Miller HWY-224 TRAILER (VIN NUMBERS BEGIN. WITH 5DL) Owner’s Manual

OM-2601
189 534J
2015−02
Description
Two-Wheel Trailer For Large EngineDriven Welder/Generators
HWY-224R
OFR-224
For Models With VIN Numbers That Begin With 5DL
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 Quality System Warranty and service information for your
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 2009−09
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_2013-09
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
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.
TILTING OF TRAILER can injure.
Only qualified persons should install, operate, maintain, and
repair this unit.
READ INSTRUCTIONS.
During operation, keep everybody, especially children, away.
FALLING EQUIPMENT can injure.
D Use equipment of adequate capacity and size
to lift and support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
D Use tongue jack or blocks to support weight.
D Properly install welding generator onto trailer
according to instructions.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
FLYING METAL OR DIRT can injure eyes.
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-2601 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 July 2005
2
Gross Trailer Weight
(Actual Loaded Weight)
3
10% Of GTW
Recommended
Bottom
View
Side
View
OM-2601 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.
LIGHTS THAT ARE NOT WORKING 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-2601 Page 3
LOOSE OR INCORRECT HARDWARE AND FASTENERS can
injure, and damage equipment.
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 manufacturer’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.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
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
Safety and Health Standards, Title 49 CFR 200 to 999, from Superintendent of Documents, U.S. Government Printing Office, Superintendent
of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone:
1-866-512-1800)
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.
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
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-2601 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, 1200 New Jersey Ave. SE, 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
3500 lb (1588 kg)
Gross Vehicle Weight Rating
2960 lb (1343 kg)
Net Payload
2650 lb (1202 kg)
Road Clearance
7-1/2 in. (191 mm)
Height Of Bed
18-1/2 in. (470 mm)
Standard Tires
B-78-13C
Weight
Net: 320 lb (145 kg)
3-2. Overall Dimensions (HWY-224R Trailer Shown)
A
18−1/2 in.
470 mm
B
12 in.
305 mm
C
37 in.
940 mm
D
OFR: 59−1/2 in.
HWY: 61 in.
OFR: 1511 mm
HWY: 1549 mm
E
105 in.
2667 mm
D
C
E
B
A
802 068-C
OM-2601 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. Assembling Axle And Springs
1
2
. Use hardware in orange bag to
assemble axle and springs.
1
Axle
2
U-Bolt
3
Leaf Spring
4
Spring Center Bolt
5
Spring Plate
6
Nut
Assemble components as shown.
. Be
sure the spring eyes point
up and the spring center bolt is
in the hole of the spring plate.
3
Cross-tighten hardware so plate is
installed evenly. Torque hardware
to 55 ft lb (74 N.m).
. The axle has a slight camber
4
5
Tools Needed:
(arch) to 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.
6
3/4 in
802 529
Notes
OM-2601 Page 6
4-2. Assembling OFR-224 Trailer (For Off-Road Use)
Tools Needed:
9
3/8, 7/16, 13/16 in.
9/16, 7/8 in.
11
3
1
2
4
10
8
5
7
6
Ref. 802 069-A
Use adequate blocks or lifting device
to support frame while installing parts.
. Install axle assembly with axle label fac-
. Use hardware in red bag to mount axle
Attach axle assembly to brackets on frame using 9/16 in. hardware. Tighten hardware to 50
ft lb (67 N.m) maximum.
!
and wheels.
1
Shackle Arm
2
Spring
Attach shackle arms to springs using 9/16 in.
hardware. Tighten hardware to 50 ft lb (67
N.m) maximum.
. Do
3
ing front or rear of trailer.
. Do not overtighten spring and shackle
arm hardware. Parts must rotate freely.
8
Snap Ring
Slide jack over collar. Use snap ring pliers to
secure jack with snap ring.
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.
4
Wheel
5
Hub
10 Cable Tree Mounting Bracket
6
Lug Nut
Mount cable tree on trailer using supplied
hardware.
not overtighten shackle arm hardware. Parts must rotate freely.
Install wheels on hubs. Tighten lug nuts to 70
ft lb (95 N.m). Block wheels.
Shackle Bracket
7
Jack
9
Cable Tree (Optional)
11 End Cap
Install end caps in end of frame.
OM-2601 Page 7
4-3. Assembling HWY-224R Trailer (For Highway Use)
Tools Needed:
3/8, 7/16, 13/16 in.
11
9/16, 7/8 in.
10
13
12
9
3
12
1
2
4
14
5
8
7
6
Ref. 802 069-B
!
Use adequate blocks or lifting device
to support frame while installing
parts.
. Use hardware in red bag to mount axle
Attach axle assembly to brackets on frame
using 9/16 in. hardware. Tighten hardware to
50 ft lb (67 N.m) maximum.
arm hardware. Parts must rotate freely.
4
Wheel
1
Shackle Arm
5
Hub
2
Spring
6
Lug Nut
Attach shackle arms to springs using 9/16 in.
hardware. Tighten hardware to 50 ft lb (67
N.m) maximum.
Install wheels on hubs. Tighten lug nuts to 70
ft lb (95 N.m). Block wheels.
7
Jack
. Do not
8
Snap Ring
3
Shackle Bracket
. Install axle assembly with axle label facing front or rear of trailer.
OM-2601 Page 8
9
Fender Bracket
. Do not overtighten spring and shackle . Install bracket with top angling in (toward
and wheels. Use hardware in green bag
to mount fenders.
overtighten shackle arm hardware. Parts must rotate freely.
When jack is not needed, pull pin and rotate
jack to horizontal position.
Slide jack over collar. Use snap ring pliers to
secure jack with snap ring.
Pull pin and rotate jack to vertical position. Pin
locks jack in place. Turn handle to raise or
lower trailer.
fender).
10 Fender
11 Light Bracket
12 Star Washer
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.
13 Cable Tree (Optional)
14 Cable Tree Mounting Bracket
Mount cable tree on trailer using supplied
hardware.
4-4. Installing Hitch And Safety Chains
3
2
7
4
6
5
1
Tools Needed:
5/8, 3/4 in.
11/16, 3/4 in.
Ref. 802 069-D / 802 068-B
!
!
Use adequate blocks or lifting device to support frame while installing parts.
Support trailer with jack. Block
wheels.
3
Chain Bracket
Attach chain to bracket with 7/16 in. hardware. Tighten hardware to 31 ft lb (40 N.m).
4
Ball Hitch
. Use hardware in blue bag to mount
5
Safety Pin
1
Block wheels.
Attach hitch to tongue using 1/2 in. hardware (2 required). Make sure bolt is
installed horizontally as shown.
2
Tighten hardware to 75 ft lb (102 N.m).
safety chain.
Wheel Block
Safety Chain
Set trailer on vehicle towing ball and push
lever down. Insert safety pin through hole in
lever to secure hitch.
6
Clevis Hitch (Optional)
Attach bars to top and bottom of tongue using 1/2-13 x 4-1/2 in. hardware (2 required).
7
Lunette Eye Hitch (Optional)
Attach lunette eye to top of tongue using
1/2-13 x 3-1/2 in. hardware (2 required).
Cross safety chains under tongue and attach to towing vehicle.
OM-2601 Page 9
4-5. Installing Light Kit (Hwy-224R Trailers Only)
3
5
2
7
Tools Needed:
4
1
3/8, 7/16 in.
5
6
1/4 in.
Wiring Connections:
Sidelight
Right Stop/
Signal Lamps
(Green)
Left Stop/
To Vehicle
Signal Lamps
(Yellow)
Green Lead
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
Sidelight
Brown Lead
802 070-B
!
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.
OM-2601 Page 10
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
in. 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 4-6).
Mount sidelight on frame using supplied selftapping screws.
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.
4-6. Installing Wiring Harness Tab Connectors
. Disconnect vehicle wiring harness plug from trailer wiring connector before beginning installation. Use wiring harness tab connectors only with
insulated wires.
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
OM-2601 Page 11
4-7. Installing Welder/Generator
1
1
Tools Needed:
1/2, 5/8, 11/16 in.
1/2 in.
OPTIONAL
2
. Tighten crossmember securing
screws to 30 ft lb (40 N.m)
802 068-C / 804 247-A
!
!
!
Use equipment of adequate capacity
to lift the generator.
. Use hardware in yellow bag to mount
should be adjusted so tongue weight is 10
− 15% of gross trailer weight.
Support front of trailer with jack.
Support rear of trailer with blocks.
Block wheels.
. The axle has a slight camber (arch) to
Tighten crossmembers and secure generator.
If trailer is not installed on vehicle,
use trailer jack to obtain desired
height and to support tongue weight
while installing welder/generator.
!
Install welder/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-2601 Page 12
welder/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
welder/generator holes. Crossmembers
. 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.
4-8. 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.
!
Support trailer with jack.
Block wheels.
!
Do not put any body part under 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).
. Replace trailer hardware only
with SAE hardware of same
grade, type and size as originally installed.
1
Tools Needed:
13/16, 1-1/2 in.
Ref. 802 071-C
OM-2601 Page 13
4-9. 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 4-8.
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. 800 441-B
OM-2601 Page 14
Notes
OM-2601 Page 15
SECTION 5 − PARTS LIST
3
. Hardware is common and
6
5
not available unless listed.
4
2
7
8
1
17
16
6
11
15
19
9
14
13
12
18
. Nut (12), washer (13), and hub (14)
not included in bearing kit (11).
21
20
10
ST-802 072-E
Figure 5-1. Complete Assembly
Item
No.
Part
No.
Description
Quantity
Figure 5-1. Complete Assembly
. . . 1 . . . 199 860 . . CHAIN, safety kit (includes blue bag hardware) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . ♦043 826 . . CABLE TREE (includes mounting hardware) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . 189 580 . . FENDER (HWY-224 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 189 581 . . FENDER, hardware kit − HWY-224 Model (includes green bag hardware) . . . . . . . . .
. . . 4 . . . 189 620 . . FENDER, mtg bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . 189 582 . . GUARD, light (HWY-224 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . 189 577 . . LIGHT KIT (HWY-224 Model − includes wiring harness) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . 189 584 . . SLIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . 197 407 . . DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 190 911 . . MOUNTING HARDWARE KIT (includes yellow bag hardware) . . . . . . . . . . . . . . . . . . .
. . . 9 . . . 189 576 . . TIRE, B-78-13C (includes rim) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . 088 879 . . WHEEL NUT, .500-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . 088 866 . . NUT, spindle (not included in bearing kit 167 787) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-2601 Page 16
1
1
2
1
2
2
1
2
1
1
2
5
2
1
1
1
1
1
1
1
2
Item
No.
Part
No.
Description
Quantity
Figure 5-1. Complete Assembly (Continued)
. . . 13 . . . 088 868
. . . 14 . . . 189 575
. . . 15 . . . 189 574
. . . . . . . . . . 236822
. . . 16 . . . 158 687
. . . 17 . . . 088 870
. . . . . . . . . 189 579
. . . 18 . . . 189 586
. . . 19 . . . 189 587
. . . 20 . . . 191 267
. . . 21 . . . 189 585
. . . . . . . . ♦043 824
. . . . . . . . ♦043 825
. . WASHER, spindle (not included in bearing kit 167 787) . . . . . . . . . . . . . . . . . . . . . . . .
. . HUB, axle #2 (not included in bearing kit 167 787) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . AXLE, #2 (includes hub − does not nclude leaf springs and mounting hardware) . . . .
. . KIT, mtg axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPRING, leaf (includes the following) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUSHING, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KIT, mtg spring, parts bag (includes red bag hardware) . . . . . . . . . . . . . . . . . . . . . . . . .
. . JACK, screw w/pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . JACK, ret ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HARNESS, trailer (also included in item 6 − light kit) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HITCH, ball 2.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LUNETTE EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLEVIS HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1
1
1
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-2601 Page 17
Notes
OM-2601 Page 18
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
1/2 in (.5 in)
OM-2601 Page 19
Notes
OM-2601 Page 20
Effective January 1, 2015
(Equipment with a serial number preface of MF 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 below, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective
* Bernard Guns (No Labor)
date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
* Accessory (Kits)
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Within the warranty periods listed below, Miller will repair or replace
Non-Electronic Controls
any warranted parts or components that fail due to such defects in
* M-Guns
material or workmanship. Miller must be notified in writing within
thirty (30) days of such defect or failure, at which time Miller will
* MIG Guns and Subarc (SAW) Torches
provide instructions on the warranty claim procedures to be
* Remote Controls and RFCS-RJ45
followed. If notification is submitted as an online warranty claim, the
* Replacement Parts (No labor)
claim must include a detailed description of the fault and the
* Roughneck Guns
troubleshooting steps taken to identify failed components and the
* Spoolmate Spoolguns
cause of their failure.
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 twelve months
after the equipment is shipped to a North American distributor or
eighteen months after the equipment is shipped to an International
distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welder/Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in,
or for a minimum of one year — whichever is
greater.)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted Separately
by the Manufacturer.)
* LiveArc Welding Performance Management System
* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems
* TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
Miller’s True Blue® Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
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.
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 2015-01
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.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
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.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2015 Miller Electric Mfg. Co.
2015−01