COUGAR 125 Plasma Cutter
18
Service Manual 0-2717
4.8 ON/OFF Power Switch
Replacement
NOTE
When ordering a replacement ON/OFF Switch, or-
der the same type as found in your unit. (Color is
not important.)
Model
Switch
Type
Dimensions
Neon
Color
Voltage
Catalog
Number
A
4 prong
1"x1-1/4"
red
115
9-0021
B
4 prong
1"x1-1/4"
amber
or red
220
9-0029
WARNING
Disconnect primary power to the system before dis-
assembling the torch, leads, or power supply.
A. Model A:
1. Remove cover/handle from unit per subsection 4.2.
2. Note all wiring connections and locations to the
On/Off Switch.
3. Disconnect wires to ON/OFF Switch.
4. Push plastic clips down on top side of Switch and
slide Switch out by pulling it through front panel.
5. Install replacement ON/OFF Switch, by reversing
steps 1-4, 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.
B. Model B:
1. Remove cover/handle from unit per subsection 4.2.
2. Disconnect wires to ON/OFF Switch.
3. Push plastic clips down on top end of Switch and
slide Switch out through front panel.
4. Check the numbering sequence of the prongs on the
ON/OFF Switch and install the switch as follows:
a. 1,2,4,5 - Install switch with prongs positioned
towards the bottom of unit.
b. 11,12,24,25 - Install switch with prongs posi-
tioned towards the top of the unit.
5. To connect the input wiring to the ON/OFF Switch
refer to subsection 4.16, steps 6-7.
6. Install cover/handle by reversing step 1, keeping in
mind the following:
NOTE
Before replacing cover, make sure all wires are care-
fully positioned to avoid pinching when the cover
and handle are secured.
4.9 Fan Replacement
1. Remove cover/handle from unit per subsection 4.2.
2. Locate Fan on front panel of unit.
3. For reference, mark two wires connected to the right
side of the Fan with correct connection designa-
tion, then disconnect two wires.
4. Remove two (2) rivets* securing Fan to the front
panel and carefully remove Fan from unit. (Gauge
Assembly may have to be rotated slightly in order
to remove Fan).
NOTE
*Some models may use screws instead of rivets.
5. Install replacement Fan. Refer to Figure 5.1 for
proper Fan orientation (or refer to the arrows marked
on the Fan chassis).
NOTE
Proper Fan orientation is essential to ensure proper
cooling of power supply parts.
4.10 Diode Bridge Rectifier
Replacement
NOTE
Refer to subsection 4.1, General Information, for
information about wire harnesses.
1. Remove cover/handle from unit per subsection 4.2.
2. Note all wire connections and locations to the Di-
ode Bridge Rectifier.
3. Disconnect wires to the Diode(s), and remove Di-
ode from unit.
4. Install replacement Diode, by reversing steps 1-3
above, noting the following:
a. Diode should be oriented with plus sign (+)
down and to the right.
