Free welding machine annual service procedure
Free welding machine annual service (PDF-ready). Covers MIG TIG stick torch cables gas flow and AS/NZS 3760 test and tag. Download free.
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Updated 26 Oct 2026
Welding Machine Annual Service Procedure
Annual maintenance and test procedure for MIG TIG stick and multi-process welding machines
Earth Lead and Work Clamp
Torch / Gun Assembly
Wire Feed System (MIG)
Gas Delivery
Cables and Electrical
Performance and Compliance
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Short answer
A welding machine annual service checklist records a yearly service of MIG, TIG, stick and multi-process machines: leads and clamps, torch and consumables, wire feed, gas flow, cables, internal cleaning, duty cycle testing and the electrical test and tag. Yearly is common practice. AS/NZS 3760:2022 clause 2.2 covers electrical test intervals by environment and equipment type, and AS/NZS 3012:2019 applies on construction sites.
Checked against AS/NZS 3760:2022 (incl. Amd 1:2022) on by the MapTrack templates team. How we check templates
Key takeaways
- The MapTrack welding machine annual service procedure contains 32 checks across 6 sections. Sections covered: Earth Lead and Work Clamp, Torch / Gun Assembly, Wire Feed System (MIG), Gas Delivery, Cables and Electrical, Performance and Compliance.
- Model WHS regulation 150 requires regular competent-person inspection and testing of plug-in equipment used in hostile operating environments.
- The three-month interval for portable equipment comes from AS/NZS 3012:2019 on construction sites, not a general AS/NZS 3760 rule.
- A welder that fails its electrical test is tagged out of service until it is repaired and retested.
- AS 1674.2:2025 replaced the 2007 edition as the electrical part of the welding safety standard.
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What is a welding machine annual service procedure?
A welding machine annual service is a comprehensive yearly preventive maintenance procedure for MIG TIG stick and multi-process welding machines. MapTrack helps workshop and maintenance teams standardise welding machine servicing with digital checklists that technicians complete on mobile and store against each asset record. The annual service covers the earth lead and work clamp torch or gun assembly consumable wear cable insulation gas flow rates electrical connections internal components and duty cycle performance testing.
Welding machines are plant and electrical equipment under the Australian WHS Regulations, and the person with management or control must ensure they are maintained, inspected and, if necessary, tested by a competent person so they remain safe for use (regulation 213). AS/NZS 3760 requires in-service inspection and testing (test and tag) of electrical equipment at intervals determined by the operating environment. An annual service is the right time to combine mechanical maintenance with the electrical safety test to keep compliance records in one place.
In Australia, welding machines are electrical equipment, and test and tag is commonly carried out to AS/NZS 3760 (In-Service Safety Inspection and Testing of Electrical Equipment) for test and tag requirements. Welding equipment used on construction sites must also comply with AS/NZS 3012. The WHS Regulations 2011 require that plant is maintained to prevent risks to health and safety.
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Benefits of using this welding machine annual service procedure
- Consistency: every welding machine receives the same structured service regardless of brand type or workshop location
- WHS compliance: documented annual service records demonstrate the PCBU has met their duty of care for electrical plant under the WHS Act
- Electrical safety: combining the annual service with AS/NZS 3760 test and tag ensures cables leads and earthing are verified each year
- Extended asset life: inspecting torch liners contact tips and drive rollers annually prevents premature wire feed motor and PCB failures
- Reduced downtime: catching worn cables frayed earth leads and gas leaks before they cause arc quality issues keeps welders productive
- Audit trail: signed digital service records support insurer audits workplace inspections and WHS regulator enquiries
Benefits of digitising forms in MapTrack
When you digitise welding machine service procedures in MapTrack, you get:
- Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
- Email the right people when a form is submitted, with an automation you set up.
- File every completed form against the asset, location or person it covers.
- Download any completed form as a PDF, with failed answers listed at the top.
- Fill in forms offline; they upload when the device is back online.
- Build conditional logic (show or hide questions based on answers).
- Take pictures or attach photos. Not possible with a paper-based form.
- Electronic signatures.
- Edit forms later without reprinting.
- Set who can view, fill in or edit forms with user roles.
- Upload a paper form (PDF, Word, Excel or a photo) and MapTrack's AI builds a digital version for you to check.
- Raise a work order from a submitted form with an automation you set up.
- Track service intervals by hours, kilometres or calendar date in one place.
- Attach supplier invoices and parts receipts to each maintenance record.
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What to include in a welding machine annual service procedure
This welding machine annual service procedure covers 8 key areas:
- Earth lead and work clamp: inspect cable insulation for cuts burns and cracking and check clamp jaw condition and spring tension
- Torch or gun assembly: inspect MIG gun liner nozzle contact tip and diffuser or TIG torch body collet cap and ceramic cup for wear or damage
- Wire feed system (MIG): check drive roller condition tension setting and wire guide alignment
- Gas delivery: test gas flow rate at the torch and inspect regulator hoses and fittings for leaks or damage
- Cable and connector condition: inspect welding cables power lead and plug for insulation damage and secure connections
- Internal inspection: remove covers and inspect PCBs contactors capacitors fan and wiring for dust buildup heat damage or loose terminals
- Duty cycle test: run the machine at rated output and verify it performs to the manufacturer duty cycle specification
- AS/NZS 3760 test and tag: perform insulation resistance earth continuity and polarity tests and apply a new test tag with the next due date
How to use this welding machine annual service procedure
- Isolate and prepare: disconnect the welding machine from the power supply and allow it to cool then gather service tools and replacement consumables
- Inspect earth lead and work clamp: check the full length of the earth cable for insulation damage and verify the clamp jaw makes a solid connection with no excessive resistance
- Service torch or gun: disassemble the MIG gun or TIG torch and inspect each consumable component then replace worn contact tips nozzles liners collets or ceramic cups
- Check wire feed system: inspect drive rollers for groove wear and verify correct roller type for the wire diameter and material then check wire guide tube alignment
- Test gas delivery: connect a flow meter at the torch and verify gas flow rate matches the welding procedure specification then check all fittings for leaks with soapy water
- Inspect internals and clean: remove side panels blow out dust with dry compressed air and inspect PCBs contactors fan and wiring for heat damage or loose connections
- Perform duty cycle test: run the machine at rated current and duty cycle and verify output voltage and current are within manufacturer tolerance
- Complete AS/NZS 3760 testing: perform insulation resistance and earth continuity tests with a calibrated appliance tester record results and apply a new test tag
- Document and close out: record all findings and test results in the service form sign off and set the next annual service date
In MapTrack, you can schedule and track maintenance digitally, by date or meter reading. Each submission is stored as a timestamped PDF against the asset record.
Get the free templateEnter your email above to download the full welding machine annual service procedure as a PDF.Back to download formHow often should you complete this service procedure?
Welding machines should receive a quarterly visual inspection and consumable check and a full annual service that includes internal inspection duty cycle testing and AS/NZS 3760 electrical testing. In heavy-use workshop or construction site environments quarterly services may need to be more thorough with six-monthly internal inspections added.
Under the Australian WHS Regulations, plant must be maintained and inspected by a competent person in line with the manufacturer recommendations (regulation 213), and plug-in electrical equipment used in hostile operating conditions must be regularly inspected and tested (regulation 150). AS/NZS 3760 specifies test and tag intervals based on the operating environment. On construction sites, AS/NZS 3012:2019 sets a three-month test interval for portable equipment, and in other hostile operating environments WHS regulation 150 requires regular inspection and testing by a competent person. For general commercial workshops testing every twelve months is typical. The annual service is the ideal time to align mechanical maintenance with electrical compliance testing.
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Frequently asked questions
Applicable regulatory standards
This template is a starting point. Check the current requirements that apply to your equipment, work and location. The template alone does not establish compliance.
| Standard | Edition | Clauses this template relies on | Source |
|---|---|---|---|
| In-service safety inspection and testing of electrical equipment and RCDsTest intervals by environment, the inspection and test methods, and how results are documented. | AS/NZS 3760:2022 (incl. Amd 1:2022) |
| Standards Australia and Standards New ZealandSold by the publisher |
| Model Work Health and Safety RegulationsRegular competent-person testing of plug-in equipment in hostile environments, and plant maintenance. Queensland uses its own electrical safety law. | Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011) |
| Safe Work Australia (drafted by the Parliamentary Counsel's Committee) |
| Electrical installations - Construction and demolition sitesInspection and testing frequency for equipment used on construction and demolition sites. | AS/NZS 3012:2019 (incl. Amd 1:2020) |
| Standards Australia and Standards New ZealandSold by the publisher |
| Electrical practices: construction and demolition sites fact sheetNSW regulator table of AS/NZS 3012:2019 intervals on construction sites: portable equipment and cords every 3 months. Guidance, not law. | SafeWork NSW web fact sheet, as published at 2026-10-26 |
| SafeWork NSW |
| Safety in welding and allied processes, Part 2: ElectricalElectrical safety in welding and allied processes; AS 1674.2:2025 supersedes the 2007 edition. | AS 1674.2:2025 | Whole instrument | Standards AustraliaSold by the publisher |
In-service safety inspection and testing of electrical equipment and RCDs
Edition: AS/NZS 3760:2022 (incl. Amd 1:2022)
Test intervals by environment, the inspection and test methods, and how results are documented.
- 2.2: Frequency of inspection and tests of electrical equipment and RCDs
- 2.4: Inspection and testing of electrical equipment and RCDs
- 2.6: Documentation of inspection and test results
Standards Australia and Standards New ZealandSold by the publisher
Model Work Health and Safety Regulations
Edition: Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011)
Regular competent-person testing of plug-in equipment in hostile environments, and plant maintenance. Queensland uses its own electrical safety law.
- reg 150: Plug-in electrical equipment used in hostile operating environments must be regularly inspected and tested by a competent person.
- Part 4.7: General electrical safety and energised electrical work, including inspection and testing and residual current devices.
- reg 213: Plant must be maintained, inspected and, if necessary, tested by a competent person, following manufacturer or competent person recommendations; annual inspection applies only if neither is practicable.
Safe Work Australia (drafted by the Parliamentary Counsel's Committee)
Electrical installations - Construction and demolition sites
Edition: AS/NZS 3012:2019 (incl. Amd 1:2020)
Inspection and testing frequency for equipment used on construction and demolition sites.
- 3.2: Frequency of verification (inspection and testing) on construction and demolition sites
Standards Australia and Standards New ZealandSold by the publisher
Electrical practices: construction and demolition sites fact sheet
Edition: SafeWork NSW web fact sheet, as published at 2026-10-26
NSW regulator table of AS/NZS 3012:2019 intervals on construction sites: portable equipment and cords every 3 months. Guidance, not law.
- Table two: Periodic verification intervals from AS/NZS 3012:2019: portable equipment and cords 3 months, fixed and transportable equipment 6 months, and RCD tests by type.
Safety in welding and allied processes, Part 2: Electrical
Edition: AS 1674.2:2025
Electrical safety in welding and allied processes; AS 1674.2:2025 supersedes the 2007 edition.
Standards AustraliaSold by the publisher
Each source was read at its publisher and the page checked on 26 October 2026. The publisher's current text is the authority.
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Welding machine annual service procedure preview
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<p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#071D49;margin:0;">Free template</p>
<p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Welding machine annual service procedure</p>
<ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
<li style="margin:4px 0;">Earth lead and work clamp: inspect cable insulation for cuts burns and cracking and check clamp jaw condition and spring tension</li>
<li style="margin:4px 0;">Torch or gun assembly: inspect MIG gun liner nozzle contact tip and diffuser or TIG torch body collet cap and ceramic cup for wear or damage</li>
<li style="margin:4px 0;">Wire feed system (MIG): check drive roller condition tension setting and wire guide alignment</li>
<li style="margin:4px 0;">Gas delivery: test gas flow rate at the torch and inspect regulator hoses and fittings for leaks or damage</li>
<li style="margin:4px 0;">Cable and connector condition: inspect welding cables power lead and plug for insulation damage and secure connections</li>
<li style="margin:4px 0;">Internal inspection: remove covers and inspect PCBs contactors capacitors fan and wiring for dust buildup heat damage or loose terminals</li>
</ul>
<p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/welding-machine-annual-service" style="color:#071D49;font-weight:600;text-decoration:none;">Welding machine annual service procedure</a> by MapTrack</p>
</div>Free to reuse, including commercially. This template is published under a Creative Commons Attribution 4.0 licence. Copy it, adapt it, put it on your own site or in your own docs. All we ask is that you credit MapTrack with a link back to this page. The snippet above already includes that credit, so if you use it as-is you’re covered.
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The MapTrack welding machine annual service procedure contains 32 checks across 6 sections.
- Short attribution
- MapTrack Welding machine annual service procedure, https://www.maptrack.com/templates/welding-machine-annual-service
- Reference list
- MapTrack. (2026). Welding machine annual service procedure [Checklist template]. Retrieved from https://www.maptrack.com/templates/welding-machine-annual-service
Free to reuse with credit under a Creative Commons Attribution 4.0 licence. If you’d rather link straight to it, the page is https://www.maptrack.com/templates/welding-machine-annual-service.
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