Miller Electric Big Blue 401Dx Users Manual A EX5 2

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Big Blue 401DX

Issued May 2008 • Index No. EX/5.2

®

Quick
Specs

Industrial Applications

Processes

Structural Work
Mining
Maintenance and Repair
Piping

DC Stick (DC SMAW)
Air Carbon Arc (CAC-A)
Cutting and Gouging
thru 6 mm (1/4 in)
DC TIG (GTAW)
Flux Cored (FCAW)

Engine Driven
Welding Generator
Rated Output at 40˚C (104˚F)
DC Amperage Range
Generator Power
Weight

400 A at 30 VDC, 40% Duty Cycle
300 A at 32 VDC, 100% Duty Cycle

40 – 400 A

3 kVA, 120/240 VAC, 26/13 A, 50/60 Hz while welding

Net: 670 kg (1475 lb)

Ship: 685 kg (1510 lb)

The Power of Blue .

®

Rugged controls with no printed
circuit boards.

The F3L2011, 3-cylinder Deutz diesel
engine provides 30 HP at 1850 RPM.
Single side service. Direct fuel injection
for fuel economy and easy starts. Air/oil
double-cooled diesel for maximum
reliability in all environments.

Remote control facility allows
precise adjustment of amperage
without walking back to the machine.
3 kW/kVA auxiliary power while
welding is available from one
120 VAC duplex receptacle and one
240 VAC duplex receptacle that are
circuit breaker protected.

Five welding ranges provide
overlapping ranges and fine current
control in each range for easy set-up
and control of welding amperage.

Compact and lightweight, this lowspeed diesel measures in at 625 x
927 x 1422 mm (24-5/8 x 36-1/2 x
56 in).

3-phase, 4-pole revolving field
technology provides efficient welding
current with less horsepower than DC
generator technology — less horsepower
per welding amp saves fuel — as much
as 20 to 30 percent. Easily connects in
parallel with no special kits for heavy
gouging or stud welding applications.

Specifications

Note: Parts and labor warranted for three years.
Engine warranted by Deutz for three years.

(Subject to change without notice.)

Weld
Mode

Weld Output
Range

Weld Output Rated at
40˚C (104˚F)

Max. Open-Circuit
Voltage

Generator Power Output
Rated at 40˚C (104˚F)

Dimensions

Weight (without fuel)***

CC/DC

40– 400 A

400 A, 30 VDC, 40% Duty Cycle
300 A, 32 VDC, 100% Duty Cycle*

95 (90)

3 kVA, 120/240 VAC,
26/13 A, 50/60 Hz while
welding

H: 927 mm (36 in)**
W: 625 mm (24-5/8 in)
D: 1422 mm (56 in)

Net: 670 kg (1475 lb)
Ship: 685 kg (1510 lb)

*NEMA output rating. **Height is 1029 mm (40-1/2 in) with muffler. ***Additional 136.5 kg (80.5 lb) with tank is full

Engine Specifications

(Subject to change without notice.)

Engine Brand

Features

HP

Type

Engine Speeds

Fuel Capacity

Oil Capacity

Automatic Engine Shutdown

Deutz
F3L2011

Tier 0, direct-injected, air/oil-cooled
engine. Right-side service access
with service intervals of 1000 hours
for oil and filters.

30.3

Three-cylinder,
industrial,
liquid-cooled
diesel

Run: 1850 RPM

43 L
(11.3 gal)

5.5 L
(6 qt)

Low Oil Pressure
High Oil Temperature

Miller Electric Mfg. Co.

International Headquarters

Web Site

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125

www.MillerWelds.com

Control Panel
1

1. Amp Range Switch
2. Engine Hour Meter
3. Oil Pressure Warning Light
4. Battery Charging Warning Light
5. Ether Starting Aid Switch*
6. Engine Control Switch (Start, Run, Idle, Off)
7. Amperage/Voltage Control
8. DC Voltmeter*
9. DC Ammeter*
10. 240 VAC Duplex Receptacle and Circuit Breaker
11. 120 VAC Duplex Receptacle and Circuit Breaker
12. Remote A/V Switch and Receptacle

7

8
9

10

2
3
4
5

11

*Optional

12

6

Performance Data
DUTY CYCLE CHART

DC VOLTS

300
250

60

40

200
20

150
100
10

0
15

20

25

30

40

50

60

80

100

% DUTY CYCLE

0

100

200

300

400

500

DC AMPS

1.67

2.00

6.81

1.50

1.80

6.06

1.33

1.60

5.30

1.17

1.40

4.54

1.00

1.20

3.79

0.83

1.00

3.03

0.67

0.80

2.27

0.50

0.60

1.51

0.33

0.40

0.76

0.17

0.20
U.S. GAL. / HR.

80

600
500
400

7.57

LITERS / HR.

800

WELDING AMPS

FUEL CONSUMPTION CURVE
RANGES:
MIN. – 70
55 – 120
90 – 190
120 – 240
200 – MAX.

IMP. GAL. / HR.

VOLT/AMP CURVES
100

1000

0

50

100

150

200

250

300

350

400

450

500

DC WELD AMPS AT 100% DUTY CYCLE

Genuine Miller Accessories
Weld Ammeter and Voltmeter
#041 567 Field
Monitors weld output. Installs on welder
control panel.
Spark Arrestor (Muffler) Kit
#042 317 Field only
Mandatory when operating on California
grasslands, brush, or forest-covered land,
and all National Forests. For other areas,
check your state and local laws.
CC-10 Canvas Cover #042 596
Attractive, blue, heavy-duty, waterproof
and mildew-resistant cover protects the
finish of your welder.

2

Stick (SMAW) Welding
Weld Leads
#173 851 2/0, 350 A, 100% duty cycle,
15 m (50 ft) stinger,
15 m (50 ft) work cable
#043 952 2/0, 300 A, 100% duty cycle,
30.5 m (100 ft) stinger,
15 m (50 ft) work cable

Remote Control
RHC-3GD34A Remote
Hand Control
#041 122
Allows for precise
adjustment of
amperage. Includes
6 m (20 ft) cord.

Trailers and Hitches
OFR-224 Trailer #043 802
A 1202 kg (2650 lb) capacity off road
trailer. Welded steel tubing frame, heavyduty axle with roller bearing hubs and
leaf spring suspension. The OFR-224
comes with jack stand and 50 mm (2 in)
ball hitch.
HWY-224 Trailer #043 805
A 1202 kg (2650 lb) capacity highway
trailer. Welded steel tubing frame, heavyduty axle with roller bearing hubs and
leaf-spring suspension. The HWY-224
comes with jack stand, 50 mm (2 in)
ball hitch, fenders and lights.

Lunette Eye 64 mm (2-1/2 in) #043 824
For use with both 224 trailers.
Cable Tree #043 826
Provides an area to conveniently wrap weld
cables and extension cords. Works on all
224 and 430 trailers.

4 West Four-Wheel Steerable Off-Road
Trailer #042 801
A heavy-duty 1166 kg (2570 lb) capacity
trailer designed for use in mines, quarries,
and other rough terrain. Has narrow 6.7 m
(22 ft) turning radius. Includes 76 mm (3 in)
lunette eye, universal hitch and safety chains.
Note: Trailers are shipped unassembled.

Trailer Specifications

(Subject to change without notice.)

Model

Gross Axle
Weight
Rating

Gross
Vehicle
Weight Rating

Net
Payload

Height
of Bed

Road
Clearance

Track
(Center to
center of tires)

Standard Tires
(Standard rating
or P-size rating)

HWY-224
OFR-224

1588 kg
(3500 lb)

1343 kg
(2960 lb)

1202 kg
(2650 lb)

18-1/2 in
(470 mm)

191 mm
(7-1/2 in)

1321 mm
(52 in)

B78-13C

Length:3112 mm (122-1/2 in)
Width: HWY– 1549 mm (61 in)*
OFR–1486 mm (58-1/2 in)

161 kg
(355 lb)

4 West

907 kg/axle
1361 kg
(2000 lb/axle) (3000 lb)

1166 kg
(2570 lb)

540 mm
(21-1/4 in)

203 mm
(8 in)

1403 mm
(55-1/4 in)

B78-13

Length:2311 mm (91 in)**
Width: 1556 mm (61-1/4 in)

1950 kg
(430 lb)

Net
Weight

Dimensions

*Width at outside of fenders. **Does not include tongue.

What Makes Miller Industrial Engine Drives So
Every component in a Miller industrial engine drive is engineered and built to assure
ultimate reliability in the most punishing conditions. And they are rigorously tested to
the toughest real-world conditions to keep working in a tough world.

Ultimate Circuit Board Protection
No matter how well it’s built, any machine can fail if its critical circuit boards are
compromised. Miller makes two types of industrial engine drives, both of which ensure
that no critical circuit boards are left vulnerable.
“CC” Stick and TIG Models — Miller’s robust, efficient constant current (CC) industrial
engine drives for Stick and TIG welding are designed with no circuit boards that are critical
to the machine’s operation. That means no boards can shut down the machine if they fail.
“CC/CV” Multiprocess Models — Miller’s Multiprocess
PRO 300 and Big Blue® models of industrial engine drives
include circuit boards for superior arc control and welding
versatility. These boards are protected by the Vault, a
hermetically-sealed aluminum case that is impenetrable to
dust, salt, and moisture.

“Other machines would cut out when we gouged too long
with them. With the Miller, I gouged hard all day in 98 degree
heat and never had a shutdown when we were running
3/8-in carbons.” When welding, “The Big Blue starts out
hot, where I want it, and stays steady on its heat all day.”
— Welder Tommy Langley, Fluor Daniel/Chevron Oil Refinery

?
Similar models to consider:
Big Blue® 400 X
See Lit. No. EDX/10.1
For the professional
heavy-duty construction
contractor, pipeline, rental
company or anyone wanting
a fuel-efficient low-speed diesel-powered
multiprocess welder/generator with precise arc
control. The heavy-duty, compact case easily
fits sideways in a standard pickup bed. This
model provides the quietest operation of Miller’s
engine-drive machines.

Big Blue® 500 X and
600 X
See Lit. No. EDX/10.11
For fleet owners, heavy-duty
construction contractors,
and rental companies who
want a low-speed dieselpowered welder/generator with rugged reliability
and proven performance. Ideal for really tough
jobs that may be using larger electrodes for Stick
welding or Carbon Arc gouging. Available in either
a Stick/TIG CC only model, or a more versatile
CC/CV multiprocess model. Easy to maintain and
always ready to weld no matter what the job or
conditions demand.

3

Ordering Information
Power Source

Stock No.

Description

Big Blue 401DX CC

#903 175

Dry Battery, 50/60 Hz

Spark Arrestor (Muffler) Kit

#042 317

Field

Weld Meter Kit

#041 567

Field

CC-10 Canvas Cover

#042 596

Qty.

Accessories

Stick Accessories
Accessory Kits

#173 851
#043 952

2/0, 350 A, 100% duty cycle, 15 m (50 ft) stinger, 15 m (50 ft) work clamp
2/0, 300 A, 100% duty cycle, 30.5 m (100 ft) stinger, 15 m (50 ft) work clamp

#041 122

Includes 6m (20 ft) cord

Remote Controls
RHC-3GD34A
Trailers and Hitches
HWY-224 Trailer

#043 805

OFR-224 Trailer

#043 802

Lunette Eye, 64 mm (2-1/2 in)

#043 824

For use with both 224 trailers

Cable Tree

#043 826

Works on all 224 and 430 trailers

4 West Trailer

#042 801

Date:

Total Quoted Price:

Distributed by:

Litho in USA

Price



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