Miller Electric Roughneck C User Manual

Roughneck®C-Series

Air-Cooled MIG (GMAW)

Welding Guns

Issued March 2004 • Index No. AY/17.0

Process

MIG (GMAW)
Flux Cored (FCAW)

Rated Output C-30 Models: 300 A C-40 Models: 400 A

C-50 Models: 500 A C-60 Models: 600 A

Duty Cycle 100% with CO

2

gas

Weight C-30 Models: 5.6 –7.5 lb (2.5 –3.4 kg)

C-40 Models: 7.5 – 10.3 lb (3.4 –4.7 kg)
C-50 Models: 9.3 – 13 lb (4.2 –5.9 kg)
C-60 Models: 10.3 – 14.5 lb (4.7 –6.6 kg)

Applications

Construction
Fabrication
Maintenance/Repair
Manufacturing

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

Web Site

www.MillerWelds.com

International Headquarters

Phone: [phone]
USA FAX: [phone]
Canadian FAX: [phone]
International FAX: [phone]

Quick
Specs

The Power of Blue®.

Reliable extended-life trigger is rated
for 1.5+ million cycles and is quickly
changeable if worn out.

Commonality of parts and consumables

between all models helps reduce inventory
and aids serviceability.

Roughneck C-Series

Simple, versatile and durable.

Die-crimped power cable
connections provides maximum

electrical conductivity and reduces
heat at power cable connection.

Patent-pending one-turn screw-on copper
and brass nozzles are available in a wide
variety of sizes to fit most welding
applications or operator preference.

Heavy-duty nozzles feature patented
reduced frontal area to decrease heat
transfer for cooler operation.

Standard aluminum jacketed
goosenecks increase gun durability,

resist spatter, and dissipate heat more
effectively than copper alone.

Interchangeable goosenecks

allow Roughneck welding guns to
adapt for hard to reach welds or
operator preference.

Steel spring strain relief

protects power cable from
wear on both ends and helps
prevent liner kinking, allowing
better wire feedability.

Optional Adapter Kits allow
Roughneck MIG welding guns to
adapt to most major brands of
welding equipment.

360˚ wrench rotatable gooseneck allows
finger or thumb actuation of the trigger
and field replacement of goosenecks.

Gun is warranted for 90 days parts and labor.

FasTip™contact tip features one fast turn

on and off. It also exhibits extended life
when compared to standard threaded
contact tips. FasTip is patented under
U.S. patents 5,760,373 and 5,911,894.

Specifications (Subject to change without notice.)

Gun Model
C-3010

C-3012
C-3015

C-4010
C-4012
C-4015

C-5010
C-5012
C-5015

C-6010
C-6012
C-6015

Part No.
#194 751

#194 752
#194 753

#194 754
#194 755
#194 756

#194 757
#194 758
#194 759

#194 760
#194 761
#194 762

Rated Output

300 Amps

400 Amps

500 Amps

600 Amps

Duty Cycle

100% using CO2(ratings with
mixed gas are reduced by 10 – 50%
depending on the gas mixture and
welding parameters)

Cable Length

10 ft (3.0 m)
12 ft (3.7 m)
15 ft (4.6 m)

10 ft (3.0 m)
12 ft (3.7 m)
15 ft (4.6 m)

10 ft (3.0 m)
12 ft (3.7 m)
15 ft (4.6 m)

10 ft (3.0 m)
12 ft (3.7 m)
15 ft (4.6 m)

Standard Wire Size

.035 – .045 in
(0.9 – 1.2 mm)

.035 – .045 in
(0.9 – 1.2 mm)

.052 – 1/16 in
(1.3 – 1.6 mm)

.052 – 1/16 in
(1.3 – 1.6 mm)

Weight

5.6 lb (2.5 kg)

6.4 lb (2.9 kg)

7.5 lb (3.4 kg)

7.5 lb (3.4 kg)

8.6 lb (3.9 kg)

10.3 lb (4.7 kg)

9.3 lb (4.2 kg)

10.8 lb (4.9 kg)

13.0 lb (5.9 kg)

10.3 lb (4.7 kg)

12.0 lb (5.4 kg)

14.5 lb (6.6 kg)

Genuine Miller Options

(Order from Miller Service Parts.)

Locking Trigger Switch #199 661

Allows trigger to be locked during long welds.

Gun Hook #199 662

Enables gun to be stored between welds.

Aluminum Conversion Kit #202 895

Steel wrapped nylon liner allows 10 ft Roughneck

®

welding guns to feed 3/64 – 1/16 in (1.2– 1.6 mm)
aluminum wire.

Miller Roughneck Consumable
Upgrade Kits for Tweco

®

Guns

300/400/500 Amp #214 893

Includes gas diffuser and neck insulator. Upgrades
a Tweco gun for use with patented Miller FasTip

™

contact tips. (Order FasTip contact tips separately.)

Tweco is a registered trademark of Thermadyne.

Heat Shields
300/400 Amp #213 229
500/600 Amp #213 230

Machine Adapter Kit #199 663

Allows Roughneck welding guns to adapt to
Hobart and Thermal Arc products (BETAMIG II,
200, 250, 251; Hefty; 2000 Series; Dual/Digital
2000; Porta-Feed and Ultra-Feed), Lincoln
products (Power MIG 255; Wirematic 250,
255; SP-T Series; Power Feed 10; DH-10; LN-10
(new style) and STT-10) and ESAB products
(Migmaster 180). Tweco style 5/8 in direct plug.
Requires ordering a new replacement liner.

Machine Adapter Kit #199 664

Allows Roughneck welding guns to adapt to
Lincoln products (LN-7, LN-8, LN-9, LN-22,
LN-25 and LN-742). Requires ordering a new
replacement liner.

DSS-8 #079 693

A 15 ft 2-position (dual pull) trigger switch that
attaches to the gun handle and is used in place
of the standard trigger for dual scheduling.
Adapter cord #157 364 is required to use the
DSS-8 with 60M wire feeders.

DSS-9 #071 833

A 15 ft 2-position slide switch that attaches to
the gun handle and is used to select the desired
welding condition for dual scheduling. Gun
trigger operates as standard trigger. Adapter
cord #157 364 is required to use the DSS-9 with
60M wire feeders.

DSS-9M #041 793

A 15 ft 2-position slide switch that attaches to
the gun handle and is used to select the desired
welding condition for dual scheduling with the
60M wire feeder. Gun trigger operates as
standard trigger.

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