Miller Electric 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

Visit our website at

www.MillerWelds.com

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.

Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The

Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard.

parts list will then help you to decide the exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

Working as hard as you do

− every power source from Miller is backed by the most hassle-free warranty in the business.

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Mil_Thank 7/03

TRAILER TOWING SAFETY PRECAUTIONS

WARNING

TRAILER TOWING can be hazardous.

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.

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.

1 Coupler

Hitch is on towing vehicle.

2 Tongue 3 Lights 4 Wheels And

Bearings 5 Rating Plate 6 Jack Stand 7 Safety Chains

3. When towing, it takes longer to start, stop, and pass − use training and practice to avoid accidents.

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.

9. Do not modify or change the trailer in any way − changes void the warranty. Read Owner’s Manual.

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.

12. Tighten all parts, bolts, nuts, and mounting hardware.

OVERLOADING can cause serious injury or equipment damage.

1. Do not overload the trailer.

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-bearing capacity 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.

Rating

Plate

GVWR − Gross Vehicle Weight Rating (Maximum Total Trailer Weight Including Its Load)

GAWR − Gross Axle Weight Rating

VIN NO − Vehicle Identification Number

Trailer

And

Coupler

Class

Gross Vehicle Weight Rating

GVWR

lb (kg)

Up to 2000 (Up to 910)

2000 to 3500 (910 to 1590)

3500 to 5000

(1590 to 2270)

Tongue − Level

Bathroom

Scale

Approximately

10% Of GTW

Gross Trailer Maximum

Weight GTW

1000 (455) 2000 (910)

2000 (910)

3500 (1590)

lb (kg)

Tongue Weight

lb (kg)

100 (45) 200 (90)

200 (90)

350 (158)

Pipe

Board

Information From SAE

J684 May 1987

Gross Trailer Weight

(Actual Loaded Weight)

10% Of GTW

Recommended

Bottom

View

Side View

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.

2. Distribute weight so that trailer tongue weight is approximately 10% of the gross trailer weight.

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.

4. Remove or adjust trailer load to get correct tongue weight.

5. Do not let tongue weight exceed coupler and hitch rating.

6. Use slower speeds when towing a trailer − never above 45 mph (72 km/h) − to prevent fishtailing.

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 dropping to ground.

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.

safety_trailer 2/98 OM-6611 Page 1

Clevis

Lunette

Eye

Ball

Couplers

Safety Pin

Trailer

Tongue

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 match coupler.

2. Be sure the hitch is properly installed onto towing vehicle.

3. On optional ball couplers, always insert hitch safety pin before towing.

4. Make sure hitch and ball are properly sized and match each other.

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.

Lug

Nuts

Breakaway

Surge-Type

Side Marker Lights

Torquing Sequence

Wheel

Bearings

Inside Hub

Self-Actuating Hydraulic

Brake System

Cable

Coupler Bracket

INCORRECTLY WORKING LIGHTS can cause accidents.

1. State and Federal regulations require trailers used on highways

Tail, Stop, And

Turn Lights

to have tail, stop, turn, and side marker lights.

2. Lights are not required for trailers designed for off-road use only.

3. Check all lights and connectors for proper installation and operation before using the trailer.

4. Check condition of wiring harness leads, plugs, and connections regularly. Repair or replace damaged parts or wires.

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

4-Hole Wheels −

Torque Lug Nuts

To 60 ft-lbs (81 N·m)

5-Hole Wheels − Torque Lug Nuts

To 70 ft-lbs (95 N·m)

and equipment damage.

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. Maintain correct tire pressure according to sidewall data on tire − underinflation is the most common cause of tire trouble.

5. Check tires for wear every six months.

6. Use only replacement tires of the same size, rating, and capacity.

INOPERATIVE SURGE-TYPE BRAKES OR

Brake Fluid

Reservoir

WRONG BREAKAWAY CABLE CONNECTION can cause accidents.

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.

5. The breakaway cable automatically applies the trailer brakes if separation occurs.

safety_trailer 8/03OM-6611 Page 2

LOOSE OR INCORRECT HARDWARE AND FASTENERS can cause injury and damage.

1. Periodically double-check all nuts and bolts for tightness and

Grade Marks.

Manufacturer’s

Identification Mark

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 original bolt. The manufacture’s identification mark is not critical and does not matter for the replacement fastener.

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 reproductive harm. Wash hands after handling.

PRINCIPAL SAFETY STANDARDS

Trailer & Camper Safety, Publication # DOT HS-802586, from U.S. Department of Transportation, National Highway Traffic Safety Administration, Washington, D.C. 20590

Safety and Health Standards, OSHA 49 CFR 200 to 999, from Superintendent 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

SAE Handbook. 1996. Volume 4. On-Highway Vehicles and Off-High- way Machinery, from Society of Automotive Engineers, Inc., 400 Commonwealth Drive, Warrendale, PA 15096-0001.

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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safety_trailer 2/98 OM-6611 Page 3

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.

. 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 summary of the more complete safety information found in the Safety Standards. Read and follow all Safety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y During operation, keep everybody, especially children, away.

FALLING UNIT can cause injury.

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 opposite side of unit or parts to prevent tipping.

D Have two people of adequate physical strength

lift trailer parts.

This group of symbols means Warning! Watch Out! possible FALLING EQUIPMENT and TILTING OF TRAILER hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

TILTING OF TRAILER can cause injury.

D Use tongue jack or blocks to support weight. D Properly install welding generator onto trailer

according to instructions.

READ INSTRUCTIONS.

D Use only genuine replacement parts from

manufacturer.

D Perform maintenance according to this

manual.

FLYING METAL, DIRT can injure eyes.

D Wear approved safety glasses with side

shields when assembling and maintaining trailer.

Read and follow all trailer towing Safety Precautions at beginning of manual before using this trailer.

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SECTION 2 − SPECIFICATIONS

NOTE

This trailer is not compatible with equipment made prior to Serial No. LB033208.

2-1. Trailer Specifications

Specification Description

Gross Axle Weight Rating 2700 lb (1225 kg)

Gross Vehicle Weight Rating 2500 lb (1134 kg)

Net Payload 2250 lb (1021 kg)

Road Clearance Unloaded: 8 in (203 mm); Loaded: 6-1/2 in (165 mm)

Height Of Bed Unloaded: 12 in (305 mm); Loaded 10-1/2 in (267 mm)

Track (Center To Center) 49-1/2 in (1257 mm)

Standard Tires B-78-13C

Weight Net: 285 lb (129 kg)

2-2. Overall Dimensions

Inches Millimeters

A Loaded: 10-1/2 267

Unloaded: 12 305

B 11-1/2 292

C 27-1/2 699

D 59 1499

E 98 2489

802 323

OM-6611 Page 5

SECTION 3 − ASSEMBLY

NOTE

This trailer is not compatible with equipment made prior to Serial No. LB033208.

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 Stop engine, and let cool.

Disconnect battery negative (−) cable.

Y 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 Mounting Bracket 2 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).

Tools Needed:

9/16 in

Ref. 190 250-A / Ref. 802 729

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