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- Page 1 ® Bernard TGX® Series Semi-Automatic Air-Cooled MIG Gun OWNER'S MANUAL March 2022 TG083-1.3 Semi-Automatic, Air-Cooled, MIG (GMAW) Welding Gun Tregaskiss.com/TechnicalSupport 1-855-MIGWELD (644-9353) (US & Canada) +1-519-737-3000 (International)
- Page 2 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.
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Page 3: Section 1 - Safety Precautions - Read Before Using
SECTION 1 — SAFETY PRECAUTIONS — READ BEFORE USING Replace worn, damaged, or cracked guns or cables. Protect yourself and others from injury – read, follow, Turn off welding power source before changing contact tip or and save these important safety precautions and operating instructions. gun parts. Keep all covers and handle securely in place. 1-1 Symbol Usage FUMES AND GASES can be hazardous. DANGER! –... -
Page 4: Welding Wire Can Injure
Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and WELDING WIRE can injure. sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Keep hands and body away from gun tip when Wear approved safety glasses with side shields under your trigger is pressed. helmet. Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc. READ INSTRUCTIONS. Wear body protection made from leather or flame-resistant clothing (FRC). Body protection includes oil-free clothing Read and follow all labels and the Owner's such as leather gloves, heavy shirt, cuffless trousers, high Manual carefully before installing, operating, shoes, and a cap. or servicing unit. Read the safety information at the beginning of the Manual and in each section. Use only genuine replacement parts from the manufacturer. HOT PARTS can burn. Perform installation, maintenance, and service according to the Owner's Manuals, industry standards, and national, state, Allow gun to cool before touching. and local codes. 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. -
Page 5: California Proposition 65 Warnings
1-3 California Proposition 65 Warnings WARNING: This product can expose you to chemicals For more information, go to www.P65Warnings.ca.gov. including lead, which are known to the state of California to cause cancer and birth defects or other reproductive harm. 1-4 Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, American Welding Safety in Welding, Cutting, and Allied Processes, CSA Standard Society standard ANSI Standard Z49.1. Website: www.aws.org. W117.2 from Canadian Standards Association. Website: www.csagroup.org. Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standard for Fire Prevention During Welding, Cutting, and Other Standards Institute. Website: www.ansi.org. -
Page 6: Section 2 - Consignes De Sécurité - Lire Avant Utilisation
SECTION 2 — CONSIGNES DE SÉCURITÉ — LIRE AVANT UTILISATION Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et UN CHOC ÉLECTRIQUE peut tuer. au mode opératoire. - Page 7 Lire et comprendre les fiches de données de sécurité et les Avertir les personnes à proximité au sujet du danger inhérent instructions du fabricant concernant les adhésifs, les au bruit. revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux. LES FILS DE SOUDAGE peuvent provoquer L'ACCUMULATION DE GAZ risquent de des blessures. provoquer des blessures ou même la mort. Éloigner les mains et le corps de la buse du Fermer l’alimentation du gaz comprimé en cas pistolet après avoir appuyé sur la gâchette. de non utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir LIRE LES INSTRUCTIONS. d’un respirateur d’adduction d’air homologué. Lire et appliquer les instructions sur les LE RAYONNEMENT DE L'ARC peut brûler les étiquettes et le Mode d’emploi avant yeux et la peau.
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Page 8: Proposition Californienne 65 Avertissements
2-3 Proposition californienne 65 avertissements AVERTISSEMENT – Ce produit peut vous exposer à des Pour plus d’informations, consulter www.P65Warnings.ca.gov. produits chimiques tels que le plomb, reconnus par l’État de Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction 2-4 Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, American Welding Safety in Welding, Cutting, and Allied Processes, CSA Standard Society standard ANSI Standard Z49.1. Website: www.aws.org. W117.2 from Canadian Standards Association. Website: www.csagroup.org. Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National ... -
Page 9: Section 3 - Precauciones De Seguridad - Lea Antes De Usar
SECTION 3 — PRECAUCIONES DE SEGURIDAD — LEA ANTES DE USAR Protéjase usted mismo y a otros contra lesiones — lea, cumpla y conserve estas importantes UNA DESCARGA ELÉCTRICA puede matarlo. precauciones de seguridad e instrucciones de utilización. Siempre use guantes aislantes secos. Aíslese usted mismo del trabajo y la tierra. No toque electrodo eléctricamente vivo o partes 3-1 Uso de símbolos eléctricamente vivas. - Page 10 EL AMONTONAMIENTO DE GAS puede El ALAMBRE de SOLDAR puede causarle enfermarle o matarle. heridas. Mantenga las manos y el cuerpo lejos del tubo Cierre el suministro de gas comprimido de contacto de la antorcha cuando se haya cuando no lo use. presionado el gatillo. Siempre dé ventilación a espacios cerrados o use un respirador aprobado que reemplaza el aire. LEER INSTRUCCIONES. LOS RAYOS DEL ARCO pueden quemar sus Lea y siga cuidadosamente las instrucciones ojos y piel. contenidas en todas las etiquetas y en el Los rayos del arco de un proceso de suelda Manual del usuario antes de instalar, utilizar o producen un calor intenso y rayos ultravioletas realizar tareas de mantenimiento en la unidad. Lea la fuertes que pueden quemar los ojos y la piel. Las ...
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Page 11: Estándares Principales De Seguridad
3-3 Advertencias de la Proposición 65 del estado de California ADVERTENCIA: Este producto puede exponerlo a químicos, Para obtener más información, acceda a incluso plomo, que el estado de California conoce como www.P65Warnings.ca.gov. causantes de cáncer, defectos de nacimiento u otros daños reproductivos. 3-4 Estándares principales de seguridad Safety in Welding, Cutting, and Allied Processes, American Welding Safety in Welding, Cutting, and Allied Processes, CSA Standard Society standard ANSI Standard Z49.1. Website: www.aws.org. W117.2 from Canadian Standards Association. Website: www.csagroup.org. Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National ... -
Page 12: Section 4 - Product Warranty
Tregaskiss (including inspection, labor, parts, testing, scrap and freight) due to warranty claims submitted by Purchaser which are not covered by Tregaskiss’ warranty. ® Bernard BTB Semi-Automatic Air-Cooled MIG Guns: 1 year; Lifetime warranty on straight handles, straight handle switches, and rear strain relief ®... - Page 13 1.0 – ASSEMBLY 1.1 ASSEMBLY INSTRUCTIONS – EASY AS 1-2-3! MIG GUNS ONLY STEP #1 NOTE: Applies to all TGX XS and XL gun models Remove gun from box and extend to full length. Slide nozzle off of front end of gun. ...
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Page 14: Installation
2.0 – INSTALLATION 2.1 INSERTING MIG GUN INTO A WIRE FEEDER For most power pins 1. Insert power pin to shoulder and secure. 2. Insert control plug to control housing of MIG gun. 3. Insert control plug into feeder. 4. Feed welding wire into power pin by hand and tighten drive rolls. -
Page 15: Installing Gun To Quick Connect Block
2.3 INSTALLING GUN TO QUICK CONNECT BLOCK Ensure correct liner and contact tip are utilized. Examine and replace power pin o-rings if necessary. STEP #1 POWER PIN REAR HANDLE WELDING WIRE TO GAS THUMB SCREW Guide welding wire into power pin. ... -
Page 16: Maintenance
The neck insulator is pressed onto the neck by hand. 3.2 CONVENTIONAL LINER REPLACEMENT NOTE: For guns equipped with thread-in power pins, Bernard, or Euro-connector, follow the procedure below. On Miller® style guns, liner is held captive by a guide cap, which must be removed and replaced when changing liner. -
Page 17: Protective Cap
NOTE: Ensure power supply is off and gun is removed from feeder before proceeding. Remove nozzle, tip and retaining head. If power pin is thread-in liner type, using a 10 mm wrench, turn thread-in liner retainer counterclockwise until liner is free from the power pin. - Page 18 STEP 4 Once the liner stops feeding, give it an extra TRIM HERE push to ensure it is inserted completely. IMPORTANT! Push liner back into gun and hold in place. Using the liner gauge, trim liner with 3/4” (19 mm) stick out. ...
- Page 19 3.5 SWITCH REPLACEMENT – XS GUN MODELS STEP #1 Twist handle lock nut in direction of arrow. Pull handle lock away from handle. Remove switch from nest in handle. Remove switch from switch lead connectors with needle nose pliers. SWITCH LEAD SWITCH ...
- Page 20 3.7 NECK REPLACEMENT – XS GUN MODELS SWITCH STEP #1 NECK UNICABLE HANDLE LOCK NUT Place neck in vise. Twist handle nut and pull away from handle. Slide handle back exposing jam nut and front of unicable. ...
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Page 21: Technical Data
4.0 – TECHNICAL DATA 4.1 NECK DIMENSIONS .75 (19 mm) (NOMINAL SIZE FOR ALL NECKS) D RAD. NECK ANGLE INCHES INCHES INCHES INCHES 205-60X 55° 4.42 3.82 2.00 1.88 405-60X 60° 4.98 4.78 3.00 1.90 4.2 GUN AMPERAGE RATINGS 60% DUTY CYCLE - MIXED GASES GUN MODEL OR 100% DUTY CYCLE - CO 180 amp (XS) -
Page 22: Troubleshooting
5.0 – TROUBLESHOOTING PROBLEM POSSIBLE CAUSE CONDUIT LINER CLOGGED OR KINKED POOR WIRE FEED INCORRECT LINER SIZE OR CONTACT TIP LINER CUT TOO SHORT AND NOT SEATING PROPERLY IN GAS DIFFUSER DRIVE ROLLS TOO TIGHT RESULTING IN SCORING OF WELDING WIRE ... -
Page 23: Exploded View And Parts Lists
6.0 – EXPLODED VIEW AND PARTS LISTS 6.1 TGX XL SERIES GUNS Numbers in this column correspond to the exploded view images above. PART # DESCRIPTION STANDARD DUTY NOZZLE (SELF-INSULATED) STANDARD DUTY TREGASKISS™ TOUGH LOCK™ CONTACT TIPS 403-14-xx 403-20-xx HEAVY DUTY TREGASKISS TOUGH LOCK CONTACT TIPS 404-26 HEAVY DUTY TREGASKISS TOUGH LOCK RETAINING HEAD 454-1-2... - Page 24 6.2 TGX XS SERIES GUNS PART # DESCRIPTION STANDARD DUTY NOZZLE (SELF-INSULATED) 403-14-xx STANDARD DUTY TREGASKISS TOUGH LOCK™ CONTACT TIPS 403-20-xx HEAVY DUTY TREGASKISS TOUGH LOCK CONTACT TIPS 404-18 STANDARD DUTY TREGASKISS TOUGH LOCK RETAINING HEAD 404-26 HEAVY DUTY TREGASKISS TOUGH LOCK RETAINING HEAD 402-7 NECK INSULATOR 205-60X...
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Page 25: Ordering Information
7.0 – ORDERING INFORMATION 7.1 TGX CHASSIS MODEL NO. AMPERAGE RATING LENGTH 10’ XS1810 12’ XS1812 15’ XS1815 10’ XS2610 12’ XS2612 15’ XS2615 10’ XS3210 12’ XS3212 15’ XS3215 10’ XL3010 12’ XL3012 15’ XL3015 10’ XL4010 12’ XL4012 15’... -
Page 26: Power Pins
POWER PINS FEEDER FEEDER MODELS PART # BETA-MIG (NEW STYLE), BETA-MIG 250 AND 251, DUAL FEEDER, DIGITAL 2000, DUAL DIGITAL, PORTA FEED 17, ULTRA FEED 1000, 2000, 2400, HOBART® (Tweco® #4 Style) HANDLER, OSCAWA, HEFTY CV/CC BETA-MIG 261, OLYMPIC 22-P, OLYMPIC VS, IRONMAN 275 214-1 WIREMATIC 250, 255, SP-85, SP-86, SP-100, SP-100T, SP-125PLUS, SP-130, SP-130T, SP-150, SP-170, SP-200, SP-250, IDEALARC SP-255, MIG PAK10,... -
Page 27: Gun Standards Chart
7.3 EXAMPLE OF STANDARD XL MODEL NO. M- XL3010 -45 Wire Size Standard Lengths - 10, 12, 15 ft Power Amperage (Manual) 30 - 300 amp 40 - 400 amp XL Series 7.4 EXAMPLE OF STANDARD XS MODEL NO. M- XS1810 -30 Wire Size Standard Lengths - 10, 12, 15 ft Power... - Page 28 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 TGX Semi-Automatic Air-Cooled MIG Gun Owner’s Manual ® Scan to view the TOUGH LOCK Consumables Spec Sheet ® Scan to view additional Bernard ® Owner's Manuals and Spec Sheets Phone: 1-855-MIGWELD (644-9353) (US & Canada) Bernard +1-519-737-3000 (International) A Division of Miller Electric Mfg. LLC 449 West Corning Road Fax: 1-708-946-6726 Beecher, Illinois 60401 USA...