55-gallon drum of TOUGH GARD anti-spatter liquid with the TOUGH GARD multi-feed system. Find out more.


New 2021 TOUGH GARD anti-spatter liquid product family

TOUGH GARD Anti-Spatter Liquid

This ready-to-use water-soluble, non-toxic product creates a sacrificial surface that reduces spatter adhesion, and unlike oil-based anti-spatter solutions, won’t clog the sprayer. This prolongs the life of your consumables and minimizes downtime due to nozzle cleaning, which can help reduce your operating and maintenance costs. Learn more.


Neck checking fixture

Neck Checking Fixture

The TOUGH GUN neck checking fixture allows you to verify and re-master your tool center point (TCP). In the event of a collision, this fixture can be used to realign the neck. Click here for additional information.

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