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.

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