Issued May 2021 • Index No. ED/4.

Trailblazer 325 Diesel ® Diesel Engine-Driven

Welder/AC Generator

Industrial Processes Output Range DC stick 20–325 A

Applications Stick (SMAW) MIG/flux-cored 15–40 V
Fabrication MIG (GMAW)* DC TIG 20–325 A
Maintenance Flux-cored (FCAW)*
Repair RMD®**
Generator Power Output Rated at 104°F (40°C)
Quick Structural steel work Pulsed MIG (GMAW-P)** 12,000 watts peak, 10,500 watts continuous
Specs Sheet metal DC TIG (GTAW) Excel™ Power (Recommended option)
Pipe Air carbon arc (CAC-A) cutting and gouging
2,400 watts (120 V, 20 A) 60 Hz pure sine power***
Rated: 3/16-inch carbons,
Capable: 1/4-inch carbons *With wire feeder.
**With ArcReach Smart Feeder only.
***Engine speed rpm may vary while welding.

Trailblazer welder/generators deliver unbeatable arc performance

providing the smoothest, most stable arc in the industry.

The Trailblazer exclusive

technologies — Auto-Speed™
and optional Excel™ power — Full control of
deliver superior runtimes, increased your machine in
fuel efficiency, and improved the palm of your
welder/generator performance. hand. See page 2.

No other compact machine in

the 300-amp class delivers more
welding power or more auxiliary
power with better fuel efficiency
and less noise — for productive,
profitable, quieter jobsites.

Parameter control at the wire feeder

or pendant without needing a control
cord. See page 2.

Optimized arc control for stick Trailblazer 325 Diesel with

welding applications. See page 2. ArcReach and optional
wireless interface control
and Excel power shown.

Welder/generator is warrantied for three years, parts and labor.

Engine is warrantied separately by the engine manufacturer.

Miller Electric Mfg. LLC Equipment Sales US and Canada MillerWelds.com

An ITW Welding Company Phone: 866-931-9730
1635 West Spencer Street FAX: 800-637-2315
P.O. Box 1079 International Phone: 920-735-4554
Appleton, WI 54912-1079 USA International FAX: 920-735-4125
 Trailblazer Technologies
®

Dynamic DIG™ technology

Ultra-adaptive arc control. Unlike conventional adjusts the amount of current required to clear a short. Delivers a
DIG that provides a preset amount of short-clearing smoother more consistent arc that can be tailored to match application,
current, Miller-exclusive Dynamic DIG technology material, fit-up and welder technique.
works on a time-based algorithm that automatically

Welding at idle speed

™
Auto-Speed technology Welding below Welding between Welding between
Matches engine speed to load — a Miller exclusive. Get the welding 135 A 136–180 A 181–210 A

power you need — plus reduced fuel consumption and lower noise
levels for a more profitable jobsite.
1,800RPM
2,400 RPM
2,800 RPM
Auto-Speed technology responds to weld requirements by automatically
adjusting engine speed to one of five rpm levels so the engine never works
harder than necessary. Weld up to 135 amps while the engine remains at
Welding between Welding above
idle (1,800 rpm), saving up to 15 percent in fuel over competitive units, 211–235 A 235 A
and drastically reducing jobsite noise.
3,200 RPM
3,600RPM

Auto-Speed in XX18 and TIG modes.

®
ArcReach technology
Parameter control at the wire feeder or ArcReach technology uses the existing weld cable to communicate
pendant without needing a control cord. welding control information between the feeder or stick/TIG remote and
An ArcReach system allows you to change weld settings from your the power source. This technology eliminates the need for control cords,
ArcReach feeder or stick/TIG remote, saving a trip to the power supply. and their associated problems and costs.

VIEW STATUS CUSTOM PROGRAMS

Wireless interface control (option) View engine status, Save custom presets in
fuel level, and battery up to four programs and
Get full control of your machine charge level of remote. easily switch between
in the palm of your hand pre-programmed settings.
so you can work hassle free. SELECT PROCESSES
With wireless interface control, you can change welding processes, adjust View and select between FINE-TUNE ARC
parameters, select and save preset programs, turn the machine on/off, get all available processes. Quickly adjust and save arc
service reminders and more from wherever you are on the jobsite. Extend control settings including
time between fill ups and maintenance intervals while eliminating the need
CONTACTOR ON/OFF DIG, DIG range inductance
Turn contactor on/off manually and Auto-Stop.
to go back to your machine to make adjustments. in remote welding mode.
Wireless interface control is a factory-installed option available on the AMP/VOLT ADJUST
Trailblazer 325 Diesel.
ENGINE ON/OFF Adjust amperage or voltage,
Turn engine on/off with remote. by increments or percentage,
while welding.

Excel™ power (option)

Power at idle — a Miller exclusive. Unlike competitive machines that
provide auxiliary power only at 3,600 rpm (max), Excel power delivers a
full 2,400 watts (20 A) of 120-volt inverter-based, pure sine-wave power
at 2,400 rpm. With Excel power you can operate jobsite tools like grinders
at quiet, fuel-saving speeds.
Refueling time and operating costs are reduced with Excel power, which
means more productivity and profitability. Plus everyone on the jobsite
gets a better working environment because noise levels and exhaust
emissions are lowered. Excel power — available only from Miller. Based on generator-only use for total runtime.

2
 Trailblazer Benefits ®

Fewer refueling trips Maximum cost savings

No other diesel welder/generator in the 300-amp class lets your crews Less money spent on fuel means more profit for you. Every Trailblazer
spend more time working and less time refueling — because only welder/generator has fuel-saving Auto-Speed technology; add optional
Trailblazer welder/generators provide Auto-Speed™ technology, plus the Excel power to save even more on fuel costs and enjoy a combination of
Excel™ power option, to deliver maximum runtime. advanced, profit-enhancing features that are only available on a Trailblazer
With optional wireless interface control, you can instantly turn your welder/generator.
machine off when needed to save you even more fuel. Maximize your savings with optional wireless interface control which allows
you to turn your machine off remotely, saving you more money on fuel.

Quieter jobsites
Quieter jobsites are more productive because work crews can
communicate easier, and work can start earlier and end later —
even in noise-sensitive areas. Miller-exclusive Auto-Speed technology
makes this welder/generator the quietest Trailblazer diesel yet — rated
at 70 db at idle (1,800 rpm). If your jobsite needs a welder/generator, it
needs a Trailblazer welder/generator — because no other diesel-fueled
choice in this category is as quiet.

Optional wireless interface control makes it easy to shut off the machine
remotely when it’s not in use, so you can lower noise levels and hear
what’s going on around you.

More portable, uses less truck and jobsite space

Trailblazer welder/generators use up to 24 percent less cubic space
and weigh up to 10 percent less than other welder/generators in their
class — which means moving them is faster and easier, for maximum
productivity. And because they take up less space, Trailblazer welder/
generators let work trucks carry more equipment and gear — so your
work crews can be ready for anything.

Unbeatable arc performance

Wide amperage output with better welding deposition rates means you personal preferences and quickly dial in the perfect parameters to
can get jobs done faster, saving time and money. The Trailblazer also has optimize weld quality and maximize productivity across a variety of
precise arc control, which allows you to fine-tune the arc to match your applications and welding processes.

3
 Specifications (Subject to change without notice.)
Welding Amp/Volt Rated Weld Output Single-Phase Net
Mode Process Ranges at 104°F (40°C)* Generator Power Sound Levels at 7 m (23 ft.) Dimensions Weight**
CC/DC Stick/TIG 20 – 325 A 325 A at 33 V, Peak Weld H: 28 in. 620 lb.
100% duty cycle 12,000 watts 135 A load: 70 dB (94 Lwa), (711 mm) (281 kg)
Continuous 325 A load: 81.5 dB (106.5 Lwa) H: 34.375 in.
10,500 watts Generator power (873 mm)
Excel™ power (optional) Excel power (optional): (to top of
CV/DC MIG/FCAW 15 – 40 V 325 A at 33 V, exhaust)
2,400 watts, 75 dB (100 Lwa),
100% duty cycle W: 20 in.
20 A at 120 V, 60 Hz 12 kW standard power:
pure generator power at 81.5 dB (106.5 Lwa) (508 mm)
2,400 rpm and while welding D: 45.375 in.
(1,153 mm)

*Rated at sea level. **Net weight without fuel. Certified by Canadian Standards Association to both the Canadian and U.S. Standards.

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

Engine Brand Fuel Oil
and Warranty Horsepower (HP) Type Weld Speed Idle Speed Capacity Capacity Standard Shutdowns
Kubota D902, 24.8 hp at 3,600 rpm Three-cylinder, industrial Auto-Speed™ 1,800 rpm or 12 gal. 3.9 qt. High coolant temperature/
2-year limited liquid-cooled diesel 1,800, 2,400, 2,800, 2,400 rpm (45 L) (3.7 L) Low oil pressure/low fuel
North American 3,200 or 3,600 rpm
warranty

Performance Data Mounting Specifications

Weld Fuel Consumption*
1.50
G 4 Holes
1.25

Engine End
A B
1.00
U.S. Gal./hour

C
0.75

D
0.50
E
F
0.25
Idle

0
A. 20 in. (508 mm)
0 50 100 150 200 250 300 350 B. 16.5 in. (419 mm)
DC Weld Amperes at 100% Duty Cycle C. 1.75 in. (44 mm)
D. 6.062 in. (154 mm)
*Fuel curve was generated using NEMA recommended voltage/amperage levels.
E. 32.75 in. (832 mm)
F. 45.375 in. (1,153 mm)
Auxiliary Power Fuel Consumption G. .406 in. (10.3 mm) diameter
2.00

1.75

1.50
U.S. Gal./hour

1.25

1.00

0.75

0.50
Excel Power
0.25
Idle
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

Watts at 100% Duty Cycle

4
Function and Benefit Guide
1 4
5

6
2

3 7

9
10

11

12

13

1. Self-calibrating digital meters with 6. Front-panel fuel-gauge LEDs indicate fuel 12. Optional Excel™ power (factory option,
SunVision™ level. Low fuel shutdown automatically see page 8) provides pure generator power
• Preset and actual amperage/voltage detects and shuts engine off prior to running at 2,400 rpm and while welding.
• Process settings out of fuel. Note: If Trailblazer is ordered without Excel power
• Maintenance functions: hour meter, option, unit is shipped with two 20 A, 120 V
oil change interval, rpm 7. Standard 14-pin receptacle for simple duplex receptacles with circuit breakers and
connection of remote controls and wire ground fault.
2. Weld process selection switch feeders. Includes Auto Remote Sense™
which automatically switches from panel to 13. 50 A, 120/240 V receptacle with
3. Pushbutton main control knob used for remote amperage/voltage (A/V) control with circuit breaker
adjusting amperage/voltage, adjusting arc remote connected. Eliminates confusion of a Note: For matching plug, order 119172.
control, and accessing the service menu. panel/remote switch.
4. Adjustable arc control adjusts DIG when 8. USB port allows software updates from a
process control is in stick modes and adjusts USB drive. A summary file of recorded data
inductance when process control is in FCAW from the unit will be saved to a USB drive
or MIG modes. The amount of DIG determines that is inserted.
how much amperage (heat) varies with
stick arc length. Inductance determines the 9. Engine control. Run/idle position adjusts
“wetness” of the weld puddle. engine to run at lower speeds depending on
total power needed for welding.
5. Maintenance interval reminder. Yellow
and red indicator lights let an operator know 10. Glow plugs assist in cold weather starting.
when the machine is approaching, and
finally in need of routine maintenance. 11. Weld output terminals

5
 Genuine Miller Options *Available as factory option. See ordering information on back page.
®

GFCI Receptacles* 300975 Field

Kit contains two GFCI 120 V duplex receptacles. Female Full KVA Plug Kit
(240 V GFCI receptacle not required.) Receptacle 119172 Field
120/240 V, 50 A plug
Cold Weather Kit 301115 Field (NEMA 14-50P) to fit full
Full KVA Adapter Cord 300517 Field
Includes block heater for improved starting, KVA receptacle.
NEMA 14-50P to NEMA 6-50R. Adapts engine
and a fuel heater for optimal filtration in cold
drive 120/240 V plug to common Millermatic®
temperatures.
and Spectrum® 240 V plug.
Diesel Engine Filter Kit 259935 Field
Spark Arrestor 043579 Field Includes air filter, oil filter, fuel pre-filter and
Mandatory when operating on California grass- primary fuel filter.
lands, brush or forest-covered land, and all
national forests. For other areas, check your
state and local laws.

Genuine Miller Accessories ®

™
ArcReach® Smart
Never Flat Tires Feeder 951733
Available on Bobcat and For use with
Trailblazer running gear. ArcReach models
• Reduce costly jobsite only (see page 2 for
downtime more information).
• Maintain constant tire pressure and will Includes drive rolls
not develop flats and Bernard®
• Protect against punctures PipeWorx 300-15 MIG
• Preserve maneuverability, even when Protective Cover 301099 gun. For MIG, FCAW,
weighed down with heavy welding cable Heavy-duty, water-resistant and mildew- and advanced RMD®
resistant cover protects and maintains the finish and pulse processes. See literature M/6.55.
of the welder.
SuitCase® 12RC
Wireless Interface Control Protective Covers Wire Feeder 951580
287594 Lightweight and
Five-pack of screen protectors for wireless flexible enough to run
interface control remote. wires up to .062-inch
diameter. Includes
MIG/Flux-cored Welding remote voltage control,
drive roll kit and
Bernard® BTB Gun 300 A. See literature M/6.5.
All-Purpose Running Gear 300477
Includes two heavy-duty 15-inch Never Flat™
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.

ArcReach® SuitCase® 8
951726 With Bernard® BTB Gun 300 A Spoolmatic® 30A Spool Gun 130831
951727 With Bernard® S-Gun™ Air-cooled, 200-amp, one-pound spool gun for
951728 With Bernard® Dura-Flux™ gun aluminum MIG. See literature M/1.73. Requires
WC-24 Control 137549.
ArcReach® SuitCase® 12
951729 With Bernard® BTB Gun 300 A XR™ Wire Feeders and Guns
951730 With Bernard® S-Gun™ Push-pull system designed to handle difficult-
Protective Cage with Cable Holders 195331 951731 With Bernard® Dura-Flux™ gun to-feed soft alloy wires such as aluminum.
Rugged cage with cable holders protects your ArcReach® SuitCase® 12 Heavy Duty See literature M/1.7 through M/1.74.
investment. Can be used with running gear, 301604 Feeder only — for 3/32-inch cored wire
gas cylinder mounting assembly, or with trailer. Portable feeder designed to run off of arc voltage.
Note: Not for use with protective cover. When paired with an ArcReach power source,
provides remote control of the power source
without a control cord — saving time and money.
See literature M/6.55.

6
 Genuine Miller Accessories ®
(Continued)

Stick (SMAW) Welding Plasma Cutting Wireless Remote Hand

Control 301582
For remote current, voltage
and contactor control. Receiver
plugs directly into the 14-pin
receptacle of Miller machine.
Up to 300-foot (91.4 m)
operating range.

Weld Leads Spectrum 375 X-TREME and 625 X-TREME shown. RHC-14 Hand Control
242211020
2/0 Stick Cable Set, 50 ft. (15 m) 173851 Spectrum 375 X-TREME 907529
® ™
Miniature hand control for
Consists of 50-foot (15 m) 2/0 electrode cable See literature PC/9.2.
remote current and contactor
with holder, and 50-foot (15 m) work cable with Spectrum® 625 X-TREME™ 907579 control. Dimensions: 4 x 4 x
clamp. 350 A, 100% duty cycle. See literature PC/9.6. 3.25 inches (102 x 102 x 82 mm).
2/0 Stick Cable Set, 100/50 ft. (30.5/15 m) Spectrum® 875 907583 Includes 20-foot (6 m) cord and 14-pin plug.
043952 See literature PC/9.8.
The Spectrum 375 X-TREME and 625 X-TREME PRHC-14 Hand Control
Consists of 100-foot (30.5 m) 2/0 electrode
come complete with protective X-CASE™ 195511
cable with holder, and 50-foot (15 m) work
(not shown). Complete current or voltage
cable with clamp. 300 A, 100% duty cycle.
control brings 120 volts GFCI
power to work area in a
AC TIG (GTAW) Welding Remote Solutions single cord. Housed in a
durable, light aluminum case
ArcReach® Stick/TIG and includes 125-foot (38 m) cord with plugs.
Dynasty ® Remote 301325
210 Series When paired with Extension Cables for 14-Pin Remote Controls
For portable an ArcReach power 242208025 25 ft. (7.6 m)
AC/DC TIG. source, provides 242208050 50 ft. (15.2 m)
See literature remote control of 242208080 80 ft. (24.4 m)
AD/4.81. the power source
without a control Remote Output Panel Kit 951850
cord — saving time If your welder/generator is mounted on a truck,
and money. See literature AY/14.5. easily locate the outputs at the point of use with
the auxiliary power and weld output remote
panel. See literature AY/20.5.

Trailers and Hitches (Note: Trailers are shipped unassembled.)

2-In-1 Document/
Fire Extinguisher Holder
301236
Cable Tree 043826 Stores documents and
Provides an area to holds a five-pound
conveniently wrap weld fire extinguisher.
cables and extension cords.
Note: Holder shown mounted
on trailer. Fire extinguisher
HWY-Mid Frame Trailer 301438 not included.
1,424-pound (646 kg) capacity highway trailer
with welded steel tubing frame, heavy-duty
axle with roller bearing hubs and leaf-spring
suspension. Includes jack stand, fenders, lights,
and dual hitch with 2-inch (50 mm) ball hitch
and 3-inch (76 mm) lunette eye.

Trailer Specifications (Subject to change without notice.)

Track (Center Standard Tires
Gross Axle Gross Vehicle Net Height Road to center of (Standard rating Net
Model Weight Rating Weight Rating Payload of Bed Clearance tires) or P-size rating) Dimensions Weight
HWY-Mid 1,605 lb. 1,424 lb. 1,424 lb. 19.5 in. 8 in. 46 in. ST175/80D-13 Length: 101 in. (2,565 mm) 181 lb.
Frame (728 kg) (646 kg) (646 kg) (495 mm) (203 mm) (1,168 mm) Load Range C Width: 55 in. (1,397 mm)* (82 kg)

*Width at outside of fenders.

7
 Ordering Information
Equipment and Options Stock No. Description Qty. Price
Trailblazer 325 Diesel
® 907799 Base model
(Kubota engine) 907799001 With GFCI receptacles
907799002 With Excel™ power and GFCI receptacles
907799003 With Excel™ power, GFCI receptacles and wireless interface control
Field Options Options listed below can be added to the above packages. Installation is required.
GFCI Receptacles 300975
Cold Weather Kit 301115
Spark Arrestor 043579
Full KVA Adapter Cord 300517
Full KVA Plug 119172
Diesel Engine Filter Kit 259935
Accessories
All-Purpose Running Gear 300477 With Never Flat™ tires
Protective Cage with Cable Holders 195331 Not for use with protective cover
Protective Cover 301099
Wireless Interface Control Protective Covers 287594 Five-pack of screen protectors for wireless interface control remote
MIG/Flux-cored Welding
ArcReach® SuitCase® 8 951726 With Bernard® BTB Gun 300 A
951727 With Bernard® S-Gun™
951728 With Bernard® Dura-Flux™ gun
ArcReach® SuitCase® 12 951729 With Bernard® BTB Gun 300 A
951730 With Bernard® S-Gun™
951731 With Bernard® Dura-Flux™ gun
ArcReach® SuitCase® 12 Heavy Duty 301604 Feeder only — for 3/32-inch cored wire
ArcReach® Smart Feeder 951733 For use with ArcReach models only. MIG/FCAW/RMD®/pulse feeder with
Bernard® PipeWorx 300-15 MIG gun. Tweco®-style connectors
SuitCase® 12RC 951580 With Bernard® BTB Gun 300 A. See literature M/6.5
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 through M/1.74
Stick Welding See page 7
TIG Welding See page 7
Plasma Cutting See page 7
Remote Solutions and Extension Cables
ArcReach® Stick/TIG Remote 301325 For use with ArcReach models only
Wireless Remote Hand Control 301582
RHC-14 Hand Control 242211020
PRHC-14 Hand Control 195511
Extension Cables See page 7
Remote Output Panel Kit 951850 For truck mounted welder/generators. Includes auxiliary power and
weld output remote panel
Trailers and Hitches
HWY-Mid Frame Trailer 301438 Trailer with lights, fenders and dual hitch. For highway use
Cable Tree 043826 Trailer-mounted cable holder
2-In-1 Document/Fire Extinguisher Holder 301236 Stores documents and holds a five-pound fire extinguisher

Date: Total Quoted Price:

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