Service Manual 0-2717
17
COUGAR 125 Plasma Cutter
4.5 Capacitor Replacement
WARNING
Disconnect primary power to the system before dis-
assembling the torch, leads, or power supply.
1. Remove cover/handle from unit per subsection 4.2.
2. Make note of all wire connections and locations to
Capacitor.
3. Remove all wire connections to Capacitor.
4. The Capacitor is held in place by a tab located on
the Transformer frame. Using a screw driver or
similar tool, pry the tab back slightly to allow the
Capacitor to slide out of the bracket.
5. Install replacement Capacitor, by reversing steps
1-4, keeping in mind the following:
a. Make sure the Capacitor is securely positioned
behind tab. Tab may need to be bent.
b. Position wire connector L4 so that it runs along
side the Transformer, avoiding contact with
metal parts.
4.6 Control PC Board
Replacement
NOTES
It may be easier to remove the PC Board if the Ca-
pacitor is removed first.
WARNING
Disconnect primary power to the system before dis-
assembling the torch, leads, or power supply.
1. Remove cover/handle from unit per subsection 4.2.
2. (Optional) Remove Capacitor per subsection 4.6.
3. Note all wiring connections and locations to the
PC Board.
4. Disconnect all wire connections to the PC Board,
removing any tie wraps where necessary.
5. Remove PC Board from unit by completing the fol-
lowing:
a. Remove two (2) fastener plastic push ons from
key slotted holes in corners of PC Board.
b. Slide PC Board up or down to disengage, then
remove from unit.
6. Install replacement key slotted PC Board by plac-
ing PC Board over standoffs and sliding Board
down into position.
7. Push a white fastener plastic push on into each
keyhole (just above standoffs) to secure the PC
Board into position.
8. Reverse steps 1-4, keeping in mind the following:
a. Make sure J2 is not offset by one or more pins.
b. Install new tie wraps on wires connected to the
PC Board, as necessary.
4.7 Power Relay Replacement
NOTE
The Control PC Board must be moved out of the
way before the Power Relay can be replaced. (It may
be easier to move the Contrl PC Board if the Ca-
pacitor is removed first.)
WARNING
Disconnect primary power to the system before dis-
assembling the torch, leads, or power supply.
1. Remove cover/handle from unit per subsection 4.2.
2. (Optional) Remove Capacitor per instructions in
4.5.
3. Remove PCB from standoffs per subsection 4.6.
4. Slide PC Board away from Relay.
5. Note all wiring connections and locations to the
Relay.
6. Remove wirings connected to Relay.
7. Slide Relay out from bracket, towards the center of
the unit.
8. Install replacement Relay, by reversing the above
steps, keeping in mind the following:
a. Position wire connector L4 so that it runs along
side the Transformer, NOT across the top of the
Transformer.
