Job Packet / WeldKing / MAG255

Packet use

Use this packet when the complaint involves crater-fill oddities, wire creep after stop, sparks at the wire tip without trigger, or spool-gun-only no-weld.
Primary guide: MAG255 guide
Bench sheet: MAG255 bench test
Brand references: WeldKing local reference manifest, WeldKing fault-branch matrix

Intake snapshot

Item	Record
Serial or shop tag
Exact complaint
Wire type and size as found
Base gun or spool gun in use
Crater-fill behavior as found
Sparks at wire tip without trigger
Arc quality on first short weld

Likely parts and accessories to stage

Item	Why stage it early
Known-good plain-steel MIG gun and consumables	removes front-end false faults quickly
Known-good clamp and lead set	current-path trouble still mimics machine faults
Spool gun and matching drive roll only if complaint requires it	keeps aluminum-only faults separate
Meter and probes	needed for pins `1` and `9`, discharge-path, and stop-behavior proving

Official parts-entry shortcuts

Use these after the bench evidence proves the complaint follows an external gun, spool-gun, or drive-roll branch.
Broad parts path: official MAG255 parts category
SpoolKing24D spool gun 07NS1000: official product page
U-groove aluminum drive roll 07000302: official product page

First branch decisions

If you see...	Stay in this branch first
Wire creeps after stop	crater-fill branch
Sparks at wire tip without trigger	discharge-path resistor branch
Base gun healthy but spool gun dead	pins `1` and `9`, spool-gun, and drive-roll branch
Rough arc after long service	capacitor-aging or shared power branch
Intermittent feed surge remains	documented PCB or control branch

Local files to open first

assets/reference_doc/WeldKing/MAG255/Mag255_disable_craterfill.pdf
assets/reference_doc/WeldKing/MAG255/mag255manual.pdf
workbook sheet MAG255 in assets/reference_doc/all_models/troubleshoot_notes.xlsx

Bench workflow

Capture crater-fill behavior and whether the complaint follows the base gun or spool gun before opening the machine.
Run MAG255 bench test.
Prove one chart-correct plain-steel base-gun baseline first.
Retest the original branch only after stop behavior and wire-tip safety are healthy.

Release signoff

Check	Result
Base MIG baseline restored	pass / fail
Stop behavior restored	pass / fail
Wire tip stays quiet with no trigger	pass / fail
Spool-gun branch restored if required	pass / fail
No abnormal run-on, discharge, or breaker trip after power cycle	pass / fail
Covers, grounds, and lead routing restored	pass / fail

Technician: __________ Date: __________