Symptom-first troubleshooting

Burnback Troubleshooting

Troubleshoot wire burning back into the contact tip using tip size, liner drag, drive roll, diffuser, and setup checks.

MIG

Most Common Causes

  • Contact tip size mismatch, wear, or spatter restriction
  • Wire feed drag from liner or gun cable condition
  • Drive roll slippage or pressure mismatch
  • Voltage, wire speed, stickout, or technique issue

Beginner Explanation

What this means in plain English

Burnback happens when the wire melts back into the contact tip. The first checks are contact tip size/condition, liner drag, drive roll setup, and wire speed.

Compatible Processes to Check

MIG

Machine and Equipment Pages to Check

Miller M-10/M-15 Gun Breakdown Machine · Miller · MIG

Miller · MIG · Millermatic 180 Auto-Set

 XR-Pistol-Pro Push-Pull Guns Machine · Miller · MIG

Miller · MIG · Millermatic 255, Millermatic 355

 V-Knurled Dual-Groove Drive Roll Machine · Miller · MIG

Miller · MIG · Millermatic 140 Auto-Set, Millermatic 180 Auto-Set

 10-Pin to 14-Pin Adapter Cord Machine · Miller · TIG · MIG

Miller · TIG / MIG · Multimatic 215, Multimatic 215 PRO

 Lincoln MIG Machine Support Machine · Lincoln · MIG

Lincoln · MIG

 Gun Convenience Kit Machine · Miller · MIG

Miller · MIG · Millermatic 251

 Hypertherm T100M-2 Machine Torch Parts Breakdown Machine · Hypertherm · MIG

Hypertherm · MIG

 Spoolmatic 15A Spool Gun Machine · Miller · MIG

Miller · MIG · Millermatic 251, Millermatic 252

Related Support Pages

Miller M-10/M-15 Gun Breakdown Machine · Miller · MIG

Miller · MIG · Millermatic 180 Auto-Set

 XR-Pistol-Pro Push-Pull Guns Machine · Miller · MIG

Miller · MIG · Millermatic 255, Millermatic 355

 XR-Pistol Air-Cooled Push-Pull Gun Parts Breakdown Parts Breakdown · Miller · MIG

Miller · MIG

 XR-Pistol Plus Air-Cooled Push-Pull Gun Parts Breakdown Parts Breakdown · Miller · MIG

Miller · MIG

 XR-Pistol Plus Water-Cooled Push-Pull Gun Parts Breakdown Parts Breakdown · Miller · MIG

Miller · MIG

 XR-Pistol Water-Cooled Push-Pull Gun Parts Breakdown Parts Breakdown · Miller · MIG

Miller · MIG

 XR-Pistol-Pro Water-Cooled Push-Pull Gun Parts Breakdown Parts Breakdown · Miller · MIG

Miller · MIG

 XR-Aluma-Pro Air-Cooled Push-Pull Gun Parts Breakdown Parts Breakdown · Miller · MIG

Miller · MIG

 XR-Aluma-Pro Water-Cooled Push-Pull Gun Parts Breakdown Parts Breakdown · Miller · MIG

Miller · MIG

 MIG Consumables Lookup Consumable Family · MIG

MIG

Long-Tail Search Phrases Covered

MIG wire burns back into tipcontact tip sticking causesburnback contact tip liner drive roll