Miller HG000000 Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

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
OWNERS
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
manufacturers
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
MILLERS
inspection
confirms
the
existence
of
such
defects.
MILLERS
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
1/16WIRE
10
FT.
053653
.045WIRE
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
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
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
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14

Miller HG000000 Owner's manual

Category
Welding System
Type
Owner's manual
This manual is also suitable for

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