Job Packet / WeldKing / CoolCut40air

Packet use

Use this packet when the complaint involves internal-air-only failure, both air paths moving together, moisture-related cut problems, or no start in one mode only.
Primary guide: CoolCut40air guide
Bench sheet: CoolCut40air bench test
Brand references: WeldKing local reference manifest, WeldKing fault-branch matrix

Intake snapshot

Item	Record
Serial or shop tag
Exact complaint
Internal mode, external mode, or both affected
Water-trap condition on arrival
Torch front-end condition
Clamp placement on arrival
Any dual-air or rear-inlet flow observed

Likely parts and accessories to stage

Item	Why stage it early
Fresh SG55 front-end stack	fastest way to remove torch-side false faults
Dry external air source	needed to separate internal-air package faults from base plasma faults
Known-good clamp and clean steel coupon	transfer complaints stay return-path heavy
Meter and insulated probes	needed when valve or compressor-control proving is required

Official parts-entry shortcuts

Use these after the diagnosis proves the fault follows the torch front end or air package branch.
Broad parts path: official CoolCut40air parts category
SG55 electrode 07Y2517003: official product page
SG55 nozzle 07Y2517004: official product page
SG55 tip 07Y2517005: use the official parts category above.

First branch decisions

If you see...	Stay in this branch first
Complaint exists only in internal mode	compressor or internal-valve branch
Both air paths move together	external solenoid or control branch
Complaint exists only in external mode	hose and external-air branch
Backward purge restores one-air-path behavior	contamination or stuck-valve branch
Moisture or sputter signs	filter, water-trap, and front-end branch

Local files to open first

assets/reference_doc/WeldKing/CoolCut40air/CC40AIR_DIAGRAM.tif
assets/reference_doc/WeldKing/CoolCut40air/W.496RM.410-C.pdf
assets/reference_doc/WeldKing/CoolCut40air/W.496RM.417-A.pdf
workbook sheet coolcut40air in assets/reference_doc/all_models/troubleshoot_notes.xlsx

Bench workflow

Normalize torch stack, clamp, and both air modes.
Run CoolCut40air bench test.
Keep internal-mode and external-mode symptoms separated, and note whether both air paths ever move together.
Warm retest after correction to catch moisture, dual-air, or valve drift.

Release signoff

Check	Result
Internal-air mode restored	pass / fail
External-air mode restored if used	pass / fail
Stable start and cut restored	pass / fail
No dual-air or contamination symptom remains	pass / fail
Covers, grounds, and lead routing restored	pass / fail

Technician: __________ Date: __________