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Trailblazer 250 G PROBLEMS

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  • Trailblazer 250 G PROBLEMS

    New here and looking for advice. Working on a Trailblazer 250 G for a friend . Got Onan engine running well but will not produce electricity at receptacles or weld. It is serial number JG 109148 . I have cleaned slipped rings and brushes , cleaned contactors , flashed the field per instructions of helpful guys in Wisconsin. I have read on this board that PC3 can be a problem [ exciter field shutdown board ] I have seen some mention that this board can be bypassed by simply connecting wires 20 and 29 on this board together. Does anyone have knowledge if this is correct and if it is , can the board otherwise be completely eliminated or would I simply leave the other components and and wires intact after removing 20 and 29 from the board and connecting them together. Any help truly appreciated. This welder is about a 1986 model .

  • #2
    Here is the manual

    https://www.millerwelds.com/files/ow...s/O426_MIL.pdf

    .

    *******************************************
    The more you know, The better you know, How little you know

    “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

    Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

    My Blue Stuff:
    Dynasty 350DX Tigrunner
    Dynasty 200DX
    Millermatic 350P w/25ft Alumapro & 30A
    Millermatic 200

    TONS of Non-Blue Equip, plus CNC Mill, Lathes & a Plasmacam w/ PowerMax-1000

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    • #3
      Thanks . I have both the owners and service manuals. I have not followed the test procedure for the board but it has obvious signs of damage. The bypass procedure I am inquiring about is not mentioned. Previous participants on this forum have discussed the bypass and mentioned it was suggested by a Miller Tech. I do appreciate you taking the time to try to help me.

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      • #4
        If Miller suggested it, why not just give them a call? They are very helpful!

        Comment


        • #5
          I just called and you are right about them being helpful. They are some of the most knowledgeable and helpful folks I have ever dealt with . They confirmed the procedure to bypass the board .

          Comment


          • #6
            It worked and I have genrator power ! Now I am wondering how concerned I should be that one of the 3 brushes is producing a yellow arc as it rides on the slip ring .

            Comment


            • #7
              Originally posted by trailbazer View Post
              It worked and I have genrator power ! Now I am wondering how concerned I should be that one of the 3 brushes is producing a yellow arc as it rides on the slip ring .
              might be a tad short...... and not getting proper contact pressure
              .

              *******************************************
              The more you know, The better you know, How little you know

              “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

              Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

              My Blue Stuff:
              Dynasty 350DX Tigrunner
              Dynasty 200DX
              Millermatic 350P w/25ft Alumapro & 30A
              Millermatic 200

              TONS of Non-Blue Equip, plus CNC Mill, Lathes & a Plasmacam w/ PowerMax-1000

              Comment


              • #8
                Can I run it without causing any major damage to the machine ? . I am a pretty fair mechanic until it comes to electrical issues and with those I am not well versed.

                Comment


                • #9
                  How dramatic is the arcing? If just very tiny little sparks, it may be OK for a bit but you need the opinion of a real tech like Cruizer. I would seek the cause of the arcing. H80N lists two of the most common. Not sure how to find out how long the brush should be, but the spring should be holding it pretty firmly against the slip ring. Another possibility is some crud got in the brush holder and the brush can't slide freely. Clean the brush holder and brush-I would use some alcohol if it were mine-and be sure it slides freely without binding.Is the arcing slip ring a different color than the other two? If it's been arcing for a while it might turn darker.

                  Your experience calling Miller is typical, and is the primary reason I have blue welders. It is rare to find that kind of support in today's world. Glad you got it working! Success is a great feeling!
                  Last edited by Aeronca41; 07-08-2016, 08:41 PM. Reason: Saw another post pop up.

                  Comment


                  • #10
                    Originally posted by Aeronca41 View Post
                    How dramatic is the arcing? If just very tiny little sparks, it may be OK for a bit but you need the opinion of a real tech like Cruizer. I would seek the cause of the arcing. H80N lists two of the most common. Not sure how to find out how long the brush should be, but the spring should be holding it pretty firmly against the slip ring. Another possibility is some crud got in the brush holder and the brush can't slide freely. Clean the brush holder and brush-I would use some alcohol if it were mine-and be sure it slides freely without binding.Is the arcing slip ring a different color than the other two? If it's been arcing for a while it might turn darker.

                    Your experience calling Miller is typical, and is the primary reason I have blue welders. It is rare to find that kind of support in today's world. Glad you got it working! Success is a great feeling!
                    Well put...

                    on brush length...... would think it's in your service manual.....

                    otherwise.... I would call Miller again... they would know
                    .

                    *******************************************
                    The more you know, The better you know, How little you know

                    “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

                    Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

                    My Blue Stuff:
                    Dynasty 350DX Tigrunner
                    Dynasty 200DX
                    Millermatic 350P w/25ft Alumapro & 30A
                    Millermatic 200

                    TONS of Non-Blue Equip, plus CNC Mill, Lathes & a Plasmacam w/ PowerMax-1000

                    Comment


                    • #11
                      I adjusted it and no more arcing . I appreciate the input

                      Comment


                      • #12
                        Sounds good; glad we could help. So is the whole machine working now?

                        Comment


                        • #13
                          If you haven't seen it this is my thread. It confirms what you already now know about bypassing the exciter board with wire 20 & 29 & leaving the rest of the board connected. Since I've done it many years ago it has been fine. Never had the issue again.

                          http://www.millerwelds.com/resources...highlight=250G
                          MM250
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                          • #14
                            I know all the outlets work . I did not have a set of cables handy before I had to quit working on it to attend to other business. I did hook up a set of jumper cables and got an arc , so yes I believe it is going to weld . Hope to test it out when I get back in town to work on it.

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