Miller Roughneck C-4015S User manual

OWNER’S MANUAL
2000 MILLER Electric Mfg. Co.
OMĆ200 386
May 2000
RoughneckEC-4015S Air-Cooled Gun
1. Specifications
Air-CooledGun For GMAW Welding
Note: Using mixed gases other than CO2reduces duty cycle ratings by 10-50%.
C-4015S Gun Feeds .045 To .068 in (1.2 To 1.7 mm) Wire
Duty Cycle Rating: 100%: 400 A With CO2Shielding Gas
Weight With 15 Ft (Heaviest) Power Cable: 10.3 lb (4.7 kg)
Ref. ST-800 797-C
2. Safety Precautions For GMAW Guns
A. Symbol Usage
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.
YMarks a special safety message.
.Means NOTE; not safety related.
B. GMAW Gun Hazards
WARNING
The symbols shown below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The
safety information given below is only a summary of the more complete safety information found in wire
feeder and welding power source manuals. Read and follow all Safety Standards.
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.
HOT SURFACES can burn skin.
1. Allow gun to cool before touching.
2. Do not touch hot metal.
3. Protect others from contact with hot metal.
FLYING PIECES OF METAL or DIRT can
injure eyes.
1. Wear safety glasses with side shields or face
shield.
WELDING WIRE can cause puncture
wounds.
1. Keep hands and body away from gun tip when
triggeris pressed.
OVERUSE can damage gun and void
warranty.
1. Followrated duty cycle.
2. Allow cooling period.
3. Reduce current or reduce duty cycle before
startingto weld again.
1. Read and follow these instructions and all safety
blocks carefully.
2. Have only trained and qualified persons install,
operate,or service this unit.
3. Call your distributor if you do not understand the
directions.
4. For WELDING SAFETY and EMF information,
read wire feeder and welding power source
manuals.

OM-200 386 Page 2
3. Gun Connection And Operation
Ref. ST-802 483-A / 802 626
1 Gun Securing Knob
2 Gun Block
3 Adapter
Loosen knob, insert adapter, and
tightenknob.
4 Gun Trigger Plug
5 Gun Trigger Receptacle
Insertplug into receptacle and tight-
en threaded collar.
6 Trigger Switch
Press switch to feed energized wire
and start gas flow.
45
3
6
12

OM-200 386 Page 3
4. Parts List
Ref. 802 630
12
3
45
Figure 4-1. Parts View
Description
Part
No.
Item
No.
Figure 4-1. Parts View
Quantity
1 200 282 NOZZLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 200 278 TIP, contact 1.2 mm wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2♦200 279 TIP, contact 1.4 mm wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2♦200 280 TIP, contact 1.6 mm wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2♦200 281 TIP, contact 1.7 mm wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 200 283 DIFFUSER, gas 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 198 856 INSULATOR, nozzle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 198 858 LINER, 1.2 mm wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5♦198 859 LINER, 1.4/1.6/1.7 mm wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
♦OPTIONAL