Processes (X-ray Quality)Stick (SMAW) MIG (GMAW) Flux-cored (FCAW) DC TIG/pulsed TIG (GTAW/GTAW-P)Air carbon arc (CAC-A) cutting and gouging Rated: 3/16-inch carbons, Capable: 1/4-inch carbons*Air plasma cutting and gouging with optional Spectrum® models Rated: 5/8-inch mild steel

*Available for 325 models only

Output Range 275 325DC stick 30–275 A 30–325 AMIG/flux-cored 10–35 V 10–35 VDC TIG/pulsed TIG 10–275 A 10–325 A

Generator Power Output Rated at 104°F (40°C)Peak: 12,000 W — Continuous: 10,500 W

Excel™ Power (325 EFI option)2,400 W (120 V, 20 A) 60 Hz pure sine power at all speeds

Electronic Fuel Injection (EFI) (325 option)Uses up to 42 percent less fuel

Battery Charge/Jump Start (325 EFI option)Battery charge: 12/24 V, 75 ABattery jump start: 12/24 V, 350 A

IndustrialApplicationsFabricationMaintenance RepairStructural steel work Sheet metalPipe

Issued April 2016 • Index No. ED/4.75

Welder/generator is warranted for three years, parts and labor. Engine is warranted separately by the engine manufacturer.

Trailblazer 325 EFI with optionalbattery charge/jump start shown.

Trailblazer®275and325 Gas or LP Engine-DrivenWelder/AC Generator

QuickSpecs

Miller Electric Mfg. Co.An ITW Welding Company1635 West Spencer StreetP.O. Box 1079Appleton, WI 54912-1079 USA

MillerWelds.comEquipment Sales US and CanadaPhone: 866-931-9730FAX: 800-637-2315International Phone: 920-735-4554International FAX: 920-735-4125

Trailblazer welder/generatorsdeliver unbeatable arcperformance providing thesmoothest, most stable arc in the industry.

The Trailblazer exclusive technologies — Auto-Speed™ and optional Excel™ power —deliver superior runtimes, increased fuelefficiency, and improved welder/generatorperformance.

No other compact machine in the 300-ampclass delivers more welding power ormore auxiliary power with better fuelefficiency and less noise — for productive,profitable, quieter jobsites.

2

Trailblazer® Technologies

Excel™ power (option)Power at idle — a Miller exclusive. Unlike competitive machines thatprovide auxiliary power only at 3,600 rpm (max), Excel power delivers afull 2,400 watts (20 A) of 120-volt inverter-based, pure sine wave powerat all speeds, including idle. With Excel power you can operate jobsitetools like grinders at quiet, fuel-saving speeds.

Refueling time and operating costs are reduced with Excel power, whichmeans more productivity and profitability. Plus everyone on the jobsitegets a better working environment because noise levels and exhaustemissions are lowered. Excel power — available only from Miller.

Trailblazer 325with EFI & Excel power

21HOURSOF RUNTIME

15HOURSOF RUNTIME

Carburetedmodels

+6HOURS

Auto-Speed technology

Electronic Fuel Injection (EFI)

Excel power

Auto-Speed technology

Electronic Fuel Injection (EFI)

Excel power

Based on typical usage — 150 amps welding 40% of the time; 20 amps generator power 30% of thetime; and idling without load 30% of the time.

Based on generator-only use for total runtime.

Auto-Speed™ technology Matches engine speed to load — a Miller exclusive. Get the weldingpower you need — plus reduced fuel consumption and lower noise levels for a more-profitable, safer jobsite.

Unlike competitive machines that operate at 3,600 rpm (max) under any load, Miller-exclusive Auto-Speed technology responds to weldrequirements by automatically adjusting engine speed to one of four rpm levels so the engine never works harder than necessary.

Refueling time and operating costs are reduced, which means moreproductivity and profitability. Plus everyone on the jobsite gets a betterworking environment because noise levels and exhaust emissions are lowered.

2,400RPM

2,800RPM

3,600RPM

Welding below150 A

Welding above250 A

Welding between151–210 A

Welding at idle speed

3,200RPM

Welding between211–250 A

Auto-Speed in XX18 mode.

Electronic fuel injection (EFI) (option)Improve fuel efficiency for maximum productivity and profitability.Adding EFI to your Trailblazer welder/generator adds multiple benefits.With EFI, you’ll get faster, more-reliable starts in any weather —no choke adjustments needed. EFI-equipped Trailblazer machines are also up to 42 percent more fuel efficient than standard carbureted models,improving profitability. Plus, refueling less frequently means you’ll spendmore of your time welding, improving productivity.

Add Excel power to your Trailblazer with EFI, and you’ll have the mostfuel-efficient compact welder/generator available.

Battery charge/jump start (option)Reduce downtime with battery charge/jump start capability. Designedand recommended for mechanics or anyone else responsible for a fleet oftrucks or equipment. By using your Trailblazer to charge dead batteries or

jump a stubborn engine, you’ll keep your crew working and the fleet upand running.

Note: Battery charge/jump cables (300422) must be ordered separately.

Unbeatable arc performanceWide amperage output with better welding deposition rates means youcan get jobs done faster, saving time and money. The Trailblazer also hasprecise arc control, which allows you to fine-tune the arc to match your

personal preferences and quickly dial in the perfect parameters tooptimize weld quality and maximize productivity across a variety ofapplications and welding processes.

Safer, more productive jobsitesQuieter jobsites are safer and more productive because work crews cancommunicate easier, and work can start earlier and end later — even innoise-sensitive areas. If your jobsite needs a welder/generator, it needs aTrailblazer welder/generator — because no other gas-fueled choice is as quiet.

More portable, uses less truck spaceTrailblazer welder/generators are up to 17 percent smaller and 10 percent lighter then competitive machines — which means movingthem is faster and easier, for maximum productivity. And because they take up less space, Trailblazer welder/generators let work truckscarry more equipment and gear — so your work crews can be ready for anything.

Cleaner and stronger generator powerCombined with a 25-horsepower engine, Trailblazer welder/generatorsoffer 12,000 watts of clean, truly usable generator power that is Accu-Rated™, not inflated: tested to deliver uninterrupted peak output for a minimum of 30 seconds for big loads, so you can get more jobs done.

An independent welder and generator power system ensures nointeraction between jobsite tools and the welding arc, while advancedgenerator technology virtually eliminates power spikes and other electricalimperfections — so welds are cleaner and jobsite tools can run withoutinterruption, maximizing quality, productivity and profit.

Runs cooler while operatingExclusive engine and generator packaging design operates cooler andmore efficiently. The engine is rotated towards the front to create moreefficient airflow. More efficient airflow and exclusive engine location aresignificant contributors to reduced sound level and size reduction. Hot airrecirculation is eliminated when machine is mounted in tight spots, andinternal parts are kept cool for optimal performance.

Fewer refueling tripsNo other gas welder/generator in the 300-amp class lets your crewsspend more time working and less time refueling — because onlyTrailblazer welder/generators provide Auto-Speed™ technology, plusExcel™ power and electronic fuel injection (EFI) options, to delivermaximum runtime.

Maximum cost savingsLess money spent on fuel means more profit for you. Every Trailblazerwelder/generator has fuel-saving Auto-Speed technology; add optionalExcel power and EFI to save even more on fuel costs and enjoy acombination of advanced, profit-enhancing features that are only availableon a Trailblazer welder/generator.

3

Trailblazer® Benefits

$571DELIVERS PAYBACK IN 2.5 YEARS

ANNUAL FUEL SAVINGS OVER LEADING COMPETITIVE MACHINE

ADD EFI & EXCEL POWER

Estimate based on fuel cost of $2.00per gallon with machine operating for25 hours per week for 50 weeks peryear under typical usage — 150 ampswelding 40% of the time; 20 ampsgenerator power 30% of the time; andidling without load 30% of the time.

4

Performance Data Mounting Specifications

Weld LP

Weld EFI

Idle EFI

0 50

0 2000 4000 6000 8000 10000 12000

100 150 200 250 300 3500

0.50

1.00

1.50

2.00

2.50

Amperes

U.S

. Gal

./hou

r

Weld Fuel Consumption

Auxiliary Power Fuel Consumption

U.S

. Gal

./hou

r

Aux PowerCarb

Aux PowerLP

Aux PowerEFI

Watts

0

0.50

1.00

1.50

2.00

2.50

Run No-Load EFI

Run No-Load Carb and LP

Run No-Load Carb and LP

Idle EFI

Run No-Load EFIIdle Carb and LP

Idle Carb and LP

Weld Carb

Excel Power Carb

Excel Power EFI

Model

Trailblazer275

Trailblazer325

WeldingMode

CC/DC

CV/DC

CC/DC

CV/DC

Battery charge/jump start (optional)

Process

Stick/TIG

MIG/FCAW

Stick/TIG

MIG/FCAW

Rated Weld Output at 104°F (40°C)*

275 A at 28 V,100% duty cycle

275 A at 28 V,100% duty cycle

325 A at 28 V,100% duty cycle

325 A at 28 V,100% duty cycle

Charge: 75 A jump start: 350 A

Amp/VoltRanges

10–275 A

10–35 V

10–325 A

10–35 V

12/24 V

Single-Phase Generator Power

Peak12,000 watts11,000 watts with LPContinuous10,500 wattsExcel™ power (optional)2,400 watts, 20 A at 120 V, 60 Hz pure generator power at idle speed and whilewelding

Sound Levels at 7 m (23 ft.)

Weld150 A load: 65 dB (90 Lwa),325 A load: 73.5 dB (98.5 Lwa)Generator powerExcel power: 65 dB (90 Lwa),12 kW standard power:73.5 dB (98.5 Lwa)

NetWeight**

275model459 lb. (208 kg)325model460 lb. (209 kg)

Dimensions

H: 28 in. (711 mm)H: 32.75 in. (832 mm) (to top of exhaust)W: 20 in. (508 mm)D: 40.5 in.(1,029 mm)

Specifications (Subject to change without notice.)

*Rated at sea level. **Net weight without fuel.

A. 20 in. (508 mm)B. 16.5 in. (419 mm)C. 1.75 in. (44.5 mm)D. 5.12 in. (130 mm)E. 22.3 in. (566 mm)F. 40.32 in. (1,024 mm)G. .406 in. (10.3 mm) diameter

4 Holes

Engi

ne E

nd

G

A B

C

DE

F

Certified by Canadian Standards Association to both the Canadian and U.S. Standards.

Model

Trailblazer 275 and 325

Trailblazer 325 EFI

Engine Brandand Warranty

Kohler CH730, 3-year warranty

Kohler ECH730, 3-year warranty

Horsepower (HP)

Gas: 23.5 hp at 3,600 rpm LP: 21 hp at 3,600 rpm

23 hp at 3,600 rpm

Weld Speed

Auto-Speed™

2,400, 2,800, 3,200 or3,600 rpm

IdleSpeed

2,400rpm

Type

Twin-cylinder, four-cycleoverhead valve, industrialair-cooled, gasoline*(carburetor or EFI) or LP

Fuel Capacity

12 gal. (45 L)

StandardShutdowns

Low oilpressure

OilCapacity

1.5 qt.(1.4 L)

Engine Specifications (Engines warranted separately by the engine manufacturer.)

*Fuel stabilizer is recommended for gas engines that are used infrequently.

5

Function and Benefit Guide1. Weld process switch

Two wire modes — solid and flux-core• Solid: Arc characteristics optimized for steel wires which most commonly use the short circuit transfer. Turn arc control (#3) to “soft” for stainless wires and to “stiff” for aluminum.• Flux-core: Arc characteristics optimized for wires commonly used in construction and hard facing applications.

Three stick modes — EXX18, EXX10 and gouge• EXX18: Optimized for the majority of stick welding applications.• EXX10: Hot start and arc characteristics optimized for pipe applications.• Gouge: Maximized output for air carbon arc cutting and gouging.

Three Lift-Arc™ TIG modes — Auto-Stop™, Auto-Crater™ and pulse• Auto-Stop: No Auto-Crater allows full control on pipe welds with short or long arc length. Auto Stop feature allows arc to be broken without loss of shielding gas. Note: Auto-Stop prevents arc flare when the arc breaks.• Auto-Crater: Ideal for most DC TIG applications. Ramps down current at the end of the weld to “crater-out” without use of a remote control.• Pulse: Ideal for out of position, thin metals, and stainless steels where a lower amount of heat is desired while welding. Note for DC TIG Pulse: background amps = 25 percent of peak, peak time = 40 percent, at 100 pps.

2. Front panel fuel gauge with six LEDs to indicate fuel level. The amber LED lights when fuel is low.

3. Arc control is active in the stick and solid wire processes. It allows the operator to customize arc characteristics to matchpreference, electrode and joint design from a softer arc with morefluid puddle to a stiffer arc with an often more controllable puddle.The star setting is optimized for most applications and pointing thecontrol at soft or stiff is optimal for most of those arc preferences.Control is fully adjustable from 0 to 25 soft or 0 to 25 stiff.

4. Self-calibrating digital meters• Preset and actual amperage/voltage• Process settings• Maintenance functions: hour meter, oil change interval, rpms

5. Standard 14-pin receptacle with Auto Remote Sense™

for simple connection of remote controls and wire feeders.

6. Engine control: Auto-Speed™ position adjusts engine to run atlower speeds depending on total power needed for welding.

7. Optional battery charge/jump start (factory option, see page 8)A. Receptacle: Provides connection to battery charge/jump start

(12 or 24 volt)B. On/off switch: Provides simple control of the batteryC. Voltage switch: Provides simple selection of battery voltage

8. Optional Excel™ power (factory option, see page 8) providespure generator power at idle speed and while welding.Note: If Trailblazer is ordered without Excel power option, unit isshipped with two standard duplex receptacles.

8

1

2

3

4

6

5

7

A B C

Easier maintenance Oil checks that can be performed from the top by the front panelToolless panels that allow for quick accessSingle-side fuel fill and oil drain/filter

1

2

3

1

2

3

3

6

GFCI Receptacles* 300975 Field Kit contains two GFCI 120 VAC duplexreceptacles. (240 VAC GFCI receptacle not required).

LP Gas*Liquid withdrawal with vaporizer and regulator.Does not include tanks, brackets, or hose fromtank to regulator.Note: Requires LP tank mounting assembly 300917.

Electric Fuel Pump* 300976 FieldRecommended for gas engine operations ataltitudes above 5,000 feet. Improves enginestarting and high-output performance.

Spark Arrestor 300924 Field Mandatory when operating on California grass -lands, brush or forest-covered land, and allnational forests. For other areas, check yourstate and local laws.

Remote Oil Drain and Filter Kit 300923 FieldFront mount for Kohler. Makes servicing easywhen engine drive is mounted in tight spots.

Full KVA Adapter Cord 300517 FieldNEMA 14-50P to NEMA 6-50R. Adapts enginedrive 120/240 V plug to common Millermatic®

and Spectrum® 240 V plug.

Full KVA Plug Kit 119172 Field120/240 V, 50 A plug (NEMA 14-50P) to fit full KVA receptacle.

Order the following from Miller Service Parts.

Engine Tune-Up Kits 230015 Field. Kohler CH730 (gas)246115 Field. Kohler ECH730 (EFI gas)252838 Field. Kohler CH730 (LP)Includes spark plugs and engine filters.

Genuine Miller® Options *Available as factory option. See ordering information on back page.

FemaleReceptacle

Genuine Miller® Accessories

Never Flat™ TiresAvailable on Bobcat andTrailblazer running gear.• Eliminate costly jobsite

downtime• Maintain constant tire pressure and will

not develop flats• Protect against punctures• Preserve maneuverability, even when

weighed down with heavy welding cable

Off-RoadRunning Gear 300909 Gas/LP, with inner tubes300910 Gas/LP, with Never Flat tiresIncludes four

heavy-duty 15-inch tires and a rugged handleto provide maximum maneuverability.

Off-Road RunningGear withProtective Cageand Never FlatTires 300912 Gas/LPRunning gear andrugged cage with

cable holders protects your investment and iseasy to move around the jobsite.

Multi-Terrain Running Gear 300913 Gas/LP,with inner tubes300914 Gas/LP,with Never Flat tiresIncludes two heavy-

duty 15-inch tires, two 8-inch rubber swivelcasters and a heavy-duty handle. Recommendedfor all surfaces and applications, and is easy tomove around the jobsite.

Protective Cage with Cable Holders 300921 Gas/LPRugged cage withcable holdersprotects yourinvestment. Can be

used with running gear, gas cylinder mountingassembly, LP tank mounting assembly, or with trailer.

Gas Cylinder Mounting Assembly 300918 GasDesigned for use withmulti-terrain runninggear, protective cage, or by itself. Includesbase tray with bottle

bracket, vertical support rack and safety chain.Note: Not for use with LP tank mounting assembly.Not recommended for use with protective cover.

Hose and LP Tank Mounting Assembly 300917 LPDesigned for use withmulti-terrain runninggear, protective cage,or by itself. Includesbracket and clamp to

mount 33- and 43-pound tanks horizontally, andhose with fittings to converter.Note: Not for use with gas cylinder mounting assembly.Not recommended for use with protective cover.

25-foot BatteryCharge/Jump Cableswith Plug 300422

Protective Covers

300919 For gasmodels withoutprotective cage orrunning gear (shown)300920 For gasmodels with protective cage and/or running gear

Heavy-duty, water-resistant and mildew-resistant covers protect and maintain the finishof the welder.

7

Stick (SMAW) Welding

Weld Leads173851 2/0, 350-amp, 100-percent duty cycle. 50-foot stinger and 50-foot work cable.043952 2/0, 300-amp, 100-percent duty cycle. 100-foot stinger and 50-foot work cable.

Plasma Cutting

Spectrum 375 X-TREME and 625 X-TREME shown.

Spectrum® 375 X-TREME™ 907529See literature PC/9.2.Spectrum® 625 X-TREME™ 907579See literature PC/9.6.Spectrum® 875 907583See literature PC/9.8.

The Spectrum 375 X-TREME and 625 X-TREMEcome complete with protective X-CASE™

(not shown).

Multiprocess Welding

Multimatic™ 215 907693Portable, all-in-one multiprocess package weighsonly 38 pounds (17.2 kg), and features excellentarc characteristics. Exclusive multi-voltage plug(MVP™) provides flexibility to plug into 120- or240-volt power. Take it anywhere you need to MIG, TIG or stick weld. See literature DC/12.59.

MIG/Flux-cored Welding

Millermatic 211 shown.

Millermatic® 141 907612See literature DC/12.42Millermatic® 190 907613See literature DC/12.44Millermatic® 211 907614See literature DC/12.58Millermatic® 212 Auto-Set™ 907405See literature DC/12.46The Millermatic line of MIG welders are completearc welding power source, wire feeder and gunpackages designed for portability and ease of use. Note: The Millermatic machines can be operatedutilizing generator power.

SuitCase® X-TREME™ 8VS Wire Feeder 951583SuitCase® X-TREME™ 12VS Wire Feeder951543Lightweight, voltage-sensing wire feeders includesecondary contactor, gas valve, drive roll kit andMIG gun. See literature M/6.42.

SuitCase® 12RC WireFeeder 951580Lightweight and flexibleenough to run a variety ofwires up to .062-inchdiameter. Includes remotevoltage control, drive roll kitand MIG gun. See literatureM/6.5.

Spoolmatic® 30ASpool Gun 130831Air-cooled, 200-amp,one-pound spool gunfor aluminum MIG.See literature M/1.73.

Requires WC-24 control (137549).

XR™ Wire Feeders and GunsPush-pull system designed to handle difficult-to-feed soft alloy wires such as aluminum. See literature M/1.7 through M/1.75.

TIG (GTAW) Welding

Dynasty®

210 SeriesFor portableAC/DC TIG. See literatureAD/4.81.

Remote Controls

Wireless Remote HandControl 300430For remote current, voltageand contactor control.Receiver plugs directly intothe 14-pin receptacle of Miller

machine. 300-foot (91.4 m) operating range.Note: Not compatible with RFCS-14 HD foot control.

RHC-14 Hand Control 242211020Miniature hand control forremote current and contactorcontrol. Dimensions: 4 x 4 x

3.25 inches (102 x 102 x 82 mm). Includes 20-foot (6 m) cord and 14-pin plug.

RFCS-14 HD FootControl 194744Heavy-duty footcurrent and contactorcontrol. Includes 20-foot (6 m) cordand 14-pin plug.

RMLS-14 129337 14-pin plugMomentary- and maintained-contact rockerswitch for contactor control. Push forward formaintained contact and back for momentarycontact. Includes 20-foot (6 m) cord.

RCC-14 Remote Contactor and Current Control151086 14-pin plugSide-to-side rotary-motion fingertip controlfastens to TIG torch using two hook-and-loopstraps. Includes 28-foot (8.5 m) control cord.

Extension Cables for 14-Pin Remote Controls242208025 25 ft. (7.6 m)242208050 50 ft. (15.2 m)242208080 80 ft. (24.4 m)

Trailers and Hitches

HWY-1000 Trailer 195013A 1,000-pound (454 kg) capacity highway trailerwith welded steel tubing frame, heavy-duty axle with roller bearing hubs and leaf-springsuspension. The HWY-1000 comes with jack stand,2-inch (50 mm) ball hitch, fenders and lights. Note: Trailer is shipped unassembled.

Cable Tree 195023Provides an area to conveniently wrap weld cablesand extension cords on the HWY-1000 trailer.

Dual Hitch 3008312-inch (50 mm) ballhitch and 3-inch (76 mm)lunette eye in onereversible assembly.

Genuine Miller® Accessories (Continued)

Ordering InformationEquipment and Options Stock No. Description Qty. Price

Trailblazer® 275 907506 Kohler engine, with GFCI receptacles

Trailblazer® 275 LP 907691 Kohler LP engine with Excel™ power and GFCI receptacles

Trailblazer® 325 907510001 Base model with Kohler engine 907510 Kohler engine, with GFCI receptacles 907510002 Kohler engine, with electric fuel pump

Trailblazer® 325 EFI 907512 Kohler engine, with electronic fuel injection 907512001 Kohler engine, with electronic fuel injection and Excel™ power 907512003 Kohler engine, with electronic fuel injection, Excel™ power and GFCI receptacles 907512002 Kohler engine, with electronic fuel injection, Excel™ power and battery charge/jump start

Field Options Options listed below can be added to the above packages. Installation is required.

GFCI Receptacles 300975

Electric Fuel Pump 300976 Recommended for gas engine operations at altitudes above 5,000 feet

Spark Arrestor 300924

Remote Oil Drain and Filter Kit 300923 Front mount for Kohler

Full KVA Adapter Cord 300517

Full KVA Plug 119172

Engine Tune-Up Kits See page 6. Order from Miller Service Parts

Accessories

Off-Road Running Gear 300909 Gas/LP models, with inner tubes 300910 Gas/LP models, with Never Flat™ tires

Off-Road Running Gear 300912 Gas/LP models, with Never Flat™ tireswith Protective Cage

Multi-Terrain Running Gear 300913 Gas/LP models, with inner tubes 300914 Gas/LP models, with Never Flat™ tires

Protective Cage w/Cable Holders 300921 Gas/LP models

Gas Cylinder Mounting Assembly 300918 Gas models. Not for use with LP tank mounting assembly. Not recommended for use with protective cover

Hose and LP Tank Mounting 300917 LP models. Not for use with gas cylinder mounting assembly.Assembly Not recommended for use with protective cover

25-foot Battery Charge/ 300422Jump Cables with Plug

Protective Covers See page 6

Stick Weld Leads See page 7

Spectrum® Plasma Cutters See page 7

Multimatic™ 215 Welder 907693 All-in-one MIG, TIG and stick welding. See literature DC/12.59

Millermatic® Series MIG Welders See page 7

SuitCase® Portable Wire Feeders See page 7

Spoolmatic® 30A Spool Gun 130831 Requires WC-24 control. See literature M/1.73

WC-24 Control 137549 See literature M/1.73

XR™ Wire Feeder Control and Guns See literature M/1.7, M/1.71, M/1.73, M/1.74 and M/1.75

Dynasty® 210 Series TIG Welders See literature AD/4.81

Remote Controls and Cords See page 7

HWY-1000 Trailer 195013

Cable Tree 195023

Dual Hitch 300831

Date: Total Quoted Price:

© 2016 Miller Electric Mfg. Co.

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