Trailblazer® 275 and 325

Trailblazer 275 and 325
Issued July 2012 • Index No. ED/4.75
Gas or LP Engine-Driven
Welder/AC Generator
Industrial Applications
Processes (X-Ray Quality)
Output Range
Structural Steel Work
Sheet Metal
Stick (SMAW)
Flux-Cored (FCAW)
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
DC Stick
Pulsed TIG (peak)
30–275 A
10–35 V
10–275 A
10–275 A
30–325 A
10–35 V
10–325 A
10–325 A
*Available for 325 models only
Uses up to 27 percent less fuel
Generator Power Output Rated at 104° F (40° C)
Peak: 12,000 W — Continuous: 10,500 W
Excel™ Power (Recommended Option)
2400 W (120 V, 20A) 60 Hz pure sine power at all speeds
Electronic Fuel Injection (EFI) (Recommended Option)
The Power of Blue .
Fewer refueling trips
Significant cost savings
Designed for the professional welder,
our Trailblazer welder/generators deliver
unbeatable arc performance in all weld
processes, providing the smoothest,
most stable arc in the industry. The
independent welder and generator power
system means no interaction between
jobsite tools and the welding arc.
Safer, more productive
108 lb.
When you add optional engineered
exclusives like Excel power and
Electronic Fuel Injection (EFI), your new
Trailblazer becomes more fuel-efficient,
cost-effective and quieter than ever before.
Trailblazer 325 EFI model shown.
Easier mobility and uses less
truck space and payload
Welder/generator is warranted for 3 years, parts and labor.
Engine is warranted separately by the engine manufacturer.
Miller Electric Mfg. Co.
Equipment Sales US and Canada
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
Base Model New Technologies
(Standard on all models.)
Smart-Cor Technology
Smart-Cor technology in our new Trailblazer® welder/generators
includes a newly designed ten-degree skewed rotor and Wave
Filter™ technology for a new level of clean generator power. The
independent welder and generator power system means no
interaction between jobsite tools and the welding arc.
Wave Filter
advanced hybrid
welding power
Wave Filter technology and 10-degree skewed rotor. The electronics found in some jobsite tools, plastic fusion welders, bore
welders and appliances — such as furnaces and air conditioners
— are sensitive to “dirty” generator power, which is measured in
terms of harmonic frequencies and crest factor.
The ten-degree skewed rotor creates cleaner generator power by
eliminating slot harmonics. Slot harmonics make up a portion of
the total harmonic frequencies in a generator, and by eliminating
them, generator power is smoother power, not spiked power.
The Wave Filter technology has taken total harmonic frequencies
to a new low, and has a nearly perfect crest factor — which means
that Trailblazer welder/generators will deliver cleaner power in any
situation and keep your jobsite tools running without interruption.
skewed rotor
12,000 watts of
clean generator
Auto-Speed Technology
Traditional high-speed welder/generators always run at maximum
speed (3600 RPM) while you’re welding — regardless of whether
you need that much power. And when you’re running harder than
you need to be, your fuel efficiency drops dramatically.
Auto-Speed technology automatically adjusts the engine speed to
match your actual weld load requirements. Need more power? The
engine will automatically ramp up. Change processes to something
requiring less power, and the Trailblazer will automatically slow the
engine down. For example, under low loads — such as welding
with a 1/8-inch stick electrode — the engine will run at idle speed
(2400 RPM). By automatically varying the engine speed, you can
significantly reduce fuel consumption — and cost.
Innovative Design
Engine is rotated to the front to create more efficient airflow.
Benefits it provides:
• Quieter operation
• Reduced size and weight
• Easier maintenance
Improved Arc Performance
We’ve engineered the new Trailblazer to provide high-quality welds
across a variety of applications — knowing quality welds begin
with a quality arc. That’s why we’ve significantly improved the
performance for all welding processes and made it easy to finetune the arc to match your personal preferences and welding style.
• Three Stick modes for optimized arc performance — XX18, XX10
and Gouge
• Two Wire modes for simplified setup — Solid and Flux-Core
• Three TIG modes for optimized arc performance — Auto-Stop™,
Auto-Crater™ and Pulse
• NEW! TIG Pulse mode available for out-of-position welding,
thin metals and stainless steel where a lower amount of heat is
desired while welding
• Infinite arc control available in the Stick and Solid Wire modes
for easier fine tuning of tough-to-weld materials and out-ofposition applications
Optional New Technologies
Add Excel Power and Electronic Fuel Injection (EFI) to Maximize your Trailblazer’s Performance
Improve generator performance with Excel power
Maximize performance with EFI
Excel power provides 120 volt, 60 hertz of pure sine wave generator
power at idle speed and while welding. When connected to the Excel
power receptacle, you get up to 2400 watts of the cleanest generator
power available. Plus, you can run most jobsite tools — like grinders,
chop saws, drills and lights — at idle speed, which provides:
EFI optimizes the air/fuel ratio for all engine speeds and loads.
Choose EFI for:
• Exceptional fuel-efficiency
• Extended runtimes
• Quieter operation
• Longer engine life
Up to 27% better fuel-efficiency
Extended runtimes up to 27%
Fast, easy starts in all climates
Reliable operation, even with infrequent use
Fewer emissions — 27% less CO and 33% lower HC+NOx levels
Exceptional Fuel Efficiency
All new Trailblazers include innovative Auto-Speed
technology, which enhances fuel-efficiency by regulating
engine speed. By adding optional Excel power and EFI,
you’ll experience even more dramatic fuel savings and
extended runtimes.
Excel Power (Recommended option)
Traditional welder/generators run at 3600 RPM when generator loads are applied.
But when you add Excel power to your Trailblazer, you can plug in most jobsite
tools and the machine will continue at idle speed (2400 RPM) — allowing you to do
the same job while burning less fuel. When combined with Auto-Speed technology,
Excel power allows you to weld and run tools at idle speed.
Electronic Fuel Injection (EFI) (Recommended option)
Electronic Fuel Injection significantly enhances fuel savings and extends runtimes
by optimizing the air/fuel ratio for all engine speeds and loads. When you add EFI to
your Trailblazer, your machine will run at peak fuel efficiency, regardless of how
you’re using it.
Annual Fuel Savings*
Previous Trailblazer
New Trailblazer
13 hrs.
New Trailblazer with
Excel power generator
14.5 hrs.
New Trailblazer with EFI
New Trailblazer with
Excel power generator
and EFI
Longest Runtimes*
16.5 hrs.
18 hrs.
19.5 hrs.
$1,600 5 hrs.
Annual fuel savings with typical usage of 25 hours
per week for 50 weeks at $4 per gallon
10 hrs.
15 hrs.
Runtime hours per 12-gallon tank
with typical usage
20 hrs.
*Based on typical usage — 150 amps welding 40% of the time; 20 amps generator power 30% of the time; and idling without load 30% of the time.
Significantly Less Noise
The new Trailblazer runs as low as 65 decibels
— that’s almost 11 fewer than previous models.*
On a typical jobsite, it would take twelve new
Trailblazers running simultaneously to equal the
sound output of only one of the older model.
Sound of 12 new Trailblazers
Sound of 1
*Sound cannot be measured using a linear scale; therefore, the decibel (dB) unit is
used. It is a logarithmic unit used to describe a ratio of power, sound pressure,
voltage or intensity that gauges the sound output.
Reversed Generator Airflow
Exclusive engine and generator packaging design operates cooler and more
efficiently. The engine is rotated towards the front to create more efficient
airflow. More efficient airflow and exclusive engine location are significant
contributors to reduced sound level and size reduction. Hot air recirculation
is eliminated when machine is mounted in tight spots, and internal parts are
kept cool for optimal performance.
(Subject to change without notice.)
Smaller and Lighter Design
Mounting Specifications
Thanks to Smart-Cor™ technology
and a new engine generator position,
the new Trailblazer welder/generator
takes up less space on trucks and
trailers — leaving more room on your truck for other equipment
and tools. Plus, they’re easier to move safely around jobsites —
even with weld cables and running gear attached.
4 Holes
Engine End
Rated Weld Output
at 104° F (40° C)*
Generator Power
10 – 275 A
275 A at 28 V,
100% Duty Cycle
10 – 35 V
275 A at 28 V,
100% Duty Cycle
10 – 325 A
325 A at 28 V,
100% Duty Cycle
10 – 35 V
325 A at 28 V,
100% Duty Cycle
12,000 watts
10,500 watts
Excel™ Power (optional):
2400 watts,
20 A at 120 V, 60 Hz
pure generator power
at idle speed and while
*Rated at sea level. **Net weight without fuel.
Engine Specifications
Engine Brand/
3-year mfg.
A. 20 in. (508 mm)
B. 16.5 in. (419 mm)
C. 1.75 in. (44.5 mm)
D. 12.18 in. (309 mm)
E. 22.1 in. (562 mm)
F. 40.32 in. (1024 mm)
G. .406 in. (10.3 mm)
Sound Levels at 7 m (23 ft.)
150 A Load: 65 dB (90 Lwa),
325 A Load: 73.5 dB (98.5 Lwa)
Generator Power:
Excel Power: 65 dB (90 Lwa),
12 kW Standard Power:
73.5 dB (98.5 Lwa)
H: 28 in.
(711 mm)
H: 32.75 in.
(832 mm)
(to top of
W: 20 in.
(508 mm)
D: 40.5 in.
(1029 mm)
459 lb.
(208 kg)
460 lb.
(209 kg)
Certified by Canadian Standards Association to both the Canadian and U.S. Standards.
(Engines warranted separately by the engine manufacturer.)
Horsepower (HP)
Weld Speed
25 HP at 3600 RPM
Twin-cylinder, four-cycle overhead
valve, industrial air-cooled, gasoline*
(carburetor or EFI) or LP
2400, 2800,
3200 or 3600 RPM
12 gal.
(45 L)
1.5 qt.
(1.4 L)
Standard Shutdowns
Low Oil Pressure
*Fuel stabilizer is recommended for gas engines that are used infrequently.
Performance Data
Weld Carb
Weld EFI
Run No-Load Carb
Run No-Load EFI
Idle Carb
Idle EFI
Aux Power
Aux Power
Run No-Load Carb
Run No-Load EFI
Idle Carb
Idle EFI
Function and Benefit Guide
1. 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 — XX18, XX10 and Gouge
• XX18: Optimized for the majority of Stick welding applications.
• XX10: Hot start and arc characteristics optimized for pipe
• 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 match
preference, electrode and joint design from a softer arc with more
fluid puddle to a stiffer arc with an often more controllable puddle.
The Star setting is optimized for most applications and pointing the
control 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
Easier Maintenance
With its intuitive design, the daily maintenance of our new Trailblazer
welder/generators is faster and easier. With front panel maintenance
displays, you know when your equipment needs to be serviced. And
servicing is simple because of:
• Oil checks that can be performed from the top by the front panel
• Sunvision™ technology that provides easy-to-read digital meter
maintenance displays in both direct sunlight and shade
• Toolless panels that allow for quick access
• Single-side fuel fill and oil drain/filter
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 at
lower speeds depending on total power needed for welding.
7. Optional Excel™ power (factory option, see page 8) provides
pure generator power at idle speed and while welding.
Note: If Trailblazer is ordered without Excel power option, unit is
shipped with two standard duplex receptacles.
Genuine Miller Options
*Available as factory option. See ordering information on back page.
GFCI Protection* #300 975 Field
Kit contains two GFCI 120 VAC duplex
receptacles. (240 VAC GFCI receptacle
not required).
LP Gas*
Liquid withdrawal with vaporizer and regulator.
Does not include tanks, brackets, or hose from
tank to regulator.
Note: Requires LP Tank Mounting Assembly #300 917.
Electric Fuel Pump* #195 214 Field
For gas models at high altitude. Improves
engine starting and high-output performance.
Spark Arrestor #300 924 Field
Mandatory when operating on California grasslands, brush or forest-covered land, and all
National Forests. For other areas, check your
state and local laws.
Rear Mount
#300 922 shown.
Remote Oil Drain and Filter Kit
#300 922 Field. Kohler, rear mount
#300 923 Field. Kohler, front mount
Makes servicing easy when engine drive is
mounted in tight spots.
Full KVA Plug Kit
#119 172 Field
120/240 VAC, 50 A plug
(NEMA 14-50P) to fit full KVA
Order the following from Miller Service Parts.
Engine Tune-Up Kits
#230 015 Field. Kohler CH 730 (Gas)
#246 115 Field. Kohler ECH 730 (EFI Gas)
#252 838 Field. Kohler CH 730 (LP)
Tune-up kits include spark plugs (gas/LP models)
and engine filters.
Adapter Cord, Full KVA #300 517 Field
NEMA 14-50P to NEMA 6-50R. Adapts engine
drive 120/240 V plug to common Millermatic®
and Spectrum® 240 V plug.
Genuine Miller Accessories
Never Flat Tires
Available on Bobcat and
Trailblazer Running Gear.
• Eliminate costly jobsite
• Maintain constant tire pressure and will
not develop flats
• Protect against punctures
• Preserve maneuverability, even when
weighed down with heavy welding cable
Running Gear
#300 909 Gas,
with inner tubes
#300 910 Gas,
with Never Flat™
Includes four heavy-duty 15-inch tires and
a rugged handle to provide maximum
Note: Not for use with Gas Cylinder Mounting Assembly
or LP Tank Mounting Assembly.
Off-Road Running
Gear with
Protective Cage
and Never Flat™
#300 912 Gas
Running gear and
rugged cage with
cable holders protects your investment and is
easy to move around the jobsite.
Note: Not for use with Gas Cylinder Mounting
Assembly or LP Tank Mounting Assembly.
Running Gear
#300 913 Gas/LP,
with inner tubes
#300 914 Gas/LP,
with Never Flat™
Includes two heavy-duty 15-inch tires, two 8-inch
rubber swivel casters and a heavy-duty handle.
Recommended for all surfaces and applications,
and is easy to move around the jobsite.
Protective Cage
with Cable Holders
#300 921 Gas/LP
Rugged cage with
cable holders
protects your
investment. Can be
used with running gear, Gas Cylinder Mounting
Assembly, LP Tank Mounting Assembly, or
with trailer.
Gas Cylinder
Mounting Assembly
#300 918 Gas
Designed for use with
Multi-Terrain Running
Gear, Protective Cage,
or by itself. Includes
base tray with bottle
bracket, vertical support rack and safety chain.
Note: Not for use with LP Tank Mounting Assembly or
Off-Road Running Gears. Not recommended for use
with Protective Cover.
Hose and LP Tank
Mounting Assembly
#300 917 LP
Designed for use with
Multi-Terrain Running
Gear, Protective Cage,
or by itself. Includes
bracket and clamp to
mount 33- and 43-pound tanks horizontally, and
hose with fittings to converter.
Note: Not for use with Gas Cylinder Mounting Assembly
or Off-Road Running Gears. Not recommended for
use with Protective Cover.
Protective Covers
#300 919 For Gas
models without
Protective Cage or
Running Gear (shown)
#300 920 For Gas
models with
Protective Cage
and/or Running Gear
Heavy-duty, water-resistant and mildewresistant covers protect and maintain the finish
of the welder.
Genuine Miller Accessories
Stick (SMAW) Welding
Weld Leads
#173 851 2/0, 350-amp, 100 percent duty
cycle. 50-foot stinger and 50-foot
work cable.
#043 952 2/0, 300-amp, 100 percent duty
cycle. 100-foot stinger and 50-foot
work cable.
Plasma Cutting
RHC-14 Hand Control
#242 211 020
Miniature hand control for
remote current and contactor
control. Dimensions: 4 x 4 x
3.25 inches (102 x 102 x 82 mm).
Includes 20-foot (6 m) cord and 14-pin plug.
SuitCase® X-TREME™ 8VS Wire Feeder
#951 181
SuitCase® X-TREME™ 12VS Wire Feeder
#951 184
Lightweight, portable, voltage-sensing
wire feeders include secondary contactor and
gas valve. See Lit. Index No. M/6.41.
Spectrum 375 X-TREME and 625 X-TREME shown.
Spectrum® 375 X-TREME™ #907 529
See Lit. Index No. PC/9.2.
Spectrum® 625 X-TREME™ #907 531
See Lit. Index No. PC/9.6.
Spectrum® 875 #907 390-01-1
See Lit. Index No. PC/9.8.
The Spectrum 375 X-TREME and 625 X-TREME
come complete with protective X-CASE™
(not shown).
MIG/Flux-Cored Welding
Millermatic® Passport® Plus #907 401
Portable, all-in-one MIG package features
ultimate arc performance, self-contained gas
bottle, and flexibility to plug into 115- or 230volt power with Miller exclusive Multi-Voltage
Plug (MVP™). See Lit. Index No. DC/12.53.
SuitCase® 8RC Wire Feeder #951 186
SuitCase® 12RC Wire Feeder #951 188
Lightweight, modular design and flexible
enough to run a variety of wires up to 5/64-inch
diameter. Comes standard with remote voltage
control. See Lit. Index No. M/6.5.
Spoolmatic® 30A
Spool Gun #130 831
Air-cooled, 200-amp,
1-pound spool gun for
aluminum MIG. See
Lit. Index No. M/1.73.
Requires WC-24 Control (#137 549).
XR™ Wire Feeders and Guns
Push-pull system designed to handle difficultto-feed soft alloy wires such as aluminum. See
Lit. Index No. M/1.7, M/1.71, and M/1.73.
RFCS-14 HD Foot
Control #194 744
Heavy-duty foot current
and contactor control.
Includes 20-foot (6 m)
cord and 14-pin plug.
RMLS-14 #129 337 14-pin plug
Momentary- and maintained-contact rocker
switch for contactor control. Push forward for
maintained contact and back for momentary
contact. Includes 20-foot (6 m) cord.
RCC-14 Remote Contactor and Current Control
#151 086 14-pin plug
Rotary-motion fingertip control fastens to TIG
torch using two Velcro® straps. Includes 28-foot
(8.5 m) control cord.
Extension Cords for 14-Pin Remote Controls
#242 208 025 25 ft. (7.6 m)
#242 208 050 50 ft. (15.2 m)
#242 208 080 80 ft. (24.4 m)
Trailers and Hitches
TIG (GTAW) Welding
Dynasty® 200 Series
For premium portable AC/DC
TIG arc quality. See Lit. Index
No. AD/4.8.
Millermatic 211 Auto-Set with MVP shown.
Millermatic® 140 Auto-Set™ #907 335
See Lit. Index No. DC/12.42
Millermatic® 180 Auto-Set™ #907 312
See Lit. Index No. DC/12.44
Millermatic® 211 Auto-Set™ with MVP™ #907 422
See Lit. Index No. DC/12.54
Millermatic® 212 Auto-Set™ #907 405
See Lit. Index No. DC/12.46
The Millermatic line of MIG welders are complete
arc welding power source, wire feeder and gun
packages designed for portability and ease of use.
Note: The Millermatic machines can be operated
utilizing generator power.
HWY-1000 Trailer #195 013
A 1000-pound (454 kg) capacity highway trailer
with welded steel tubing frame, heavy-duty
axle with roller bearing hubs and leaf-spring
suspension. The HWY-1000 comes with jack stand,
2-inch (50 mm) ball hitch, fenders and lights.
Remote Controls
Note: Trailer is shipped unassembled.
Wireless Remote Hand
Control #300 430
For remote current,
voltage and contactor
control. Receiver plugs
directly into the 14-pin
receptacle of Miller machine. 300-foot (91.4 m)
operating range.
Cable Tree #195 023
Provides an area to conveniently wrap weld cables
and extension cords on the HWY-1000 trailer.
Dual Hitch #300 831
2-inch (50 mm) ball
hitch and 3-inch (76 mm)
lunette eye in one
reversible assembly.
Ordering Information
Equipment and Options
Stock No.
Trailblazer 275 (Kohler)
#907 506-001
#907 506
With GFCI Receptacles
Trailblazer 275 EFI (Kohler)
#907 508
Electronic Fuel Injection with Excel™ Power
Trailblazer 275 LP (Kohler)
#907 509
#907 509-001
LP Engine
LP Engine with Excel™ Power
Trailblazer® 325 (Kohler)
#907 510-001
#907 510
#907 510-002
#907 510-003
With GFCI Receptacles
With Electric Fuel Pump
With Excel™ Power
Trailblazer® 325 EFI (Kohler)
#907 512
#907 512-001
Electronic Fuel Injection
Electronic Fuel Injection with Excel™ Power
GFCI Protection
#300 975
Electric Fuel Pump
#195 214
Field. For gas engines at high altitudes
Spark Arrestor
#300 924
Remote Oil Drain and Filter Kit
#300 922
#300 923
Field. Rear mount for Kohler
Field. Front mount for Kohler
Adapter Cord, Full KVA
#300 517
Full KVA Plug
#119 172
Field. See page 6. (Order from Miller Service Parts)
Engine Tune-Up Kits
Off-Road Running Gear
#300 909
#300 910
Gas models, with inner tubes. Not for use with Gas Cylinder or LP Tank Mounting Assembly
Gas models, with Never Flat™ tires. Not for use with Gas Cylinder or LP Tank Mounting Assembly
Off-Road Running Gear
with Protective Cage
#300 912
Gas models, with Never Flat™ tires. Not for use with Gas Cylinder or LP Tank Mounting Assembly
Multi-Terrain Running Gear
#300 913
#300 914
Gas/LP models, with inner tubes
Gas/LP models, with Never Flat™ tires
Protective Cage w/Cable Holders
#300 921
Gas/LP models
Gas Cylinder Mounting Assembly
#300 918
Gas models. Not for use with LP Tank Mounting Assembly or Off-Road RGs.
Not recommended for use with protective cover.
Hose and LP Tank Mounting
#300 917
LP models. Not for use with Gas Cylinder Mounting Assembly or Off-Road RGs.
Not recommended for use with protective cover.
Protective Covers
See page 6
Spectrum Plasma Cutters
See page 7
Millermatic® Passport® Plus
#907 401
Includes gas bottle and MVP. See Lit. Index No. DC/12.53
Millermatic® Series MIG Welders
See page 7
SuitCase® Portable Wire Feeders
See page 7
Spoolmatic® 30A Spool Gun
#130 831
Requires WC-24 Control. See Lit. Index No. M/1.73
WC-24 Control
#137 549
See Lit. Index No. M/1.73
XR™ Wire Feeder Control and Guns
See Lit. Index No. M/1.7, M/1.71, and M/1.73
Dynasty® 200 Series TIG Welders
See Lit. Index No. AD/4.8
Remote Controls and Cords
See page 7
HWY-1000 Trailer
#195 013
Cable Tree
#195 023
Dual Hitch
#300 831
Total Quoted Price:
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