Service Manual 0-2717
19
COUGAR 125 Plasma Cutter
4.11 Resistor Replacement
NOTE
The COUGAR 125 has two Resistors. The top Re-
sistor is 1K ohm and the bottom Resistor is .5 ohm.
These parts are not interchangeable. Be sure to or-
der the correct replacement part. To replace the bot-
tom Resistor, the top Resistor must be removed first.
1. Remove cover/handle from unit per subsection 4.2.
2. Note all wire connections and locations to the
Resistor(s).
3. Disconnect al l wiring connections to the Resistor(s).
4. Remove two nuts and washers securing Resistor to
chassis.
5. Remove Resistor(s).
6. Install replacement Resistor(s) by reversing steps 1-
5, noting the following:
a. The top Resistor is 1K ohm and the bottom Re-
sistor is .5 ohm.
b. Tighten screws securely.
4.12 Transformer/Ferrite Core
Assembly Replacement
WARNINGS
Disconnect primary power at source before assem-
bling or disassembling the power supply.
1. Remove cover/handle from unit per subsection 4.2.
2. Wire connections are as follows:
Connector
Location
L1
E6 on PCB
L2
E1 on PCB
L3
E2 on PCB
L4
Brass Torch
Lead Fitting
3. Disconnect wire connections. Pull L4 connector
through loose tie wrap if available.
4. Remove two Ferrite Core Assembly screws which
hold the Transformer/Ferrite Core Assembly in
position. Remove Transformer/Ferrite Core As-
sembly from unit.
5. Install replacement Transformer/Ferrite Core As-
sembly by reversing steps 1-4, keeping in mind the
following:
a. Pull L4 through loose tie wrap if available.
b. Position wire connector L4 so that it runs along
side the Transformer, NOT across the top of the
Transformer or near any metal parts.
4.13 Input Voltage Changeover
(For 208/230 VAC Service
Only)
All 208/230 VAC units are factory set for 230 VAC. To
switch to 208VAC input power operation, complete the
following:
WARNINGS
Do not touch live electrical parts.
Disconnect primary power at source before assem-
bling or disassembling the power supply, torch
parts or torch and leads assemblies.
1. Remove cover/handle from unit per subsection 4.2.
2. Locate the wiring on the end of the Capacitor.
3. Remove tie wrap and orange sleeving from wire
#208VAC.
4. Remove wire #230VAC from Capacitor and replace
with wire #208VAC.
5. Slide orange sleeving over wire #230VAC, fold over
and secure with a tie wrap.
WARNING
Do not leave other input wire unprotected inside
unit.
6. Replace cover.
