Page 1
June
1975
FORM:
OM-1504A
MODEL
MCA-1A
.030
.035
.045
1/16
WIRE
WIRE
WIRE
WIRE
STOCK
lOFT
078912
078913
078914 078919
078915
NO.
15FT
078917
078918
078 920
MODEL/STOCK
NO.
OWNERS
MILLER
APPLETON,
SERIAL/STYLE
NO.
MANUAL
ELECTRIC
WISCONSIN,
DATE
MFG.
USA
PURCHASED
CO.
54911
ADDITIONAL
PRICE
25
CENTS
COPY
NWSA
CODE
NO.
4579
Page 2
t
Page 3
Rating:
Duty
350
With
100
Cycle,
Amperes
CO2
PCT.
dcrp
J_
.045
.030
SECTION
Wire
Dia.
(.7mm)
(1.1mm)
To
Hard
Cable
Hose
Figure
-
1
INTRODUCTION
and
Length
10
15
1-1.
Specifications
Cooling
Method
Air
Air
Net
Weight
14
Lbs.
(6.3
(7.2
Kilos)
Kilos)
16
Lbs.
Ship
Weight
Lbs.
16
(7.2
(8.1
Kilos)
Kilos)
18
Lbs.
1-1.
GENERAL
This
izin~
tenance,
tion
presented
assure
1-2.
RECEIVING-HANDLING
Prior
from
that
or
damage
the
purchaser
and
freight
occasion
When
essential
Serial
DESCRIPTION
1-3.
This
Gas
the
with
ordered.
used
manual
personnel
and
optimum
to
installing
around
have
may
that
bill
file
to
requesting
that
(or
Style)
is
designed
gun
Metal-Arc
the
necessary
Through
with
.030,
has
been
prepared
with
the
troubleshooting
herein
design,
should
performance
this
equipment,
unit
the
with
Model
occurred
have
may
the
will
be
claim
information
Numbers
(MIG)
minor
.035,
and
during
occurred
carrier.
furnished
arises.
Description
of
specifically
Welding
components
changes
or
.045,
especially
installation,
of
this
be
given
of
this
clean
carefully
shipment.
in
A
copy
by
concerning
and/or
the
equipment
for
process.
for
1/16
for
equipment.
careful
equipment.
all
inspect
Any
transit
of
the
carrier
this
Stock
in
use
The
the
specific
in
parts
wire.
SECTION
in
familiar
use
operation,
All
informa
consideration
material
packing
for
damage
any
claims
filed
be
must
of
the
bill
on
request
equipment,
Number
be
supplied.
conjunction
is
shipped
gun
wire
the
gun
may
main
for
lading
with
2-
1-4.
to
loss
by
if
It
is
and
size
be
INSTALLATION
SAFETY
The
NOTE
and
I
Under
tenance
not
personnel.
U
I
Under
tenance
not
meht.
I
Under
found
efficient
following
definitions
blocks
found
this
heading,
proceduresorpractices
carefully
followed
II
this
heading,
procedures
this
heading,
that
need
operation
followed
carefully
to
apply
throughout
CAUTION,
this
CAUTION
installation,
may
operating,
will
create
a
IMPORTA~
installation,
or
practices
may
result
operating,
will
in
damagetoequip.
r~E1
explanatory
special
of
the
emphasis
equipment.
statements
to
manual:
found
be
safety
be
obtain
IMPORTANT,
and
main
that
hazard
and
main
found
that
will
the
I
if
to
I
I
if
I
be
most
2-1.
2-2.
Prior
feeder
disconnected
power
SHIELDING
Secure
output
that
istobe
shielding
GUN
SWITCH
the
Insert
Switch
inserted
will
turn
the
receptacle
tension.
to
and
supplies.
the
shielding
connector
gas
amphenol
Control
into
in
installing
welding
from
GAS
HOSE
gas
the
on
for
used
hose
connector
CONNECTION
plug
Receptacle
the
receptacle,
clockwise
a
and
prevent
the
gun,
source
power
the
respective
CONNECTION
hose
connector
control/feeder
on-off
control
has
from
the
on
rotate
direction;
the
that
ensure
are
or
of
the
hand
right
(Figure
Gun
the
Switch
control/feeder.
the
plug
this
will
from
plug
the
both
completely
input
(Figure
the
in
shielding
whatever
to
shielding
threading.
2-1)
fully
collar
lock
coming
control/
electrical
device
gas.
into
Once
far
as
the
plug
under
Out
2-1)
gas
The
the
fully
it
as
in
2-3.
2-4.
ELECTRODE
2-1)
ure
Proceed
tor
as
the
into
1.
Rotate
the
counterclockwise
Insert
outlet
ing
Rotate
the
the
guide
roll
the
2.
3.
clockwise
Rotate
4.
the
will
it
as
CHANGING
time
will
1/16
the
be
necessary
necessary
wire.
Each
it
holesinthese
the electrode
dures
or
follows
drive
Gun
Electrode
pin
Electrode
direction.
Gun
turn
WIRE
size
components
wire.
WIRE
to
assembly
Connector
direction
hole
with
inside
Connector
clockwise
in
a
of
the
to
The
to
adapt
OUTLET
install
Wire
of
Wire
SIZES
electrode
change
following
the
the
the
on
four
Gun
flat
the
the
Gun
Securing
(Figure
certain
will
gun
Securing
outlet
direction.
CONNECTION
Electrode
control/feeder:
Wire
Knob
complete
Connector
the
of
side
Connector
guide
Knob
hole.
2-1)
wire
being
components
permit
proper
explain
steps
either
to
.030, .035,
Gun
or
turns.
fully
connector
90
Screw
or
used
movement
OM-1504
Connec
Screw
into
degrees
is
changed
that
so
the
proce
(Fig
in
the
fac
in
far
as
the
of
.045,
Page
a
a
1
Page 4
If
from
3
gun
to
the
1.
2.
3.
4.
5.
6.
itisdesired
.045
to
2-1)
Figure
is
equipped
convert
to
following
Cut
off
tends
beyond
Pull
out
monocoil
Remove
Remove
If
converting
remove
wire,
from
ing
remove
(7).and
To
adapt
(1)
into
contact
insulator
to
1/16
will
for
.045
steps
portion
any
the
of
all
and
rewind
nozzle
contact
from
insulator
.045
centering
nut
(8).
the
gun
head
the
tube
(3)
To
(2).
convert
wire,
have
.030
or
will
end
the
(4).
tube
or
into
adapt
NOTE
to
or
1/16
have
of
of
electrode
it
(3).
.030
1/16
insulator
for
.030
tube,
adapter
from
only
be
changed.
.035
wire
be
to
the
the
Onto
.035
or
and
(2)
wire
or
insulator
the
gun
.030
the
contact
wire
(or
vice
performed.
electrode
contact
wire
which
the
wire
wireto.045
adapter
to
(5),
adapter
.035
wire,
(2)
and
(1),
for
.045
.035
to
tube
However,
anditis
versa),
wire
tube
is
spool.
(1).
.030
or
install
onto
nozzle
or
wire
(item
if
desired
all
which
(3).
in
the
or
If
convert
.035
(6),
adapter
(4)
1/16
4
or
the
of
ex
gun
1/16
wire,
washer
adapter
(1),
onto
wire,
the
install
(8),
adapter
(5)
Onto
and
nozzle
Loosen
7.
Pull
8.
I
Out
nector
nut
adapter
set
monocoil
(10).
(8)
(4)
screw
onto
(6)
onto
into
(6),
(9).
the
contact
nut
(11)
head
head
(8).
from
tube,
tube,
tube
Electrode
washer
centering
into
(3)
Wire
adapter
(7)
on
insulator
Gun
nut
(6),
Con
IMPORTANT
new
the
(12)
Out
is
as
Wire
flush
and
with
monocoil
the
Gun
monocoil
with
(10).
old
t
monocoil
compressed
9.
10.
11.
12.
recommended
old
Lay
cut
and
monocoil.
Insert.
Connector
Continue
casing
end
the
Tighten
that
both
(11)
air
priortoassembly.
monocoil
monocoil
new
monocoil
(10).
feed
to
the
until
(12)
Electrode
of
the
set
screw
the
have
(11)
(11)
monocoil
endofthe
(9).
monocoil
the
along
to
into
Wire
inside
the
the
side
same
(11)
monocoil
Gun
casing
blown
of
length
Electrode
intO
Connector
3
2
5
6
7
8
Gas
jielding
Connector
Hose
10
11
Page
Electrode
Gun
12
Gun
Figure
2-1.
Components
Gun
Connector
Switch
Plug
Wire
TB-078
912-2
2
Page 5
June
1975
FORM:
OM-1504A
MODEL
MCA-1A
.030
.035
.045
1/16
WIRE
WIRE
WIRE
WIRE
STOCK
FT
10
912
078
078913
078 914
915
078
NO.
15
078917
078
078919
078
Ft
918
920
MODEL/STOCK
NO.
SERIAL/STYLE
PARTS
MILLER
APPLETON,
ELECTRIC
WISCONSIN,
NO.
LIST
MFG.
USA
DATE
PURCHASED
CO.
54911
NWSA
CODE
NO.
4579
Page 6
3,
9
10
36
35
39
32
41
40
31
42
-12
22
13
19
18
20
ii
OM-1504
Page
43
Includes
A
Figure
1
Exploded
Items
26
View
912A
TC-078
of
Gun
Assembly
Page 7
Item
No.
Figure
1
2
3
4
5
5
5
5
6
6
7
8
9
10
11
12
13
13
14
15
16
17
18
19
20
20
20
20
21
21
22
23
24
25
26
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
BE
SURE
Factory
Part
No.
A
076179
076026
076086
075892
075788
075
789
075613
075614
076029
075953
073225
075946
073778
075928
076175
078863
078970
078971
604550
056172
010606
056851
076051
079021
075814
075963
075815
075964
000951
000
952
078049
381
078
073493
073820
003616
003617
073
329
073
331
077650
604525
603
886
604874
604
866
603 887
604311
057
027
057171
601
845
056847
602087
056845
010497
073476
TO
Description
Of
tube
tube
-
nozzle
.030
.035
.045
1/16
Gun
-
contact
wire
wire
wire
Exploded
TUBE,
head
INSULATOR,
ADAPTER,
INSULATOR,
TUBE,
TUBE,
TUBE,
TUBE,
contact
contact
contact
contact
View
NOZZLE
NOZZLE
INSULATOR,
ADAPTER,
WASHER,
nozzle
NUT,
HANDLE,
SCREW,
HOSE,
HOSE,
gas
gas
HOSE,
centering
-
tube
contact
phenolic
gun
machine-steel
ft
10
(consisting
ft
15
(consisting
whippet
3/16
-
.FERRULE,.475lDx23/32long
-
swivel
brass
NUT,
NIPPLE,
brass-hose
INSULATOR,adapter
-
steel
SCREW,
LINER,
LINER,
LINER,
LINER,
set
monocoil
monocoil
monocoil
monocoil
CABLE/CONDUIT,
CABLE/CONDUIT,
BODY,
gun
ADAPTER,
.0-RING
SPRING,
CORD,
CORD,
PLUG,
CLAMP,
TUBING,
CORD,
NUT,
strain
power
power
4
pin
cable
18
steel-hex
WASHER,
SWITCH
socket
gun/feeder
relief
10
ft.
15
ft.
97-3106A-18-4P
97-3057-10-6
No.
vinyl
2
conductor
ga
2-56
-
lock
steel
10
i5ft
.SCREW,roundhd2-56x
GROMMET,
RELIEF,
LEVER,
NUT,
SPRING
rubber
strain
actuating
steel-self
-
locking
.SCREW,roundhd8-32x
HOUSING
hose
strap
7/32to1-3/4
-
rubber
AND
CLAMP,
CLAMP,
PROVIDE
STOCK
Assembly
head
wire
-
head
tube
flat
hd
flat
1/4-20x3/8
of)
of)
1
x
(orderbyfoot)
5/8-18
right
inch
3/16
hd
3/8-16
ft
(consisting
(consisting
(consisting
(consisting
7x
split
1/4
switch
MODEL
of)
of)
3/4
(orderbyfoot)
No.
1/2
ID
x
3/8
hex
8-32
1-1/4
NUMBERS
hand
2
x
hole
1/2
of)
of)
.
WHEN
Quantity
Model
lOFoot
-
.8MM .9MM
.031
.030
1
5
1 1
1 1 1
1 1 1 1
1 1 1
lift. lift.
1
1 1
1 1
1
1
1
1 1 1
i 1 1
1
2 2 2
i
1
1 1 1 1 1 1 1
1 1 1 1 1 1
2 2
12
ft.12ft.
2 2 2 2 2
2 2 2 2 2
1 1
2
1 1 1 1
1
1
1
1
1 1 1 1
1 1
1
10
ORDERING
12MM
.035
.035 .045
.047
1
1
1
1
5
1 1 1
1
5
1 1
1 1
1
1 1
1
lift. lift.
1 1
1
1
1
1
1
1 1
1 1 1
1 1
1
1
1 1
2 2 2 2
12
ft.
1
2
1
1
1 1
1
1 1
10
2 2
1
1
1 1
1
10
REPLACEMENT
1.6MM
.063
1/16
1
5
1
1
1
1
1 1
1 1
1 1
1
1 1
1
1
1
2
1
1
2
1
1
1
1 1
1 1
1
10
.8MM .9MM
.031
.035
.030 .035
1
5
5
1 1
1 1 1 1
1
1 1
l6ft.
i6ft.
1 1 1
1
1 1 1
1
1 1 1
i
1
1
1 1
1
1 1 1
1
1
2
2 2 2
1 1 1
1
ft.
17
ft.
1
7
ft.
2
2
1
1
2 2
1
1
1 1
1
1
1 1
1
1
1 1
1
1 1
15
15
PARTS.
15
Foot
1.2MM
.047
.045
1 1
1
5
1 1
1 1
1 1
1
1
i6ft.
1
1
1 1
1.
1
1
2
17
2
2
1
2 2
1
1
1
1
1
1
i
15
ft.
1.6MM
.063
1/16
5
1
1
1
l6ft.
1
1
1
1
1
1
2
17
2
2
1
1
1
1
1
1
1
1
1
15
1
ft.
aM-i
504
Page
2
Page 8
THE
SiZE
Item
No
3
4
5
5
5
5
6
6
7
8
9
10
20
20
20
20
FOLLOWING
TO
ANOTHER.
Factory
Part
No.
076086
892
075
788
075
075 789
613
075
075614
029
076
953
075
225
073
946
075
778
073
928
075
075814
075963
075815
075964
WIRE
SEE
GUIDE
VIEW
Description
Guide
Wire
Kit,
ADAPTER,tube-contact
contact
contact
nozzle
.030
.035
.045
wire
wire
wire
INSULATOR,
TUBE,
contact
TUBE,
TUBE,
TUBE,contactl/l6wire
NOZZLE
NOZZLE
INSULATOR,
ADAPTER,
WASHER,
nozzle
NUT,
centering
-
tube
contact
phenolic
-
flat
LINER,monocoil
LINER,monocoil
LINER,monocoil
LINER,monocoil
ON
KITS
-
head
PAGE
ARE
tube
AVAILABLE
FOR
1
TO
IDENTIFICATION
10
.031
N
N
(0 (0
N N
o o
1
1
5
1
1
.9MM
.035
.035
N
N N
N
1 1
1
5
1 1
1
.8MM
.
CHANGE
Foot
1.2MM
.047
.045
C)
N
(0
N
0
OF
THE
ITEM
GUN
NUMBERS.
FROM
ONE
WIRE
Quantity
Model
Foot
15
.047
0
N
0
5
1
1
1
1
1.6MM
.063
1/16
N
0
CO
N
0
5
1
1
1
1
1
1
1.6MM
.063
1/16
~
N
N
(0
N
0
.8MM
.031
.030
0)
0
0
~
N
0
.9MM
1.2MM
.035
.035~
1
.045
0
0
N
0
1
1
5
5
5
5
1
1
1
1
1
1
1
1
1
1
.
.
1 1
1 1
1
1
1
BE
SURE TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Page
3
Page 9
Page 10
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