4 Common Miller Trailblazer 325 Problems and Solutions

Trailblazer 325 Problems
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Miller Trailblazer is an engine Driven Welder Generator. In terms of welding and auxiliary power, the miller trailblazer 325 is considered one of the finest. Miller uses the best engine in the world which is Kohler. As a result of the technology in the trailblazer generation, the arc performance has been unmatched. Compared to a 200-amp engine, the 300-amp engine produces more power and is less noisy.

As a machine, Miller Trailblazer might have some problems even with all these amazing qualities and features. There is a high probability that any machine will experience problems after some usage. So, in this article, we are going to talk about the common problems of Miller Trailblazer 325 and the solutions.

Common Miller Trailblazer 325 Problems

  1. Engine does not start
  2. Engine will not crank
  3. Engine does not return to idle speed
  4. Battery discharges between uses.

Problems and Solutions of Miller Trailblazer 325

The problems of Miller Trailblazer should not be a matter of concern as they can be solved with the proper actions. It becomes very easy to solve problems when you know the reasons behind them. Also, if you need you can seek help from an expert as there is a matter of safety while repairing a generator.  So, the common problems and the solutions are given below:

1. Engine does not start

If you experience your generator engine not starting then the reason behind it might be a problematic carburetor. Chances are good that the fuel valve is also clogged if the carburetor is blocked with debris or dirt. Also, not having enough fuel in the engine is also a reason for the engine not starting.


The first thing you should do to solve your generator’s engine starting problem is turn the gas and fuel relief valves on the top of the tank to the open position. After that, check whether gasoline can flow through the fuel line if your generator still won’t start after unplugging the fuel hose. Clean the debris or dirt if the carburetor is clogged.

2. Engine will not crank

It is necessary to rotate an engine at a sufficient speed prior to it running. Therefore, the engine is able to run on its own power because fuel is injected into the cylinders and ignited. An engine’s crankshaft rotates the engine so that it can be powered by turning it. But this will not function if there is something wrong with the engine. It can happen when the engine battery is dying and loose connection. 


To solve the engine cranking problem, you should check the battery first. If the battery is expired or dead, replacing it will solve the problem. However, if your generator battery is not the issue, then you can check for loose connection. Tightening connection will solve the engine cranking problem.

3. Engine does not return to idle speed

There is a certain speed that the engine maintains for running. If it does not reach up to the speed, there will be a problem supplying enough backup power to get your generator running.


Make sure the engine Control switch is set to Auto Speed. Disconnect all power loads coupled to welding and generators. Turn off any remote device that is connected to Remote Receptacle. Examine circuit board and current transformer with factory authorized service agents for safety.

4. Battery discharges between uses

Occasionally, the engine battery might completely discharge while the engine is running smoothly. This is a serious issue and needs to be resolved properly.  If it is not solved then the generator will not provide enough power.


When the unit is not running, place the Engine Control switch in the Off position to fix the battery discharging issue. Periodically recharge the battery at least once every three months with a baking soda and water solution. If necessary, replace the battery. And make sure to check the voltage regulator regularly as instructed by the manufacturer for detecting problems in advance.

Frequently Asked Questions

1. How much does a Miller Trailblazer 325 weight?

Answer. The Miller Trailblazer 325 weighs about 460 lbs. It is not heavy or large in size like the ones used for commercial spaces, but it is enough for average residential spaces even for a large one.

2. Can I use the welder as a generator?

Yes. You can use a welder as a generator. Among the best features of a welder generator is its ability to serve as an independent power source. As a result, you will not have to run two machines at the same time, as this will save you both space and money.

3. What kind of oil does a Miller Trailblazer 325 take?

Miller Trailblazer 325 generator model runs on Kohler engine and it usually uses a multi-viscosity, SAE SJ grade or better oil. The Kohler motor oil weight recommendation is 10W-30 weight, which provides adequate protection in most conditions.

Final Thoughts

Generators are very useful machines that back up power when the electricity goes out. So, make sure you buy a good and effective one. You can keep faith in Miller Trailblazer 325 for a trustworthy generator for excellent service. However, do not let the problems make you worry as they can be easily solved with the given solutions.

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