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.

3

2

1

35

7

6

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

3

4

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

1

2

3

Gross Vehicle
Weight Rating

GVWR

1

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)

3500 (1590)

2

lb (kg)

Tongue Weight

lb (kg)

100 (45)
200 (90)

200 (90)

350 (158)

350 (158)

Pipe

Board

3

1

Information From SAE

J684 May 1987

2

Gross Trailer Weight

(Actual Loaded Weight)

3

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

OR

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

1

3

2

1

3

5

4-Hole Wheels −

4

Torque Lug Nuts

To 60 ft-lbs (81 N·m)

4

5-Hole Wheels −
Torque Lug Nuts

To 70 ft-lbs (95 N·m)

2

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.

mod11.1 8/94

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.

safety_trailer 8/03OM-6611 Page 4

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

D

C

A

B

E

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

1

2

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

OM-6611 Page 6

3-2. Mounting Wheels And Brackets On Axles

4

6

7

6

. Use hardware in Red bag to

mount wheels.

1 Wheel

2 Hub

3 Lug Nut

Install wheels on hubs. Install lug

5

2

1

nuts and tighten to 70 ft lb (95 N

4 Mounting Bracket

5 1/2-13 x 1-1/2 in Screw

6 1/2 ID Flat Washer

7 1/2 ID Lock Nut

Attach mounting brackets to brack­ets on axle. Save remaining hard­ware to mount unit on trailer (see
Section 3-7).

.

m).

. 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

3-3. Mounting Axle On Frame

NOTE

All directions are given as facing the towing vehicle. The word “front” means the
hitch end of the trailer.

6

5

3/4 in

802 812

1 Axle Assembly

1

2

3

7

6

4

2 Welded Stop

3 Frame

4 Plate

5 3/8-16 x 4 in Screw

6 3/8 ID Flat Washer

7 3/8 ID Lock Nut

Position frame against the right side of
the welded stop on the axle. Attach
axle to frame using supplied hardware.
Tighten hardware to 30 ft lb (41 N.m).

8 Jack

Pull pin and rotate jack to vertical posi­tion. Pin locks jack in place. Turn han­dle to raise or lower trailer.

When jack is not needed, pull pin and
rotate jack to horizontal position.

8

Tools Needed:

9/16 in

9/16 in

802 813

OM-6611 Page 7

3-4. Installing Hitch And Safety Chains

Lunette Eye Hitch Optional Ball Hitch

8

7

3

5

4

9

6

2

10

5

3

4

9

6

8

11

2

Y Use adequate blocks or lifting de-

vice to support frame while instal­ling parts.

Y Support trailer with jack. Block

wheels.

1 Wheel Block
Block wheels.
2 Safety Chain
3 Chain Bracket
4 7/16-14 x 2-1/2 Screw
5 7/16 ID Flat Washer
6 7/16 ID Lock Nut
Attach chain to bracket with 7/16 in hard-

ware. Tighten hardware to 31 ft lb (40 N.m).

OM-6611 Page 8

7 Lunette Eye Hitch

8 1/2-13 x 4 in Screw

9 1/2 ID Lock Nut

Attach lunette eye to top of tongue as
shown using supplied 1/2 in hardware.

Tighten hardware to 75 ft lb (102 N.m).

Connect trailer to towing vehicle.

Cross safety chains under tongue and at­tach to towing vehicle.

1

Tools Needed:

5/8, 3/4 in

11/16, 3/4 in

Ref. 802 813

10 Ball Hitch (Optional)

11 Safety Pin

Attach hitch to tongue as shown using sup­plied 1/2 in hardware. Make sure bolts are
installed horizontally as shown.

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.

Cross safety chains under tongue and at­tach to towing vehicle.

3-5. Installing Taillight And Sidelight Wiring

Brown
Lead

Brown And
Green Leads

2

Brown And
Yellow Leads

Use tab connectors to
splice sidelight brown
leads to taillight brown
leads. Tuck connector
through hole in frame.

Brown
Lead

Slide clips on frame
to secure wiring.

1

Tools Needed:

802 814

Y Support trailer with jack. Block

wheels.

1 Wiring Clips
2 Grommet
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.

Route brown and green leads along axle to-

ward right wheel and brown and yellow leads
along axle to left wheel. Secure wiring to axle
with supplied cable ties.

Cut 45 in (1143 mm) from brown, green, and
yellow leads. Save cutoff wiring for connect­ing side lights. Install taillights and sidelights
according to Section 3-10.

To install sidelight wiring: Use 45 in (1143
mm) wiring saved from taillight wiring to wire
sidelights. Separate brown leads from green

and yellow leads. Discard green and yellow
leads.

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.

Install wiring for other sidelight the same way.

Install sleeving on taillight and harness plug
electrical leads.

OM-6611 Page 9

3-6. Installing Wiring Harness Tab Connectors

NOTE

Disconnect vehicle wiring harness plug from trailer wiring connector before
beginning installation. Use wiring harness tab connectors only with insulated wires.

1

2

3

4

5

1 Connector
2 Run Wire
3 Tap Wire
Place unstripped run wire in slotted channel.

Notes

Insert unstripped tap wire into other channel
until it hits internal stop.

4 Contact

5 9 Inch Linemans Pliers

Ref. S-0448

Use pliers to push contact down flush with
top of connector.

Close top cover.

OM-6611 Page 10

3-7. Mounting Welding Generator

NOTE

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

Y Do not use lifting

eye to lift unit.
See warning
statements.

Recommended Lifting Procedure

Y Do not use lifting eye to lift unit dur-

ing this procedure. Mounting the
unit requires removal of center up­right hardware and lifting eye will not
safely support unit with hardware
removed.

Y Use equipment of adequate capacity

to lift the generator.

Y Support front of trailer with jack.

Support rear of trailer with blocks.
Block wheels.

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 Install welding generator on trailer

with engine end toward hitch end of
trailer.

. Use remaining mounting bracket hard-

ware to mount welding generator (see
Section 3-3).

. When properly installed, tongue weight

is 7 − 8 % of gross trailer weight.

1 5/8-11 x 1-1/2 Screw

2 5/8 ID Lock Nut

3 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 Sec­tion 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

Remove center upright
bottom screw and re­place with supplied

2

5/8-11 x 1-1/2 Screw.

3

Tools Needed:

1/2, 9/16, 3/4, 15/16 in

9/16, 3/4, 15/16 in

802 817 / 802 818

OM-6611 Page 11

3-8. Tightening Trailer Hardware

Tighten
to 30 ft lb
(41 N.m).

Final-tighten trailer hardware installed in
earlier steps to torque values shown.

Tighten lug
nuts to 70 ft

.

lb (95 N

m).

Tighten to
75 ft lb
(102 N.m).

OM-6611 Page 12

Tighten to
150 ft lb
(203 N.m).

Tighten to 30
ft lb (41 N

Tighten to
150 ft lb
(203 N.m).

.

m).

Tighten to 75 ft
lb (101 N

.

m).

Tools Needed:

1/2, 9/16, 3/4, 15/16 in

9/16, 3/4, 15/16 in

802 817 / 802 818

3-9. Mounting Fenders

4

3

1

5

8

7

98

9

2

7

8

4

6

. Use hardware in green bag to mount

fenders

. The front and rear fender brackets are

not interchangeable.

1 Front Fender Bracket

2 Rear Fender Bracket

3 3/8-16 x 3/4 Self-Tapping Screw

4 3/8 Star Washer

5 Light Bracket

6 Fender

7 3/8-16 x 1-1/2 Screw

8 3/8 ID Flat Washer

9 3/8 Lock Nut

Tools Needed:

1/2, 9/16 in

802 818

Mount front and rear fender brackets using
supplied 3/8 in self-tapping screws, star
washers, and existing holes in welding gen­erator base.

Be sure to install star washers between rear
fender brackets and base, and between
rear fender brackets and light brackets.

Mount fenders on fender brackets using
supplied 3/8 in hardware.

OM-6611 Page 13

3-10. Installing Taillight And Sidelight Wiring

Wiring Connections:

2

5

6

7

3

1

8

9

2

Sidelight

RIGHT

4

Tools Needed:

7/16, 9/16, 10 mm

1/4 in

Right Stop/

Signal Lamps

Left Stop/

Signal Lamps

(Yellow)

Taillights

(Brown)

Y Support trailer with jack. Block

wheels.

(Green)

Ground
(White)

White Ground Lead

(Ground To Trailer Frame)

. Use hardware in green bag to install

lights.

1 Wiring Harness White Ground Lead

2 Sleeving

3 3/4 Sheet Metal Screw

4 Taillight

5 License Plate Holder

6 1/4 ID Lock Washer

7 1/4 ID Nut

Short

To TrailerTo Vehicle

8 Sidelight

9 8-32 x 5/8 Self-Tapping Screw

To connect taillights: Strip insulation from
end of white ground lead and crimp on sup­plied ring terminal. Attach ground lead ring
terminal to chain bracket using 3/4 in sheet
metal screw.

Strip 1/2 in (12.7 mm) insulation from ends of
taillight brown, green, and yellow leads.

Insert stripped end of green lead into right tail­light hole marked STOP & TURN (GREEN).
Insert stripped end of yellow lead into left tail­light hole marked STOP & TURN (YELLOW).

Brown Lead

Brown Lead

Lead

Short

Lead

Green

Lead

Yellow

Lead

Sidelight

Insert stripped end of brown leads into TAIL
(BROWN) holes in each light.

Mount taillights and license holder on brack­ets using supplied 1/4 in hardware.

To connect sidelights:

Connect brown lead to sidelight.

Mount sidelight on frame using supplied self­tapping screws.

Install other sidelight the same way.

Install sleeving on taillight and harness plug
electrical leads.

Ta b

Connector

Ta b

Connector

LEFT

802 074-A / 802 818

Taillights

OM-6611 Page 14

3-11. Maintenance

NOTE

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.

Replace trailer hardware
only with SAE hardware of
same grade, type and size
as originally installed.

Y Support trailer with jack.

Block wheels.

Y Do not put any body part un-

der trailer while lifting or per­forming maintenance.

Once a year, lubricate all moving
parts on trailer with SAE 20W oil.
Lubricate more often if trailer is ex­posed to elements or subject to fre­quent off-road use.

1 Wheel Bearings

Every 12,000 miles, check wheel
bearings. Repack bearings if nec­essary using a good quality lithium­based extreme pressure grease.

When reinstalling wheels, be sure
wheel nuts are properly tightened
(see Trailer Towing Safety Precau­tions at beginning of manual).

Tools Needed:

1

802 819

OM-6611 Page 15

3-12. Torquing Wheel Bearings

0.01 in (0.2 mm)
endplay maximum

Y Loss of control hazard. To

prevent injury and damage,
check and repack wheel
bearings once a year or ev­ery 12,000 miles (19,500
km), whichever comes
first.

Y Use proper equipment to

lift and support unit.

Y 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.

Check hub endplay. If loose,

remove wheel and go to next step.

Torque to 12 ft lb
(16 N·m)

Torque nut while turning hub forward. Turn nut until “just loose.”

Remove cap and cotter pin.

Tools Needed:

13/16, 1-1/2 in

OM-6611 Page 16

Y Do not loosen nut

more than 1/8 turn
in this step.

Further loosen nut until first slot

in nut aligns with hole in spindle.

Y Pin must not rub on

cap.

Install new cotter pin and bend ends around nut. Install cap.

Install wheel (See Safety Precautions) and recheck endplay.

Ref. 800 441-B

Notes

OM-6611 Page 17

SECTION 4 − PARTS LIST

9

5

6

4

2

1

3

8

7

. Hardware is common and

not available unless listed.

15

14

13

9

16

12

Figure 4-1. Complete Assembly

10

11

802 736−A

OM-6611 Page 18

Item

No.

Part

No.

Description Quantity

Figure 4-1. Complete Assembly

1 199 860 Chain, Safety Kit W/Latch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 043 824 Hitch, 2−1/2 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, .500−20 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 189 576 Tire, 13 in C 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 189 575 Hub, Axle #2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

167 787 Kit, Bearing 1−3/8 − 1−1/16 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

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.

Your distributor also gives
you ...

Service

You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.

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.

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

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.

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.

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.

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)

* Water Coolant Systems (Integrated)

* Intellitig
* Maxstar 150
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by
the engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* DS-2 Wire Feeder
* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)
* Process Controllers
* 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

Blue for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets

* APT & SAF Model Plasma Cutting Torches

* Remote Controls

* Accessory Kits

* Replacement Parts (No labor)

* Spoolmate Spoolguns

* Canvas Covers

Miller’s True Blue Limited Warranty shall not apply to:

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.)

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.

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.

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.

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.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
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.

miller_warr 6/04

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service

Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
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

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information
and Parts)

Circuit Diagrams

Welding Process Handbooks

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

European Headquarters −
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier to:

PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04

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.