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  • trailblazer problem

    I have a TB250G, 1100 hrs. Thursday went to a job & welded about 15 ft. with mig & when I went to grind, welder revved up but no 110v power. Swapped grinder, eliminated ext. cord, checked breaker resets, all o/k. Shut off machine while thinking, started it up to see if it would weld & it had 110v power now. Finished grinding, grab the gun & now no juice to the feeder. Shut it down & started it up again now all is well. Friday no problem. Today on my second job I was stick welding & changed rods & now it won't weld. Checked all the connections, flipped switches, nothing worked so I shut it down, started it back up & it worked fine. Happened again a little while later & after shutting it down it worked fine again. Finished up the last couple rods & packed up. Now I'm worried about it crapping out somewhere in the middle of an important job. I don't know where to start to look, any ideas?
    MM250
    Trailblazer 250g
    22a feeder
    Lincoln ac/dc 225
    Victor O/A
    MM200 black face
    Whitney 30 ton hydraulic punch
    Lown 1/8x 36" power roller
    Arco roto-phase model M
    Vectrax 7x12 band saw
    Miller spectrum 875
    30a spoolgun w/wc-24
    Syncrowave 250
    RCCS-14

  • #2
    What year was your 250G manufactured? You can do a little searching above, under "resources", with your serial number you can find out.

    I had the exact same problem, with one made in 1988. Ran into a Miller rep at a trade show, called him a few days later with a serial number, problem was something to do with the exciter. He sent me a new circuit board, with a red push-button switch, some wires, and instructions, free, this was a factory update dealing with a defect in this machine, manufactured at that particular time. My little brother was an electronic tech at the time, had no problem doing the install. Anytime after that, if the power went off, the red button glowed, just push it, and keep welding/grinding.
    Obviously, I'm just a hack-artist, you shouldn't be listening to anything I say .....

    Comment


    • #3
      JH184714 which makes it a 1987. I'll have to check with Miller about the exciter. This is the first time it's happened.
      Last edited by MMW; 07-31-2010, 07:24 PM. Reason: changed last 3 digits-174 to 714
      MM250
      Trailblazer 250g
      22a feeder
      Lincoln ac/dc 225
      Victor O/A
      MM200 black face
      Whitney 30 ton hydraulic punch
      Lown 1/8x 36" power roller
      Arco roto-phase model M
      Vectrax 7x12 band saw
      Miller spectrum 875
      30a spoolgun w/wc-24
      Syncrowave 250
      RCCS-14

      Comment


      • #4
        Check your oil level, possible dirty slip rings, slip ring brush not making contact or weak control bridge?
        Last edited by cruizer; 07-31-2010, 06:10 PM.

        Comment


        • #5
          Oil level is good. I'll check the brushes & slip rings tomorrow or Monday.
          MM250
          Trailblazer 250g
          22a feeder
          Lincoln ac/dc 225
          Victor O/A
          MM200 black face
          Whitney 30 ton hydraulic punch
          Lown 1/8x 36" power roller
          Arco roto-phase model M
          Vectrax 7x12 band saw
          Miller spectrum 875
          30a spoolgun w/wc-24
          Syncrowave 250
          RCCS-14

          Comment


          • #6
            Checked brushes/slip rings & they looked o/k. Cleaned slip rings & brushes with 150 paper & then 400 today. It is working now so I hope it stays working.
            MM250
            Trailblazer 250g
            22a feeder
            Lincoln ac/dc 225
            Victor O/A
            MM200 black face
            Whitney 30 ton hydraulic punch
            Lown 1/8x 36" power roller
            Arco roto-phase model M
            Vectrax 7x12 band saw
            Miller spectrum 875
            30a spoolgun w/wc-24
            Syncrowave 250
            RCCS-14

            Comment


            • #7
              Same thing happened twice today in about 6 hrs. run time. Once while grinding & once while stick welding. Shut it down for a minute then start it & all is well. Cruizer you mentioned the control bridge might be weak. What/where is it & how would you test it? I know close to nothing when it comes to electronics.
              MM250
              Trailblazer 250g
              22a feeder
              Lincoln ac/dc 225
              Victor O/A
              MM200 black face
              Whitney 30 ton hydraulic punch
              Lown 1/8x 36" power roller
              Arco roto-phase model M
              Vectrax 7x12 band saw
              Miller spectrum 875
              30a spoolgun w/wc-24
              Syncrowave 250
              RCCS-14

              Comment


              • #8
                You really want to check your oil level properly, Yours probably has a yellow cap and o-ring. Don't press the dipstick all the way to check, just put the dipstick to the o-ring. I think the level is kinda on the line, not quite shutting down but enough to disrupt the electronics when hot.

                Comment


                • #9
                  Oil level is good. It is an Onan engine & dipstick has black cap. Directions say to screw it in (1/4 turn) to check level & it is full. Truck is on a level area when this happened. Right now it is only inconvenient when it happens but I'm afraid that sometime the power won't come back on. I know a repair center might be guessing because it's very intermittant. When I get a chance I'll call & see what they say.
                  MM250
                  Trailblazer 250g
                  22a feeder
                  Lincoln ac/dc 225
                  Victor O/A
                  MM200 black face
                  Whitney 30 ton hydraulic punch
                  Lown 1/8x 36" power roller
                  Arco roto-phase model M
                  Vectrax 7x12 band saw
                  Miller spectrum 875
                  30a spoolgun w/wc-24
                  Syncrowave 250
                  RCCS-14

                  Comment


                  • #10
                    Brushes

                    I haven't seen how the brushes are on the TB but I have problems with grinders where the spring holding them in place somehow slip and push the brushes in on an angle and they intermitenly stop working. The springs still have a lot of tension on them but when I took the brushes out, they were on a 15* angle about.


                    Hope this is helpful and I don't look stupid because the brushes are mounted a better way on the TB then on the metabos

                    Comment


                    • #11
                      Well the actual power for the weld and auxillary circuits is derived directly from the rotor, so yes it may be a sticking or worn brush in the holder

                      Comment


                      • #12
                        I had a 1987 TB 250G & had the same issue. I take it you are saying the engine continues to run, but you lose weld current & aux power?

                        Call Miller & talk to John in performance engine drive. He explained to me it was a defect in the design of the electronic system that causes the shutoff. A simple bypass of a couple wires fixes the issue. Much like the drop in board JSFAB referred to, only a simple 5 minute splicing of a couple wires.

                        Here's the best part: I used to have it wrote down in the hard copy of the technical manual I had for it & I let it go with the machine when I sold it. Someone else asked this question on another board a year or so ago & I tore the house apart looking for that manual & then realized what had happened.

                        Either way, give them a call & talk to John. He'll fix you up. Take it to service & if they don't know about that particular issue, you'll be wasting your money.

                        Ask me how I know that....

                        I bypassed the wires he told me to & never had another issue.

                        Good luck.
                        So you're telling me...You're not nostalgic? Then, give me another word for it......

                        Comment


                        • #13
                          Update--spoke to Dan at Miller in the engine drive dept. Settled on 2 items. #1 was the varistor on the side of the rectifier, he said to do a visual & also to check the ocv where you attach the leads. The varistor looked o/k & the ocv metered within spec. #2 was the exciter control board. I didn't get into how to test it but it cost $628. He told me to unplug wires #20 & #29 from this board & connect them together. This will bypass the board which he said is an added safety measure for the machine that the earlier model did not have. It can be used with out the board. I haven't done that yet so I'll update in the future.
                          MM250
                          Trailblazer 250g
                          22a feeder
                          Lincoln ac/dc 225
                          Victor O/A
                          MM200 black face
                          Whitney 30 ton hydraulic punch
                          Lown 1/8x 36" power roller
                          Arco roto-phase model M
                          Vectrax 7x12 band saw
                          Miller spectrum 875
                          30a spoolgun w/wc-24
                          Syncrowave 250
                          RCCS-14

                          Comment


                          • #14
                            Update--I ordered new brushes since the old ones were worn but still in tolerence & a new veristor/suppressor since that was something Dan at Miller mentioned. The parts were only $40 so I figured it was worth a try. While waiting for the parts to arrive it was getting worse so I bypassed the board (PC3) & it worked fine for about 35 hours. New parts came, I installed them & hooked up the board & it did not have electrical power. Restarted it a few times before power came on which only lasted a couple minutes & then it would shut down the electric. Very intermittant as to wether it would excite or not. So I bypassed the board again & will run it like that from now on. I am assuming the board is going bad & was told it was really not needed as they only put these in for a couple years. My OCV is fine & steady so I won't worry about it, I'll just check it every so often.
                            MM250
                            Trailblazer 250g
                            22a feeder
                            Lincoln ac/dc 225
                            Victor O/A
                            MM200 black face
                            Whitney 30 ton hydraulic punch
                            Lown 1/8x 36" power roller
                            Arco roto-phase model M
                            Vectrax 7x12 band saw
                            Miller spectrum 875
                            30a spoolgun w/wc-24
                            Syncrowave 250
                            RCCS-14

                            Comment

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