Miller Electric Big Blue 401DX User Manual

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: [phone]
USA FAX: [phone]
Canadian FAX: [phone]
International FAX: [phone]

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 low­speed 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. 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

0

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

1

2
3
4
5

6

7

8

9

10

11

12

1000

800

600
500
400

300
250

200

WELDING AMPS

150

100

DUTY CYCLE CHART

5015 20 3025 40 6010 80 100

% DUTY CYCLE

100

80

60

40

DC VOLTS

20

0

0

VOLT/AMP CURVES

RANGES:
MIN. – 70

55 – 120
90 – 190
120 – 240
200 – MAX.

200 300 400100 500

DC AMPS

1.67

2.00

7.57

1.50

1.80

6.81

1.33

1.60

6.06

1.17

1.40

5.30

1.00

1.20

4.54

0.83

1.00

3.79

0.67

0.80

3.03

0.50

0.60

2.27

0.33

0.40

1.51

0.17

0.20

0.76

LITERS / HR.

U.S. GAL. / HR.

IMP. GAL. / HR.

FUEL CONSUMPTION CURVE

20050 100 150 2500 300 350

DC WELD AMPS AT 100% DUTY CYCLE

50

450400