HIPower HW400A Service Manual Download

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SERVICE MANUAL

WARNING

This equipment is designed and built with safety in mind. However, your overall

safety can be increased by your full understand followed by the content in this
manual.

Read this manual and familiarize yourself with its contents for your safety.
This equipment should only be operated and maintained by trained and qualified
personnel.

This equipment is designed for arc welding and generating power source of
electric tools, home appliances and lights.

Do not install, operate or service this equipment without reading this manual and

unless you clearly understand this manual.

Generating application for this equipment is 60Hz ONLY.

Specifications subject to change without notice.

Summary of Contents for HW400A

Page 1: ...for your safety This equipment should only be operated and maintained by trained and qualified personnel This equipment is designed for arc welding and generating power source of electric tools home...

Page 2: ...ion contained in this service manual describes equipment available at the time of publication While every attempt has been made to give you the very latest information about your product there may be...

Page 3: ...utput Voltage at no load 18 6 3 Component Parts Resistance Value 19 6 4 Display Mode by LED 20 6 5 Power Controller 21 1 Generating Output Adjustment 21 2 Welding Output Adjustment 21 3 CV Control Vol...

Page 4: ...ice and maintenance of the equipment for understanding of the equipment safety instructions and cautions Throughout this manual are special attention statements A statement preceded by the triangular...

Page 5: ...nt is used in poorly ventilated area such as inside of the building Entangled Injuries under By Moving Component NEVER reach and touch the moving component during operation ALWAYS stop the engine duri...

Page 6: ...e Before replacing the label s make sure to place the new label s in the same position STOP the equipment immediately when abnormal circumstances are noticed STSTOP the equipment immediately whenever...

Page 7: ...1 Phase 3 Phase Rated Voltage V 120 240 480 Power Factor 1 0 1 0 0 8 Rated Output kVA 2 2 4 3 15 AC Generator Rating Continuous Model Kubota D1005 Type Vertical Water Cooled 4 Cycle Diesel Engine Disp...

Page 8: ...4 General 4 1 Appearance 4 2 Dimension Unit in the drawings below is shown by mm 5...

Page 9: ...6...

Page 10: ...coil resistance decreasing These factors have made the alternator high efficient The high efficient alternator has decreased the engine load The high efficiency alternator has decreased the load to en...

Page 11: ...oned Starter Switch Feature Selector switch to start stop and preheat engine Welding Terminal B Feature Connect welding terminal Remote Control Receptacle Feature Receptacle to Incorporates with a rem...

Page 12: ...ding AC Voltage Adjusting Dial Feature A dial to adjust AC output Fuel Meter Feature Display fuel volume in the fuel tank Output Selector Switch Feature Change output by adjusting engine speed Slow Do...

Page 13: ...with thyristor and rectify AC to DC 10 This unit is equipped with monitoring functions and the cautioned lamp flashes to indicate defect Investigate and correct cause s when any of the monitor lamps t...

Page 14: ...nor lever Fuel Filter Feature Filter water or dust in the fuel Sub Tank Feature Keep coolant water level in the radiator Drain Hose Feature Drain water from the top cover Generator Feature A device to...

Page 15: ...re Inlet to inject engine oil Use the oil of CD or higher grade in American Petroleum Institute Injection Pump Feature Supply fuel to the injection nozzle 12 Resistor Feature Upgrade welding feature i...

Page 16: ...kVA 12kW 1 Phase Receptacle 120V Feature Supply AC output Max output 2 2kVA 2 2kW 1 Phase Receptacle 120 240V Feature Supply AC output Max output 4 3kVA 4 3kW Receptacle Inside View Fuel Drain Plug Fe...

Page 17: ...14 Standard Accessory Owners Manual Engine Manufacturer s Warranty Statement Starter Key 2 sets Tool Set Tool Bag Screw Driver Plug Wrench Spanner 3 sets...

Page 18: ...securely fastened against abrasion and damage to bring by vibration Bracket 3 phase Terminal Over 10M at DC500V Disconnect grounding Insulation Check Insulation Resistance Optional Tester Bracket Side...

Page 19: ...1 Current Adj Dial MAX Slow down ON Rod 6mm Over 3300 min 1 A V No Load min 1 Current Adj Dial MAX Slow down OFF Rod 6mm 82 0 3V A Over 160A 1 V 42 0 2V Loaded min 1 Current Adj Dial MAX Slow down ON...

Page 20: ...Tester Output Adj Dial Terminals T R 248 6V No Load V 120 1V A 18 0 0 5A Single Loaded V Output Adj Dial Terminals R N 120 3V 1 Phase 120V No Load V 68 3V A 18 0 0 5A Eco Loaded V Output Adj Dial Ter...

Page 21: ...V V W W U 268 266 325 321 417 414 480 475 552 548 1 P 240V R T 137 144 166 173 213 223 245 255 280 290 R N N T 1P 3 Wire Receptacle 3 AC Output 1 P 120V R N 1P 2 Wire Receptacle AC 67 72 83 86 105 11...

Page 22: ...W B L AW AU B L B R 22mm 2 0 014 AU OA B R B Gr AV OA B W B Gr A side AW OA B L B Gr 22mm 2 1 25mm 2 0 017 BU BV B B B Y BV BW B Y B G BW BU B G B B 22mm 2 0 014 BU OB B B B Br BV OB B Y B Br Welding...

Page 23: ...output selector switch in the control panel and equipment loaded or no load is shown by the LED lamp ON OFF combination in the power controller LED Indication LED Mode LED1 Red Single LED2 Yellow Sole...

Page 24: ...to the table below Follow to the procedure below for the VR adjustment 1 Turn the output selector switch right to Single 2 Set CC CV selector switch left to CC 3 Turn A side current adjusting dial cl...

Page 25: ...not rotate 4 Starter motor does not rotate Ref Fuse Condition Normal Cut Off Monitor Display ON OFF Note After the starter switch is turned to operation the lamp shows ON for few second 5 Protection...

Page 26: ...minal Side Bolt Shim M5 18 2 5 3 4 25 35 Thyristor and Rectifier Attached 10 Socket Drain Plug M12x1 25x13 3 39 3 49 400 500 11 Flexible Tube Flange Nut M8 6 17 7 21 5 180 220 12 Terminal Rest Welding...

Page 27: ...Add Coolant 6 Coolant Change or 2 years 7 Clean Fuel Filter 1 st 2 nd 8 Change Fuel Filter 9 Drain Water Clean Fuel Tank 10 Check Leakage Fuel Oil Water 11 Check Add Battery Liquid 12 Clean Air Eleme...

Page 28: ...ays check oil coolant and fuel volume before processing to trouble shooting YES Starter Motor works Dead Battery Damaged Starter Motor Damaged Starter Switch Burnt 20A Fuse Burnt 50A Fuse Lead wire di...

Page 29: ...r size and length of cables Simultaneous use with Generator Output Stop using Generator Output Check Engine Speed at no load Slow Eco 2100 20 min 1 Regular Speed 3600 20 min 1 No Load Welding Output V...

Page 30: ...Damaged Rectifier Damaged Damaged PCB Main Controller Damaged Resistor Weak contact of lead wires and connector Rotor Damaged Stator Damaged Initial Exciter Circuit Damaged Refer to Resistance Value N...

Page 31: ...fer to Component Parts Resistance Value Both Exciter Voltage and Amperage low Damaged Rotor Damaged Stator Exciter Circuit Damaged Note To measure resistance on coil Milliohm Tester is necessary Multi...

Page 32: ...w AC Output Voltage each unbalanced Rectifier on rotor Damaged Thyristor Damaged Stator Damaged Short circuit Broken etc Refer to the resistances value When turning auto idle Switch to high idle Engin...

Page 33: ...burned NO Engine won t return to idle Switch is selected AUTO or ECO Check Welding and Generating Voltage Short circuit Rectifier for welding Short circuit Thyristor for welding Short Circuit Breaker...

Page 34: ...9 Wiring Diagram 9 1 Generator Wiring Diagram 31...

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Page 40: ...HIMOINSA POWER SYSTEMS INC 16002 West 110th Street Lenexa KS 66219 1312 Tel 913 495 5557 Fax 913 710 2988 Toll Free 866 710 2988 www hipowersystems com...

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