COUGAR 125 Plasma Cutter
20
Service Manual 0-2717
4.14 Torch & Leads
Replacement
1. Remove cover/handle from unit per subsection 4.2.
2. Disconnect the following (refer to Figure 4-4):
• Faston Connector (to CD Coil) from the Brass
Torch Lead Fitting
• Brass Torch Lead Fitting from the 90 degree White
Nylon Fitting.
• 2-pin Connectors.
• Torch Lead Faston Connector (red) from bottom
Resistor.
3. Loosen the Strain Relief Nut from the Strain Relief
and remove Torch Lead Assembly from unit.
4. Install Strain Relief on replacement torch.
5. Insert Torch leads through front hole on unit.
6. Slide Strain Relief Nut over the end of the torch lead.
7. Allow one inch clearance between the end of the
torch lead sheath and the hole in the front panel
then tighten the Strain Relief Nut. (This allows al-
low enough length in the torch lead to make all the
connections inside the unit.)
8. Reconnect all connections by reversing step 2.
9. Replace cover by reversing step 1.
4.15 Work Cable Replacement
1. Remove cover/handle from unit per subsection
4.2.
2. Disconnect the Work Cable Faston from mount-
ing tab on bottom of Rectifier.
3. Loosen Strain Relief and remove Work Cable from
unit.
4. Install Strain Relief on replacement Work Cable 5
1/2 inches from Faston.
5. Install replacement Work Cable by reversing steps
1-3.
Work Cable
Strain Relief
(Install 5 1/2" from Faston)
A-02011
Work Cable Faston
(Connect to mounting
tab at bottom of Rectifier)
Bridge
Rectifier
Figure 4-5 Work Cable Replacement
Torch Leads Assembly
Strain Relief Nut
Strain Relief
1" Clearance
Strain
Relief
Torch Lead Faston Connector (Red)
(Connect to Bottom Resistor)
2-Pin Connectors
Torch
Lead
Faston Connector
to CD Coil
90˚White
Nylon Fitting
Brass Torch
Lead Fitting
A-02009
Nylon Nut
Front Panel
Hole Location
Note: Do not remove strain relief from torch lead.
Figure 4-4 Torch & Leads Replacement
