Miller Electric Welding System RCT 224 Trailer User Manual

OM-6611  
201 233A  
September 2004  
Description  
Two-Wheel Trailer For Engine-Driven  
Welding Generators  
RCT-224 Trailer  
This Trailer Is Not Compatible With Equipment  
Made Prior To Serial No. LB033208  
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TRAILER TOWING SAFETY PRECAUTIONS  
TRAILER TOWING can be hazardous.  
WARNING  
In trailer towing, as in most driving situations, exposure to certain hazards occurs. Trailer towing is safe when  
precautions are taken. The following safety information is only a summary of the more complete information found in  
the Safety Standards listed at the end of these precautions. Read and follow all Safety Standards. In addition, the  
end user must check and comply with all federal, state, and local laws before use.  
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY  
QUALIFIED PEOPLE.  
3
1
Coupler  
3. When towing, it takes longer to start, stop, and pass use  
training and practice to avoid accidents.  
Hitch is on towing vehicle.  
4. Turning and backing up present new problems plan ahead.  
5. Require each driver to be fully trained and experienced in trailer  
towing before going out on the road.  
6. Holes are provided for mounting weld/power generator.  
7. Be sure trailer is fully prepared and connected to towing vehicle.  
8. Observe maximum speed of 45 mph (72 kph) when towing.  
2
3
4
Tongue  
Lights  
2
Wheels And  
Bearings  
Rating Plate  
Jack Stand  
1
7
3
4
5
6
7
5
3
9. Do not modify or change the trailer in any way changes void the  
warranty. Read Owner’s Manual.  
6
Safety Chains  
10. Use only genuine factory parts as replacements.  
11. Adjust load on trailer so tongue weight is approximately 10% of  
the gross trailer weight and center load side-to-side to reduce  
fishtailing.  
1. Use a towing vehicle prepared and capable of handling the load.  
2. Towing any trailer requires special awareness because of the  
changed driving situation.  
12. Tighten all parts, bolts, nuts, and mounting hardware.  
OVERLOADING can cause serious injury or  
equipment damage.  
1. Do not overload the trailer.  
GVWR Gross Vehicle  
Weight Rating (Maximum  
Total Trailer Weight In-  
cluding Its Load)  
2. The Gross Vehicle Weight Rating (GVWR) is the maximum total  
trailer weight with the engine driven welding generator and all  
equipment, such as tools, cables, and shielding gas cylinder,  
installed.  
3. The Gross Axle Weight Rating (GAWR) is the maximum  
load-bearingcapacity of the axle(s).  
4. Weigh trailer adjust weight by removing accessory equipment if  
necessary call local authorities for nearest scale location.  
5. Use gross trailer weight to select a proper towing vehicle.  
GAWR  
Gross Axle  
Weight Rating  
VIN NO Vehicle Identifi-  
cation Number  
Rating  
Plate  
UNCONTROLLED TILTING OF TRAILER can result  
in personal injury or equipment damage.  
1. Install generator according to Owner’s Manual with engine end  
toward hitch end of trailer.  
Tongue Level  
2. Distribute weight so that trailer tongue weight is approximately  
10% of the gross trailer weight.  
Bathroom  
Scale  
Pipe  
INCORRECT TONGUE WEIGHT can cause  
fishtailing and loss of control of towing vehicle  
resulting in serious injury and equipment damage.  
3. Tongue weight is the amount of trailer weight that rests on the  
towing vehicle hitch that is, the downward pressure on the  
coupler.  
Approximately  
10% Of GTW  
Board  
Trailer Gross Vehicle  
Gross Trailer  
Weight GTW  
lb (kg)  
Maximum  
And  
Weight Rating  
GVWR  
2
3
Tongue Weight  
lb (kg)  
Coupler  
1
Class  
lb (kg)  
Up to 2000  
(Up to 910)  
1000 (455)  
2000 (910)  
100 (45)  
200 (90)  
1
2
1
2
3
Information From SAE  
J684 May 1987  
4. Remove or adjust trailer load to get correct tongue weight.  
5. Do not let tongue weight exceed coupler and hitch rating.  
2000 to 3500  
2000 (910)  
200 (90)  
350 (158)  
Gross Trailer Weight  
(Actual Loaded Weight)  
(910 to 1590) 3500 (1590)  
6. Use slower speeds when towing a trailer never above 45 mph  
3500 to 5000  
3500 (1590)  
10% Of GTW  
Recommended  
3
350 (158)  
(72 km/h) to prevent fishtailing.  
(1590 to 2270)  
SAFETY CHAINS CAN PREVENT RUNAWAY  
TRAILER in case hitch/coupler fails.  
1. Always use safety chains when towing.  
2. Cross safety chains under coupling to prevent tongue from  
droppingto ground.  
Bottom  
View  
3. Allow only enough slack for tight turns.  
4. Do not let safety chains drag on ground.  
5. Twist safety chains equally from hook ends to take up slack.  
6. Use safety chains rated equal to or greater than twice the  
maximum gross trailer weight rating.  
Side  
View  
safety_trailer 2/98  
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Couplers  
OR  
INCORRECT SIZE OR RATING OF HITCH can  
cause trailer to break loose from towing vehicle.  
1. Be sure towing vehicle hitch is correct type, size, and rating to  
Clevis  
match coupler.  
2. Be sure the hitch is properly installed onto towing vehicle.  
3. On optional ball couplers, always insert hitch safety pin before  
Trailer  
Tongue  
towing.  
Lunette  
Eye  
4. Make sure hitch and ball are properly sized and match each  
other.  
Ball  
Safety Pin  
WHEELS MUST BE CHOCKED when trailer is  
uncoupled from vehicle.  
1. Chock in direction of grade.  
2. Position chock snugly behind tire.  
3. Place chock square to the tire.  
4. Tap chock into place.  
5. For added protection, chock both sides of tire.  
UNEXPECTED TILTING OF TRAILER can cause  
injury and damage.  
1. When trailer is uncoupled from towing vehicle, use jack on front  
and block rear to prevent tilting.  
2. Use proper blocks that are large enough and able to support the  
necessary weight.  
3. Always chock the wheels when uncoupled.  
INCORRECTLY WORKING LIGHTS can cause  
accidents.  
1. State and Federal regulations require trailers used on highways  
to have tail, stop, turn, and side marker lights.  
Tail, Stop, And  
Turn Lights  
2. Lights are not required for trailers designed for off-road use only.  
3. Check all lights and connectors for proper installation and  
operationbefore using the trailer.  
4. Check condition of wiring harness leads, plugs, and connections  
regularly. Repair or replace damaged parts or wires.  
Side Marker Lights  
Torquing Sequence  
5. Replace any broken lenses, reflectors, or bulbs.  
INCORRECT TORQUE on lug nuts or INCORRECT  
TIRE PRESSURE or BEARING MAINTENANCE can  
cause loss of control resulting in serious injury  
and equipment damage.  
1
1. Recheck lug nut torque after first 50 miles (80 km) and once each  
year or every 12,000 miles (19,500 km) thereafter, whichever  
comes first.  
2. When checking lug nuts, keep them clean, dry, and unlubricated.  
3. Check and repack wheel bearings once each year or every  
12,000 miles (19,500 km), whichever comes first.  
4-Hole Wheels −  
Torque Lug Nuts  
3
4
To 60 ft-lbs (81 N·m)  
2
1
4. Maintaincorrect tire pressure according to sidewall data on tire −  
underinflationis the most common cause of tire trouble.  
3
4
Wheel  
5-Hole Wheels −  
Torque Lug Nuts  
To 70 ft-lbs (95 N·m)  
Lug  
Nuts  
5. Check tires for wear every six months.  
6. Use only replacement tires of the same size, rating, and capacity.  
Bearings  
Inside Hub  
5
2
Self-Actuating Hydraulic  
Brake System  
INOPERATIVE  
SURGE-TYPE BRAKES OR  
WRONG BREAKAWAY CABLE CONNECTION can  
cause accidents.  
Brake Fluid  
Reservoir  
Breakaway  
Cable  
1. Check brake fluid level before use.  
2. Do not use sway control devices keep coupler free to telescope  
during braking.  
3. Always connect breakaway cable to towing vehicle be sure it  
has a direct free pull.  
4. Do not wrap cable around safety chains, tongue, wiring, or any  
other parts.  
Surge-Type  
Coupler  
Bracket  
5. The breakaway cable automatically applies the trailer brakes if  
separation occurs.  
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LOOSE OR INCORRECT HARDWARE AND  
FASTENERS can cause injury and damage.  
1. Periodically double-check all nuts and bolts for tightness and  
condition.  
2. If necessary, always replace any fastener with one of equal  
size, grade, and type.  
3. Be sure the grade marks on replacement fastener match the  
originalbolt. The manufacture’s identification mark is not critical  
and does not matter for the replacement fastener.  
Grade Marks.  
Manufacturer’s  
Identification Mark  
PRE-TOWING CHECKLIST  
Check gross trailer weight, tongue weight, and total weight distribution do not overload this trailer.  
Check that the correct hitch is properly installed on towing vehicle.  
When coupling, check that coupler locking device (safety pin), safety chains, and breakaway cable (if applicable) are properly connected.  
Check that tires are properly inflated and that wheel nuts are properly torqued.  
If applicable, check that all lights are working properly.  
CALIFORNIA PROPOSITION 65 WARNINGS  
Y
Welding or cutting equipment produces fumes or gases which  
contain chemicals known to the State of California to cause  
birth defects and, in some cases, cancer. (California Health &  
Safety Code Section 25249.5 et seq.)  
Y
Battery posts, terminals and related accessories contain lead  
and lead compounds, chemicals known to the State of  
California to cause cancer and birth defects or other  
reproductiveharm. Wash hands after handling.  
PRINCIPAL SAFETY STANDARDS  
Trailer & Camper Safety, Publication # DOT HS-802586, from U.S. De-  
partment of Transportation, National Highway Traffic Safety Adminis-  
tration, Washington, D.C. 20590  
SAE Handbook. 1996. Volume 4. On-Highway Vehicles and Off-High-  
way Machinery, from Society of Automotive Engineers, Inc., 400 Com-  
monwealthDrive, Warrendale, PA 15096-0001.  
Safety and Health Standards, OSHA 49 CFR 200 to 999, from Superin-  
tendent of Documents, U.S. Government Printing Office, Washington,  
D.C. 20402  
REPORTING SAFETY DEFECTS  
If you believe that your vehicle has a defect which  
could cause a crash or could cause injury or death,  
you should immediately inform the National Highway  
Traffic Safety Administration (NHTSA) in addition to  
notifying MILLER Electric Mfg. Co.  
If NHTSA receives similar complaints, it may open an  
investigation, and if it finds that a safety defect exists  
in a group of vehicles, it may order a recall and remedy  
campaign. However, NHTSA cannot become  
involved in individual problems between you, your  
dealer, or MILLER Electric Mfg. Co.  
To contact NHTSA, you may either call the Auto  
Safety Hotline toll-free at 1-800-424-9393 (or  
366-0123 in Washington, D.C. area) or write to:  
NHTSA, U.S. Department of Transportation,  
Washington D.C. 20590. You can also obtain other  
information about motor vehicle safety from the  
Hotline.  
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Section 1 ASSEMBLY SAFETY PRECAUTIONS  
1-1. Symbol Usage  
Means Warning! Watch Out! There are possible hazards  
with this procedure! The possible hazards are shown in  
the adjoining symbols.  
Y
Marks a special safety message.  
This group of symbols means Warning! Watch Out! possible FAL-  
LING EQUIPMENT and TILTING OF TRAILER hazards. Consult  
symbols and related instructions below for necessary actions to avoid  
the hazards.  
. Means “Note”; not safety related.  
1-2. Assembly Hazards  
Y
The symbols shown below are used throughout this manual to  
call attention to and identify possible hazards. When you see  
the symbol, watch out, and follow the related instructions to  
avoid the hazard.The safety information given below is only a  
summaryof the more complete safety information found in the  
Safety Standards. Read and follow all Safety Standards.  
TILTING OF TRAILER can cause injury.  
D
D
Use tongue jack or blocks to support weight.  
Properly install welding generator onto trailer  
according to instructions.  
Y
Y
Only qualified persons should install, operate, maintain, and  
repair this unit.  
READ INSTRUCTIONS.  
During operation, keep everybody, especially children, away.  
D
Use only genuine replacement parts from  
manufacturer.  
FALLING UNIT can cause injury.  
D
Perform maintenance according to this  
manual.  
D
Use equipment and blocks of adequate capac-  
ity and size to lift and support unit.  
D
If using lift forks to move unit or parts, be sure  
forks are long enough to extend beyond oppo-  
site side of unit or parts to prevent tipping.  
Have two people of adequate physical strength  
lift trailer parts.  
FLYING METAL, DIRT can injure eyes.  
D
Wear approved safety glasses with side  
shields when assembling and maintaining  
trailer.  
D
Read and follow all trailer towing Safety Precautions at beginning of manual before using this  
trailer.  
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SECTION 2 SPECIFICATIONS  
This trailer is not compatible with equipment made prior to Serial No. LB033208.  
NOTE  
2-1. Trailer Specifications  
Specification  
Description  
Gross Axle Weight Rating  
Gross Vehicle Weight Rating  
Net Payload  
2700 lb (1225 kg)  
2500 lb (1134 kg)  
2250 lb (1021 kg)  
Road Clearance  
Unloaded: 8 in (203 mm); Loaded: 6-1/2 in (165 mm)  
Unloaded: 12 in (305 mm); Loaded 10-1/2 in (267 mm)  
49-1/2 in (1257 mm)  
Height Of Bed  
Track (Center To Center)  
Standard Tires  
B-78-13C  
Weight  
Net: 285 lb (129 kg)  
2-2. Overall Dimensions  
Inches  
Millimeters  
A
Loaded:10-1/2  
Unloaded: 12  
267  
305  
B
C
D
E
11-1/2  
27-1/2  
59  
292  
699  
1499  
2489  
98  
D
B
C
A
E
802 323  
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SECTION 3 ASSEMBLY  
This trailer is not compatible with equipment made prior to Serial No. LB033208.  
NOTE  
All directions are given as facing the towing vehicle. The word “front” means the  
hitch end of the trailer.  
3-1. Preparing Unit For Kit Installation  
Y
Y
Stop engine, and let cool.  
Disconnect battery negative  
() cable.  
Do not weld on base. Weld-  
ing on base can cause fuel  
tank fire or explosion. Weld  
only on the four mounting  
brackets or bolt unit down.  
. Go to Section 3-2 if mounting  
brackets are already installed  
as shown.  
1
1
2
Mounting Bracket  
3/8-16 x 1 in Screws  
(Supplied)  
Remove hardware securing the  
rear mounting brackets to the base.  
Reverse rear brackets and reattach  
to base with original hardware.  
Tighten hardware to 30 ft lb (41  
.
N m).  
2
Tools Needed:  
9/16 in  
Ref. 190 250-A / Ref. 802 729  
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3-2. Mounting Wheels And Brackets On Axles  
. Use hardware in Red bag to  
mount wheels.  
1
2
3
Wheel  
Hub  
4
Lug Nut  
Install wheels on hubs. Install lug  
.
nuts and tighten to 70 ft lb (95 N m).  
6
5
1
4
5
6
7
MountingBracket  
1/2-13 x 1-1/2 in Screw  
1/2 ID Flat Washer  
1/2 ID Lock Nut  
2
Attach mounting brackets to brack-  
ets on axle. Save remaining hard-  
ware to mount unit on trailer (see  
Section 3-7).  
7
6
. Do not tighten hardware until  
unit is mounted on trailer (see  
Sections 3-7 and 3-8).  
3
Tools Needed:  
3/4, 13/16 in  
3/4 in  
802 812  
3-3. Mounting Axle On Frame  
All directions are given as facing the towing vehicle. The word “front” means the  
hitch end of the trailer.  
NOTE  
1
2
3
4
5
6
7
Axle Assembly  
Welded Stop  
Frame  
1
6
7
Plate  
3/8-16 x 4 in Screw  
3/8 ID Flat Washer  
3/8 ID Lock Nut  
4
Position frame against the right side of  
the welded stop on the axle. Attach  
axle to frame using supplied hardware.  
6
.
5
Tighten hardware to 30 ft lb (41 N m).  
8
Jack  
Pull pin and rotate jack to vertical posi-  
tion. Pin locks jack in place. Turn han-  
dle to raise or lower trailer.  
2
When jack is not needed, pull pin and  
rotate jack to horizontal position.  
3
Tools Needed:  
8
9/16 in  
9/16 in  
802 813  
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3-4. Installing Hitch And Safety Chains  
Lunette Eye Hitch  
Optional Ball Hitch  
8
5
3
7
4
9
3
5
4
6
2
9
6
2
8
10  
11  
1
Tools Needed:  
5/8, 3/4 in  
11/16, 3/4 in  
Ref. 802 813  
Y
Use adequate blocks or lifting de-  
vice to support frame while instal-  
ling parts.  
Support trailer with jack. Block  
wheels.  
7
8
9
Lunette Eye Hitch  
1/2-13 x 4 in Screw  
1/2 ID Lock Nut  
10 Ball Hitch (Optional)  
11 Safety Pin  
Y
Attach hitch to tongue as shown using sup-  
plied 1/2 in hardware. Make sure bolts are  
installed horizontally as shown.  
1
Wheel Block  
Attach lunette eye to top of tongue as  
shown using supplied 1/2 in hardware.  
Block wheels.  
.
2
3
4
5
6
Safety Chain  
Chain Bracket  
7/16-14 x 2-1/2 Screw  
7/16 ID Flat Washer  
7/16 ID Lock Nut  
Tighten hardware to 75 ft lb (102 N m).  
.
Tighten hardware to 75 ft lb (102 N m).  
Set trailer onto towing ball and push lever  
down. Insert safety pin through hole in lever  
to secure hitch.  
Connect trailer to towing vehicle.  
Attach chain to bracket with 7/16 in hard-  
Cross safety chains under tongue and at-  
tach to towing vehicle.  
Cross safety chains under tongue and at-  
tach to towing vehicle.  
.
ware. Tighten hardware to 31 ft lb (40 N m).  
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3-5. Installing Taillight And Sidelight Wiring  
Brown And  
Green Leads  
2
Brown And  
Yellow Leads  
Brown  
Lead  
Use tab connectors to  
splice sidelight brown  
leads to taillight brown  
leads. Tuck connector  
through hole in frame.  
Brown  
Lead  
1
Slide clips on frame  
to secure wiring.  
Tools Needed:  
802 814  
Y
Support trailer with jack. Block ward right wheel and brown and yellow leads and yellow leads. Discard green and yellow  
wheels.  
along axle to left wheel. Secure wiring to axle leads.  
with supplied cable ties.  
1
2
Wiring Clips  
Grommet  
Splice sidelight short leads to wiring harness  
brown leads using supplied tab connector  
(see Section 3-6). Route brown leads along  
top of frame and along back of crossmember.  
Secure leads with wiring clips and cable ties.  
Cut 45 in (1143 mm) from brown, green, and  
yellow leads. Save cutoff wiring for connect-  
ing side lights. Install taillights and sidelights  
Locate wiring harness (packaged with tail-  
lights).  
Route wiring harness leads through trailer  
frame and out hole near axle. Slide grommet  
over leads and install grommet in hole.  
Install wiring for other sidelight the same way.  
To install sidelight wiring: Use 45 in (1143  
mm) wiring saved from taillight wiring to wire Install sleeving on taillight and harness plug  
Route brown and green leads along axle to- sidelights. Separate brown leads from green electrical leads.  
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3-6. Installing Wiring Harness Tab Connectors  
Disconnect vehicle wiring harness plug from trailer wiring connector before  
beginning installation. Use wiring harness tab connectors only with insulated wires.  
NOTE  
1
3
4
5
2
Ref. S-0448  
1
2
3
Connector  
Run Wire  
Tap Wire  
Insert unstripped tap wire into other channel  
until it hits internal stop.  
Use pliers to push contact down flush with  
top of connector.  
4
5
Contact  
Place unstripped run wire in slotted channel.  
9 Inch Linemans Pliers  
Close top cover.  
Notes  
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3-7. Mounting Welding Generator  
This trailer is not compatible with equipment made prior to Serial No. LB033208.  
NOTE  
RecommendedLifting Procedure  
Y
Do not use lifting eye to lift unit dur-  
ing this procedure. Mounting the  
unit requires removal of center up-  
right hardware and lifting eye will not  
safely support unit with hardware  
removed.  
Y
Y
Use equipment of adequate capacity  
to lift the generator.  
Support front of trailer with jack.  
Support rear of trailer with blocks.  
Block wheels.  
Y
Y
If trailer is not installed on vehicle,  
use trailer jack to obtain desired  
height and to support tongue weight  
while installing welding generator.  
Y
Do not use lifting  
eye to lift unit.  
Install welding generator on trailer  
with engine end toward hitch end of  
trailer.  
See  
warning  
statements.  
. Use remaining mounting bracket hard-  
ware to mount welding generator (see  
. When properly installed, tongue weight  
is 7 8 % of gross trailer weight.  
1
2
3
5/8-11 x 1-1/2 Screw  
5/8 ID Lock Nut  
3/8-16 x 3/4 Self Tapping Screw  
Remove bottom screws securing welding  
generator center upright. Discard screws.  
Install mounting screws in base far enough  
to tap holes. Remove mounting screws.  
Place generator on trailer so front panel  
faces rear. Align holes in base with holes in  
trailer mounting brackets. Install 3/8 in.  
self-tapping screws and tighten to 30 ft  
.
lb (41 N m).  
Install 5/8 in. center upright screws and  
.
tighten to 150 ft lb (203 N m).  
Tighten 1/2 in hardware (installed in Sec-  
tion 3-2) on bottom of mounting bracket  
.
to 75 ft lb (101 N m).  
Tighten 5/8 in. front mounting bracket  
.
hardware to 150 ft lb (203 N m).  
1
3
3
Tools Needed:  
Remove center upright  
bottom screw and re-  
place with supplied  
5/8-11 x 1-1/2 Screw.  
1/2, 9/16, 3/4, 15/16 in  
9/16, 3/4, 15/16 in  
2
802 817 / 802 818  
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3-8. Tightening Trailer Hardware  
Final-tighten trailer hardware installed in  
earlier steps to torque values shown.  
Tighten  
to 30 ft lb  
.
(41 N m).  
Tighten lug  
nuts to 70 ft  
.
lb (95 N m).  
Tighten to  
75 ft lb  
.
(102 N m).  
Tighten to  
150 ft lb  
.
(203 N m).  
Tighten to  
150 ft lb  
.
(203 N m).  
Tighten to 30  
Tools Needed:  
.
ft lb (41 N m).  
1/2, 9/16, 3/4, 15/16 in  
Tightento 75 ft  
.
lb (101 N m).  
9/16, 3/4, 15/16 in  
802 817 / 802 818  
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3-9. Mounting Fenders  
4
3
2
1
5
7
8
4
6
8
8
9
9
7
Tools Needed:  
1/2, 9/16 in  
802 818  
4
5
6
7
8
9
3/8 Star Washer  
Light Bracket  
Fender  
Mount front and rear fender brackets using  
supplied 3/8 in self-tapping screws, star  
washers, and existing holes in welding gen-  
erator base.  
. Use hardware in green bag to mount  
fenders  
. The front and rear fender brackets are  
not interchangeable.  
Be sure to install star washers between rear  
fender brackets and base, and between  
rear fender brackets and light brackets.  
3/8-16 x 1-1/2 Screw  
3/8 ID Flat Washer  
3/8 Lock Nut  
1
2
3
Front Fender Bracket  
Rear Fender Bracket  
Mount fenders on fender brackets using  
supplied 3/8 in hardware.  
3/8-16 x 3/4 Self-Tapping Screw  
OM-6611 Page 13  
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3-10. Installing Taillight And Sidelight Wiring  
4
2
5
6
7
Tools Needed:  
3
1
8
9
2
7/16, 9/16, 10 mm  
1/4 in  
Wiring Connections:  
Sidelight  
RIGHT  
Green  
Lead  
Right Stop/  
Short  
Lead  
Tab  
Signal Lamps  
Connector  
(Green)  
Left Stop/  
To Vehicle  
To Trailer  
Brown Lead  
Brown Lead  
Signal Lamps  
(Yellow)  
Taillights  
Taillights  
(Brown)  
Tab  
Connector  
Short  
Lead  
Ground  
(White)  
Yellow  
Lead  
White Ground Lead  
(Ground To Trailer Frame)  
LEFT  
Sidelight  
802 074-A / 802 818  
Y
Support trailer with jack. Block  
wheels.  
8
9
Sidelight  
8-32 x 5/8 Self-Tapping Screw  
Insert stripped end of brown leads into TAIL  
(BROWN) holes in each light.  
Mount taillights and license holder on brack-  
ets using supplied 1/4 in hardware.  
. Use hardware in green bag to install  
To connect taillights: Strip insulation from  
end of white ground lead and crimp on sup-  
plied ring terminal. Attach ground lead ring  
terminal to chain bracket using 3/4 in sheet  
metal screw.  
lights.  
To connect sidelights:  
1
2
3
4
5
6
7
Wiring Harness White Ground Lead  
Sleeving  
Connect brown lead to sidelight.  
3/4 Sheet Metal Screw  
Taillight  
Strip 1/2 in (12.7 mm) insulation from ends of  
taillightbrown, green, and yellow leads.  
Mount sidelight on frame using supplied self-  
tapping screws.  
Insert stripped end of green lead into right tail-  
light hole marked STOP & TURN (GREEN).  
License Plate Holder  
1/4 ID Lock Washer  
1/4 ID Nut  
Install other sidelight the same way.  
Insert stripped end of yellow lead into left tail- Install sleeving on taillight and harness plug  
light hole marked STOP & TURN (YELLOW). electrical leads.  
OM-6611 Page 14  
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3-11. Maintenance  
Do not use trailer if any part is damaged or not working properly. When performing  
maintenance, check trailer for worn, damaged, or non-working parts. Check for  
free rotation of assemblies mounted on bushings or bearings.  
NOTE  
Y
Y
Support trailer with jack.  
Block wheels.  
Do not put any body part un-  
der trailer while lifting or per-  
forming maintenance.  
Once a year, lubricate all moving  
parts on trailer with SAE 20W oil.  
Lubricate more often if trailer is ex-  
posed to elements or subject to fre-  
quent off-road use.  
1
Wheel Bearings  
Every 12,000 miles, check wheel  
bearings. Repack bearings if nec-  
essary using a good quality lithium-  
based extreme pressure grease.  
Replace trailer hardware  
only with SAE hardware of  
same grade, type and size  
as originally installed.  
When reinstalling wheels, be sure  
wheel nuts are properly tightened  
(see Trailer Towing Safety Precau-  
tions at beginning of manual).  
1
Tools Needed:  
802 819  
OM-6611 Page 15  
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3-12. Torquing Wheel Bearings  
Y
Loss of control hazard. To  
prevent injury and damage,  
check and repack wheel  
bearings once a year or ev-  
ery 12,000 miles (19,500  
km), whichever comes  
first.  
Y
Y
Use proper equipment to  
lift and support unit.  
Do not put any body part  
under trailer while lifting or  
performing maintenance.  
. Torque wheel bearings when-  
ever hub nut is removed or  
hub is too loose.  
Repack bearings according to  
Section 3-11.  
0.01 in (0.2 mm)  
endplay maximum  
Check hub endplay. If loose,  
remove wheel and go to next step.  
Remove cap and cotter pin.  
Tools Needed:  
13/16, 1-1/2 in  
Torque to 12 ft lb  
(16 N·m)  
Torque nut while turning hub forward.  
Turn nut until “just loose.”  
Y
Do not loosen nut  
more than 1/8 turn  
in this step.  
Y
Pin must not rub on  
cap.  
Further loosen nut until first slot  
in nut aligns with hole in spindle.  
Install new cotter pin and bend ends around nut. Install cap.  
Install wheel (See Safety Precautions) and recheck endplay.  
Ref. 800 441-B  
OM-6611 Page 16  
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Notes  
OM-6611 Page 17  
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SECTION 4 PARTS LIST  
9
. Hardware is common and  
not available unless listed.  
8
5
6
7
4
3
2
1
12  
9
10  
14  
11  
13  
15  
16  
802 736A  
Figure 4-1. Complete Assembly  
OM-6611 Page 18  
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Item  
No.  
Part  
No.  
Description  
Quantity  
. . . 1 . 199 860 . . . . . . . . . . . Chain, Safety Kit W/Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 2 . 043 824 . . . . . . . . . . Hitch, 21/2 In Lunnette Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 3 . 202 542 . . . . . . . . . . . Axle, Drawbar Assy (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . 202 541 . . . . . . . . . . . . Axle, 2700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . 202 543 . . . . . . . . . . . . Drawbar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . 202 544 . . . . . . . . . . . . Brkt, Mtg Axle W/Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 4 . 202 545 . . . . . . . . . . . Plates, Mtg Machine W/Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . 202 693 . . . . . . . . . . Hardware Kit, Mounting Machine 7/16 Rct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 5 . 202 835 . . . . . . . . . . Fender Assy (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 6 . 189 580 . . . . . . . . . . . . Fender, Poly (80) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 7 . 202 685 . . . . . . . . . . . . Bracket, Mtg Fender Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 7 . 202 686 . . . . . . . . . . . . Bracket, Mtg Fender Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . 202 690 . . . . . . . . . . . . Fender, Hrdw Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 8 . 189 582 . . . . . . . . . . . Guard, Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 9 . 189 577 . . . . . . . . . . . Light, Kit (includes trailer wiring harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 10 . 088 879 . . . . . . . . . . . Wheel Nuts, .50020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
. . . 11 . 189 576 . . . . . . . . . . . Tire, 13 in C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 12 . 189 575 . . . . . . . . . . . Hub, Axle #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . 167 787 . . . . . . . . . . . Kit, Bearing 13/8 11/16 Tapered Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 13 . 189 586 . . . . . . . . . . . Jack, Screw W/Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . 189 587 . . . . . . . . . . . Jack, Ret Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 15 . . . . . . . . . . . . . . . . . . . . . Harness, Trailer (included with Item 9, Light Kit) . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 16 . 189 585 . . . . . . . . . . Hitch, ball 2 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
OPTIONAL  
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested  
Replacement Parts. Model and serial number required when ordering parts from your local distributor.  
OM-6611 Page 19  
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Effective January 1, 2004  
(Equipment with a serial number preface of “LE” or newer)  
This limited warranty supersedes all previous Miller warranties and is exclusive with no other  
guarantees or warranties expressed or implied.  
Warranty Questions?  
LIMITED WARRANTY Subject to the terms and conditions  
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to  
its original retail purchaser that new Miller equipment sold after  
the effective date of this limited warranty is free of defects in  
material and workmanship at the time it is shipped by Miller.  
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER  
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE  
WARRANTIES OF MERCHANTABILITY AND FITNESS.  
*
*
*
*
*
*
*
Induction Heating Coils and Blankets  
APT & SAF Model Plasma Cutting Torches  
Remote Controls  
Call  
1-800-4-A-MILLER  
for your local  
Miller distributor.  
Accessory Kits  
Replacement Parts (No labor)  
Spoolmate Spoolguns  
Within the warranty periods listed below, Miller will repair or  
replace any warranted parts or components that fail due to such  
defects in material or workmanship. Miller must be notified in  
writing within thirty (30) days of such defect or failure, at which  
time Miller will provide instructions on the warranty claim  
procedures to be followed.  
Canvas Covers  
Your distributor also gives  
you ...  
Miller’s True BlueLimited Warranty shall not apply to:  
Service  
1. Consumable components; such as contact tips,  
cutting nozzles, contactors, brushes, slip rings,  
relays or parts that fail due to normal wear. (Exception:  
brushes, slip rings, and relays are covered on Bobcat,  
Trailblazer, and Legend models.)  
You always get the fast,  
reliable response you  
need. Most replacement  
parts can be in your  
hands in 24 hours.  
Miller shall honor warranty claims on warranted equipment  
listed below in the event of such a failure within the warranty  
time periods. All warranty time periods start on the date that the  
equipment was delivered to the original retail purchaser, or one  
year after the equipment is sent to a North American distributor  
or eighteen months after the equipment is sent to an  
International distributor.  
2. Items furnished by Miller, but manufactured by others,  
such as engines or trade accessories. These items are  
covered by the manufacturer’s warranty, if any.  
Support  
Need fast answers to the  
tough welding questions?  
Contact your distributor.  
The expertise of the  
distributor and Miller is  
there to help you, every  
step of the way.  
3. Equipment that has been modified by any party other than  
Miller, or equipment that has been improperly installed,  
improperly operated or misused based upon industry  
standards, or equipment which has not had reasonable  
and necessary maintenance, or equipment which has  
been used for operation outside of the specifications for the  
equipment.  
1. 5 Years Parts — 3 Years Labor  
*
*
Original main power rectifiers  
Inverters (input and output rectifiers only)  
2. 3 Years — Parts and Labor  
*
*
*
*
Transformer/Rectifier Power Sources  
Plasma Arc Cutting Power Sources  
Semi-Automatic and Automatic Wire Feeders  
Inverter Power Sources (Unless Otherwise Stated)  
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND  
USE BY COMMERCIAL/INDUSTRIAL USERS AND  
PERSONS TRAINED AND EXPERIENCED IN THE USE AND  
MAINTENANCE OF WELDING EQUIPMENT.  
*
*
*
*
Water Coolant Systems (Integrated)  
Intellitig  
Maxstar 150  
Engine Driven Welding Generators  
(NOTE: Engines are warranted separately by  
the engine manufacturer.)  
In the event of a warranty claim covered by this warranty, the  
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)  
replacement; or, where authorized in writing by Miller in  
appropriate cases, (3) the reasonable cost of repair or  
replacement at an authorized Miller service station; or (4)  
payment of or credit for the purchase price (less reasonable  
depreciation based upon actual use) upon return of the goods at  
customer’s risk and expense. Miller’s option of repair or  
replacement will be F.O.B., Factory at Appleton, Wisconsin, or  
F.O.B. at a Miller authorized service facility as determined by  
Miller. Therefore no compensation or reimbursement for  
transportation costs of any kind will be allowed.  
3. 1 Year — Parts and Labor Unless Specified  
*
*
DS-2 Wire Feeder  
Motor Driven Guns (w/exception of Spoolmate  
Spoolguns)  
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Process Controllers  
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES  
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE  
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR  
Positioners and Controllers  
Automatic Motion Devices  
RFCS Foot Controls  
Induction Heating Power Sources and Coolers  
Water Coolant Systems (Non-Integrated)  
Flowgauge and Flowmeter Regulators (No Labor)  
HF Units  
Grids  
Maxstar 85, 140  
Spot Welders  
Load Banks  
Arc Stud Power Sources & Arc Stud Guns  
Racks  
Running Gear/Trailers  
Plasma Cutting Torches (except APT & SAF  
Models)  
Field Options  
(NOTE: Field options are covered under True  
Bluefor the remaining warranty period of the  
product they are installed in, or for a minimum of  
one year — whichever is greater.)  
DIRECT,  
INDIRECT,  
SPECIAL,  
INCIDENTAL  
OR  
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF  
PROFIT), WHETHER BASED ON CONTRACT, TORT OR  
ANY OTHER LEGAL THEORY.  
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND  
ANY  
IMPLIED  
WARRANTY,  
GUARANTY  
OR  
REPRESENTATION AS TO PERFORMANCE, AND ANY  
REMEDY FOR BREACH OF CONTRACT TORT OR ANY  
OTHER LEGAL THEORY WHICH, BUT FOR THIS  
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION  
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,  
INCLUDING  
ANY  
IMPLIED  
WARRANTY  
OF  
MERCHANTABILITY OR FITNESS FOR PARTICULAR  
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT  
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED  
BY MILLER.  
Some states in the U.S.A. do not allow limitations of how long an  
implied warranty lasts, or the exclusion of incidental, indirect,  
special or consequential damages, so the above limitation or  
exclusion may not apply to you. This warranty provides specific  
legal rights, and other rights may be available, but may vary  
from state to state.  
*
In Canada, legislation in some provinces provides for certain  
additional warranties or remedies other than as stated herein,  
and to the extent that they may not be waived, the limitations  
and exclusions set out above may not apply. This Limited  
Warranty provides specific legal rights, and other rights may be  
available, but may vary from province to province.  
4. 6 Months — Batteries  
5. 90 Days — Parts  
*
MIG Guns/TIG Torches  
miller_warr 6/04  
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Owner’s Record  
Please complete and retain with your personal records.  
Model Name  
Purchase Date  
Distributor  
Address  
Serial/Style Number  
(Date which equipment was delivered to original customer.)  
City  
State  
Zip  
For Service  
to locate a DISTRIBUTOR or SERVICE AGENCY near you.  
Always provide Model Name and Serial/Style Number.  
Contact your Distributor for:  
Welding Supplies and Consumables  
Options and Accessories  
Personal Safety Equipment  
Service and Repair  
Miller Electric Mfg. Co.  
An Illinois Tool Works Company  
1635 West Spencer Street  
Appleton, WI 54914 USA  
Replacement Parts  
Training (Schools, Videos, Books)  
International HeadquartersUSA  
USA Phone: 920-735-4505 Auto-Attended  
USA & Canada FAX: 920-735-4134  
International FAX: 920-735-4125  
Technical Manuals (Servicing Information  
and Parts)  
Circuit Diagrams  
European Headquarters −  
United Kingdom  
Phone: 44 (0) 1204-593493  
FAX: 44 (0) 1204-598066  
Welding Process Handbooks  
www.MillerWelds.com  
Contact the Delivering Carrier to:  
File a claim for loss or damage during  
shipment.  
For assistance in filing or settling claims, contact  
your distributor and/or equipment manufacturer’s  
Transportation Department.  
PRINTED IN USA  
2004 Miller Electric Mfg. Co. 1/04  
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