Miller HCA-1A Owner's manual

Miller
Brand
Miller
Model
HCA-1A
Category
Welding System
Type
Owner's manual

This manual is also suitable for

November
1976
FORM:
OM-1505A
MODEL
HCA-1A
3/32
WIRE
7/64
WIRE
1/8
WIRE
078
922
078
923
078924
078
926
078 927
078928
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
OWNERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
F~LE
COPY
RETURN
TO
FOLDER
STOCK
NO.
lOFT
15FT
ADDITIONAL
COPY
PRICE
25
CENTS
La~
~
L~
~
~
~
~
t~~
%.~
L~P
~
LIMITED
WARRANTY
EFFECTIVE:
NOVEMBER
1,
1976
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
elusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTYMiller
Electric
Mfg.
Co.,
Apple-
3.
All
welding
guns
and
feeder/guns
9()
days
ton,
Wisconsin
warrants
to
Customer
that
all
new
and
unused
4.
All
other
Millermatic
Feeders
I
year
Equipment
furnished
by
Miller
is
free
from
defect
in
workman-
provided
that
the
user
so
notifies
Miller
in
writing
within
thirty
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
(30)
days
of
the
date
of
such
failure.
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other items
manufactured
by
others.
Such
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
warran-
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
?
ties
of
their
respective
manufacturers,
if
any.
At
the
present
time,
AND ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REP-
the
manufacturers
warranty
on
the
Mag-Diesel
engine
on
DEL-
RESENTAT1ON
AS
TO
PERFORMANCE,
AND
ANY
200
is
limited
to
six
months
and
on
all
other
engines
to
one
year.
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICA
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
TION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
therefor
shall
be,
at
Millers
option,
(I)
repair
or
(2)
replace-
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
ment
or,
where
authorized
in
writing
by
Miller
in
appropriate
WARRANTY
OF
MERCHANTABILITY
OR
OF
FITNESS
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
authorized
Miller
service
station
or
(4)
payment
of
or
credit
for
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
the
purchase
price
(less
reasonable
depreciation
based
upon
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
ex
pense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
Miller
shall
instruct
the
claimant
on
the
warranty
claim
proce-
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
dures
to
be
followed.
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUS
TRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
As
a
matter
of
general
policy
only,
Miller
may
honor
an
origi-
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
nal
users
warranty
claims
on
warranted
Equipment
in
the
event
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
of
failure
resulting
from
a
defect
within
the
following
periods
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
from
the
date
of
delivery
of
Equipment
to
the
original
user:
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RE-
I.
Arc
welders,
power
sources,
and
components
...
1
year
SELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WAR
2.
Original
main
power
rectifiers
3
years
RANTIES
TO,
ANY
CONSUMER.
t,
.r
t,
~r
November
1976
FORM:
OM-1505A
MODEL
HCA-1A
3/32
WIRE
7/64
WIRE
1/8
WIRE
STOCK
NO.
lOFT
15FT
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
078
922
078
923
078
924
078926
078
927
078 928
NWSA
CODE
NO.
4579
22
TC-078
922-A
i
20
19
2
24
25
18~
28
26
1
OM-1505
Page
1
Figure
A
Exploded
View
of
Gun
Assembly
&
Optional
Flux
Hopper
SECTION
1
-
INTRODUCTION
Rating:
100
PCT.
Wire
Cable
and
Cooling
Net
Ship
Duty
Cycle,
dcrp
Dia.
Hose
Length
Method
Weight
Weight
3/32
(2.3mm)
To
10
Air
14
Lbs.
(6.3
Kilos)
16
Lbs.
(7.2
Kilos)
500
Amperes
1/8
(3.1mm)
Flux
Core
15
Air
16
Lbs.
(7.2
Kilos)
18
Lbs.
(8.1
Kilos)
1-1.
GENERAL
Figure
1-1.
Specifications
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.
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughout
this
manual:
flTANT
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
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
3/32, 7/64,
and
1/8
flux-cored
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
!
I
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.
IMPORTANT
I
It
is
recommended
that
the
monocoil
casing
have
the
inside
blown
Out
with
compressed
air
occasionally.
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.
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.
~~ntacttubeisthreededandne~onlyberotated
in
a
counterclockwise
direction
to
be
removed
and
a
clockwise
direction
to
be
installed.
2-3.
LUBRICATION
CUP
The
Lubrication
Cup
located
on
the
Electrode
Wire
Gun
Con
nector
will
supply
lubricant
to
the
electrode
wire
in
order
to
aid
in
ease
of
wire
feed
through
the
Gun.
It
is
recommended
that
the
Lubrication
Cup
be
filled
with
Magna
Welder
Lubricant
or
equivalent,
1-4.
SAFETY
1-2.
RECEIVING-HANDLING
(
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.
1-3.
DESCRIPTION
I
U
I
I
I
.1
2-2.
CHANGING
WIRE
SIZES
OM-1
505
Page
1
I,
I
k\
1
-Is
-
-t
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Miller HCA-1A Owner's manual

Miller
Brand
Miller
Model
HCA-1A
Category
Welding System
Type
Owner's manual
This manual is also suitable for
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