Miller Electric Welding System HWY 210 User Manual

OM-699  
189 553  
February 1998  
Description  
Two-Wheel Trailer For Small Engine-  
Driven Welding Generators  
HWY-210 & OFR-210  
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TRAILER TOWING SAFETY PRECAUTIONS  
TRAILER TOWING can be hazardous.  
WARNING  
In trailer towing, as in most driving situations, exposure to certain hazards occurs. Trailer towing is safe when  
precautions are taken. The following safety information is only a summary of the more complete information found in  
the Safety Standards listed at the end of these precautions. Read and follow all Safety Standards. In addition, the  
end user must check and comply with all federal, state, and local laws before use.  
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY  
QUALIFIED PEOPLE.  
3
1
Coupler  
3. When towing, it takes longer to start, stop, and pass use  
training and practice to avoid accidents.  
Hitch is on towing vehicle.  
4. Turning and backing up present new problems plan ahead.  
5. Require each driver to be fully trained and experienced in trailer  
towing before going out on the road.  
6. Holes are provided for mounting weld/power generator.  
7. Be sure trailer is fully prepared and connected to towing vehicle.  
8. Observe maximum speed of 45 mph (72 kph) when towing.  
2
3
4
Tongue  
Lights  
2
Wheels And  
Bearings  
Rating Plate  
Jack Stand  
1
7
3
4
5
6
7
5
3
9. Do not modify or change the trailer in any way changes void the  
warranty. Read Owner’s Manual.  
6
Safety Chains  
10. Use only genuine factory parts as replacements.  
11. Adjust load on trailer so tongue weight is approximately 10% of  
the gross trailer weight and center load side-to-side to reduce  
fishtailing.  
1. Use a towing vehicle prepared and capable of handling the load.  
2. Towing any trailer requires special awareness because of the  
changed driving situation.  
12. Tighten all parts, bolts, nuts, and mounting hardware.  
OVERLOADING can cause serious injury or  
equipment damage.  
1. Do not overload the trailer.  
GVWR Gross Vehicle  
Weight Rating (Maximum  
Total Trailer Weight In-  
cluding Its Load)  
2. The Gross Vehicle Weight Rating (GVWR) is the maximum total  
trailer weight with the engine driven welding generator and all  
equipment, such as tools, cables, and shielding gas cylinder,  
installed.  
3. The Gross Axle Weight Rating (GAWR) is the maximum  
load-bearingcapacity of the axle(s).  
4. Weigh trailer adjust weight by removing accessory equipment if  
necessary call local authorities for nearest scale location.  
5. Use gross trailer weight to select a proper towing vehicle.  
GAWR  
Gross Axle  
Weight Rating  
VIN NO Vehicle Identifi-  
cation Number  
Rating  
Plate  
UNCONTROLLED TILTING OF TRAILER can result  
in personal injury or equipment damage.  
1. Install generator according to Owner’s Manual with engine end  
toward hitch end of trailer.  
Tongue Level  
2. Distribute weight so that trailer tongue weight is approximately  
10% of the gross trailer weight.  
Bathroom  
Scale  
Pipe  
INCORRECT TONGUE WEIGHT can cause  
fishtailing and loss of control of towing vehicle  
resulting in serious injury and equipment damage.  
3. Tongue weight is the amount of trailer weight that rests on the  
towing vehicle hitch that is, the downward pressure on the  
coupler.  
Approximately  
10% Of GTW  
Board  
Trailer Gross Vehicle  
Gross Trailer  
Weight GTW  
lb (kg)  
Maximum  
And  
Weight Rating  
GVWR  
2
3
Tongue Weight  
lb (kg)  
Coupler  
1
Class  
lb (kg)  
Up to 2000  
(Up to 910)  
1000 (455)  
2000 (910)  
100 (45)  
200 (90)  
1
2
1
2
3
Information From SAE  
J684 May 1987  
4. Remove or adjust trailer load to get correct tongue weight.  
5. Do not let tongue weight exceed coupler and hitch rating.  
2000 to 3500  
2000 (910)  
200 (90)  
350 (158)  
Gross Trailer Weight  
(Actual Loaded Weight)  
(910 to 1590) 3500 (1590)  
6. Use slower speeds when towing a trailer never above 45 mph  
3500 to 5000  
3500 (1590)  
10% Of GTW  
Recommended  
3
350 (158)  
(72 km/h) to prevent fishtailing.  
(1590 to 2270)  
SAFETY CHAINS CAN PREVENT RUNAWAY  
TRAILER in case hitch/coupler fails.  
1. Always use safety chains when towing.  
2. Cross safety chains under coupling to prevent tongue from  
droppingto ground.  
Bottom  
View  
3. Allow only enough slack for tight turns.  
4. Do not let safety chains drag on ground.  
5. Twist safety chains equally from hook ends to take up slack.  
6. Use safety chains rated equal to or greater than twice the  
maximum gross trailer weight rating.  
Side  
View  
safety_trailer 10/96  
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Couplers  
OR  
INCORRECT SIZE OR RATING OF HITCH can  
cause trailer to break loose from towing vehicle.  
1. Be sure towing vehicle hitch is correct type, size, and rating to  
Clevis  
match coupler.  
2. Be sure the hitch is properly installed onto towing vehicle.  
3. On optional ball couplers, always insert hitch safety pin before  
Trailer  
Tongue  
towing.  
Lunette  
Eye  
4. Make sure hitch and ball are properly sized and match each  
other.  
Ball  
Safety Pin  
WHEELS MUST BE CHOCKED when trailer is  
uncoupled from vehicle.  
1. Chock in direction of grade.  
2. Position chock snugly behind tire.  
3. Place chock square to the tire.  
4. Tap chock into place.  
5. For added protection, chock both sides of tire.  
UNEXPECTED TILTING OF TRAILER can cause  
injury and damage.  
1. When trailer is uncoupled from towing vehicle, use jack on front  
and block rear to prevent tilting.  
2. Use proper blocks that are large enough and able to support the  
necessary weight.  
3. Always chock the wheels when uncoupled.  
INCORRECTLY WORKING LIGHTS can cause  
accidents.  
1. State and Federal regulations require trailers used on highways  
to have tail, stop, turn, and side marker lights.  
Tail, Stop, And  
Turn Lights  
2. Lights are not required for trailers designed for off-road use only.  
3. Check all lights and connectors for proper installation and  
operationbefore using the trailer.  
4. Check condition of wiring harness leads, plugs, and connections  
regularly. Repair or replace damaged parts or wires.  
Side Marker Lights  
Torquing Sequence  
5. Replace any broken lenses, reflectors, or bulbs.  
INCORRECT TORQUE on lug nuts or INCORRECT  
TIRE PRESSURE or BEARING MAINTENANCE can  
cause loss of control resulting in serious injury  
and equipment damage.  
1
1. Recheck lug nut torque after first 50 miles (80 km) and once each  
year or every 12,000 miles (19,500 km) thereafter, whichever  
comes first.  
2. When checking lug nuts, keep them clean, dry, and unlubricated.  
3. Check and repack wheel bearings once each year or every  
12,000 miles (19,500 km), whichever comes first.  
4-Hole Wheels −  
Torque Lug Nuts  
3
4
To 60 ft-lbs (81 N·m)  
2
1
4. Maintaincorrect tire pressure according to sidewall data on tire −  
underinflationis the most common cause of tire trouble.  
3
4
Wheel  
5-Hole Wheels −  
Torque Lug Nuts  
To 70 ft-lbs (95 N·m)  
Lug  
Nuts  
5. Check tires for wear every six months.  
6. Use only replacement tires of the same size, rating, and capacity.  
Bearings  
Inside Hub  
5
2
Self-Actuating Hydraulic  
Brake System  
INOPERATIVE  
SURGE-TYPE BRAKES OR  
WRONG BREAKAWAY CABLE CONNECTION can  
cause accidents.  
Brake Fluid  
Reservoir  
Breakaway  
Cable  
1. Check brake fluid level before use.  
2. Do not use sway control devices keep coupler free to telescope  
during braking.  
3. Always connect breakaway cable to towing vehicle be sure it  
has a direct free pull.  
4. Do not wrap cable around safety chains, tongue, wiring, or any  
other parts.  
Surge-Type  
Coupler  
Bracket  
5. The breakaway cable automatically applies the trailer brakes if  
separation occurs.  
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LOOSE OR INCORRECT HARDWARE AND  
FASTENERS can cause injury and damage.  
1. Periodically double-check all nuts and bolts for tightness and  
condition.  
2. If necessary, always replace any fastener with one of equal  
size, grade, and type.  
3. Be sure the grade marks on replacement fastener match the  
originalbolt. The manufacture’s identification mark is not critical  
and does not matter for the replacement fastener.  
Grade Marks.  
Manufacturer’s  
Identification Mark  
PRE-TOWING CHECKLIST  
Check gross trailer weight, tongue weight, and total weight distribution do not overload this trailer.  
Check that the correct hitch is properly installed on towing vehicle.  
When coupling, check that coupler locking device (safety pin), safety chains, and breakaway cable (if applicable) are properly connected.  
Check that tires are properly inflated and that wheel nuts are properly torqued.  
If applicable, check that all lights are working properly.  
PRINCIPAL SAFETY STANDARDS  
Trailer & Camper Safety, Publication # DOT HS-802586, from U.S. De-  
partment of Transportation, National Highway Traffic Safety Adminis-  
tration, Washington, D.C. 20590  
SAE Handbook. 1996. Volume 4. On-Highway Vehicles and Off-High-  
way Machinery, from Society of Automotive Engineers, Inc., 400 Com-  
monwealthDrive, Warrendale, PA 15096-0001.  
Safety and Health Standards, OSHA 49 CFR 200 to 999, from Superin-  
tendent of Documents, U.S. Government Printing Office, Washington,  
D.C. 20402  
REPORTING SAFETY DEFECTS  
If you believe that your vehicle has a defect which  
could cause a crash or could cause injury or death,  
you should immediately inform the National Highway  
Traffic Safety Administration (NHTSA) in addition to  
notifying MILLER Electric Mfg. Co.  
If NHTSA receives similar complaints, it may open an  
investigation, and if it finds that a safety defect exists  
in a group of vehicles, it may order a recall and remedy  
campaign. However, NHTSA cannot become  
involved in individual problems between you, your  
dealer, or MILLER Electric Mfg. Co.  
To contact NHTSA, you may either call the Auto  
Safety Hotline toll-free at 1-800-424-9393 (or  
366-0123 in Washington, D.C. area) or write to:  
NHTSA, U.S. Department of Transportation,  
Washington D.C. 20590. You can also obtain other  
information about motor vehicle safety from the  
Hotline.  
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SECTION 1 ASSEMBLY SAFETY PRECAUTIONS  
trail_safety 2/98  
1-1. Symbol Usage  
Means Warning! Watch Out! There are possible hazards  
with this procedure! The possible hazards are shown in  
the adjoining symbols.  
This group of symbols means Warning! Watch Out! possible FAL-  
LING EQUIPMENT and TILTING OF TRAILER hazards. Consult  
symbols and related instructions below for necessary actions to avoid  
the hazards.  
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  
summaryof the more complete safety information found in the  
Safety Standards. Read and follow all Safety Standards.  
TILTING OF TRAILER can cause injury.  
D
D
Use tongue jack or blocks to support weight.  
Properly install welding generator onto trailer  
according to instructions.  
Y
Y
Only qualified persons should install, operate, maintain, and  
repair this unit.  
READ INSTRUCTIONS.  
During operation, keep everybody, especially children, away.  
D
D
Use only genuine MILLER replacement parts.  
Perform maintenance according to this  
manual.  
FALLING UNIT can cause injury.  
D
Use equipment and blocks of adequate capac-  
ity and size to lift and support unit.  
FLYING METAL OR DIRT can injure eyes.  
D
If using lift forks to move unit or parts, be sure  
forks are long enough to extend beyond oppo-  
site side of unit or parts to prevent tipping.  
Have two people of adequate physical strength  
lift trailer parts.  
D
Wear approved safety glasses with side  
shields when assembling and maintaining trail-  
er.  
D
Read and follow all Trailer Towing Safety Precautions at start of manual before using this trailer.  
SECTION 2 SPECIFICATIONS  
2-1. Trailer Specifications  
Specification  
Description  
Gross Axle Weight Rating  
Gross Vehicle Weight Rating  
Net Payload  
1500 lb (680 kg)  
1610 lb (730 kg)  
1350 lb (612 kg)  
6-1/2 in (165 mm)  
18-1/2 in (470 mm)  
4.8 12  
Road Clearance  
Height Of Bed  
Standard Tires  
Weight  
Net: 265 lb (120 kg)  
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2-2. Overall Dimensions  
Inches  
18-1/2  
10  
Millimeters  
470  
A
B
C
D
E
254  
36-3/4  
59  
933  
1499  
94  
2388  
D
C
E
B
A
ST-802 067  
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SECTION 3 ASSEMBLY  
All directions are given as facing the towing vehicle. The word “front” means the  
hitch end of the trailer.  
NOTE  
3-1. Assembling Trailer  
Tools Needed:  
11  
3/8, 7/16 in  
13  
9/16, 7/8 in  
10  
12  
9
15  
12  
3
1
2
4
14  
8
5
16  
7
6
ST-802 073  
Y
Use adequate blocks or lifting device  
to support frame while installing  
parts.  
6
Lug Nut  
11 Light Bracket (Optional)  
12 Star Washer  
Install wheels on hubs. Tighten lug nuts to 60  
ft lbs (81 N m). Block wheels.  
.
Mount fender brackets, light brackets, and  
fenders on trailer using supplied 3/8 in hard-  
ware. Be sure to install star washers between  
light brackets and fenders, and between  
fender brackets and frame.  
1
2
Shackle Arm  
Spring  
7
8
Jack  
Snap Ring  
Attach shackle arms to springs using 9/16  
inch hardware. Tighten until bolt and nut are  
tight against arms, then loosen nut 1/8 to 1/4  
turn so spring moves freely.  
Slide jack over collar. Use snap ring pliers to  
secure jack with snap ring.  
13 Cable Tree (Optional)  
Rotate jack to down position. Pull pin and ro-  
tate jack to vertical position. Pin locks jack in  
place. Turn handle to raise or lower trailer.  
14 Cable Tree Mounting Bracket  
3
Shackle Bracket  
Mount cable tree on trailer using supplied  
hardware.  
Attach axle assembly to brackets on frame  
using 9/16 inch hardware. Tighten hardware  
until bolt and nut are tight against brackets,  
then loosen nut 1/8 to 1/4 turn so spring  
moves freely.  
When jack is not needed, pull pin and rotate  
jack to horizontal position.  
15 End Caps  
9
Fender Bracket (Optional)  
Install end caps in end of frame.  
16 Reflective Amber Label  
. Install bracket with top angling in (toward  
4
5
Wheel  
Hub  
fender).  
Apply labels to frame. Labels not required if  
installing optional light kit (see Section 3-3).  
10 Fender (Optional)  
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3-2. Installing Hitch And Safety Chains  
2
7
3
4
6
5
1
Tools Needed:  
9/16, 3/4 in  
11/16, 3/4 in  
ST-802 067 / Ref. ST-802 073  
Y
Use adequate blocks or lifting de-  
vice to support frame while instal-  
ling parts.  
Attach chain to bracket with 7/16 in hard-  
6
Clevis Hitch (Optional)  
.
ware. Tighten hardware to 31 ft lb (40 N m).  
Attach bars to top and bottom of tongue us-  
ing 1/2-13 x 4-1/2 in hardware (2 required).  
4
5
Ball Hitch  
Safety Pin  
Y
Support trailer with jack. Block  
wheels.  
Attach hitch to tongue using 1/2 in hardware  
(2 required). Make sure bolt is installed hori-  
zontally as shown.  
7
Lunette Eye Hitch (Optional)  
1
Wheel Block  
Attach lunette eye to top of tongue using  
1/2-13 x 3-1/2 in hardware (2 required).  
.
Block wheels.  
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.  
2
3
Safety Chain  
Cross safety chains under tongue and at-  
tach to towing vehicle.  
Chain Bracket  
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3-3. Installing Optional Light Kit  
Insert  
Brown  
Lead  
Insert Green Lead  
3
2
Tools Needed:  
4
1
3/8, 7/16 in  
Wiring Connections:  
Sidelight  
Brown Lead  
Short Lead  
Right Stop/  
Signal Lamps  
(Green)  
RIGHT  
To Vehicle  
To Trailer  
Left Stop/  
Signal Lamps  
(Yellow)  
Green Lead  
Yellow Lead  
Taillights  
Tab Connectors  
Taillights  
(Brown)  
LEFT  
Ground  
(White)  
Short Lead  
White Ground Lead  
(Ground To Trailer Frame)  
Brown Lead  
ST-802 074  
Sidelight  
Y
Support trailer with jack. Block side of frame to end of trailer. Route brown Mount lights on brackets using supplied 1/2  
wheels.  
and yellow leads along left side.  
nuts.  
Strip 1/2 in (12.7 mm) insulation from ends of  
brown, green, and yellow leads.  
4
Sidelight  
1
Wiring Harness White Ground Lead  
Pull a small length of brown lead thru hole in  
side of trailer.  
Secure ground lead ring terminal to the chain  
bracket using 1/4-20 x 3/4 hardware.  
3
Taillight  
Insert stripped end of green lead into right tail- Splice sidelight short lead to wiring harness  
2
Grommet  
light hole marked STOP & TURN (GREEN).  
Insert stripped end of yellow lead into left tail-  
light hole marked STOP & TURN (YELLOW).  
Insert stripped end of brown leads into TAIL  
(BROWN) holes in each light.  
brown lead using supplied tab connector (see  
Section 3-4).  
Locate holes for routing wire near each tail-  
light. Insert grommet in each hole.  
Secure sidelight to frame as shown.  
Install other sidelight the same way.  
Route brown and green leads along right in-  
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3-4. Installing Wiring Harness Tab Connectors  
Disconnect vehicle wiring harness plug from trailer wiring connector before  
beginning installation. Use wiring harness tab connectors only with insulated wires.  
NOTE  
1
2
3
Connector  
Run Wire  
Tap Wire  
1
3
Place unstripped run wire in slotted  
channel.  
Insert unstripped tap wire into other  
channel until it hits internal stop.  
4
5
Contact  
9 Inch Linemans Pliers  
4
Use pliers to push contact down  
flush with top of connector.  
5
2
Close top cover.  
Ref. S-0448  
3-5. Installing Welding Generator  
Y
Y
Y
Use equipment of adequate  
capacity to lift the generator.  
Support trailer with jack. Block  
wheels.  
If trailer is not installed on ve-  
hicle, use trailer jack to obtain  
desired height and to support  
tongue weight while installing  
welding generator.  
1
Y
Y
1
Install welding generator on  
trailer with engine end toward  
hitch end of trailer.  
Distribute weight so trailer  
tongue weight is approximate-  
ly 10% of gross trailer weight.  
1
Crossmember Mounting Holes  
Use supplied hardware to install gen-  
erator so front panel faces rear.  
Move crossmembers to correct posi-  
tion on trailer frame so mounting  
holes align with welding generator  
holes. Crossmembers should be ad-  
justed so tongue weight is 10 15%  
of gross trailer weight.  
Tighten crossmembers and secure  
generator.  
Tools Needed:  
9/16 in  
ST-802 067  
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3-6. 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.  
NOTE  
Y
Y
Support trailer with jack.  
Block wheels.  
Do not put any body part un-  
der trailer while lifting or per-  
forming maintenance.  
Once a year, lubricate all moving  
parts on trailer with SAE 20W oil.  
Lubricate more often if trailer is ex-  
posed to elements or subject to fre-  
quent off-road use.  
1
Wheel Bearings  
Every 12,000 miles, check wheel  
bearings. Repack bearings if nec-  
essary using a good quality lithium-  
based extreme pressure grease.  
When reinstalling wheels, be sure  
wheel nuts are properly tightened  
(see Trailer Towing Safety Precau-  
tions at beginning of manual).  
1
Tools Needed:  
13/16, 1-1/8 in  
ST-802 075  
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3-7. Torquing Wheel Bearings  
Y
Loss of control hazard. To  
prevent injury and damage,  
check and repack wheel  
bearings once a year or ev-  
ery 12,000 miles (19,500  
km), whichever comes  
first.  
Y
Y
Use proper equipment to  
lift and support unit.  
Do not put any body part  
under trailer while lifting or  
performing maintenance.  
. Torque wheel bearings when-  
ever hub nut is removed or  
hub is too loose.  
0.01 in (0.2 mm)  
endplay maximum  
Repack bearings according to  
Section 3-6.  
Check hub endplay. If loose,  
remove wheel and go to next step.  
Remove cap and cotter pin.  
Tools Needed:  
13/16, 1-1/2 in  
Torque to 12 ft lb  
(16 N·m)  
Torque nut while turning hub forward.  
Turn nut until “just loose.”  
Y
Do not loosen nut  
more than 1/8 turn  
in this step.  
Y
Pin must not rub on  
cap.  
Further loosen nut until first slot  
in nut aligns with hole in spindle.  
Install new cotter pin and bend ends around nut. Install cap.  
Install wheel (See Safety Precautions) and recheck endplay.  
Ref. ST-800 441-A  
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SECTION 4 PARTS LIST  
. Hardware is common and  
not available unless listed.  
6
5
2
4
3
7
8
1
11  
9
13  
12  
6
10  
14  
ST-802 076  
Figure 4-1. Complete Assembly  
Item  
No.  
Part  
No.  
Description  
Quantity  
. . . 1 . . . . 189 588 . . CHAIN, safety kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 2 . . . . . . . . . . . CABLE TREE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 3 . . . . 189 594 . . FENDER (HWY-210 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . . . . 189 581 . . FENDER, hardware kit (HWY-210 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 4 . . . . 189 595 . . FENDER, mtg bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 5 . . . . 189 582 . . GUARD, light (HWY-210 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 6 . . . . 189 577 . . LIGHT KIT (HWY-210 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . 189 578 . . GROMMET KIT (HWY-210 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 7 . . . . 189 597 . . SLIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 8 . . . . 189 596 . . DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . 189 693 . . MOUNTING HARDWARE KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . 189 591 . . TIRE, 12.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 10 . . . . 189 593 . . HUB, axle #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 11 . . . . 189 592 . . AXLE, #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . 189 579 . . AXLE, parts bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 12 . . . . 189 586 . . JACK, screw w/pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 13 . . . . 189 587 . . JACK, ret ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . . . 189 585 . . HITCH, ball 2.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . 043 824 . . LUNETTE EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . 043 823 . . ADJUSTABLE HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . 043 825 . . CLEVIS HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-699 Page 9  
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Notes  
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Notes  
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Effective January 1, 1998  
(Equipment with a serial number preface of “KJ” or newer)  
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, 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  
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting  
Torches  
*
*
*
*
Remote Controls  
Accessory Kits  
Replacement Parts (No labor)  
Spoolmate 185  
IMPLIED, INCLUDING  
THE  
WARRANTIES OF  
MERCHANTABILITY AND FITNESS.  
Miller’s True Blue® Limited Warranty shall not apply to:  
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.  
1. 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.  
2. Consumable components; such as contact tips, cutting  
nozzles, contactors, brushes, slip rings, relays or parts  
that fail due to normal wear.  
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.  
3. Equipment that has been modified by any party other  
than Miller, or equipment that has been improperly  
installed, improperly operated or misused based upon  
industry standards, or equipment which has not had  
reasonable and necessary maintenance, or equipment  
which has been used for operation outside of the  
specifications for the equipment.  
1. 5 Years Parts 3 Years Labor  
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.  
*
*
Original main power rectifiers  
Inverters (input and output rectifiers only)  
2. 3 Years — Parts and Labor  
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.  
*
*
*
*
*
*
Transformer/Rectifier Power Sources  
Plasma Arc Cutting Power Sources  
Semi-Automatic and Automatic Wire Feeders  
Inverter Power Supplies  
Warranty Questions?  
Intellitig  
Engine Driven Welding Generators  
(NOTE: Engines are warranted separately by the  
engine manufacturer.)  
Call  
1-800-4-A-MILLER  
for your local  
Miller distributor.  
3. 1 Year — Parts and Labor  
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Motor Driven Guns (w/exception of Spoolmate 185)  
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.  
Process Controllers  
Positioners and Controllers  
Automatic Motion Devices  
Robots  
IHPS Power Sources  
Water Coolant Systems  
HF Units  
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.  
Grids  
Spot Welders  
Load Banks  
SDX Transformers  
Miller Cyclomatic Equipment  
Running Gear/Trailers  
Plasma Cutting Torches (except APT, ZIPCUT &  
PLAZCUT Models)  
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.  
*
*
Deutz Engines (outside North America)  
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.)  
In Canada, legislation in some provinces provides for certain  
additional warranties or remedies other than as stated  
herein, and to the extent that they may not be waived, the  
limitations and exclusions set out above may not apply. This  
Limited Warranty provides specific legal rights, and other  
rights may be available, but may vary from province to  
province.  
4. 6 Months — Batteries  
5. 90 Days — Parts and Labor  
*
MIG Guns/TIG Torches  
miller_warr 1/98  
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Owner’s Record  
Please complete and retain with your personal records.  
Model Name  
Purchase Date  
Distributor  
Address  
Serial/Style Number  
(Date which equipment was delivered to original customer.)  
City  
State  
Zip  
Resources Available  
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  
To locate distributor nearest you call  
1-800-4-A-Miller.  
Miller Electric Mfg. Co.  
An Illinois Tool Works Company  
1635 West Spencer Street  
Appleton, WI 54914 USA  
Replacement Parts  
Training (Schools, Videos, Books)  
International HeadquartersUSA  
USA Phone: 920-735-4505 Auto-Attended  
USA & Canada FAX: 920-735-4134  
International FAX: 920-735-4125  
Technical Manuals (Servicing Information  
and Parts)  
Circuit Diagrams  
European Headquarters −  
United Kingdom  
Phone: 44 (0) 1204-593493  
FAX: 44 (0) 1204-598066  
Welding Process Handbooks  
www.MillerWelds.com  
Contact the Delivering Carrier for:  
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  
© 1998 Miller Electric Mfg. Co. 9/98  
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