miller blue charger
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  1. #1
    Join Date
    Mar 2017
    Posts
    21

    miller blue charger

    so i pick up a miller blue charger the other day with a onan p218. i didn't pay much for it got it home and tried to get it going com to find out moister got in the exhaust and caused the valve to rust and fill the cylinder with rusty water and a litte build up on the walls but sins the block is aluminum its not pitting or rusting im letting it sit with the cyilinder filed with marvel mystery oil and see if it cleans up . but what i am wondering is if any one know of a used engine off a miller legend or bobcat that would work ive been looking for a welder with a bad generator or something if i cant get the old motor going thanks Name:  IMG_4228.jpg
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  2. #2
    Join Date
    Mar 2018
    Posts
    44

    Re: miller blue charger

    My trailblazer had a similar situation with water but the engine was stuck.
    Let it soak be patient pull the heads off and clean all the carbon rust etc out on the pistons and heads make sure the valves are freed up as well.
    I gave mine a light hone and it seems to be fine even with light pitting in the cilinders runs great no smoke .
    I think the Lincoln ranger used a p218 as well Lot of times the Onans can be saved there pretty tough pretty sure those are cast iron lined sleeves.
    Keep us posted
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  3. #3
    Join Date
    Mar 2017
    Posts
    21

    Re: miller blue charger

    so i worked on the blue charger to day and found a pit or sand hole in the cylinder wall so that engine is not going to run again. im on the look out for a replacement engine

  4. #4
    Join Date
    Mar 2017
    Location
    bar stool
    Posts
    2,097

    Re: miller blue charger

    LOCATION is everything when it comes to finding Onan parts

  5. #5
    Join Date
    May 2008
    Location
    Orange, TX
    Posts
    17,296

    Re: miller blue charger

    Finding an exact replacement engine may be harder than you think. Many that you will find will have a straight output shaft whereas you need the correct Miller tapered shaft.

    That said, a couple other options would be to have your block bored or sleeved or put your crank in another engine that you find that has a different output configuration.

    As for parts, member onanparts.com can help you there.
    https://www.onanparts.com/
    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

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  6. #6
    Join Date
    Oct 2016
    Posts
    61

    Re: miller blue charger

    Those engines were used in JD garden tractors like the 318 might have better luck finding a rebuilder looking into those, but you will ikely have to swap cranks.
    Onanparts did a good rebuild thread. https://weldingweb.com/showthread.ph...-Dead-or-Alive

  7. #7
    Join Date
    Mar 2017
    Posts
    21

    Re: miller blue charger

    ok so a up date on the blue charger. so i got the engine running even with the sand hole i lapped the valves on both cylinders and got around 120 in one and 110 psi in the other so had trouble with it only firing once then dying com to find out its a bad oil switch jumped that and she ran. now my problem is 120 power is putting out about 190v idk why that would be i dint know if any may know thanks

  8. #8
    Join Date
    Mar 2010
    Location
    Ceres, California
    Posts
    3,365

    Re: miller blue charger

    Check the engine rpm and the voltage frequency. if frequency is around 65 hz voltage will be higher. Find a frequency meter and set engine speed for 61hz with no load on the welder.
    It will drop to 60hz soon as a load is applied. Then look for a voltage adjustment. Some times the weld voltage knob will also control the aux power. If you want an owners manual, you will need to call miller and have them e-mail you one.

  9. #9
    Join Date
    May 2008
    Location
    Orange, TX
    Posts
    17,296

    Re: miller blue charger

    Based on the unit SN you posted, this should be the Operator's Manual for the machine:
    https://www.millerwelds.com/files/ow.../O429D_MIL.pdf
    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!

  10. #10
    Join Date
    Mar 2017
    Posts
    21

    Re: miller blue charger

    ok thanks so I changed the rims and got the 120 volts but then I lost all ac power I checked the breaker there all good no power are getting to them . I still have the 100 hz power and I did see that I had a broken wire that hooks to the suppressor I re hooked to the other terminal on the same side and still no power. an ideas

  11. #11
    Join Date
    Oct 2016
    Posts
    61

    Re: miller blue charger

    You know that these dont produce 120/240 at weld speed? Just checking.
    At weld speed- 3000 rpm the outlets should be dead, only the single 100 hz outlet should be live. When it idles down to 1860 rpm the outlets come live.
    Even without welding you can check to see if the idle module is good by using something like a drill on the 100 hz outlet, the machine should go to weld speed when a load is applied, and idle back down after about 10 seconds after the load is removed.
    If you have the top off, have a look at the big resistors to the front, check that the straps are good on them. They may not be making contact if old and rusty. Also take a look at the slip rings and brushes, might have a stuck brush?
    I take it you got the engine running, thats good to hear, I have a legend, great machine.
    Duaneb55 is a good resource of knowledge here, he knows these machines well.

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