COUGAR 125 Plasma Cutter
16
Service Manual 0-2717
To Install Replacement Torch Head Assembly:
NOTE
Refer to Figure 4-2 for parts identification.
1. Place replacement torch head in torch head split
holder halves and secure with 2 screws removed
in step 9 above (K). Do not disturb PIP connec-
tions.
2. Install O-ring removed in step 8 above (L).
3. Optional: Install orange sleeving on replacement
torch head gas input.
4. Place torch head in correct orientation, then insert
lead cable into torch butt slice and crimp (M).
5. Remove vise grips.
6. Lubricate torch head glands lightly with silicone
and push hose back onto barbs up to the point
where the teflon tubing and brass fitting meet (N).
7. Install tie wrap onto hose in correct position (C),
removing any excess.
8. Connect pilot lead to pilot lead terminal by placing
washer between terminal and connector and in-
stalling screw (O).
9. Push pilot lead under cable jacket until there is no
excess.
Install Pilot
Lead Screw
Butt Splice
Insert Cable Into
Butt Splice & Crimp
Install
O-Ring
Install Screws
New Torch Head
J
K
M
N
Teflon Tubing
A-02296
L
O
Washer
4-2 Installing Torch Head Assembly
4.4 Torch Switch Only
Replacement
NOTE
This procedure requires the following tools (or
equivalent): screwdriver, soldering iron, flux.
WARNING
Disconnect primary power to the system before dis-
assembling the torch, leads, or power supply.
1. Remove consumable parts from front end of torch.
2. Remove the six screws from the torch handle as-
sembly and remove torch and leads assembly.
3. Using soldering iron, carefully remove solder where
orange wire connects to switch terminal.
NOTE
Be careful not to overheat the torch switch while
removing soldering from terminals.
4. Apply Flux to orange wire and to switch post. In-
sert orange wire in switch post hole and solder,
keeping solder at a minimum required for good
joint.
5. Repeat steps 3 and 4, this time for the white wire.
Torch Switch
PIP Pin
PIP Pin
Shield Cup
To Control
Cable Wiring
Butt Splice
A-00784
Figure 4-3 Torch Switch Schematic
6. Place the torch head in the torch handle bottom.
Carefully return the torch switch and button w/
springs to their proper position. Replace cover on
the handle assembly, and screw together with six
screws.
NOTE
Make sure torch switch wires are seated in their
guides so that the wires are not pinched when the
handle is secured.
7. Install consumables parts in front end of torch.
