Miller | KA000000 | Owner Manual | Miller HWY 430 TRAILER User manual

Miller HWY 430 TRAILER User manual
OM-2602
190 485C
2007−06
Description
Four-Wheel Trailer For Large EngineDriven Welding Generators
HWY-430
File: Accessory,
Trailer
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 parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
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 specification 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 4/05
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
SECTION 1 − ASSEMBLY SAFETY PRECAUTIONS
safety_trailer 2007−04
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Assembly Hazards
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.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
FALLING UNIT can cause injury.
D Use equipment and blocks of adequate capacity 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.
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 Read Owner’s Manual before using or servicing unit.
D Use only genuine replacement parts from
manufacturer.
D Perform maintenance according to this
manual.
FLYING METAL OR DIRT can injure eye
D Wear approved safety glasses with side shields
when assembling and maintaining trailer.
Read and follow all Trailer Towing Safety Information at the beginning of manual before using this trailer.
OM-2602 Page 1
SECTION 2 − TRAILER TOWING SAFETY PRECAUTIONS
3
1
Hitch is on towing vehicle.
2 Tongue
3 Lights
4 Wheels And
Bearings
5 Rating Plate
6 Jack Stand
7 Safety Chains
2
1
3
5
3
4
6
7
S Use a towing vehicle prepared and capable of handling the load.
Coupler
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.
S Towing any trailer requires special awareness because of the
changed driving situation.
S When towing, it takes longer to start, stop, and pass − use training
and practice to avoid accidents.
S Turning and backing up present new problems − plan ahead.
S Require each driver to be fully trained and experienced in trailer
towing before going out on the road.
S Holes are provided for mounting weld/power generator.
S Be sure trailer is fully prepared and connected to towing vehicle.
S Observe maximum speed of 45 mph (72 kph) when towing.
S Do not modify or change the trailer in any way − changes void the
warranty. Read Owner’s Manual.
S Use only genuine factory parts as replacements.
S Adjust load on trailer so tongue weight is approximately 10% of
the gross trailer weight and center load side-to-side to reduce
fishtailing.
S Tighten all parts, bolts, nuts, and mounting hardware.
OVERLOADING can cause serious injury or equipment
damage.
Rating
Plate
GVWR − Gross Vehicle
Weight Rating (Maximum
Total Trailer Weight Including Its Load)
GAWR − Gross Axle
Weight Rating
VIN NO − Vehicle Identification Number
UNCONTROLLED TILTING OF TRAILER can result in personal
injury or equipment damage.
S Install generator according to Owner’s Manual with engine end
toward hitch end of trailer.
Tongue − Level
Bathroom
Scale
Maximum
Tongue Weight3
lb (kg)
Up to 2000
(Up to 910)
1000 (455)
2000 (910)
100 (45)
200 (90)
2
2000 to 3500
(910 to 1590)
2000 (910)
3500 (1590)
200 (90)
350 (158)
3500 to 5000
(1590 to 2270)
3500 (1590)
INCORRECT TONGUE WEIGHT can cause fishtailing and loss
of control of towing vehicle resulting in serious injury and
equipment damage.
Board
1
3
S Distribute weight so that trailer tongue weight is approximately
10% of the gross trailer weight.
Pipe
Approximately
10% Of GTW
Trailer Gross Vehicle
And
Weight Rating Gross Trailer2
Weight GTW
Coupler
GVWR
Class 1
lb (kg)
lb (kg)
350 (158)
1
Information From SAE
J684 May 1987
2
Gross Trailer Weight
(Actual Loaded Weight)
3
10% Of GTW
Recommended
Bottom
View
Side
View
OM-2602 Page 2
S Do not overload the trailer.
S 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.
S The Gross Axle Weight Rating (GAWR) is the maximum
load-bearing capacity of the axle(s).
S Weigh trailer − adjust weight by removing accessory equipment if
necessary − call local authorities for nearest scale location.
S Use gross trailer weight to select a proper towing vehicle.
S Tongue weight is the amount of trailer weight that rests on the
towing vehicle hitch − that is, the downward pressure on the
coupler.
S Remove or adjust trailer load to get correct tongue weight.
S Do not let tongue weight exceed coupler and hitch rating.
S 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.
S Always use safety chains when towing.
S Cross safety chains under coupling to prevent tongue from
dropping to ground.
S Allow only enough slack for tight turns.
S Do not let safety chains drag on ground.
S Twist safety chains equally from hook ends to take up slack.
S Use safety chains rated equal to or greater than twice the
maximum gross trailer weight rating.
Couplers
Clevis
OR
Trailer
Tongue
Lunette
Eye
INCORRECT SIZE OR RATING OF HITCH can cause trailer to
break loose from towing vehicle.
S Be sure towing vehicle hitch is correct type, size, and rating to
match coupler.
S Be sure the hitch is properly installed onto towing vehicle.
S On optional ball couplers, always insert hitch safety pin before
towing.
S 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.
S
S
S
S
S
Chock in direction of grade.
Position chock snugly behind tire.
Place chock square to the tire.
Tap chock into place.
For added protection, chock both sides of tire.
UNEXPECTED TILTING OF TRAILER can cause injury and
damage.
S When trailer is uncoupled from towing vehicle, use jack on front
and block rear to prevent tilting.
S Use proper blocks that are large enough and able to support the
necessary weight.
S Always chock the wheels when uncoupled.
INCORRECTLY WORKING LIGHTS can cause accidents.
S State and Federal regulations require trailers used on highways
to have tail, stop, turn, and side marker lights.
Tail, Stop, And
Turn Lights
S Lights are not required for trailers designed for off-road use only.
S Check all lights and connectors for proper installation and
operation before using the trailer.
S Check condition of wiring harness leads, plugs, and connections
regularly. Repair or replace damaged parts or wires.
S Replace any broken lenses, reflectors, or bulbs.
Side Marker Lights
INCORRECT TORQUE on lug nuts or INCORRECT TIRE
PRESSURE or BEARING MAINTENANCE can cause loss of
control resulting in serious injury and equipment damage.
Torquing Sequence
1
3
4
4-Hole Wheels −
Torque Lug Nuts
To 60 ft-lbs (81 N·m)
2
1
Lug
Nuts
Wheel
Bearings
Inside Hub
3
5
Self-Actuating Hydraulic
Brake System
Breakaway
Cable
Surge-Type
Coupler
Bracket
4
5-Hole Wheels −
Torque Lug Nuts
2 To 70 ft-lbs (95 N·m)
Brake Fluid
Reservoir
S 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.
S When checking lug nuts, keep them clean, dry, and unlubricated.
S Check and repack wheel bearings once each year or every
12,000 miles (19,500 km), whichever comes first.
S Maintain correct tire pressure according to sidewall data on tire −
underinflation is the most common cause of tire trouble.
S Check tires for wear every six months.
S Use only replacement tires of the same size, rating, and capacity.
INOPERATIVE SURGE-TYPE BRAKES OR WRONG
BREAKAWAY CABLE CONNECTION can cause accidents.
S Check brake fluid level before use.
S Do not use sway control devices − keep coupler free to telescope
during braking.
S Always connect breakaway cable to towing vehicle − be sure it
has a direct free pull.
S Do not wrap cable around safety chains, tongue, wiring, or any
other parts.
S The breakaway cable automatically applies the trailer brakes if
separation occurs.
OM-2602 Page 3
LOOSE OR INCORRECT HARDWARE AND FASTENERS can
cause injury and damage.
Grade Marks.
Manufacturer’s
Identification Mark
S Periodically double-check all nuts and bolts for tightness and
condition.
S If necessary, always replace any fastener with one of equal
size, grade, and type.
S 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
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.)
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
Towing a Trailer − Being Equipped for Safety, Publication from U.S. Department of Transportation, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, D.C. 20590
SAE Handbook. 2005. Volume 4. On-Highway Vehicles and Off-Highway Machinery, from Society of Automotive Engineers, Inc., 400 Commonwealth Drive, Warrendale, PA 15096-0001.
Safety and Health Standards, Title 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
OM-2602 Page 4
become involved in individual problems between you, your dealer, or
MILLER Electric Mfg. Co.
To contact NHTSA, you may call the Auto Safety Hotline toll-free at
1−888−327−4236, visit the website at www.nhtsa.gov or write to:
NHTSA, 400 Seventh Street, SW, Washington D.C. 20590. You can
also obtain other information about motor vehicle safety from these
sources.
SECTION 3 − SPECIFICATIONS
3-1. Trailer Specifications
Specification
Description
Gross Axle Weight Rating
2200 lb/axle (998 kg/axle)
Gross Vehicle Weight Rating
4280 lb (1941 kg)
Net Payload
3750 lb (1701 kg)
Road Clearance
8-1/2 in (216 mm)
Height Of Bed
19-1/4 in (489 mm)
Standard Tires
B-78-13B
Weight
Net: 530 lb (240 kg)
3-2. Overall Dimensions
A
18−1/2 in.
470 mm
B
12 in.
305 mm
C
37 in.
940 mm
D
61 in.
1549 mm
E
157 in.
3988 mm
D
C
E
B
A
ST-802 155-A
OM-2602 Page 5
SECTION 4 − ASSEMBLY
. All directions are given as facing the towing vehicle. The word “front” means the hitch end of the trailer.
4-1. Installing Fenders, Light Brackets, And Optional Cable Tree
Tools Needed:
9/16 in
4
3
5
2
6
5
8
7
1
Ref. ST-802 194
!
Support trailer with jack. Block
wheels
. Use
1
. Install bracket with top angling in (toward
fender).
hardware in green bag to mount
fenders.
3
Fender
4
Light Bracket
Jack
5
Star Washer
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.
Mount fender brackets, light brackets, and
fenders on trailer using supplied 3/8 in hardware. Be sure to install star washers between
light brackets and fenders, and between
fender brackets and frame.
2
6
Fender Bracket
OM-2602 Page 6
Cable Tree (Optional)
7 Cable Tree Mounting Bracket
Mount cable tree on trailer using supplied
hardware.
8 Parking Brake
Use brake to manually apply trailer brakes
when trailer is parked.
To use brake, push handle forward until handle is nearly horizontal.
To release brake, pull handle back to vertical
position.
See Section 4-6 for parking brake adjustment
procedure.
4-2. Installing Light Kit
3
5
2
7
Tools Needed:
3/8, 7/16 in
6
5
4
1
1/4, 9/16 in
Sidelight
Wiring Connections:
Green Lead
Right Stop/
Signal Lamps
Left Stop/ (Green)
To Vehicle
Signal Lamps
(Yellow)
Short Lead
RIGHT
To Trailer
Brown Lead
Taillights
Tab Connectors
Taillights
(Brown)
Yellow Lead
Ground
(White)
LEFT
White Ground Lead
(Ground To Trailer Frame)
Short Lead
Brown Lead
ST-802 070-A
Sidelight
!
Support trailer with jack. Block
wheels.
. Use
hardware in green bag to install
lights.
. Use supplied wire to route harness leads
through trailer frame.
1
Wiring Harness White Ground Lead
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.
Locate holes for routing wire near each taillight.
Route brown and green leads inside of right
frame to exit hole. Route brown and yellow
leads inside left side.
2
Grommet
Route leads through grommets. Install grommets in holes in trailer frame.
Strip 1/2 in (12.7 mm) insulation from ends of
brown, green, and yellow leads.
3
Taillight
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).
Insert stripped end of brown leads into TAIL
(BROWN) holes in each light.
Mount lights on brackets using supplied 1/4
nuts.
4
Sidelight
Pull a small length of brown lead thru hole in
side of trailer.
Splice sidelight short lead to wiring harness
brown lead using supplied tab connector (see
Section 4-3).
Secure sidelight to frame as shown.
Install other sidelight the same way.
5
Sleeving
Install sleeving on taillight and harness plug
electrical leads.
6
Hanging Cable Tie
Install cable tie in 1/4 in (6 mm) hole in bottom
of tongue. Use tie to secure harness and
sleeving.
7
End Cap
Install caps in end of trailer.
OM-2602 Page 7
4-3. 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.
1
3
1
Connector
2
Run Wire
3
Tap Wire
Place unstripped run wire in slotted
channel.
Insert unstripped tap wire into other
channel until it hits internal stop.
4
5
2
4
Contact
5
9 Inch Linemans Pliers
Use pliers to push contact down
flush with top of connector.
Close top cover.
Ref. S-0448
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-2602 Page 8
4-4. Installing Safety Chains, Breakaway Cable, And Optional Hitches
9
2
3
4
7
8
5
6
Tools Needed:
5/8, 15/16 in
5/8, 15/16 in
1
Ref. ST-802 195-B
!
Use adequate blocks or lifting device to support frame while installing parts.
!
Support trailer with jack. Block
wheels.
Cross safety chains under tongue and attach to towing vehicle.
4
Mounting Channel
. Use hardware in blue bag to mount
safety chain.
Hitch may be mounted in four different positions on channel. Use position that provides
level connection between trailer and towing
vehicle.
1
Wheel Block
5
Ball Hitch (Optional)
Block wheels.
6
Safety Pin
2
Safety Chain
3
Chain Bracket
Attach hitch to tongue using 5/8 -11 x 4-1/2
in hardware (2 required). Make sure bolt is
installed horizontally as shown.
Attach chain to bracket with 7/16 in hardware. Tighten hardware to 31 ft lb (40 N.m).
Tighten hardware to 75 ft lb (102 N.m).
Set trailer on vehicle towing ball and push
lever down. Insert safety pin through hole in
lever to secure hitch.
7 Clevis Hitch (Optional)
Attach clevis to channel using 5/8 -11 x
4-1/2 in hardware (2 required).
Tighten hardware to 75 ft lb (102 N.m).
8 Lunette Eye Hitch (Optional)
Attach lunette eye to channel using 5/8 -11
x 4-1/2 in hardware (2 required).
Tighten hardware to 75 ft lb (102 N.m).
9 Breakaway Cable
Attach cable to towing vehicle above hitch.
Cable applies trailer brakes if trailer is separated from towing vehicle.
OM-2602 Page 9
4-5. Installing Welding Generator
1
Tools Needed:
5/8 in
1/2 in
OPTIONAL
2
. Tighten crossmember securing
screws to 30 ft lb (40 N.m)
Ref. ST-802 195-A / 804 247-A
!
Use equipment of adequate capacity
to lift the generator.
. Use hardware in yellow bag to mount
!
Support front of trailer with jack.
Block wheels.
. The axle has a slight camber (arch) to
!
If trailer is not installed on vehicle,
use trailer jack to obtain desired
height and to support tongue weight
while installing welding generator.
!
Install welding generator on trailer
with engine end toward hitch end of
trailer.
!
Distribute weight so trailer tongue
weight is approximately 10% of
gross trailer weight.
OM-2602 Page 10
welding generator.
help the tires wear properly when the
trailer is loaded. With no load on the
trailer the tires appear to tilt outward.
When the trailer is loaded, the tires
straighten out and wear evenly.
1
Crossmember Mounting Holes
2
Crossmember Securing Screw
Use supplied hardware to install generator
so front panel faces rear.
Move crossmembers to correct position on
trailer frame so mounting holes align with
welding generator holes. Crossmembers
should be adjusted so tongue weight is 10
− 15% of gross trailer weight.
Tighten crossmembers and secure generator.
. Tighten
crossmember
securing
screws to 30 ft lb (40 N.m)
If permanent placement is desired, crossmembers may additionally be welded in
place. Ensure that all applicable accessories are in place and that tongue weight is
10 − 15% of gross trailer weight before
welding crossmembers. Be sure to remove
sidelight and move wiring harness before
welding crossmembers. Reinstall wiring
harness and sidelight when done welding.
4-6. 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.
Tools Needed:
BRAKE
FLUID
13/16, 1-1/2 in
6
5
5
4
1
2
3
1
ST-802 196-A
!
Support trailer with jack. Block
wheels.
!
Do not put any body part under trailer while lifting or performing maintenance.
. Replace trailer hardware only with SAE
grade 5 hardware of same type and
size as originally installed.
. When
reinstalling wheels, be sure
wheel nuts are properly tightened (see
Trailer Towing Safety Precautions at
beginning of manual).
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 lithium-based extreme pressure
grease.
2 Brake Linings
Check linings every 20,000 miles and replace if necessary.
3 Brake Fluid Reservoir
Check fluid level in reservoir at least 3 times
yearly. Add fluid if not up to full mark. Use
DOT Series 3 brake fluid from a sealed container. See brake actuator Owner’s Manual.
4 Parking Brake Handle
To adjust parking brake, release brake and
turn handle. Turn clockwise to increase
brake pressure or counterclockwise to decrease brake pressure.
Adjust brake so less than 30 ft lb (41 N.m)
of force is required to apply or release brake
handle.
If parking brake cannot be adjusted by turning handle, proceed as follows:
Release parking brake. Turn parking brake
handle counterclockwise as far as possible.
5 Lock Nut
6 Adjustment Nut
Loosen lock nuts. Tighten adjustment nut to
remove slack from brake cable. Tighten
lock nuts.
Turn handle clockwise until parking brake is
properly adjusted.
OM-2602 Page 11
4-7. Torquing Wheel Bearings
!
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.
!
Use proper equipment to
lift and support unit.
!
Do not put any body part
under trailer while lifting or
performing maintenance.
. Torque wheel bearings whenever hub nut is removed or
hub is too loose.
Repack bearings according to
Section 4-6.
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.
!
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.
Turn nut until “just loose.”
!
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. ST-800 441-B
OM-2602 Page 12
Notes
OM-2602 Page 13
SECTION 5 − PARTS LIST
. Hardware is common and
not available unless listed.
5
4
6
3
7
2
8
1
10
14
15
9
10
9
11
13
12
16
6
21
23
16
20
19
18
17
22
. Nut (17)
and washer (18) not
included in bearing kit (16).
ST-802 197-C
Figure 5-1. Complete Assembly
OM-2602 Page 14
Item
No.
Part
No.
Description
Quantity
Figure 5-1. Complete Assembly
. . . 1 . . . 191 258 . . KIT, parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . ♦043 826 . . CABLE TREE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . 189 580 . . FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 190 480 . . FENDER, hardware kit − (includes green bag hardware) . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 190 484 . . KIT, fender bolt bag dual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 190 477 . . FENDER, light kit dual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . 189 620 . . FENDER, mtg bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . 189 582 . . GUARD, light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . 189 577 . . LIGHT KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . 190 482 . . DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . 189 584 . . SLIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 190 911 . . MOUNTING HARDWARE KIT (includes yellow bag hardware) . . . . . . . . . . . . . . . . . . .
. . . 9 . . . 191 262 . . KIT, bearing 1-1/16 (includes seal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . 191 263 . . . . SEAL, grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . 191 261 . . WHEEL w/ tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 190 471 . . TIRE, 13.000 B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . 088 879 . . WHEEL NUT, .500-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . 190 479 . . HUB, axle #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . 190 472 . . AXLE, #1 (2200 lb) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 190 473 . . AXLE DUAL, parts bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . 190 515 . . AXLE, brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . 167 787 . . KIT, bearing 1-1/16 tapered axle (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . GREASE CAP, 1 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . PIN, cotter .125 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . BEARING, L44649 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . CUP, L44610 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . CUP, L68111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . BEARING, L68149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . OIL SEAL, 1-3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . 088 866 . . NUT, SPINDLE (not included in bearing kit 167 787) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . 088 868 . . WASHER, SPINDLE (not included in bearing kit 167 787) . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . 191 265 . . HUB DRUM, wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . 189 586 . . JACK, screw w/pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . 189 587 . . JACK, ret ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . 191 267 . . HARNESS, trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . 199 860 . . CHAIN, safety kit (includes blue bag hardware) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . ♦043 864 . . HITCH, ball 2.000 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . ♦043 863 . . LUNETTE EYE 3.000 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . ♦043 823 . . CLEVIS HITCH (not for highway use) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
4
1
1
1
4
2
1
1
3
1
2
2
4
4
5
2
1
1
1
2
1
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
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-2602 Page 15
Notes
Effective January 1, 2007
(Equipment with a serial number preface of “LH” or newer)
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.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
* Induction Heating Coils and Blankets, Cables, and
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
Non-Electronic Controls
its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
the effective date of this limited warranty is free of defects in
* Remote Controls
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Accessory (Kits)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
* Canvas Covers
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 delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
1.
5 Years Parts — 3 Years Labor
2.
3 Years — Parts and Labor
*
*
*
*
*
*
*
*
*
3.
Original main power rectifiers
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
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.)
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches and Subarc (SAW) Guns
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 2007−01
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
Contact 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.
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
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
© 2007 Miller Electric Mfg. Co. 2007−01
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
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