HIPower HW400A Manual de usuario

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 0Hz ONLY.

Specifications subject to change without notice.

File №DGW-360_HW400A

This service manual is edited for authorized person to perform repair,

maintenance, and trouble-shooting to 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.

The information 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 some

differences between your equipment and the equipment described in this

manual. We reserve the right to make changes to equipments without prior

notice, and without obligation to make alterations to equipments previously

manufactured.

For service of the engine, refer to Workshop (Service) Manual provided by

the engine manufacturer described below.

MANUFACTURER

MODEL WORKSHOP MANUAL

Kubota D1005 05-E3B/05-E3BG Series

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. General Par ts Description

········································································· 8

5.1 Main Parts and Feature ···················································································· 8

5.2 Main Components ···························································································· 8

6. Ser vice Data

··············································································································

6.1 Periodical Check······························································································ 15

6.2 Output Voltage (at no load)··············································································· 18

6.2.1 Output 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 Voltage Adjustment ······································································ 21

(4) Fuse··············································································································· 22

(5) Protection Feature ·························································································· 22

7. ightening orque

···································································································

7.1.1 Periodical Check for Engine··········································································· 24

8. rouble Shooting

·····································································································

8.1 Engine won’t start ···························································································· 25

8.2 Weak arc ········································································································· 26

8.3 No Welding Arc ································································································ 27

8.4 No AC Output··································································································· 27

8.5 Check Rotor, Stator and Excitor Circuit ····························································· 28

8.6 Auto Idle won’t work ························································································· 29

8.7 Engine Speed won’t return to idle ····································································· 30

9. Wiring Diagram

····························································································· 31

9.1 Generator Wiring Diagram················································································ 31

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.

・

Throughout this manual are special attention statements.

A statement preceded by the triangular attention symbol and the word “WARNING”

contains information that should be acted upon to prevent serious bodily injury.

A statement preceded by the triangular attention symbol and the word “CAUTION”

contains information that should be acted upon to prevent mechanical damage.

WARNING

CAU ION

2. General Safety Instructions

ELECTRICSHOCK

NEVER touch the output terminals

during operation

NEVER touch the output terminal during

operation even though the breaker on the

load is being set at “OFF” position.

ALWAYS stop engine and make sure it

stopped before you will connect the loads to

the output terminals.

Suffocation by exhaust gas

NEVER run the engine indoors! Make

sure there is always good ventilation.

Fumes from engine exhaust cause

serious injury.

ALWAYS operate the equipment in the

ventilated area.

When the equipment is used in a tunnel, hall

or any other indoor, the equipment for

ventilation must be used to prevent serious

accident caused by suffocation.

NEVER direct the exhaust fume to

houses nearby while considering the wind

flow direction.

Exhaust gas contains many harmful

elements that would cause affect to human.

Be free from suffocation when the

equipment is used in poorly ventilated area

such as inside of the building.

Entangled Injuries under

By Moving Componen

NEVER reach and touch the moving

component during operation!

ALWAYS stop the engine during inspection

to prevent serious bodily injury by entangled

accident under moving component.

Electric shock/Injuries/Burns

Never inspect equipment during

use

Never serve and inspect when equipment is

being operated.

It may cause electric shock, injuries or

burns.

WARNING-Use good judgment

①NEVER run the engine when

transporting the equipment.

②

ALWAYS stop the equipment

immediately if it suddenly begins to

violate or abnormal noise. Inspect for

broken, missing or improperly installed

parts.

③

ALWAYS keep the equipment as clean

as practical. Keep it free of loose

vegetation, mud, etc.

DO NOT make unauthorized

modifications or alterations to this equipment

of any of its components. YAMABIKO must

authorize alterations and modifications in

writing. Unauthorized modifications or

alterations may alter the equipment

operation and could jeopardize personal

safety during operation.

WARNING

Work Safely

Generators and welders operate at very high

speeds and can do serious damage or injury

if they are misused or abused. Never allow a

person without training or instruction to

operate and serve this equipment!

Attention to CAUTION LABEL！

Caution labels are placed on this equipment

and it would request special attention for

operation. Make sure to locate the labels

and understand the content of the caution.

・Check the caution labels is legible. Always

keep the labels clean or replace them when

worn or damaged

・Clean the labels by cloth, water or

detergent and never use organic solvent or

gasoline which may cause label peel off due

to adhesive solvent.

・Make sure to replace the labels when

damaged and illegible.

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

abnormal circumstances are noticed such

as unusual noise, smell, vibration and etc.

It may lead serious accident or fatal damage

of the equipment or properties.

Inflammables！

Keep the equipment far away from fire such

as cigarettes when refueling fuel, oil or

battery fluid.

NEVER operate or service the equipment

nearby fire as the equipment may catch

fire.

No Modification！

NEVER modify the equipment without

manufacturer’s advanced approval. .

It may lead serious safety issue and damage

the equipment.

Inspect the equipment before engine

start for operation and periodical inspection

without fail！

Make sure to serve initial check before start

engine and periodical inspection for safety

and longer life of the equipment.

CAUTION

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) MAX 85

Current Adj. Range (A) 110 - 400Single Welding Rod Diameter (in.) 3/32 - 5/16

Current Adj. Range (A) 55 - 210Dual Welding Rod Diameter (in.) 5/64 - 5/32

Current Adj. Range (A) 40 - 220

Welding Generator

Output Change

(CC power)

Eco Welding Rod Diameter (in.) 5/64 - 3/16

Rated Frequency (Hz) 60

Rated Speed (rpm ) 3600

Phase 1-Phase 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

Displacement (cu.in./liters) 61/1.001

Rated Output (hp/rpm) 27.4/3600

Fuel ASTM No.2 Diesel Fuel or Equivalent

Lube Oil API Class CC or Higher

Lube Oil Volume (gal./liters) 1.35/5.1

Cooling Water Volume (gal./liters) 1.14/4.3

Engine

Starting Method 12V DC Starter Motor

Battery 12V-45AH(55B24L)

Fuel Tank Capacity (gal./liters) 9.8 /37

Length (in./mm) 59.8/1519

Width (in./mm) 27.6/700

Dimen

sion

Height (in./mm) 29.9/760

Dry Weight (lbs./kg) 972/441

* Specifications subject to change without notice.

** Generating application is for 60Hz ONLY.

4. General

4.1 Appearance

4.2 Dimension

Unit in the drawings below is shown by mm.

Rotor for Multi-Pole

Welder and Generator

Main Stator

Exciter Stator

(Magnetic field)

Exciter(Armature)

Rotor

Short pitch Coil

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. 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 engine, which will bring the

engine life longer. In addition to that, it has become less occasion of engine

overheat owing to wider engine power margin.

4.3.2 Low Noise and Low Fuel Consumption

・The engine speed is automatically controlled to comply with the load, which has made

low noise and fuel consumption. The fuel consumption is remarkably low. It is

approx. 29 hour successive operation at 220A welding with full fuel tank, for example.

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