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HIPower HW400A Service Manual

Welder generator
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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.

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  • Page 1 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.
  • Page 2 HIPOWER Diesel Engine Generator Welder, Model Designation HW400A. It is inevitably necessary to maintain and adjust HIPOWER products periodically in order to use fully and safely for long time. Therefore, understand this service manual fully enough before use and proper maintenance.

  • Page 3: Table Of Contents

    Table of Contents 1. Attention Statements ···························································································· 2. General Safety Instructions ··············································································· 3. Specifications ··········································································································· 4. General ························································································································ 4-1 Appearance ····································································································· 5 4-2 Dimension ······································································································· 5 4-3 Welding Feature······························································································· 7 4.3.1 Duty Cycle ······························································································ 7 4.3.2 Low Noise and Low Fuel Consumption ····················································· 7 5.

  • Page 4: Attention Statements

    1. Attention Statements ・Technicians only who own enough knowledge and experience should work for maintenance and operational check after maintenance. ・Before maintenance, always read this service manual as well as owner’s manual and familiarize contents thoroughly before starting the service and maintenance of the equipment for understanding of the equipment, safety instructions and cautions.

  • Page 5: General Safety Instructions

    2. General Safety Instructions WARNING ELECTRIC SHOCK Entangled Injuries under NEVER touch the output terminals Moving Componen during operation NEVER touch the output terminal during NEVER reach and touch the moving operation even though the breaker on the component during operation! load is being set at “OFF”...
  • Page 6 CAUTION Work Safely STOP the equipment immediately when Generators and welders operate at very high abnormal circumstances are noticed! STSTOP the equipment immediately whenever speeds and can do serious damage or injury if they are misused or abused. Never allow a abnormal circumstances are noticed such as unusual noise, smell, vibration and etc.

  • Page 7: Specifications

    3. Specifications Model Name HW400A Model Code DGW400DM - C Generating Method Rotating Field Rated Current (A) 390 @ 60% Duty Cycle, 302 @ 100% Duty Cycle Rated Voltage (V) 35.6 Rated Speed (rpm ) 3600 No Load Voltage (A)

  • Page 8: General

    4. General 4.1 Appearance 4.2 Dimension Unit in the drawings below is shown by mm.

  • Page 10: Welding Feature

    4.3 Welding Feature 4.3.1 Duty Cycle ・ High efficient alternator has achieved the rated duty cycle 60% for 390A and 100% for 302A. Multi-pole rotor has made the stator winding pitch short (i.e. coil length short) which has brought the coil resistance decreasing. In addition to it, bigger diameter coil has also brought coil resistance decreasing.

  • Page 11: General Parts Description

    5. General Parts Description 5.1 Main Parts and Feature (1) Unit Serial Number (2) Engine Serial Number Monitor Lamp Feature: Light a monitor lamp when equipment is 5.2 Main Components malfunctioned. Starter Switch Feature: Selector switch to start, stop and preheat engine Remote Control Receptacle Feature: Receptacle...
  • Page 12 AC Voltage Adjusting CC/CV Selector Switch Dial Feature: Feature: A dial to adjust Voltage is adjusted when AC output. the switch is turned to CV. Current is adjusted when the switch is turned to CC. Caution: Do not change the selector switch when welding.
  • Page 13 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 turns on. WATER TEMP: when a coolant temperature rises higher than 230° i n Fahrenheit. CHARGE: when a battery charge is insufficient.
  • Page 14 Right Side Door Inside Air Cleaner Feature: Clean intake air. Generator Feature: A device to convert mechanical energy to electrical energy. Fuel Filter Drain Hose Sub Tank Feature: Filter water or dust Feature: Drain water Feature: Keep coolant in the fuel. from the top cover.
  • Page 15 Injection Pump Feature: Supply fuel to the injection nozzle. Engine Oil Inlet Feature: Inlet to inject engine oil. Use the oil of CD or higher grade in American tute. Petroleum Insti Left Side Door Inside Resistor Feature: Upgrade welding feature, increasing voltage at no load with rectifier.
  • Page 16 1-Phase Receptacle (120/240V) 3-Phase Receptacle (480V) Feature: Supply AC output. Feature: Supply AC output. Max. output: 4.3kVA (4.3kW) Max. output: 15kVA (12kW) Circuit Breaker Feature: Protect an electric circuit from damage by overload or short circuit. Receptacle Inside View 1-Phase Receptacle (120V) Feature: Supply AC output.
  • Page 17 Standard Accessory ① Owners Manual ② Engine Manufacturer’s Warranty Statement ③ Starter Key – 2 sets ④ Tool Set ・ Tool Bag ・ Screw Driver ・ Plug Wrench ・ Spanner – 3 sets...

  • Page 18: Service Data

    6. Service Data 6.1 Periodical Check ELECTRIC SHOCK Never touch the output terminals during operation. Never touch the output terminal during operation even though the breaker on the load being set at OFF. Be sure to check and confirm the engine stop whenever touching terminals to connect loads. Items Article Method...
  • Page 19 Items Article Method Condition to verify Criterion Slow-down OFF 82.0+/-3V Voltage Regulator Max 335+/-5A ※1 Current Adj. Dial MAX Slow-down ON 42.0+/-2V Rod φ6mm Over 3150 min Over 400A Current Adj. Dial MAX Slow-down ON Over 32V Rod φ6mm Over 3300 min Current Adj.
  • Page 20 Items Article Method Condition to verify Criterion Slow-down OFF Output Adj. Dial 556+/-25V Max. Optional Tester Slow-down OFF No Load Output Adj. Dial 421+/-20V 3-Phase 480V Output Adj. Dial Terminals: U-V, 480+/-3V V-W, W-U 480+/-6V Meter Ditto attached 63+/-1Hz Ditto 14.4+/-0.5A Optional Loaded...

  • Page 21: Output Voltage (At No Load)

    6.2 Output Voltage (at no load) 6.2.1 Output Voltage (at no load) Welding Selector Switch Single/Dual Speed Slow Normal Engine 2100±20min 3800±20min Full Full AC Output Voltage Adj. Dial Position Min. Mid. Max. Range Range Single [45] [75] [82] [84] Dual (A) [44] [74]...

  • Page 22: Component Parts Resistance Value

    (Br) (Or) (Gr) Black White Green Yellow Brown Blue Orange Gray Note 1: The value shown in the above is measured when engine is cold. Note 2: Instrument used for measurement is a voltage meter for a movable coil type and iron type with accuracy of 0.5 classes.

  • Page 23: Display Mode By Led

    *2：Connect the power lead terminal for wire feeder into the bottom of the plate controller located inside of the front control panel. *3：The magnet switches located besides the terminal board for generator and the welding magnet switch is located at the plate controller in the back of AC receptacles. Note: Each coil resistance value should be measured by milli-ohm tester or low resistance measuring instruments.

  • Page 24: Power Controller

    ● ● ○ Yellow 《○》 Yellow ＯＮ ○ Green ○ Green ● ● ● ● ＣＣ 《○》 Green ● ● ● ＯＦＦ ○ Green ● DUAL ● ● ○ Yellow 《○》 Yellow ＯＮ ● ○ Green ○ Green ● ○ Orange ○...

  • Page 25: Fuse

    Generating Output Welding Output CV Control Voltage Generating/Welding (VR2) (VR1) (VR3) Frequency 60Hz 60Hz 60Hz Output 3-P 480V Single, CC Single, CV Ampere 14.4A 492A Output 140A Set Value Voltage 480V Common VR Position for reference (4) Fuse Fuse Monitor Engine Starter Switch Water...

  • Page 26: Tightening Torque

    7. Tightening Torque Torque Part to Allowance Nomenclature Size Reference tighten Nm(kgf/cm) 3.0-4.9 Exciter Stator Bolt M5x45 (30-50) Rear Bracket 29.5-32.3 Bolt M12x160 (Main Stator) (300-330) Bolt, 19.7-24.5 Generator Stator M10x30 Shim (200-250) 40.7-49.5 Rotor Bolt M10x1.25x30 (415-505) Bolt, 9.9-14.7 M8x25 Shim (100-150)

  • Page 27: Periodical Check For Engine

    7.1.1 Periodical Check for Engine ●Consult Kubota Service Dealer ○User Check ◎Replace Parts Checking interval Start up Items Check Every Every Every Every Every 50hrs 100hrs 200hrs 400hrs 1000hrs 2000hrs ○ Check and Supply Fuel Check and Supply Engine ○ ◎...

  • Page 28: Trouble Shooting

    8. Trouble Shooting ＜ Pre-check ＞ Always check the volume of oil, coolant, and fuel before processing to trouble shooting. 8.1 Engine won’t start ＜Pre-check＞ Always check oil, coolant and fuel volume before processing to trouble shooting. Dead Battery Starter Motor works Damaged Starter Motor Damaged Starter Switch Burnt 20A Fuse...

  • Page 29: Weak Arc

    8.2 Weak Arc Check position of switch and dial Turn Current Adjusting Dial clockwise Current Adjusting Dial Welding Cable Use proper size and length of cables Simultaneous use with Stop using Generator Output Generator Output <Slow/Eco> 2100±20 Change Power Controller Change speed control Motor for <Regular Speed>...

  • Page 30: No Welding Arc

    8.3 No Welding Arc Welding Output Welding Output Coil Voltage Thyristor Damaged Coil Voltage Remove Lead Wires and measure Rectifier Damaged Damaged PCB AU-AV, AV-AW, AW-AU:35V (Main Controller) AU-OA, AV-OA, AW-OA:20V Damaged Resistor BU-BV, BV-BW, BW-BU:35V Weak contact of lead wires and connector When values displayed are as per the page “output voltage (at no...

  • Page 31: Check Rotor, Stator And Excitor Circuit

    8.5 Check Rotor, Stator and Exciter Circuit Damaged Rotor Damaged Stator Exciter Circuit Damaged Note: To measure resistance on coil, Milliohm Tester is necessary. Multipurpose Tester cannot be used due to too large fudge factor. 【Phenomenon】 1. Check Initial Exciter Circuit No voltage energized at all or extremely low voltage Compensate Coil on Exciter Stator (Orange~Brown)

  • Page 32: Auto Idle Won't Work

    3. Check Rotor and Stator Measure output voltage at each coil on stator Refer to the voltages Rotor Damaged (Coil Broken or Rectifier Damaged) In Case 3-P Voltage reads 315V (Rated AC Output Voltage each equally 480V), one rotor coil (out of 2) broken or Rectifier on rotor damaged AC Output Voltage each unbalanced Rectifier on rotor Damaged...

  • Page 33: Engine Speed Won't Return To Idle

    8.7 Engine Speed won’t return to idle <Caution> Be sure to make operation check within a few seconds while the circuit may be short-circuited in this case. (Measure and judge short-circuit currents on welding side and generating side within a few seconds) Otherwise the stator should be burned. Check Welding and Short circuit Rectifier for Engine won’t return to idle.

  • Page 34: Wiring Diagram

    9. Wiring Diagram 9.1 Generator Wiring Diagram...
  • Page 40 HIMOINSA POWER SYSTEMS, INC. 16002 West 110 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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