Miller Electric Roughneck C-Series User's Manual
Contents
1. Applications Construction Quick Fabrication Maintenance Repair Specs Manufacturing The Power of Blue Standard aluminum jacketed goosenecks increase gun durability resist spatter and dissipate heat more effectively than copper alone 360 wrench rotatable gooseneck allows finger or thumb actuation of the trigger and field replacement of goosenecks Interchangeable goosenecks allow Roughneck welding guns to adapt for hard to reach welds or operator preference Optional Adapter Kits allow Roughneck MIG welding guns to adapt to most major brands of welding equipment Die crimped power cable connections provides maximum electrical conductivity and reduces heat at power cable connection Steel spring strain relief protects power cable from wear on both ends and helps prevent liner kinking allowing better wire feedability Q Miller E5 Issued March 2004 e Index No AY 17 0 Air Cooled MIG GMAW Welding Guns Rated Output C 30 Models 300A C 40 Models 400 A C 50 Models 500 A C 60 Models 600 A Duty Cycle 100 with CO gas Weight C 30 Models 5 6 7 5 Ib 2 5 3 4 kg C 40 Models 7 5 10 3 Ib 3 4 4 7 kg C 50 Models 9 3 13 Ib 4 2 5 9 kg C 60 Models 10 3 14 5 Ib 4 7 6 6 kg Process MIG GMAW Flux Cored FCAW 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 dut2. HEAVY DUTY 3 4 ORIFICE COPPER 199 617 a STANDARD 1 2 ORIFICE BRASS 199 610 OR Lj COPPER 199 615 intel STANDARD 5 8 ORIFICE BRASS 199 613 OR COPPER 198 855 a STD ON 300 400A BRASS 199 611 OR STANDARD 3 4 ORIFICE a COPPER 199 616 SCREW ON COPPER TAPERED NOZZLES P 1 2 ORIFICE 209 036 D 3 8 ORIFICE 209 035 SLIP ON COPPER TAPERED NOZZLES mail 1 2 ORIFICE 209 033 C il 3 8 ORIFICE 209 034 HEAVY DUTY FASTIP CONTACT TIPS 023 3 32 WIRE MT VALUE MULTI TURN FASTIP CONTACT TIPS 023 5 64 WIRE C M EXTRA HEAVY DUTY FASTIP CONTACT TIPS 035 1 8 WIRE C ND HEAVY DUTY FASTIP CONTACT TIPS 023 3 32 WIRE i 045 206 179 STD ON 300 400A 1 16 206 190 STD ON 500 600A TAPERED FASTIP CONTACT TIPS 023 1 16 WIRE C ip TAPERED FASTIP CONTACT TIPS 023 1 16 WIRE C DID SPOT DIFFUSER Eii 209 099 VALUE MULTI TURN DIFFUSERS FLUSH 199 622 MILLER ROUGHNECK CONSUMABLES 1 8 RECESS 199 621 EXTRA HEAVY DUTY DIFFUSERS FLUSH 1 8 RECESS 198 857 STANDARD INSULATOR STANDARD GOOSENECKS DIFFUSERS T 198 856 FLUSH 6 0 STRAIGHT 213 450 1 8 RECESS STD ON ALL GUNS 4 5 48 BEND 206 195 360 SWIVEL K STD ON 300 400A 199 625 1 4 RECESS 210 664 6 48 BEND 360 SWIVEL STD ON 500A
3. See page 3 for options and above for consumables Total Quoted Price Price
4. 199 626 8 48 BEND 360 SWIVEL STD ON 600A 199 627 SLIP ON TAPERED DIFFUSERS TAPERED INSULATOR FLUSH 209 032 SI 209 047 1 8 RECESS 209 031 Q Milter Consumables continued Order from Miller Service Parts Consumables Heavy Duty FasTip Contact Tips 023 in 0 6 mm 030 in 0 8 mm 035 in 0 9 mm 040 in 1 0 mm 045 in 1 2 mm 052 in 1 3 mm or 3 64 in 1 2 mm aluminum wires 1 16 in 1 6 mm 068 in 1 7 mm steel and aluminum wires 5 64 in 2 0 mm 3 32 in 2 4 mm Extra Heavy Duty FasTip Contact Tips 035 in 0 9 mm 040 in 1 2 mm 045 in 1 2 mm 052 in 1 3 mm or 3 64 in 1 2 mm aluminum wires 1 16 in 1 6 mm 068 in 1 7 mm steel and aluminum wires 5 64 in 2 0 mm 3 32 in 2 4 mm 7 64 1 8 in 2 8 mm Value Multi Turn Contact Tips 023 in 0 6 mm 030 in 0 8 mm 035 in 0 9 mm 045 in 1 2 mm 3 64 in 1 2 mm aluminum wires 052 in 1 3 mm 1 16 in 1 6 mm 1 16 in 1 6 mm aluminum wires 068 in 1 7 mm 5 64 in 2 0 mm Tapered FasTip Contact Tips 023 in 0 6 mm 030 in 0 8 mm 035 in 0 9 mm 045 in 1 2 mm 3 64 in 1 2 mm aluminum wires 052 in 1 3 mm 1 16 in 1 6 mm Note All contact tips are packaged in bags of 25 Ordering Information Equipment and Options C 3010 C 3012 C 3015 C 4010 C 4012 C 4015 C 5010 C 5012 C 5015 C 6010 C 6012 C 6015 Opti
5. FasTip contact tips Flush tip for extra heavy duty FasTip contact tips 1 8 in tip recess for value multi turn contact tips Flush tip for value multi turn contact tips Insulators Diffuser to gooseneck insulator included with goosenecks Gooseneck nut cover included with goosenecks Goosenecks 4 5 in 48 Aluminum jacketed with wrench swivel 6 in 48 Aluminum jacketed with wrench swivel 8 in 48 Aluminum jacketed with wrench swivel 6 in 180 Aluminum jacketed Stock No 199 610 199 611 199 612 199 613 199 614 199 615 199 616 199 617 198 855 199 6187 202 889 202 890 202 891 202 892 202 893 202 894 202 895 206 195 210 664 206 196 198 857 199 623 199 621 199 622 198 856 202 292 199 625 199 626 199 627 213 450 Standard on 300 and 400 Amp guns Standard on 500 and 600 Amp guns Standard on all guns Description 10 ft 3 0 m Maximum wire size 5 64 in 12 ft 3 7 m Maximum wire size 5 64 in 15 ft 4 6 m Maximum wire size 5 64 in 10 ft 3 0 m Maximum wire size 5 64 in 12 ft 3 7 m Maximum wire size 5 64 in 15 ft 4 6 m Maximum wire size 5 64 in 10 ft 3 0 m Maximum wire size 1 8 in 12 ft 3 7 m Maximum wire size 1 8 in 15 ft 4 6 m Maximum wire size 1 8 in 10 ft 3 0 m Maximum wire size 1 8 in 12 ft 3 7 m Maximum wire size 1 8 in 15 ft 4 6 m Maximum wire size 1 8 in
6. m 500 Amps 3 7 m 15 ft 4 6 m 100 using CO ratings with 300 Amps i i i mixed gas are reduced by 10 50 depending on the gas mixture and welding parameters 400 Amps 600 Amps Genuine Miller Options order trom milter 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 Fas Tip 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 Il 200 250 251 Hefty 2000 Series Dual Digital 2000 Porta Feed and Ultra Feed Lincoln products Power MIG 255 Wirematic 250 299 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
7. 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 035 045 in 5 6 Ib 2 5 kg 0 9 1 2 mm 6 4 Ib 2 9 kg 7 5 Ib 3 4 kg 035 045 in 7 5 Ib 3 4 kg 0 9 1 2 mm 8 6 Ib 3 9 kg 10 3 Ib 4 7 kg 052 1 16 in 9 3 Ib 4 2 kg 1 3 1 6 mm 10 8 Ib 4 9 kg 13 0 Ib 5 9 kg 052 1 16 in 10 3 Ib 4 7 kg 1 3 1 6 mm 12 0 Ib 5 4 kg 14 5 Ib 6 6 kg 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 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 041 793 CONSUMABLES order trom Miller Service Parts SPOT NOZZLES AC FLAT 176 238 UL lt E No INSIDE CORNER 176 240 OUTSIDE CORNER 176 242 SCREW ON NOZZLES COPPER 5 8 ORIFICE 15 16 O D 207 313 HEAVY DUTY 5 8 ORIFICE BRASS 199 614 OR COPPER 199 618 STD ON 500 600A CD BRASS 199 612 OR
8. ons and Consumables Order from Miller Service Parts Date Distributed by H Miller Litho in USA Stock No 206 184 206 185 206 186 206 187 206 188 206 189 206 1902 206 191 206 192 206 193 199 605 199 606 198 851 198 852 198 853 198 854 199 607 199 608 199 609 087 300 071 825 054 202 054 201 199 593 044 006 047 566 202 933 199 594 047 565 209 024 209 025 209 026 209 027 209 028 209 029 209 030 Stock 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 Consumables Screw On Brass Nozzles 1 2 in orifice 3 4 in orifice 3 4 in orifice heavy duty 5 8 in orifice 5 8 in orifice heavy duty Screw On Copper Nozzles 1 2 in orifice 3 4 in orifice 3 4 in orifice heavy duty 5 8 in orifice 5 8 in orifice heavy duty Replacement Liners 023 030 in dia wire x 15 ft round wound 035 045 in dia wire x 15 ft round wound 052 1 16 in dia wire x 15 ft round wound 1 16 078 in dia wire x 15 ft flat wound 5 64 3 32 in dia wire x 15 ft flat wound 7 64 1 8 in dia wire x 15 ft flat wound 3 64 1 16 in dia aluminum wires Gas Diffusers 1 8 in tip recess for heavy duty FasTip contact tips 1 4 in tip recess for heavy duty FasTip contact tips Flush tip for heavy duty FasTip contact tips 1 8 in tip recess for extra heavy duty
9. y nozzles feature patented reduced frontal area to decrease heat transfer for cooler operation Reliable extended life trigger is rated for 1 5 million cycles and is quickly changeable if worn out al 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 Roughneck C Series simple versatile and durable Commonality of parts and consumables between all models helps reduce inventory and aids serviceability PRUEBE Gun is warranted for 90 days parts and labor 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 920 735 4505 USA FAX 920 735 4134 Canadian FAX 920 735 4169 International FAX 920 735 4125 ISO 9001 2000 REGISTERED QUALITY SYSTEM Specifications subject to change without notice PartNo Gun Model Cable Length Rated Output Duty Cycle Standard Wire Size Weight 194 751 194 752 194 753 194 754 194 755 194 756 194 757 194 758 194 759 194 760 194 761 194 762 C 3010 C 3012 C 3015 C 4010 C 4012 C 4015 C 5010 C 5012 C 5015 C 6010 10 ft 3 0 m C 6012 3 10 ft an 15 ft ae 10 ft 3 0 m 15 ft 4 6 m C 6015 15 ft 4 6 m 3 0 m 3 7 m 4 6 m 10 ft 3 0
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