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Thank You for Choosing Bernard Thank you for selecting a Bernard product. Before installing, compare the equipment received against the invoice to verify that the shipment is complete and undamaged. It is the responsibility of the purchaser to file all claims of damage or loss that may have occurred during transit with the carrier. The owner’s manual contains general information, instructions and maintenance to help better maintain your MIG gun or peripheral. Please read, understand and follow all safety precautions. While every precaution has been taken to assure the accuracy of this owner’s manual, Bernard assumes no responsibility for errors or omissions. Bernard assumes no liability for damages resulting from the use of information contained herein. The information presented in this owner’s manual is accurate to the best of our knowledge at the time of printing. Please reference Tregaskiss.com for updated material. For customer support and special applications, please call the Bernard Customer Service Department at 1-855-MIGWELD (644-9353) (US & Canada) or +1-519-737-3000 (International), fax 1-708-946-6726, or email at cs@itwmig.com. Our trained Customer Service Team is available between 8:00 a.m. and 5:30 p.m. EST, and will answer your product application or repair questions. Bernard manufactures premium semi-automatic (GMAW) and FCAW (flux-cored) welding guns, consumables, accessories and manual arc products. For more information on other Bernard products, contact your local Bernard distributor or visit us on the web at Tregaskiss.com. OM-BTB-2.7...
SECTION 3 — PRECAUCIONES DE SEGURIDAD — LEA ANTES DE USAR 3-1 Uso de símbolos 3-2 Peligros en soldadura de arco 3-3 Advertencias de la Proposición 65 del estado de California 3-4 Estándares principales de seguridad 3-5 Información sobre los campos electromagnéticos (EMF) SECTION 4 — PRODUCT WARRANTY 4-1 Product Warranty SECTION 5 — SPECIFICATIONS 5-1 Specifications 5-2 Duty Cycle and Overheating SECTION 6 — INSTALLATION 6-1 Installing to a Feeder with a Power Pin 6-2 Installing to a Feeder with a Euro or a Bernard® Power Pin SECTION 7 — OPERATION 7-1 Pulling the Trigger SECTION 8 — REPLACEMENT 8-1 Changing Consumables 8-2 Changing AccuLock™ S Consumables 8-3 Changing the Liner OM-BTB-2.7...
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8-4 Changing the Neck 8-5 Changing the Handle and Switch 8-6 Changing the Power Pin SECTION 9 — PARTS LIST 9-1 B Series Regular and Small Curved Handles with Yellow Trigger 9-2 O Series Small Curved Handle with Blue Trigger 9-3 O Series Curved Handle with Blue Trigger 9-4 T Series Small Straight Handle with Black Trigger 9-5 T Series Straight Handle with Silver Trigger 9-6 C Series Straight Handle with Black Trigger SECTION 10 — CONSUMABLE PARTS 10-1 AccuLock™ S Consumable Series 10-2 Centerfire™ Consumable Series 10-3 Centerfire HD Consumable Series 10-4 Quik Tip™ Consumable Series 10-5 Quik Tip HD Consumable Series 10-6 TOUGH LOCK™ Consumable Series SECTION 11 — TROUBLESHOOTING 11-1 Troubleshooting Table NOTES ADDITIONAL SUPPORT MATERIALS OM-BTB-2.7...
DECLARATION OF CONFORMITY for European Community (CE marked) products Bernard, 449 West Corning Rd., Beecher, IL 60401 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s). Product/Apparatus Identification: Product Stock Number Bernard Q20 Series – 200A...
Always wear dry insulating gloves. Insulate yourself from work and ground. Do not touch live electrode or electrical parts. OM-BTB-2.7...
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Do not touch hot metal. Protect hot metal from contact by others. NOISE can damage hearing. Noise from some processes or equipment can damage hearing. Check for noise level limits exceeding those specified by OSHA. Use approved ear plugs or ear muffs if noise level is high. Warn others nearby about noise hazard. OM-BTB-2.7...
1-5 EMF Information Electric current flowing through any conductor causes localized 3. Do not coil or drape cables around your body. electric and magnetic fields (EMF). The current from arc welding 4. Keep head and trunk as far away from the equipment in the (and allied processes including spot welding, gouging, plasma arc welding circuit as possible. cutting, and induction heating operations) creates an EMF field 5. Connect work clamp to workpiece as close to the weld as around the welding circuit. EMF fields may interfere with some possible. medical implants, e.g. Pacemakers. Protective measures for 6. Do not work next to, sit or lean on the welding power source. persons wearing medical implants have to be taken. For example, 7. Do not weld whilst carrying the welding power source wire restrict access for passersby or conduct individual risk assessment feeder. for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: About Implanted Medical Devices: Implanted Medical Device wearers should consult their doctor and 1. Keep cables close together by twisting or taping them, or using the device manufacturer before performing or going near arc a cable cover. welding, spot welding, gouging, plasma arc cutting, or induction 2. Do not place your body between welding cables. Arrange heating operations. If cleared by your doctor, then following the cables to one side and away from the operator. above procedures is recommended. OM-BTB-2.7...
Ne pas effectuer le soudage sur des conteneurs fermés tels possession d'un diplôme reconnu, d'un certificat ou d'un statut que des réservoirs, tambours, ou conduites, à moins qu’ils professionnel, ou qui, par une connaissance, une formation et une expérience approfondies, a démontré avec succès sa capacité à n’aient été préparés correctement conformément à AWS F4.1 résoudre les problèmes liés à la tâche, le travail ou le projet et a et AWS A6.0 (voir les Normes de Sécurité). reçu une formation en sécurité afin de reconnaître et d'éviter les Prendre garde aux incendies et toujours avoir un extincteur à risques inhérents. proximité. Au cours de l'utilisation, tenir toute personne à l'écart et plus particulièrement les enfants. OM-BTB-2.7...
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Le BRUIT peut endommager l’ouie. Le bruit des processus et des équipements peut affecter l’ouïe. Vérifier si les niveaux de bruit excèdent les limites spécifiées par l’OSHA. Utiliser des bouche-oreilles ou des serre-tête antibruit approuvés si le niveau de bruit est élevé. OM-BTB-2.7...
5. Connecter la pince sur la pièce aussi près que possible de la électromagnétique (CEM) autour du circuit de soudage. Les champs électromagnétiques produits peuvent causer interférence à soudure. certains implants médicaux, p. ex. les stimulateurs cardiaques. Des 6. Ne pas travailler à proximité d’une source de soudage, ni mesures de protection pour les porteurs d’implants médicaux s’asseoir ou se pencher dessus. doivent être prises: par exemple, des restrictions d’accès pour les passants ou une évaluation individuelle des risques pour les 7. Ne pas souder tout en portant la source de soudage ou le soudeurs. Tous les soudeurs doivent appliquer les procédures dévidoir. suivantes pour minimiser l’exposition aux CEM provenant du circuit En ce qui concerne les implants médicaux : de soudage: Les porteurs d’implants doivent d’abord consulter leur médecin 1. Rassembler les câbles en les torsadant ou en les attachant avant de s’approcher des opérations de soudage à l’arc, de soudage avec du ruban adhésif ou avec une housse. par points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les 2. Ne pas se tenir au milieu des câbles de soudage. Disposer les procédures précédentes. câbles d’un côté et à distance de l’opérateur. OM-BTB-2.7...
Siempre mire que no haya fuego y mantenga un extinguidor reconocida, o gracias a su gran conocimiento, capacitación y de fuego cerca. experiencia, haya demostrado con éxito la capacidad para Lea y entienda las Hojas de datos del material (SDS) y las solucionar o resolver problemas relacionados con el trabajo, el instrucciones del fabricante relacionadas con los adhesivos, proyecto o el tema en cuestión, además de haber asistido a una metales, consumibles, recubrimientos, limpiadores, capacitación en seguridad para reconocer y evitar los peligros que refrigerantes, desengrasadores, fundentes y metales. implica el proceso. Durante su operación mantenga lejos a todos, especialmente a los niños. OM-BTB-2.7...
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Use tapas para los oídos o cubiertas para los oídos si el nivel del ruido es demasiado alto. Advierta a otros que estén cerca acerca del peligro del ruido. OM-BTB-2.7...
5. Conecte la pinza de masa en la pieza lo más cerca posible de la campos EMF pueden interferir con algunos dispositivos médicos soldadura. implantados como, por ejemplo, los marcapasos. Por lo tanto, se 6. No trabaje cerca de la fuente de alimentación para soldadura, ni deben tomar medidas de protección para las personas que utilizan se siente o recueste sobre ella. estos implantes médicos. Por ejemplo, aplique restricciones al acceso de personas que pasan por las cercanías o realice 7. No suelde mientras transporta la fuente de alimentación o el evaluaciones de riesgo individuales para los soldadores. Todos los alimentador de alambre. soldadores deben seguir los procedimientos que se indican a Acerca de los aparatos médicos implantados: continuación con el objeto de minimizar la exposición a los campos Las personas que usen aparatos médico implantados deben EMF generados por el circuito de soldadura: consultar con su médico y el fabricante del aparato antes de llevar a 1. Mantenga los cables juntos retorciéndolos entre sí o cabo o acercarse a soldadura de arco, soldadura de punto, ranurar, uniéndolos mediante cintas o una cubierta para cables. hacer corte por plasma, u operaciones de calentamiento por inducción. Si su doctor lo permite, entonces siga los 2. No ubique su cuerpo entre los cables de soldadura. Disponga procedimientos de arriba. los cables a un lado y apártelos del operario. OM-BTB-2.7...
® Tregaskiss Automatic MIG Guns: 1 year ® ® Tregaskiss TOUGH GUN Reamer: 1 year When factory-equipped with lubricator: 2 years when factory-equipped with lubricator When (i) factory-equipped with lubricator and (ii) used ® ® exclusively with Tregaskiss TOUGH GARD Anti- Spatter Liquid: 3 years when both (i) and (ii) ® ® Tregaskiss TOUGH GUN Robotic Peripheral (Clutch, Sprayer, Wire Cutter, Arms): 1 year ® Tregaskiss Low-Stress Robotic Unicables (LSR Unicables): 6 months OM-BTB-2.7...
300 amp gun feeds maximum wire size of 5/64" (2.0 mm) Duty Cycle Rating: 100%: 300 amp with CO Shielding Gas 60%: 300 amp with Mixed Gases 400 amp gun feeds maximum wire size of 5/64" (2.0 mm) Duty Cycle Rating: 100%: 400 amp with CO Shielding Gas 60%: 400 amp with Mixed Gases 500 amp gun feeds maximum wire size of 3/32" (2.4 mm) Duty Cycle Rating: 100%: 500 amp with CO Shielding Gas 60%: 500 amp with Mixed Gases 600 amp gun feeds maximum wire size of 1/8" (3.2 mm) Duty Cycle Rating: 100%: 600 amp with CO Shielding Gas 60%: 600 amp with Mixed Gases 5-2 Duty Cycle and Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Using mixed gases other than CO reduces duty cycle ratings 10-50% depending on gas mixture and welding parameters. Please reference Section 5 — Specifications on page 11 for duty cycle ratings by amperage. OM-BTB-2.7...
6-1 Installing to a Feeder with a Power Pin 1. Insert power pin to shoulder and secure tightly. Figure 6-A 2. Insert control plug into feeder. 3. Feed welding wire into power pin by hand and tighten drive rolls. ® 6-2 Installing to a Feeder with a Euro or a Bernard Power Pin A. Euro Power Pin Figure 6-B 1. Insert the Euro power pin to face of receptacle. 2. Thread Euro hand nut clockwise to tighten. ...
E. Changing AccuLock R Consumables counterclockwise rotation. To install, firmly secure gas diffuser 1. Remove the slip-on nozzle with a twisting and pulling motion. with an appropriate wrench in a clockwise rotation. Torque to 2. Cut electrode and remove all burrs before removing the 144 in-lbs. contact tip. Remove the AccuLock contact tip from the gas diffuser with a counterclockwise turn. To replace, slid the contact tip over electrode into gas diffuser and tighten with a C. Changing Centerfire™ Consumables clockwise rotation. Torque to 30 in-lbs (3.5 Nm). NOTE: Use 1. Cut electrode and remove all burrs before removing contact Tregaskiss® AccuLock tip tool part # T-ALTOOL for best tip. Remove threaded nozzle by turning in a counterclockwise results. direction. 3. Gas diffuser may be removed with an appropriate wrench in a 2. Pull the Centerfire contact tip from the gas diffuser. To replace, counterclockwise rotation. To install, firmly secure gas diffuser slide the contact tip over electrode into gas diffuser and lock by with an appropriate wrench in a clockwise rotation. Torque to installing nozzle onto gas diffuser. Nozzle is used to secure 144 in-lbs. contact tip. 3. Gas diffuser may be removed with an appropriate wrench in a counterclockwise rotation. To install, firmly secure gas diffuser with an appropriate wrench in a counterclockwise rotation. Torque to 144 in-lbs. OM-BTB-2.7...
to avoid kinking until the brass end of the liner stops on the neck face. 2. Reinstall gas diffuser by threading in a clockwise rotation. Tighten with a wrench and torque to 144 in-lbs (12 ft-lbs). Figure 8-C 3. Reinstall the contact tip by threading into the gas diffuser by hand and tighten with non-marring pliers. Torque to 30 in-lbs (3.5 Nm). NOTE:AccuLock tip tool part # T-ALTOOL is recommended. 4. Reinstall the thread-on nozzle by turning clockwise onto the gas diffuser and hand tighten. To reinstall a slip-on nozzle, press the nozzle toward the gas diffuser by hand until you feel a positive stop. 5. Place the power pin cap over the liner extending from the rear of the gun, and thread the cap onto the power pin. 6. Tighten cap snug against the power pin shoulder with welding pliers. 7. Lay the gun straight, making sure there are no twists in the cable. Holding a hex wrench by its shank, tighten the set screw “finger tight” against the liner. 8. Hold the hex wrench by the handle and tighten the set screw an additional half turn (180°) to fully secure the liner. 9. Trim the exposed portion of the liner flush with power pin cap. 10. Insert a piece of welding wire into the liner to check for burrs or obstructions. If needed, loosen screw slightly until wire slides freely. OM-BTB-2.7...
8-3 Changing the Liner Figure 8-D A. Changing Bernard Conventional Liner 1. Remove front-end consumables and lay cable straight. 2. Using a 10 mm wrench, turn liner counterclockwise until it is free from the power pin. Remove liner from gun assembly. 3. With cable laying straight, insert new liner into power pin and feed through gun using short strokes to prevent kinking. Twist liner clockwise if necessary. 4. Use a 10 mm wrench to turn liner lock clockwise to tighten into power pin. 5. Trim to dimensions shown in the New Liner Trim Lengths chart shown below. 6. Remove all burrs from end of liner and replace gas diffuser retaining head, contact tip and nozzle. New Liner Trim Lengths Centerfire Diffuser Part Number Liner Trim Length 9/16"...
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5. Once the liner stops feeding, give it an extra push to ensure it is seated correctly. 6. Push liner into gun and trim to dimensions shown in New Liner Trim Lengths chart on previous page. 7. Remove all burrs from end of liner and replace gas diffuser, contact tip and nozzle. D. Changing a Jump Liner Figure 8-F 1. Remove the nozzle, contact tip, gas diffuser and neck. 2. Remove used jump liner from the back end of the neck. 3. Insert new jump liner, making sure the liner stop is fully seated at the back of the neck. 4. Take the tapered end of the neck and insert into end fitting of the gun handle. 5. Install the neck. 6. Trim jump liner to dimensions shown in New Liner Trim Lengths change on previous page. 7. Deburr the jump liner past the nozzle end of the neck. 8. Install gas diffuser, contact tip and nozzle. OM-BTB-2.7...
3. To install the neck, perform the above instructions in reverse order and tighten lock nut to 16 ft-lbs (21.7 Nm). Be sure nut insulator is in place. 4. Liner may need to be changed if switching to a neck of a different bend angle or length. Figure 8-I C. Changing the Neck - Fixed with T Series Straight Handle 1. Place neck in vise. Remove both switch housing mounting screws with an 8 mm nut driver. 2. Slide handle back, exposing the cable connection. Loosen the cable/neck connection using a 7/8" wrench. 3. Remove from vise and unthread neck by hand. 4. Thread the neck into the cable connection (hand tighten). Place neck in vise and tighten with a wrench to within 1/8" (3.2 mm) spacing between cable connection and neck. 5. Install the switch and reposition handle and switch housing. 6. Reinstall switch housing mounting screws. 7. Liner may need to be changed if switching to a neck of a different bend angle or length. OM-BTB-2.7...
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10. Reinstall handle lock nut, locking collar and screw. 11. Liner may need to be changed if switching to a neck of different bend angle or length. E. Changing the Neck - Fixed with C Series Figure 8-K Straight Handle 1. Place neck in vise. Remove both switch housing mounting screws with a Phillips screwdriver. 2. Remove both the top and bottom pods from handle. 3. Slide handle back, exposing the cable connection. Loosen the cable/neck connection using a 7/8" wrench. 4. Remove from vise and unthread neck by hand. 5. Thread the new neck into the cable connection (hand tighten). 6. Place neck in vise and tighten with a wrench to within 1/8" (3.2 mm) spacing between the cable connection and neck. 7. Install the switch and reposition handle and switch housing. 8. Reinstall switch housing mounting screws. 9. Liner may need to be changed if switching to a neck of a different bend angle or length. OM-BTB-2.7...
A. B Series Regular and Small Curved Handle 1. Remove screws and post fasteners from handles. 2. Separate handle halves and remove trigger. 3. Remove switch lead connectors with needle nose pliers. 4. To replace trigger, connect switch lead connectors onto terminals of new switch. Position handle half and trigger on cable so trigger leads are not pinched and movement of the trigger is not impaired. 5. Position the remaining handle half in place. 6. Reinstall post fasteners and screws. Torque to 10 in-lbs (1.1 Nm). Figure 8-M B. O Series Regular and Small Curved Handle 1. Loosen screws, but do not fully remove. 2. Pry open bottom side of handle halves with a flat blade screwdriver. Trigger should be able to be removed. 3. To replace trigger, install into handle halves with pivot posts inserted into handle cavities so movement is not impaired. 4. Tighten screws. Torque to 10 in-lbs (1.1 Nm). OM-BTB-2.7...
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4. Push switch lead connectors firmly onto new switch terminals with needle nose pliers. 5. Depress switch housing into nest on handle (switch leads must lay parallel). 6. Align housing holes with threaded holes in body and insert mounting screws first before tightening with 8 mm nut driver to even alignment. E. C Series Straight Handle (Switch Only) Figure 8-P 1. Remove both switch mounting screws with a Phillips screwdriver. 2. Remove both the top and bottom pods from the handle. 3. Ease switch out of switch housing with needle nose pliers. 4. Remove switch from switch lead connectors with needle nose pliers. 5. Push lead connectors onto new switch using needle nose pliers. 6. Depress switch housing into nest on handle (switch leads must lay parallel). 7. Align the holes of body housing with the holes in the handle to start screws by hand. Finish tightening with a Phillips screwdriver. OM-BTB-2.7...
3. Thread new power pin into adaptor block and use wrenches in a clockwise direction to thread power pin into adaptor block. Torque to 18 ft-lbs (24 Nm). 4. Reinstall liner by following the steps listed in section 8-3 Changing the Liner on page 16. Figure 8-R B. Euro Power Pin 1. Remove liner, strain relief cap/spring, strain relief top half, screw cover and the screw that attaches the strain relief to the Euro block. 2. Slide strain relief bottom toward cable, exposing Euro block. 3. Remove Euro block from end fitting using appropriate wrenches in a counterclockwise rotation. 4. Disconnect the Euro block control leads from the gun by cutting as close as possible on both sides of the butt connectors to preserve wire length for later re-termination. 5. Remove adaptor nut and install onto new Euro block. 6. Assemble Euro block onto end fitting in a clockwise rotation using appropriate wrenches. Torque to 18 ft-lbs (24 Nm). Adaptor nut should rotate freely. 7. Strip the cable control leads 1/4" (6.5 mm) and re-terminate with appropriate butt connectors. 8. Align strain relief bottom with threaded hole in Euro block and install screw, assemble strain relief and liner. OM-BTB-2.7...
10-3 Centerfire HD Consumable Series Centerfire HD Consumable Series is not configurable and will need to be ordered separately. Couple the Centerfire HD nozzle body with a Centerfire HD nozzle cone to form a complete Centerfire HD nozzle. OM-BTB-2.7...
Series 2 Contact Tip T2023 0.023" (0.6 mm) T2045 0.045" (1.2 mm) T2052 0.052" (1.4 mm) T2030 0.030" (0.8 mm) T2364 3/64" (1.2 mm) T2116 1/16" (1.6 mm) T2035 0.035" (0.9 mm) 10-5 Quik Tip HD Consumable Series Quik Tip HD Consumable Series is not configurable and will need to be ordered separately. Couple the Quik Tip HD nozzle body with the Quik Tip HD nozzle cone to form a complete Quik Tip HD nozzle. OM-BTB-2.7...
DUAL TAPER PART NUMBER Heavy Duty 404-20-25 404-26-25 Heavy Duty 404-20 404-26 Heavy Duty 404-20-250 404-26-250 Standard Duty 404-14-25 404-18-25 Standard Duty 404-14 404-18 THREAD-ON RETAINING HEADS FOR NEW STYLE THREAD-ON NOZZLES Heavy Duty 404-53-25 OM-BTB-2.7...
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2.74" Flush 401-40-38 Standard Duty 3/8" Brass 0.938" 2.81" 1/16" Recess 401-4-62 Standard Duty 5/8" Copper 0.938" 2.88" 1/8" Recess 401-8-62 Standard Duty 5/8" Copper 0.938" 2.63" 1/8" Stick-Out 401-9-62 Standard Duty 5/8" Copper 0.938" 2.51" 1/4" Stick-Out 401-4-75 Standard Duty 3/4" Copper 0.938" 2.88" 1/8" Recess OM-BTB-2.7...
3. Extreme heat or duty cycle. 3. Replace with heavy duty consumables. See appropriate Spec Sheet for details. 4. Short contact tip life. 1. Contact tip size 1. Replace with proper size. 2. Electrode eroding contact tip. 2. Inspect and/or change drive rolls. 3. Exceeding duty cycle. 3. Replace with properly rated Bernard MIG Gun. 5. Erratic arc. 1. Worn contact tip. 1. Replace contact tip. 2. Buildup inside of liner. 2. Replace liner, check condition of electrode. 3. Wrong tip size. 3. Replace with correct tip size. 4. Not enough bend in neck. 4. Replace with 45° or 60° neck. 6. Erratic wire feeding.
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9. See ‘Electrode does not feed’. 10. Worn, cut or missing o-rings. 10. Replace o-rings. 11. Loose fittings. 11. Tighten gun and cable connections to specified torque. See Section 8 — Replacement on page 14. 12. AccuLock S power pin cap not 12. Tighten power pin cap to specified torque. See section 8-2 torqued to the correct spec. Changing AccuLock™ S Consumables on page 15. 9. Gun running hot. 1. Exceeding duty cycle. 1. a. Replace with properly rated Bernard MIG Gun. b. Decrease parameters to within gun rating. 2. Loose or poor power connection. 2. a. Clean, tighten or replace cable grounding connection. b. Tighten gun and cable connections to specified torque. See Section 8 — Replacement on page 14. 10. Liner is discolored full 1. Short circuit to electrode. 1. Isolate electrode reel from feeder and drive block. Consult length. ...
ADDITIONAL SUPPORT MATERIALS For additional support materials such as Spec Sheets, troubleshooting information, how-to guides and videos, animations, online configurators and much more, please visit Bernard. Scan the QR Code with your smart phone for immediate access to Tregaskiss.com/TechnicalSupport. Scan to view the B TB MIG Gun Owner’s Manual Scan to view the BTB MIG Gun Spec Sheet Scan to view the A ccuLock™ S (Semi-Auto) Consumables Spec Sheet Scan to view the Centerfire ® Consumables Spec Sheet Scan to view the Quik Tip™ Consumables Spec Sheet Scan to view the TOUGH LOCK ® Consumables Spec Sheet Scan to view the QUICK LOAD ® Liner and AutoLength™ Pins Spec Sheet Phone: 1-855-MIGWELD (644-9353) (US & Canada) Bernard +1-519-737-3000 (International) ...