Post-Repair Verification Standard

This reference defines how repairs should be closed so a machine is not returned with the original fault still hiding in the setup, accessory path, or load condition.

Universal close-out steps

• Reassemble the machine fully and confirm no covers, strain reliefs, or grounds were left loose.
• Restore the machine to a known-good baseline process before retesting specialty features.
• Repeat the original complaint path if it can be done safely.
• Verify the repair both from a cold start and after the machine has warmed up enough to expose intermittent faults.
• Record the exact accessory package and power source used for verification.

MIG and flux-cored verification

• Perform a bare-wire feed test with the tip removed.
• Reinstall the correct tip and run repeated weld starts on clean steel.
• Confirm no abnormal heating at the clamp, front connector, power plug, or gun neck.
• If the original complaint involved pulse, spool gun, or aluminum, prove the standard steel MIG baseline first and then retest the specialty path.

TIG and stick verification

• Confirm gas pre-flow, start behavior, arc stability, and post-flow.
• Prove local control first, then retest pedal or remote if that was part of the complaint.
• For AC/DC TIG, retest the same AC or pulse feature that originally failed after a stable DC or simple baseline is proven.
• For stick complaints, retest with a known-good rod on clean plate and verify output-lug and clamp temperature.

Plasma verification

• Retest on known material thickness with known-good clamp placement and dry air.
• Separate manual handheld verification from mechanized verification.
• Confirm pilot behavior, transfer, cut quality, and post-cut fault state.
• If the complaint was cartridge, torch, or consumable related, verify that recent faults do not immediately return with a known-good consumable path.

Multiprocess verification

• Prove one healthy baseline process first.
• Retest the exact process that originally failed only after the shared power-source path is proven.
• If the complaint followed a process change, power cycle and retest the machine in both the baseline process and the complaint process.
• Confirm lead placement, polarity, and accessory package before closing the repair.

Engine-driven verification

• Verify start, idle, governed speed, and warm restart.
• Confirm weld output under load and auxiliary output under load if the machine provides both.
• Retest with the same feeder, remote, or compressor load that exposed the fault if applicable.
• Do not close the job on idle-only validation.

Do not close the repair if

• the machine only works on a different power source than the one used by the customer and the cause of that difference is not explained
• the machine only works with a substitute accessory and the original accessory has not been bounded or condemned clearly
• the machine passes cold but fails hot and the hot condition was not reproduced
• the original fault code or warning returns during verification