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Hypertherm Freedom 38 PPA, Руководство по обслуживанию

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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

.

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

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DANSK / DANISH

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

.

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 (문서 라이브러리)' 

에서도 모든 언어로 이용할 수 있는 설명서 사본을 얻을수 있습니다.

Содержание Freedom 38 PPA

Страница 1: ...Freedom 38 PPA Large Autonomous Plasma Cutting System Service Manual 809010 Revision 0 English ...

Страница 2: ...ax 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 ...

Страница 3: ...Freedom 38 PPA Service Manual 809010 Revision 0 English March 2017 Hypertherm Inc Hanover NH 03755 USA www hypertherm com ...

Страница 4: ...02 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 S...

Страница 5: ...ngshandleiding 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 DANSK DANISH ADVARSEL Inden Hypertherm udsty...

Страница 6: ... din cadrul secţiunii Bibliotecă documente aflată pe site ul 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 bası...

Страница 7: ...duct 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 c...

Страница 8: ...umber 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 o...

Страница 9: ...ace 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...

Страница 10: ...lbow 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 Mechanize...

Страница 11: ...operly 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 The warranty set forth ...

Страница 12: ...erein shall be null and void and you will have no further recourse against Hypertherm under the Warranty or otherwise Waterjet product warranty coverage 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 ab...

Страница 13: ... 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...

Страница 14: ...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 Allow the system s internal components to cool before servicing Do not remove the pressure cap from the radiator while the eng...

Страница 15: ...nd 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 ...

Страница 16: ... 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 bo...

Страница 17: ...re 2 Plasma side Figure 3 Generator side 1 Oil fill level for air compressor 2 Service panel 3 Lift truck slots 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 2 1 3 2 3 1 4 ...

Страница 18: ...ation 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 ...

Страница 19: ...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 br...

Страница 20: ... an explanation of these controls refer to the Basic System Operations section in the Powermax125 Operator Manual Figure 5 Plasma cutting system controls 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 ...

Страница 21: ...an 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 ...

Страница 22: ...ave 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 ...

Страница 23: ... F Turn the system OFF and allow the air compressor 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 E...

Страница 24: ...ge 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 s...

Страница 25: ...ly or is faulty Make sure the actuator is connected properly Have an authorized Deutz service dealer examine the engine 51 or 60 2 Digital output fault due to a short circuit or damaged cable Have an authorized Deutz service dealer examine the engine 84 8 Tachometer failed or tachometer cable connection interrupted Have an authorized Deutz service dealer examine the engine 100 1 or 2 Oil pressure ...

Страница 26: ... 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 231 12 9 or 14 Controller area network CAN bus communication fault Have an authorized Deutz service dealer examine the engine 240 253 or 254 2 or 12 Program logic or memory fault Turn OFF the system then turn ON the system If the fault persists have an auth...

Страница 27: ...e 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 threshol...

Страница 28: ...ir 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 F...

Страница 29: ...ter 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 st...

Страница 30: ...e 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...

Страница 31: ... air leak in the fuel line Have an authorized Hypertherm Freedom 38 PPA repair 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 ...

Страница 32: ... 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 ba...

Страница 33: ...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 ...

Страница 34: ...cal 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...

Страница 35: ...utz service dealer examine the engine 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 syste...

Страница 36: ...all 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 valv...

Страница 37: ...ressor 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 ...

Страница 38: ...sma 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 trans...

Страница 39: ... 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 ...

Страница 40: ...s not transfer to the workpiece 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 The arc blows out but re ignites when the torch trigger is pressed again Inspect the consumable ...

Страница 41: ...o 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 0 13 AC input unstable Warning the system continues to operate Blinks 3 Hz Off Check the generator alternator for possible power related issues See Troubleshoot power related issues genera...

Страница 42: ... 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 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 ...

Страница 43: ...asma supply and recycle the power switch on the back of the plasma supply 0 60 AC input voltage error On On This fault code displays when you turn 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 bre...

Страница 44: ... 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 s...

Страница 45: ...gnator Description I Current set read C LCD 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 Fau...

Страница 46: ...e 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 CAUTION Point the torch...

Страница 47: ...u 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...

Страница 48: ...ator 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 ...

Страница 49: ...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 ...

Страница 50: ...ber 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 Pres...

Страница 51: ... 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 ...

Страница 52: ...52 Freedom 38 PPA Service Manual 809010 1 Troubleshooting ...

Страница 53: ...umid 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 filt...

Страница 54: ...ay 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 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...

Страница 55: ... 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 Inspect the system for signs of wear or damage Engine generator 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 2...

Страница 56: ...lters Alternately the following oils from Shell can also be used ROTELLA T Triple Protection ROTELLA T3 or ROTELLA T4 Triple Protection Air compressor Adjust the tension of the air compressor belt Plasma cutting system 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 applica...

Страница 57: ... a vacuum To do this 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 o...

Страница 58: ...nance Air compressor Change the oil separation filter See page 81 Clean the finned surface of the air oil cooler Hypertherm strongly recommends that only authorized service technicians do this maintenance Every 6 000 operating hours System component Recommended maintenance Engine generator Change the timing belt At a minimum replace the timing belt once every 5 years Have an authorized Deutz servi...

Страница 59: ... 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 Handle all engine filters fuel and lubricating oils with care Fuel...

Страница 60: ...n or the pit depth is greater than 1 6 mm 1 16 inch deep Swirl ring The surface inside the swirl ring for damage or wear and the gas holes for blockages Replace swirl ring if the surface is damaged or worn or any of the gas holes are blocked The O ring for damage or wear If the O ring is worn or damaged replace the swirl ring The length of the swirl ring If the length of the swirl ring is less tha...

Страница 61: ...ank 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 CAUTION Drain condensate from the compressed air tank to make su...

Страница 62: ...l 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 ex...

Страница 63: ...round not at an incline Figure 13 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 interna...

Страница 64: ...l 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 NOTICE Use oil of the same type as that already in the machine Do not mix different oils from different manufacturers and different viscos...

Страница 65: ... 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 5 Dispose of the condensate in compliance with local and national regulations 6 Put the serv...

Страница 66: ... 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 circu...

Страница 67: ... 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 WARNING 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 an...

Страница 68: ...68 Freedom 38 PPA Service Manual 809010 2 Routine Maintenance 9 Put the service panel back in place Figure 15 Air drying filter ...

Страница 69: ...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 batt...

Страница 70: ...e is cooled by the lubricating oil so the oil must be drained from both the oil pan and the heat exchanger 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 typ...

Страница 71: ... 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...

Страница 72: ...e 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 ...

Страница 73: ...ay 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 ...

Страница 74: ...74 Freedom 38 PPA Service Manual 809010 2 Routine Maintenance Figure 18 Engine fuel filter Hand pump ...

Страница 75: ...ew 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 unti...

Страница 76: ...mpressed 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 cle...

Страница 77: ...er 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 m...

Страница 78: ...D 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 Ne...

Страница 79: ... 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 t...

Страница 80: ...a 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 was...

Страница 81: ... seal on the new oil separation filter 7 Screw the oil separation filter into place Tighten by hand WARNING 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...

Страница 82: ...82 Freedom 38 PPA Service Manual 809010 2 Routine Maintenance 8 Put the service panel back in place Figure 21 Air compressor s oil separation filter ...

Страница 83: ...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 ...

Страница 84: ...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 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 INJU...

Страница 85: ... 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 WARNIN...

Страница 86: ...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 th...

Страница 87: ... 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 3 3 ...

Страница 88: ...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 panel...

Страница 89: ... 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 ch...

Страница 90: ...able 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...

Страница 91: ... 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 te...

Страница 92: ...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...

Страница 93: ...Freedom 38 PPA Service Manual 809010 93 3 System Level Components Figure 26 J6 J4 J3 J7 J5 ...

Страница 94: ...o 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 ...

Страница 95: ...t 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 washe...

Страница 96: ...t 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 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 Re...

Страница 97: ...e 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 ...

Страница 98: ...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 p...

Страница 99: ...cy stop button Remove the emergency stop button 1 Loosen and remove the emergency stop button by turning counterclockwise Figure 31 Install the emergency stop button 1 Tighten the new emergency stop button by turning clockwise Kit number Description 428498 Kit Emergency Stop button ...

Страница 100: ...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 loosen...

Страница 101: ...rect terminal slots Figure 33 Circuit breaker wiring connections 2 Mount the circuit breaker to the bracket The top breaker is 60 A The bottom breaker is 10 A Make sure the black DIN rail holder secures the circuit breaker to the bracket See Figure 32 on page 100 3 Reinstall the circuit breaker bracket to the AC connection cabinet 4 Reinstall the cover to the top of the AC connection cabinet 5 Rei...

Страница 102: ... Remove the 4 screws and washers that secure the 480 V receptacle to the front panel Figure 34 4 Pull the receptacle out from the front panel and loosen the box terminal screws to disconnect the wires from the receptacle Mark the order of the wire colors and location to the receptacle Check that the wires are stripped clean and there are no stray wire strands Kit number Description 428525 Kit 480 ...

Страница 103: ...ceptacle until the screws start to apply pressure to the walls 3 Insert each of the 4 wires red black white and orange into the proper box terminal on the receptacle Tighten the box terminal screws for each wire to 34 56 kg cm 30 in lb minimum 4 Make sure there are no stray wire strands 5 Set the receptacle and gasket into the front panel with the hinge facing up Secure using the 4 screws and torq...

Страница 104: ...el compression latch 1 Insert the compression latch into the service panel Secure with 4 nuts and lock washers 2 With the latch in the closed position adjust the jam nut to position the cam to point toward the top of the panel See Figure 35 Secure with nuts and lock washers When you put the service panel in place you may need to adjust the cam position by positioning the jam nuts and lock washers ...

Страница 105: ...t the wires from the outlet Install the 120 V auxiliary outlet 1 On the new outlet connect the green wire to the ground green screw Connect the white wire to the silver screw Connect the black wire to the brass screw Figure 36 2 Insert the new outlet into the electrical box Secure using 2 screws Make sure the screws make contact with the threaded holes of the electrical box not the holes of the me...

Страница 106: ...ton Pull the breaker out from the rear of the panel Figure 37 5 Disconnect the 2 blade connectors from the circuit breaker Install the 120 V auxiliary outlet circuit breaker 1 Push the 2 blade connectors onto the new circuit breaker 2 Push the circuit breaker through the hole on the front panel Make sure the nomenclature on the button is oriented correctly as viewed from the front panel Secure by ...

Страница 107: ...Air pressure gauge See Remove the air pressure gauge on page 171 Fuel shutoff relay See Remove the fuel shutoff relay on page 151 12 V circuit breaker See Remove the 12 V circuit breaker on page 95 Alternator lamp See Remove the alternator lamp on page 94 ON OFF power switch See Remove the ON OFF power switch on page 96 120 V outlet See Remove the 120 V auxiliary outlet on page 105 120 V circuit b...

Страница 108: ...or assembly 2 480 V outlet electrical box 3 120 V outlet electrical box 4 120 V outlet 5 120 V circuit breaker 6 ON OFF power switch 7 12 V circuit breaker 8 Alternator lamp 9 CPC connector 10 Emergency stop contact assembly and button 11 Ground terminal 12 480 V outlet 13 120 V outlet cover 14 Front panel breaker cover 15 Dynagen controller 16 Air pressure gauge 17 Edge trim 18 Front panel ...

Страница 109: ...2 bottom screws securing the front panel to the base one on each side See Figure 48 on page 124 Install the front panel 1 On the new front panel replace the edge trim on the top of the panel and on the plasma supply door slot 2 Place the yellow emergency stop sticker in place See Figure 41 on page 110 3 Reinstall the plasma door assembly and the front panel circuit breaker door 4 Place the new fro...

Страница 110: ...Install the 120 V auxiliary outlet on page 105 9 Place the 480 V electrical box and wires against the rear of the front panel Run the wires through to the front and secure the electrical box using 4 screws Reinstall the 480 V outlet See Install the 480 V auxiliary outlet on page 103 10 Put the ground terminal in place on the front panel Secure with the screw and washer Make sure all metal to metal...

Страница 111: ...lacement 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 ...

Страница 112: ...ay 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 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...

Страница 113: ...www hypertherm com Replace the air filter element and air filter bowl in the plasma supply on page 114 Detach the plasma supply power cord on page 115 Unfasten the plasma supply on page 118 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 separ...

Страница 114: ...lasma cutting system s rear panel The air filter element is inside the filter bowl The air filter bowl in your plasma supply may differ slightly from the one shown in this picture Install the air filter element and air filter bowl 1 Refer to the Maintenance and Repair chapter in the Powermax125 Operator Manual to install a new air filter element and air filter bowl 2 Reconnect the compressed air h...

Страница 115: ... front panel is in the OFF O position 2 Turn OFF O the plasma supply power switch located on the rear panel of the plasma supply 3 Wait for 30 seconds then disconnect the battery s negative ground cable 4 Remove the top cover and both side panels from the system See Remove the cover on page 86 5 Remove the connections from the rear of the plasma supply See Detach the plasma supply on page 118 6 Re...

Страница 116: ...e ground stud See Figure 43 Remove the terminal block to access the ground stud Remove the 6 screws that secure the terminal block These are located outside the AC connection cabinet on the plasma side Figure 43 8 Disconnect the power cord s black white and red wires See Figure 44 Figure 44 2 3 4 4 3 2 5 6 7 5 6 7 8 ...

Страница 117: ...in Figure 44 4 Connect the green ground wire to the ground stud in the AC connection cabinet See Figure 43 on page 116 Reconnect any ground wires that were removed to access the plasma supply ground Secure remaining ground wires with nut 5 Reinstall the terminal block See Figure 43 on page 116 6 Connect the black red and white wires as shown in Figure 44 on page 116 7 Tighten the strain relief See...

Страница 118: ...lasma supply power cord on page 115 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 and plasma side panel from the system See Remove the cover on page 86 4 Set the power switch on the back of the plasma supply to OFF O 5 Disconnect the compressed air hose 6 ...

Страница 119: ...s 8 Lift the rear of the plasma supply and work the rear bracket free from the plasma supply and mounting plate Figure 46 9 Grip the front and rear handles at the top of the plasma supply Slide the plasma supply forward to free it from the front bracket 4 4 5 5 ...

Страница 120: ...ges the front bracket See Figure 46 Lift the rear of the plasma supply and work the rear bracket into place Make sure the bracket is seated correctly Secure the rear bracket with 2 screws See page 118 4 Reconnect the compressed air hose and machine interface CPC connector to the back of the plasma supply See Figure 45 on page 118 5 Set the power switch on the back of the plasma supply to ON I 6 Re...

Страница 121: ...nly 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 ...

Страница 122: ... 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 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...

Страница 123: ...place the control system wiring harness on page 140 Replace the generator wiring harness on page 142 Replace the engine wiring harness on page 148 Replace the relays on page 150 Replace the fuel shutoff relay on page 151 Replace the cooling unit fan relay on page 152 Replace the generator rectifiers on page 153 WARNING ELECTRIC SHOCK CAN KILL Disconnect or turn OFF electrical power before performi...

Страница 124: ...ached and set aside with many of the connections remaining intact 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 and both side panels from the system See Remove the cover on page 86 4 Remove the 4 screws and nuts that secure the CPC connector to the front p...

Страница 125: ...g door may be necessary Figure 49 Reattach the front panel 1 Place the front panel back in position Secure with 2 screws near the base board See Figure 48 on page 124 Make sure all the wires are connected securely on the back of the panel 2 Reconnect the air line from the air tank to the pressure gauge if detached 3 Reconnect the CPC connector to the front panel using the 4 screws and nuts 4 Put t...

Страница 126: ... the OFF O position 2 Remove the top cover and both side panels from the system See Remove the cover on page 86 3 Detach the front panel from the system See Unfasten the front panel on page 124 4 Remove the plasma supply See Detach the plasma supply on page 118 5 Remove the 6 screws and washers that secure the plasma supply bracket Set aside the bracket and hardware Figure 50 Kit number Descriptio...

Страница 127: ... Remove the front black base board 7 Remove the condensate valve and auxiliary air bracket Disconnect the hoses on the condensate valve if necessary 8 Remove the transformer screws Figure 51 9 Have another person help to carefully lift the transformer out of the system 1 2 2 1 ...

Страница 128: ...rmer This will be replaced by the old cover panel with the terminal block and cables 2 Connect the 2 ground wires from the old cover to the new transformer box chassis ground stud See Figure 52 Connect the ground from the new transformer black wire E SS to the same spot 3 Connect the wires H1 H2 H3 H4 X1 X2 X3 X4 from the new transformer to the terminal block See Figure 53 In case the cable wires ...

Страница 129: ...ses to the air condensate valve if removed Reconnect the condensate valve and auxiliary air bracket 8 Put the front black base board back into place Hand tighten only to position the board in place When the black base board is set correctly tighten all the screws 9 Reinstall the plasma supply bracket with the 6 screws and washers 10 Reinstall the plasma supply See page 120 11 Reattach the front pa...

Страница 130: ... 30 seconds then disconnect the battery s negative ground cable 3 Remove the top cover and the plasma side panel from the system See Remove the cover on page 86 4 Loosen the hose clamp on the rubber elbow located after the air filter housing Work the pipe loose from the elbow 5 Loosen the hose clamps on both sides of the air intake shut off valve Unplug the wire harness connection Figure 54 Kit nu...

Страница 131: ...e the rubber hoses from both sides of the old emergency air intake shut off valve Install the rubber hoses on the new valve 2 Place 2 hose clamps removed earlier on each rubber hose section on the emergency air intake shut off valve 3 Put the assembly back into place between the air intake pipe and the air intake opening 4 Tighten the 4 hose clamps Reconnect the plug from the wiring harness 5 Plac...

Страница 132: ...air intake pipe has not worked itself free Reconnect if necessary Figure 56 7 Make sure the emergency air intake shut off valve is set to the OPEN position 8 Put the system s top cover and plasma side panel back in place See Install the cover on page 88 9 Reconnect the negative ground cable to the battery 8 8 9 9 ...

Страница 133: ...e 3 Remove the on board plasma supply to gain access to the AVR See Detach the plasma supply on page 118 When the plasma supply is removed you can access the AVR through that opening in the front panel 4 Remove the cover panel from the AVR See Figure 57 5 Remove the 4 screws that secure the AVR 6 Disconnect the 4 wire connections from the top of the AVR 7 Remove the AVR from the alternator Figure ...

Страница 134: ...nnection Set the stability selection wire to the D B link Set the frequency tab to 60 Hz The label on the inside of the AVR cover panel identifies all the configurable components on the AVR as shown in Figure 59 on page 135 2 Connect the 4 wire connections to the top of the AVR exactly as shown in Figure 58 Figure 58 3 Install the 4 screws to secure the AVR to the alternator 4 Reconnect the negati...

Страница 135: ...e Manual included with your system You can find the STAMFORD manual in the same PDF file as the Stadco Operation and Maintenance Manual Use the top adjustment to set the voltage Turn clockwise to increase the voltage Turn counterclockwise to decrease the voltage Use the middle adjustment to set the drooping effect Turn clockwise to increase the drooping effect Turn counterclockwise to decrease the...

Страница 136: ...ower 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 and the plasma side panel from the system See Remove the cover on page 86 4 Remove the screw and nut from the grounding bracket to remove the 2 ring terminals Unplug the blade connector from the fuel sensor to the wiring harness Cut cable ties if ...

Страница 137: ...ors that accommodate 16 AWG wire blue 2 Make sure the area around the fuel sensor opening is clean and that nothing can fall into the opening when replacing the sensor 3 Plug the blade connector from the new fuel sensor into the wire harness Secure with cable ties Reconnect the ring terminals from the wiring harness and the new fuel sensor to the grounding bracket on the fuel tank Figure 61 NOTICE...

Страница 138: ...wiring harness connects to the circuit breaker and current sensors Dynagen system controller 10 A circuit breaker and current sensors Removing this harness requires access into the AC connection cabinet located on top of the generator 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 both side panels from the system See Remove t...

Страница 139: ...nnect the wires to the neutral stud 420 220 See Figure 62 on page 139 3 Connect the wires to the circuit breaker See Install the front panel circuit breaker on page 101 Make sure there are no stray loose strands Make sure the wires are in the correct terminal slots 231 232 and 233 Make sure the black and white wires are also properly connected to the terminal slots 4 Check that there are no unconn...

Страница 140: ...cover on page 86 4 Unplug the J6 J4 and J3 wire connectors from the back of the system controller 5 Disconnect the following components Alternator lamp See Remove the alternator lamp on page 94 12 V circuit breaker See Remove the 12 V circuit breaker on page 95 ON OFF power switch See Remove the ON OFF power switch on page 96 Emergency stop contact block See Remove the emergency stop contact block...

Страница 141: ...cy stop contact block See Install the emergency stop contact block on page 98 ON OFF power switch See Install the ON OFF power switch on page 97 12 V circuit breaker See Install the 12 V circuit breaker on page 96 Alternator lamp See Install the alternator lamp on page 94 Fuel shutoff relay See Install the fuel shutoff relay on page 151 3 Reconnect the diagnose plug 4 Reconnect the 2 gray connecto...

Страница 142: ... then disconnect the battery s negative ground cable 3 Remove the top cover both side panels and rear panel from the system See Remove the cover on page 86 4 Start from the engine side Cut the cable tie and unplug the top large gray connector from the generator Figure 65 5 Unplug the connection to the engine wire harness located near the gas port Cut the cable ties to free the connectors Figure 66...

Страница 143: ...Located on the generator below the air filter housing is the interconnect between the generator and control harnesses Disconnect the 2 gray connectors Figure 67 7 Move to the plasma side Remove the nut and washer to disconnect the ground terminal wires from the engine Figure 68 ...

Страница 144: ... starter motor The red power cable from the battery will need to be removed to disconnect the red wires from the starter Figure 69 Starter motor connections 9 Disconnect the red wire from the battery positive terminal connection Figure 70 10 Disconnect the fuel level sensor See Remove the fuel level sensor on page 136 1 2 1 2 ...

Страница 145: ...ingle red wire and the double red wire harness connections 13 Disconnect the red and blue wires connected to the alternator Figure 72 Alternator and circuit breaker connections 14 Unplug the connector from the emergency air shutoff relay if installed This is an option See Figure 54 on page 130 15 Disconnect the yellow brown wire from the air compressor s temperature switch See Remove the temperatu...

Страница 146: ...ter plug harness connections 17 Unplug the 2 wires from the cooling unit fan connector Figure 74 Cooling unit fan wiring harness connections 18 Unplug the relay on the cooling unit fan harness Remove the screw and remove the relay socket from the fan bracket assembly 19 Remove the red protective cover on the circuit breaker and disconnect the 2 wires 7 7 8 9 10 8 9 10 ...

Страница 147: ...ctions to the circuit breaker located next to the relay housings Connect the red and blue wires to the alternator See Figure 72 9 Plug the connector to the emergency air shutoff relay if installed This is an option If this option is not installed check that there is a cover over the plug to protect the connections See Figure 54 on page 130 10 Connect the red wire terminal to the battery positive t...

Страница 148: ...t for 30 seconds then disconnect the battery s negative ground cable 3 Remove the top cover and engine side panel See Remove the cover on page 86 4 Cut the cable tie and unplug the lower large gray connector from the generator Figure 75 5 Unplug the connection to the engine wire harness located near the gas port Cut the cable ties to free the connectors See Figure 66 on page 142 Kit number Descrip...

Страница 149: ...nnector from the new harness into the receptacle on the generator Secure with a cable tie See Figure 75 2 Connect the plug to the engine harness near the gas port See Figure 66 on page 142 3 Connect the 4 remaining plugs into the appropriate connections on the engine See Figure 76 4 Put the system s top cover and engine side panel back in place See Install the cover on page 88 5 Reconnect the nega...

Страница 150: ...ge 151 To replace the cooling unit fan relay see Replace the cooling unit fan relay on page 152 Remove engine mounted relay 1 Turn OFF the system Make sure the power switch on the front panel is in the OFF O position 2 Remove the plasma side service panel 3 Wait for 30 seconds then disconnect the battery s negative ground cable 4 There are 4 relays mounted on the engine towards the left looking in...

Страница 151: ...lay s tabs Figure 78 Install the fuel shutoff relay 1 Attach the 4 wires from the cable harness to the new fuel shutoff relay as previously marked Connect red with black stripe to the terminal marked 86 Connect brown to the terminal marked 85 Connect red to the terminal marked 30 Connect the 2 wire red with black stripe to the terminal marked 87 2 Secure the relay to the rear of the front panel us...

Страница 152: ...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 Unplug the relay from the relay housing Figure 79 Install the cooling unit fan relay 1 Plug the new relay into the relay housing 2 Put the system s top cover back in place See Install the cover on page 88 3 Reconnect the negative ground cable to the battery Kit numbe...

Страница 153: ... a cutout on the generator s bearing housing A soldering iron is needed for the wire connections on the rectifiers This procedure requires 2 people to complete Remove the generator rectifiers 1 Turn OFF the system Make sure the power switch on the front panel is in the OFF O position 2 Remove the front panel See Unfasten the front panel on page 124 3 Remove the plastic end cover on the generator F...

Страница 154: ...pe 6 Rotate the engine to align the varistor with the cutout on the bearing housing Remove the varistor Install the generator rectifiers 1 Smear Dow Corning 340 heatsink compound or equivalent heatsink compound on the underside of the replacement diode Do not apply heatsink compound to the threads Install the new diode and torque from 20 7 24 16 kg cm 17 97 21 inch pounds Solder the wire to the di...

Страница 155: ...y 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 ...

Страница 156: ...t 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 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 IN...

Страница 157: ... Read the separate Safety and Compliance Manual 80669C included with your system for more safety precautions pertaining to plasma cutting WARNING RISK OF INJURY HANDLE COMPRESSED AIR WITH CARE THESE PROCEDURES 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 co...

Страница 158: ...ilot unloader valve vents excess pressure through the muffler This maintains the pressure within desired levels The orifice adapter in the pilot unloader valve maintains enough pressure in the system when venting to allow oil to flow back to the compressor through the oil mist line The pilot unloader valve has been specially calibrated for the system and must not be adjusted A temperature switch m...

Страница 159: ...ter 6 Temperature switch 7 Compressor 8 Separation tank 9 Air cooler 10 Oil cooler 11 Air intake 12 Compressor inlet valve 13 Oil mist line 14 Oil return line 15 Compressed air and oil out 16 Air drying filter 17 Auxiliary air line 18 Pressure gauge 19 Plasma supply air line 20 Condensate drain 21 Scavenge orifice 11 12 13 6 14 15 7 13 14 1 2 3 4 7 8 9 10 16 18 19 15 20 5 17 21 ...

Страница 160: ...lieve pressure on the belt Start with the outer nut Then loosen the inner nut until the belt can be removed from the compressor drive pulley 6 Remove the belt from the engine pulley Figure 83 Replace the air compressor belt 1 Work the replacement belt onto the engine pulley then down onto the compressor drive pulley 2 Position the tension pulley to apply pressure from the outside of the belt inwar...

Страница 161: ...and need to be cleared and cleaned before installation Remove the air compressor and drive pulley When loosening or tightening hose connections use 2 wrenches one to hold the fitting stationary and the other to loosen or tighten the compression nut 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 negati...

Страница 162: ...en and remove 6 screws that secure the compressor bracket assembly Remove the assembly 11 With the compressor assembly out of the system remove the drive pulley from the compressor Note that this nut is reverse threaded Figure 85 12 Remove the compressor inlet valve oil line elbow fitting and tee elbow fitting 13 Remove 3 screws and washers that secure the compressor to the bracket 1 2 3 1 4 2 3 5...

Страница 163: ...nut is reverse threaded The thin washer goes behind the pulley not between the pulley and the nut The side of the pulley with the nubs must be facing out towards the nut away from the compressor and bracket See Figure 85 on page 162 Torque the nut to 40 7 N M 30 foot pounds The compressor shaft is free spinning There is no way to grip the shaft when tightening the nut Use an impact tool to obtain ...

Страница 164: ... compressor belt See Replace the air compressor belt on page 160 8 Clean up any oil that spilled inside the system Dispose of the old oil in compliance with local and national regulations 9 Put the system s cover both side panels and rear panel back in place See Install the cover on page 88 10 Reconnect the negative ground cable to the battery 11 Turn ON the system and allow it to run for 2 3 minu...

Страница 165: ...the compressor assembly Retain the screw nut spacer and all the washers Install the compressor tension pulley 1 Attach the new tension pulley to the compressor assembly using the screw nut spacer and washers Make sure to place a flat washer between the bracket and shaft Figure 88 Air compressor tension pulley assembly 2 Perform the following procedure starting at the installation of the compressor...

Страница 166: ...rom the control valve and remove the valve from the compressor Remove the O ring between the control valve and the compressor Clean the exposed surface of the compressor Be careful not to get any dirt or debris in the compressor while the control valve is removed Install the compressor inlet valve 1 Apply a continuous bead of LOCTITE 573 to the connecting compressor surface Surround the outer edge...

Страница 167: ... separation tank by pulling the relief valve on the separation tank manifold See page 79 5 Remove the black base board that is under the rear panel 6 Disconnect the wire connector from the temperature switch Figure 89 Temperature switch connector 7 Place a small container or pan under the front of the air compressor to catch any oil that spills 8 Use a large adjustable wrench to remove the tempera...

Страница 168: ...r removed from fitting 9 Remove the elbow fitting from the compressor 10 Remove the tee fitting elbow fitting or straight adapter as needed Disconnect the 45 fitting when replacing the tee fitting 11 Dispose of any oil that spilled in compliance with local and national regulations Figure 91 1 2 1 3 4 1 2 3 4 ...

Страница 169: ...ompressor check valve and scavenge line orifice When loosening or tightening hose connections use two wrenches one to hold the fitting stationary and the other to loosen or tighten the compression nut Remove the air compressor check valve and scavenge line orifice 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 ...

Страница 170: ...t number 330116 thread sealant Apply a thread seal bead on 2 3 threads of each threaded connection Do not over apply to avoid air line contamination 4 Connect the oil mist line to the adapter Clean up any oil drippings 5 Replace the black base plate that is below the rear panel 6 Reconnect the battery s negative ground cable 7 Run the system to distribute the oil Set the power switch on the front ...

Страница 171: ...r on page 86 4 From behind the front panel disconnect the air hose from the 90 fitting at the back of the air pressure gauge Cut any cable ties if necessary Figure 93 5 Loosen the 2 screws in the bracket that secure the air pressure gauge to the front panel The screws do not need to be removed from the bracket When loose the bracket can be removed with a twist 6 Remove the air pressure gauge from ...

Страница 172: ...ver on page 88 Replace the unloader valve Remove the unloader valve 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 Drain the air tank to release pressure See page 61 4 Remove the plasma side service panel 5 Release pressure from the separation tank by pulling the ring on the pr...

Страница 173: ...e 94 Install the unloader valve 1 Use 2 wrenches to connect the valve assembly to the separation tank manifold 2 Use 2 wrenches to connect the output hose to the valve s elbow fitting 3 Reconnect the battery s negative ground cable 4 Replace the plasma side service panel 1 2 3 ...

Страница 174: ...the air tank to release pressure See page 61 5 Release pressure from the separation tank by pulling the ring on the pressure relief valve 6 To remove only the muffler proceed to step 7 Use 2 wrenches to remove the muffler and orifice adapter from the unloader valve Place one wrench on the orifice adapter Place the other wrench on the unloader valve to hold it steady Turn the orifice adapter wrench...

Страница 175: ... wrench to attach 5 Reconnect the battery s negative ground cable 6 Put the plasma side service panel back in place Replace the separation tank Remove the separation tank 1 Run the system to heat the oil Set the power switch on the front panel to ON and press the RUN button on the system controller 2 After the unit starts up allow it to run for approximately 5 minutes 3 Press the OFF O button on t...

Страница 176: ...ve 2 screws and washers that secure the tank to the system s chassis The tank can be removed at this point Figure 96 11 Remove the oil gauge and washer valve and elbows oil cap and input elbow connector from the old tank The valve and elbows need to be disassembled to remove them from the bottom of the tank Figure 97 1 2 3 4 1 2 3 4 ...

Страница 177: ...amp s tightening screw location will not interfere with the side panel when installed 4 Make sure the ball valve at the bottom of the tank is closed 5 Install the manifold to the top of the tank See Install the separation tank manifold on page 179 6 Pour oil into the separation tank See page 80 7 Reconnect the battery s negative ground cable 8 Run the system to distribute the oil Set the power swi...

Страница 178: ...n tank by pulling the ring on the pressure relief valve See page 79 5 Remove the top cover and plasma side panel from the system See Remove the cover on page 86 6 Remove the pilot unloader valve See Remove the unloader valve on page 172 7 Disconnect the following hoses Position the hoses in a vertical position with the disconnected fittings facing upward to avoid spilling oil Air oil line from the...

Страница 179: ...d hand tighten the screws until the silicone begins to squeeze out around the manifold 3 Allow the silicone to dry for one hour Lube and torque the screws to 184 kg cm 160 in lb Torque the screws alternately to 1 3 the torque value then 2 3 then the final value Allow 24 hours for the silicone to fully cure 4 Remove the relief valve and minimum pressure valve from the old manifold Install these ite...

Страница 180: ...81 9 Install a new oil filter Lightly apply clean oil to the seal Screw the oil filter into place Tighten by hand See page 78 10 Reconnect the battery s negative ground cable 11 Run the system to distribute the oil Set the power switch on the front panel to ON and press the RUN button on the system controller 12 After the unit starts up allow it to run for approximately 5 minutes 13 Press the OFF ...

Страница 181: ...6 5 Release pressure from the separation tank by pulling the ring on the pressure relief valve See page 79 6 Disconnect the pressure fittings from the cooling unit being replaced Position the oil cooler unit hoses so no oil leaks out 7 Remove the 4 screws and nuts that secure the outer shroud fan assembly and the mounting bracket that enclose the cooling units The cooler units are secured by foam ...

Страница 182: ...pper mounting holes and assemblies Set the upper screws in place Press the cooling assembly together to maximize effectiveness of the fan 5 Secure the assemblies together with the 4 nuts on the upper and lower screws 6 Make sure the 2 wires from the wire harness are connected to the fan connector These may have come loose during the disassembly Check that the red wire from the harness connects to ...

Страница 183: ...ing fan Some early units may not have weld nuts on the fan plenum These require disassembly of the fan and cooling unit assembly to replace the fan Remove the compressor cooling fan 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 side panels and rear panel f...

Страница 184: ...tor Figure 103 3 Reconnect the battery s negative ground cable 4 Replace the top cover side panels and rear panel on the system See Install the cover on page 88 5 Set the power switch on the front panel to ON and press the RUN button on the system controller 6 Make sure the fan blows air out the back of the unit If the fan is blowing air into the unit check the polarity of the wires on the fan con...

Страница 185: ...nk to release pressure See page 61 5 Release pressure from the separation tank by pulling the ring on the pressure relief valve Figure 104 6 Unscrew the pressure relief valve from the manifold Install the pressure relief valve on the separator tank 1 Install the new pressure relief valve Use part number 330116 thread sealant on the relief valve Apply a thread seal bead on 2 3 threads Do not over a...

Страница 186: ... the tank accumulates opposite the oil level gauge 8 Remove the gauge and washer from the separation tank Install the oil level gauge 1 Install the new oil level gauge and washer Use part number 330116 thread sealant on the threads Apply a thread seal bead on 2 3 threads Do not over apply to avoid oil contamination 2 Set the tank back in place Align the brackets at the bottom with the mounts in th...

Страница 187: ... the separation tank by pulling the ring on the pressure relief valve See Figure 104 on page 185 5 Remove the top cover and plasma side panel from the system See Remove the cover on page 86 6 Remove the pressure relief valve See Remove the pressure relief valve on the air drying filter assembly on page 190 7 Disconnect the unloader valve hose 8 Disconnect the air tank hose 9 Remove the adapter fro...

Страница 188: ...supply and the other hose is from the auxiliary air outlet 11 Remove the tee fitting from the air drying filter assembly Figure 106 12 Remove the screws nuts and washers that secure the air drying filter assembly to the chassis Remove the air drying filter assembly from the unit Cut any cable ties necessary to free the part Figure 107 5 6 7 5 6 7 8 ...

Страница 189: ...s Do not over apply to avoid air line contamination Make sure the final position does not interfere with the adjacent port 5 Connect the hose from the plasma power supply to the tee fitting 6 Connect the hose from the auxiliary air outlet to the tee fitting 7 Install the adapter to the right rear port where the air tank hose was attached Use part number 330116 thread sealant on the adapter Apply a...

Страница 190: ...the air tank to release pressure See page 61 5 Pull the ring on the air drying filter relief valve to ensure there is no pressure left 6 Unscrew the pressure relief valve from the air drying filter assembly Figure 108 Install the air pressure relief valve on the air drying filter assembly 1 Install the new pressure relief valve Use part number 330116 thread sealant on the relief valve Apply a thre...

Страница 191: ...ressure relief valve See Figure 104 on page 185 5 Remove the top cover and plasma side panel from the system See Remove the cover on page 86 6 Drain the oil from the separation tank See page 79 7 Remove the drain hose from the elbow fitting attached to the ball valve 8 Loosen and remove the large hose clamp around the separation tank Remove 2 bolts and washers that secure the tank to the system ch...

Страница 192: ... sure that the hose clamp s tightening bolt location will not interfere with the side cover when installed 5 Make sure the ball valve is closed 6 Clean up any oil that spilled Dispose of the old oil in compliance with local and national regulations 7 Pour oil into the separation tank See page 80 8 Reconnect the battery s negative ground cable 9 Run the system to distribute the oil Set the power sw...

Страница 193: ... Remove the condensate release lever 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 Drain the air tank to release pressure See page 61 4 Remove the top cover and engine side panel from the system See Remove the cover on page 86 5 Remove 7 screws from the front panel base plate ...

Страница 194: ...ead on 2 3 threads of each threaded connection Do not over apply to avoid air line contamination Figure 112 2 Connect the 2 hoses to the elbow fittings The line from the air tank connects to the machined brass fitting side of the lever assembly 3 Secure the lever assembly to the bracket using 2 screws 4 Replace the front panel black base plate 5 Replace the 2 screws behind the front panel These ar...

Страница 195: ...ment parts accessories plasma torches and consumables for your system Refer to the Powermax125 Service Manual 808070 for a complete list of replacement parts for the Powermax125 plasma supply and Duramax Hyamp hand torches and machine torches You can download this manual from the Documents library at www hypertherm com ...

Страница 196: ...over for machine interface CPC receptacle not shown 127204 3 Kit Emergency Stop button 428498 Kit Contactor for Emergency Stop button 428497 Kit Yellow warning sticker for Emergency Stop button 428508 4 Kit Protective panel for main circuit breaker and transformer circuit breaker 428523 Kit Main circuit breaker 60 A 3 pole top 428514 Kit Transformer circuit breaker 10 A 3 pole bottom 428578 1 2 3 ...

Страница 197: ...r cover panels contains a set of 15 screws washers and lock washers 428587 10 Kit 480 V 60 A auxiliary outlet replacement 428525 11 Dynagen system controller 428545 12 Kit Front panel hardware not included 428518 Kit Rear panel hardware not included not shown 428517 Kit Ventilation screen for rear panel not shown 428515 Kit Freedom 38 PPA decal for front and rear panels not shown 428507 Kit Labels...

Страница 198: ...placement screws and washers for cover panels contains a set of 15 screws washers and lock washers 428587 5 Kit Fill cap for fuel tank 428550 6 Kit Side panel generator side hardware not included 428516 7 Kit Protective edge lining for cover panels and service panels 428558 8 Kit Top cover hardware not included 428519 9 Kit Cap for engine exhaust pipe 428499 Kit Freedom 38 PPA decal for side panel...

Страница 199: ...mponents Description Part number 1 Kit Primary filter for engine air cleaner Donaldson P827653 428503 2 Kit Safety filter for engine air cleaner Donaldson P829332 428504 3 Kit Deutz brand oil filter for engine Deutz 01174416 428613 4 Kit Deutz brand fuel filter for engine Deutz 01174482 428511 2 1 5 6 3 4 ...

Страница 200: ...t available from Deutz 05069139 Deutz part number 6 Kit Air compressor belt Gates Corporation 6846 428500 Description Part number 7 Kit Emergency air intake shutoff valve 428509 8 Kit Automatic voltage regulator AVR for generator alternator 480 VAC 428548 Description Part number 11 12 7 8 9 10 13 14 ...

Страница 201: ...10 Kit Circuit breaker 14 VDC 40 A 428577 11 Kit Electrical relay 12 VDC 40 A 428575 12 Kit Transformer 120 VAC 428549 13 Kit Battery cable positive 428522 14 Kit Battery cable negative 428521 Kit Service parts generator rectifiers 428486 Kit Fuel level sensor 428735 Description Part number ...

Страница 202: ... replaceable parts To replace the other wiring harnesses for the engine contact an authorized Deutz service dealer Figure 117 Description Part number 1 Kit Wiring harness for engine 428711 2 Kit Wiring harness for AC sensors 428712 3 Kit Wiring harness for control panel 428573 4 Kit Wiring harness for generator 428574 1 2 3 4 ...

Страница 203: ...Freedom 38 PPA Service Manual 809010 203 7 Parts Figure 118 Air compression system kits 2 3 4 8 7 12 13 14 1 15 10 16 6 11 7 5 9 ...

Страница 204: ...fler 428540 6 Kit Orifice adapter 428638 7 Kit Muffler 428547 8 Kit Air tank 428539 9 Kit Air compressor oil cooler 428532 10 Kit Air drying filter assembly for air compressor includes filter 428441 11 Kit Pressure relief valve 428581 12 Kit Air compressor manifold 428538 13 Kit Manifold relief valve for the air compressor 428543 14 Kit Oil level gauge for the air compressor includes washer 428542...

Страница 205: ...t Temperature switch for air compressor includes washer 428536 21 Kit Air compressor drive pulley tension 428524 22 Kit Air compressor drive pulley 428541 23 Kit Nut for air compressor pulley includes spacer 428580 24 Kit Adapter straight oil line 428738 25 Kit Adapter straight 428739 26 Kit Elbow fitting compressor output 428740 27 Kit Tee fitting temperature switch 428741 28 Kit Orifice scavenge...

Страница 206: ... PPA Service Manual 809010 7 Parts Figure 120 Description Part number 29 Kit Elbow fitting for air compressor 428554 30 Kit Elbow coupler for air compressor 428555 31 Kit Ball valve for air compressor 428553 29 30 31 ...

Страница 207: ... 4 Kit Air compressor hose from heat exchanger to air tank 428567 5 Kit Air compressor hose from air tank to water separation 428568 6 Kit Access air line hose 428569 7 Kit Air line hose for on board plasma cutting system 428570 8 Kit Check valve hose for air compressor 428571 9 Kit Pilot hose unloader 428572 428566 428567 428569 428570 428571 428572 428564 787 4 cm 31 00 in 428565 1117 6 cm 44 00...

Страница 208: ...208 Freedom 38 PPA Service Manual 809010 7 Parts Figure 122 Air compression hose locations 1 2 3 4 5 6 7 8 9 5 6 7 ...

Страница 209: ...rvice Manual 808290 Download the manual from www hypertherm com Part Number Description 059492 Duramax Hyamp 85 hand torch assembly with 7 6 m 25 foot lead 059493 Duramax Hyamp 85 hand torch assembly with 15 m 50 foot lead 059494 Duramax Hyamp 85 hand torch assembly with 23 m 75 foot lead 059495 Duramax Hyamp 15 hand torch assembly with 7 6 m 25 foot lead 059496 Duramax Hyamp 15 hand torch assembl...

Страница 210: ...amax Hyamp 180 full length machine torch assembly with 7 6 m 25 foot lead 059521 Duramax Hyamp 180 full length machine torch assembly with 10 7 m 35 foot lead 059522 Duramax Hyamp 180 full length machine torch assembly with 15 m 50 foot lead 059523 Duramax Hyamp 180 full length machine torch assembly with 23 m 75 foot lead 059514 Duramax Hyamp 180 mini machine torch assembly with 4 6 m 15 foot lea...

Страница 211: ...max Hyamp nozzle 65 A 220975 Duramax Hyamp nozzle 105 125 A 220971 Duramax Hyamp electrode 220997 Duramax Hyamp swirl ring Part Number Description 420112 Duramax Hyamp gouging shield for maximum removal standard 420509 Duramax Hyamp gouging shield for maximum control optional 220977 Duramax Hyamp retaining cap 420001 Duramax Hyamp gouging nozzle 220971 Duramax Hyamp electrode 220997 Duramax Hyamp ...

Страница 212: ...58 Duramax Hyamp nozzle 45 A 420169 Duramax Hyamp nozzle 65 A 220975 Duramax Hyamp nozzle 105 125 A 220971 Duramax Hyamp electrode 220997 Duramax Hyamp swirl ring Part Number Description 420112 Duramax Hyamp gouging shield 220977 Duramax Hyamp retaining cap 420001 Duramax Hyamp gouging nozzle 220971 Duramax Hyamp electrode 220997 Duramax Hyamp swirl ring Part Number Description 420152 Duramax Hyam...

Страница 213: ...6 m 25 feet 223296 Kit 125 A work lead with ring terminal 15 m 50 feet 223297 Kit 125 A work lead with ring terminal 23 m 75 feet 008539 Ground hand clamp 500 A 024548 Brown leather torch sheathing 7 6 m 25 foot 024877 Black leather torch sheathing with Hypertherm logo 7 6 m 25 foot 017053 Hyamp deluxe circle cutting guide 428348 Gouging heat shield for Duramax Hyamp torches 017031 Hyamp helmet fa...

Страница 214: ...214 Freedom 38 PPA Service Manual 809010 7 Parts ...

Страница 215: ...dom 38 PPA Service Manual 809010 215 Section 8 Wiring Diagrams This section contains the following wiring diagrams AC wiring diagram Freedom 38 PPA Hypertherm 12 VDC wiring diagram Freedom 38 PPA Hypertherm ...

Страница 216: ...216 Freedom 38 PPA Service Manual 809010 8 Wiring Diagrams ...

Страница 217: ...217 AC wiring diagram AC WIRING DIAGRAM FREEDOM 38 PPA HYPERTHERM ...

Страница 218: ...218 12 VDC wiring diagram 12VDC WIRING DIAGRAM FREEDOM 38 PPA HYPERTHERM ...

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