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

Spoolmatic Spool Gun Machine · Miller · MIG

Miller · MIG · Millermatic 252, Millermatic 255 · Miller Spoolmatic Spool Guns · 000442, 000443

 XR-Pistol-Pro Push-Pull Gun Machine · Miller · CARBON-ARC · MIG

Miller · Carbon Arc / MIG · Multimatic 255 · Miller XR-Pistol-Pro Push-Pull Guns · 050116, 144862

 XR-Aluma-Pro Push-Pull Gun Machine · Miller · CARBON-ARC · MIG

Miller · Carbon Arc / MIG · Multimatic 255 · Miller XR-Aluma-Pro Push-Pull Guns · 198855, 206186

 Miller MIGmatic M-100 / M-150 MIG Guns Parts Breakdown Machine · Miller · MIG

Miller · MIG · Multimatic 215 PRO, Multimatic 220 AC/DC · M-100 / M-150, Miller MIGmatic M-100 / M-150 MIG Guns · 000067, 000068

 Miller MDX-250 Parts Lookup Machine · Miller · MIG

Miller · MIG · Millermatic 252, Millermatic 255 · Miller M-25 MIG Gun, Miller MDX-250 EZ Select MIG Gun · 1880275, 1880276

 Miller MDX-100 MIG Gun Parts Breakdown Machine · Miller · MIG

Miller · MIG · Millermatic 142, Millermatic 211 PRO · Miller AccuLock MDX-100 Gun Breakdown, MDX-100 · 1880272, 1880273

 Spoolmate 100 Machine · Miller · MIG

Miller · MIG · Millermatic 142, Millermatic 211 PRO · Miller Spoolmate 100 Spool Gun · 186405, 186406

 Spoolmate 150 Machine · Miller · MIG

Miller · MIG · Millermatic 142, Millermatic 211 PRO · Miller Spoolmate 150 Spool Gun · 050622, 199387

Related Support Pages

Hobart 3035-20 Spool Gun Parts Breakdown Gun / Torch · Hobart · MIG

Hobart · MIG · 186405, 186406

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

Miller · MIG · Miller M-10/M-15 Gun Breakdown · 000067, 000068

 Miller XR-Pistol Plus Push-Pull Guns Parts Breakdown Gun / Torch · Miller · CARBON-ARC · MIG

Miller · Carbon Arc / MIG · Miller XR-Pistol Plus Push-Pull Guns · 050116, 144862

 Miller XR-Pistol Push-Pull Guns Parts Breakdown Gun / Torch · Miller · CARBON-ARC · MIG

Miller · Carbon Arc / MIG · Miller XR-Pistol Push-Pull Guns · 050116, 144862

 Spoolmatic Spool Gun Machine · Miller · MIG

Miller · MIG · Millermatic 252, Millermatic 255 · Miller Spoolmatic Spool Guns · 000442, 000443

 XR-Pistol-Pro Push-Pull Gun Machine · Miller · CARBON-ARC · MIG

Miller · Carbon Arc / MIG · Multimatic 255 · Miller XR-Pistol-Pro Push-Pull Guns · 050116, 144862

 Miller XR-Aluma-Pro Plus Push-Pull Guns Parts Breakdown Gun / Torch · Miller · CARBON-ARC · MIG

Miller · Carbon Arc / MIG · Miller XR-Aluma-Pro Plus Push-Pull Guns · 229887, 229891

 XR-Aluma-Pro Push-Pull Gun Machine · Miller · CARBON-ARC · MIG

Miller · Carbon Arc / MIG · Multimatic 255 · Miller XR-Aluma-Pro Push-Pull Guns · 198855, 206186

 Miller XR-Aluma-Pro Lite Push-Pull Gun Parts Breakdown Gun / Torch · Miller · CARBON-ARC · MIG

Miller · Carbon Arc / MIG · Miller XR-Aluma-Pro Lite Push-Pull Gun · 258541, 258542

 Miller Spoolmate 200 Light-Duty Barrel Consumables Consumable Family · Miller · MIG

Miller · MIG · 186405, 186406

Long-Tail Search Phrases Covered

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