Page 1
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 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.
Page 2
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
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3
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.
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.
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 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.
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
Page 4
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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