Job Packet / WeldKing / CoolCut30

Packet use

Use this packet when the complaint involves no HF, high or low OCV split, pilot with no transfer, self-switching, or fan or 24 V instability.
Primary guide: CoolCut30 guide
Bench sheet: CoolCut30 bench test
Brand references: WeldKing local reference manifest, WeldKing fault-branch matrix

Intake snapshot

Item	Record
Serial or shop tag
Exact complaint
No start, no HF, pilot-only, or no-transfer complaint
Air source and pressure-under-flow state
Clamp placement on arrival
Torch front-end condition
Fan and 24 V indicator behavior

Likely parts and accessories to stage

Item	Why stage it early
Fresh SG55 front-end stack	fastest way to remove front-end false faults
Known-good clamp and clean steel coupon	transfer complaints stay return-path heavy
Dry air source	wet air creates repeated false machine faults
Meter and insulated probes	needed for 24 V, fan, and OCV branch checks

Official parts-entry shortcuts

Use these after the diagnosis proves the fault follows the torch front end or air branch.
Broad parts path: official CoolCut30 parts category
SG55 electrode 07Y2517003: official product page
SG55 tip 07Y2517005: official product page
SG55 nozzle 07Y2517004: official product page

First branch decisions

If you see...	Stay in this branch first
No HF with high OCV	relay or capacitor-board branch
No HF with lower OCV	upper-board or inverter branch
Green 24 V light drops or fan collapses	support-power branch
Pilot but no transfer	torch front-end, clamp, and air branch
Fan or 24 V instability	support-power branch

Local files to open first

assets/reference_doc/WeldKing/CoolCut30/CoolCut30_service_manual.pdf
assets/reference_doc/WeldKing/CoolCut30/COOLCUT30 AND STICK160.doc
workbook sheet CoolCut30 in assets/reference_doc/all_models/troubleshoot_notes.xlsx

Bench workflow

Normalize the SG55 torch stack, dry air, and clamp before opening the case.
Run CoolCut30 bench test.
Keep no-HF and no-transfer complaints separated, and record whether OCV is high, low, or absent.
Warm retest after correction to catch support drift or green-24 V collapse.

Release signoff

Check	Result
Green 24 V indicator remains stable	pass / fail
Stable start restored	pass / fail
Stable transfer restored	pass / fail
Short cut completed cleanly	pass / fail
Covers, grounds, and lead routing restored	pass / fail

Technician: __________ Date: __________