P40 No-Cut Live Case

Case Setup

• Model: P40
• Incoming complaint: "Air comes on, but it won’t really cut."
• Arrival condition: machine arrives with a worn torch front end, mixed consumables in a bag, and no record of air-source quality
• Hidden trap: the trainee must not collapse no-cut, weak-HF, and air-only complaints into one internal diagnosis

Trainer Prompt

Use this intake statement:

"Customer says it still blows air and sometimes sparks a little, but it won’t cut cleanly anymore. They’re asking if the plasma board is gone."

Only reveal these if the trainee asks:

• the torch tip and electrode are heavily worn
• the air source was a small portable compressor on the last job
• the customer never checked consumable stack order

Allowed Document Flow

1. P40 fault workflow router
2. P40 measurement card
3. P40 parts substitution card
4. P40 board opening map only if the torch stack and support path are bounded
5. P40 guide

Trainer Injects

• If the trainee skips the torch stack, reveal that the consumables were mixed from another box.
• If the trainee asks about air quality, reveal the compressor was small and water management is unknown.
• If the trainee jumps to internal HF failure, ask what has been proved about the external torch and air path.

Pass Markers

• separates no-cut, weak-HF, and air-only complaints into distinct branches
• proves torch stack, consumables, and air path before internal escalation
• checks support-voltage or start-path reasoning in the correct order
• stops at the correct point before opening the machine

Automatic Fail Conditions

• assumes no-cut equals failed HF or main power section
• ignores mixed consumables or torch-front-end condition
• skips the air path and compressor story

Debrief Focus

• plasma complaints punish sloppy complaint classification
• the torch stack and air path stay cheap to prove and expensive to ignore
• the best trainees separate branches before they chase parts

Companion Docs

• KickingHorse certification checkoff
• KickingHorse training progression
• P40 guide