MAINTENANCE AND TROUBLESHOOTING
2
Inconsistent /
interrupted
wire feed
Adjusting wrong dial
Be sure to adjust the wire feed and
voltage dials for MIG welding. The
amperage dial is for MMA and TIG
welding mode
Wrong polarity selected
Select the correct polarity for the wire
being used - see machine setup guide
Incorrect wire speed setting
Adjust the wire feed speed
Voltage setting incorrect
Adjust the voltage setting
Mig torch lead too long
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
Wrong size 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
Worn drive rollers
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
Contaminated mig wire
Use clean dry rust free wire. Do not
lubricate the wire with oil, grease etc
4.3 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.
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ADVANCEMIG 255C
