Miller Electric Big Blue 401Dx Users Manual A EX5 2

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Specifications (Subject to change without notice.)

Engine Specifications (Subject to change without notice.)

Processes

DC Stick (DC SMAW)

Air Carbon Arc (CAC-A)

Cutting and Gouging

thru 6 mm (1/4 in)

DC TIG (GTAW)

Flux Cored (FCAW)

Rated Output at 40˚C (104˚F) 400 A at 30 VDC, 40% Duty Cycle

300 A at 32 VDC, 100% Duty Cycle

DC Amperage Range 40 – 400 A

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

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

Industrial Applications

Structural Work

Mining

Maintenance and Repair

Piping

Quick

Specs

Big Blue®401DX Engine Driven

Welding Generator

Issued May 2008 • Index No. EX/5.2

The Power of Blue®

.

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

Web Site

www.MillerWelds.com

International Headquarters

Phone: 920-735-4505

USA FAX: 920-735-4134

Canadian FAX: 920-735-4169

International FAX: 920-735-4125

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.

Five welding ranges provide

overlapping ranges and fine current

control in each range for easy set-up

and control of welding amperage.

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.

Compact and lightweight, this low-

speed diesel measures in at 625 x

927 x 1422 mm (24-5/8 x 36-1/2 x

56 in).

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.

Note: Parts and labor warranted for three years.

Engine warranted by Deutz for three years.

Rugged controls with no printed

circuit boards.

Weld Output

Range

40– 400 A

Weld

Mode

CC/DC

Max. Open-Circuit

Voltage

95 (90)

Weld Output Rated at

40˚C (104˚F)

400 A, 30 VDC, 40% Duty Cycle

300 A, 32 VDC, 100% Duty Cycle*

Generator Power Output

Rated at 40˚C (104˚F)

3 kVA, 120/240 VAC,

26/13 A, 50/60 Hz while

welding

Weight (without fuel)***

Net: 670 kg (1475 lb)

Ship: 685 kg (1510 lb)

Dimensions

H: 927 mm (36 in)**

W: 625 mm (24-5/8 in)

D: 1422 mm (56 in)

*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 Brand

Deutz

F3L2011

HP

30.3

Type

Three-cylinder,

industrial,

liquid-cooled

diesel

Engine Speeds

Run: 1850 RPM

Fuel Capacity

43 L

(11.3 gal)

Automatic Engine Shutdown

Low Oil Pressure

High Oil Temperature

Oil Capacity

5.5 L

(6 qt)

Features

Tier 0, direct-injected, air/oil-cooled

engine. Right-side service access

with service intervals of 1000 hours

for oil and filters.

2

Control Panel

1

2

11

10

7

8

9

12

3

5

4

6

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

*Optional

Performance Data

20050 100 150 2500 300 350

FUEL CONSUMPTION CURVE

0.20

0.40

0.60

0.80

1.20

1.40

1.60

1.80

2.00

1.00

0.17

0.33

0.50

0.67

1.00

1.17

1.33

1.50

1.67

0.83

U.S. GAL. / HR.

IMP. GAL. / HR.

LITERS / HR.

0.76

1.51

2.27

3.03

4.54

5.30

6.06

6.81

7.57

3.79

50

0

450400

DC WELD AMPS AT 100% DUTY CYCLE

% DUTY CYCLE

WELDING AMPS

300

100

150

200

250

400

500

1000

600

800

5015 20 3025 40 6010 80 100

DUTY CYCLE CHART

DC AMPS

VOLT/AMP CURVES

DC VOLTS

20

40

0

200 300 400100 500

0

60

80

100

RANGES:

MIN. – 70

55 – 120

90 – 190

120 – 240

200 – MAX.

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, water proof

and mildew-resistant cover protects the

finish of your welder.

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.

Genuine Miller Accessories

3

HWY-224 Trailer #043 805

A 1202 kg (2650 lb) capacity highway

trailer. Welded steel tubing frame, heavy-

duty 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.

OFR-224 Trailer #043 802

A 1202 kg (2650 lb) capacity off road

trailer. Welded steel tubing frame, heavy-

duty axle with roller bearing hubs and

leaf spring suspension. The OFR-224

comes with jack stand and 50 mm (2 in)

ball hitch.

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.

Trailers and Hitches

Trailer Specifications (Subject to change without notice.)

Net

Payload

1202 kg

(2650 lb)

1166 kg

(2570 lb)

Gross

Vehicle

Weight Rating

1343 kg

(2960 lb)

1361 kg

(3000 lb)

Gross Axle

Weight

Rating

1588 kg

(3500 lb)

907 kg/axle

(2000 lb/axle)

Model

HWY-224

OFR-224

4 West

Height

of Bed

18-1/2 in

(470 mm)

540 mm

(21-1/4 in)

Road

Clearance

191 mm

(7-1/2 in)

203 mm

(8 in)

Net

Weight

161 kg

(355 lb)

1950 kg

(430 lb)

Track

(Center to

center of tires)

1321 mm

(52 in)

1403 mm

(55-1/4 in)

Standard Tires

(Standard rating

or P-size rating)

B78-13C

B78-13

Dimensions

Length:3112 mm (122-1/2 in)

Width: HWY– 1549 mm (61 in)*

OFR–1486 mm (58-1/2 in)

Length:2311 mm (91 in)**

Width: 1556 mm (61-1/4 in)

*

Width at outside of fenders.

**

Does not include tongue.

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.

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 diesel-

powered 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.

What Makes Miller Industrial Engine Drives So ?

“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

Power Source Stock No. Description Qty. Price

Big Blue 401DX CC #903 175 Dry Battery, 50/60 Hz

Accessories

Spark Arrestor (Muffler) Kit #042 317 Field

Weld Meter Kit #041 567 Field

CC-10 Canvas Cover #042 596

Stick Accessories

Accessory Kits #173 851 2/0, 350 A, 100% duty cycle, 15 m (50 ft) stinger, 15 m (50 ft) work clamp

#043 952 2/0, 300 A, 100% duty cycle, 30.5 m (100 ft) stinger, 15 m (50 ft) work clamp

Remote Controls

RHC-3GD34A #041 122 Includes 6m (20 ft) cord

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:

Ordering Information

Litho in USA

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