MIG Troubleshooting Guide
COMPARE YOUR MIG GUN
A. Wire not feeding or bumpy feeding
Possible Cause
Feeder relay/malfunction
Broken control lead
Poor adapter connection
Incorrect type of drive roll
Improper drive rolls size
Drive roll tension misadjusted
Burn back to contact tip
Wrong size liner
Buildup inside of liner
Worn drive roll
Improper guide tube relationship
Improper wire guide diameter
Gaps at liner into gas diffuser
B. Premature contact tip failure
Possible Cause
Improper voltage or wire feed speed
Erratic wire feeding
Improper tip stick-out
Improper electrode stick-out
C. MIG gun running hot
Possible Cause
Exceeding duty cycle
Loose or poor power connection
D. Porosity in weld
Possible Cause
Nozzle/Insulator/O-rings worn
Retaining head spring/band
Extreme heat or duty cycle
Gas not getting to the weld
Gas ports plugged
Loose fittings or cut gas hose
941-753-7557 800-342-8477
MIG
Possible Solution
Consult feeder manufacturer Made in the USA by American Torch Tip
Connect spare control leads VIRTUALLY INDESTRUCTIBLE
Test and replace leads and/or contact pins
Use manufacturers recommended drive rolls • Protective inner armor
Replace with proper size to guard against wear and
Adjust tension at feeder extend nozzle life
See “E. Contact tip burn back.”
Replace with correct size
• Virtually indestructible
Replace liner, check condition of electrode
Replace with new drive roll handle
Eliminate all gaps in electrode path
Replace with proper guide diameter
• Lifetime Warranty on handle
Reset liner and lock or replace with new liner
and trigger switch
• Kink- and impact-resistant
Possible Solution
Set parameters Hytrel inner tubing
See “G. Erratic arc”
Adjust nozzle/tip relationship
• Designed for quick, easy
Change length of wire stick-out
consumable change-outs
Possible Solution
Replace with properly rated duty cycle MIG gun. Compare to Lightning®
Decrease parameters to within gun rating
Clean and re-tighten all electrical connections.
Check rating and condition of ground clamp.
Start Comparison
Possible Solution LightningMIG.com/compare
Replace
Replace retaining head
Use extra heavy duty consumables
Check gas regulator/flowmeter/cylinder
Clean or replace gas diffuser/nozzle
Tighten or repair hose lines
www.AmericanTorchTip.com
MIG Troubleshooting Guide
E. Contact tip burn back
Possible Cause
Improper voltage and/or wire feed speed
Erratic wire feeding
Improper tip stick-out
Improper electrode stick-out
Faulty ground
F. Tip disengages from retaining head
Possible Cause
Worn retaining head
Improper tip installation
G. Erratic arc
Possible Cause
Worn contact tip
Buildup inside of liner
Wrong tip size
Incorrect welding parameters
H. Excess spatter
Possible Cause
Improper machine parameters
Incorrect tip or installation
Incorrect nozzle or shielding
Contaminated wire or work piece
I. Discolored liner
Possible Cause
Short circuit to electrode
Cuts in outer jacker, copper exposed
941-753-7557 800-342-8477
MIG
COMPARE YOUR MIG GUN
Possible Solution
Set parameters Made in the USA by American Torch Tip
See “G. Erratic arc” VIRTUALLY INDESTRUCTIBLE
Adjust nozzle/tip relationship
Adjust torch to base relationship • Protective inner armor
Repair all cables and connectors to guard against wear and
extend nozzle life
Possible Solution • Virtually indestructible
Replace tip and/or retaining head handle
Finger tighten then slightly tighten w/ right tool
• Lifetime Warranty on handle
and trigger switch
Possible Solution
Replace
Replace liner, check condition of electrode • Kink- and impact-resistant
Replace with correct tip size Hytrel inner tubing
Use wire manufacturers parameters
• Designed for quick, easy
consumable change-outs
Possible Solution
Adjust parameters
Adjust nozzle/tip relationship
Use correct nozzle and shielding gas coverage Compare to Lightning®
Replace wire and clean work piece
Possible Solution
Check for wire short circuiting in feeder
Start Comparison
Replace gun LightningMIG.com/compare
www.AmericanTorchTip.com