Miller HCA-1B Owner's manual
- Category
- Welding System
- Type
- Owner's manual
This manual is also suitable for
Miller HCA-1B is a wire welding gun designed specifically for use with the self shielding Flux Cored Arc (FCAW) Welding process. It features the capability to change the contact tube, liner, and centering sleeve to accommodate different wire sizes ranging from 1/16 to 1/8 inches. This flexibility allows users to switch between wire sizes to suit their welding needs. Additionally, the gun has a curved head tube to provide better access to welding areas and a lubricator cup to ensure smooth wire feeding.
Miller HCA-1B is a wire welding gun designed specifically for use with the self shielding Flux Cored Arc (FCAW) Welding process. It features the capability to change the contact tube, liner, and centering sleeve to accommodate different wire sizes ranging from 1/16 to 1/8 inches. This flexibility allows users to switch between wire sizes to suit their welding needs. Additionally, the gun has a curved head tube to provide better access to welding areas and a lubricator cup to ensure smooth wire feeding.
January
~198O
FORM:
OM15051i
Effective
With
Style
No.
HH-6
MODEL
HCA-1B
OWNERS
MANUAL
T.
hullER
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON,
WI
54912
USA
ADDITIONAL
COPY
PRICE
20
CENTS
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A.
t;,.~~2~
~
%j~
LIMITED
WARRANTY
EFFECTIVE:
JUNE
1.
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY-Subject
to
the
terms
and
conditions
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
(
furnished
by
Miller
is
free
from
defect
in
workmanship
and
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
ranty
is
made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millers
option
(1)
repair
or
12)
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
(4)
payment
of
or
credit
for
the
purchase
bi
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
date
of
original
purchase.
return
of
the
goods
at
Customers
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clai-
Except
as
specified
below,
Millers
warranty
does
not
apply
martt
on
the
warranty
claim
procedures
to
be
followed.
d
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PRQVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
IMPLIED
WARRANTY.
GUARANTY
OR
REPRESENTA-
j~
wire
including
nozzles
and
nozzle
insulators
where
failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE.
WITH
RESPECT
TO
(
ment
to
the
original
user:
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
..
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
(labor
-
1
year
only)
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
All
welding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL.
4.
All
other
Millermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
5.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
EXPERIENCED
IN
THE USE
AND
MAINTENANCE
OF
6.
Batteries
6
months
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
WARRANTIES
DO
NOT
EXTEND
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
of
the
date
of
such
failure.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
.
~,
~
~,
~
.j~
~t,
,J~
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.~b
J~
y
1-1.
GENERAL
SECTION
1
-
INTRODUCTION
-
-
-
Figure
1-1.
Specifications
This
mwual
has
been
prepared
especially
for
use
in
familiar
izing
personnel
with
the
design,
installation,
operation,
main
tenance,
and
troubleshooting
of
this
equipment.
All
inform.
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.
1-3.
DESCRIPTION
This
gun
is
designed
sp~Cifically
for
use
in
conjunction
with
the
self
shielding
Flux
Cored
Arc
(FCAW)
Welding
process.
The
gun
is
shipped
with
the
necessary
components
f
or
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.
Cooling
Net
Ship
Method
Weight
Weight
Air
15
Lbs.
(6.8
Kilos)
17
Lbs.
(7.7
Kilos)
Air
17
Lbs.
(7.7
Kilos)
19
Lbs.
(8.6 Kilos)
1-4.
SAFETY
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughout
this
manual:
CAUTION.
I
Under
this
heading,
in
tenance
procedures
or
stallati
pracs
on,
opera~nd
main.
Ices
will
be
found
that
if
not
carefully
followed
may
create
a
safety
hazard
to
personnel.
.
I
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.
T
rr
.
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
their
respective
input
electrical
power
supplies.
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.
tube
is
th
readed
be
rotated
in
a
counterclockwise
directIon
to
be
removed
and
a
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.
Rating:
100
PCT.
Duty
Cycle,
dcrp
Wire
Dia.
I
1/16(1.6mrn)To
500
Amperes
11/8
(3.1mm)
Flux
Core
Cable
Length
10
15
I
2-2.
CHANGING
WIRE
SIZES
IMPORTANT
1
It
is
recommended
that
the
monocoil
casing
have
the
inside
blown
out
with
compressed
air
occasionally.
OM-1505
Page
1
9.
Insert
the
new
monocoil
liner
(1/16
and
5/64
inch
liners
must
be
inserted
from
the
head
tube
adapter
~1/8
inch
ulled
out
and
removed
end).
liners
may
be
p
10.
Slide
the
insulator
over
the
gun/feeder
adapter.
from
either
end.
1/16
and
5/64
inch
liners
must
be
pulled
out
and
removed
from
the
head
tube
adapter
11.
Reinstall
the
lubricating
cup.
end.
12.
Tighten
the
socket-head
liner
set
screw
located
in
the
handle.
5.
Remove
the
monocoil
liner.
13.
Reposition
the
hand
guard
and
tighten
the
clamp
se
6.
Slide
the
insulator
off
of
the
gun/feeder
adapter
to
curing
it
to
the
handle.
gain
access
to
the
rear
centering
sleeve
set
screw.
14.
Reinstall
the
head
tube.
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.
V
OM-1
505
Page
2
January
1980
FORM:
OM-1505C
PARTS
LIST
Effective
With
Style
No.
HH-6
MODEL
HCA-1B
29
1
TC-009
230-B
Figure
A
Exploded
View
Of
Gun
And
Optional
Flux
Hopper
(Gun
With
1/16
Wire
Illustrated)
*As
Required.
tOptional
Equipment.
BE
SURE
TO
PROVIDE
STOCK,
MODEL.
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
1~
26
31
32
25.
FLUX
HOPPER
-
OPTIONAL
2
16
13
14
24
17
23
OM-1505
Page
1
Item
No.
Figure
A
A
B
C
0
E
F
G
H
J
K
L
601
957
602
066
602
091
602
241
602
207
602
204
602
199
601
865
601
862
601
859
602 088
Factory
Part
No.
Description
Exploded
View
of
Gun
Assembly
Quantity
Mnd~l
1.6MM
2.0MM
2.4MM
2.8MM
3.2MM
.063
.079
.094
.110
.126
1/16
5/64
3/32
7/64
1/8
A
1
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
17
18
19
20
21
22
23
24
24
24
24
25
26
27
28
29
30
31
32
33
34
35
009 709
052
055
008
926
008
925
008
924
008
934
008
932
008
931
075 625
075 855
075
626
078
981
008
948
010
860
008
928
602
177
075
628
073
357
605 789
008
127
004
747
004
750
004
728
004
733
004
732
004
729
075 644
007
500
009 624
009
625
048
823
048
824
078 894
t052
789
006
868
006
861
006 870
052 759
006
862
006 865
006
866
052
808
076
183
006
863
5
1
1
2
1
2
2
1
*
1
TUBE,
contact
1/16
wire
TUBE,
contact
5/64
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
-
1/8
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
cEamp
dia
GUARD,
shield
-
hand
SCREW,
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)
or
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
1/16-5/64wirex
lOft
or
LINER,monocoil
1/16-5/64wirex
l5ft
LINER,monocoil3/32-1/8wirelOftor
LINER,
monocoil
3/32
-
1/8
wire
15
ft
SCREW,
machine.-
steel flat
hd
1/4-20
x
3/8
FLUX
HOPPER,
hand
-
held
(consisting
of)
-
COVER,
flux
hopper
CLIP,
spring
-
cover
BODY,
flux
hopper
-
LINER,
monocoil
1/16
-
1/8
wire
x
8-1/4
NOZZLE,
flux
-
flux
hopper
-
SHIM,
torch
-
adapter
ADAPTER,
gun
-
flux
hopper
-
TUBE,
head
-
curved
(consisting
of)
..TUBE,
fiber
.HINGE,cover
Attaching
Hardware
For
Optional
Flux
Hopper
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
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
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
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
OM-1505
Page
2
J
1~
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
Miller HCA-1B Owner's manual
- Category
- Welding System
- Type
- Owner's manual
- This manual is also suitable for
Miller HCA-1B is a wire welding gun designed specifically for use with the self shielding Flux Cored Arc (FCAW) Welding process. It features the capability to change the contact tube, liner, and centering sleeve to accommodate different wire sizes ranging from 1/16 to 1/8 inches. This flexibility allows users to switch between wire sizes to suit their welding needs. Additionally, the gun has a curved head tube to provide better access to welding areas and a lubricator cup to ensure smooth wire feeding.
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