Technician Intake And Evidence Capture

This checklist standardizes what should be captured before the machine is opened or parts are replaced.

Core machine identity

• Brand, model, and exact nameplate designation
• Serial number, code number, SKU, or revision marking
• Input-voltage label and plug style
• Bundled package or accessory package if applicable

Customer complaint capture

• Exact complaint in plain language
• Process in use when the failure occurred
• Material, thickness, filler, gas, or cartridge in use
• Whether the fault is constant, intermittent, cold-only, hot-only, or accessory-specific
• Whether the machine ever worked correctly in the current setup

Power-path evidence

• Receptacle type and stated branch rating
• Extension cord or adapter in use
• Generator, engine-driven auxiliary output, or inverter source in use
• Measured or observed branch condition if available
• Any visible heating at plug, adapter, disconnect, or lugs

Accessory and consumable state

• Exact gun, torch, spool gun, feeder, pedal, cooler, or mechanized interface attached
• Contact tip, liner, nozzle, diffuser, tungsten, or cartridge state
• Clamp location and work-return condition
• Gas bottle type, regulator state, and hose routing
• Air filter, separator, compressor, or air-dryer condition for plasma

Digital and control-state capture

• Fault code, LED pattern, or screen message exactly as shown
• Menu settings, process selection, and stored program in use
• Software, firmware, or UI version if the machine displays it
• Whether the fault appeared after a process change, update, reset, or accessory change

Minimum evidence pack

• Photo of the front panel with the fault present
• Photo of the rear/input connection
• Photo of the attached accessories and work clamp
• Photo of the consumable or cartridge state if relevant
• Short note stating what baseline setup has already been tried

Process-specific intake notes

MIG and flux-cored

• Wire type and diameter
• Polarity as found
• Gas type if applicable
• Roll groove and pressure state
• Whether bare-wire feed has been checked with the tip removed

TIG and stick

• Remote or local mode as found
• Pedal, hand control, or torch-switch path
• Tungsten size, prep, and cup/gas lens state
• Stick electrode type and condition

Plasma

• Cartridge or consumable family
• Manual or mechanized use
• Air source, air treatment, and pressure-under-flow observation
• Whether pilot exists and whether transfer fails

Engine-driven

• Fuel type and age
• Battery and starting behavior
• Governor-speed behavior under load
• Auxiliary-output complaint versus weld-output complaint

Intake rule

Do not start replacing internal parts until:

• the machine identity is confirmed
• the complaint has been reproduced or bounded
• the utility and accessory path has been documented
• the current process baseline has been normalized