Service Manual 0-2717
15
COUGAR 125 Plasma Cutter
WARNINGS
Disconnect primary power to the system before dis-
assembling the torch, leads, or power supply.
4.2 Removing Cover/Handle
1. Remove 2 screws in handle, 2 screws in end pan-
els, and four screws near base to remove cover and
handle from unit.
NOTE
When replacing cover, make sure all wires are care-
fully positioned so that the wires are not pinched
when the cover and handle are secured.
4.3 Torch Head Assembly
Replacement
WARNINGS
Disconnect primary power to the system before dis-
assembling the torch or power supply.
Torch parts may get quite hot during normal op-
eration. Always wear light cutting gloves when
changing torch parts just after operating the COU-
GAR 125 system.
To Remove Torch Head Assembly:
NOTE
Refer to Figure 4-1 for parts identification.
1. Remove consumable parts from front end of torch.
2. Remove six screws from torch handle assembly (A).
3. Remove both torch handle halves from the torch
and leads assembly , then complete the following:
a. Disconnect positive pilot lead connection at
torch head by removing pilot lead screw (B).
b. Cut tie wrap from torch hose (C).
c. Using X-acto knife or other small cutting tool,
cut torch lead 1" (25.4 mm) from the end of
black sleeve (D) to reveal butt splice.
4. Pull torch head away from torch lead to expose 1/
2"-3/4" of cable.
5. Clamp down with vise grips on black sleeve of
lead so that cable cannot spring back into lead (E).
6. Cut cable at end of butt splice and remove torch
head assembly (F).
7. Remove orange insulating sleeving from torch head
gas input (G). Note: Sleeving is optional. Some
torch assemblies may not have sleeving.
8. Remove torch O-ring from torch split holder (H).
9. Remove the two screws from the torch head split
holder and separate the halves (I).
10. Remove the torch head from the holder. Do not
disturb PIP connections.
1.000
O-Ring
Remove Screws
Orange Torch
Sleeving
(Optional)
Cut Cable Here
Place Vise
Grips Here
Remove Pilot
Lead Screw
Cut Black
Hose
Cut Tie Wrap
Remove Six Screws
Switch
A
B
C
D
E
F
G
H
I
A-02295
Washer
Figure 4-1 Removing Torch HeadAssembly
