August
1977
FORM:
OM-1505B
MODEL
HCA-1B
1/16
WIRE
3/32
WIRE
7/64
WIRE
1/8
WIRE
STOCK
NO.
lOFT
15FT
009
605
009
606
008817
008820
008818
008821
008819
008822
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
OWNERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
NWSA
CODE
NO.
4579
ADDITIONAL
COPY
PRICE
20
CENTS
liP ~~P
L~P
~
L~:&P
~
(
LIMITED
WARRANTY
EFFECTIVE:
NOVEMBER
1,
1976
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTYMiller
Electric
Mt
g.
Co.,
Apple-
1.
Arc
welders,
power
sources,
and
components
. . .
I
year
ton,
Wisconsin
warrants
to
Customer
that
all
new
and
unused
2.
Original
main
power
rectifiers
3
years
Equipment
furnished
by
Miller
is
free
from
defect
in
workman-
(Labor
I
year
only)
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
3.
All
welding
guns
and
feeder/guns
~)()
(lays
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
4.
All
other
Millermatic
Feeders
I
year
trade
accessories
and
other
items
are
sold
subject
to
the
warran-
provided
that
the
user
so
notifies
Miller
in
writing
within
thirty
ties
of
their
respective
manufacturers,
if
any.
At
the
present
time,
(30)
days
of
the
date
of
such
failure.
the
manufacturers
warranty
on
the
Mag-Diesel
engine
on
DEL-
200
is
limited
to
six
months
and
on
all
other
engines
to
one
year.
5.
Replacement
or
repair
parts
exclusive
of
labor
.
.
60
days
ii.
(
MILLER
warranty
does
not
apply
to
components
having
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REP-
tips,
relay
and
contactor
points,
MILLERMATIC
parts
that
RESENTATION
AS
TO
PERFORMANCE,
AND
ANY
come
in
contact
with
the
welding
wire
including
nozzles
and
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
nozzle
insulators
where
failure
does
not
result
from
defect
in
FOR
THIS
PROVISION,
MIGHT
ARISE
BY IMPLICA
workmanship
or
material.
TION,
OPERATION OF
LAW,
CUSTOM
OF
TRADE
OR
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
WARRANTY
OF
MERCHANTABILITY
OR
OF
FITNESS
therefor
shall
be,
at
Millers
option,
(I)
repair
or
(2)
replace-
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
ment
or,
where
authorized
in
writing
by
Miller
in
appropriate
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
authorized
Miller
service
station
or
(4)
payment
of
or
credit for
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
TN
the
purchase
price
(less
reasonable
depreciation
based
upon
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
actual
use)
upon
return
of the
goods
at
Customers
risk
and
cx-
ULTIMATE
PURCHASE
BY
COMMERCJAL/INDUS
pense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
TRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
Miller
shall
instruct
the
claimant
on
the
warranty
claim
proce-
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
dures
to
be
followed.
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
As
a
matter
of
general
policy
only,
Miller
may
honor
an
origi-
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
nal
users
warranty
claims
on
warranted
Equipment
in
the
event
WARRANTIES
DO
NOT
EXTEND
TO.
AND
NO
RE
&
of
failure
resulting
from
a
defect
within
the
following
periods
SELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WAR-
C
from
the
date
of
delivery
of
Equipment
to
the
original
user:
RANTIES
TO,
ANY
CONSUMER.
~
....~
......~
j
~
,j~
s,
~
~,
J~
i,
.r
~t.
-..J1,
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
HCA-1B
5/64
WIRE
10
FT.
052
970
HCA-1B
5/64
WIRE
15
FT.
052
971
AMENDMENT
TO
SECTION
1
INTRODUCTION
Amend
Section
1-3.
DESCRIPTION
This
gun
is
designed
specifically
for
use
in
conjunction
with
the
self
shielding
Flux
Cored
Arc
(FCAW)
Welding
process.
The
gun
is
shipped
with
the
necessary
components
for
the
specific
wire
size
ordered.
Through
minor
changes
in
parts
the
gun
may
be
used
with
1/16,
5/64, 3/32,
7/64,
and
1/8
flux-cored
wire.
AMENDMENT
TO
SECTION
2
INSTALLATION
Amend
Section
2-2
as
follows:
Each
time
the
size
of
the
electrode
wire
being
used
is
changed
it
will
be
necessary
to
change
the
contact
tube
so
that
the
hole
in
the
contact
tube
will
permit
proper
movement
of
the
electrode
wire.
I
NOTE~
I
The
contact
tube
is
threaded
and
need
only
be
rotated
in
a
counterclockwise
direction
to
be
removed
and
a
1
clockwise
direction
to
be
installed.
When
changing
to
1/16
or
5/64
wire
from
any
other
size
it
will
be
necessary
to
change
the
monocoil
liner
and
add
a
rear
centering
sleeve
(see
parts
list).
When
changing
from
1/16
or
5/64
wire
to
any
other
size
it
will
be
necessary
to
change
the
monocoil
liner
and
remove
the
rear
centering
sleeve.
To
change
the
liner
and add
or
remove
the
centering
sleeve
proceed
as
follows:
1.
Remove
the
head
tube.
2.
Loosen
the
clamp
securing
the
hand
guard
and
slide
the
hand
guard
back
on
the
gun
handle
to
gain
access
to
the
liner
set
screw.
3.
Loosen
the
socket-head
liner
set
screw.
4.
Remove
the
lubricator
cup.
INOTEI
3/32
.
1/8
inch
liners
may
be
pulled
out
and
removed
from
either
end.
1/16
and
5/64
inch
liners
must
be1
I
pulled
out
and
removed
from
the
head
tube
adapter
end.
I
5.
Remove
the
monocoil
liner.
6.
Slide
the
insulator
off
of
the
gun/feeder
adapter
to
gain
access
to
the
rear
centering
sleeve
set
screw.
7.
Loosen
the
set
screw.
8.
When
changing
from
1/16
or
5/64
to
any
other
size
wire,
remove
the
rear
centering
sleeve.
When
changing
to
1/16
or
5/64
from
any
other
size
wire,
insert
the
centering
sleeve
into
the
gun/feeder
adapter,
rotate
the
sleeve
until
the
notched
portion
lines
up
with
the
lubricator
cup
hole,
and
secure
the
set
screw.
9.
Insert
the
new
monocoil
liner
(1/16
and
5/64
inch
liners
must
be
inserted
from
the
head
tube
adapter
end).
OM-1505B
Page
A
Item
Factory
No.
Part
No
1
052
055
2
008
934
3
008
932
4
008931
5
075625
6
075855
7
075626
8
078981
9
008
948
10
010860
11
008928
12
602
177
13
075628
14
073357
15
605789
16
008127
17
004747
17
004750
18
004728
19
004733
20
004732
21
004729
22
075
644
23
007 500
24
009 624
24
009
625
25
078 894
29
052
759
Quantity
Model
2.0MM
2.0MM
5/64
5/64
lOft.
l5ft.
0
N
N
0)
0)
C.,
If)
U)
o
0
5
5
1 1
1 1
1 1
1 1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1 1
1
1
1
1
1
1
1
BE
SURE TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1505B
Page
B
10.
Slide
the
insulator
over
the
gun/feeder
adapter.
11.
Reinstall
the
lubricating
cup.
12.
Tighten
the
socket-head
liner
set
screw
located
in
the
handle.
13.
Reposition
the
hand
guard
and
tighten
the
clamp
securing
it
to
the
handle.
14.
Reinstall
the
head
tube.
The
item
numbers
appearing
in
the
item
number
columr~
on
the
following
Errata
Sheet
parts
list
are
referenced
to
the
item
numbers
appearing
on
the
exploded
view
in
the
back
of
this
manual.
Description
TUBE,
contact
5/64
wire
TUBE,
head
.
curved
INSULATOR,
handle
LINER,
monocoil
3/32
-
1/8
wire
x
7.1/4
KIT,
connector
-
head
tube
(consisting
of)
INSULATOR,
nut
-
head
tube
NUT,
brass
-
head
tube
.RING-HALF,gun
GUARD,
w/clamp
-
shield
hand
(consisting
of)
CLAMP,
hose
13/16
-
1-3/4
clamp
dia
GUARD,
shield
-
hand
SCR
EW,
set
-
steel
socket
hd
1/4-20
x
1/4
HANDLE,
gun
CUP.
lubricator
SCREW,
set
-steel
socket
hd
10-24
x
1/4
SLEEVE,
rear
centering
CABLE,
conduit
10
ft.
(consisting
of)
CABLE,
conduit
15
ft.
(consisting
of)
ADAPTER,
gun/feeder
CLAMP,
cable
-
conduit
CLAMP,
cable
-
conduit
ADAPTER,
head
tube
INSULATOR,
body
-
lubricator
SPRING,
compression
LINER,
monocoil
1/16
-
5/64
wire
x
lOft
LINER,
monocoil
1/16
-
5/64
wire
x
15
ft
SCREW,
machine
-
steel
fillister
head
1/4-20
x
3/8
LINER,
monocoil
1/16-1/8
wire
x
8-1/4
1
1
2
2
1
1
1
1
1
2
2
1
1
1
1
1
1
SECTION
1
-
INTRODUCTION
Rating:
100
PCT.
Wire
I
1/16
(1.6mm)
To
Duty
Cycle,
dcrp
Dia.
500
Amperes
1/8
(3.1mm)
Flux
Core
Cable
Coo
10
Ai
Length
Met
15
Al
ling
Net
r
15
Lbs.
(6.8
Kil
hod
Weight
r
17
Lbs.
(7.7
Kil
os)
17
~
os)
19
Ship
Lbs.
(7.7
Weight
Lbs.
(8.6
~1
Kilos)1
I
Kilos)
Figure
1-1.
Specifications
1-1.
GENERAL
1-2.
RECEIVING-HANDLING
This
gun
is
designed
sp~bifically
for
use
in
conjunction
with
the
self
shielding
Flux
Cored
Arc
(FCAW)
Welding
process.
The
gun
is
shipped
with
the
necessary
components
for
the
specific
wire
size
ordered.
Through
minor
changes
in
parts
the
gun
may
be
used
with
1/16,
3/32,
7/64,
and
1/8
flux-cored
wire.
1-4.
SAFETY
I
~I~~II.1~III1
Under
this
heading,
explanatory
Statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
SECTION
2-
INSTALLATION
I
Prior
to
installing
the
gun,
ensure
that
the
control/
feeder
and
welding
power
source
are
both
completely
disconnected
from
the
respective
input
electrical
power
supplies.
U
I
2-2.
CHANGING
WIRE
SIZES
Each
time
the
size
of
the
electrode
wire
being
used
is
changed
it
will
be
necessary
to
change
the
contact
tube
so
that
the
hole
in
the
contact
tube
will
permit
proper
movement
of
the
electrode
wire.
NOTE
2-1.
ELECTRODE
WIRE
OUTLET
CONNECTION
Proceed
as
follows
to
install
the
Electrode
Wire
Gun
Con
nector
into
the
drive
assembly
on
the
control/feeder.
1.
Rotate
the
Gun
Connector
Securing
Knob
or
Screw
in
a
counterclockwise
direction
four
complete
turns.
2.
Insert
the
Electrode
Wire
Gun
Connector
fully
into
the
outlet
guide
hole
with
the
flat
side
of
the
connector
facing
the
roll
pin
inside
of
the
outlet
guide
hole.
3.
Rotate
the
Electrode
Wire
Gun
Connector
90
degrees
in
a
clockwise
direction.
4.
Rotate
the
Gun
Connector
Securing
Knob
or
Screw
as
far
as
it
will
turn
in
a
clockwise
direction.
I
It
is
recommended
that
the
monocoil
casing
have
the
inside
blown
out
with
compressed
air
occasionally.
I
I
The
contact
tube
is
threaded
and
need
only
be
rotated
in
a
counterclockwise
direction
to
be
removed
and
a
clockwise
direction
to
be
installed
When
changing
to
1/16
wire
from
any
other
size
it
will
be
necessary
to
change
the
monocoil
liner
and
add
a
rear
center
ing
sleeve
(see
parts
list).
When
changing
from
1/16
wire
to
any
other
size
it
will
be
necessary
to
change
the
monocoil
liner
and
remove
the
rear
centering
sleeve.
To
change
the
liner
and add
or
remove
the
centering
sleeve
proceed
as
follows:
1.
Remove
the
head
tube.
2.
Loosen
the
clamp
securing
the
hand
guard
and
slide
the
hand
guard
back
on
the
gun
handle
to
gain
access
to
the
liner
set
screw.
3.
Loosen
the
socket-head
liner
set
screw.
4.
Remove
the
lubricator
cup.
This
manual
has
been
prepared
especially
for
use
in
familiar
izing
personnel
with
the
design,
installation,
operation,
main
tenance,
and
troubleshooting
of
this
equipment.
All
informa
tion
presented
herein
should
be
given
careful
consideration
to
assure
optimum
performance
of
this
equipment.
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughout
this
manual:
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
and
freight
bill
will
be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equipment,
it
is
essential
that
Model
Description
and/or
Stock
Number
and
Serial
(or
Style)
Numbers
of
the
equipment
be
supplied.
1-3.
DESCRIPTION
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
safety
hazard
to
personnel.
:
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equip-
mont.
NOTE
J
I
I
I
OM-1505
Page
1
~1/8
inch
line
rs
me
pulled
out
and
remo
Ved
from
either
end.
1/16
inch
liners
must
be
pulled
out
and
removed
from
the
head
tube
adapter
end.
5.
Remove
the
monocoil
liner.
6.
Slide
the
insulator
off
of
the
gun/feeder
adapter
to
gain
access
to
the
rear
centering
sleeve
set
screw.
7.
Loosen
the
set
screw.
8.
When
changing
from
1/16
so
any
other
size
wire,
remove
the
rear
centering
sleeve.
When
changing
to
1/16
from
any
other
size
wire,
insert
she
centering
sleeve
into
the
gun/feeder
adapter,
rotate
the
sleeve
until
the
notched
portion
lines
up
with
the
lubricator
cup
hole,
and
secure
the
set
screw.
9.
Insert
the
new
monocoil
liner
(1/16
inch
liners
must
be
inserted
from
the
head
tube
adapter
end).
10.
Slide
the
insulator
over
the
gun/feeder
adapter.
11.
Reinstall
the
lubricating
cup.
12.
Tighten
the
socket-head
liner
set
screw
located
in
the
handle.
13.
Reposition
the
hand
guard
and
tighten
the
clamp
se
curing
it
to
the
handle.
14.
Reinstall
the
head
tube.
OM-1505
Page
2
August
1977
FORM:
OM-1505B
MODEL
HCA-1B
1/16
WIRE
3/32
WI
RE
7/64
WIRE
1/8
WIRE
STOCK
10
FT
009
605
008 817
008 818
008
819
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
NO.
15
FT
009 606
008
820
008
821
008
822
NWSA
CODE
NO.
4579
29
1
30
Figure
A
Exploded
View
Of
Gun
And
Optional
Flux
Hopper
(Gun
With
1/16
Wire
Illustrated)
TC-009
230-B
f
I
28
27
31
32
25
35
FLUX
HOPPER
-
OPTIONAL
2
16
15
14
22
OM-1505
Page
1
Item
Factory
No.
Part
No
Figure
A
Exploded
View
Of
Gun
Assembly
Quantity
Model
TUBE,
contact
1/16
wire
TUBE,
contact
3/32
wire
TUBE,
contact
7/64
wire
TUBE,
contact
1/8
wire
TUBE,
head
-
curved
INSULATOR,
handle
LINER,
monocoil
3/32-1/8wirex
7-1/4
KIT,
connector-head
tube
(consisting
of)
INSULATOR,
nut
-
head
tube
NUT,
brass
-
head tube
RING
-
HALF,
gun
GUARD,
w/clamp
.
shield
hand
(consisting
of)
10
010
860
.
CLAMP,
hose
13/16
-
1-3/4
(consisting
of)
26
006
868
.
COVER,
flux
hopper
(attaching
hardware
B,
G
&
K)
27
006
861
.
CLIP,
spring-cover
(attaching
hardware
F,L&J)
BODY,
flux
hopper
LINER,
monocoil
1/16-1/8
wire
x
7-7/8
NOZZLE,
flux
-
flux
hopper
SHIM,
torch
-
adapter
ADAPTER,
gun-flux
hopper
(attaching
hardware
A,
C,
D,
F
&
H)
TUBE,
head-curved
(consisting
of)
TUBE,fiber
-
HINGE,
cover-flux
hopper
(attaching
hardware
B,
G
&
K)
1
1 1
1 1 1
1
1 1
1
1 1
1
1
2
2
2
2 2
2
2
2 2
2
2
2
2
2
1
1
1
1 1
1
1
1
1
1
1
1 1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1
1
1
1 1
1
1
1
1
1
1 1
1 1
1
1
1
1 1 1 1
1
1
1
1
1
1
1 1
1
1
1 1
1
1
1
1
1
1
1
1
1
1
1
1
* *
4
* * *
*
1
1
1
1 1
1
1
1
1
1
1 1 1
1
1
1
1
1 1 1
1
1 1 1 1 1
1
1
Description
10
Foot
1.6MM
2.4MM
2.8MM
3.2Ml~1
.063
.094
.110
.126
1/16
3/32
7/64
1/8
15
Foot
1.6MM
2.4MM
2.8MM
3.2MM
.063
.094
.110
.126
1/16
3/32
7/64
1/8
1
009
709
1
008
926
1
008
925
1
008
924
2
008934
3
008932
4
008931
5
075625
6
075855
7
075626
8
078981
9
008
948
5
5
5
5
5
5
5
1
1
1
1
1
1 1
1
1 1 1
1
1 1 1 1
1
1
1
1
1
1 1 1
2
2 2
2
5
1 1 1
1
1 1 1
1
1 1 1
1
1 1
1
1
1 1
1
1
1
1
1
1
2 2 2
2
1
1
1
1 1
1
1
1
1
1
1
1
1 1
1
1
1 1
1 1
1 1
1 1
1 1 1 1
1
1
1 1
1
1
1
1 1
1
1
1
1
1
1
1
1
1
1
1
1
1
clamp
diameter
11
008928
.GUARD,shield-harid
12
602
177
SCREW,
set
-
steel
socket
hd
1/4-20
x
1/4
13
075628
HANDLE,gun
14
073
357
CUP,
lubricator
15
605
789
SCREW,
set-steel
socket
hd
10-24
x
1/4
16
008
127
SLEEVE,
rear
-
centering
17
004
747
CABLE,
conduit
10
ft
(consisting
of)
17
004
750
CABLE,
conduit
15
ft
(consisting
of)
18
004
728
.
ADAPTER,
gun/feeder
19
004
733
.
CLAMP,
cable
.
conduit
20
004
732
.
CLAMP,
cable
-
conduit
21
004
729
ADAPTER,
head
tube
22
075
644
INSULATOR,
body
-
lubricator
23
007
500
SPRING,compression
24
009
624
LINER,
monocoil
1/1
6-5/64
wire
x
10
ft
24
009707
LINER,monocoil3/32-1/8wirex
loft
24
009625
LINER,monocoil
l/16-5/64wirex
l5ft
24
009708
LINER,monocoil
3/32-l/8wirex
l5ft
25
078
894
SCREW,
machine-steel
fillister
head
1/4-20
x
3/8
t052
789
FLUX
HOPPER,
hand
-
held
2
2
1
1
*
1
1
1
1
28
006870
-
-
29
008045
30
006862
31
006865
32
006 866
33
052
808
34
076183
35
006
863
OM-1
505
Page
2
1.6MM
2.4MM 2.8MM
3.2MM
1.6MM
2.4MMJ2.8MM
3.2MM
.063
.094
.110
.126 .063
.094
.110
.126
Description
1/16
3/32
7/64
1/8
1/16
3/32
7/64
1/8
Figure
A
Exploded
View
Of
Gun
Assembly
(Contd.)
Attaching
Hardware
For
Optional
Flux
Hopper
A
601
957
B
602
066
C
602091
D
602241
E
602
207
F
602 204
G
602199
H
601
865
J
601
862
K
601
859
L
602
088
As
Required
Item
Factory
No.
Part
No.
Quantity
Model
10
Foot
15
Foot
SCREW,
cap
-
steel
hex
hd
1/4-20
x
1-1/2
SCREW,
machine-steel
truss
hd
6-32
x
1/4
SCREW,
machine-steel
round
hd
10-32
x
1/2
WASHER,
flat
-
steel
SAE
1/4
WASHER,
lock
-
steel
split
1/4
WASHER,
lock
.
steel
external
tooth
No.
10
WASHER,
lock
-
steel
external
tooth
No.
6
NUT,
steel
-
hex
full
1/4-20
NUT,
steel
-
hex
10-32
NUT,
steel
-
hex
6-32
SCREW,
machine-steel
round
hd
10-32
x
14
tOptional
Equipment
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1
505
Page
3
/