This document is a quick and dirty write up of how to install the Cougar Revitalize Kit sensors.
In this document we presume you know how to work your way around the TM Cougar.

 

WARNING

1. Before you start working on the TM Cougar:
   UNPLUG the HOTAS from your computer… seriously UNPLUG it.
   
   
2. NEVER connect a TQS sensor to the stick or a stick sensor to the TQS.
   If somehow this is the case you won’t damage the TM Cougar electronics but the CRK sensor will be damaged and unusable, so make sure you use the correct sensor when installing the CRK!

Notes

1. In some series of the TM Cougar, the TQS D-slot in the physical throttle axis is a fraction too wide. The magnet holders are designed using the default measurements of the potentiometer.  If your TM Cougar TQS has a bigger D-slot just apply a layer or two of Scotch tape around the stem of the magnet holder. This way it will fit tightly into the D-slot.
   
   
   
2. In the lower production series on the TQS PCB there is an additional resistor in the power supply trace to the pot connector. Once the throttle sensor is placed it won’t work. This can be resolved by shorting R1 on the PCB. (See picture below) 
   * This is not defect in the CRK setup, it is just the way TM constructed the earlier versions of the TM Cougar PCB.

Installation Guide

TQS

1. Disconnect the DB-connector from the Cougar stick base, and unscrew the eight screws on the bottom. There are four longer screws holding the middle and four shorter screws that hold each corner. Take out all the screws , then the bottom cover can be removed.
   
   
2. Now you have access to the potentiometer, disconnect the cable from the PCB.  Pull the potentiometer and the thick black physical axis out of their sockets. Remove the potentiometer.  Do not throw it away.  Store it somewhere safe just in case.
   
   
3. Place the magnet in the D-slot. You might need to wiggle it in place a bit cause it is a tight fit. Push it all the way in until the square surface touches the physical axis.
   
   
4. Place the sensor in the aluminium place holder push it all the way down.
   
   
5. Reattach the connector to its receptacle on the PCB and screw the lid down in place.
   

STICK

1. Unscrew the four bolt receptacles of the DB-connectors.
   
   
2. Turn the stick upside down and remove the four screws on the bottom and remove the bottom cover.
   
   
3. Now that you have access to the stick internals,  unscrew the four bolts from the PCB. Note: At one corner  there is a ground wire is attached to the screw. You need to place it back when you reassemble the TM Cougar Stick.
   
   
4. Turn the PCB over and disconnect the two potentiometer connectors.
   
   
5. Unscrew the pots and remove them
   (again don’t throw them away, store them somewhere).
   
   
6. In the stick package there are two sensor sets.
   One magnet’s color differs from the rest of the set.
   Place this magnet in the X-axis slot *.
   Place the other magnet in the Y-axis slot.
   
   * This is important because the magnetic direction needs to be different.
   It has been designed this way so you do not need to inverts axis in the cougar control panel.
   If you don’t take this step, you need to invert the x-axis in the cougar control panel.
   
   
7. Place the sensors in position and screw them down.
   
   
8. Connect the wires to the receptacles on the PCB and screw the PCB and the ground wire back in place.
   
   
9. Place the bottom cover and screw it down.
   
   
10. Reinstall the DB-connector receptacle screws. 
    
    

Job done!

 

Calibrating

1. Connect the TQS back on the stick and plug in the USB cable.
   
   
2. Open up the Cougar control panel and go to the start-up & calibration tab.
   
   
3. In the calibration option thick the manual calibration checkbox and click the “manual calibration” button.
   
   
4. Follow the calibration steps.
   
   
5. Save the calibration.
   
   
6. Open up the viewer and check if everything works as it should.

 

Congratulations!

You have upgraded your TM Cougar HOTAS with hall-effect sensors.
Now it is time to kick the tires and light the fires!!