Bench Test / WeldKing / ThunderCut65

Test intent

Separate torch-head rebound, air-pressure, and RV1 pilot-current faults from true control faults.
Verify stable pilot, transfer, and restrike after repair.
Catch the common false-fault pattern where postflow is normal but start is still blocked by torch mechanics.

Tools and setup

Multimeter
Dry air source
Fresh A81 front-end stack
Clean mild-steel coupon
Known-good work clamp

Pre-power checks

Check	Expected condition	Result
Torch head	mechanically healthy and returning correctly after trigger release	pass / fail
Clamp placement	bright metal, tight return path	pass / fail
Air pressure under flow	stable in the normal working range	pass / fail
Guide hardware if used	no bent guide carriage or stand-off hardware	pass / fail
Freehand baseline state	machine proven freehand before guided proving	pass / fail

Electrical checkpoints

Checkpoint	Expected value or behavior	Record actual
Postflow sequence	normal and repeatable
Pilot behavior	stable, repeatable, no abnormal long delay
Pressure sensitivity	complaint does not clear only at a narrow pressure setting
Restrike behavior	machine restrikes without unusual wait time

Functional proof

Test	Pass condition	Result
Cold start	normal pilot and start on clean steel	pass / fail
Transfer test	clean transition into the cut	pass / fail
Short cut	stable cut with no dropout	pass / fail
Warm restrike	no delayed restrike or pilot loss after repeated starts	pass / fail
Guided retest if required	guided hardware does not create the complaint after freehand proves healthy	pass / fail

If it fails

Postflow normal but no start: stay in torch-head mechanics first.
Pilot improves only when pressure or RV1 is moved: stay outside the boards.
Tracking complaint with healthy start: keep diagnosis in guide and stand-off hardware.
Freehand healthy but guided cut bad: stay in guide, stand-off, or circle-kit hardware first.
Stable torch mechanics but no useful start: move deeper only after air and front-end proving are done.

Direct official parts pages

Use these only after the complaint has been proven to follow the torch, guide, or air branch.
ThunderCut65 parts category: official ThunderCut65 parts path
A81 torch ecosystem: official A81 parts path
Guide carriage 07CV0051: official product page
Stand-off guide 07CV0028: official product page

Post-repair release

Signoff item	Result
Stable pilot restored	pass / fail
Stable transfer restored	pass / fail
Freehand baseline restored before guide proving	pass / fail
Short cut completed cleanly	pass / fail
No abnormal restrike delay or pressure sensitivity after retest	pass / fail

Technician: __________ Date: __________ Serial or shop tag: __________