The Miller Roughneck 1E is a portable arc welder/generator combination. The unit employs an electric-start, gas-powered engine. Miller has manufactured welders since 1929, and you can find its units throughout the world. Problems that may occur include low or no weld output, dirty spark plugs and air filters, and low power output. Perform a little troubleshooting on your own before calling a Miller technician for a service.

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Take care of your welds with the Miller 1E Welder.

Step 1

Place the "Weld/Power" switch in the "Power" position if the unit has no power output. Place the throttle in the "Power" position.

Step 2

Move the "Weld/Power" switch to the "Weld" position if the welder has no weld output. Check that the connections to the switch remain secure.

Step 3

Twist the jack plugs connected to both the work and electrode receptacles if the weld current is erratic. Twist the jack plugs clockwise to secure them.

Step 4

Adjust the engine speed if the weld output is low. Start the engine, and place the throttle against the stop in the "Power" position. Place the "Weld/Power" switch in the "Power" position. Rotate the nuts on the power speed adjustment until the engine runs at 1,800 revolutions per minute (rpm). Check the speed of the engine with a tachometer. Place the throttle in the "Weld" position. Check that the throttle sits against the stop. Place the "Weld/Power" switch in the "Weld" position. Loosen the weld speed adjustment screw on the throttle with a screwdriver until the engine runs at 3,600 rpm. Tighten the adjustment screw. Press the governor arm toward the carburetor until the engine idles. While holding the arm, rotate the idle adjustment screw until the engine runs at 1,500 rpm. (The idle adjustment screw is on the carburetor.)

Step 5

Clean the collector rings with 120-grit sandpaper if the welder has low power and low weld output, or no power and no weld output. The brushes may have become defective; have them replaced if necessary.

Step 6

Remove the spark plug with a Spark plug socket wrench to check for dirt or corrosion. Clean the plug with a wire brush. Replace the plug if the insulation has sustained damage.

Step 7

Turn the choke fully counterclockwise before starting the welder engine when the engine is cold. Slowly rotate the choke clockwise as the engine warms up. Rotate the choke until you have rotated it clockwise as far as it can go.

Step 8

Remove and clean the paper air cleaner, or filter. Tap lightly against the filter to dislodge debris. Do not use compressed air on the filter, which could perforate the surface. Always cover the air filter hole when cleaning the filter to prevent dirt from falling into the carburetor.