Roughneck 2E, low voltage from 120 outlets
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  1. #1
    Join Date
    Sep 2014
    Location
    texas
    Posts
    163

    Roughneck 2E, low voltage from 120 outlets

    Serial number is HK347656. I have not checked the output on the welding side yet. I'm only seeing about 9-12 volts from the outlets, and it didn't get much higher when I manually held the throttle open. The slip rings are clean and the brushes are free in the holders. I also noticed that it isn't charging the battery. Didn't have a lot of time to work on it today, but I did visually check for broken or disconnected wires. Only problem wires went to the coil under the flywheel, which I found because it had no spark. Fixing the wires cured the no spark problem. What do I need to look for next?

  2. #2
    Join Date
    May 2008
    Location
    Orange, TX
    Posts
    16,642

    Re: Roughneck 2E, low voltage from 120 outlets

    Have you downloaded the unit manual and reviewed the Troubleshooting section?

    https://www.millerwelds.com/files/ow.../O420L_MIL.pdf

    One thing the first troubleshooting item doesn't cover is a failed field bridge rectifier SR1 which can cause a failed fuse F1.
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  3. #3
    Join Date
    Sep 2014
    Location
    texas
    Posts
    163

    Re: Roughneck 2E, low voltage from 120 outlets

    Probably won't have time to fool with it again until this weekend. I'll pull the cover back off, check/replace the fuse, and test/replace the rectifier. It's obviously been sitting a while.

    I noticed that in the manual it listed the engine as a Tecumseh OH160. Mine has an OH140.

  4. #4
    Join Date
    Sep 2014
    Location
    texas
    Posts
    163

    Re: Roughneck 2E, low voltage from 120 outlets

    Ok, so I just went down and pulled the cover off to look for a fuse and a bridge rectifier. I found neither...so I came back here to the house to study the diagram a little more thoroughly. The manual you linked is for a newer model than mine...I think O420E is the correct one. The schematic number in it matches the one inside the machine cover anyway.

    After sitting here looking at it for a few minutes, I've realized that both of the rectifiers are made of individual diodes on the circuit board and that the "fuse" is actually what I would call a fusible link. I was expecting to see a replaceable glass acg type fuse and those little square four terminal rectifiers. Do you happen to have any idea of what value that "fuse" should be? I'm going to guess based on the diodes that it needs to be around 3 amps. It appears to be intact, but I may replace it with a board mounted acg fuseholder/fuse.

  5. #5
    Join Date
    May 2008
    Location
    Orange, TX
    Posts
    16,642

    Re: Roughneck 2E, low voltage from 120 outlets

    My bad. I grabbed the wrong link. You are correct, the proper manual for your unit SN is O420E.

    https://www.millerwelds.com/files/ow.../O420E_MIL.pdf

    I would go with your conclusion regarding the capacity of fuse F1.
    MM200 w/Spoolmatic 1
    Syncrowave 180SD
    Bobcat 225G Plus - LP/NG
    MUTT Suitcase Wirefeeder
    WC-1S/Spoolmatic 1
    HF-251D-1
    PakMaster 100XL
    '68 Red Face Code #6633 project
    Star Jet 21-110

    Save Second Base!

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