Hypertherm Freedom 38 PPA, Service Manual

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Freedom 38 PPA Service Manual 809010 29
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.