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Miller Trailblazer 250G, Full power on all settings.

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  • Miller Trailblazer 250G, Full power on all settings.

    I got this welder used, don't know much about it. I serviced the engine, new battery and replaced both battery cables. The welder goes full bore on all settings, cannot turn it down. Gouges 1/2 plate with a 1/4 7018.

    At the welding lugs OC, 100-145V.

    I have AC power, 122VAC 60Hz AT IDLE, At high idle. 100Hz-300Hz.

    S# KC328408

    At least it works, that good for a used purchase, eh. Thank you, for any help with this. I would like to figure it out, however might drop it off at the Miller service center, next week.

  • #2
    Is your frequency meter accurate? Did you check it against utility power?

    If the meter is accurate that machine is spinning WAY TOO FAST.

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    • #3
      Didn't think of checking it. Just tried now, 120Hz from the utility. It's out to lunch. I have a meter at work I will try. (Mechanic, by trade.) I will see if I can find out what RPM, it's running at.

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      • #4
        Originally posted by Zero67 View Post
        Didn't think of checking it. Just tried now, 120Hz from the utility. It's out to lunch. I have a meter at work I will try. (Mechanic, by trade.) I will see if I can find out what RPM, it's running at.
        Nothing like a eefed up test device to make the whole job harder.
        Getting people to verify test equipment before beginning is a great difficulty in the world.

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        • #5
          Ok, checked my gear and got my better meter home.

          1705 RPM Idle 40-100Hz. didn't get voltage at idle.

          3550 RPM High idle, 230Hz Ish.(all over the map, over 120Hz.) 122VAC.

          The Tachometer is not the most accurate, but passable. +100RPM, It showed my truck at a lower RPM, then that Tach and scan tool. So ok ballpark.

          The Unit stopped charging, it was at 14.5V. Now not charging anymore. Not sure if I should fix that first, or work on the lack of Voltage control.

          Thanks for any help.

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          • #6
            Just a hunch, I'd work back from the battery first.

            I have a pretty good feeling everything on that machine functions using battery as a reference if not source.

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            • #7
              I will work on that tomorrow, bit late to fire it up. to check the Stator and Volt regulator out. I will get that problem fixed, and see if that fixes my unit.

              (Bugging me, and downstairs left. So fair game to start it.)
              Did a little testing.
              -Voltage Reg has B+ at all three connections. B+ only on one wire,
              -Stator .3 ohms, OL to case.
              -50V VAC

              Looks to me the Voltage reg is fried out of it mind. Going to get one, when I find a place in town, or Amazon. (Canadian, might take a week to get it.) Or get a old ford reg and wire it in. IDK.
              Last edited by Zero67; 11-05-2019, 10:12 PM.

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              • #8
                Well my part came in, couldn't get a Onan Reg, got a Kohler, at least it was only $75. Charging perfect now, 14.7V. However the welding part is still the same and my AC is still that same. So fixed A problem, just not THE problem.


                However there is one thing, when it's switched to remote OC voltage drops to 1-2V. not sure if that is helpful. Not willing to buy a remote at this time, I would like to get it working properly first, before buying items. Going to drop it off at the service center on the 25th. (I have 2 Mondays a month off.) See if they have any idea.
                Last edited by Zero67; 11-10-2019, 09:49 AM.

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