Miller Roughneck C, C-50, C-60, C-30, C-40 Owner's Manual

OM-199 706A

August 2001

Processes

MIG (GMAW) Welding

Flux Cored (FCAW) Arc
Welding

Description

Semi-Automatic, Air-Cooled,
MIG (GMAW) Welding Gun



Roughneck C-Series

Visit our website at

www.MillerWelds.com

300, 400, 500, And 600 Ampere MIG Welding Guns

From Miller to You

Thank you and congratulations on choosing Miller.
Now you can get the job done and get it done right. We
know you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldn’t afford anything less. Miller
products had to be more than the best they could be.
They had to be the best you could buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will

Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.

help you figure out what the problem is. The
parts list will then help you to decide which
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.

Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.

Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. T o obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMA W-P.

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.
(California Health &
Safety Code Section

25249.5 et seq.)

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 –SAFETY PRECAUTIONS FOR GMAW WELDING GUNS – READ BEFORE USING 1.

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. GMAW Gun Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EMF INFORMATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – INSTALLATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Duty Cycle And Overheating 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Gun Connection And Operation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – MAINTENANCE & TROUBLESHOOTING 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Routine Maintenance 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Replacing The Contact Tip 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Installing Or Replacing The Liner 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Replacing Feeder Connector 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Installing Optional Gun Hook 199 662 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Installing Replacement Trigger 199 628 And Optional Locking Trigger 199 661 7. . . . . . . . . .

3-7. Troubleshooting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – PARTS LIST 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-199 706

SECTION 1 –SAFETY PRECAUTIONS FOR GMAW

WELDING GUNS – READ BEFORE USING

1-1. Symbol Usage

SR7_7/01

Means Warning! Watch Out! There are possible hazards with this
procedure! The possible hazards are shown in the adjoining symbols.

This group of symbols means Warning! Watch Out! Possible ELECTRIC SHOCK and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions to avoid the hazards.

Y Marks a special safety message.

. Means NOTE; not safety related.

1-2. GMAW Gun Hazards

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.

In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information found in the wire feeder
and welding power source Owner’s Manuals. Read and follow all safety precautions.

HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.

ELECTRIC SHOCK can kill.

1. Always wear dry insulating gloves.

2. Insulate yourself from work and ground.

3. Do not touch live electrode or electrical parts.

4. Repair or replace worn, damaged, or cracked
gun or cable insulation.

5. Turn off welding power source before changing
contact tip or gun parts.

6. Keep all covers and handle securely in place.

GMAW WELDING can be hazardous.

ARC RAYS can burn eyes and skin.

1. Wear welding helmet with correct shade of filter.

2. Wear correct eye and body protection.

3. Cover exposed skin with spatter-resistant
clothing.

HOT SURFACES can burn skin.

1. Allow gun to cool before touching.

2. Do not touch hot metal.

3. Protect hot metal from contact by others.

FUMES AND GASES can be hazardous
to your health.

1. Keep your head out of the fumes.

2. Ventilate area, or use breathing device.

3. Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.

WELDING can cause fire or explosion.

1. Do not weld near flammable material.

2. Do not weld on closed containers.

3. Watch for fire; keep extinguisher nearby.

BUILD UP OF GAS can injure or
kill

1. Shut of f shielding gas supply when not in
use.

2. Always ventilate confined spaces or use
approved air-supplied respirator.

NOISE can damage hearing; SOME
APPLICATIONS, SUCH AS PULSING,
are noisy.

1. Check for noise level limits exceeding those
specified by OSHA.

2. Use approved ear plugs or ear muffs if noise level
is high.

3. Warn others nearby about noise hazard.

WELDING WIRE can cause puncture
wounds.

1. Keep hands and body away from gun tip when
trigger is pressed.

OM-199 706 Page 1

EMF INFORMATION

NOTE

The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological

Effects of Power Frequency Electric & Magnetic Fields –
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.

Government Printing Office, May 1989): “. . . there is now a very large
volume of scientific findings based on experiments at the cellular
level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us t o draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”

Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields

To reduce magnetic fields in the workplace, use the following
procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around the body.

4. Keep welding power source and cables as far away as practical.

5. Connect work clamp to workpiece as close to the weld as
possible.

About Pacemakers:

The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.

mod10.1 4/93

OM-199 706 Page 2

2-1. Specifications

Ref. ST-800 797-C

SECTION 2 – INSTALLATION

Air-Cooled Guns For GMAW Welding

Note: Using mixed gases other than CO2 reduces duty cycle ratings by 10-50%.
C-30 Gun Feeds .023 To 5/64 in (0.6 To 2.0 mm) Wire

Duty Cycle Rating:
100%: 300 A With CO

Weight With 15 Ft (Heaviest) Power Cable: 7.5 lb (3.4 kg)
Maximum Recommended Wire Size – 5/64 in

C-40 Gun Feeds .023 To 5/64 in (0.6 To 2.0 mm) Wire
Duty Cycle Rating:

100%: 400 A With CO
Weight With 15 Ft (Heaviest) Power Cable: 10.3 lb (4.7 kg)
Maximum Recommended Wire Size – 5/64 in

C-50 Gun Feeds .023 To 1/8 in (0.6 To 3.2 mm) Wire
Duty Cycle Rating:

100%: 500 A With CO
Weight With 15 Ft (Heaviest) Power Cable: 13 lb (5.9 kg)
Maximum Recommended Wire Size – 1/8 in

C-60 Gun Feeds .023 To 1/8 in (0.6 To 3.2 mm) Wire
Duty Cycle Rating:

100%: 600 A With CO
Weight With 15 Ft (Heaviest) Power Cable: 14.5 lb (6.6 kg)
Maximum Recommended Wire Size – 1/8 in

Shielding Gas

2

Shielding Gas

2

Shielding Gas

2

Shielding Gas

2

2-2. Duty Cycle And Overheating

100% Duty Cycle At Following Amperes:

C-30 Gun: 300 A With CO
C-40 Gun: 400 A With CO
C-50 Gun: 500 A With CO
C-60 Gun: 600 A With CO

Continuous Welding

Overheating

Shielding Gas

2

Shielding Gas

2

Shielding Gas

2

Shielding Gas

2

0

Minutes

15

A or V

OR

Reduce Duty Cycle

Duty Cycle is percentage of 10 mi n ­utes 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 p a r a m e t ers.

Y Exceeding duty cycle can

damage unit and void
warranty.

sduty1 5/95

2

OM-199 706 Page 3

2-3. Gun Connection And Operation

1

2

3

6

1 Gun Securing Knob
2 Gun Block
3 Feeder Connector
Loosen knob. Insert feeder connec-

tor until it is as close as possible to
drive rolls without touching. T ighten
knob.

4 Gun Trigger Plug
5 Gun Trigger Receptacle
Insert plug into receptacle and tight-

en threaded collar.
6 Trigger Switch
Press switch to feed energized wire

and start gas flow .

5

4

802 631

SECTION 3 – MAINTENANCE & TROUBLESHOOTING

3-1. Routine Maintenance

Clean

Nozzle

And Check

Contact Tip

Replace

Damaged Or

Unreadable

Labels

Y Disconnect power

before maintaining.

Each Spool Of Wire

3 Months

Clean And

Tighten

Weld

Terminals

. Maintain more often

during severe conditions.

Blow Out Gun

Casing

Repair Or Replace

Cracked Cables

Replace Damaged

Gas Hose

And Cords

OM-199 706 Page 4

3-2. Replacing The Contact Tip

3

2

1

Tools Needed:

3-3. Installing Or Replacing The Liner

Turn off welding power source/wire feeder.

1

7

6

5

2

1

Threaded End

Turn off welding power source/wire
feeder. Cut off wire at contact tip.

1 Nozzle
2 Contact Tip
3 Diffuser

. Correct wire size is stamped on

tip. Be sure to use indicated
wire size.

Ref. 802 661

1 Liner
2 Feeder Connector
3 Nozzle
4 Contact Tip
5 Diffuser
6 Fiber Washer
7 Insulator
Lay gun cable out straight. Remove

washer, nozzle, tip, diffuser and in­sulator. Remove existing liner from
adapter by unscrewing threaded
end of liner and removing liner from
gun cable.

Insert new liner into feeder connec­tor and feed liner into connector.
Rotate threaded end of liner into
adapter to secure liner in place.

At opposite end of gun cable, cut lin­er so 7/8 in extends beyond end of
gooseneck as shown. Reinstall in­sulator, washer, diffuser, tip and
nozzle.

4

3

Tools Needed:

802 648-A

OM-199 706 Page 5

3-4. Replacing Feeder Connector

Threaded End

7

6

8

6

5

4

3

2

1

Flatted Side

Y Turn off welding power

source and wire feeder.

1 Nozzle
2 Contact Tip
3 Diffuser
4 Fiber Washer
5 Insulator
6 Liner
7 Feeder Connector
Lay gun cable out straight.
Remove nozzle, contact tip, diffus-

er, fiber washer, and insulator. Re­move existing liner from feeder con­nector by unscrewing threaded end
of liner and removing liner from gun
cable.

8 Screw
Remove screw. Move handle back

to reveal flatted side on handle in­sert. Using wrenches on handle in­sert and feeder connector, remove
feeder connector from insert.

Install new feeder connector.

. Gun cable must be straight

when new liner is inserted or

Old Feeder Connector

New Feeder Connector

new liner will be cut to incorrect
length, causing wire feed
problems.

Insert new liner into new feeder
connector and feed liner into feeder
connector. Rotate threaded end of
liner into feeder connector to se­cure liner in place. Slide handle for­ward and tighten screw .

At opposite end of gun cable, cut lin­er so 7/8 in (22 mm) extends be­yond end of gooseneck as shown.
Reinstall insulator, fiber washer, dif­fuser , tip and nozzle.

Tools Needed:

5/8, 15/16

OM-199 706 Page 6

7/8 in (22 mm)

Ref. 802 874 / 802 648

3-5. Installing Optional Gun Hook 199 662

2

1

Tools Needed:

Y Turn Off welding power

source and wire feeder and
be sure gun is cool before
proceeding.

1 Retaining Screw
2 Gun Hook
Remove single retaining screw in

location shown, position gun hook
in place, and reinstall retaining
screw.

Ref. 802 658

3-6. Installing Replacement Trigger 199 628 And Optional Locking Trigger 199 661

Y Turn Off welding power

source and wire feeder and
be sure gun is cool before
proceeding.

1 Left Half Of Handle
2 Retaining Screw (Four Total)

. When retaining screws are re-

moved, matching nuts are not
held in place.

Remove retaining screws and left
half of handle as shown.

3 Trigger
4 Locking Trigger
Align tabs on applicable trigger

(see illustration) with indentations
in handle portion still on gun and
install trigger in place. Reinstall
handle portion removed earlier and
secure in place with retaining
screws.

Tabs

Tabs locations are

the same on locking

trigger.

2

1

3

Or

4

Tools Needed:

3-7. Troubleshooting

Trouble Remedy

Wire does not feed. Check contact tip and check for kinks in gun cable.

Check connections at welding power source/wire feeder.
Have nearest Factory Authorized Service Agent check gun trigger switch.

Wire is not energized. Check contact tip and check for kinks in gun cable.

Have nearest Factory Authorized Service Agent check gun trigger switch.

Wire feeds unevenly. Check contact tip. Check for kinks in gun cable. Blow out liner and gun casing.

Ref. 802 660-A

OM-199 706 Page 7

SECTION 4 – PARTS LIST

12

11

10

17

13

16

14

9

15

OM-199 706 Page 8

9

6

8

7

5

4

3

2

1

Figure 4-1. C-30, C-40, C-50, And C-60 Guns

802 630-B

Item

No.

Part

No.

Description

Figure 4-1. C-30, C-40, C-50, And C-60 Guns

Nozzles

1 ♦199 610 NOZZLE, screw on brass 1/2 in orifice tapered 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ♦199 611 NOZZLE, screw on brass 3/4 in orifice straight 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ♦199 612 NOZZLE, screw on brass 3/4 in orifice straight Heavy Duty 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ♦199 613 NOZZLE, screw on brass 5/8 in orifice tapered 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ♦199 614 NOZZLE, screw on brass 5/8 in orifice tapered Heavy Duty 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ♦199 615 NOZZLE, screw on copper 1/2 in orifice tapered 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ♦199 616 NOZZLE, screw on copper 3/4 in orifice straight 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ♦199 617 NOZZLE, screw on copper 3/4 in orifice straight Heavy Duty 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

1 198 855 NOZZLE, screw on copper 5/8 in orifice tapered . . . . . . . . . . . . . . .

(standard on 300 & 400 amp models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 199 618 NOZZLE, screw on copper 5/8 in orifice tapered Heavy Duty . . . . . . . . . . . . . . .

(standard on 500 & 600 amp models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard FasTiptContact Tips*

2 ♦206 175 .023 in (0.6 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦206 176 .030 in (0.8 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦206 177 .035 in (0.9 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 206 179 .045 in (1.2 mm) (standard on 300 & 400 amp models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦206 180 .052 in (1.3 mm) or 3/64 in (1.2 mm) aluminum wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦206 181 1/16 in (1.6 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦206 182 .068 in (1.7 mm) or 1/16 in (1.6 mm) aluminum wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦206 183 5/64 in (2.0 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heavy Duty FasTiptContact Tips*

Quantity

2 ♦206 186 .035 in (0.9 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦206 187 .040 in (1.0 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦206 188 .045 in (1.2 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦206 189 .052 in (1.3 mm) or 3/64 in (1.2 mm) aluminum wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 206 190 1/16 in (1.6 mm) (standard on 500 & 600 amp models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦206 191 .068 in (1.7 mm) or 1/16 in (1.6 mm) aluminum wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦206 192 5/64 in (2.0 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦206 193 3/32 in (2.4 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Extra Heavy Duty FasTiptContact Tips*

2 ♦199 605 .035 in (0.9 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦199 606 .040 in (1.0 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦198 851 .045 in (1.2 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦198 852 .052 in (1.3 mm) or 3/64 in (1.2 mm) aluminum wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦198 853 1/16 in (1.6 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦198 854 .068 in (1.7 mm) or 1/16 in (1.6 mm) aluminum wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦199 607 5/64 in (2.0 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦199 608 3/32 in (2.4 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦199 609 7/64–1/8 in (2.8 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Value Multi–Turn Contact Tips*

2 ♦087 300 .023 in (0.6 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦071 825 .030 in (0.9 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦054 202 .035 in (0.9 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦054 201 .045 in (1.2 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦199 593 .3/64 in (1.2 mm) aluminum wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦044 006 .052 in (1.3 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦047 566 1/16 in (1.6 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦202 933 1/16 in (1.6 mm) aluminum wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦199 594 .068 in (1.7 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦047 565 5/64 in (2.0 mm) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-199 706 Page 9

Item

No.

Part

No.

Description

Figure 4-1. C-30, C-40, C-50, And C-60 Guns (continued)

Gas Diffusers

3 206 195 1/8 in tip recess – for standard and heavy duty FasTip contact tips. . . . . . . . . . . . . . .

(standard on all guns) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 ♦206 196 Flush tip – for standard and heavy duty FasTip contact tips 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 ♦198 857 1/8 in tip recess – for extra heavy duty FasTip contact tips 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 ♦199 623 Flush tip – for extra heavy duty FasTip contact tips 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 ♦199 621 1/8 in tip recess – for value multi–turn contact tips 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 ♦199 622 Flush tip – for value multi–turn contact tips 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Insulators

4 201 157 WASHER, fiber 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 198 856 INSULATOR, Teflon 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 202 292 COVER, Nut. . . . . . . . . . . . . . .

Liners

7 ♦202 889 LINER, monocoil .023–.030 wire x 16.5 ft round wound 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 202 890 LINER, monocoil .035–.045 wire x 16.5 ft round wound . . . . . . . . . . . . . . .

(standard on 300 & 400 amp models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 202 891 LINER, monocoil .052–1/16 wire x 16.5 ft round wound. . . . . . . . . . . . . . .

(standard on 500 & 600 amp models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 ♦202 892 LINER, monocoil 1/16–.078 wire x 16.5 ft flat wound 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 ♦202 893 LINER, monocoil 5/64–3/32 wire x 16.5 ft flat wound 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 ♦202 894 LINER, monocoil 7/64–1/8 wire x 16.5 ft flat wound 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 ♦202 895 LINER, monocoil 3/64–1/16 AL wire x 16.5 ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Goosenecks

Quantity

8 +199 625 GOOSENECK, jacketed 4.5 in/50deg wrench swivel. . . . . . . . . . . . .

8 +199 626 GOOSENECK, jacketed 6 in/50deg wrench swivel. . . . . . . . . . . . .

8 +199 627 GOOSENECK, jacketed 8 in/50deg wrench swivel. . . . . . . . . . . . .

(standard on 300 & 400 amp models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(standard on 500 amp models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(standard on 600 amp models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-199 706 Page 10

Item

No.

Part

No.

Description

Figure 4-1. C-30, C-40, C-50, And C-60 Guns (continued)

Parts

9 199 630 HANDLE KIT, 300 & 400 amp models (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 632 SCREW, M4 x 18 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 633 NUT, M4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 634 SCREW, M3 x 11 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 635 NUT, M3 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 647 LABEL, gun handle Miller Roughneck 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 199 631 HANDLE KIT, 500 & 600 amp models (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 632 SCREW, M4 x 18 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 633 NUT, M4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 647 LABEL, gun handle Miller Roughneck 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 199 648 LABEL, back-end C-3010 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 199 649 LABEL, back-end C-3012 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 199 650 LABEL, back-end C-3015 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 199 651 LABEL, back-end C-4010 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 199 652 LABEL, back-end C-4012 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 199 653 LABEL, back-end C-4015 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 199 654 LABEL, back-end C-5010 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 199 655 LABEL, back-end C-5012 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 199 656 LABEL, back-end C-5015 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 199 657 LABEL, back-end C-6010 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 199 659 LABEL, back-end C-6012 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 199 660 LABEL, back-end C-6015 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 199 637 SCREW, machine binding head 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 199 640 ADAPTER, Miller power pin (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 079 974 O-RING, Miller power pin 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 079 878 HOUSING, plug and pins (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

079 531 CONN, circ cpc clamp str rlf size 11 .453 OD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 ♦199 661 SWITCH, locking trigger 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 199 628 SWITCH, trigger (standard on all guns) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 199 629 SWITCH, contact pin 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦199 662 HOOK, gun 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦199 663 KIT, adapter Miller to old Hobart/Thermal/Tweco (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202 916 ADAPTER, Roughneck to old Hobart 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 727 CONTROL LEADS, Hobart 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦199 664 KIT, adapter Miller to Lincoln (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202 918 ADAPTER, Roughneck to Lincoln 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 728 CONTROL LEADS, Lincoln 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

♦OPTIONAL

+Includes nozzle insulator 198 856, fiber washer 201 157, and threaded nut cover 202 292.

*All contact tips are packaged in bags of 25.

BE SURE TO PROVIDE MODEL WHEN ORDERING REPLACEMENT PARTS.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model is required when ordering parts from your local distributor.

OM-199 706 Page 11

Standard Consumables Chart

300 Amp Guns 400 Amp Guns 500 Amp Guns 600 Amp Guns

Contact Tip 206 179 206 179 206 190 206 190
Nozzle 198 855 198 855 199 618 199 618
Diffuser* 206 195 206 195 206 195 206 195
Liner 202 890 202 890 202 891 202 891
Gooseneck 199 625 199 625 199 626 199 627

*The use of optional Extra Heavy Duty FasTip contact tips requires the use of Diffusers 198 857 and 199 623.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model is required when ordering parts from your local distributor.

OM-199 706 Page 12

Notes

OM-199 706 Page 13

Notes

OM-199 706 Page 14

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.

Y our distributor also gives
you ...

Service

Y ou always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.

Support

Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.

Effective January 1, 2000

(Equipment with a serial number preface of “LA” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.

1. 5 Years Parts – 3 Years Labor

* Original main power rectifiers
* Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Supplies
* Intellitig
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by
the engine manufacturer .)

3. 1 Year — Parts and Labor

* DS-2 Wire Feeder
* Motor Driven Guns (w/exception of Spoolmate

185 & Spoolmate 250)
* Process Controllers
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources
* Water Coolant Systems
* HF Units
* Grids
* Maxstar 140
* Spot Welders
* Load Banks
* Miller Cyclomatic Equipment
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF

Models)
* Field Options

(NOTE: Field options are covered under True

Blue for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches
* Induction Heating Coils and Blankets

guarantees or warranties expressed or implied.

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches
* Remote Controls
* Accessory Kits
* Replacement Parts (No labor)
* Spoolmate 185 & Spoolmate 250
* Canvas Covers

Miller’s True Blue Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.

2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation bas e d u p o n a c tual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. I N N O EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.

miller_warr 7/00

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service

Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

Miller Electric Mfg. Co.

An Ill inoi s Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters–USA

USA Phone: [phone] Auto-A t t ended
USA & Canada FAX: [phone]
International FAX: [phone]

European Headquarters –
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier for:

For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.

PRINTED IN USA  2001 Miller Electric Mfg. Co. 1/01

File a claim for loss or damage during
shipment.