March
1977
FORM:
OM-1508A
MODEL
HPA-1B
.045
WIRE
1/16
WIRE
5/64
WIRE
3/32
WIRE
7/64
WIRE
1/8
WIRE
STOCK
10
FT.
007
551
007
552
007
553
007
554
007
555
007
556
NO.
15
FT.
007
557
007
558
007
559
007
560
007
561
007
562
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
OWNERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
ADDITIONAL
COPY
PRICE
20
CENTS
~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
Mfg.
Co.,
Apple-
1.
Arc
welders,
power
sources,
and
components
.
1
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
1
year
only)
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
3.
All
welding
guns
and
feeder/guns
90
days
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
1
year
trade
accessories
and
other
items
are
sold
subject
to
the
warran-
provided
that
the
user
so
notifies
Miller
in
writing
within
thirty
j
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
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,
(1)
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
IN
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
COMMERCIAL/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-
from
the
date
of
delivery
of
Equipment
to
the
original
user:
RANTIES
TO,
ANY
CONSUMER.
~
d~~b
~
.~Js,
~
~
j~.Jt,
~
...~
.~
~
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
Item
Part
No.
Listed
Replaced
With
No.
In
Parts
List
Part
No.
Description
Quantity
2
078
288
078
289
HANDLE,
gun
-
left
hand
molded
1
22
078
286
078
287
HANDLE,
gun
-
right
hand
molded
1
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1
508A
Page
A
p
SECTION
1
-
INTRODUCTION
Rating:
100
PCT.
Wire
Cable
and
Cooling
Net
Ship
Duty
Cycle,
dcrp
Dia.
Hose
Length
Method
Weight Weight
500
Amperes
.045
(1.1mm)
Hard
To
10
Air
13
Lbs.
(5.9
Kilos)
15
Lbs.
(6.8
Kilos
With
CO2
1/8
(3.1mm)
Flux
Cored
15
Air
15
Lbs.
(6.8
Kilos)
17
Lbs.
(7.6
Kilos)
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.
1-2.
RECEIVING-HANDLING
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:
~thisheading,ins
tallation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
hazard
to
per
sonnel.
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.
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.
2-4.
CHANGING
WIRE
SIZES
(Figure
2-1)
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
mutt
be
changed.
Refer
to
the
Parts
List
to
determine
proper
compo
nents.
TA~
-
1-3.
DESCRIPTION
I
~A~T
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.
NOTE
I
CAUTION
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
I
I
E~J
Whenever
the
electrode
wire
size
is
changed,
blow
out
both
the
monocoil
and
monocoil
casing
with
corn
pressed
air.
OM-1508
Page
1
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.
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
top
of
the
gun
handle.
3.
Loosen
the
monocoil
set
screw
located
on
the
insula
tor
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.
Steps
4
-
6
permit
other
size
liners
to
be
inserted
or
removed.
sleeve
does
or
removed,
proceed
to
step
12.
Steps
8
-
12
provide
instructions
for
the
installation
or
removal
of
the
centering
sleeve.
8.
Slide
the
insulator
off
of
the
gun/feeder
adapter
to
gain
access
to
the
centering
sleeve
set
screw.
9.
Loosen
the
set
screw.
10.
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.
11.
Reposition
the
insulator
over
the
gun/feeder
adapter.
12.
Lay
the
gun
out
flat
(no
coils
in
the
cable/conduit).
13.
Insert
the
new
monocoil
liner.
14.
Tighten
the
monocoil
liner
set
screws
located
on
top
of
the
gun
handle
and
on
the
insulator.
~monocoill
iner
will
be
longer
than
necessary
Cut
off
the
excess
liner
flush
with
the
gun/feeder
~
adapter.
Deburr
the
liner
if
necessary.
I
15.
Reinstall
the
head
tube.
4.
Disconnect
the
gas
hose
from
the
gas
tube
on
the
headtube
body.
16.
Reinstall
the
head
tube
body.
17.
Reconnect
the
gas
hose
to
the
gas
tube
on
the
head
tube
body.
NOZZLE
TD
ooe
756
I
I
)NTACT
TUBE
HEAD
TUBE
BODY
5.
Loosen
the
knurled
body
nut
and
remove
the
head
tube
body.
6.
Remove
the
head
tube.
7.
Pull
out
and
remove
the
monocoil
liner.
HEAD
TUBE
BODY
NUT
MO
NO
CO
IL
SET
SCREW,
CABLE/CONDUIT
FRONT
MONOCOIL
CENTERING
SLEEVE
CENTERING
SLEEVE
SET
SCREW
MONOCOIL
LINER
REAR
MON0COIL*
CENTERING
SLEEVE
GUN
SWITCH
CONNECTOR
Figure
2-1.
Gun
Components
*045,
1/16
or
5/64
MONOCOIL
LtNERS
ONLY
Page
2
March
1977
FORM:
OM-1508A
MODEL
HPA-1B
.045
WIRE
1/16
WIRE
5/64
WIRE
3/32
WIRE
7/64
WIRE
1/8
WIRE
STOCK
NO.
10
FT.
15
FT.
007
551
007
557
007
552
007
558
007
553
007
559
007
554
007
560
007 555
007
561
007
556
007
562
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
NWSA
CODE
NO.
4579
11
Figure
A
Exploded
View
of
Gun
Assembly
TO-078
940
I
10
7
8
6
4
5
3
2
33
34
I
Includes
OM-1
508
Page
1
Item
Factory
No.
Part
No;
Description
Figure
A
Exploded
View
Of
Gun
Assembly
1
073
476
2
078
288
3
079235
4
007501
5
602179
6
075671
7
073779
8
007
395
8
007 394
9
007 550
10
054972
10
054545
10
054353
10
054354
10
054355
10
054356
11
008620
12
601
941
13
011070
14
604723
15
007579
16
078458
17
604311
18
004890
19
602240
20
079018
21
601
954
22
078 286
23
007 500
24
076051
25
079021
26
601
865
27
605
789
28
008127
29
009
627
29
009 628
29
009
624
29
009
625
29
007
594
29
007
595
30
004
745
30
004
749
31
004
731
32
004
728
33
004
733
34
004
732
35
056
462
35
056
542
36
010606
37
010603
38
604
550
39
076023
39
076024
40
073
329
41
073331
1-1/8
x3/16
x3/16
TUBE,
contact
0.045
wire
TUBE,
contact
1/l6wire
TUBE,
contact
5/64
wire
TUBE,
contact
3/32
wire
TUBE,
contact
7/64
wire
TUBE,
contact
1/8
wire
NOZZLE,
screw
type
1-3/16
-
16
x
2-3/8
long
SCREW,
cap
-
steel
hex
hd
1/4-20
x
1-3/4
SWITCH,
rocker
operated
DPST
(consisting
of)
-
SCREW,
machine-brass
binding
hd
4-40
x
3/4
BRACKET,
mounting
-
guard
handle
SCREW,
machine-steel
round
hd
4-40
x
5/16
GROMMET,
rubber
1/4
ID
x
3/8
mounting
hole
GUARD,
trigger
WASHER,
flat
-
steel
1/4
NUT,
steel
-
hex
jam
1/4-28
SCREW,
cap-steel
hex
hd
1/4-20x
3/4
HANDLE,
gun
-
right
hand
SPRING,
compression
INSULATOR,
adapter
-
gun/feeder
SCREW,
set-steel
socket
hd
3/8-16
x
1/2
NUT,
steel
-
hex
full
1/4-20
SCREW,
set-steel
socket
hd
10-24
x
1/4
SLEEVE,
rear-centering
monocoil
0.045-1/16
LINER,
monocoil
0.045
wire
x
10
ft
LINER,
monocoil
0.045
wire
x
15
ft
LINER,
monocoil
1/16-5/64
wire
x
10
ft
LINER,
monocoil
1/16-5/64
wire
x
15
ft
LINER,
monocoil
3/32-1/8
wire
x
10
ft
LINER,
monocoil
3/32-1/8
wire
x
15
ft
CABLE/CONDUIT,
lOft
(consisting
of)
CABLE/CONDUIT,
15
ft
(consisting
of)
-
ADAPTER,
head
tube
ADAPTER,
gun/feeder
CLAMP,
cable
-
conduit
-
CLAMP,
cable
-
conduit
HOSE
ASSEMBLY,
gas
10
ft
(consisting
of)
HOSE
ASSEMBLY,
gas
15
ft
(consisting
of)
FITTING,
hose-brass
nut
5/8-18
RH
FITTING,
hose-brass
barbed
nipple
1/4
TBG
-
HOSE,
neoprene
No.
1
(order
by
foot)
CORD,
trigger
10
ft
(consisting
of)
CORD,
trigger
15
ft
(consisting
of)
-
PLUG,
4
pin
97-3106A-18-4P
CLAMP,
cable
*
* *
*
1 1 1 1
1
2 2 2 2 2
2 2 2 2
2
1 1 1 1 1
1 1 1 1 1
2
2 2
2 2
1 1
1
1 1
1
1
1
1
1
5
1
1
1 1
5
5
1
1
1
1
1 1 1 1
1
1 1
1
4
4
4
4
1
1 1 1
4 4
4
4
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 1
1
1
1
1
1 1 1
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
Quantity
Model
And
lOFT
15F1
1.2MM 1.6MM
2.0MM 2.4MM
2.8MM
3.2MM
.047
.063
.079
.094
.110
.126
.045
1/16
5/64
3/32
7/64
1/8
CLAMP,
strap
-
rubber
5
holes
HANDLE,
gun
-
left
hand
SCREW,
machine-steel
round
hd
1/4-28
x
WASHER,
flat-nylon
17/64
ID
x
7/16
OD
SCREW,
set
-steel
socket
hd
1/4-20
x
1/2
NUT,
body
WASHER,
flat-phenolic
5/8
ID
x
1.11
OD
TUBE,
head
0.045
wire
TUBE,
head
1/16-1/8
wire
BODY,
head
tube
5
5
*
2
2
2
5
1
1
4
4
1
2
1
1
4
1
4
1
2
1
OM-1
508
Page
2
Item
Factory
No.
Part
No.
Description
Quantity
Model
lOFT
And
15FT
1.2MM
1.6MM
2.0MM
2.4MM
2.8MM
3.2MM
.047
.063
.079
.094
.110
.126
.045
1/16
5/64 3/32
7164
118
Figure
A
Exploded
View
Of
Gun
Assembly
(Contd.)
42
604
525
.
CORD,
portable
No.
182/c
(order
by
foot)
*
43
074
445
.
TERMINAL,
ring
tongue
No.
6
stud
22-18
2
077
650
.
TUBING,
vinyl
No.
7
x
3/4
2
* *
* *
*
2 2
2
2
2
2 2 2 2
2
*As
Required.
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
The
Following
Parts
Are
Required
To
Change
The
Gun
From
One
Wire
Size
To
Another.
(Some
Parts
Are
Common
To
More
Than
One
Wire
Size.)
See
View
On
Page
1
For
Identification
Of
Item
Numbers.
Item
Factory
No.
Part
No.
Description
_
Model
lOFT
And
15FT
1.2MM
1.6MM
2.0MM 2.4MM
2.8MM
3.2MM
.047
.063
.079
.094
.110 .126
.045
1/16
5/64 3/32 7/64
1/8
8
007
395
8
007
394
10
054972
10
054545
10
054353
10
054354
10
054355
10
054356
28
008127
29
009
627
29
009
628
29
009
624
29
009
625
29
007
594
29
007
595
TUBE,
head
0.045
wire
TUBE,head
1/16-1/Bwire
TUBE,
contact
0.045
wire
TUBE,
contact
1/l6wire
TUBE,
contact
5/64
wire
TUBE,
contact
3/32
wire
TUBE,
contact
7/64
wire
TUBE,
contact
1/8
wire
SLEEVE,
rear-centering
monocoil
0.045
-
1/16
LINER,
monocoil
0.045
wire
x
10
ft
LINER,
monocoil
0.045
wire
x
15
ft
LINER,
monocoil
1/1
6-5/64
wire
x
10
ft
LINER,
monocoil
1/1
6-5/64
wire
x
15
ft
LINER,
monocoil
3/32-1/8wirex
lOft
LINER,
monocoil
3/32-1/8
wire
x
15
ft
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
x
x
x x
x
x
x
x
x
x
x
x
x
x
S
x
x
x
x
x
x
x x
x
x
x x
Page
3
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