WeldKing Service Workflow Bundle

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

Routing order

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

Highest-value model routing

CoolArc160 and CoolArc200 workflow rules

• CoolArc160: prove a real 230 V branch first, then separate low OCV from no OCV before inverter-board blame.
• CoolArc160: treat fan speed as a proof target, not just a cooling symptom. Keep the capacitor-board 24 V auxiliary path and revision-sensitive fan connector behavior in play first.
• CoolArc200: prove actual input class first, and keep J3 sense behavior in the workflow before blaming control logic.
• CoolArc200: separate VRD versus non-VRD low OCV behavior before calling the output stage dead.
• CoolArc200: if blink or no-output symptoms track a stalled or shorted fan, keep the fan branch alive before deeper board escalation.

MultiSonic220 and PulseWave200 workflow rules

• MultiSonic220: prove one healthy process first so MIG-only or TIG-only faults do not get misread as whole-machine failures.
• MultiSonic220: clear hidden debug state with the documented 2T/4T reset before display, ribbon, or power-board blame.
• MultiSonic220: if MIG is dead while stick and TIG still work, keep the diagnosis in polarity connector, MIG-only accessory path, or process-state logic first.
• MultiSonic220: if the feeder runs full speed at idle, keep support power, power board, and feedback path in play before shared output-stage calls.
• PulseWave200: start on simple DC TIG, pulse off, clean steel, and torch negative before AC-inverter or HF-board escalation.
• PulseWave200: hold moderate gas flow and remove remote-only variables before treating no-HF or bad-start complaints as internal faults.
• PulseWave200: if the panel shows all 8s or the state behavior is corrupt, use the documented reset-state path before deeper teardown.

MAG workflow rules

• MAG211: start with one plain-steel MIG baseline, chart-correct settings, and a known-good Bernard front end before any internal call.
• MAG211: prove real solenoid actuation, smooth bare-wire feed, and base-gun health before letting the complaint drift into a shared MAG or transformer diagnosis.
• MAG211: if the complaint is one-gun-only or aluminum-only, keep the whole workflow on the spool-gun and drive-roll branch until base MIG is proven healthy.
• MAG251: if output ripple is high, keep capacitor condition first. Do not flatten a 6 to 7 VAC ripple complaint into a random board call.
• MAG251: after PCB or motor work, verify feed direction and breaker behavior before treating the replacement board as defective.
• MAG251: if the base gun is healthy and the complaint only follows one accessory branch, go back out of the chassis workflow and prove that branch directly.
• MAG255: if wire creeps after stop, keep the crater-fill branch first and isolate it before deeper teardown.
• MAG255: if the spool-gun branch will not weld, prove welding voltage at pins 1 and 9 in spool-gun mode before condemning the accessory or the main transformer.
• MAG255: if sparks appear at the wire tip without trigger command, keep the capacitor-discharge resistor branch alive before control-board blame.
• MAG255: if the complaint changes immediately when crater-fill is simplified or the base gun is restored, stop and keep the diagnosis out of random PCB escalation.

CoolTIG220, CoolCut40air, and ThunderCut65 workflow rules

• CoolTIG220: start with plain DC TIG on clean steel, pulse off, minimal controls, and the intended HF-versus-no-HF version already identified.
• CoolTIG220: if gas correction, torch-front-end rebuild, or one remote-only branch changes the complaint immediately, stop and keep the diagnosis external.
• CoolTIG220: only add pulse, AC, or alternate control branches after the simple DC baseline is healthy.
• CoolCut40air: prove whether the complaint exists in internal-air mode, external-air mode, or both. That split matters more than on a normal plasma platform.
• CoolCut40air: if both air paths move at once in internal mode, keep dual-valve contamination, external-solenoid hold-open, or valve-drive behavior in play before control-board blame.
• CoolCut40air: do not move past the SG55 stack, dry air under flow, water-trap path, and bright-metal clamp proof early.
• ThunderCut65: keep postflow-with-no-start separate from pilot-loss and transfer-loss complaints; normal postflow alone does not condemn a board.
• ThunderCut65: if start improves with pressure-window correction or RV1 pilot-maintain-current adjustment, stay outside the main boards.
• ThunderCut65: if torch-head rebound, guide carriage, or stand-off hardware changes the complaint, keep diagnosis in the A81 torch and guide-hardware branch first.

MigSonic145, MigSonic252S+SS20, TIG200PACDC, CUT40, and CUT65 workflow rules

• MigSonic145: start with stable 24 V support behavior, one healthy base MIG setup, and the exact fitted torch generation before board escalation.
• MigSonic145: if the machine clicks on and off at startup, keep capacitor-board or support-power logic ahead of gun or motor replacement.
• MigSonic145: if the machine has healthy bus and support voltage but the trigger still does nothing, prove the trigger wire and generation split before blaming the control PCB.
• MigSonic252S+SS20: prove the power-source baseline first. The feeder has no PCB, so frozen readouts, stuck gas, or weird source-side controls stay in the power source first.
• MigSonic252S+SS20: if the spool gun feeds full speed, keep connection, branch selection, and spool-gun drive-roll logic ahead of motor or feeder replacement.
• TIG200PACDC: start with plain DC TIG on clean steel, pulse off, and no optional pedal assumptions before AC or pulse calls.
• TIG200PACDC: if the complaint follows one pedal only, prove the documented 4K7 remote branch before opening the machine.
• TIG200PACDC: keep odd preset-display expectations separate from true output failure so the machine is not misread as dead when the display is only behaving like this model family.
• CUT40: keep external-air hose condition, valve routing, CB50 front end, and clamp proof ahead of board suspicion.
• CUT40: if guide carriage, stand-off, or extended-tip hardware changes the complaint, stay on the torch and guide-hardware branch first.
• CUT65: keep pressure-window behavior, RV1 pilot-maintain-current adjustment, and torch-head rebound ahead of board suspicion.
• CUT65: if postflow is normal but there is still no start, split torch mechanics and A81 hardware from control electronics before opening the machine.

Official Parts Exit Shortcuts

• If the workflow proves the complaint is external, stop before internal repair and move into the matching official parts path.
• CoolArc160: after real 230 V, clamp, and fan-auxiliary proof still leave the fault external, use parts category, TIG kit 07003650, ground clamp 07000461, holder 07000460
• CoolArc200: after J3 input-sense and VRD versus non-VRD proof still leave the fault external, use parts category, TIG kit 07003750, adapter 07001825, ground clamp 07000462
• MultiSonic220: after debug-state, one-process-still-healthy, and polarity-connector proof still leave the fault external, use parts category, aluminum kit XOM99035, spool gun 07NS1010, PRO17 torch WAT31100, pedal 07002510
• PulseWave200: after torch-negative, reset-state, gas-flow, and AC-versus-DC proof still leave the fault external, use parts category, PRO17 torch WAT31100, FC25-HD 07002510, FC25-WL 07002515
• MAG211: after chart-correct plain-steel setup and bare-wire feed proof still leave the fault external, use parts category, SpoolKing24D 07NS1000, U-groove drive roll 07000302
• MAG251: after ripple, solenoid, and feed-direction proof still leave the fault external, use parts category, SpoolKing24D 07NS1000, and the MAG251 drive-roll family
• MAG255: after crater-fill, spool-gun-voltage, and discharge-path proof still leave the fault external, use parts category, SpoolKing24D 07NS1000, U-groove drive roll 07000302
• CoolTIG220: after simple DC TIG, gas-path, and remote-branch proof still leave the fault external, use parts category, PRO17 torch WAT31100, FC25-HD pedal 07002510
• CoolCut40air: after internal-versus-external air-mode proof still leaves the fault external, use parts category, SG55 electrode 07Y2517003, SG55 nozzle 07Y2517004, shared SG55 tip path 07Y2517005
• ThunderCut65: after torch-head, pressure-window, and RV1 proof still leave the fault external, use parts category, A81 torch path, guide carriage 07CV0051, stand-off guide 07CV0028
• MigSonic145: after startup, 24 V, and trigger-wire proof still leave the fault external, use parts category, NT-1 gun 07000422, SpoolKing-200 07NS2000, and the gas-side branch
• MigSonic252S+SS20: after source-side proving still leaves the fault external, use parts category, SpoolKing24D 07NS1000, and drive roll 07NS1007
• TIG200PACDC: after simple DC TIG, gas-path, and 4K7 remote proof still leave the fault external, use parts category, gas regulator branch 07000510, and gas hose branch 072611120
• CUT40: after hose, valve, CB50 front-end, and clamp proof still leave the fault external, use parts category, CB50 torch 07001710, guide carriage 07CV0037, and extended tip 07PD0063-10
• CUT65: after pressure-window, RV1, A81 front-end, and torch-head proof still leave the fault external, use parts category, A81 torch 07001400, 2-leg stand-off 07CV0026, and circle kit 07CV0052

Stop Before Internal Repair When

• clamp, holder, adapter, TIG kit, torch, pedal, spool gun, or aluminum kit proof changes the complaint immediately
• one external branch fails while the stripped-down base machine stays healthy
• VRD, wake-up, reset-state, or package-state behavior explains the symptom without hardware replacement
• CoolArc160 clears when clamp quality, fan auxiliary behavior, or the revision-specific fan branch is restored
• CoolArc200 clears when input class, J3 sense, or VRD state is understood correctly
• MultiSonic220 clears after debug reset, polarity-connector correction, one-process-only isolation, or accessory removal
• PulseWave200 clears on torch-negative, simple DC TIG baseline, moderate gas-flow correction, remote removal, or reset-state recovery
• MAG211 clears on chart-correct setup, Bernard front-end rebuild, or spool-gun and drive-roll correction
• MAG251 clears on capacitor or ripple correction, feed-direction restoration, or the right drive-roll branch
• MAG255 clears on crater-fill isolation, spool-gun branch correction, or capacitor-discharge repair
• CoolTIG220 clears on simple DC TIG baseline, gas-path correction, torch-front-end rebuild, or remote removal
• CoolCut40air clears when internal versus external air mode, SG55 stack, water-trap path, or clamp placement explains the complaint
• ThunderCut65 clears on torch-head rebound correction, pressure-window or RV1 correction, or guide-hardware correction
• MigSonic145 clears on stable 24 V, trigger-wire correction, generation-correct gun branch, or gas-side correction
• MigSonic252S+SS20 clears when the source-side state is healthy and only the feeder package or spool-gun branch was wrong
• TIG200PACDC clears on simple DC TIG baseline, gas-path correction, or the correct 4K7 remote branch
• CUT40 clears when CB50 front-end, hose routing, clamp placement, or guide-hardware correction explains the complaint
• CUT65 clears on pressure-window correction, RV1 correction, torch-head rebound repair, or A81 hardware correction

Intake sheet

Diagnosis log

Parts and wear items used

Bench-test signoff

Release signoff

Technician: __________ Date: __________