Lincoln Electric K2636-1 Instructions / Assembly
Contents
1. TWO WHEEL TRAILER ASSEMBLY INSTRUCTIONS K2635 1 SMALL K2636 1 MEDIUM K2637 2 LARGE The K2635 1 trailer is designed to be used at highway speeds only with the following engine driven Lincoln welders Ranger 225 250GXT Eagle 10 000 Plus 305D 305G Red D Arc GX300 The K2636 1 trailer is designed to be used at highway speeds only with the following engine driven Lincoln welders Classic 300D Pipeliner 200D SAE 300 Vantage 300 400 500 Perkins 500CE Air Vantage 500 Vantage 500 Deutz The K2637 2 trailer is designed to be used at highway speeds only with the following engine driven Lincoln welders SAE 400 SAE 500 SAE 500 Severe Duty Air Vantage 650 700 Includes a DUO HITCH Patent Pending 2 Ball Lunette Eye combination hitch DUO HITCH is the property of the Lincoln Electric Company Trailer design is the property of Tri State Industries IMPORTANT SAFETY NOTES HAVE ALL INSTALLATION OPERATION REPAIR AND MAINTENANCE DONE BY QUALIFIED PERSONNEL The mounted welder may be equipped with the light and fender kit and the cable rack The trailer is designed for road off road in plant and yard towing If this trailer is to be used on public highways check applicable county state and local laws regarding specific requirements which may include fenders lights reflectors safety chains brakes etc Tow only with vehicles equipped for the weight and hitch type Limit towing speeds2. Shackle bolt may require tapping with a hammer to fully seat in shackle before tightening nuts 2 Tighten hardware to a maximum of 50 ft lb do not over tighten Spring parts must rotate freely between the shackles 3 Attach axle assembly to shackles with red bag hardware Tighten hardware to 50 ft lb do not over tighten Parts must rotate freely 4 instali the end caps into ends of tube at back of trailer LINCOLN TIRE INSTALLATION Use the following procedure to install the tires to the axie deck assembly TIRE TRAILER MODEL ITEM SIZE K2635 4 K2636 1 K2637 2 PART NO A 9TO 13B A 9TO 13C A 9TO 14C B NUT LUG WHEEL TIRE ASSEMBLY LUG NUT Attach wheels to axle hubs as shown Tighten all lug nuts to 70 ft lb Rotate jack to support trailer when jack is not needed or being transported pull pin and rotate jack so the jack is parallel to the trailer deck frame ON SAFETY NOTE Recheck lug nut torque after the first 50 miles and once a year or every 12 000 miles there after LINCOLN INSTALLING DUO HITCH AND SAFETY CHAINS Use the following procedure to install the hitch and safety chains to the deck assembly ITEM PART NO SAFETY CHAIN KIT Z 9TO SFC2 HITCH MOUNTING BAGS B BAG HC1 rl so Te lee T 2 BALL HITCH END FRONT VIEW LUNETTE EYE HITCH END BOTTOM VIEW 1 Support trailer with jack and
3. block wheels to prevent movement 2 Attach safety chains to trailer as shown with hardware kit supplied 3 Bolt the DUO HITCH to trailer as shown using hardware supplied in B BAG HC1 and torque the bolts to 85 ft lb The DUO HITCH assembly is mounted on top of the trailer drawtube and bolted through the side of the hitch 10 LINCOLN Welder Installation Trailer Description A L Bag Color Eagle 10 000 Plus Ranger 225 250GXT 305G x 41 2 54 0 k2635 1 Small Red D Arc GX300 Engine Yellow Ranger 305D K2636 1 Medium K2637 2 Large A END OF MACHINE TOWARDS FRONT OF TRAILER FOR AIR VANTAGE 500 VANTAGE 500 DEUTZ FOR CLASSIC ee ae PIPELINER SAE 300 r IT CONTROL PANEL END BOTTOM VIEW OF WELDERS WELDER MOUNTING INSTRUCTIONS 1 Chock both wheels front amp back Adjust the parking leg to level the trailer 2 Loosen the sliding cross member bolts and position according to dimensions of applicable model shown above Note In some cases the sliding cross member may need to be removed amp replaced in another location 3 Using a suitable lifting device position the welder about above the top of the sliding cross members 4 Ensure the welder is centered laterally on trailer 5 With mounting hardware in place and started l
4. to those at which the unit is stable When towing stop periodically and inspect hitch connections and trailer LINCOLNA LIMITED WARRANTY Effective JANUARY 1 2007 This warranty supersedes all previous Tri State Industries warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Tri State Industries Hammond Indiana warrants that all new and unused equipment furnished by Tri State Industries is of merchantable quality fit for the purpose intended free from defect in workmanship material and seller s design as of the time and place of delivery Except as a result of the seller s own acts or recommendations the foregoing warranties will not apply to any defect which has been solely caused by another s misuse neglect improper installation improper operation improper maintenance repair or alteration accident or unusual deterioration of the Products or parts thereof due to physical environment beyond the requirements of the Product specifications No warranty is made by Tri State Industries with respect to trade accessories or other items manufactured by others Such trade accessories and other items are sold subject to the warranties of their respective manufacturers if any In the case of Tri State Industries breach of warranty or any other duty with respect to the quality of any goods the exclusive remedies therefore shall be at Tri State Industries 1 rep
5. PLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY TRI STATE INDUSTRIES IS EXCLUDED AND DISCLAIMED INCLUDING ANY AND ALL CONSEQUENTIAL DAMAMGES BY TRI STATE INDUSTRIES EXCEPT AS EXPRESSLY PROVIDED BY TRI STATE INDUSTRIES IN WRITING TRI STATE INDUSTRIES PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY END USERS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF TRAILER EQUIPMENT TRI STATE INDUSTRIES WILL NOT BE RESPONSIBLE FOR ANY DAMAGES RESULTING FROM THE END USERS NEGLIGENCE OR INEXPERIENCE IN USING THE EQUIPMENT FOR THE PURPOSE INTENDED TRI STATE INDUSTRIES INC 4923 Columbia Avenue Hammond IN 46327 219 933 1710 219 933 1719 2 LINCOLN TRAILER OPERATING INFORMATION Towing any trailer requires special awareness because of the changed driving situation When towing it takes longer to start stop and pass use training and practice to avoid accidents Turning and backing up present new problems plan ahead Require each driver to be fully trained and experienced in trailer towing before going out on the road Insure that the vehicle used for towing is capable of handling the load Insure the towing vehicle hitch is the correct type size and rating to match coupler Be sure that the trailer is fully prepared and connected to the towing vehicle Drive at moderate speeds Trailer instability sway is more likely to occur as speed in
6. To prevent injury and damage check and repack wheel bearings once a year or every 12 000 miles 19 500 km which ever comes first Use proper equipment to lift and support unit Do not put any body part under trailer while lifting or performing maintenance NOTE TORQUE WHEEL BEARINGS WHENEVER HUB NUT IS REMOVED OR HUB IS TOO LOOSE TORQUE HUB NUT TO 25 ft lb THEN BACK OFF NUT 1 8 TO 1 4 TURN TO LINE UP COTTER KEY HOLE IN SPINDLE WITH SLOT IN CASTLE NUT OVERLOADING Do not overload the trailer overloading can cause serious injury or equipment damage Use the following tips to insure this does not occur 1 Gross Vehicle Weight Rating GVWR is the maximum total trailer weight with the engine driven welder and equipment such as tools cables shielding and gas cylinder installed 2 Gross Axle Weight Rating GAWR is the maximum load bearing capacity of the axle 3 Weigh trailer adjust weight by removing accessory equipment if necessary call local authorities for the nearest location 4 Use gross trailer weight to select a proper towing vehicle incorrect tongue weight can cause fishtailing and loss of control of towing vehicle resulting in serious injury and equipment damage Use the following tips to insure this does not occur Adjust the load on the trailer so tongue weight is approximately 10 of the gross trailer weight and center the load side to side to reduce fishtailing 2 Tongue weight is the amount of the trailer weight tha
7. Welding and Cutting Products Sales and Service through Subsidiaries and ome Worldwide Cleveland Ohio 44117 1199 U S A ETERNIT
8. air 2 replacement 3 payment of or credit for the purchase price upon authorized return of the goods at Tri State Industries risk and expense Upon receipt of notice of apparent defect or failure Tri State Industries shall instruct the claimant on the warranty claim procedures to be followed As a matter of general policy only Tri State Industries may honor an original end user s warranty claims with proof of purchase on warranted equipment in the event of failure resulting from a defect within one year of the purchase date by the end user Notification of any failure must be made in writing within 30 days of such failure A copy of the invoice showing the date of sale must accompany products returned for authorized warranty repair or replacement All equipment returned to Tri State Industries for service must be properly packaged to guard against damage from shipping Tri State Industries will not be responsible for any damages resulting from negligent shipping practices methods Normal surface transportation charges both ways for products returned for warranty repair or replacement will be borne by Tri State Industries except for products sold to foreign markets ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IM
9. creases State and Federal regulations require trailers used on highways to have tail stop turn and side marker lights Lights are not required for trailers designed for off road use TOWING WONOARWN gt Trailer wheels must be chocked when the trailer is uncoupled from vehicle Use the following procedures to properly chock trailer wheels 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 AWN Unexpected lifting of trailer can cause injury or damage When the trailer is uncoupled from the towing vehicle use the trailer jack to support the front and chock the tires to prevent tilting Use blocks that are large enough and able to support the necessary weight when chocking tires Always chock the wheels when uncoupled SAFETY CHAIN PLACEMENT Safety chains can prevent a runaway trailer in case of a hitch coupler failure Use the following tips to insure this does not occur i Always use safety chains when towing 2 Cross safety chains under the coupling to prevent the trailer tongue from dropping to the ground Allow only enough slack for tight turns Do not let safety chains drag on the ground Twist safety chains equally from hook ends to take up slack Use safety chains rated equal to or greater than twice the maximum gross trailer weight rating TRAILER HITCH The use of an incorrect size or rating o
10. f trailer hitches can cause a trailer to break loose from the tow vehicle Use the following tips to insure this does not occur 1 Be sure the towing vehicle hitch is correct type size and trailer rating to match coupler 2 Be sure the hitch is properly installed onto towing vehicle 3 On optional ball couplers always insert hitch safety pin before towing 4 Make sure hitch and ball are properly sized and match each other Nore LINCOLNI 3 TRAILER OPERATING INFORMATION CONTINUED TIRE Incorrect torque on lug nuts or incorrect tire pressure or improper bearing maintenance can cause loss of control resulting in serious injury and equipment damage Use the following maintenance tips to insure proper trailer function 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 free from lubrication 3 Check and repack wheel bearings once a year or every 12 000 miles 19 500 km whichever comes first 4 Maintain correct tire pressure according to sidewall data on tire Under inflation is the most common cause to tire trouble 5 Check tires for wear every six months 6 Use only replacement tires of the same size rating and capacity WHEEL BEARINGS Every 12 000 miles 19 500 km check wheel bearings Repack if necessary using a quality lithium based extreme pressure grease
11. on the trailer the tires will appear to tilt outward due to the axle camber TRAILER MODEL HARDWARE PARTS BAG K2635 1 B BAG TP1 ORANGE K2636 1 K2637 2 B BAG TP2 ORANGE FIXED CROSSMEMBER RIGHT FIXED CROSSMEMBER LEFT 1 1 Assembie the axle as shown using the hardware found in the orange bag Be sure the spring eyes point up and the spring center boltis in the hole of the axle spring plate 2 Place nuts on to u bolts so that each nut starts freely and then binds before passing over the end of the u bolt The binding of the nut when fully threaded upon the u bolt will create a locking feature for the hardware The u bolt and nuts are single use hardware and both must be replaced after being disassembled 3 Cross tighten hardware so the tie plate is installed evenly Torque hardware to 55 ft lb LINCOLNE 7 DECK AND AXLE ASSEMBLY DESCRIPTION PART NO SPRING AXLE SUB ASSEMBLY DECK Z 9DK 063 K2635 1 K2636 1 or Z 9DK 080 K2637 2 SCHACKLES B SHK 2WH RED TRAILER PARTS BAG B BAG TLIA SLIDING CROSS MEMBER Z 8TO SXM Supplied installed Z8TO FXM R BE FIXED CROSS MEMBER Z8TOFXM L END CAP Z 7TO CAP FOR EASE OF ASSEMBLY INSTALL THE SPRINGS AND AXLE WITH TRAILER DECK UPSIDE DOWN AS SHOWN 1 Assemble the four shackles to the deck brackets with the red bag hardware Nuts are self locking and may be hard to start Be sure not to start the crushed locking end
12. ower welder into place and fully tighten all mounting hardware and sliding cross member bolts and torque to 28 32 ft lb 1 d REPLACEMENT PARTS LIST K2635 1 K2636 1 K2637 2 Description SMALL MEDIUM LARGE Z 9DK 063 7 9TO B BAG TL1A Red Trailer Parts Bag Z 9HC BLN 02 DUO HITCH Patent Pending Assembly Z 8TO aoon aC Te J aoon faete o ooo a ZencBA Bail Coupler Oy y zox zone e 1500 Ib Axe Spring zxr S600 Ade OE Z 9AX S04B 3500 Ib Axle Spring Z8TO DHWL Warning Decal Z 8TO FXM R FIXED CROSS MEMBER RIGHT L Z 8TO FXM L FIXED CROSS MEMBER LEFT GENERAL MAINTENANCE Do not use the trailer if any part is damaged or not working properly When performing maintenance check trailer for worn damaged or non working parts Perform maintenance according to this manual If necessary always replace any fastener with one of equal size grade and type Be sure the grade marks on the replacement fastener match the original boit The manufacturer s identification mark is not critical and does not matter for the replacement fastener Once a year lubricate all moving parts on trailer with SAE20W oil Lubricate more often if trailer is exposed to elements or subject to frequent off road use Periodically double check all nuts and bolts for tightness and condition Bey THE LINCOLN ELECTRIC COMPANY Worid s Leader in
13. se only genuine factory parts as replacements 2 Tighten all parts bolts nuts and mounting hardware TOOLS REQUIRED 1 2 13mm Socket 4 point 9 16 14mm Socket amp Socket Wrench 9 16 14mm Wrench 3 4 19mm Socket amp Socket Wrench 3 4 19mm Wrench 7 8 23mm Socket amp Socket Wrench 13 16 21mm Wrench Torque Wrench with 0 100 ft lb span TON ONO K2635 1 SMALL TRAILER PARTS LIST YELLOW MACHINE MTG HARDWARE Z 8T0 SxXM DECK CROSSWEWBER 2 Z OAK SO1 Z9HC BLN 02 DUO HITCH ASSEMBLY 1 K2636 1 MEDIUM TRAILER PARTS LIST COMPONENT DESCRIPTION A 9TO 13C 13C TIRE B BAG LIN 2 BLACK MACHINE MTG HARDWARE B BAG LIN 4 NAVY MACHINE MTG HARDWARE B BAG HC 1 CLEAR HITCH MTG HARDWARE D gt ol 4 lt Z 8TO FXM R FIXED CROSSMEMBER RIGHT Z 8TO FXM L 6 LINCOLNI FIXED CROSSMEMBER LEFT RED TRAILER PART BAG ORANGE TIE PLATE BAG 3500 BLUE SAFETY CHAIN BAG Z 9DK 063 63 DECK ADJUSTABLE PARKING LEG w PAD 3500 Ib AXLE SPRING 3500 Ib AXLE Z 9HC BLN 02 DUO HITCH ASSEMBLY K2637 2 LARGE TRAILER PARTS LIST ADJUSTABLE PARKING LEG w PAD 3500 Ib AXLE SPRING 3500 Ib AXLE DUO HITCH ASSEMBLY Z 8TO FXM R Z 8TO FXM L AXLE ASSEMBLY Use the following steps to assemble the axle The axle is built with a slight camber arch to help the tires wear properly when the trailer is loaded With no load
14. t rests on the towing vehicle hitch that is the downward pressure on the coupler 3 Remove and adjust the trailer load to get correct tongue weight 4 Do not let tongue weight exceed coupler and hitch rating LIGHTS Optional Incorrectly working lights can cause accidents Use the following maintenance tips to insure proper trailer function 4 Check all lights and connectors for proper installation and operation before using the trailer 2 Check condition of wiring harness leads plugs and connections regularly Repair or Replace damaged parts or wires Replace any broken lenses reflectors and bulbs 4 Tele TE ELECTRIC TRAILER SPECIFICATIONS TRAILER MODEL K2635 1 SMALL 63 DECK TIRE LOAD RATING B 1100 Ibs ea TRAILER MODEL K2636 1 MEDIUM 63 DECK SPECIFICATION DESCRIPTION AXLE RATING 3500 Ibs SPRING RATING 1750 Ibs ea 3500 ibs TIRE LOAD RATING C 1360 Ibs ea 2720 Ibs TIRE LOAD RATING C 1760 Ibs ea 3520 Ibs LINCOLN ASSEMBLY PRECAUTIONS When assembling the trailer insure that you wear approved safety glasses with side shields Flying metal or dirt can injure eyes Do not modify or change the trailer in any way changes will void the warranty The following is a list of safety precautions that must be followed when assembling the trailer 1 Read and follow instructions and safety precautions in this Owner s Manual U
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