Job Packet / WeldKing / CoolArc160

Packet use

Use this packet when the incoming complaint involves low OCV, weak arc, fan slowdown, intermittent arc loss, or lift-TIG start trouble.
Primary guide: CoolArc160 guide
Bench sheet: CoolArc160 bench test
Brand references: WeldKing local reference manifest, WeldKing fault-branch matrix

Intake snapshot

Item	Record
Serial or shop tag
Exact complaint
Stick or lift-TIG in use
Input source and branch rating
Extension cord or adapter in use
Clamp and holder condition on arrival
Fan behavior on arrival
Prior repair or board history

Likely parts and accessories to stage

Item	Why stage it early
Known-good clamp and holder lead set	current-path faults still mimic board failure
Simple TIG torch and fresh tungsten	needed to prove lift-TIG branch after stick baseline
Fan branch repair materials or known-good fan path	fan slowdown and auxiliary-supply complaints are common
Basic meter leads and insulated probes	CN101 and fan-branch checks are central on this model

Official parts-entry shortcuts

Use these after the measurement path proves the complaint follows the external current path or TIG-kit branch.
Broad parts path: official CoolArc160 parts category
TIG welding kit 07003650: official product page
Heavy-duty ground clamp 07000461: official product page
Heavy-duty electrode holder 07000460: official product page

First branch decisions

If you see...	Stay in this branch first
OCV around 30 V with healthy bus	capacitor-board branch
Low OCV with healthy high-voltage bus	capacitor-board branch
No OCV with healthy bus	inverter-board branch
Fan slows and arc dies	auxiliary-supply or capacitor-board branch
Lift-TIG tungsten sticking	start-current, control, or calibration-sensitive branch

Local files to open first

assets/reference_doc/WeldKing/CoolArc160/COOLARC160_Test_instruction.pdf
workbook sheet CoolArc160 in assets/reference_doc/all_models/troubleshoot_notes.xlsx
assets/reference_doc/WeldKing/CoolArc160/CoolArc160manual_web.pdf

Bench workflow

Capture branch power, clamp condition, and fan behavior before opening the case.
Run the electrical checkpoints in CoolArc160 bench test.
Prove a simple stick baseline first and separate low OCV from no OCV before deeper repair.
Only after stick passes, prove lift-TIG if the complaint or package requires it.

Release signoff

Check	Result
Stick baseline restored	pass / fail
Lift-TIG branch restored if required	pass / fail
Fan remains stable through warm test	pass / fail
No abnormal heat at plug, clamp, or holder	pass / fail
Covers, grounds, and lead routing restored	pass / fail

Technician: __________ Date: __________