Miller Matic 200This is the feed wheels that feed the wire into the lining. The top feed wheel is in the open position.

.030 is the size of the groove on the feed wheel, meaning that this should have .030 wire in the Spool.

These Feed Wheels can be turned around for different feed sizes. As you can see on one side it has .030 on the other is is .035. Whatever number is facing OUT is the size you are using as the wheel has two sets of grooves. It is meant for you to be able to look into the welder and see what size you are using without having to take the wheel off.

Insure this feed tip is not so far back that it interrupts the feed wheel. You will put gouges in the feed wheel (like you see here if you zoom in) and this can create feed problems to the gun.

Close this lid down on the wire to allow the feed wheels to feed the wire.

Lift this into place to lock the feed wheels. You can turn this nob to increase the pressure on the wire, you should not need a lot of pressure here if everything is running correctly and clean.

This knob is what loosens the the feed tip that feeds the wire through to the Gun

This is the feed tip that will be loosened along with the rest of the gun and the hose that houses the wire.

This is the size of the wire in the spool. As you can see, the wire is .035. in the previous picture the feed wheel was smaller than the wire. This will cause the feed wheel to make the wire oblong and lead to broken linings and tips.

This is an adapter that allows you to utilize a different gun on a miller welder. If you have one of these, the gun isn't a miller and or original to the welder. The reason for this adapter is the gas is routed through the clear tube into the hose instead of through the welder on the inside.

Liner that houses the wire that travels through the tube to the Gun. MOST typical issue with feed problems.

This is what keeps the sleeve around the tip in place!

This is pretty much what the tip of the gun looks like right before you take it apart.

This is the tip. This is the only part that should ever touch the feed wire of the wire inside that enables you to complete the circuit and to weld.

All Tips should be round, if this is oblong or out of round it can cause you to get sporadic welds and intermittent spark as the wire will only weld if its in contact with the metal tip to complete the circuit.

These are holes that enable the gas to be fed into the tip to be able to weld! Check these to be sure they are clean and clear.

Insulator, this is what keeps the wire from touching anything else other than the tip.

This is the feeder tip that will probably be the dirtiest of all of them. Keep this clean and it will help to keep rust and dirt out of the liner and extend the life.

To test the liner, pull some wire out and make a loop. Loop the wire around your hand with the tube straight out from the welder and pull on the wire. If the wire is easy to pull and you don't feel any “noise” or feed back in the wire when you pull... this is a good sign.

If its hard to pull or you feel grinding or noise or feedback, this is a good indication there is dirt, rust or the liner has grooves inside of it and needs to be replaced.

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How to tell what year your Miller Matic 200 was built.

If your Serial number is for example JK5874521 Your Welder was built in 1989

The easiest way to set up your welder for welding is to use this chart which is on the inside cover of the welder near the wire spool. Look for the metal thickness of what you want to weld, then utilize the corresponding range/Voltage/wire speed to give you a good starting point, then fine tune.

If you get lost, Miller was kind enough to provide a guide as to what each part is called! This is on the inside cover of where the wire is fed.