July
1976
FORM:
OM-1506A
MODEL
HCA-2A
5/64
Wire
3/32
Wire
7/64
Wire
1/8
Wire
STOCK
NO.
10
FT.
15
FT.
078930
078935
078
931
078932
078933
078
936
078
937
078
938
MObEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
OWNERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
ADDITIONAL
COPY
PRICE
25
CENTS
NWSA
CODE
NO.
4579
,SIW
TI0
LIMITED
WARRANTY
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin,
warrants
all
new
equipment
to
be
free
from
defects
in
c
material
and
factory
workmanship
for
the
periods
indicated
below,
provided
the
equipment
is
installed
and
~
operated
according
to
manufacturers
instructions.
C
~
C
C
~
C)
MILLER
Electric
Mfg.
Co.s
obligation,
underthis
warranty,
is
expressly
limited
to
replacing
or
repairing
C
any
defective
part
or
correcting
any
manufacturing
defect
without
charge
during
the
warranty
period
if
c
MILLERS
inspection
confirms
the
existence
of
such
defects.
MILLERS
option
of
repair
or
replacement
C
will
be
f.o.b.
factory
at
Appleton,
Wisconsin
or
f.o.b.
a
MILLER
authorized
service
facility,
and
therefore
~
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
ci
Ci
The
warranty
period,
beginning
on
the
date
of
sale
to
the
original
purchaser-user
of
the
equipment,
will
be
as
follows:
1.
Arc
welders,
power
sources,
and
components
1
year
2.
Original
main
power
rectifiers
3
years
(unconditionally)
3.
20E,
20K,
and
all
welding
guns.
90
days
4.
All
other
Millermatic
Feeders
1
year
5.
All
engines
1
year
Engine
Warranties
are
covered
by
the
engine
manufacturers,
subject
to
their
procedures
and
to
be
handled
through
their
authorized
local
Service
Stations
or
agencies.
No
warranty
will
be
made
in
respect
to
trade
accessories,
such
being
subject
to
the
warranties
of
their
respective
manufacturers.
MILLER
Electric
Mfg.
Co.
will
not
be
liable
for
any
loss
or
consequential
damage
or
expense
accruing
directly
or
indirectly
from
the
use
of
equipment
covered
in
this
warranty.
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
C
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
HCA-2A
.045
WIRE
10
FT.
053
651
1/16WIRE
10
FT.
053653
.045WIRE
15
FT.
053652
1/16
WIRE
15
FT.
053
654
AMENDMENT
TO
SECTION
1
INTRODUCTION
FILE
Copy
Amend
Figure
1-1
as
follows:
RETURN
TO
FOLDER
Rating:
100
PCI.
Wire
Cable
and
Cooling
Net
Ship
Duty
Cycle,
dcrp
Dia.
Hose
Length
Method
Weight
Weight
500
Amperes
.045
(1.1mm)
To
10
Air
15
Lbs.
(6.8
Kilos)
17
Lbs.
(7.6
Kilos
With
CO2
1/8
(3.1mm)
Flux
Cored
15
Air
17
Lbs.
(7.6
Kilos)
19
Lbs.
(8.6
Kilos)
Figure
1-1.
Specifications
Amend
Section
1-3.
DESCRIPTION
This
gun
is
designed
specifically
for
use
in
conjunction
with
the
Gas
Metal-Arc
(GMAW)
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
.045,
1/16,
5/64,
3/32,
7/64,
or
1/8
wire.
AMENDMENT
TO
SECTION
2
INSTALLATION
Amend
Section
2-4
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.
When
changing
from
3/32,
7/64,
or
1/8
to
.045,
1/16,
or
5/64
wire,
the
monocoil
liner
must
be
changed
and
a
rear
centering
sleeve
must
be
added.
When
changing
from
.045,
1/16,
or
5/64,
to
3/32,
7/64
or
1/8
wire,
the
monocoil
liner
must
be
changed
and
the
rear
centering
sleeve
must
be
removed.
When
changing
from
1/16
or
5/64
to
.045
wire,
the
monocoil
liner
must
be
changed.
When
changing
from
.045
to
1/16
or
5/64
wire,
the
monocoil
liner
must
be
changed.
IN0TEI
Refer
to
the
Parts
List
to
determine
proper
components.
I
IMPORTANT~
the
electrode
wire
size
is
changed,
blow
out
both
the
monocoil
and
monocoil
casing
with
~~ff~pressed
air.
A.
Changing
The
Contact
Tube
1.
Cut
off
any
portion
of
the
electrode
wire
which
extends
beyond
the
end
of
the
contact
tube.
2.
Pull
out
all
of
the
electrode
wire
which
is
in
the
gun
monocoil
and
rewind
it
onto
the
wire
spool.
OM-1506A
Page
A
S.
3.
Remove
the
nozzle.
4.
Remove
the
contact
tube
by
turning
the
contact
tube
in
a
counterclockwise
direction.
5.
Select
the
proper
contact
tube
for
the
wire
size
to
be
used
and
install
the
contact
tube
into
the
head
tube
by
rotating
the
contact
tube
in
a
clockwise
direction.
6.
Replace
the
nozzle.
B.
Changing
The
Monocoil
Liner
And
Rear
Centering
Sleeve.
1.
Remove
the
gun
from
the
control/feeder.
2.
Loosen
the
monocoil
set
screw
located
on
side
of
the
gun
handle.
3.
Loosen
the
monocoil
set
screw
located
on
the
insulator
near
the
control/feeder
end.
The
monocoil
liner
used
for
3/32,
7/64,
or
1/8
wire
may
be
inserted
or
removed
from
either
end.
Any
other
size
liner
must
be
inserted
or
removed
from
the
end
nearest
the
head
tube.
Step
4
permits
other
size
~liners
to
be
inserted
or
removed.
4.
Remove
the
head
tube.
5.
Pull
out
and
remove
the
monocoil
liner.
IN0T~1
If
the
rear
centering
sleeve
does
not
have
to
be
added
or
removed,
proceed
to
step
10.
Steps
6-10
provide
instructions
for
the
installation
or
removal
of
the
centering
sleeve.
6.
Slide
the
insulator off
of
the
gun/feeder
adapter
to
gain
access
to
the
centering
sleeve
set
screw.
7.
Loosen
the
set
screw.
8.
When
changing
from
.045,
1/16,
or
5/64
to
3/32,
7/64,
or
1/8
wire,
remove
the
rear
centering
sleeve.
When
changing
from
3/32,
7/64
or
1/8
to
.045,
1/16,
or
5/64
wire,
insert
the
centering
sleeve
into
the
gun/feeder
adapter,
rotate
the
sleeve
until
the
notched
portion
lines
up
with
the
monocoil
set
screw
hole,
and
secure
the
centering
sleeve
set
screw.
9.
Reposition
the
insulator
over
the
gun/feeder
adapter.
10.
Lay
the
gun
out
flat
(no
coils
in
the
cable/conduit).
11.
Insert
the
new
monocoil
liner.
12.
Tighten
the
monocoil
liner
set
screws
located
on
side
of
the
gun
handle
and
on
the
insulator.
-
INOTE1
The
new
monocoil
liner
will
be
longer
then
necessary.
Cut
off
the
excess
liner
flush
with
the
gun/feeder
adapter.
Deburr
the
liner
if
necessary.
13.
Reinstall
the
head
tube.
OM-1506A
Page
B
The
item
numbers
appearing
in
the
item
number
column
on
the
following
Errata
Sheet
parts
list
are
referenced
to
the
item
numbers
appearing
on
the
exploded
view
in
the
back
of
this
manual.
Item
Factory
No.
Part
No.
Description
NOZZLE
TUBE,
contact
.045
wire
TUBE,
contact
1/16
wire
ADAPTER,
nozzle
WASHER,
silicon
-
flat
TUBE,
head
(consisting
of)
INSULATOR,
centering
-
head
tube
HANDLE,
gun
SCREW,
machine
-
steel
flat
hd
1/4-20
x
3/8
HOSE,
gas
10
ft.
(consisting
of)
HOSE,
gas
15
ft.
(consisting
of)
HOSE,
whippet
3/16
x
1
(order
by
foot)
NUT,
brass
-
swivel
5/8-18
right
hand
.
FITTING,
hose
-
brass
barbed
nipple
1/4
SCREW,
set
-
steel
socket
hd
3/8-16
x
1/2
CABLE/CONDUIT,
10
ft.
(consisting
of)
-.
CABLE/CONDU
IT,
15
ft.
(consisting
of)
ADAPTER,
gun/feeder
BODY,
gun
LINER,
monocoil
LINER,
monocoil
LINER,
monocoil
LINER,
monocoil
INSULATOR,
adapter
SPRING,
compression
CORD,
power
10
ft.
(consisting
of)
CORD,
power
15
ft.
(consisting
of)
PLUG,
4
pin
97-3106A-18-4P
CLAMP,
cable
97-3057-10-6
.TUBING,vinylNo.6x
3/4
CORD,
portable
18
ga
2
conductor
type
SV
NUT,
steel
-
hex
2-56
WASHER,
lock
-
steel
split
No.
2
SWITCH
SCREW,
machine
-
steel
round
hd
2-56
x
1/2
GROMMET,
rubber
1/4
ID
x
3/8
hole
1/16
groove
.RELIEF,strain
LEVER,
actuating
-
switch
NUT,
steel
-
self
locking
hex
8-32
.SPRING
SCREW,
machine
-
steel
round
hd
8-32
x
1-1/4
HOUSING
CLAMP,
hose
7/32
to
1-3/4
clamp
dia
CLAMP,
strap
-
rubber
5
holes
3/8
-
4-5/8
SLEEVE,
centering
-
rear
SCREW,
set
10-24
x
1/4
Quantity
Model
1.6MM
1.2MM
.045
1/16
15
ft.
10
ft.
N
LU
LU LU
LU
LU LU
C)
C) C)
LU
-
LU LU
0 0
0
1
1
1
3
3
3
3
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
ft.
i6ft.
lift.
16
ft.
1
1
1
1
1
1
1 1
1
11
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1
12
ft.
17
ft.
12
ft.
17
ft.
2
2
2
2
2
2
2
2
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
10
10
10
10
1
1
1
1
1
1
1
1
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1506A
Page
C
I
1.6MM
.045
10
ft.
1.2MM
1/16
15
ft.
LU
LU
C)
LU
0
(order
by
ftj
1
075659
2
075613
2
075614
3
075948
4
07~3
777
5
076173
6
076130
8
076175
9
078894
10
056462
10
056542
ii
604550
13
010606
14
010603
15
079021
16
004746
16
004748
18
004728
19
005589
20
053722
20
053721
20
059063
20
059
064
21
076051.
22
007
500
23
003616
23
003617
24
073
329
25
073331
26
077 658
27
604
525
28
603886
29
604 874
30
604
866
31
603887
32
604311
33 057
027
34
057
171
35
601
845
36
056847
37
602
087
38
056
845
39
010497
40
073476
008
127
605
789
1
1
1
1
1
1
1
1
SECTION
1
-
INTRODUCTION
Cable
and
Cooling
Hose
Length
Method
Figure
1-1.
Specifications
1-1.
GENERAL
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.
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.
1-4.
SAFETY
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughout
this
manual:
th
is
h
eading,
installation,
opera
ti
ng
,
a
nd
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
safety
hazard
to
personnel.
a
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
ment.
This
gun
is
designed
specifically
for
use
in
conjunction
with
the
Gas
Metal-Arc
(MIG)
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
5/64, 3/32, 7/64.
or
1/8
wire.
NOTE
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
SECTION
2
-
INSTALLATION
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.
2-1.
SHIELDING
GAS
HOSE
CONNECTION
(Figure
2-1)
Secure
the
shielding
gas
hose
connector
in
the
shielding
gas
output
connector
on
the
control/feeder
or
to
whatever
device
that
is
to
be used
for
on-off
control
of
the
shielding
gas.
The
shielding
gas
hose
connector
has
right
hand
threading.
2-2.
GUN
SWITCH
CONNECTION
(Figure
2~1)
Insert
the
amphenol
plug
from
the
Gun
Switch
fully
into
the
Switch
Control
Receptacle
on
the
control/feeder.
Once
fully
inserted
into
the
receptacle,
rotate
the
plug
collar
as
far
as
it
will
turn
in
a
clockwise
direction;
this
will
lock
the
plug
in
the
receptacle
and
prevent
the
plug
from
coming
Out
under
tension.
2-3.
ELECTRODE
WIRE
OUTLET
CONNECTION
(Fig
ure
2-1)
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.
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
move
ment
of
the
electrode
wire.
The
following
steps
explain
the
procedures
necessary
to
adapt
the
gun
to
either
5/64,
3/32,
7/64,
or
1/8
wire.
1.
Cut
off
any
portion
of
the
electrode
wire
which
extends
beyond
the
end
of
the
contact
tube.
2.
Pull
out
all
of
the
electrode
wire
which
is
in
the
gun
monocoil
and
rewind
it
onto
the
wire
spool.
3.
Remove
the
nozzle.
4.
Remove
the
contact
tube
by
turning
the
contact
tube
in
a
counterclockwise
direction.
5.
Select
the
proper
contact
tube
for
the
wire
size
to
be
used
and
install
the
contact
tube
into
the
head
tube
by
rotating
the
contact
tube
in
a
clockwise
direction.
6.
Replace
the
nozzle.
IMPORTANT
Whenever
the
electrode
wire
size
is
changed,
blow
out
both
the
monocoil
and
monocoil
casing
with
com
pressed
air.
Net
Ship
Weight
Weight
~ir
15
Lbs.
(6.8
Kilos)
17
Lbs.
(7.6
Kilos)
ir
17
Lbs.
(7.6
Kilos)
19
Lbs.
(8.6
Kilos)
1-2.
RECElVING-HANDL~NG
1-3.
DESCRIPTION
I
1
I
U
2-4.
CHANGING
WIRE
SIZES
(Figure
2-1)
I
I
OM-1506
Page
1
Nozzle
tB-Q79
~3O-2
Tube
Gas
Connector
OM-1
506
Page
2
Figure
2-1.
Gun
Components
July
1976
FORM:
OM-1506A
MODEL
HCA-2A
5/64
WI
RE
3/32
WIRE
7/64
WIRE
1/8
WIRE
078
930
078
931
078
932
078
933
078
935
078936
078
937
078 938
MODELISTOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
STOCK
NO.
lOFT
15FT
NWSA
CODE
NO.
4579
C.,
T~O
1
Figure
A
Exploded
View
of
Gun
Assembly
a
36
$7
.5
35
34
33
32
31
ao
8
29
28
19
16
15
20
21
22
Includes
Items
28thru
39
27
26
-V
23
25~
TC-078
930-A
0M1506
Page
1
1
075659
2
075615
2
075616
2
075617
2
075618
3
075948
4
073777
5
076173
6
076130
7
078695
8
076175
9
078
894
10
078970
10
078971
11
604550
12
056112
13
010606
14
056851
15
079021
16
079387
16
079386
17
073672
18
075643
19
076176
20
075646
20
075648
21
076051
22
073820
23
003616
23
003617
24
073
329
25
073331
26
077
650
27
604
525
28
603
886
29
604
874
30
604
866
31
603
887
32
604311
33
057027
34
057171
35
601
845
36
056
847
37
602087
38
056845
39
010497
40
073476
Quantity
10ft
Ii
5ft.
BE
SURE TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
R~PLACEMENT
PARTS.
ttem
Factory
No.
Part
No.
Figure
A
Exploded
View
of
Gun
Assembly
Description
3
3
3
3
1
1
1
1
1
lift.
1
1
1
1
1
2
1
1
1
1
2
3
3
3
3
l6ft.
2
2
NOZZLE
TUBE,
contact
5/64
wire
TUBE,
contact
3/32
wire
TUBE,
contact
7/64
wire
TUBE,
cofltact
1/8
wire
ADAPTER,
nozzle
WASHER,
silicon
-
flat
TUBE,
head
(consisting
of)
INSULATOR,
centering
.
head
tube
LINER,headtube
HANDLE,
gun
SCREW,
machine
-
steel
flat
hd
1/4-20
x
3/8
HOS~,
gas
10
ft
(consisting
of)
HOSE,
gas
15
ft
(consisting
of)
HOSE,
whippet
3/16
x
1
(order
by
foot)
.FERRULE,.475IDx23/32long
NUT,
brass
-
swivel
5/8-18
right
hand
NIPPLE,
brass
-
hose
3/16
inch
SCREW,
set
-
steel
socket
hd
3/8-16
x
1/2
CABLE/CONDUIT,
lOft
(consisting
of)
CABLE/CONDUIT,
l5ft
(consisting
of)
.0-RING
ADAPTER,
gun/feeder
.BODY,gun
LINER,
monocoil
LINER,
monocoil
INSULATOR,
adapter
SPRING,
strain
relief
CORD,
power
lOft.
(consisting
of)
CORD,
power
15
ft.
(consisting
of)
PLUG,
4
pin
97-3106A-18-4P
CLAMP,
cable
97-3057-10-6
TUBING,
vinyl
No.
7x
3/4
CORD,
portable
18
ga
2
conductor
type
SV
(order
by
fQot)
NUT,
steel
-
hex
2-56
WASHER,
lock
-
steel
split
No.
2
SWITCH
SCREW,
machine
-
steel
round
hd
2-56
x
1/2
GROMMET,
rubber
1/4
IDx
3/8
hole
1/16
groove
RELIEF,
strain
LEVER,
actuating
-
switch
NUT,
steel
-
self
locking
hex
8-32
SPRING
SCREW,
machine
-
steel
round
hd
8-32
x
1.1/4
.HOUSING
CLAMP,
hose
7/32
to
1-3/4
clamp
dia
l2ft.17ft.
CLAMP,
strap
-
rubber
22
2
2
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1 1
1
1
1
1
10
15
OM-1506
Page
2
The
Following
Wire
Guide
Kits
Are
Available
To
Change
The
Gun
From
One
Wire
Size
To
Another.
See
View
On
Page
1
For
Identification
of
Item
Numbers.
Quantity
-
-
Mod~I
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Factory
No.
Part
No.
Kit,
Wire
Guide
Description
2.0MM
.079
5/64
L~)
0
B
1
075
659
NOZZLE
2
075
615
TUBE,
contact
5/64
wire
2
075
616
TUBE,
contact
3/32
wire
2
075617
TUBE,
contact
7/64
wire
2
075618
TUBE,contact
1/8
wire
1
3
2.4MM
2.8MM 3.2MM
.094
.110
126
3/32
7/64
1/8
N-
~
a
a
N
N
0
0
0
1
1
1
3
3
3
Page
3
/
