Miller Electric Welding System 401DX User Manual

Issued May 2008 • Index No. EX/5.2  
Engine Driven  
®
Welding Generator  
Big Blue 401DX  
Industrial Applications  
Structural Work  
Mining  
Processes  
Rated Output at 40˚C (104˚F) 400 A at 30 VDC, 40% Duty Cycle  
DC Stick (DC SMAW)  
Air Carbon Arc (CAC-A)  
Cutting and Gouging  
thru 6 mm (1/4 in)  
DC TIG (GTAW)  
300 A at 32 VDC, 100% Duty Cycle  
Quick  
DC Amperage Range 40400 A  
Maintenance and Repair  
Piping  
Specs  
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)  
Flux Cored (FCAW)  
®
The Power of Blue.  
Rugged controls with no printed  
circuit boards.  
The F3L2011, 3-cylinder Deutz diesel  
engineprovides 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 low-  
speed 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 technologyless horsepower  
per welding amp saves fuelas much  
as 20 to 30 percent. Easily connects in  
parallel with no special kits for heavy  
gouging or stud welding applications.  
Note: Parts and labor warranted for three years.  
Engine warranted by Deutz for three years.  
Specifications  
(Subject to change without notice.)  
Weld  
Mode  
Weld Output  
Range  
Weld Output Rated at  
40˚C (104˚F)  
Max. Open-Circuit Generator Power Output  
Voltage  
Rated at 40˚C (104˚F)  
Dimensions  
Weight (without fuel)***  
40400 A  
CC/DC  
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) Ship: 685 kg (1510 lb)  
D: 1422 mm (56 in)  
Net: 670 kg (1475 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  
30.3  
Three-cylinder, Run: 1850 RPM 43 L  
5.5 L  
(6 qt)  
Low Oil Pressure  
High Oil Temperature  
engine. Right-side service access  
with service intervals of 1000 hours  
for oil and filters.  
industrial,  
liquid-cooled  
diesel  
(11.3 gal)  
Miller Electric Mfg. Co.  
An Illinois Tool Works Company  
1635 West Spencer Street  
Appleton, WI 54914 USA  
International Headquarters Web Site  
Phone: 920-735-4505  
USA FAX: 920-735-4134  
Canadian FAX: 920-735-4169  
International FAX: 920-735-4125  
 
Trailers and Hitches  
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.  
HWY-224 Trailer #043 805  
4 West Four-Wheel Steerable Off-Road  
Trailer #042 801  
Lunette Eye 64 mm (2-1/2 in) #043 824  
For use with both 224 trailers.  
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.  
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.  
Cable Tree #043 826  
Provides an area to conveniently wrap weld  
cables and extension cords. Works on all  
224 and 430 trailers.  
Note: Trailers are shipped unassembled.  
Trailer Specifications (Subject to change without notice.)  
Gross Axle  
Weight  
Rating  
Gross  
Vehicle  
Weight Rating Payload  
Track  
(Center to  
Standard Tires  
(Standard rating  
Net  
Height  
of Bed  
Road  
Net  
Weight  
Model  
Clearance center of tires) or P-size rating) Dimensions  
HWY-224 1588 kg  
OFR-224 (3500 lb)  
1343 kg  
(2960 lb)  
1202 kg  
(2650 lb) (470 mm)  
18-1/2 in  
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)*  
OFR1486 mm (58-1/2 in)  
161 kg  
(355 lb)  
4 West  
907 kg/axle  
(2000 lb/axle) (3000 lb)  
1361 kg  
1166 kg  
(2570 lb) (21-1/4 in)  
540 mm  
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)  
*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.  
?
Similar models to consider:  
Big Blue® 400 X  
See Lit. No. EDX/10.1  
Ultimate Circuit Board Protection  
For the professional  
heavy-duty construction  
contractor, pipeline, rental  
company or anyone wanting  
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.  
a fuel-efficient low-speed diesel-powered  
“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.  
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.  
“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.  
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.  
“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  
3
 
Ordering Information  
Power Source  
Stock No.  
#903 175  
Description  
Qty.  
Price  
Big Blue 401DX CC  
Dry Battery, 50/60 Hz  
Accessories  
Spark Arrestor (Muffler) Kit  
Weld Meter Kit  
#042 317  
#041 567  
#042 596  
Field  
Field  
CC-10 Canvas Cover  
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  
Remote Controls  
RHC-3GD34A  
#041 122  
Includes 6m (20 ft) cord  
Trailers and Hitches  
HWY-224 Trailer  
OFR-224 Trailer  
#043 805  
#043 802  
#043 824  
#043 826  
#042 801  
Lunette Eye, 64 mm (2-1/2 in)  
Cable Tree  
For use with both 224 trailers  
Works on all 224 and 430 trailers  
4 West Trailer  
Date:  
Total Quoted Price:  
Distributed by:  
Litho in USA  
 

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