Welding equipment maintenance log

Equipment profile

Item	Notes
Machine or tool	MIG / TIG / stick / multi-process / plasma cutter / fume extractor / other
Make, model, and serial number
Primary process and material
Manual location
Last full inspection date
Assigned owner or shop lead
Out-of-service tag needed	Yes / no / not sure

Daily or pre-use checks

Check	Pass / fail / notes
Power cord, plug, strain relief, and case condition
Work lead, clamp, stinger, torch, and cable insulation
Gas cylinder secured, cap status, regulator condition, and hose condition
Contact tip, nozzle, diffuser, collet, cup, electrode holder, or consumable condition
Drive rolls, liner feeding, spool tension, and wire condition
Ground connection and work surface cleanliness
Cooling fan, vents, filters, and dust buildup
Helmet lens, batteries, cover plates, headgear, gloves, jacket, and respirator fit
Fire watch area, combustibles, ventilation, and fume controls

Maintenance interval plan

Interval	Task	Owner	Date done
Each use	Blow off dust from exterior vents if the manual allows it
Each use	Check leads, torch, work clamp, and PPE for damage
Weekly	Clean nozzle, replace worn contact tips, inspect liner symptoms
Weekly	Check regulator, hose, flowmeter, and leak-test practice allowed by the manual
Monthly	Inspect drive rolls, spool hub, gun connection, and cable strain points
Monthly	Review helmet lens response, batteries, cover lenses, and headgear
Quarterly	Compare replacement-part use with weld defects and downtime notes
Manual interval	Record manufacturer-specific service items

Symptom-to-maintenance notes

Symptom	Possible maintenance checks before changing technique
Wire stubbing or birdnesting	Drive-roll tension, liner condition, tip size, spool brake, wire rust
Porosity	Gas flow, leaks, wind, nozzle blockage, base-metal contamination, wire condition
Excess spatter	Contact tip wear, polarity, gas mix, wire type, settings, dirty work clamp
Arc starts poorly	Work clamp, cable damage, electrode condition, contact tip, machine connections
Helmet flashes or feels delayed	Battery, sensors, cover lens dirt, shade setting, helmet replacement need
Fume or odor increase	Material coating, ventilation, extraction filter, respirator cartridge, SDS review

Consumables and wear parts

Part	On hand	Minimum stock	Last changed	Notes
Contact tips
Nozzles or cups
Liners
Drive rolls
Tungsten or electrodes
Filler wire or rods
Abrasives and brushes
Helmet cover lenses and batteries
Fume extraction filters or respirator cartridges

Repair and follow-up log

Date	Issue found	Action taken	Parts used	Back in service?

Stop-and-escalate conditions

• Damaged insulation, exposed conductors, cracked plugs, loose strain reliefs, or case damage.
• Gas cylinders not secured, damaged regulators, suspected leaks, or missing caps during storage.
• Repeated breaker trips, burning smell, unusual noise, overheating, or fan failure.
• Helmet auto-darkening failure, cracked lens, poor fit, or respiratory protection that no longer seals.
• Welding on unknown coatings, confined spaces, galvanized material, stainless, nickel alloys, or painted parts without proper ventilation and hazard review.
• Any weld that will carry structural, pressure, vehicle, lifting, or life-safety loads without qualified procedures and inspection.