Incorrect wire speed setting
Adjust the wire feed speed
Voltage setting incorrect
Adjust the voltage setting
Small diameter wires and soft wires like
aluminium don’t feed well through long
torch leads - replace the torch with a
lesser length torch
Mig torch lead kinked or too sharp
angle being held
Remove the kink, reduce the angle or
bend
Contact tip worn, wrong size,
wrong type
Replace the tip with correct size and type
Liner worn or clogged (the most
common causes of bad feeding)
Try to clear the liner by blowing out with
compressed air as a temporary cure, it is
recommended to replace the liner
Install the correct size liner
Blocked or worn inlet guide tube
Clear or replace the inlet guide tube
Wire misaligned in drive roller
groove
Locate the wire into the groove of the
drive roller
Incorrect drive roller size
Fit the correct size drive roller eg; 0.8mm
wire requires 0.8mm drive roller
Wrong type of drive roller selected
Fit the correct type roller (e.g. knurled
rollers needed for flux cored wires
Replace the drive rollers
Drive roller pressure too high
Can flatten the wire electrode causing it
to lodge in the contact tip - reduce the
drive roller pressure
Too much tension on wire spool
hub
Reduce the spool hub brake tension
Wire crossed over on the spool or
tangled
Remove the spool untangle the wire or
replace the wire
Use clean dry rust free wire. Do not
lubricate the wire with oil, grease etc
§5.3 DC TIG welding trouble shooting
The following chart addresses some of the common problems of DC TIG welding. In all cases
of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to
and followed.
Tungsten burning
away quickly
Use pure Argon. Check cylinder has
gas, connected, turned on and torch
valve is open
Check the gas is connected, check
hoses, gas valve and torch are not
restricted.
Back cap not fitted correctly
Make sure the torch back cap is fitted
so that the o-ring is inside the torch
body
Connect the torch to the DC- output
terminal
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