KickingHorse Service Workflow Bundle

This is the print-ready KickingHorse shop workflow bundle. Use it when the machine is in the KickingHorse family and you want one packet to route the job from intake to release.

Routing order

1. Start with KickingHorse brand index.
2. Use KickingHorse service triage dashboard for the first complaint-to-model split.
3. Use KickingHorse fault-branch matrix if the subsystem is not yet clear.
4. Open KickingHorse local reference manifest when you need the exact local file.
5. Move to the matching packet in KickingHorse job packet pack.
6. Run the matching sheet in KickingHorse bench test pack.

Highest-value model routing

Arc-specific workflow rules

• A100: prove a real 120 V / 20 A branch first, or a healthy 3 kW non-inverter generator path, before treating weak output, hard starts, or collapse as internal failure.
• A100: prove correct DCEN / DCEP lead placement for the actual rod test before swapping boards, leads, or controls.
• A100: prove a supported stick baseline with clean steel and 3/32 in 7018 or 6010/6011 before any internal escalation.
• A100: if the complaint only exists on an improvised TIG setup, stop there because that is not a supported process path for this machine.
• A220: prove a real 208/230 V source first and use an ideally 50 A branch or healthy 5 kW generator path before treating top-end weakness as internal failure.
• A220: prove correct DCEN / DCEP lead placement and a healthy current path before treating spatter, bad arc blow, or weak rod behavior as inverter failure.
• A220: prove a supported stick baseline with clean steel and 7018 or 6010/6011 before opening the machine.
• A220: if the complaint only exists on an improvised TIG setup, stop there because that is not a supported process path for this machine.

MIG-specific workflow rules

• F130: return the machine to factory 0.035 in flux-core baseline first, or prove a proper 0.030 in conversion before any deeper teardown.
• F130: do not treat 0.023 in wire, DCEP wire expectations, a weak branch, or a non-compliant extension-cord path as internal evidence.
• M185: prove a real 208/230 V source first, and respect the manual 40 A normal or 50 A time-delay breaker guidance for rated-output proof.
• M185: reset inductance to a sane baseline and confirm preset-versus-actual display behavior before treating the display PCB as the lead suspect.

MA200TS and P40 workflow rules

• MA200TS: prove one healthy baseline process first, then retest the failing process so a MIG-only or TIG-only complaint does not get misread as a whole-machine failure.
• MA200TS: if the unit powers up for one second and shuts down, keep wall-power quality, switch path, support-power board behavior, and loose motor or feedback wiring in play before main-inverter blame.
• MA200TS: if one process is healthy, keep the diagnosis in process state, accessory path, polarity, feedback cable, or process-button branch first.
• P40: prove dry air under flow, about 65 psi / 4.5 bar minimum, a fresh SG55 front-end stack, and clean clamp placement before any control-board or HF-board call.
• P40: verify the HF gap at about 1.5 mm, confirm the HF board sees about 24 VDC, and check OCV only at the correct machine-output point with the HF wire unplugged.

Official Parts Exit Shortcuts

• If the workflow proves the complaint is external, stop before internal repair and move into the matching official parts path.
• A100: only after correct polarity and a supported stick baseline are proven, use accessories path, ground clamp 07000461, holder 07000460
• A220: only after correct polarity and a supported stick baseline are proven, use accessories path, ground clamp 07000461, holder 07000460
• F130: accessories path, contact tip KOM32135, product page
• MA200TS: accessories path, aluminum kit XOM99035, product page
• M185: product page, torch KAM31003, contact tip KOM32135
• P40: accessories path, electrode 07Y2517003, owner manual

Stop Before Internal Repair When

• branch power, clamp, holder, torch stack, consumables, gas path, or optional kit proof changes the complaint immediately
• one external package branch fails while the stripped-down base machine stays healthy
• startup-state, process-state, or support-state behavior explains the symptom without hardware replacement
• A100 clears on better 120 V / 20 A power, a healthy 3 kW generator path, corrected DCEN / DCEP, or abandoning an improvised TIG complaint
• A220 clears on a real 208/230 V source, a better branch or generator path, corrected DCEN / DCEP, heavier external current path, or abandoning an improvised TIG complaint
• F130 clears on correct wire-size setup, proper front-end hardware, or a real 120 V / 20 A or 3 kW source
• M185 clears on sane inductance, correct breaker path, or a stronger 208/230 V source
• MA200TS clears when the machine is simplified to one healthy process, the correct polarity path, and the right accessory kit
• P40 clears with a fresh SG55 stack, dry air, correct pressure, clean clamp, or correct HF-gap setup

Intake sheet

Diagnosis log

Parts and wear items used

Bench-test signoff

Release signoff

Technician: __________ Date: __________