TOUGH GUN™ CA3 Robotic Air-Cooled MIG Guns


Designed for high-volume production environments, fully configurable TOUGH GUN™ CA3 Robotic Air-Cooled MIG Guns are engineered for precision, durability, accuracy, repeatability, minimal downtime and fast and easy maintenance.

The TOUGH GUN CA3 Robotic Air-Cooled MIG Gun combines the most valuable product features of our TOUGH GUN G1 and G2 Series platforms, along with performance improvements in our unicable technology that extends service life.

NEW!! Gun Part Number Conversion Tool

Click here to convert your legacy TOUGH GUN G1 Series MIG Gun part number to a TOUGH GUN CA3 Robotic Air-Cooled MIG Gun part number!

 

Download PDFSpec Sheet: English  |  Español  |  Português

Features and Benefits

  • NEW! Replaceable conventional unicable design offers extended service life and ease of serviceability
    • New 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.

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®, Motoman®, OTC Daihen®, Panasonic®, Reis®

Technical Documentation

IMPORTANT NOTE: Flash is required to utilize our online configurators. Click here to install Puffin Free Web Browser on your mobile device.

Customize your TOUGH GUN™ CA3 Robotic Air-Cooled MIG Gun online

Find the gun part number you need, get a parts list breakdown for the gun you build and access its technical documentation using our convenient online configurator. You will even have the option to request a quote or contact us for more information.

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

TOUGH GUN CA3 Configure

Our online configurator provides the option to configure an entire system or just your robotic MIG gun.

If you would like to learn more about these or other system components, please click here.
 

 


NEW!! 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!

The Consumable Advantage

 

Nozzles

Contact Tips

Retaining Heads

Liners

 Nozzles  Contact tips  Retaining Heads  Liners


Nozzles

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

401-6-62

HD - 5/8" bore, 1/8" recess (copper)

401-5-62

HD - 5/8” bore, 1/4" recess (copper)

401-6-50

HD - 1/2" bore, 1/8” recess (copper)

401-81-62

HD - 5/8” bore, 1/8” stick out (copper)

401-7-62

HD - 5/8” bore, 1/4" recess (copper)

401-7-75

HD - 3/4" bore, 1/8” recess (brass)

401-8-62

SD - 5/8” bore, 1/8” stick out (copper)

401-42-50

SD - 1/2" bore, 1/8” stick out (bottleneck, brass)

401-48-50

SD - 1/2" bore, 1/8” stick out (bottleneck, brass)

401-48-62

HD - 5/8” bore, flush tip (bottleneck, copper)

401-44-50

SD - 1/2" bore, 1/4" stick out (bottleneck, brass)

401-49-50

HD - 1/2" bore, flush tip (bottleneck, brass)

401-71-62

HD - 5/8” bore, 1/8” recess (brass), straight bore

401-87-62

HD - 5/8” bore, 1/8” stick out (brass)

401-91-62

HD - 5/8” bore, 1/8” stick out (brass), straight bore

401-72-62

HD - 5/8” bore, 1/8” recess (brass)

401-51-62

HD - 5/8” bore, flush tip (bottleneck, brass)

 

Back to Top

Thread-On (use with 404-52 retaining heads)

401-8-62BRT

SD - 5/8" bore, 1/8" stick out (brass)

401-47-51

SD - 1/2" bore, 1/8" recess (copper)

 

Back to Top

TOUGH ACCESS™ Nozzles* (use with 404-54 retaining heads)

401-54-50

1/2" bore, 1/8” recess (bottleneck)

401-55-50

1/2" bore, flush tip (bottleneck)

401-56-50

1/2" bore, 1/8” stick out (bottleneck)

401-57-50

1/2" bore, 1/4" stick out (bottleneck)

 

TOUGH ACCESS Nozzles* (use with 404-50 or 404-54 retaining heads)

401-54-62

5/8” bore, 1/8” recess, straight bore

401-55-62

5/8” bore, flush tip, straight bore

401-56-62

5/8” bore, 1/8” stick out, straight bore

401-57-62

5/8” bore, 1/4" stick out, straight bore

*TCP will be different from TOUGH LOCK™ Consumables (verify X, Y, Z offset)

Back to Top

 

Contact Tips

TOUGH LOCK™ Standard Duty (SD) Contact Tips (use with 404-18 or 404-54 retaining heads)

403-14-30

for 0.030" (0.8 mm) wire

403-14-35

for 0.035" (0.9 mm) wire

403-14-1.0

for 1.0 mm wire

403-14-45

for 0.045" (1.2 mm) wire

 

 Back to Top

TOUGH LOCK Standard Duty Tapered Contact Tips (use with 404-18 or 404-54 retaining heads)

403-12-30

for 0.030" (0.8 mm) wire

403-12-35

for 0.035" (0.9 mm) wire

403-12-1.0

for 1.0 mm wire

403-12-45

for 0.045" (1.2 mm) wire

 

 Back to Top

TOUGH LOCK Heavy Duty (HD) Contact Tips (use with 404-32, 404-52 or 404-50 retaining heads)

403-20-30

for 0.030" (0.8 mm) wire

403-20-35

for 0.035" (0.9 mm) wire

403-20-1.0

for 1.0 mm wire

403-20-45

for 0.045" (1.2 mm) wire

403-20-364

for 3/64" (1.2 mm) wire

403-20-52

for 0.052" (1.3 mm) wire

403-20-1.4

for 1.4 mm wire

403-20-116

for 1/16" (1.6 mm) wire

403-20-1.8

for 1.8 mm wire

403-20-78

for 0.078" (2.0 mm) wire

403-20-564

for 5/64" (2.0 mm) wire

403-20-332

for 3/32" (2.4 mm) wire

 

Back to Top

TOUGH LOCK Extended Life Heavy Duty (EHD) Contact Tips (use with 404-32, 404-52 or 404-50 retaining heads)

403-27-30

for 0.030" (0.8 mm) wire

403-27-35

for 0.035" (0.9 mm) wire

403-27-1.0

for 1.0 mm wire

403-27-45

for 0.045" (1.2 mm) wire

403-27-364

for 3/64" (1.2 mm) wire

403-27-116

for 1/16" (1.6 mm) wire

 

Back to Top

TOUGH LOCK Heavy Duty Tapered Contact Tips (use with 404-32, 404-52 or 404-50 retaining heads)

401-21-30

for 0.030" (0.8 mm) wire

401-21-35

for 0.035" (0.9 mm) wire

401-21-1.0

for 1.0 mm wire

401-21-45

for 0.045" (1.2 mm) wire

 

Back to Top

TOUGH LOCK Teach Tips (used for robotic programming)

403-20-01

Adjustable teach tip

403-20-05

Teach tip 1/2" CTWD

403-20-062

Teach tip 5/8" CTWD

403-20-075

Teach tip 3/4" CTWD

403-20-10mm

Teach tip 10 mm CTWD

403-20-15mm

Teach tip 15 mm CTWD

Back to Top

 

Retaining Heads

TOUGH LOCK™ Retaining Heads

404-18

SD - retaining head for slip-on nozzles

404-32

HD - retaining head for slip-on nozzles

404-52

HD - retaining head for thread-on nozzles

 

 Back to Top

TOUGH ACCESS™ Retaining Heads*

404-50

HD - retaining head

404-54

SD - retaining head

*TCP will be different from TOUGH LOCK Consumables (verify X, Y, Z offset)
 

 Back to Top

 

Liners

QUICK LOAD™ Liners

415-26

QUICK LOAD Liner Retainer

415-24

QUICK LOAD Liner Retainer (required for 3/32" wire)

415-30-6Q

QUICK LOAD Liner for 0.030" (0.8 mm) wire; 6' (1.8 m)

415-30-15Q

QUICK LOAD Liner for 0.030" (0.8 mm) wire; 15' (5.0 m)

415-35-6Q

QUICK LOAD Liner for 0.035" (0.9 mm) - 0.045" (1.2 mm) wire; 6' (1.8 m)

415-35-10Q

QUICK LOAD Liner for 0.035" (0.9 mm) - 0.045" (1.2 mm) wire; 10' (3.05 m)

415-35-15Q

QUICK LOAD Liner for 0.035" (0.9 mm) - 0.045" (1.2 mm) wire; 15' (5.0 m)

415-116-6Q

QUICK LOAD Liner for 0.052" (1.3 mm) - 1/16 (1.6 mm) wire; 6' (1.8 m)

415-116-10Q

QUICK LOAD Liner for 0.052" (1.3 mm) - 1/16" (1.6 mm) wire; 10' (3.05 m)

415-116-15Q

QUICK LOAD Liner for 0.052" (1.3 mm) - 1/16" (1.6 mm) wire; 15' (5.0 m)

415-564-6Q

QUICK LOAD Liner for 1/16" (1.6 mm) - 5/64" (2.0 mm) wire; 6' (1.8 m)

415-564-15Q

QUICK LOAD Liner for 1/16" (1.6 mm) - 5/64" (2.0 mm) wire; 15' (5.0 m)

415-332-6Q

QUICK LOAD Liner for 0.078" (2.0 mm) - 3/32" (2.4 mm) wire; 6' (1.8 m) (requires 415-24 retainer)

415-332-15Q

QUICK LOAD Liner for 0.078" (2.0 mm) - 3/32" (2.4 mm) wire; 15' (5.0 m) (requires 415-24 retainer)

 

 Back to Top

QUICK LOAD Liners for Cored Wire

415-31

QUICK LOAD Liner Retainer (required for QUICK LOAD Liners for cored wire)

415-35-062Q

QUICK LOAD Liner for 0.035" (0.9 mm) - 0.045" (1.2 mm) cored wire; 6' (1.8 m)

415-116-062Q

QUICK LOAD Liner for 0.045" (1.2 mm) - 1/16" (1.6 mm) cored wire; 6' (1.8 m)

 

Back to Top

Conventional Liners (required for MIG guns equipped with wire brake only)

415-30-6

for 0.030" (0.8 mm) wire; 6' (1.8 m) - round wound

415-30-15

for 0.030" (0.8 mm) wire; 15' (5.0 m) - round wound

415-35-6

for 0.035" (0.9 mm) - 0.045" (1.2 mm) wire; 6' (1.8 m) - round wound

415-35-10

for 0.035" (0.9 mm) - 0.045" (1.2 mm) wire; 10' (3.05 m) - round wound

415-35-15

for 0.035" (0.9 mm) - 0.045" (1.2 mm) wire; 15' (5.0 m) - round wound

415-116-6

for 0.052" (1.3 mm) - 1/16" (1.6 mm) wire; 6' (1.8 m) - round wound

415-116-10

for 0.052" (1.3 mm) - 1/16" (1.6 mm) wire; 10' (3.05 m) - round wound

415-116-15

for 0.052" (1.3 mm) - 1/16" (1.6 mm) wire; 15' (5.0 m) - round wound

415-564-6

for 1/16" (1.6 mm) - 5/64" (2.0 mm) wire; 6' (1.8 m) - round wound

415-564-15

for 1/16" (1.6 mm) - 5/64" (2.0 mm) wire; 15' (5.0 m) - flat wound

415-332-6

for 0.078" (2.0 mm) - 3/32" (2.4 mm) wire; 6' (1.8 m) - flat wound

415-332-15

for 0.078" (2.0 mm) - 3/32" (2.4 mm) wire; 15' (5.0 m) - flat wound

 

 Back to Top

Jump Liners (required for MIG guns equipped with wire brake only; to be used with conventional liners)

495-18-35

for 0.035" (0.9 mm) - 0.045" (1.2 mm) wire; 26"

495-18-116

for 0.045" (1.2 mm) - 1/16" (1.6 mm) wire; 26"

 

Back to Top

 

TOUGH GUN™ TT3 Reamer

The TOUGH GUN TT3 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, benefitting both your bottom line and your production uptime and throughput. Learn more about the TOUGH GUN TT3 Reamer or the TOUGH GUN TT3E Reamer.

TOUGH GUN TT3 Reamer

   

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.

TOUGH GARD Anti-Spatter Multi-Feed System

   

TOUGH GARD Anti-Spatter Liquid

This ready-to-use water-soluble, non-toxic product creates a sacrificial surface that reduces spatter adhesion. 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.

TOUGH GARD Anti-Spatter Liquid

   

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.

Neck Checking Fixture

Product Literature

How-To Guides

Articles

Additional Resources

  • Get answers to Frequently Asked Questions (FAQs):  English  |  Français
  • See how to easily upgrade your existing TOUGH GUN G1 Series Conventional Guns to TOUGH GUN CA3 Guns

 

Tech Connection Product News