KickingHorse Fault-Branch Matrix

This matrix groups recurring KickingHorse failures by subsystem so technicians can jump straight to the right branch before they over-diagnose a small machine as a full power-source failure.

How to Use This Matrix

Start here when the complaint is clear but the failing subsystem is not.
Open the listed model guides first because they hold the strongest workbook-backed logic for that branch.
Use the listed local references after the guide has narrowed the failure path.

Branch Matrix

Subsystem branch	Recurring symptoms	Strongest models to open first	Best local references	Prove before escalation
Utility path, branch quality, and current return	weak arc, bad arc blow, hard start with normal OCV, machine acts better on another outlet, plug or clamp heating	A100, A220, MA200TS	workbook sheets `A100`, `A220`, and `MA200TS`, plus owner manuals for fitted input expectations	for `A100`, prove real `120 V / 20 A` or a healthy `3 kW` generator path first; for `A220`, prove real `208/230 V` and ideally `50 A` or a healthy `5 kW` generator path first; then prove clamp bite, hot current-path hardware, and correct `DCEN / DCEP` before internal repair; then move into the A100 router or A220 router
Support power, startup collapse, and fan-related branch	one-second power-up then shutdown, blinking power light, fan oddities, machine wakes and collapses	A100, MA200TS, P40	`MA200TS_Service_manual.pdf`, `B.067RM.419-C_main.pdf`, workbook sheets `A100`, `MA200TS`, and `P40`	wall outlet quality, switch path, fan branch, and support supply before condemning the main inverter; then move into the A100 board opening map when the complaint stays internal
Display, control, and feedback branch	display pegged at max, wrong A or V reading, strange panel behavior, feed and display faults together, process button trouble	M185, MA200TS	`MA200TS_Service_manual.pdf`, local `MA200TS` panel photos, workbook sheets `M185` and `MA200TS`	whether welding still works with bad display, whether preset-versus-actual display behavior is wrong, and whether the fault follows the display or feedback branch rather than the power stage
Wire-feed, trigger, and torch-front-end branch	no wire feed, wire feeds at power-up, poor arc at higher wire-speed settings, breaker trip, front-end misassembly, birdnest	F130, M185, MA200TS	`B.067RM.600-C.pdf`, `B.067RM.601-D.pdf`, local MIG workbook sheets, and multiprocess service notes	bare-wire feed with tip removed, trigger path, drive pressure, correct torch-front-end assembly, and for `F130` the correct `0.035 in` baseline or proper `0.030 in` conversion
MIG-only versus shared power-source branch	stick works but MIG does not, one process healthy while another is dead, shared machine blamed too early	MA200TS, M185, F130	workbook sheets `MA200TS`, `M185`, and `F130`	one healthy baseline process first, then retest the failing branch; for `M185` prove real `208/230 V` source and sane inductance first, and for `F130` prove real `120 V / 20 A` or `3 kW` source first
Plasma HF, control, and torch-stack branch	no HF, HF but no OCV, air but no cut, pilot without transfer, fan-voltage drift, blocked orifice	P40	`B.067RM.418-C_HF.pdf`, `B.067RM.410-C_control.pdf`, `B.067RM.419-C_main.pdf`, `P40_parts_breakdown.pdf`, and local P40 reference images	`1.5 mm` HF gap, `24 V` support to HF board, fresh SG55 stack, clean clamp, and dry air under flow
Package, accessory, and kit branch	aluminum complaints on multiprocess unit, TIG branch weirdness, wrong package installed, post-service fitment problems	MA200TS, P40, A220	`P40_parts_breakdown.pdf`, local multiprocess workbook sheets, and the `A220` workbook sheet	exact fitted kit, torch, clamp, lead, and regulator package before electronics diagnosis; for `A100` and `A220`, stop if the complaint is really improvised TIG use because that is not a supported process path

Fast Starting Points

If the complaint sounds like...	Start here
`A100` weak arc or collapse that changes with outlet, clamp, or polarity	utility path, branch quality, and current return
`A220` top-end weakness or bad arc blow that changes with source, clamp, or polarity	utility path, branch quality, and current return
unstable stick output that changes with outlet or clamp quality	utility path, branch quality, and current return
powers up for a second then dies, or blinks strangely	support power, startup collapse, and fan-related branch
wire feed and display are both wrong	display, control, and feedback branch
feed problem with odd torch or front-end behavior	wire-feed, trigger, and torch-front-end branch
compact MIG only works on one outlet or after changing wire size	MIG-only versus shared power-source branch
one process works and another does not	MIG-only versus shared power-source branch
plasma has air or HF but still will not cut	plasma HF, control, and torch-stack branch

Notes

KickingHorse has fewer models, but the local workbook notes make branch-level diagnosis unusually strong on MA200TS and P40.
A100 and A220 are straightforward machines, which makes current-path and branch-power proof even more important before internal escalation.
A100 should not be treated as internal until a real 120 V / 20 A or healthy 3 kW path, correct DCEN / DCEP, and a supported stick baseline are proven.
A220 should not be treated as internal until real 208/230 V, ideally 50 A or healthy 5 kW, correct DCEN / DCEP, and a supported stick baseline are proven.
A100 and A220 improvised TIG complaints are not valid evidence against the machines because that process is not supported.
F130 and M185 now have stronger brand-level routing for wire-size baseline, source quality, display behavior, and inductance, so the MIG family no longer has to fall back to generic compact-MIG assumptions.
A100 and A220 now have dedicated measurement cards, job packets, opening maps, and routers, so the arc family can be run through the same fast technician workflow as the MIG, multiprocess, and plasma models.