Freedom 38 PPA™
Large Autonomous Plasma Cutting System
Service Manual
809010 | Revision 0 | English
Freedom 38 PPA, Powermax, Duramax, Smart Sense, FastConnect, FineCut, and Hypertherm are trademarks of Hypertherm Inc. and
may be registered in the United States and other countries. All other trademarks are the property of their respective holders.
© 2017 Hypertherm Inc.
Freedom 38 PPA
Service Manual
809010
Revision 0
English
March 2017
Hypertherm Inc.
Hanover, NH 03755 USA
www.hypertherm.com
Hypertherm Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
info@hypertherm.com (Main Office Email)
800-643-9878 Tel (Technical Service)
technical.service@hypertherm.com (Technical Service Email)
800-737-2978 Tel (Customer Service)
customer.service@hypertherm.com (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
return.materials@hypertherm.com (RMA email)
Hypertherm México, S.A. de C.V.
Avenida Toluca No. 444, Anexo 1,
Colonia Olivar de los Padres
Delegación Álvaro Obregón
México, D.F. C.P. 01780
52 55 5681 8109 Tel
52 55 5683 2127 Fax
Soporte.Tecnico@hypertherm.com (Technical Service Email)
Hypertherm Plasmatechnik GmbH
Sophie-Scholl-Platz 5
63452 Hanau
Germany
00 800 33 24 97 37 Tel
00 800 49 73 73 29 Fax
31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
technicalservice.emea@hypertherm.com (Technical Service Email)
Hypertherm (Singapore) Pte Ltd.
82 Genting Lane
Media Centre
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Singapore 349567, Republic of Singapore
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65 6841 2490 Fax
Marketing.asia@hypertherm.com (Marketing Email)
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Hypertherm Japan Ltd.
Level 9, Edobori Center Building
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Osaka 550-0002 Japan
81 6 6225 1183 Tel
81 6 6225 1184 Fax
HTJapan.info@hypertherm.com (Main Office Email)
TechSupportAPAC@hypertherm.com (Technical Service Email)
Hypertherm Europe B.V.
Vaartveld 9, 4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
technicalservice.emea@hypertherm.com
(Technical Service Email)
Hypertherm (Shanghai) Trading Co., Ltd.
B301, 495 ShangZhong Road
Shanghai, 200231
PR China
86-21-80231122 Tel
86-21-80231120 Fax
86-21-80231128 Tel (Technical Service)
techsupport.china@hypertherm.com
(Technical Service Email)
South America & Central America: Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
tecnico.sa@hypertherm.com (Technical Service Email)
Hypertherm Korea Branch
#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
Marketing.korea@hypertherm.com (Marketing Email)
TechSupportAPAC@hypertherm.com
(Technical Service Email)
Hypertherm Pty Limited
GPO Box 4836
Sydney NSW 2001, Australia
61 (0) 437 606 995 Tel
61 7 3219 9010 Fax
au.sales@Hypertherm.com (Main Office Email)
TechSupportAPAC@hypertherm.com
(Technical Service Email)
Hypertherm (India) Thermal Cutting Pvt. Ltd
A-18 / B-1 Extension,
Mohan Co-Operative Industrial Estate,
Mathura Road, New Delhi 110044, India
91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
HTIndia.info@hypertherm.com (Main Office Email)
TechSupportAPAC@hypertherm.com
(Technical Service Email)
ENGLISH
WARNING! Before operating any Hypertherm equipment, read the safety
instructions in your product’s manual and in the Safety and Compliance Manual
(80669C). Failure to follow safety instructions can result in personal injury or in
damage to equipment.
Copies of the manuals may accompany the product in electronic and printed
formats. You can also obtain copies of the manuals, in all languages available
for each manual, from the “Documents library” at www.hypertherm.com.
DANSK / DAN ISH
ADVARSEL! Inden Hypertherm udstyr tages i brug skal
sikkerhedsinstruktionerne i produktets manual og i Manual om sikkerhed og
overholdelse af krav (80669C), gennemlæses. Følges sikkerhedsvejledningen
ikke kan det resultere i personskade eller beskadigelse af udstyret.
Kopier af manualerne kan ledsage produktet i elektroniske og trykte formater.
Du kan også få kopier af manualer, på alle sprog der er til rådighed for hver
manuel, fra “Dokumentbiblioteket” på www.hypertherm.com.
DEUTSCH / GERMAN
WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen
Sie bitte die Sicherheitsanweisungen in Ihrer Bedienungsanleitung sowie im
Handbuch für Sicherheit und Übereinstimmung (80669C). Das Nichtbefolgen
der Sicherheitsanweisungen kann zu Verletzungen von Personen oder
Schäden am Gerät führen.
Bedienungsanleitungen und Handbücher können dem Gerät in
elektronischer Form oder als Druckversion beiliegen. Alle Handbücher
und Anleitungen können in den jeweils verfügbaren Sprachen auch in der
„Dokumente-Bibliothek“ unter www.hypertherm.com heruntergeladen werden.
FRANÇAIS / FRENCH
AVERTISSEMENT! Avant d’utiliser tout équipement Hypertherm, lire les
consignes de sécurité importantes dans le manuel de votre produit et dans
le Manuel de sécurité et de conformité (80669C). Le non-respect des
consignes de sécurité peut engendrer des blessures physiques ou des
dommages à l’équipement.
Des copies de ces manuels peuvent accompagner le produit en format
électronique et papier. Vous pouvez également obtenir des copies de chaque
manuel dans toutes les langues disponibles à partir de la «Bibliothèque
de documents» sur www.hypertherm.com.
ESPAÑOL / SPANISH
¡ADVERTENCIA! Antes de operar cualquier equipo Hypertherm, leer las
instrucciones de seguridad del manual de su producto y del Manual de
Seguridad y Cumplimiento (80669C). No cumplir las instrucciones
de seguridad podría dar lugar a lesiones personales o daño a los equipos.
Pueden venir copias de los manuales en formato electrónico e impreso
junto con el producto. También se pueden obtener copias de los manuales,
en todos los idiomas disponibles para cada manual, de la “Biblioteca
de documentos” en www.hypertherm.com.
ITALIANO / ITALIAN
AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni
sulla sicurezza nel manuale del prodotto e nel Manuale sulla sicurezza e
la conformità (80669C). Il mancato rispetto delle istruzioni sulla sicurezza può
causare lesioni personali o danni all’attrezzatura.
Il prodotto può essere accompagnato da copie elettroniche e cartacee
del manuale. È anche possibile ottenere copie del manuale, in tutte le lingue
disponibili per ogni manuale, dall’“Archivio documenti” all’indirizzo
www.hypertherm.com.
NEDERLANDS / DUTCH
WAARSCHUWING! Lees voordat u Hypertherm-apparatuur gebruikt
de veiligheidsinstructies in de producthandleiding en in de Veiligheids- en
nalevingshandleiding (80669C). Het niet volgen van de veiligheidsinstructies
kan resulteren in persoonlijk letsel of schade aan apparatuur.
De handleidingen kunnen in elektronische en gedrukte vorm met het
product worden meegeleverd. De handleidingen, elke handleiding
beschikbaar in alle talen, zijn ook verkrijgbaar via de “Documentenbibliotheek”
op www.hypertherm.com.
PORTUGUÊS / PORTUGUESE
ADVERTÊNCIA! Antes de operar qualquer equipamento Hypertherm, leia as
instruções de segurança no manual do seu produto e no Manual de Segurança
e de Conformidade (80669C). Não seguir as instruções de segurança pode
resultar em lesões corporais ou danos ao equipamento.
Cópias dos manuais podem acompanhar os produtos nos formatos eletrônico
e impresso. Também é possível obter cópias dos manuais em todos os idiomas
disponíveis para cada manual na “Biblioteca de documentos” em
www.hypertherm.com
日本語 / JAPANESE
警告 ! Hypertherm 機器を操作する前に、安全に関する重要な情報につい
て、この製品説明書にある安全情報、および製品に同梱されている別冊の
「安全とコンプライアンスマニュアル」 (80669C) をお読みください。安全
情報に従わないと怪我や装置の損傷を招くことがあります。
説明書のコピーは、電子フォーマット、または印刷物として製品に同梱さ
れています。各説明書は、 www.hypertherm.com の「ドキュメントライブラ
リ」から各言語で入手できます。
简体中文 / CHINESE (SIMPLIFIED)
警告！ 在操作任何海宝设备之前，请阅读产品手册和 《安全和法规遵守手
册》 (80669C) 中的安全操作说明。若未能遵循安全操作说明，可能会造成
人员受伤或设备损坏。
随产品提供的手册可能提供电子版和印刷版两种格式。您也可从
“Documents library” （文档资料库）中获取每本手册所有可用语言的副本，
网址为 www.hypertherm.com.
NORSK / NORWEGIAN
ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese
sikkerhetsinstruksjonene i produktets håndbok og i Håndboken om sikkerhet
og samsvar (80669C). Unnlatelse av å følge sikkerhetsinstruksjoner kan føre
til personskade eller skade på utstyr.
Eksemplarer av håndbøkene kan medfølge produktet i elektroniske og trykte
utgaver. Du kan også få eksemplarer av håndbøkene i alle tilgjengelige språk
for hver håndbok fra dokumentbiblioteket på www.hypertherm.com.
SVENSKA / SWEDISH
VARNING! Läs häftet säkerhetsinformationen i din produkts säkerhets- och
efterlevnadsmanual (80669C) för viktig säkerhetsinformation innan du
använder eller underhåller Hypertherm-utrustning. Underlåtenhet att följa
dessa säkerhetsinstruktionerkan resultera i personskador eller skador
på utrustningen.
Kopior av manualen kan medfölja produkten i elektronisk och tryckform.
Du hittar även kopior av manualerna i alla tillgängliga språk
i dokumentbiblioteket (Documents library) på www.hypertherm.com.
한국어 / KOREAN
경고! Hypertherm 장비를 사용하기 전에 제품 설명서와 안전 및 규정
준수 설명서 (80669C)에 나와 있는 안전 지침을 읽으십시오. 안전 지침을
준수하지 않으면 신체 부상이나 장비 손상을 초래할 수 있습니다.
전자 형식과 인쇄된 형식으로 설명서 사본이 제품과 함께 제공될
수 있습니다. www.hypertherm.com 의 'Documents library (문서라이브러리)'
에서도모든언어로이용할수있는설명서사본을얻을수있습니다.
.
ČESKY / CZECH
VAROVÁNÍ! Před uvedením jakéhokoliv zařízení Hypertherm do provozu
si přečtěte bezpečnostní pokyny v příručce k produktu a v Manuálu pro
bezpečnost a dodržování předpisů (80669C). Nedodržování bezpečnostních
pokynů může mít za následek zranění osob nebo poškození majetku.
Kopie příruček a manuálů mohou být součástí dodávky produktu, a to
v elektronické i tištěné formě. Kopie příruček a manuálů ve všech jazykových
verzích, v nichž byly dané příručky a manuály vytvořeny, naleznete v „Knihovně
dokumentů“ na webových stránkách www.hypertherm.com.
TÜRKÇE / TURKISH
UYARI! Bir Hypertherm ekipmanını çalıştırmadan önce, ürün kullanım
kılavuzunda ve Güvenlik ve Uyumluluk Kılavuzu’nda (80669C) yer alan
güvenlik talimatlarını okuyun. Güvenlik talimatlarına uyulmaması durumunda
kişisel yaralanmalar veya ekipman hasarı meydana gelebilir.
Kılavuzların kopyaları, elektronik ve basılı formatta ürünle birlikte verilebilir.
Her biri tüm dillerde yayınlanan kılavuzların kopyalarını www.hypertherm.com
adresindeki “Documents library” (Dosyalar kitaplığı) başlığından da elde
edebilirsiniz.
POLSKI / POLISH
OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu firmy
Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa
zamieszczonymi w podręczniku produktu oraz w Podręczniku bezpieczeństwa
i zgodności (80669C). Nieprzestrzeganie instrukcji bezpieczeństwa może
skutkować obrażeniami ciała i uszkodzeniem sprzętu.
Do produktu mogą być dołączone kopie podręczników w formacie
elektronicznym i drukowanym. Kopie podręczników, wkażdym udostępnionym
języku, można również znaleźć w„Bibliotece dokumentów” pod adresem
www.hypertherm.com.
PУССКИЙ / RUSSIAN
БЕРЕГИСЬ! Перед работой с любым оборудованием Hypertherm
ознакомьтесь с инструкциями по безопасности, представленными
в руководстве, которое поставляется вместе с продуктом, а также
в Руководстве по безопасности и соответствию (80669J). Невыполнение
инструкций по безопасности может привести к телесным повреждениям
или повреждению оборудования.
Копии руководств, которые поставляются вместе с продуктом, могут быть
представлены в электронном и бумажном виде. Копии руководств на всех
языках, на которые переведено то или иное руководство, можно также
загрузить в разделе «Библиотека документов» на веб-сайте
www.hypertherm.com.
SUOMI / FINNISH
VAROITUS! Ennen minkään Hypertherm-laitteen käyttöä lue tuotteen
käyttöoppaassa olevat turvallisuusohjeet ja turvallisuus- ja
vaatimustenmukaisuusohje (80669C). Turvallisuusohjeiden laiminlyönti
voi aiheuttaa henkilökohtaisen loukkaantumisen tai laitevahingon.
Käyttöoppaiden kopiot voivat olla tuotteen mukana elektronisessa ja
tulostetussa muodossa. Voit saada käyttöoppaiden kopiot kaikilla kielillä
”latauskirjastosta”, joka on osoitteessa www.hypertherm.com.
БЪЛГAPCКИ / BULGARIAN
ПРЕДУПРЕЖДЕНИЕ! Преди да работите с което и да е оборудване
Hypertherm, прочетете инструкциите за безопасност в ръководството на
вашия продукт и „Инструкция за безопасност и съответствие“ (80669C).
Неспазването на инструкциите за безопасност би могло да доведе
до телесно нараняване или до повреда на оборудването.
Копия на ръководствата може да придружават продукта в електронен и в
печатен формат. Можете да получите копия на ръководствата, предлагани
на всички езици, от „Documents library“ (Библиотека за документи)
на адрес www.hypertherm.com.
ROMÂNĂ / ROMANIAN
AVERTIZARE! Înainte de utilizarea oricărui echipament Hypertherm, citiți
instrucțiunile de siguranță din cadrul manualului produsului și din cadrul
Manualului de siguranță și conformitate (80669C). Nerespectarea
instrucțiunilor de siguranță pot rezulta în vătămare personală sau în avarierea
echipamentului.
Produsul poate fi însoțit de copii ale manualului în format tipărit și electronic.
De asemenea, dumneavoastră puteţi obţine copii ale manualelor, în toate limbile
disponibile pentru fiecare manual, din cadrul secţiunii „Bibliotecă documente”
aflată pe site-ul www.hypertherm.com.
MAGYAR / HUNGARIAN
VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne, olvassa
el a biztonsági információkat a termék kézikönyvében és a Biztonsági és
szabálykövetési kézikönyvben (80669C). A biztonági utasítások betartásának
elmulasztása személyi sérüléshez vagy a berendezés károsodásához vezethet.
A termékhez a kézikönyv példányai elektronikus és nyomtatott formában
is mellékelve lehetnek. A kézikönyvek példányai (minden nyelven) a
www.hypertherm.com
könyvtár) részben is beszerezhetők.
ΕΛΛΗΝΙΚΆ / GREEK
ΠΡΟΕΙΔΟΠΟΙΗΣΗ! Πριν θέσετε σε λειτουργία οποιονδήποτε εξοπλισμό της
Hypertherm, διαβάστε τις οδηγίες ασφαλείας στο εγχειρίδιο του προϊόντος
και στο Εγχειρίδιο ασφάλειας και συμμόρφωσης (80669C). Η μη τήρηση
των οδηγιών ασφαλείας μπορεί να επιφέρει σωματική βλάβη ή ζημιά στον
εξοπλισμό.
Αντίγραφα των εγχειριδίων μπορεί να συνοδεύουν το προϊόν σε ηλεκτρονική
και έντυπη μορφή. Μπορείτε, επίσης, να λάβετε αντίγραφα των εγχειριδίων σε
όλες τις γλώσσες που διατίθενται για κάθε εγχειρίδιο από την ψηφιακή
βιβλιοθήκη εγγράφων (Documents library) στη διαδικτυακή τοποθεσία
www.hypertherm.com
繁體中文 / CHINESE (TRADITIONAL)
警告！ 在操作任何 Hypertherm 設備前，請閱讀您產品手冊和 《安全和法務
遵從手冊》(80669C) 內的安全指示。不遵守安全指示可能會導致人身傷害
或設備損壞。
手冊複本可能以電子和印刷格式隨附產品提供。您也可以在
www.hypertherm.com 的 「文檔資料庫」內獲取所有手冊的多語種複本。
SLOVENŠČINA / SLOVENIAN
OPOZORILO! Pred uporabo katerekoli Hyperthermove opreme preberite
varnostna navodila v priročniku vašega izdelka ter v Priročniku za varnost
in skladnost (80669C). Neupoštevanje navodil za uporabo lahko povzroči
telesne poškodbe ali materialno škodo.
Izdelku so lahko priloženi izvodi priročnikov v elektronski ali tiskani obliki. Izvode
priročnikov v vseh razpoložljivih jezikih si lahko prenesete tudi iz knjižnice
dokumentov “Documents library” na naslovu www.hypertherm.com.
SRPSKI / SERBIAN
UPOZORENJE! Pre rukovanja bilo kojom Hyperthermovom opremom
pročitajte uputstva o bezbednosti u svom priručniku za proizvod i u Priručniku
o bezbednosti i usaglašenosti (80669C). Oglušavanje o praćenje uputstava
o bezbednosti može da ima za posledicu ličnu povredu ili oštećenje opreme.
Može se dogoditi da kopije priručnika prate proizvod u elektronskom
i štampanom formatu. Takođe možete da pronađete kopije priručnika, na svim
jezicima koji su dostupni za svaki od priručnika, u “Biblioteci dokumenata”
(“Documents library”) na www.hypertherm.com.
SLOVENČINA / SLOVAK
VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm
si prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia
avManuáli o bezpečnosti a súlade s normami (80669C). V prípade
nedodržania bezpečnostných pokynov môže dôjsť k ujme na zdraví alebo
poškodeniu zariadenia.
Kópia návodu, ktorá je dodávaná s produktom, môže mať elektronickú
alebo tlačenú podobu. Kópie návodov, vo všetkých dostupných jazykoch,
sú k dispozícii aj v sekcii z „knižnice Dokumenty“ na www.hypertherm.com.
weboldalon a „Documents library” (Dokumentum
.
Contents
Warranty ..................................................................................................................................SC-11
Attention ....................................................................................................................................................................................SC-11
General .....................................................................................................................................................................................SC-11
Patent indemnity .....................................................................................................................................................................SC-11
Limitation of liability ................................................................................................................................................................SC-11
National and local codes .......................................................................................................................................................SC-11
Liability cap ..............................................................................................................................................................................SC-12
Insurance ..................................................................................................................................................................................SC-12
Transfer of rights .....................................................................................................................................................................SC-12
Waterjet product warranty coverage .................................................................................................................................SC-12
Product ..............................................................................................................................................................................SC-12
Parts coverage .................................................................................................................................................................SC-12
1 Troubleshooting .......................................................................................................................... 13
Where to go for help .................................................................................................................................................................... 13
System components .................................................................................................................................................................... 16
Controls and indicators ............................................................................................................................................................... 18
System controller .................................................................................................................................................................. 18
Plasma cutting system ......................................................................................................................................................... 20
Check engine and generator status ......................................................................................................................................... 21
Reset the control system ............................................................................................................................................................ 21
System faults ................................................................................................................................................................................. 22
Active faults and cleared faults .......................................................................................................................................... 22
System faults triggered by predefined thresholds ........................................................................................................ 23
Engine faults (SPN and FMI codes) ................................................................................................................................. 25
Find system fault codes in events history ............................................................................................................................... 27
Freedom 38 PPA Service Manual 809010 7
Contents
Troubleshoot engine issues ....................................................................................................................................................... 28
Reset emergency air intake shutoff valve (if equipped) ............................................................................................... 28
Engine will not start .............................................................................................................................................................. 29
Keep the fuel system clean ................................................................................................................................................ 30
Use the hand pump to bleed the fuel system ................................................................................................................ 31
Jump-start the battery .......................................................................................................................................................... 32
Common engine and generator issues ............................................................................................................................ 35
Troubleshoot air flow issues (air compressor) ....................................................................................................................... 36
Troubleshoot power-related issues (generator/alternator) ................................................................................................. 38
Troubleshoot plasma cutting issues ......................................................................................................................................... 40
Common cutting issues ...................................................................................................................................................... 40
Plasma cutting system fault codes and solutions ......................................................................................................... 41
Find serial numbers ...................................................................................................................................................................... 47
Serial number for the system ............................................................................................................................................. 47
Serial number for the generator ........................................................................................................................................ 48
Serial number for the engine .............................................................................................................................................. 48
Serial number for the alternator ......................................................................................................................................... 49
Serial number and version numbers for the system controller ................................................................................... 50
Serial number for the air compressor ............................................................................................................................... 51
Serial number for the plasma cutting system ................................................................................................................. 51
2 Routine Maintenance ................................................................................................................ 53
Maintenance schedules .............................................................................................................................................................. 53
Routine maintenance procedures ............................................................................................................................................. 59
Every use ................................................................................................................................................................................ 60
Every day ................................................................................................................................................................................ 62
Every week ............................................................................................................................................................................. 63
Every month ........................................................................................................................................................................... 66
Every 3 months (or 500 operating hours) ....................................................................................................................... 69
Every 6 months ...................................................................................................................................................................... 73
Every year ............................................................................................................................................................................... 78
Every 4,000 operating hours .............................................................................................................................................. 81
3 System-Level Components ...................................................................................................... 83
Remove and install the system’s cover ............................................................................................................................ 86
Replace the battery .............................................................................................................................................................. 89
Replace the Dynagen system controller .......................................................................................................................... 92
Replace the alternator lamp ............................................................................................................................................... 94
Replace the 12 V circuit breaker on the front panel ..................................................................................................... 95
Replace the ON/OFF power switch ................................................................................................................................ 96
Replace emergency stop contact block .......................................................................................................................... 98
8 Freedom 38 PPA Service Manual 809010
Contents
Replace emergency stop button ...................................................................................................................................... 99
Replace front panel circuit breaker ................................................................................................................................. 100
Replace the 480 V auxiliary outlet .................................................................................................................................. 102
Replace the service panel compression latch ............................................................................................................. 104
Replace the 120 V auxiliary outlet .................................................................................................................................. 105
Replace 120 V auxiliary outlet circuit breaker .............................................................................................................. 106
Replace the front panel ..................................................................................................................................................... 107
4 Plasma Components ............................................................................................................... 111
Replace the air filter element and air filter bowl in the plasma supply .................................................................... 114
Detach the plasma supply power cord .......................................................................................................................... 115
Unfasten the plasma supply ............................................................................................................................................. 118
5 Generator and Engine Components .................................................................................... 121
Unfasten the front panel .................................................................................................................................................... 124
Replace the transformer .................................................................................................................................................... 126
Replace the emergency air intake shut-off valve ......................................................................................................... 130
Replace the automatic voltage regulator (AVR) .......................................................................................................... 133
Replace the fuel-level sensor ........................................................................................................................................... 136
Replace the AC sensor wiring harnesses ..................................................................................................................... 138
Replace the control system wiring harness .................................................................................................................. 140
Replace the generator wiring harness ........................................................................................................................... 142
Replace the engine wiring harness ................................................................................................................................ 148
Replace the relays .............................................................................................................................................................. 150
Replace the fuel shutoff relay ........................................................................................................................................... 151
Replace the cooling unit fan relay ................................................................................................................................... 152
Replace the generator rectifiers ...................................................................................................................................... 153
6 Air Compression Components .............................................................................................. 155
Replace the air compressor belt ..................................................................................................................................... 160
Replace the air compressor and drive pulley ............................................................................................................... 161
Replace the compressor tension pulley ........................................................................................................................ 165
Replace the compressor inlet valve ................................................................................................................................ 166
Replace the air compressor temperature switch, tee fitting, elbow fitting, and adapter .................................... 167
Replace the air compressor check valve and scavenge line orifice ........................................................................ 169
Replace the air pressure gauge ...................................................................................................................................... 171
Replace the unloader valve .............................................................................................................................................. 172
Replace the muffler and orifice adapter ........................................................................................................................ 174
Replace the separation tank ............................................................................................................................................. 175
Replace the separation tank manifold ............................................................................................................................ 178
Replace the cooler unit ..................................................................................................................................................... 181
Freedom 38 PPA Service Manual 809010 9
Contents
Replace the compressor cooling fan ............................................................................................................................. 183
Replace the pressure relief valve on the separation tank .......................................................................................... 185
Replace the oil level gauge .............................................................................................................................................. 186
Replace the air drying filter assembly ............................................................................................................................ 187
Replace the pressure relief valve on the air drying filter assembly .......................................................................... 190
Replace the ball valve, elbow fitting, and elbow coupler on the separation tank ................................................ 191
Replace the condensate release lever ........................................................................................................................... 193
7 Parts ............................................................................................................................................. 195
System parts ................................................................................................................................................................................ 196
Exterior, front panel ............................................................................................................................................................ 196
Exterior, sides ...................................................................................................................................................................... 198
Interior, engine and generator .......................................................................................................................................... 199
Wiring harnesses ................................................................................................................................................................ 202
Interior, air compression system ...................................................................................................................................... 204
Air compression hoses ...................................................................................................................................................... 207
Plasma torches ............................................................................................................................................................................ 209
Hand torches ....................................................................................................................................................................... 209
Machine torches ................................................................................................................................................................. 210
Plasma torch consumables ...................................................................................................................................................... 211
Hand cutting ........................................................................................................................................................................ 211
Mechanized cutting ............................................................................................................................................................ 212
Accessory parts for plasma cutting ........................................................................................................................................ 213
8 Wiring Diagrams ....................................................................................................................... 215
AC wiring diagram ...................................................................................................................................................................... 217
12 VDC wiring diagram ............................................................................................................................................................ 218
10 Freedom 38 PPA Service Manual 809010
Warranty
Attention
Genuine Hypertherm parts are the factory-recommended replacement
parts for your Hypertherm system. Any damage or injury caused by the
use of other than genuine Hypertherm parts may not be covered by the
Hypertherm warranty, and will constitute misuse of the Hypertherm
Product.
You are solely responsible for the safe use of the Product. Hypertherm
does not and cannot make any guarantee or warranty regarding the safe
use of the product in your environment.
General
Hypertherm Inc. warrants that its Products shall be free from defects in
materials and workmanship for the specific periods of time set forth
herein and as follows: if Hypertherm is notified of a defect (i) with respect
to the plasma power supply within a period of two (2) years from the date
of its delivery to you, with the exception of Powermax brand power
supplies, which shall be within a period of three (3) years from the date of
delivery to you, and (ii) with respect to the torch and leads within a period
of one (1) year from its date of delivery to you, with the exception of the
HPRXD short torch with integrated lead, which shall be within a period of
six (6) months from the date of delivery to you, and with respect to torch
lifter assemblies within a period of one (1) year from its date of delivery to
you, and with respect to Automation products one (1) year from its date
of delivery to you, with the exception of the EDGE Connect CNC,
EDGE Connect T CNC, EDGE Connect TC CNC, EDGE Pro CNC,
EDGE Pro Ti CNC, MicroEDGE Pro CNC, and ArcGlide THC, which
shall be within a period of two (2) years from the date of delivery to you,
and (iii) with respect to HyIntensity fiber laser components within a
period of two (2) years from the date of its delivery to you, with the
exception of laser heads and beam delivery cables, which shall be within
a period of one (1) year from its date of delivery to you.
All third-party engines, engine accessories, alternators, and alternator
accessories are covered by the respective manufacturers’ warranties and
not covered by this warranty.
This warranty shall not apply to any Powermax brand power supplies that
have been used with phase converters. In addition, Hypertherm does not
warranty systems that have been damaged as a result of poor power
quality, whether from phase converters or incoming line power. This
warranty shall not apply to any product which has been incorrectly
installed, modified, or otherwise damaged.
The warranty set forth above is exclusive and is in lieu of all other
warranties, express, implied, statutory, or otherwise with respect to the
Products or as to the results which may be obtained therefrom, and all
implied warranties or conditions of quality or of merchantability or fitness
for a particular purpose or against infringement. The foregoing shall
constitute the sole and exclusive remedy for any breach by Hypertherm
of its warranty.
Distributors/OEMs may offer different or additional warranties, but
Distributors/OEMs are not authorized to give any additional warranty
protection to you or make any representation to you purporting to be
binding upon Hypertherm.
Patent indemnity
Except only in cases of products not manufactured by Hypertherm or
manufactured by a person other than Hypertherm not in strict conformity
with Hypertherm’s specifications and in cases of designs, processes,
formulae, or combinations not developed or purported to be developed
by Hypertherm, Hypertherm will have the right to defend or settle, at its
own expense, any suit or proceeding brought against you alleging that
the use of the Hypertherm product, alone and not in combination with
any other product not supplied by Hypertherm, infringes any patent of
any third party. You shall notify Hypertherm promptly upon learning of any
action or threatened action in connection with any such alleged
infringement (and in any event no longer than fourteen (14) days after
learning of any action or threat of action), and Hypertherm’s obligation to
defend shall be conditioned upon Hypertherm’s sole control of, and the
indemnified party’s cooperation and assistance in, the defense of the
claim.
Limitation of liability
In no event shall Hypertherm be liable to any person or entity for
any incidental, consequential direct, indirect, punitive or
exemplary damages (including but not limited to lost profits)
regardless of whether such liability is based on breach of
contract, tort, strict liability, breach of warranty, failure of
essential purpose, or otherwise, and even if advised of the
possibility of such damages. Hypertherm shall not be liable for
any losses to Distributor based on down time, lost production or
lost profits. It is the intention of the Distributor and Hypertherm
that this provision be construed by a court as being the
broadest limitation of liability consistent with applicable law.
Hypertherm provides repair, replacement or adjustment of the Product as
the sole and exclusive remedy, if and only if the warranty set forth herein
properly is invoked and applies. Hypertherm, at its sole option, shall
repair, replace, or adjust, free of charge, any defective Products covered
by this warranty which shall be returned with Hypertherm’s prior
authorization (which shall not be unreasonably withheld), properly
packed, to Hypertherm’s place of business in Hanover, New Hampshire,
or to an authorized Hypertherm repair facility, all costs, insurance and
freight pre paid by the customer. Hypertherm shall not be liable for any
repairs, replacement, or adjustments of Products covered by this
warranty, except those made pursuant to this paragraph and with
Hypertherm’s prior written consent.
National and local codes
National and local codes governing plumbing and electrical installation
shall take precedence over any instructions contained in this manual.
In no event shall Hypertherm be liable for injury to persons or property
damage by reason of any code violation or poor work practices.
Safety and compliance SC-11
Warranty
Liability cap
In no event shall Hypertherm’s liability, if any, whether such
liability is based on breach of contract, tort, strict liability,
breach of warranties, failure of essential purpose or otherwise,
for any claim, action, suit or proceeding (whether in court,
arbitration, regulatory proceeding or otherwise) arising out of or
relating to the use of the Products exceed in the aggregate the
amount paid for the Products that gave rise to such claim.
Insurance
At all times you will have and maintain insurance in such quantities and
types, and with coverage sufficient and appropriate to defend and to hold
Hypertherm harmless in the event of any cause of action arising from the
use of the products.
Transfer of rights
You may transfer any remaining rights you may have hereunder only in
connection with the sale of all or substantially all of your assets or capital
stock to a successor in interest who agrees to be bound by all of the
terms and conditions of this Warranty. Within thirty (30) days before any
such transfer occurs, you agree to notify in writing Hypertherm, which
reserves the right of approval. Should you fail timely to notify Hypertherm
and seek its approval as set forth herein, the Warranty set forth herein
shall be null and void and you will have no further recourse against
Hypertherm under the Warranty or otherwise.
Waterjet product warranty coverage
Product Parts coverage
HyPrecision pumps 27 months from the ship date, or 24 months
from the date of proven installation, or
4,000 hours, whichever occurs first
PowerDredge
abrasive removal
system
EcoSift abrasive
recycling system
Abrasive metering
devices
On/off valve air
actuators
Diamond orifices 600 hours of use with the use of a thimble
Consumable parts are not covered by this warranty. Consumable parts
include, but are not limited to, high-pressure water seals, check valves,
cylinders, bleed-down valves, low-pressure seals, high-pressure tubing,
low- and high-pressure water filters and abrasive collection bags. All
third-party pumps, pump accessories, hoppers, hopper accessories,
dryer boxes, dryer box accessories and plumbing accessories are
covered by the respective manufacturers’ warranties and not covered by
this warranty.
15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first
15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first
15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first
15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first
filter and compliance with Hypertherm’s
water quality requirements
SC-12 Safety and compliance
Section 1
Troubleshooting
This section provides an overview of the most common problems that may arise when using this system and explains how
to solve them.
Where to go for help
If you cannot fix the problem by following the troubleshooting guidelines in this section, or if you need further assistance:
1. Call your authorized Hypertherm Freedom 38 PPA distributor or repair facility.
2. For engine support, locate the nearest authorized Deutz service dealer at www.deutzamericas.com
3. Call the nearest Hypertherm office listed in the front of this manual.
4. For warranty claims or questions:
Contact Hypertherm regarding claims for the plasma supply.
Contact Hypertherm regarding system-level claims and claims for the air compressor, alternator, and digital
controller. Hypertherm will connect you to the proper manufacturer, if needed.
Contact Deutz regarding claims for the engine:
Telephone: 770-564-7100
Website: www.deutzamericas.com
.
DANGER!
TOXIC GAS CAN BE FATAL
DO NOT OPERATE THIS SYSTEM INDOORS!
Exhaust from the generator contains carbon monoxide, which is an invisible, odorless gas. Inhaling
too much carbon monoxide will result in serious injury or death.
Only operate this system outdoors, away from windows and vents.
Freedom 38 PPA Service Manual 809010 13
1 – Troubleshooting
ELECTRIC SHOCK CAN KILL
Turn OFF the power before removing the cover from the system. In the U.S., use a
“lock-out / tag-out” procedure until the service or maintenance work is complete. In other
countries, follow appropriate national or local safety procedures.
Before servicing the engine or generator, turn OFF the system, wait for 30 seconds, then
disconnect the battery’s negative (-) ground cable.
Do not touch live electrical parts! If power is required for servicing, use extreme caution
when working near live electrical circuits. Dangerous voltages exist inside the system that
can cause serious injury or death.
Do not attempt to repair printed circuit boards. Do not cut away or remove any protective
conformal coating from circuit boards. To do so will risk a short circuit between the AC
input circuit and the output circuit and may result in serious injury or death.
HOT PARTS CAN CAUSE SEVERE BURNS
WARNING!
Allow the system’s internal components to cool before servicing.
Do not remove the pressure cap from the radiator while the engine is still hot.
MOVING PARTS CAN CAUSE INJURY
Use extreme caution if you need to work on a running engine.
Keep hands, clothing, jewelry, and tools away from moving parts.
Keep your hands away from the engine’s fan.
Do not wear loose clothing or jewelry that can catch on moving parts.
Remove safety guards only when necessary. Replace the safety guards as soon
as maintenance is complete.
Close the service panels when maintenance is complete. Repair or replace the
panels if they are damaged.
14 Freedom 38 PPA Service Manual 809010
1 – Troubleshooting
CAUTION!
FILTERS, FUEL, AND LUBRICATING OILS CAN CAUSE DISCOMFORT
Handle all engine filters, fuel, and lubricating oils with care. Fuel and lubricating oils can irritate skin.
Some filters can cause discomfort if they come in contact with the eyes or mouth.
Wash thoroughly if your skin comes in contact with fuel or oil from the engine.
NOTICE
STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS
Put on a grounded wrist strap before handling printed circuit boards.
Freedom 38 PPA Service Manual 809010 15
1 – Troubleshooting
1
2
3
4
5
6
7
8
9
10
11
13
14
12
15
16
1 Plasma supply
2 Plasma torch connection
3 Work lead connection
4 Air pressure gauge
5 Machine interface (CPC) connection
6 Emergency Stop button
7 System controller
8 Main circuit breaker (60 A) and transformer circuit
breaker (10 A)*
9 Alternator lamp
10 12 V circuit breaker (RESET button)
11 ON (I)/OFF (O) power switch
12 Circuit breaker to reset 120 V auxiliary outlet
13 120 V auxiliary – 2 GFCI receptacles (1-phase,
20 A) (neutral bonded to frame)
14 480 V auxiliary – 1 receptacle (3-phase, 60 A,
4-pole, 5-wire)
15 Lever to drain condensate from air tank
16 Auxiliary air hose connector
System components
Figure 1 – Front panel
* The main circuit breaker provides power to the on-board plasma cutting system and the 480 V auxiliary outlet. The transformer
circuit breaker provides power to the 120 V auxiliary outlet.
16 Freedom 38 PPA Service Manual 809010
1 Oil fill level for air compressor
2
1
3
2
3
1
4
2 Service panel
3 Lift truck slots
1 – Troubleshooting
Figure 2 – Plasma side
1 Fuel fill cap (diesel fuel only)
2 Oil drain hose caps for:
Oil pan drain hose
Heat exchanger drain hose
3 Service panel
4 Lift truck slots
Figure 3 – Generator side
Freedom 38 PPA Service Manual 809010 17
1 – Troubleshooting
1
4 5 6
7
8
2
3
ON (I)
OFF (O)
9
Controls and indicators
Familiarize yourself with the controls and indicators on the system before you start the engine and begin cutting.
System controller
Figure 4 – Primary system controls
1 LCD screen
Use the LCD screen to view engine and generator operating information as well as warning and failure
notifications. From this screen you can view, navigate, and update system status, engine parameters,
and settings.
2 Navigation buttons
Use the UP and DOWN arrow buttons to navigate through menus on the LCD screen, to change the
values for some settings, and to change the parameter screen.
Use the ENTER button to display the menu system on the LCD screen and to confirm settings you
changed. You can also use this button to lock the LCD screen when you view parameters.
18 Freedom 38 PPA Service Manual 809010
3 System status LED indicator
The LED indicator displays the current status of the system:
Solid green = engine is running
Solid amber = warning
Solid red = failure
For example, the LED indicator displays amber if the engine oil approaches its maximum temperature.
If the engine oil exceeds its maximum temperature, the LED indicator displays red, and the engine
shuts off.
For information on how to clear faults, see System faults on page 22.
4 OFF button
Use the OFF button to turn OFF the engine.
5 AUTO button
Use the AUTO button to view engine status details without turning on the engine, such as fuel
remaining, oil pressure, engine hours, engine temperature, and battery voltage.
1 – Troubleshooting
The AUTO button does not start the engine. Press the OFF button to exit AUTO mode.
6 RUN button
Use the RUN button to start the engine. When you press the RUN button, the engine continues to run
until you press the OFF button or activate an emergency stop, or until a failure occurs.
7 Alternator lamp
The alternator lamp monitors the charging current of the engine’s battery. This lamp illuminates if the
alternator is not properly charging the system.
8 12 V circuit breaker (RESET button)
The 12 V (10 A) circuit breaker protects DC circuits against shorted or overloaded circuits.
When the breaker is tripped, the RESET button in the center of the circuit breaker extrudes. Correct
the fault condition, then press the RESET button to reset the circuit breaker.
9 ON/OFF power switch
Use the power switch to turn ON (I) and OFF (O) 12 VDC power to control the system. You cannot
start the engine when the power switch is in the OFF (O) position.
The ON/OFF power switch should remain in the OFF (O) position when
the unit is not being used. When this switch is in the ON (I) position and
the unit is not running, the 12 VDC control system drains the battery over
time.
Freedom 38 PPA Service Manual 809010 19
1 – Troubleshooting
1
2
3
4
5
6
7
8
1 Status screen
2 Fault LED (yellow)
3 Automatic/manual pressure setting mode selector
4 Current/gas selector
5 Power ON LED (green)
6 Operating modes
7 Operating mode switch
8 Adjustment knob
Plasma cutting system
Figure 5 shows the controls and indicators for the plasma cutting system. For an explanation of these controls, refer to
the Basic System Operations section in the Powermax125 Operator Manual.
Figure 5 – Plasma cutting system controls
20 Freedom 38 PPA Service Manual 809010
1 – Troubleshooting
Check engine and generator status
Several engine and generator status details display on the system controller’s LCD screen when the engine is running,
such as:
Total operating hours for the engine
Oil pressure
Percentage of fuel remaining
Battery voltage
Engine temperature
Total time the engine has been running since it was started
Generator current (A)
The transformer circuit breaker must be ON (I) in order to view the output current on the
system controller.
Generator voltage (V)
AC frequency (Hz)
You can also view the following engine status details without starting the engine by pressing the AUTO button:
Total operating hours for the engine
Oil pressure
Percentage of fuel remaining
Battery voltage
Engine temperature
Press the OFF button to exit AUTO mode.
Reset the control system
When a system fault condition occurs, the engine shuts OFF and the LED indicator on the front panel illuminates solid
red.
To clear the fault, reset the control system:
1. Examine the LCD screen for the notification that describes why the engine shut down. Correct the fault before
continuing.
2. Press the OFF button on the system controller.
3. Press the RUN button to start the engine.
4. If the control system still needs to be reset, turn the main power switch OFF (O) and then back ON (I).
Freedom 38 PPA Service Manual 809010 21
1 – Troubleshooting
Active fault with SPN and FMI codes and
OC (occurrence count)
Fault message that displays after system shuts off
Displayed DTC message, active DTC messages
System faults
Active faults and cleared faults
Active faults display on the system controller’s LCD screen when they occur. The fault notification remains on the LCD
screen until the fault is cleared.
An active DTC (diagnostic trouble code) displays along with the fault codes. Engine-related faults may include numeric
fault codes called an SPN (suspect parameter number) and FMI (failure mode indicator). Make note of these codes when
they display. You may be asked to provide the codes if you contact an authorized Deutz service dealer for support. The
OC (occurrence count) appears with SPN and FMI codes. The OC identifies the number of times the failure has
occurred.
Non-active faults, or faults that have been cleared, are saved in the system’s events history. For instructions on how to
view faults that occurred in the past, see Find system fault codes in events history on page 27.
In some cases, you may see a combination of fault notifications. For example, if the temperature sensor in the engine is
faulty, you may first see a “Check Engine” fault with SPN code 0110 and FMI code 02. The system continues to operate
until the engine reaches a predefined temperature. At that point, the system shuts off, and the “High Engine Temp” fault
message displays. See Figure 6.
For more information on predefined conditions that trigger faults, see System faults triggered by predefined
thresholds on page 23.
For more information on SPN and FMI codes, see Engine faults (SPN and FMI codes) on page 25.
Figure 6 – Active faults
22 Freedom 38 PPA Service Manual 809010
1 – Troubleshooting
System faults triggered by predefined thresholds
Several preset thresholds are programmed into the system to define acceptable operating parameters.
When the system reaches a warning threshold:
A warning message displays.
The LED indicator illuminates solid amber.
You can continue to operate the system.
When the system reaches a failure threshold:
A fault message displays.
The LED indicator illuminates solid red.
The system shuts off.
The following table lists the conditions that trigger these warning and failure notifications and suggests how to clear each
fault:
Fault condition
Air
compressor
overheated
Warning
threshold
None 110°C (230°F) • Turn the system OFF, and allow the air compressor
System failure
threshold
Solutions
components to cool.
• Make sure the air compressor has enough oil. See
page 63.
• Change the oil and oil filter in the air compressor.
See page 78.
• Replace the temperature switch for the air
compressor. See page 167.
Crank failed 2 failed attempts None • This warning message displays when the system
fails to start the engine after 2 consecutive
attempts. See Engine will not start on page 29.
High battery
voltage
15 V None • Turn the system OFF. Replace the battery. See
page 89.
• If a new battery does not clear the fault, have an
authorized service dealer examine the alternator.
High engine
temperature
127°C (260°F) 129°C (265°F) • Make sure the system has adequate ventilation. Do
not block the ventilation screens or louvers.
• Check engine oil level. See page 62.
• Change the oil and oil filter in the engine. See
page 70.
• If the problem persists, have an authorized Deutz
service dealer examine the engine.
Freedom 38 PPA Service Manual 809010 23
1 – Troubleshooting
Fault condition
Low battery
voltage
Low fuel
level
Loss of ECM
communication
Low oil
pressure
Warning
threshold
11 V None • Check the connections on the battery. Clean and
25% None • Add clean, low-sulfur diesel fuel. Do not overfill the
Communication
with the electronic
control module
(ECM) was
interrupted
1.4 bar (20 psi) 1 bar (15 psi) • Make sure the engine has enough oil. See page 62.
System failure
threshold
6 seconds after
loss of ECM
communication
Solutions
tighten the connectors as needed. See page 69.
• Jump-start or charge the battery. See page 32.
• Replace the battery. See page 89.
• If a new battery does not clear the fault, have an
authorized service dealer examine the alternator.
fuel tank.
• Examine the wiring harnesses. Replace as needed.
See page 138.
• Install a new Deutz-brand oil filter. See Change the
oil and oil filter in the engine on page 70.
• If the problem persists, have an authorized Deutz
service dealer examine the engine.
Over current 55 AAC None • The generator’s amperes alternating current (AAC)
is too high. See Troubleshoot power-related issues
(generator/alternator) on page 38.
Over speed 1,980 RPM 2,160 RPM • Combustible gas in the air may cause the engine to
exceed operating speed. Make sure there are no
combustible or flammable gases in the area.
• Have an authorized Deutz service dealer examine
the engine.
Under speed 1,620 RPM 1,530 RPM • This fault can be triggered by a low fuel level. Check
the fuel level. See page 21. Add clean, low-sulfur
diesel fuel. Do not overfill the fuel tank.
• The system may be overloaded. Remove or
disconnect equipment from the 120 V and 480 V
auxiliary outlets to reduce load on the system.
• If the problem persists, have an authorized Deutz
service dealer examine the engine.
24 Freedom 38 PPA Service Manual 809010
Engine faults (SPN and FMI codes)
SPN code FMI code Occurrence count
SPN and FMI codes (or suspect parameter
number and failure mode indicator, respectively)
in a fault notification indicate that the fault is
engine-related. The following table lists a few
common SPN and FMI codes and suggests
how to clear each fault.
If you see an SPN or FMI code not listed in this
table, have an authorized Deutz service dealer
examine the system.
SPN FMI Description Solutions
1 – Troubleshooting
23 7 Injection pump or actuator warning.
The injection pump/actuator is stuck
or is not connected properly. The
actuator is not calibrated properly.
24 12 or 13 Actuator warning. The actuator is not
connected properly or is faulty.
51 or 60 2 Digital output fault due to a short
circuit or damaged cable.
84 8 Tachometer failed or tachometer cable
connection interrupted.
100 1 or 2 Oil pressure warning. The oil pressure
is too low, or the oil pressure sensor is
faulty.
• Make sure the actuator is connected properly.
• Have an authorized Deutz service dealer check the
fault limits for the actuator and reprogram them as
needed.
• Have an authorized Deutz service dealer examine
the injection pump, actuator, actuator rods, and
actuator cable and replace as needed.
• Have an authorized Deutz service dealer examine
the engine.
• Make sure the actuator is connected properly.
• Have an authorized Deutz service dealer examine
the engine.
• Have an authorized Deutz service dealer examine
the engine.
• Have an authorized Deutz service dealer examine
the engine.
• Check the oil level in the engine. Add oil as needed.
See page 62.
• Change the oil and oil filter in the engine. See
page 70.
• Have an authorized Deutz service dealer examine
the engine.
108 12 Atmospheric pressure warning. The
atmospheric pressure is too high or
too low.
110 0 or 2 Coolant temperature warning. The
coolant temperature is too high, or the
coolant sensor is faulty.
• Turn OFF the system. Allow the system to cool. Turn
ON the system. If the fault persists, have an
authorized Deutz service dealer examine the engine.
• This engine is oil-cooled, so first check the oil level
in the engine. Add oil as needed. See page 62.
• Change the oil and oil filter in the engine. See
page 70.
• Have an authorized Deutz service dealer examine
the engine.
Freedom 38 PPA Service Manual 809010 25
1 – Troubleshooting
SPN FMI Description Solutions
171 12 The electronic control unit is too hot
or too cold.
190 0 or 8 Engine speed warning. The engine is
running too far under or over
1800 RPMs.
231 12, 9, or 14Controller area network (CAN) bus
communication fault.
240, 253,
or 254
524287 31 No fault present. • No active faults are still present. Reset the control
2 or 12 Program logic or memory fault. • Turn OFF the system, then turn ON the system. If
• Turn OFF the system. Allow the system to cool. Turn
ON the system. If the fault persists, have an
authorized Deutz service dealer examine the engine.
• An under speed issue can be triggered by a low fuel
level. Add clean, low-sulfur diesel fuel. Do not
overfill the fuel tank.
• Have an authorized Deutz service dealer examine
the engine.
• Have an authorized Deutz service dealer examine
the engine.
the fault persists, have an authorized Deutz service
dealer examine the engine.
system if needed. See page 21.
26 Freedom 38 PPA Service Manual 809010
1 – Troubleshooting
SPN code FMI code Occurrence count
Find system fault codes in events history
The system records and saves faults that occur – even those that cause the engine to shut off. You can access the fault
details via the system controller’s LCD screen when you need that information for troubleshooting.
1. Turn ON (I) the power switch.
2. Press the ENTER button to display the
menu commands on the LCD screen.
If AUTO mode is enabled on the
system controller, press the OFF
button. Then press the ENTER
button to display the menu
commands.
3. Use the arrow buttons to navigate to the
Events History command.
4. Press the ENTER button to display the
system’s events history, which includes fault
notifications. The most recent events are listed first. Use the arrow buttons to scroll through the list.
As shown in Figure 7, 2 types of fault notifications display in events history:
WARNING and FAULTS notifications represent predefined operating thresholds that were met or exceeded. See
System faults triggered by predefined thresholds on page 23.
Check Engine notifications include SPN and FMI codes and are specific to the engine. See Active faults and
cleared faults on page 22 and Engine faults (SPN and FMI codes) on page 25.
Figure 7 – Faults recorded in events history
Freedom 38 PPA Service Manual 809010 27
1 – Troubleshooting
Troubleshoot engine issues
Reset emergency air intake shutoff valve (if equipped)
Your system may include an emergency air intake shutoff valve that stops the flow of air to the engine in case of a
“runaway engine.”
If the air intake shutoff valve was engaged (closed), use the following procedure to reset (open) the valve:
1. Make sure the system is OFF.
2. Remove the service panel on the plasma side of the system.
3. Pull down the black handle at the bottom of the shutoff valve, and hold it in place. Turn the RESET switch at the top
of the valve 90° counterclockwise. Release the black handle.
4. Put the service panel back in place.
Figure 8 – Air intake shutoff valve CLOSED Figure 9 – Air intake shutoff valve OPEN
28 Freedom 38 PPA Service Manual 809010
1 – Troubleshooting
Engine will not start
By default, the system cranks for 15 seconds, then pauses for 15 seconds before it tries to start the engine again.
If the engine fails to start at the end of a second consecutive 15-second crank cycle:
The engine stops cranking.
The “Crank failed” warning notification displays on the LCD screen.
When this fault condition occurs, the control system must be reset. See Reset the control system on page 21.
If the engine still will not start, do the following checks in the order listed:
1. Does the engine crank but not start, or does the engine make a clicking sound and not crank at all?
If the engine cranks but does not start, continue with the next step.
If the engine makes a clicking sound and does not crank (and battery voltage is good), the starter may be faulty.
First clean and tighten the connections on the battery, then jump-start the battery. See page 32. If the engine still
does not crank, have an authorized Deutz service dealer examine the starter.
2. Are you trying to start the engine in very cold temperatures?
If yes, use winter-grade diesel fuel. Summer-grade fuel can “gel” and clog the fuel filter. Install a new
Deutz-brand fuel filter, if needed. See Change the fuel filter in the engine on page 73.
A lighter grade oil can be used in cold climates to help maintain sufficient lubrication and ease of engine starting.
Refer to the Deutz engine operator manual for winter lubricating oil specifications.
Run 2 preheat cycles. After the first cycle starts but before the engine cranks press STOP on the
controller. Press RUN to initiate another cycle and then let the engine start. This extended heating
of the manifold should help the engine start in very cold conditions.
Do not use ether to help start the engine in extremely cold temperatures. Doing so can result in
severe damage to the engine.
If no, continue with the next step.
3. Check the fuel level. See page 21. Make sure the engine has enough fuel. Add clean, low-sulfur diesel fuel as
needed. Do not overfill the fuel tank.
The “Under Speed” fault notification can indicate that the engine is low on fuel.
4. Does the system controller turn ON?
If yes, continue with the next step.
If no, check the 12 V circuit breaker on the front
panel to see if it tripped. Reset the circuit
breaker by pressing the extruded RESET button
in the center of the circuit breaker.
5. Do any fault notifications display on the system controller’s LCD screen?
If yes, clear the fault condition before starting the engine. Some faults cause the engine to shut off (for example,
if the engine temperature is too high or the oil pressure is too low). See System faults on page 22.
If no, continue with the next step.
Freedom 38 PPA Service Manual 809010 29
1 – Troubleshooting
6. Check the electrical connectors on the battery. Tighten as needed. See page 69.
7. Does the battery have enough power (12 V) to start the engine?
If yes, continue with the next step.
If no, jump-start or replace the battery. See Jump-start the battery on page 32 or Replace the battery on
page 89.
8. Use the hand pump to bleed the fuel system. See page 31.
9. Check the fuel filter. If it is clogged or damaged, install a new one. See page 73.
10. Clean the fuel pump screen. See page 75.
11 . If none of these steps resolve the issue, have an authorized Deutz service dealer examine the engine.
Keep the fuel system clean
Many common problems with diesel engines are caused by the following fuel-related problems:
Using the wrong fuel
Bio-diesel fuel is not recommended for this engine.
Using poor quality fuel
Allowing water to enter the fuel line
Using the wrong fuel filter
Using a fuel filter for too long without replacing it
To keep the fuel system clean and the engine running properly:
Use only clean, low-sulfur diesel fuel.
Keep fuel storage containers clean and free from water and other contaminants.
Use only Deutz-brand fuel filters.
Replace the fuel filter regularly. See Maintenance schedules on page 53.
30 Freedom 38 PPA Service Manual 809010
Use the hand pump to bleed the fuel system
Hand pump
You may have trouble starting the engine if:
The fuel level in the engine is very low.
You recently worked on some part of the fuel system.
The system has not been used for a long period of time.
If you have trouble starting the engine, use the hand pump to bleed the fuel system.
If you frequently need to bleed the fuel system in order to start the engine, this may
ind ica te an ai r l ea k i n t he f ue l l in e. Ha ve an aut ho ri ze d H yp er th er m Fr ee do m 38 PPA re pa ir
facility examine the fuel supply lines, or have an authorized Deutz service dealer examine
the engine.
1. Turn OFF the system.
2. Remove the service panel on the generator
side of the system.
3. Push in the hand pump several times in
quick succession until you feel a resistance
and until you no longer hear fuel moving
through the fuel supply lines.
1 – Troubleshooting
4. Start the engine, but leave the main circuit
breaker and the transformer circuit breaker
off. Run the engine without load for 2–3
minutes. This allows air to return to the fuel
tank via the return fuel line.
5. Put the service panel back in place.
Freedom 38 PPA Service Manual 809010 31
1 – Troubleshooting
Jump-start the battery
WARNING!
RISK OF EXPLOSION – WEAR EYE PROTECTION
Always wear eye protection when jump-starting or charging the battery.
When a lead acid battery is charged or discharged, an explosive chemical
change occurs. If anything is present that ignites this explosive gas, the
explosion can throw sulfuric acid into your eyes, causing blindness.
CAUTION!
Follow these precautions when jump-starting or charging the battery.
ALWAYS:
Make sure the system and all electrical accessories are OFF before attaching jump-start
cables.
Attach the negative (-) ground cable last, and remove it first.
Use ONLY equal voltage for jump-starting. Using higher voltage will damage the electrical
system.
NEVER:
Reverse the battery cables. Doing so can damage the alternator.
Remove the vent caps from the battery.
Check the battery by producing sparks between the positive (+) and negative (-) posts.
32 Freedom 38 PPA Service Manual 809010
1 – Troubleshooting
WARNING!
RISK OF FIRE OR EXPLOSION – WEAR PROTECTIVE CLOTHING
Turn OFF the engine before performing any battery checks or maintenance.
Avoid contact with sulfuric acid from the engine’s battery. It can cause serious injury
if it comes in contact with eyes or skin.
Always wear protective glasses, gloves, and clothing when servicing the battery.
Wash your hands thoroughly after touching the battery and its connectors.
Examine the battery regularly to make sure:
All electrical connections are clean and secure. Loose connections can cause
sparks that result in a fire. See Check the battery and cable connectors on
page 69.
None of the electrical wires are frayed. Replace any frayed wires before starting
the engine.
When the battery is charged or discharged, an explosive chemical change occurs.
Avoid all conditions that can ignite this explosive gas:
Keep any open flames or sparks away from the top of the battery.
Do not smoke cigarettes near a battery that is being charged.
Never place a metal object across the battery’s terminal posts to check its
charging status. Instead, use a voltmeter or hydrometer.
Never charge a frozen battery.
Never charge a battery in an enclosed room that lacks proper ventilation.
Never disconnect any charging unit circuit or battery circuit cable from the
battery while it is being charged. Doing so can produce dangerous sparks.
Apply the cable connections correctly if you jump-start the battery. Attach the
negative (-) ground cable last, and remove it first.
Always dispose of old batteries in compliance with local and national regulations.
Examine the chassis ground strap connection regularly. Without a solid ground
strap connection, electrical discharge can damage the engine and electrical system.
This system requires a 12 VDC battery with a capacity of 750 cold cranking amperes (CCA).
If the battery is severely discharged, the alternator may not be able to fully recharge the battery, even after jump-starting.
In this case, fully charge the battery to the correct voltage with a battery charger (with the engine turned off), or install a
new battery. See Replace the battery on page 89.
Always dispose of old batteries in compliance with local and national regulations.
Freedom 38 PPA Service Manual 809010 33
1 – Troubleshooting
Connect positive (+) cable here
1. Turn OFF the system.
2. Remove the service panel on the plasma side of the system.
3. Connect one positive (+) end of the jump-start cable to the positive (+) cable terminal of the battery in the system.
See Figure 10. Connect the other positive (+) end of the jump-start cable to the positive (+) cable terminal of the
electrical source.
4. Connect one negative (-) end of the jump-start cable to the negative (-) cable terminal of the electrical source.
Connect the other negative (-) end of the jump-start cable to the engine block or to the chassis ground.
5. Turn ON the system and start the engine.
6. As soon as the engine starts, disconnect the jump-start cables in the reverse order of that listed in step 3 and step 4.
Make sure the first cable you disconnect is the negative (-) cable connected to the engine block or
chassis ground.
7. Put the service panel back in place.
Figure 10
34 Freedom 38 PPA Service Manual 809010
1 – Troubleshooting
Common engine and generator issues
Problem Solutions
The engine emits a lot of black smoke. • Black smoke indicates a fuel-related issue. There is too much fuel in the
fuel system or not enough air.
• The engine is wet stacking and should be run under a heavy load. The
diesel engine is meant to operate optimally at moderate to heavy loads.
Running under a light load or no load for extended periods of time may
cause wet stacking or other engine damage. Do not idle the engine
longer than necessary.
• If the problem persists, have an authorized Deutz service dealer examine
the engine.
The engine emits blue smoke. • In many cases, blue smoke indicates that the engine is burning oil. This
problem can be caused, or made worse, by using the wrong engine oil
and oil filter. Use only Deutz-brand oil and filters. Alternately, the
following oils from Shell can also be used: ROTELLA
®
Protection
, ROTELLA T3, or ROTELLA T4 Triple Protection. See
page 70.
• If the problem persists after changing the oil and filter, have an
authorized Deutz service dealer examine the engine.
®
T Triple
The fuel filter gets clogged in cold
weather.
• If the fuel tank contains summer-grade fuel, the cold temperatures can
cause some of this fuel to “gel.” This thicker fuel can clog the fuel filter.
Add winter-grade diesel fuel to the fuel tank, and install a new
Deutz-brand fuel filter. See Change the fuel filter in the engine on
page 73.
When you try to turn on the system, the
engine clicks but does not crank. Voltage
is present.
• Check the connections on the battery. Clean and tighten the connectors
as needed. See page 69.
• Jump-start or charge the battery. See page 32.
• Have an authorized Deutz service dealer examine the engine.
The 120 V auxiliary outlet is not working. • Make sure the transformer circuit breaker on the front panel is turned
ON (I). This switch must be turned on before you can use the 120 V
auxiliary outlet.
• Test the GFCI protection on the 120 V auxiliary outlet. See page 66.
• If the outlet still does not work, it may be faulty. Replace the 120 V
auxiliary outlet.
The system controller LCD screen does
not display output current (amperage) for
the generator.
• Make sure the transformer circuit breaker on the front panel is turned
ON (I). This switch must be turned on in order to view the generator’s
output current on the system controller.
Freedom 38 PPA Service Manual 809010 35
1 – Troubleshooting
Troubleshoot air flow issues (air compressor)
The air pressure for this system must be between 5.9 bar – 9.3 bar (85 psi – 135 psi) to operate the on-board plasma
cutting system.
If needed, you can use the plasma cutting system to test whether proper air flow is
reaching the torch. See Run a gas test on page 46.
If the system’s air pressure is too low, if there is no air pressure at all, or if the 0-12, 0-20, or 0-22 fault code displays on
the plasma cutting system’s LCD screen, do the following checks in the order listed:
1. Does the 0-12 fault code display on the plasma cutting system’s LCD screen?
If yes, install a new air filter element in the plasma cutting system. See page 114.
If no, continue with the next step.
2. Turn off the system. Inspect the consumables in the torch. Are they installed incorrectly?
If yes, remove the consumables, then install them properly.
If no, continue with the next step.
3. Inspect the torch. Are there any signs of damage that might be causing air to leak?
If yes, have a Hypertherm distributor or authorized repair facility examine the torch and torch lead.
If no, continue with the next step.
If you have another torch available, you can also connect that to the plasma supply to
see if the same problem occurs.
4. Is the valve open that is used to drain condensate from the air tank?
If yes, rotate the lever underneath the front panel to close the valve. See Drain the condensate from the air tank
on page 61.
If no, continue with the next step.
5. Is the valve open that is used to drain condensate from the air/oil separation tank?
If yes, close the valve underneath the tank. See Drain the condensate from the air compressor’s air/oil separation
tank on page 65.
If no, continue with the next step.
6. Check the oil level in the air compressor. Is the oil level too low?
If yes, add oil to the compressor’s air/oil separation tank, as needed. See Check the oil level in the air
compressor on page 63.
If no, continue with the next step.
36 Freedom 38 PPA Service Manual 809010
1 – Troubleshooting
7. Is the primary filter in the engine air cleaner clogged or damaged?
Filtered air from the primary and safety filters is used by both the engine and the compressor. If the engine
primary filter is clogged or dirty, use moisture-free compressed air to gently clean it. Do not remove the safety
filter. See Service the engine air cleaner on page 76.
If the primary filter is damaged, install a new one. If the safety filter is damaged, replace it too; otherwise, do not
remove the safety filter. See Service the engine air cleaner on page 76.
If no, continue with the next step.
8. Is the air drying filter clogged or damaged?
If yes, install a new filter. See Replace the air drying filter on page 67.
If no, continue with the next step.
9. Is the air compressor’s oil separation filter clogged or damaged?
If yes, install a new filter. See Change the oil separation filter in the air compressor on page 81.
If no, continue with the next step.
10. Is the air compressor’s oil filter clogged or damaged?
If yes, install a new filter. See Change the oil and oil filter in the air compressor on page 78.
If no, continue with the next step.
11 . Is the air pressure between 5.9 bar – 9.3 bar (85 psi – 135 psi)?
If yes, continue with the next step.
If no, replace the unloader valve. See page 172.
12. Is the air compressor’s belt loose, worn, or damaged?
If yes, tighten or replace the belt. See page 160.
If no, continue with the next step.
13. Is the scavenge orifice loose or missing?
If yes, tighten or install the scavenge orifice. See page 166 and page 169.
If no, continue with the next step.
14. Is the separation tank release valve releasing air but there is no pressure on the front panel gauge?
If yes, check for clogged airlines. Check the unloader valve and scavenger line orifices for blockage or ice. Check
the minimum pressure relief valve on the separation tank manifold.
If no, continue with the next step.
15. Is the ambient temperature cold enough for water in the system to freeze?
If yes, allow the system to thaw. Ice can impede the compression system’s operation.
If none of these steps resolve the issue, the air compressor itself may be faulty. Replace the air compressor. See
page 161.
Freedom 38 PPA Service Manual 809010 37
1 – Troubleshooting
ON (I)OFF (O)
Troubleshoot power-related issues (generator/alternator)
To troubleshoot possible power-related issues with the generator/alternator, do the following checks in the order listed:
1. Is the engine running, and are the main circuit
breaker (top) and the transformer circuit breaker
(bottom) turned ON (I)?
If yes, continue with the next step.
If no, make sure the main circuit breaker (top)
and the transformer circuit breaker (bottom) are
turned ON (I). If the engine is not running, check
the engine to see if it requires maintenance. See
Troubleshoot engine issues on page 28.
2. Are you using the auxiliary outlets to power external
devices?
If yes, disconnect the devices from the auxiliary
outlets. You can exceed the generator’s output
capacity if you power external devices from the
auxiliary outlets while running the on-board
plasma cutting system at full output.
If no, continue with the next step.
3. Did the circuit breaker for the 120 V auxiliary outlet
trip?
If yes, reset the circuit breaker by pressing the
button above the 120 V outlet.
If no, continue with the next step.
The transformer circuit breaker on the
front panel must be turned ON (I) in
order to use the 120 V auxiliary outlet.
4. Did the main circuit breaker or the transformer circuit
breaker trip?
If yes, turn OFF the on-board plasma cutting
system by turning OFF (O) its power switch.
Remove any source of external load from the
generator. Reset the main circuit breaker and
the transformer circuit breaker. Turn the plasma
cutting system back ON (I).
If no, continue with the next step.
5. Is the system controller displaying a generator voltage of 480 V for each phase, AC frequency of 60 Hz, and an
engine speed of 1800 RPM? Use the LCD screen on the system controller to check. See Check engine and
generator status on page 21.
If yes, continue with the next step.
If no, have an Hypertherm Freedom 38 PPA repair facility examine the system.
38 Freedom 38 PPA Service Manual 809010
6. Is the automatic voltage regulator (AVR) configured
properly for this system? See page 134.
If yes, continue with the next step.
If no, examine all settings on the AVR to make
sure they are correct.
7. Is the automatic voltage regulator (AVR) faulty?
If yes, replace the AVR. See page 133.
If no, have an Hypertherm Freedom 38 PPA
repair facility examine the generator/alternator.
If the problem is isolated to the 120 V
auxiliary outlet the transformer may be
faulty.
1 – Troubleshooting
Freedom 38 PPA Service Manual 809010 39
1 – Troubleshooting
Troubleshoot plasma cutting issues
The following table provides an overview of the most common problems that can arise when using the plasma cutting
system and explains how to solve them.
Fault icons and corresponding fault codes appear in the LCD screen on the plasma
cutting system. See Plasma cutting system fault codes and solutions on page 41.
If a fault occurs, turn OFF the system, wait 60 to 70 seconds, and turn ON the system.
If you are unable to fix the problem by following this basic troubleshooting guide, or if you need further assistance:
1. Call your Hypertherm distributor or authorized Hypertherm repair facility.
2. Call the nearest Hypertherm office listed in the front of this manual.
Common cutting issues
Problem Solutions
The arc does not transfer to the
workpiece.
The arc blows out, but re-ignites when
the torch trigger is pressed again.
The cut quality is poor. • Make sure the torch is being used correctly. Refer to the Hand Cutting
• Clean the area where the ground clamp contacts the workpiece to
ensure a good metal-to-metal connection.
• Inspect the ground clamp for damage, and repair as necessary.
• The pierce-height distance may be too large. Move the torch closer to
the workpiece and fire the torch again.
• Inspect the consumable parts and replace them if they are worn or
damaged. See Inspect the plasma torch consumables on page 60.
• Replace the air filter element in the back of the plasma supply if it is
contaminated. See page 114.
or Mechanized Cutting section in the Powermax125 Operator Manual.
• Inspect the consumables for wear and replace as necessary. See
Inspect the plasma torch consumables on page 60.
• Make sure the cutting mode switch is in the proper position for the
cutting operation.
• Make sure the correct consumables are installed.
40 Freedom 38 PPA Service Manual 809010
1 – Troubleshooting
Plasma cutting system fault codes and solutions
The following table provides suggestions for solving several common faults related to plasma power and air flow.
A label with descriptions for these common fault codes can be found inside the front cover of the Powermax125
Operator Manual. You can peel off the label and place it on the system’s top cover or side panel for reference.
For a complete list of all fault codes, and for additional troubleshooting guidelines related
to the plasma cutting system, refer to the Powermax125 Service Manual (808070). You
can download this manual from www.hypertherm.com
If a fault occurs, turn OFF the system, wait 60 to 70 seconds, and turn ON the system.
.
Fault
code
0-12 Low input air pressure or
0-13 AC input unstable: Warning
0-19 Power board hardware
Description
unstable air pressure: Warning
(the system continues to
operate)
(the system continues to
operate)
protection. One or more power
board hardware faults (or noise)
detected.
Power
LED
On Off • The air inlet pressure is below the minimum
Blinks
(3 Hz)
On On • The inverter shuts down and does not fire
Fault
LED
Off • Check the generator/alternator for
Fault
icon
Solutions
5.9 bar (85 psi) required to operate the
plasma cutting system. Check the system’s
air flow components. You may need to
install a new air filter element in the plasma
cutting system. See Troubleshoot air flow
issues (air compressor) on page 36.
possible power-related issues. See
Troubleshoot power-related issues
(generator/alternator) on page 38.
again for several seconds. If the fault is
caused by electrical noise, the fault clears
in a few seconds and the machine
operates normally.
• A true 0-19 fault may display for up to
60 seconds before fault code 0-99
displays on the operator screen. A
qualified service technician must service
the plasma cutting system. Contact your
Hypertherm distributor or authorized repair
facility.
• 0-19 can indicate a fault that occurs 10
times without removing power. Fault code
0-99 displays. A qualified service
technician must service the plasma cutting
system. Contact your Hypertherm
distributor or authorized repair facility.
Freedom 38 PPA Service Manual 809010 41
1 – Troubleshooting
Fault
code
0-20 Low air pressure On On • Make sure the compressed air hose is
0-21 Excessive arc voltage change:
0-22 No air input On On • Connect the compressed air hose to the
Description
check consumables, air flow
Power
LED
On On • Restore the air inlet pressure and restart
Fault
LED
Fault
icon
Solutions
connected to the back of the plasma
supply.
• Adjust the air pressure to the acceptable
range using Manual mode. Refer to the
Basic System Operations section in the
Powermax125 Operator Manual. Perform
a quick restart.
• Make sure the air compression system is
working. See Troubleshoot air flow issues
(air compressor) on page 36.
the plasma supply.
• Check the torch lead for leaks or kinking.
• Change consumables.
back of the plasma supply, then restart the
plasma supply.
• Make sure the air compression system is
working. See Troubleshoot air flow issues
(air compressor) on page 36.
0-30 Torch consumables stuck
This indicates either a “torch
stuck open” or a “torch stuck
closed” situation.
0-32 End of consumable life On On • Replace the electrode and nozzle.
0-40 Over/under temperature On On • Leave the system ON to allow the fan in
On On • If the consumables became loose or were
removed while the plasma supply was ON,
turn OFF the power, correct the problem
and then turn ON the power to clear this
fault.
• Change consumables.
• If the consumables appear to be installed
correctly, the torch may be damaged.
Contact your Hypertherm distributor or
authorized repair facility.
• Check the remaining consumables for
wear and replace as needed.
the plasma supply to cool the plasma
supply.
• If the internal temperature of the plasma
supply approaches -30°C (-22°F), move
the system to a warmer location.
42 Freedom 38 PPA Service Manual 809010
1 – Troubleshooting
Fault
code
0-50 Retaining cap off On On • Turn OFF (O) the system. Verify that the
0-51 Start/trigger signal on at power
0-52 Torch not connected On On • Plug a torch lead into the FastConnect
0-60 AC input voltage error On On • This fault code displays when you turn
Description
up
This situation indicates that the
plasma supply is receiving a
start signal. It is sometimes
referred to as a “stuck start.”
Power
LED
On On • If the system is turned on while the torch
Fault
LED
Fault
icon
Solutions
consumables are installed correctly in the
plasma torch. Turn the system back ON (I).
• If the consumables appear to be installed
correctly, the torch may be damaged.
Contact your Hypertherm distributor or
authorized repair facility.
trigger is pressed, the plasma cutting
system is disabled. Release the trigger and
recycle the power switch on the back of
the plasma supply (or turn the system OFF
and then back ON again).
receptacle on the front of the plasma
supply and recycle the power switch on
the back of the plasma supply.
OFF (O) the main circuit breaker and the
transformer circuit breaker while the
engine and generator are running. Wait
approximately 1 minute to allow the fault to
clear on its own before turning ON (I) the
main circuit breaker and the transformer
circuit breaker and starting to cut again.
• If the fault persists, check the
generator/alternator for possible
power-related issues. See Troubleshoot
power-related issues
(generator/alternator) on page 38.
0-61 AC input unstable: Shutdown On On • Check the generator/alternator for
possible power-related issues. See
Troubleshoot power-related issues
(generator/alternator) on page 38.
0-99 System hardware fault –
service required
Indicates a major fault with the
system.
On On • A qualified service technician must service
the plasma cutting system. Contact your
Hypertherm distributor or authorized repair
facility.
Freedom 38 PPA Service Manual 809010 43
1 – Troubleshooting
Automatic/manual mode
selector
Current/gas
mode selector
Display the service screen on the plasma cutting system
You can view system information that aids troubleshooting by accessing the service screen on the plasma cutting system.
This screen displays recent fault codes, arc hours, the software version your system is running, and several additional
details. You can also run a gas test from this screen.
For example, if a fault code displays on the status screen (in the format N-nn) while you are operating the system, you can
check the service screen for an additional four-digit fault code (in the format N-nn-n). If qualified service technicians must
service the system, these four-digit fault codes help them diagnose the problem.
To display the service screen, simultaneously press the automatic/manual and current/gas mode selectors for
approximately two seconds.
44 Freedom 38 PPA Service Manual 809010
1 – Troubleshooting
1
3
5
2
4
6
To navigate the service screen, move the field selector (*) between fields by pressing the current/gas mode selector. The
asterisk (*) indicates the selected field.
To exit the service screen, simultaneously press the automatic/manual and current/gas mode selectors. The operator
screen displays.
Designator Description
I Current set/read
CLCD contrast
B LCD brightness (percent)
P Pressure set/read
G Gas test enable (1)/disable (0)
VL Incoming AC line voltage
TI Inverter module temperature (°C)
VB DC bus voltage
AH Arc hours
F Live four-digit fault code for diagnosing system errors
T Torch identifier (amperage/hand (H) or machine (M)/lead length in feet)
S DSP/control board software versions
(callouts 1 – 6) Fault log of recent fault codes recorded by the system (0-00-0) and the
last three digits of the arc hour count when the fault occurred (000).
Freedom 38 PPA Service Manual 809010 45
1 – Troubleshooting
Run a gas test
CAUTION!
Point the torch away from you before performing a gas test. Always keep hands, clothes, and objects
clear of the torch tip, and never point the torch toward yourself or others.
1. Display the service screen on the plasma cutting system by simultaneously pressing the automatic/manual and
current/gas mode selectors for approximately two seconds.
2. Select the gas test field by pressing the current/gas mode selector until the asterisk (*) is next to the “G.”
3. Use the adjustment knob to set the gas test field from 0 to 1.
If gas does not flow, call your Hypertherm distributor or authorized repair facility, or call the nearest Hypertherm office
listed in the front of this manual.
4. Use the adjustment knob to set the gas test field back to 0.
5. Simultaneously press the automatic/manual and current/gas mode selectors to exit the service screen.
46 Freedom 38 PPA Service Manual 809010
1 – Troubleshooting
Find serial numbers
The system has its own serial number. Each major component also has its own serial number.
The following topics show where to find each serial number. You may need these numbers if you contact the
manufacturers with warranty or support questions.
For instructions on how to remove the cover from the system, see Remove and install the system’s cover on page 86.
Serial number for the system
The serial number for the system is located on the system’s data plate. The data plate is located in 2 places:
On the system’s front panel
On the lift-eye frame on the generator side of the system.
Freedom 38 PPA Service Manual 809010 47
1 – Troubleshooting
Serial number for the generator
The serial number for the generator is located on the generator near the front panel. You may need to remove the cover on
the generator side of the system to see the serial number.
Serial number for the engine
The serial number for the engine is located on top of the engine near the rear panel. Remove the top cover from the
system to see the serial number.
48 Freedom 38 PPA Service Manual 809010
1 – Troubleshooting
Serial number for the alternator
The serial number for the alternator is located in 2 places:
On the outer side of the alternator behind the fuel tank fill valve. You may need to remove the cover on the generator
side of the system to see this serial number.
On the inner side of the alternator behind the plasma cutting system. Move the plasma cutting system to see this
serial number. You may also need to remove the cover on the plasma side of the system.
Freedom 38 PPA Service Manual 809010 49
1 – Troubleshooting
Serial number and version numbers for the system controller
When you select the device information command on the system controller’s LCD screen, you can see the controller’s:
Serial number
Hardware version
Software version
You can also find the serial number on the back of the system controller. Lift up or remove
the top cover to see this serial number.
1. Set the power switch to the ON (I) position.
2. Press the ENTER button to display the
menu commands on the LCD screen.
If AUTO mode is enabled on the
system controller, press the OFF
button. Then press ENTER to
display the menu commands.
3. Use the arrow buttons to navigate to the
Device Info command.
4. Press the ENTER button to display the
system controller’s hardware version (HV),
software version (SV), and serial number
(SN).
50 Freedom 38 PPA Service Manual 809010
1 – Troubleshooting
Serial number for the air compressor
The serial number for the air compressor is located on the air compressor at the base of the system behind the rear panel.
Remove the rear panel to see the serial number.
Serial number for the plasma cutting system
The serial number for the plasma cutting system is located on the data plate on the system’s rear panel, next to its power
cord.
Freedom 38 PPA Service Manual 809010 51
1 – Troubleshooting
52 Freedom 38 PPA Service Manual 809010
Section 2
Routine Maintenance
Maintenance schedules
The maintenance intervals in this section apply for normal system use in normal environmental conditions. Adjust these
intervals as needed to match the workload and conditions under which you are operating the system.
For example, clean or replace items more frequently if you operate the system in conditions that are extremely humid,
extremely dusty or dirty, or at very high altitudes.
CAUTION!
To ensure safe operation of the system at all times, and to maximize the life of the product, use only
replacement parts that are approved by the manufacturers.
CAUTION!
FILTERS, FUEL, AND LUBRICATING OILS CAN CAUSE DISCOMFORT
Handle all engine filters, fuel, and lubricating oils with care. Fuel and lubricating oils can irritate skin.
Some filters can cause discomfort if they come in contact with the eyes or mouth.
Wash thoroughly if your skin comes in contact with fuel or oil from the engine.
NOTICE
Do not use a pressure washer to clean the outside of the system.
Freedom 38 PPA Service Manual 809010 53
2 – Routine Maintenance
ELECTRIC SHOCK CAN KILL
Turn OFF the power before removing the cover from the system or from the plasma supply.
In the U.S., use a “lock-out / tag-out” procedure until the service or maintenance work is
complete. In other countries, follow appropriate national or local safety procedures.
Before servicing the engine or generator, turn OFF the system, wait for 30 seconds, then
disconnect the battery’s negative (-) ground cable.
Do not touch live electrical parts! If power is required for servicing, use extreme caution
when working near live electrical circuits. Dangerous voltages exist inside the system that
can cause serious injury or death.
Do not attempt to repair printed circuit boards. Do not cut away or remove any protective
conformal coating from circuit boards. To do so will risk a short circuit between the AC
input circuit and the output circuit and may result in serious injury or death.
HOT PARTS CAN CAUSE SEVERE BURNS
WARNING!
Allow the system’s internal components to cool before servicing.
Do not remove the pressure cap from the radiator while the engine is still hot.
MOVING PARTS CAN CAUSE INJURY
Use extreme caution if you need to work on a running engine.
Keep hands, clothing, jewelry, and tools away from moving parts.
Keep your hands away from the engine’s fan.
Do not wear loose clothing or jewelry that can catch on moving parts.
Remove safety guards only when necessary. Replace the safety guards as soon
as maintenance is complete.
Close the service panels when maintenance is complete. Repair or replace the
panels if they are damaged.
NOTICE
STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS
Put on a grounded wrist strap before handling printed circuit boards.
54 Freedom 38 PPA Service Manual 809010
This system includes a service hour meter. You
can view the engine’s total operating hours on
the system controller’s LCD screen. See Check
engine and generator status on page 21.
Every use
System component Recommended maintenance
2 – Routine Maintenance
Engine/generator
Check the system controller for any fault LEDs or notifications. Correct any fault
conditions.
Check the plasma supply’s front panel for any fault LEDs and its LCD screen for
any fault icons. Correct any fault conditions.
Plasma cutting system
Inspect the consumables on the plasma torch for proper installation and wear.
See page 60.
Air compressor
Drain condensate from the air tank. See page 61.
Every day
System component Recommended maintenance
System
Engine/generator
Inspect the system for signs of wear or damage.
Check the oil level in the engine. See page 62.
Check the fuel level. The percentage of fuel remaining displays on the system
controller’s LCD screen. See page 21.
Every week
System component Recommended maintenance
Air compressor
Drain condensate from the air/oil separation tank. See page 65.
Check the oil level in the air compressor. See page 63.
Every month
System component Recommended maintenance
Engine/generator
Air compressor
Test the GFCI protection on the 120 V auxiliary outlet. See page 66.
Replace the air drying filter. See page 67.
Freedom 38 PPA Service Manual 809010 55
2 – Routine Maintenance
Every 3 months (or 500 operating hours)
System component Recommended maintenance
Check the battery and electrical cable connectors. Tighten as needed. Replace
any cracked or broken wires. See page 69.
Engine/generator
Air compressor
Plasma cutting system
Change the oil and oil filter in the engine. At a minimum, change the oil and filter
once per year. See page 70. Use only Deutz-brand oil and filters. Alternately, the
following oils from Shell can also be used: ROTELLA T Triple Protection,
ROTELLA T3, or ROTELLA T4 Triple Protection.
Adjust the tension of the air compressor belt.*
Inspect the plasma torch lead. Replace if damaged.
Inspect the plasma torch trigger for damage. Inspect the
torch body for cracks and exposed wires. Replace any
damaged parts.
If applicable, inspect the screws on the machine
torch that connect the torch body to the mounting
sleeve. Tighten the screws, if needed.
* Hypertherm strongly recommends that only authorized service technicians do this maintenance.
56 Freedom 38 PPA Service Manual 809010
Every 6 months (or 1,000 operating hours)
System component Recommended maintenance
Change the fuel filter. See page 73. Use only Deutz-brand fuel filters.
Clean the fuel pump screen. See page 75.
Change the air cleaner filter.
year. Change the safety filter once for every 3 primary filter changes. See Service
the engine air cleaner on page 76.
2 – Routine Maintenance
*
At a minimum, change the primary filter once per
Engine/generator
Adjust the tension of the engine belt.
Check the air hose clamps and connectors. Tighten as needed.
Check the clearance of the valves. Adjust as needed.
Check the electrical heater plugs. At a minimum, replace the heater plugs once
†
every 2 years.
Check the mounting hardware and engine mounts. Tighten as needed.
Clean the inside of the plasma supply with
moisture-free compressed air or a vacuum. To do this
Plasma cutting system
maintenance, remove the plasma supply from the
system. See page 115.
* In very dusty or dirty environments, check the primary filter approximately once every 2 weeks. Use moisture-free compressed air
to gently clean the filter, as needed. Do not remove the safety filter unless you are installing a new one.
† Have an authorized Deutz service dealer do this maintenance.
Every year (or 2,000 operating hours)
System component Recommended maintenance
Check the fuel tank.
Clean the dust discharge valve. For optimum performance, clean the dust
discharge valve any time you service the engine air cleaner. See page 76.
Engine/generator
Clean the heat exchanger.
Check the electrical wiring and AC load cables. Tighten as needed. Replace any
cracked or broken wires.
Change the oil and the oil filter in the air compressor.* At a minimum, change the
oil and filter once per year. See page 78.
Air compressor
In very dusty or dirty environments, change the oil more
than once per year.
* Hypertherm strongly recommends that only authorized service technicians do this maintenance.
Freedom 38 PPA Service Manual 809010 57
2 – Routine Maintenance
Every 3,000 operating hours
System component Recommended maintenance
Change the fuel injector nozzles.*
Engine/generator
* Have an authorized Deutz service dealer do this maintenance.
System component Recommended maintenance
Make sure the electrical engine protection and monitoring devices are
functioning properly.
Every 4,000 operating hours
Air compressor
* Hypertherm strongly recommends that only authorized service technicians do this maintenance.
Change the oil separation filter.* See page 81.
Clean the finned surface of the air/oil cooler.*
Every 6,000 operating hours
System component Recommended maintenance
Engine/generator
* Have an authorized Deutz service dealer do this maintenance.
Change the timing belt.* At a minimum, replace the timing belt once every
5years.
Every 12,000 operating hours
System component Recommended maintenance
Engine/generator
* Have an authorized Deutz service dealer do this maintenance.
Overhaul the engine.*
58 Freedom 38 PPA Service Manual 809010
Routine maintenance procedures
WARNING!
ELECTRIC SHOCK CAN KILL
Disconnect or turn OFF electrical power before doing any maintenance that
involves removing the cover from the system or the consumables from the
plasma torch.
Read the separate Safety and Compliance Manual included with your system
for more safety precautions pertaining to plasma cutting.
CAUTION!
FILTERS, FUEL, AND LUBRICATING OILS CAN CAUSE DISCOMFORT
2 – Routine Maintenance
Handle all engine filters, fuel, and lubricating oils with care. Fuel and lubricating oils can irritate skin.
Some filters can cause discomfort if they come in contact with the eyes or mouth.
Wash thoroughly if your skin comes in contact with fuel or oil from the engine.
See Every use on page 60.
See Every day on page 62.
See Every week on page 63.
See Every month on page 66.
See Every 3 months (or 500 operating hours) on page 69.
See Every 6 months on page 73.
See Every year on page 78.
See Every 4,000 operating hours on page 81.
Freedom 38 PPA Service Manual 809010 59
2 – Routine Maintenance
Good Worn
Max. 1.6 mm (1/16 inch)
Every use
Inspect the plasma torch consumables
Part Inspect Action
The center hole for roundness. Replace the shield if the hole is no longer
round.
Shield
Nozzle
Electrode
Swirl ring
The gap between the shield and the
nozzle for accumulated debris.
The center hole for roundness. Replace nozzle if the center hole is not
The surface inside the swirl ring for
damage or wear and the gas holes for
blockages.
The O-ring for damage or wear. If the O-ring is worn or damaged, replace
The length of the swirl ring. If the length of the swirl ring is less than
Remove the shield and clean away any
material.
round.
Replace electrode if the surface is worn or
the pit depth is greater than 1.6 mm
(1/16 inch) deep.
Replace swirl ring if the surface is damaged
or worn or any of the gas holes are blocked.
the swirl ring.
32 mm (1.27 inches), replace it.
The surface for damage, wear, or a lack
of lubrication.
Torch O-ring
If the O-ring is dry, lubricate it and the
threads with a thin layer of silicone lubricant.
If the O-ring is worn or damaged, replace it.
60 Freedom 38 PPA Service Manual 809010
2 – Routine Maintenance
Rotate lever down to drain air tank
Drain the condensate from the air tank
CAUTION!
Drain condensate from the compressed air tank to make sure the tank operates safely.
Condensation inside the tank causes corrosion over time and weakens the integrity of the tank walls.
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. Facing the plasma side of the system, make sure the
pressure release opening near the front corner of the base
is not obstructed. Air and condensate exit from the air tank
through this opening.
3. Facing the front of the system, slowly rotate the lever so
that it is facing down. The lever is in the recessed cutout
under the generator. See Figure 11.
4. When the air draining from the tank is clear, close the
valve by rotating the lever towards you until it is parallel
with the bottom of the system.
Figure 11
Freedom 38 PPA Service Manual 809010 61
2 – Routine Maintenance
Every day
Check the oil level in the engine
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. Wait for 30 seconds, then disconnect the battery’s negative (-) ground cable.
3. Leave the system at rest for 2 minutes. This allows the oil to drain back into the oil pan.
4. Remove the service panel on the generator side of the system.
5. Remove the oil dipstick from the engine. See Figure 12. Wipe any oil off the dipstick.
6. Fully insert the dipstick back into the engine.
7. Remove the dipstick from the engine. Make sure the oil level is between the low and high marks.
8. Reconnect the negative (-) ground cable to the battery.
9. Put the service panel back in place.
Do not exceed the maximum fill level. For details on how to add oil to the engine, see Change the oil and oil filter in
the engine on page 70.
Figure 12 – Engine oil dipstick
62 Freedom 38 PPA Service Manual 809010
Every week
Maximum fill level
(when the system is OFF)
Do not exceed the maximum fill
level.
Minimum fill level
(when the system is OFF)
Check the oil level in the air compressor, below
Drain the condensate from the air compressor’s air/oil separation tank on page 65
Check the oil level in the air compressor
Check the air compressor’s oil level only when the system is:
Turned OFF and any foam in the air/oil separation tank has had time to subside.
Positioned on level ground, not at an incline.
Figure 13
2 – Routine Maintenance
To add oil to the air compressor:
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. Remove the top cover and the plasma-side panel from the system.
3. Slowly pull the pressure relief valve above the air/oil
separation tank straight out approximately 5 mm
(1/4 inch). Use the ring at the end of the valve. This
discharges internal pressure from the air
compressor.
4. Drain the air tank to release pressure. See page 61.
Freedom 38 PPA Service Manual 809010 63
2 – Routine Maintenance
5. Unscrew the fill cap from the top of the air/oil separation tank to remove it. See Figure 14.
NOTICE
Use oil of the same type as that already in the machine. Do not mix different oils from different
manufacturers and different viscosities (grades).
The unit ships with Chicago Pneumatic Rotair Plus synthetic oil (manufacturer’s part number
1630144405).
6. Pour new oil into the air/oil separation tank to the recommended fill line:
Use oil of the same type as that already in the machine. Do not mix different oil types.
Use a funnel to direct the flow of oil.
Do not exceed the maximum fill level. See Figure 13 on page 63.
7. Screw the fill cap back onto the top of the air/oil separation tank.
8. Put the system’s panels back in place. See Install the cover on page 88.
Figure 14
64 Freedom 38 PPA Service Manual 809010
Drain the condensate from the air compressor’s air/oil separation tank
1. Make sure the system has been turned OFF for a minimum of 8 consecutive hours.
2. Remove the service panel on the plasma side of the system.
3. Slowly turn the valve on the bottom of the
air/oil separation tank to gradually discharge
the condensate.
4. When you see the first traces of oil, close
the valve. The condensate exits through the
baseboard on the plasma side of the system
by the rear panel.
2 – Routine Maintenance
5. Dispose of the condensate in compliance
with local and national regulations.
6. Put the service panel back in place.
Freedom 38 PPA Service Manual 809010 65
2 – Routine Maintenance
RESET
TEST
Every month
Test the GFCI outlet, below
Replace the air drying filter on page 67
Test the GFCI outlet
The 120 V auxiliary outlet on the generator is GFCI-protected. GFCI (ground fault circuit interrupter) outlets protect the
operator from electric shock in case a machine plugged into one of the receptacles experiences a ground fault.
The GFCI outlet provides protection only for ground faults. A chance of electric shock is
still present if a short circuit occurs.
The transformer circuit breaker on the front panel must be turned ON (I) in order to use
the 120 V auxiliary outlet.
In the 120 V GFCI outlet, the neutral conductor is bonded to the frame.
Test the GFCI protection on the 120 V auxiliary outlet
once per month:
1. Unplug any external tools from the 120 V auxiliary
receptacles.
2. Set the power switch to the ON (I) position, then
press the RUN button on the system controller.
3. Set the main circuit breaker and the transformer
circuit breaker on the front panel to the ON (I)
position.
The transformer circuit breaker provides
power to the 120 V auxiliary outlet. It must
be turned ON to perform this test.
4. Press the Test button on the GFCI outlet.
5. Did the GFCI Reset button extrude?
If yes, press the Reset button. GFCI protection is working properly.
If no, have an authorized service technician replace the GFCI outlet.
66 Freedom 38 PPA Service Manual 809010
Replace the air drying filter
When servicing air compressor components:
Discharge internal pressure from the air compressor before performing
maintenance on any compressor parts. Trapped air pressure can discharge
violently and cause serious injury.
Do not inhale compressed air. Serious injury can result.
If air that was under pressure pierces your skin, seek medical treatment
immediately.
Never disable or disconnect any safety mechanisms for the air compressor.
Check all air compressor hoses and connections for leaks and damage before
operating the system again.
2 – Routine Maintenance
WARNING!
RISK OF INJURY – HANDLE COMPRESSED AIR WITH CARE
NOTICE
Replace the air drying filter regularly. When the cartridge inside an overused filter begins to
deteriorate, small pieces of the cartridge can get into the plasma cutting’s system air supply and
cause damage to the plasma supply.
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. Remove the service panel on the plasma side of the system.
3. Slowly pull the pressure relief valve above
the air drying filter straight out approximately
5 mm (1/4 inch). Use the ring at the end of
the valve. This discharges internal pressure
from the air compressor.
4. Drain the air tank to release pressure. See
page 61.
5. Unscrew the air drying filter to remove it.
See Figure 15. Dispose of old filters in
compliance with local and national
regulations.
6. Use a clean, dry cloth to wipe away any dirt
or other contaminants from the threads and mounting surface where the new filter will be installed.
7. Lightly apply clean oil to the seal on the new air drying filter.
8. Screw the air drying filter into place. Tighten by hand plus a 3/4 turn.
Freedom 38 PPA Service Manual 809010 67
2 – Routine Maintenance
9. Put the service panel back in place.
Figure 15 – Air drying filter
68 Freedom 38 PPA Service Manual 809010
Every 3 months (or 500 operating hours)
Check the battery and cable connectors, below
Change the oil and oil filter in the engine on page 70
Check the battery and cable connectors
RISK OF FIRE OR EXPLOSION – WEAR PROTECTIVE CLOTHING
Turn OFF the engine before performing any battery checks or maintenance.
Avoid contact with sulfuric acid from the engine’s battery. It can cause serious injury
if it comes in contact with eyes or skin.
Always wear protective glasses, gloves, and clothing when servicing the battery.
Wash your hands thoroughly after touching the battery and its connectors.
Examine the battery regularly to make sure:
2 – Routine Maintenance
WARNING!
All electrical connections are clean and secure. Loose connections can cause
sparks that result in a fire.
None of the electrical wires are frayed. Replace any frayed wires before starting
the engine.
When the battery is charged or discharged, an explosive chemical change occurs.
Avoid all conditions that can ignite this explosive gas:
Keep any open flames or sparks away from the top of the battery.
Do not smoke cigarettes near a battery that is being charged.
Never place a metal object across the battery’s terminal posts to check its
charging status. Instead, use a voltmeter or hydrometer.
Never charge a frozen battery.
Never charge a battery in an enclosed room that lacks proper ventilation.
Never disconnect any charging unit circuit or battery circuit cable from the
battery while it is being charged. Doing so can produce dangerous sparks.
Apply the cable connections correctly if you jump-start the battery. Attach the
negative (-) ground cable last, and remove it first. See Jump-start the battery on
page 32.
Always dispose of old batteries in compliance with local and national regulations.
Examine the chassis ground strap connection regularly. Without a solid ground
strap connection, electrical discharge can damage the engine and electrical system.
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. Remove the service panel on the plasma side of the system.
Freedom 38 PPA Service Manual 809010 69
2 – Routine Maintenance
1
2
1
2
3. Check the positive (+) and negative (-) cable connections on the battery. Tighten as needed.
4. Put the service panel back in place.
Figure 16
Change the oil and oil filter in the engine
WARNING!
HOT OIL CAN CAUSE BURNS
Avoid contact with the oil as you drain it from the engine. Engine oil can become very hot
and can cause scalding or severe burns if it comes in contact with skin.
NOTICE
When changing the oil in the engine, always use the same type of oil. Do not mix different types of oil.
Use only Deutz-brand oil filters.
This engine is cooled by the lubricating oil, so the oil must be drained from both the oil
pan and the heat exchanger.
70 Freedom 38 PPA Service Manual 809010
2 – Routine Maintenance
1. Turn ON the system, and allow it to run for 2–3 minutes to warm the oil in the engine.
Do not drain the oil when the engine is cold. Waste particles in the oil settle on the
bottom of the oil pan when the oil is cold and do not get removed during the oil change.
2. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position. Wait for 30 seconds,
then disconnect the battery’s negative (-) ground cable.
3. Leave the system at rest for 2 minutes. This allows the oil to drain back into the oil pan.
4. Remove the service panel on the generator side of the system.
5. Place a container underneath the oil filter to catch any oil that spills as you remove the filter. See Figure 17 on
page 72.
If needed, remove the top cover and the generator-side panel to better access the filter.
See Remove the cover on page 86.
6. Use a band-type gripping tool to unscrew the oil filter from the engine. Dispose of the old oil and filter in compliance
with local and national regulations.
7. Use a clean, dry cloth to wipe away any dirt or other contaminants from the threads and mounting surface where the
new filter will be installed.
Make sure the rubber seal from the old filter did not stick to the mounting surface when
you removed the filter.
8. Lightly apply clean oil to the seal on the new oil filter.
9. Screw the new oil filter into place. Tighten to 15–17 N·m (11–12.5 foot·pounds).
10. Remove the oil fill cap. See Figure 17 on page 72. Clean the cap, and set it aside.
11 . Pull one of the drain hoses out from the system, and place a container underneath the end of the hose.
See Figure 17.
One hose drains the oil from the oil pan. The other hose drains the oil from the heat
exchanger. The oil pan and heat exchanger must both be drained at every oil
change.
12. Remove the cap from the end of the drain hose to drain the oil into the container.
13. When the oil has drained, put the cap back on the end of the drain hose. Push the hose back inside the system.
14. Pull the other drain hose out from the system, and move the container underneath the end of the hose. Repeat
step 12 and step 13 to drain the oil from the second hose.
15. Dispose of the old oil in compliance with local and national regulations.
Freedom 38 PPA Service Manual 809010 71
2 – Routine Maintenance
Oil dipstick
Oil fill cap
Drain hoses for
oil pan and
heat exchanger
Oil filter
16. Pour new oil into the engine where you removed the oil fill cap in step 10. Use only Deutz-brand oil and filters.
Alternately, the following oils from Shell can also be used: ROTELLA T Triple Protection, ROTELLA T3, or
ROTELLA T4 Triple Protection.
Fill the oil to the “high” mark on the oil dipstick – approximately 14 liters (14.8 quarts). Remove the dipstick as
needed to check the oil level. Do not exceed the maximum fill level.
17. Put the oil fill cap back in place.
18. Reconnect the negative (-) ground cable to the battery.
19. Turn ON the system. Allow the engine to run for 3–5 minutes to circulate the oil.
20. Turn OFF the system.
21. Leave the system at rest for 2 minutes to allow the oil to drain back into the oil pan.
22. Remove the dipstick to check the oil level. Add more oil as needed, but do not exceed the maximum fill level.
23. Put the top cover and the generator-side panel back in place, if you removed them. See Install the cover on page 88.
24. Put the service panel back in place.
Figure 17
72 Freedom 38 PPA Service Manual 809010
2 – Routine Maintenance
Every 6 months
Change the fuel filter in the engine, below
Clean the fuel pump screen on page 75
Service the engine air cleaner on page 76
Change the fuel filter in the engine
WARNING!
RISK OF FIRE OR EXPLOSION
Do not allow any open flames or sparks near the system when working on
fuel system components. Do not smoke cigarettes when working on fuel
system components. Serious injury can result from fire or explosion.
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. Wait for 30 seconds, then disconnect the battery’s negative (-) ground cable.
3. Remove the service panel on the generator side of the system.
4. Place a container underneath the fuel filter to catch any fuel that spills as you remove the filter. See Figure 18 on
page 74.
5. Use a band-type gripping tool to unscrew the fuel filter from the engine. Dispose of the old fuel and filter in
compliance with local and national regulations.
6. Use a clean, dry cloth to wipe away any dirt or other contaminants from the threads and mounting surface where the
new filter will be installed.
Make sure the rubber seal from the old filter did not stick to the mounting surface when
you removed the filter.
7. Lightly apply clean diesel fuel to the seal on the new fuel filter.
8. Screw the new fuel filter into place on the engine. Tighten to 10–12 N·m (7.4–8.9 foot·pounds).
9. Push in the hand pump several times in quick succession until you feel resistance and until you no longer hear fuel
moving through the fuel supply lines. This circulates fuel through the new filter. See Figure 18.
You may need to push in the hand pump as many as 20 times.
10. Reconnect the negative (-) ground cable to the battery.
11 . Put the service panel back in place.
Freedom 38 PPA Service Manual 809010 73
2 – Routine Maintenance
Hand pump
Figure 18 – Engine fuel filter
74 Freedom 38 PPA Service Manual 809010
2 – Routine Maintenance
Cover of fuel pump screenHand pump
Clean the fuel pump screen
WARNING!
RISK OF FIRE OR EXPLOSION
Do not allow any open flames or sparks near the system when working on
fuel system components. Do not smoke cigarettes when working on fuel
system components. Serious injury can result from fire or explosion.
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. Wait for 30 seconds, then disconnect the battery’s negative (-) ground cable.
3. Remove the service panel on the generator side of the system.
4. Place a container underneath the fuel pump
screen to catch any fuel that spills as you
remove the screen.
5. Remove the cover from the fuel pump
screen by removing the screw that holds it
in place.
6. Remove the fuel pump screen. Dispose of
any spilled fuel in compliance with local and
national regulations.
7. Is the fuel pump screen damaged in any
way?
If yes, obtain a new fuel pump screen.
Continue with the next step.
If no, clean the fuel pump screen and
the O-ring with clean diesel fuel.
Continue with the next step.
8. Install the fuel pump screen. Make sure the
O-ring is positioned correctly.
9. Install the cover to the fuel pump screen. Tighten the screw you removed in step 5.
10. Push in the hand pump several times in quick succession until you feel resistance and until you no longer hear fuel
moving through the fuel supply lines.
11 . Reconnect the negative (-) ground cable to the battery.
12. Put the service panel back in place.
13. Turn ON the system. Make sure there are no fuel leaks.
Freedom 38 PPA Service Manual 809010 75
2 – Routine Maintenance
Cover of air cleaner
Clips
Service the engine air cleaner
NOTICE
Replace the air cleaner filters regularly. Never run the engine when the air cleaner filters are missing
or damaged. The air cleaner filters prevent airborne debris from entering the air inlet. Dirt or other
debris that enters the engine can cause premature wear and damage to engine components that is
difficult and expensive to repair.
The engine air cleaner contains 2 filters:
A primary filter that fits over the outlet tube, which creates a critical seal on the inside diameter of the filter
endcap
A safety filter that fits inside the outlet tube, which creates a critical seal on the outside diameter of the filter
endcap
Replace the safety filter every 3 air cleaner services or every 2 years, whichever interval is less.
In very dusty or dirty environments, check the primary filter approximately once every 2 weeks. Use moisture-free
compressed air to gently clean the filter, as needed. Never remove the safety filter except to install a new one.
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. Wait for 30 seconds, then disconnect the battery’s negative (-) ground cable.
3. Remove the service panel on the generator side of the system.
4. Pull back the 3 clips, and remove the cover from the air cleaner. See Figure 19.
Figure 19
76 Freedom 38 PPA Service Manual 809010
2 – Routine Maintenance
Primary filter Safety filter
5. Carefully remove the primary filter by gently moving it
side-to-side to break the seal.
6. Are you replacing the safety filter?
If yes, carefully remove the safety filter by gently
moving it side-to-side to break the seal.
If no, continue with the next step.
7. Use a clean, dry cloth to wipe away any dirt or other
contaminants from the sealing surfaces of the outlet
tube.
Do not leave any dirt on the sealing surfaces
of the outlet tube because it can prevent a
good seal with the new filters or enter the
engine.
8. Examine the old filters for signs of damage. For example, a streak of dust on the inside surface of the filter indicates a
possible leak. Remove or repair any possible causes of leaks in the air cleaner before installing new filters.
9. Examine the new filters for signs of damage. Do not install damaged filters.
10. Are you installing a new safety filter?
If yes, insert the safety filter into the air cleaner housing. Make sure it sits fully in the housing.
If no, continue with the next step.
11 . Insert the new primary filter over the safety filter in the air cleaner housing. Insert the filter by hand, and make sure it
sits fully in the housing.
12. Put the cover back on the air cleaner, and hold it in place by folding down the 3 clips.
The cover should go on easily, with no added force required. If the cover hits the primary
filter before it is in place, push the filter further into the housing before putting the cover
back on.
13. Empty the air cleaner’s dust discharge valve by
pinching the discharge slot. After the valve is empty,
clean the discharge slot.
14. Reconnect the negative (-) ground cable to the
battery.
15. Put the service panel back in place.
Freedom 38 PPA Service Manual 809010 77
2 – Routine Maintenance
Every year
Change the oil and oil filter in the air compressor
RISK OF INJURY – HANDLE COMPRESSED AIR WITH CARE
THIS PROCEDURE MUST BE PERFORMED ONLY BY EXPERIENCED SERVICE
TECHNICIANS.
When servicing air compressor components:
Discharge internal pressure from the air compressor before performing
maintenance on any compressor parts. Trapped air pressure can discharge
violently and cause serious injury.
Do not inhale compressed air. Serious injury can result.
If air that was under pressure pierces your skin, seek medical treatment
immediately.
Never disable or disconnect any safety mechanisms for the air compressor.
WARNING!
Check all air compressor hoses and connections for leaks and damage before
operating the system again.
NOTICE
Use oil of the same type as that already in the machine. Do not mix different oils from different
manufacturers and different viscosities (grades).
The unit ships with Chicago Pneumatic Rotair Plus synthetic oil (manufacturer’s part number
1630144405).
For best performance use Rotair Plus (or Roto-inject fluid) oils. Mineral oil can be used provided the following
precautions are taken:
Old oil is drained and the system is flushed. This should be done by a qualified Chicago Pneumatic technician.
Contact your local Chicago Pneumatic service center.
Both the compressor oil filter and oil separation filter are changed.
The oil meets the following properties: high quality mineral oil with oxidation inhibitors and anti-foam and anti-wear
properties. The viscosity grade must correspond to the ambient temperature and ISO 3448:
Ambient temperature Viscosity grade Viscosity index
Consistently above 25°C (77°F) ISO VG 68 Minimum 95
Between 25°C (77°F) and 0°C (32°F) ISO VG 46 Minimum 95
78 Freedom 38 PPA Service Manual 809010
2 – Routine Maintenance
1. Discharge internal pressure from the air compressor:
a. Turn ON the system, and allow it to run for 2–3 minutes. This warms the oil in the air compressor.
b. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
c. Slowly pull the pressure relief valve
above the air/oil separation tank
straight out approximately 5 mm
(1/4 inch). Use the ring at the end of
the valve. This discharges internal
pressure from the air compressor.
d. Drain the air tank to release pressure.
See page 61.
2. Drain the oil from the air/oil
separation tank:
a. Connect a hose with a fitting or place a
container under the small black hole at the
bottom rear corner of the plasma side
panel. The oil drains through this hole.
This aperture is threaded with
1/4 inch NPT female threads.
b. Slowly turn the valve on the bottom of the
air/oil separation tank. Condensate may
discharge from the tank before the oil
starts to drain.
c. After the oil drains from the tank, close the
valve. Dispose of the old oil in compliance
with local and national regulations.
Freedom 38 PPA Service Manual 809010 79
2 – Routine Maintenance
1
2
3
1
2
3
3. Replace the oil filter:
a. Unscrew the oil filter to remove it. See Figure 20. Dispose of the old filter in compliance with local and
national regulations.
b. Lightly apply clean oil to the seal on the new oil filter.
c. Screw the oil filter into place. Tighten by hand.
4. Add new synthetic oil to the air/oil separation tank:
a. Unscrew the fill cap from the top of the air/oil separation tank to remove it. See Figure 20. Set the fill cap
and its washer aside.
If needed, remove the top cover and the plasma-side panel to better access the tank.
See Remove the cover on page 86.
b. Pour new oil into the air/oil separation tank to the recommended fill line:
Use oil of the same type as that already in the machine. Do not mix different oil types.
Use a funnel to direct the flow of oil.
Do not exceed the maximum fill level. See Check the oil level in the air compressor on
page 63.
c. Screw the fill cap and its washer back onto the top of the air/oil separation tank.
d. Put the top cover and the plasma-side panel back in place, if you removed them. See Install the cover on
page 88.
e. Turn ON the system, and allow it to run until the cooler unit is hot. Shut down the system and check the oil level.
Figure 20 – Air compressor’s oil filter and air/oil separation tank
80 Freedom 38 PPA Service Manual 809010
Every 4,000 operating hours
Change the oil separation filter in the air compressor
RISK OF INJURY – HANDLE COMPRESSED AIR WITH CARE
When servicing air compressor components:
Discharge internal pressure from the air compressor before performing
maintenance on any compressor parts. Trapped air pressure can discharge
violently and cause serious injury.
Do not inhale compressed air. Serious injury can result.
If air that was under pressure pierces your skin, seek medical treatment
immediately.
Never disable or disconnect any safety mechanisms for the air compressor.
Check all air compressor hoses and connections for leaks and damage before
operating the system again.
2 – Routine Maintenance
WARNING!
NOTICE
Use oil of the same type as that already in the machine. Do not mix different oils from different
manufacturers and different viscosities (grades).
The unit ships with Chicago Pneumatic Rotair Plus synthetic oil (manufacturer’s part number
1630144405).
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. Remove the service panel on the plasma side of the system.
3. Slowly pull the pressure relief valve above
the air/oil separation tank straight out
approximately 5 mm (1/4 inch). Use the ring
at the end of the valve. This discharges
internal pressure from the air compressor.
4. Drain the air tank to release pressure. See
page 61.
5. Unscrew the oil separation filter to remove
it. See Figure 21. Dispose of old oil and
filters in compliance with local and national
regulations.
6. Lightly apply clean oil to the seal on the new oil separation filter.
7. Screw the oil separation filter into place. Tighten by hand.
Freedom 38 PPA Service Manual 809010 81
2 – Routine Maintenance
8. Put the service panel back in place.
Figure 21 – Air compressor’s oil separation filter
82 Freedom 38 PPA Service Manual 809010
Section 3
System-Level Components
CAUTION!
To ensure safe operation of the system at all times, and to maximize the life of the product, use only
replacement parts that are approved by the manufacturers.
CAUTION!
FILTERS, FUEL, AND LUBRICATING OILS CAN CAUSE DISCOMFORT
Handle all engine filters, fuel, and lubricating oils with care. Fuel and lubricating oils can irritate skin.
Some filters can cause discomfort if they come in contact with the eyes or mouth.
Wash thoroughly if your skin comes in contact with fuel or oil from the engine.
Freedom 38 PPA Service Manual 809010 83
3 – System-Level Components
ELECTRIC SHOCK CAN KILL
Turn OFF the power before removing the cover from the system or from the plasma supply.
In the U.S., use a “lock-out / tag-out” procedure until the service or maintenance work is
complete. In other countries, follow appropriate national or local safety procedures.
Before servicing the engine or generator, turn OFF the system, wait for 30 seconds, then
disconnect the battery’s negative (-) ground cable.
Do not touch live electrical parts! If power is required for servicing, use extreme caution
when working near live electrical circuits. Dangerous voltages exist inside the system that
can cause serious injury or death.
Do not attempt to repair printed circuit boards. Do not cut away or remove any protective
conformal coating from circuit boards. To do so will risk a short circuit between the AC
input circuit and the output circuit and may result in serious injury or death.
HOT PARTS CAN CAUSE SEVERE BURNS
WARNING!
Allow the system’s internal components to cool before servicing.
Do not remove the pressure cap from the radiator while the engine is still hot.
MOVING PARTS CAN CAUSE INJURY
Use extreme caution if you need to work on a running engine.
Keep hands, clothing, jewelry, and tools away from moving parts.
Keep your hands away from the engine’s fan.
Do not wear loose clothing or jewelry that can catch on moving parts.
Remove safety guards only when necessary. Replace the safety guards as soon
as maintenance is complete.
Close the service panels when maintenance is complete. Repair or replace the
panels if they are damaged.
NOTICE
STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS
Put on a grounded wrist strap before handling printed circuit boards.
84 Freedom 38 PPA Service Manual 809010
3 – System-Level Components
WARNING!
ELECTRIC SHOCK CAN KILL
Disconnect or turn OFF electrical power before performing any maintenance
that involves removing the cover from the system or the consumables from
the plasma torch.
Read the separate Safety and Compliance Manual (80669C) included with
your system for more safety precautions pertaining to plasma cutting.
The system-level components cover the removal of the top cover and panels to access the internal components.
System-level components also include the front panel controls, indicators, and connections.
Remove and install the system’s cover on page 86
Replace the battery on page 89
Replace the Dynagen system controller on page 92
Replace the alternator lamp on page 94
Replace the 12 V circuit breaker on the front panel on page 95
Replace the ON/OFF power switch on page 96
Replace emergency stop contact block on page 98
Replace emergency stop button on page 99
Replace front panel circuit breaker on page 100
Replace the 480 V auxiliary outlet on page 102
Replace the service panel compression latch on page 104
Replace the 120 V auxiliary outlet on page 105
Replace 120 V auxiliary outlet circuit breaker on page 106
Replace the front panel on page 107
Freedom 38 PPA Service Manual 809010 85
3 – System-Level Components
1
1
2
2
Remove and install the system’s cover
Remove the cover
WARNING!
RISK OF SEVERE BURNS
Allow the exhaust pipe and top cover to cool before starting this procedure. This area gets extremely
hot when the engine is running.
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. When the exhaust pipe on the top of the system is cool enough to
touch, remove the cap from the exhaust pipe .
3. Remove both service panels.
4. Remove the screws and washers from the top cover.
5. Remove the top cover. Make sure you lift it above the exhaust pipe.
Carefully set aside the cover and all of its screws and washers.
6. Remove the screws and washers from the back, engine-side, or
plasma-side panels as needed.
You may need to remove the fuel fill cap in order to remove the engine-side panel. If you
do, be sure to put the cap back in place as soon as the panel is removed.
You must remove both side panels before you can remove the rear panel.
Remove only the screws and washers that attach the side panels. Leave the front panel
and rear panel screws that secure the bottoms to the chassis until removing those
assemblies.
Figure 22
86 Freedom 38 PPA Service Manual 809010
3 – System-Level Components
3
3
7. To remove the rear panel and black base plate, remove 7 screws . Remove the rear panel and baseplate as one
assembly. Set aside with all the screws and washers.
Figure 23
NOTICE
Do not remove the front panel unless absolutely necessary.
All of the front panel controls must be disconnected before the front panel can be removed. See
page 107.
Freedom 38 PPA Service Manual 809010 87
3 – System-Level Components
1
1
Install the cover
1. Before replacing any panels, clean off any dirt or debris to avoid contaminating the engine compartment.
2. If you removed the rear panel, put it back in place first. Hand tighten all screws and washers first, then tighten when
the panel is properly in place.
3. Attach the side panels. The bottom corners of the panel should rest on the corners of the base boards.
4. Hand tighten all screws and washers first, then tighten when the panel is properly in place. Do not install screws in
the top-most slots – these slots are used to install the top cover. See Figure 24.
Figure 24
5. Make sure the fuel fill cap is in place.
6. Set the top cover in place. Hand tighten all screws and washers first, then tighten when the cover is properly in place.
7. Put both service panels back in place.
8. Install the cap on top of the exhaust pipe.
NOTICE
The cap must be put back in place on the exhaust pipe. If it is left off, water, debris, and other
contaminants can enter the pipe and cause severe damage to the engine.
88 Freedom 38 PPA Service Manual 809010
Replace the battery
RISK OF FIRE OR EXPLOSION – WEAR PROTECTIVE CLOTHING
Turn OFF the engine before performing any battery checks or maintenance.
Avoid contact with sulfuric acid from the engine’s battery. It can cause serious injury
if it comes in contact with eyes or skin.
Always wear protective glasses, gloves, and clothing when servicing the battery.
Wash your hands thoroughly after touching the battery and its connectors.
Examine the battery regularly to make sure:
All electrical connections are clean and secure. Loose connections can cause
None of the electrical wires are frayed. Replace any frayed wires before starting
3 – System-Level Components
WARNING!
sparks that result in a fire. See Check the battery and cable connectors on
page 69.
the engine.
When the battery is charged or discharged, an explosive chemical change occurs.
Avoid all conditions that can ignite this explosive gas:
Keep any open flames or sparks away from the top of the battery.
Do not smoke cigarettes near a battery that is being charged.
Never place a metal object across the battery’s terminal posts to check its
charging status. Instead, use a voltmeter or hydrometer.
Never charge a frozen battery.
Never charge a battery in an enclosed room that lacks proper ventilation.
Never disconnect any charging unit circuit or battery circuit cable from the
battery while it is being charged. Doing so can produce dangerous sparks.
Apply the cable connections correctly if you jump-start the battery. Attach the
negative (-) ground cable last, and remove it first. See Jump-start the battery on
page 32.
Always dispose of old batteries in compliance with local and national regulations.
Examine the chassis ground strap connection regularly. Without a solid ground
strap connection, electrical discharge can damage the engine and electrical system.
Freedom 38 PPA Service Manual 809010 89
3 – System-Level Components
1
2
3
4
WARNING!
WEAR PROTECTIVE CLOTHING
Turn OFF the engine before performing any battery checks or maintenance.
Always wear protective glasses and gloves when servicing the battery. Avoid
contact with sulfuric acid from the engine’s battery. It can cause serious
injury if it comes in contact with eyes or skin.
Remove the battery
The Freedom 38 PPA requires a 12 VDC battery with a capacity of 750 cold cranking amperes (CCA).
The system ships with a Battery Charging Indicator (BCI) group 34/78 12 V battery. Replace it with a battery of
comparable specifications and size. Approximate dimensions for replacement batteries:
Length: 26 cm (10.25 inches)
Width: 18 cm (7 inches)
Height: 18 cm (7 inches)
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. Remove the service panel on the plasma side of the system.
3. Disconnect the negative (-) cable from the battery first to prevent electric shock. Pull back the black
cover to expose the negative (-) terminal. See Figure 25 on page 91.
4. Disconnect the positive (+) cable from the battery . Pull back the red cover to expose the positive (+) terminal.
Remove the connection from the fan harness , then remove the positive cable.
5. Remove the nuts and washers from the long screws that hold the battery in place. Set the nuts and washers
aside.
The washers in your system may differ slightly from those shown in Figure 25.
6. Use the handle on top of the battery to lift the battery straight up. Keep in mind the battery can weigh 30–40 pounds.
As you lift the battery straight up, make sure both sides of the support bracket come off the long screws.
7. Set the support bracket aside.
8. Dispose of the old battery in compliance with local and national regulations.
90 Freedom 38 PPA Service Manual 809010
3 – System-Level Components
4
2
3
1
1
2
4
3
Install the battery
1. Set the new battery in place next to the air compressor’s air/oil separation tank. Make sure:
The battery’s negative (-) terminal is nearest the outside edge of the system.
The battery sits flat and is not angled up in any direction.
2. Set the support bracket in place over the battery. The bracket should fit over the long screws. See Figure 25.
3. Install the washers and nuts over the long screws. Tighten by hand.
4. Attach the positive (+) cable to the positive (+) terminal on the battery . Attach the ring terminal from the fan
harness . Cover the terminal with the red sleeve from the cable, as shown in Figure 25.
5. Attach the negative (-) cable to the negative (-) terminal on the battery . Connect the negative (-) cable last to
prevent electric shock. Cover the terminal with the black sleeve from the cable, as shown in Figure 25.
6. Make sure both battery cable connections are tightened securely before starting the system.
7. Put the service panel back in place.
Figure 25
Freedom 38 PPA Service Manual 809010 91
3 – System-Level Components
Replace the Dynagen system controller
Kit number Description
428545 Dynagen® system controller
The system controller is preprogrammed and ready to install into the system.
Remove the Dynagen system controller
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. Wait for 30 seconds, then disconnect the battery’s negative (-) ground cable.
3. Remove the top cover from the system. See Remove the cover on page 86.
4. From behind the front panel, disconnect the J6, J4, J3, J7, and J5 wire connectors from the back of the system
controller. Press down the tab on each connector to remove it. See Figure 26.
This system does not use the J1 USB connector.
5. Remove the 2 screws from the bracket at the top of the controller. Slide the bracket forward towards the panel, then
upward to remove it from the controller.
6. Remove the 2 screws from the bracket at the bottom of the controller. Slide the bracket forward towards the panel,
then downward to remove it from the controller.
7. Facing the front of the system, slide the system controller straight out to remove it from the front panel.
Install the Dynagen system controller
1. Set the new system controller in place in the front panel.
2. From behind the front panel, slide the bracket into place at the top of the controller. Secure the bracket to the front
panel using the 2 screws.
3. Slide the bracket into place at the bottom of the controller. Secure the bracket to the front panel using the 2 screws.
4. Plug the 5 wire connectors into the back of the system controller as shown in Figure 26. Be careful to plug the J7
and J5 wire groups into the correct connectors:
Plug the J7 generator supply voltage wire group (4 orange wires) into the top right connector.
Plug the J5 current draw (amperes) wire group (4 pink wires) into the bottom right connector.
5. Reconnect the negative (-) ground cable to the battery.
6. Put the system’s top cover back in place. See Install the cover on page 88.
7. Set the power switch on the front panel to the ON (I) position. Examine the LCD screen to make sure the new system
controller is working properly.
92 Freedom 38 PPA Service Manual 809010
Figure 26
J6
J4
J3
J7
J5
3 – System-Level Components
Freedom 38 PPA Service Manual 809010 93
3 – System-Level Components
1
2
3
4
312
4
3
1
4
2
Replace the alternator lamp
Kit number Description
428546 Kit: Alternator lamp
Remove the alternator lamp
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. Wait for 30 seconds, then disconnect the battery’s negative (-) ground cable.
3. Remove the top cover from the system. See Remove the cover on page 86.
4. From behind the front panel, disconnect the red wire and the blue wire from the back of the alternator lamp .
See Figure 27. Be careful not to damage the resistor as you disconnect the wires.
5. Push in the tabs on both sides of the alternator lamp, and push the lamp through the front panel to remove it.
Install the alternator lamp
1. Push the new alternator lamp into the hole in the front panel until it clicks into place. See Figure 27.
2. Connect the red wire to the negative (-) tab on the alternator lamp.
3. Connect the blue wire to the positive (+) tab on the alternator lamp.
4. Make sure the resistor is securely connected to both wires.
5. Put the system’s top cover back in place. See Install the cover on page 88.
6. Reconnect the negative (-) ground cable to the battery.
Figure 27
94 Freedom 38 PPA Service Manual 809010
3 – System-Level Components
1
2
3
2
3
1
4
3
4
4
Replace the 12 V circuit breaker on the front panel
Kit number Description
428743 Kit: 12 V circuit breaker 10 A
Remove the 12 V circuit breaker
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. Wait for 30 seconds, then disconnect the battery’s negative (-) ground cable.
3. Remove the top cover from the system. See Remove the cover on page 86.
4. From behind the front panel, disconnect the red wire and the red and red/black wire pair from the back of the
12 V circuit breaker .
Figure 28
5. Gently pull on the circuit breaker from outside the front panel. At the same time, slowly push the back of the circuit
breaker through the lock washer .
Freedom 38 PPA Service Manual 809010 95
3 – System-Level Components
3
4
2
1
1
2
3
Install the 12 V circuit breaker
1. Put the new 12 V circuit breaker into place in the front panel. See Figure 28 on page 95.
Orient the circuit breaker right side up.
Make sure the flat side is on the bottom.
2. Firmly press the circuit breaker against the front panel. At the same time, push the lock washer over the back of
the circuit breaker until it sits up against the front panel. Make sure the internal teeth of the lock washer point away
from the front panel.
3. Connect the red and red/black wire pair to the bottom tab on the back of the circuit breaker.
4. Connect the single red wire to the top tab on the back of the circuit breaker.
5. Put the system’s top cover back in place. See Install the cover on page 88.
6. Reconnect the negative (-) ground cable to the battery.
Replace the ON/OFF power switch
Kit number Description
428510 Kit: ON/OFF power switch, 12 V
Remove the ON/OFF power switch
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. Wait for 30 seconds, then disconnect the battery’s negative (-) ground cable.
3. Remove the top cover from the system. See Remove the cover on page 86.
4. From behind the front panel, disconnect the red wire and the red/black wire from the back of the power
switch . Set the screws aside. See Figure 29 on page 97.
5. Carefully remove the rubber cover from the front of the power switch. To do this, hold the back of the power switch in
place. At the same time, unscrew the base of the rubber cover until you can remove it from the power switch. Set the
rubber cover aside.
96 Freedom 38 PPA Service Manual 809010
Figure 29
3
1
2
3
2
1
3 – System-Level Components
Install the ON/OFF power switch
1. Put the new power switch into place in the front panel. Orient the power switch vertically with one of the screw
tabs at the bottom of the switch.
2. Slide the rubber cover over the front of the power switch.
3. Firmly press the power switch against the back of the front panel. At the same time, screw the base of the rubber
cover onto the power switch until the rubber cover presses up against the front panel.
4. Make sure the power switch is still positioned vertically with the screw tab at the bottom of the switch.
5. Make sure the rubber cover is not twisted.
6. Connect the red/black wire to the bottom prong on the back of the power switch. See Figure 29.
7. Connect the red wire to the top prong on the back of the power switch.
8. Make sure the power switch is in the OFF (O) position (pointing down).
9. Put the system’s top cover back in place. See Install the cover on page 88.
10. Reconnect the negative (-) ground cable to the battery.
Freedom 38 PPA Service Manual 809010 97
3 – System-Level Components
1
2
1
2
2
1
Replace emergency stop contact block
Kit number Description
428497 Kit: Contactor for Emergency Stop button
Remove the emergency stop contact block
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. Wait for 30 seconds, then disconnect the battery’s negative (-) ground cable.
3. Remove the top cover from the system. See Remove the cover on page 86.
4. Loosen the 2 screws that secure the emergency stop contact block.
5. Unscrew the terminals from the contact block. Mark the locations in reference to the assembly.
Figure 30
Install the emergency stop contact block
1. Connect the 2 terminal wires to the new contact block.
2. Secure the contact block to the emergency stop plate by tightening the 2 screws .
3. Put the system’s top cover back in place. See Install the cover on page 88.
4. Reconnect the negative (-) ground cable to the battery.
98 Freedom 38 PPA Service Manual 809010
Replace emergency stop button
Kit number Description
428498 Kit: Emergency Stop button
Remove the emergency stop button
1. Loosen and remove the emergency stop button by turning counterclockwise.
Figure 31
3 – System-Level Components
Install the emergency stop button
1. Tighten the new emergency stop button by turning clockwise.
Freedom 38 PPA Service Manual 809010 99
3 – System-Level Components
1
1
2
Replace front panel circuit breaker
Kit number Description
428514 Kit: Main circuit breaker, 60 A, 3 pole (top)
428578 Kit: Transformer circuit breaker, 10 A, 3 pole (bottom)
There are 2 front panel circuit breakers, one 60 A (top) and one 10 A (bottom). This procedure can be used to replace
either one.
Remove the front panel circuit breaker
1. Turn OFF the system. Make sure the power switch on the front panel is in the OFF (O) position.
2. Detach the front panel. See Unfasten the front panel on page 124.
3. Remove the cover from the top of the AC connection cabinet that is located on top of the generator. See Figure 42
on page 115.
4. Remove the 2 screws that secure the circuit breaker bracket to the AC connection cabinet.
5. Remove the circuit breaker that needs replacement from the bracket. (The top breaker is 60 A. The bottom breaker is
10 A.) Unscrew the wires from the breaker by loosening the terminal screws and pulling the wires out. See
Figure 32.
Figure 32
100 Freedom 38 PPA Service Manual 809010
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